Note: Descriptions are shown in the official language in which they were submitted.
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DECK STRUCTURE
BACKGROUND OF THE INVENTION
The present invention relates to a flooring
system which is especially directed to outdoor types of
decks which are subject to the elements.
It is believed that there is no single deck
system in existence which has all the features of the
present deck structure as enumerated hereafter.
BRIEF SUMMARY OF THE INVENTION
It is one object of the present invention to
provide a flooring system, especially for outdoor use,
which will not warp, twist or be subject to insect attack
and which does not require any maintenance.
Another object of the present invention is to
provide a flooring system which is easily installed
because the tiles of the deck structure fit between
adjacent joists and are either attached thereto by
fasteners or simply snap into place without requiring
measuring or cutting and which totally finish the deck
without the need for trim or flashing.
A further obj ect of the present invention is to
provide a flooring system which inherently includes
spacings between tiles which not only allow for expansion
and contraction but also provides for water drainage,
thereby eliminating puddles.
Yet another object of the present invention is
to provide a flooring system which not only can be
installed without use of exposed fasteners but also
preserves wooden floor joists by preventing water from
laying on the top of the joist which could produce rot.
A still further object of the present invention
is to provide a flooring system consisting only of four
major components which are of relatively small dimensions
so that the system can easily be transported in relatively
small packages, thereby enhancing the ease and economy of
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transporting it from the manufacturer to the ultimate
consumer.
A still further object of the present invention
is to provide a flooring system which utilizes modular
tiles which can easily be replaced if they are damaged.
Yet another object of the present invention is
to provide a flooring system consisting of improved
plastic tiles which can be secured to underlying joists by
fasteners in an extremely simple manner with or without
utilizing channels which overlie the joists. Other
objects and attendant advantages of the present invention
will readily be perceived hereafter.
The present invention relates to a resin tile
comprising a plate having an upper surface and a lower
surface, a plurality of inner flanges extending downwardly
from said plate, a plurality of outer flanges extending
downwardly from said plate outwardly of said inner
flanges, and said outer flanges being of less height than
said inner flanges.
The present invention also relates to a plastic
tile as set forth above which can be secured to underlying
joists by fasteners extending through the outer edge
portions thereof.
The present invention also relates to a tile
assembly including a plurality of tiles as set forth above
mounted between adjacent joists with said inner flanges
positioned alongside the sides of said joists and said
outer flanges resting on the edges of said joists.
The present invention will be more fully
understood when the following portions of the
specification are read in conjunction with the
accompanying drawings wherein:
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
FIG. 1 is a fragmentary plan view, partially in
cross section, showing the improved floor tile system
installed as a deck on joists which extend outwardly from
a structure such as a house;
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FIG. 2 is a bottom plan view of a molded plastic
inner tile which is located within the edge tiles secured
to the joists;
FIG. 3 is a bottom plan view of an outer edge
tile which is to be secured along the outer edges of the
deck;
FIG. 4 is a fragmentary plan view of inner
channels which are to be mounted on the inner joists of a
deck with the inner channels in end-to-end relationship;
FIG. 5 is a fragmentary plan view of edge
channels which are to be mounted on the edge joists of a
deck with the edge channels in end-to-end relationship;
FIG. 5A is an elevational view of an edge
channel taken substantially in the direction of arrows 5A
5A of FIG. 5 and showing the edge channel mounted on a
fragmentary representation of a joist;
FIG. 6 is an end elevational view of an inner
channel taken substantially in the direction of arrows 6-6
of FIG. 4 with said channel mounted on a fragmentary
representation of a joist;
FIG. 7 is a fragmentary side elevational view
