Note: Descriptions are shown in the official language in which they were submitted.
CA 02225988 1997-12-30
1 FIELD OF THE INVENTION
2 The invention relates to a plastic tile for use with a wooden deck. It
3 also relates to the combination of the tiles with underlying troughs for
4 surfacing the deck. The assembly of tiles and troughs is designed to provide
a deck surface which prevents rainwater reaching the wood.
6
7 BACKROUND OF THE INVENTION
8 In recent years, extruded hollow plastic planks have been developed
9 for use in connection with decks. The planks are commonly nailed or screwed
to underlying wooden joists or the plywood sheeting of a deck. Since the
11 plastic planks are impervious to moisture, they do not rot like wooden
planks
12 will over time.
13 However, plastic expands and contracts more than wood does with
14 variations in temperature. In winter it is not unusual for the plastic to
split
where a nail or screw fastener has been driven through it. Furthermore,
16 ~ moisture can leak down along the fastener and still penetrate the
supporting
17 wood structure.
18 The present invention addresses these problems in the context of
19 providing plastic tiles to overlie a supporting wooden sub-structure
(referred to
hereinafter as the "wooden deck").
2
CA 02225988 1997-12-30
1 SUMMARY OF THE INVENTION
2 A water-impermeable tile is provided for application on sloped wooden
3 decks. The tile is designed to be used in combination with underlying water-
4 impermeable sluice-ways. Preferably the sluice-ways are U-shaped troughs.
The rainwater runs down the tile, drops through the cracks or spaces between
6 the tile and its neighbors, and is delivered into the underlying troughs.
The
7 troughs convey the water to the edge of the deck, where it is released.
8 The tile comprises:
9 ~ a preferably rectangular block having a plurality of laterally spaced,
downwardly extending legs or ribs for spacing the block above the
11 underlying troughs so that the water may pass beneath it;
12 ~ the block has at least one protrusion extending forwardly from its
13 peripheral front edge. The protrusion is narrow, relative to the
14 block, for a reason which will be explained. Its top surface is
recessed relative to the top surface of the block (the protrusion is
16 preferably about one half the height of the tile). The tiles are
17 designed so that the protrusion of one tile can slide snugly under
18 the next tile. Immediately adjacent the edge of the block, the
19 protrusion preferably forms a laterally extending channel. Water
falling over the front edge of the block in the region of the protrusion
21 drops into this channel and is conveyed laterally for release into the
22 underlying troughs. The protrusion further provides a structure,
23 forward of the channel, through which a screw or nail fastener may
24 be driven to affix the tile to the wooden deck. When the protrusion
3
CA 02225988 1997-12-30
1 is hidden beneath the next tile, water is kept from reaching the
2 fastener; and
3 ~ the peripheral side and front and rear edges of the block are
4 provided with tenon and mortice means (such as tongue and
groove on the sides and lap joint elements at the ends) for forming
6 joints and interlocking adjacent tiles to resist warping and to provide
7 gapping to allow some thermal expansion without the tiles butting
8 up against each other and buckling.
9 As previously stated, the tiles are used in conjunction with underlying
water-
impervious sluice-ways, preferably troughs. More particularly:
11 ~ the trough may comprise an elongated rectangular flat strip of
12 plastic or sheet metal having upturned side edges;
13 ~ the troughs are positioned across the deck in side-by-side, narrowly
14 spaced apart arrangement so that slots) open to the wood, are
formed between them. The tiles are positioned so that their
16 protrusions register with the slots. Thus the fasteners can be driven
17 directly into the wood, without piercing the troughs.
18 The foregoing describes the preferred best mode of the invention as
19 presently embodied. It is characterized by the following advantages:
~ the tile is relatively short in comparison to the prior art plastic planks
21 - thus the heat expansion problem is less severe with the tile;
22 ~ the tile is aesthetically improved because fasteners are hidden;
23 ~ the assembly of the tiles and troughs is designed to prevent water
24 reaching the wood or the fastener; and
4
CA 02225988 1999-OS-13
1 ~ the tiles are designed to permit some thermal expansion without
2 having a tile butting into its neighbors.