taken in the direction of arrows 7-7 of FIG. 6 and showing
the structure of the pins which extend outwardly from the
leg of the channel;
FIG. 8 is a fragmentary cross sectional view
taken substantially along line 8-8 of FIG. 1 and showing
the edge tiles and inner tiles mounted on the inner and
edge channels, respectively, mounted on the joists;
FIG. 8A is a fragmentary enlarged section of a
side member of a tile showing the slot structure for
receiving the pins of the channels;
FIG. 9 is a fragmentary cross sectional view
taken substantially along line 9-9 of FIG. 8 and showing
the edge channels which are mounted on the edge joist;
FIG. 10 is an enlarged fragmentary cross
sectional view showing a post mounted on the deck and
secured to a joist;
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FIG. il is a perspective view partially broken
away of an alternate type of inner channel;
FIG. 12 is an end elevational view of the inner
channel of FIG. 11 secured to a fragmentary representation
of an inner joist;
FIG. 13 is a perspective view of an alternate
type of edge channel;
FIG. 14 is an end elevational view of the edge
channel of FIG. 13 mounted on a fragmentary representation
of an edge j oist ;
FIG. 15 is a view of the upper surface of a tile
having a specific type of nonskid configuration;
FIG. 16 is a view of the upper surface of a tile
having still another type of configuration;
FIG. 17 is a perspective view of a tile showing
especially the upper surface which is convex from its
midpoint;
FIG. 18 is a perspective view of another
embodiment of a molded plastic inner tile which has
provisions for being nailed to the joists;
FIG. 19 is an inverted cross sectional view
taken substantially along line 19-19 of FIG. 18;
FIG. 20 is an inverted cross sectional view
taken substantially along line 20-20 of FIG. 18;
FIG. 21 is a perspective view of the underside
of an edge tile which is to be secured along the outer
edges of a deck;
FIG. 22 is a cross sectional view taken
substantially along line 22-22 of FIG. 21;
FIG. 23 is a cross sectional view taken
substantially along line 23-23 of FIG. 21;
FIG. 24 is a fragmentary perspective view of the
corner of a tile which has been fastened to an underlying
joist;
FIG. 25 is a fragmentary cross sectional view
taken substantially along line 25-25 of FIG. 24; and
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FIG. 26 is a top plan view of the tile of FIG.
18 with a different hole placement for receiving screws or
nails.
DETAILED DESCRIPTION OF THE INVENTION
5 The deck structure 10 of the present invention
includes a plurality of resin inner tiles il which are
secured to inner channels 12 mounted on joists 13 which
extend between a structure, such as house 14 and facia
joist 15. A first series of resin edge tiles 17 are
mounted between a plurality of end-to-end inner channels
12 mounted on an inner joist 13 and a plurality of end-to-
end edge channels 19 which are mounted on edge joist 20.
A second series of resin edge tiles 17 are mounted between
ends of inner channels 12 and a plurality of end-to-end
edge channels 19 mounted on facia joist 15.
The inner channels 12 (FIGS. 4, 6 and 7) are
each fabricated of molded resin having a web 21 and legs
22. Pins 23 are molded integrally with legs 22, and a
support rib or gusset 24 is molded integrally with each of
the pins 23 and the portion of adjacent leg 22. As can be
seen from FIGS. 4 and 6, the pins 23 extend outwardly from
both legs 22. The edge channel 19 is also fabricated of
molded resin, and it consists of a web 25 with depending
legs 27. Edge channel 19 includes spaced pins 29 which
extend outwardly from only one leg 27 thereof . A support
rib or gusset 30, which is molded integrally with each pin
29 and leg 27, is located below each pin 29. Each rib 30
has the same configuration as rib 24 of FIGS. 6 and 7.
Channels 12 and 19 are secured to j oists 13 and
20 by nails or screws which pass through the webs 21 and
25 at appropriate intervals, such as every foot, and are
received in the respective joists. As will become
apparent hereafter, the nails or screws are the only metal
fasteners which are used in the floor system and they are
not exposed because they are hidden by the tiles 11 and 17
which are mounted on the channels. Also, since the
channels 12 and 19 are essentially caps for the wooden
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joists, they tend to preserve them by preventing water
from laying on the tops of the joists which causes rot.
The use of resin for the tiles and channels provides a
flooring system that does not require maintenance, will
not warp and is not subject to insect attack.
The inner tiles 11 (FIGS. 1, 2, 8 and 9) each
include a plate 31 having an upper surface 32 and a lower
surface 33. Upger surface 32 is formed with a suitable
tread to tend to prevent people slipping thereon. A
plurality of identical inner side members or inner flanges
34 are molded integrally with and extend downwardly from
lower surface 33 of plate 31 (FIGS. 2, 8 and 9) . Central
ribs 35 (FIGS. 2, 8 and 9) extend between opposite pairs
of inner side members 34. Additionally, central portions
of ribs 35 are located in a crossover pattern (FIG. 2) and
are molded to each other at intersections 37 in addition
to being molded integrally at their outer ends with side
members 34 at 39. The upper edges of ribs 35 are molded
integrally with the lower surface 33 of plate 31. Thus,
ribs 35 rigidize both upper plate 31 and side members 34.
Outer side members or outer flanges 40 (FIGS. 2
and 9) extend downwardly from plate 31 at the outer edges
thereof and are molded integrally therewith. They are
also molded integrally with each other at their adjacent
ends 42. Ribs 41 are molded integrally with the lower
surface 33 of plate 31 and they are molded integrally with
and extend between outer side members 40 and side members
34 to thereby rigidize them. As can be seen from FIG. 9,
inner flanges 34 have a greater vertical height than outer
flanges 40, and outer side members 40 rest on the tops of
channels 12 when tiles 11 are in their installed position.
The inner tiles 11 are installed in the
following manner. It is merely necessary to align slots
43 in side members 34 with pins 23 which extend outwardly
from inner channels 12. Thereafter, it is only necessary
to bear downwardly on the edges of the tile until the pins
23 enter slots 43 (FIG. 8A) and come to rest in the ends
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44 of slots 43. The neck 45 of each slot 43 is slightly
smaller than the diameter of the pins 23 which it
receives. Therefore, the edges of slot portion 45 will
deflect slightly as each pin 23 enters slot portion 44,
and thereafter they will snap back into their unstressed
position to thereby essentially lock side members 34
against moving upwardly out of engagement with pins 23.
Thus, it can readily be seen that tools are not required
to assemble tiles 11 onto channels 12. When the tiles 11
are fully installed, they will be firmly supported on
joists 13 because of the above locking of pins 23 in slots
34 and further because outer side members 40 rest on
channels 12. The pin and slot connections 23, 43 are
merely to properly locate the tile ll~relative to the
channels 12 and retain the tiles in position; the loading
on the tiles is borne by the outer flanges 40 bearing on
the channels 12. It will be appreciated that other
structure can be substituted for the pin and slot 23, 43
connections, such as protrusions and dimples. If it
becomes necessary to remove a tile for replacement, it is
merely necessary to force it upwardly so that the pins 23
will be released from slots 43.
It is also to be noted from FIG. 4 that end pins
23 of each installed adjacent channel 12 are spaced apart
the same distance M as the pairs of the closest pins 23 on
the central portion of channel 12. Therefore, an assembly
of a plurality of channels 12 in end-to-end relationship
will be the equivalent of a single elongated channel.
According to the geometry and dimensions of the channels
12 and tiles il, as expressed in the table set forth
hereafter, the spaces 47 (FIG. 1) between adjacent tiles
will be approximately 1/8" which in turn permits drainage
from the surfaces of the tiles into the spaces 47 (FIG. 9)
between the adjacent tiles 11. The drainage is enhanced
by the fact that the upper surface 32 of each tile plate
31 is slightly convex downwardly from its midpoint.