3 Broadly stated, the invention involves a tile for covering a wooden deck
4 comprising: a water impermeable block having top and bottom surfaces and
peripheral side, front and back edges; said block having a plurality of
laterally
6 distributed, downwardly projecting legs extending from its bottom surface
for
7 spacing the block above the deck; the block rear edge protruding rearwardly
8 beyond the legs to form a laterally extending, covered, downwardly and
9 rearwardly opening space; said block having a protrusion, preferably
relatively
narrow relative to the block itself, extending forwardly from its front edge,
said
11 protrusion having a top surface recessed below the block's top surface,
said
12 protrusion top surface preferably forming a laterally extending channel
13 immediately adjacent the block's front edge so that water dropping over the
14 edge in the region of the protrusion will be conveyed laterally a short
distance
and then released, said protrusion providing a structure, forward of the
16 channel, for receiving a nail or screw fastener to affix the tile to the
deck.
17 DESCRIPTION OF THE DRAWINGS
18 Figure 1 is a perspective view of two joined tiles and troughs, viewed
19 from above;
Figure 2 is a plan view of the assembly of Figure 1;
21 Figure 3 is a sectional longitudinal view showing the assembly of
22 Figure 1;
23 Figure 4 is a sectional transverse view showing the assembly of Figure
24 1;
5
CA 02225988 1999-OS-13
1 Figure 5 is a perspective view of the underside of a tile; and
2 Figure 6 is a perspective view of an alternative version of the tile.
3 DESCRIPTION OF THE PREFERRED EMBODIMENT
4 Having reference to Figures 1 - 5, the tile 1 comprises a rectangular
block 2 having top and bottom surfaces 3, 4 and peripheral side, back and
6 front edges 5, 6, land 8. A plurality of laterally spaced ribs or legs 9
extend
7 downwardly from the underside surface 4 for spacing the block 2 above the
8 deck 10 and troughs 11 on which it stands. A pattern of ribs12 is integral
with
9 the block 2 on its underside and functions to strengthen and rigidify the
tile.
The block's front edge 8 forms an upwardly opening groove 13 and
11 shoulder 14. The back edge 7 forms a shoulder 15 which protrudes beyond
12 the rear ends of legs 9 to define a laterally extending and downwardly
opening
13 covered space 16. When the front edge 8 of one tile engages the rear edge 7
14 of an adjacent tile, the groove 13, space 16 and shoulders 14, 15 form a
lap
joint. One side edge 5 of the block 2 forms a pair of spaced apart ribs 17, 18
16 defining a side opening groove 19. The other side edge 6 forms an outwardly
17 projecting rib 20. When the side edge 6 of one tile engages the side edge 5
18 of another tile, the ribs 17, 18, 20 and groove 19 form a tongue and groove
19 joint.
A protrusion 30 projects forwardly from the block's front edge 8. The
21 top surface 31 of the protrusion is recessed so that the protrusion may
slide
22 under the rear of the next tile ahead. The protrusion 30 forms a laterally
23 extending channel 32 for conveying water dropping through the crack
24 between tiles and delivering it to the troughs 11. The protrusion 30 also
forms
a hole 33 through which a screw 34 extends to affix the tile 1 to the deck 10.
6
CA 02225988 1999-OS-13
1 The bottom surface 35 of the rear end of the block 2 forms a central
2 walled recess 36 for receiving the protrusion 30.
3 The protrusion 30 is preferably narrow relative to the width of the block
4 2. We have found that if the protrusion 30 is too wide, the water in the
channel 32 may overflow and reach the screw 34.
6 As shown in Figure 1, the troughs 11 are spaced apart to define a slot
7 40 open to the deck 10. The tile 1 is positioned centrally over the slot 40
so
8 that the protrusion 30 registers with it. Thus the screw 34 can be driven
into
9 the wood. The laterally extending channel 32 catches water entering through
the crack between tiles and conveys it across the slot 40 for delivery into
the
11 adjacent troughs 11.
12 An alternative form of the tile 1 is shown in Figure 6. In this
13 embodiment, the recessed protrusion 30 extends the full width of the tile.
This
14 version of the tile can be used with a single wide sluice-way. In this
assembly
the lateral channel is not required.
16 The tile 1 is preferably formed of high density polyethylene. The trough
17 11 can be formed of plastic or sheet metal.
18 The scope of the invention is defined in the claims now following.
7