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Edge tiles 17 have the same outer dimensions and
the same structure as inner tiles 11 except that their rib
structure is slightly different. Therefore, where the
same numerals are applied to edge tiles 17 which are
applied to inner tiles 11, they will denote identical
elements of structure, thereby obviating the necessity to
describe the edge tiles in detail. The slightly different
edge tile structure includes ribs 41' (FIG. 3) which are
longer than ribs 41 between outer positioning members 40
and side members 34 (FIGS. 3 and 8). This dimensioning
permits the positioning members 40 on the outer edges of
the deck to lie only slightly inwardly of the leg 27 of
channel 19 (FIGS. 8 and 10), thereby eliminating the
necessity for trim at the outer edges of tiles 17. It can
thus be seen that ribs 41' at the left and lower portions
of FIG. 3 are longer than ribs 41. However, in order to
maintain the dimensions D of the corner openings 47, ribs
35" have been moved closer to their adjacent parallel ribs
35' than the spacing between ribs 35' themselves which is
identical to the spacing between ribs 35 of inner tile 11.
Other than the foregoing, the edge tiles 17 are identical
to inner tiles 11. The edge tiles 17 are locked in
position in substantially the same manner as described
above relative to inner tiles 11, namely, by pins 23 and
29 being locked into slots 43 and by outer side members 40
resting on channels 12 and 20.
Because of the outer dimensions of tiles 17 and
the fact that the slots 43 in sides 34 are positioned
identically to those described above relative to inner
tile 11, the horizontal spaces 47 between edge tiles 17 in
FIG. 1 will be the same as horizontal spaces 47 between
the inner tiles 11. There will also be vertical spaces 49
(FIGS. 1 and 8) between the tiles in order to permit
drainage from the convex top surfaces 31 of the tile
plates 11 and 17 (FIG. 8). This drainage will be onto the
tops of channels 12, and this drainage will either leak
out along the sides of channels 12 or move to the
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intersections of spaces 47 and 49 and thereafter pass
downwardly along the sides of channels 12. The spaces 47
and 49 will be approximately 1/8 inch. This spacing
allows for expansion for the tiles 11 and 17 due to
temperature changes. Also, if the tiles contract, they
will still be supported by the outer side members 40 which
rest on the channels. The above geometry is capable of
achievement because of the dimensions set forth in the
following representative table. However, it will be
appreciated that other dimensions can be utilized to
obtain comparable results.
ITEM DIMENSION IN INCHES
A 16
B 15 1/4
C 15 7/8
D 4
E 2 7/16
F 11
G 1 1/2
H 15/16
I 1 3/4
J 48
K 2 1/2
L 11
M 5
N 1 1/2
It can be seen that because of the above
described structure, there are only four parts required to
construct a deck once the inner joists 13 and outer joists
15 and 20 have been built with the centers therebetween
represented by dimensions A and B in the above table.
These four parts are the inner channels 12, the outer
channels 19, the inner tiles 11, and the edge tiles 17.
Thus, the parts can be packaged for ease of shipping and
handling. Furthermore, the channels 12 and 19 are
conveniently fabricated in four foot lengths for ease of
shipping and handling. In addition, as noted briefly
above, the end pins on channels 12 and 19 are spaced such
that when two channels are placed in end-to-end
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relationship, the spacing M therebetween is the same as
the spacing M between the closest spaced pins on the
central portions of the channels. In addition to the
foregoing, there need be no specific orientation of the
5 inner tiles 11 when they are being snapped into position,
other than aligning their slots 43 with the pins 23 of the
channels because the four sides of each tile il are
identical. However, the edge tiles 17 have to be oriented
with their outer positioning members 40, which are
l0 adjacent ribs 41~, located at the extreme outer edge of
the deck. If they are not oriented in this position, it
will not be possible to install them because the side
edges 34 adjacent ribs 41 will prevent the edge tiles 17
from entering the spaces between channels 12 and 19.
A preferred inner channel 60 is shown in FIG.
11. Channel 60 is an extrusion which has holes 61 drilled
in the opposite legs 62. These holes are spaced apart the
same amount as pins 23 of inner channel 12 (FIG. 4). In
fact, the only difference between inner channel 12 of FIG.
4 and inner channel 60 of FIG. il is that the latter has
holes 61 whereas the former has pins 23. Channel 60 is
installed on inner joist 13 (FIG. 12) by inserting nails
63 through holes 61. The nails 63 are of slightly smaller
diameter than holes 61. However, nails 63 have a diameter
which is the same as the diameter of pins 23 so that they
will be received in slots 43 of side members 34 in the
same manner described above relative to pins 23. The
nails 63 function as pins when they are received in slots
43. When inner channels 60 are used, there is no need to
attach channels 62 to joists 13 by the use of nails which
pass through the webs of the channels.
A preferred edge channel 64 is shown in FIG. 13.
Edge channel 64 is an extrusion which is identical in all
respects to edge channel 19 of FIG. 5 except that it only
has holes 65 drilled in one side 67 thereof. Edge channel
64 is an extrusion. It is attached to edge joist 20 by
driving nails 63 through holes 65. The nails 63 protrude
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from side 67, as shown, to receive slots 43 in side
members 34 as described above relative to edge channels 19
(FIG. 5A). As noted above, holes 65 are drilled only into
one leg 67.
In FIG. 15 the top surface of a tile lla is
shown. Tile lla may be identical in all respects to tile
11 described above except that it has a wood grain finish
69 which has depth to both provide an anti-skid surface
and a decorative finish. In FIG. 16 a tile llb is shown
which has a brick pattern finish 70 on its upper surface
which is both anti-skid and decorative. It will be
appreciated that any suitable designs can be embossed into
the upper surfaces of the tiles.
Railing posts 50 (FIGS. 1 and 10) can be
installed in the following manner. The portion of plate
31 having the dimension D at the corner of the tile 17 is
cut out to provide an opening 47 and the post 50 is
inserted therethrough. Thereafter, it is bolted into
position by bolts 51 which pass through edge joists 20 and
the lower portion of post 50. Additionally, a shim 52 is
located between the bottom end of the post and joists 20.
The thickness of this shim is equal to the combined
thicknesses of channel leg 19 and side member 34.
The above description has referred to the tiles
11 and 17 as being made of a resin. In this respect high
density polyethylene is preferred, but it will be
appreciated that any other suitable resin including but
not limited to polypropylene, polystyrene and
polyvinylchloride may be used.
In FIGS. 18-26 other embodiments of the present
invention are disclosed. These embodiments include an
inner tile 55 (FIG. 18) which is analogous to inner tile
11, and an edge tile 57 (FIG. 21) which is analogous to
edge tile 17. The embodiments also include an inner tile
55' (FIG. 26) which is a variation of inner tile 55. The
tiles 55, 57 and 55' are fabricated of molded plastic, as
are tiles 11 and 17. While tiles 55 and 57 have a
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slightly different rib structure than tiles 11 and 17,
respectively, the only major difference is that the inner
tile 55 has bores 59 at its four corners, and tile 57 has
bores 60 at its four corners. The bores 59 in tile 55 are
located in solid plastic blocks 58 which are integrally
molded with the remainder of the tile. The bores 60 in
tile 57 are located in solid plastic blocks 66 which are
molded integrally with the remainder of the tile. The
blocks 58 are of the same depth as ribs 73 , and blocks 66
are the same depth as ribs 79 and 73'. Tile 55' has bores
87 along its edge portions 89. The bores 87 in tile 55'
are in plastic blocks 92 which extend between side members
or flanges 67 and 71 and they are of the same depth as
ribs 73. The bores 59, 60 and 87 are for receiving
fasteners in the nature of screws or nails 61 (FIG. 25)
for fastening each individual inner tile 55 and 55' to
joists 13 (FIGS. 1 and 24) and for fastening the edge tile
57 between joists 13 and edge members 20 or 15, as also
depicted in FIG. 1.
Each inner tile 55 includes a plate 62 (FIG. 19)
having an upper surface 63 and a lower surface 64. Upper
surface 63 is convex or crowned, as depicted by the
dimensions 65 at the left of FIGS. 19 and 20. A plurality
of identical inner side members 67 are molded integrally
with and extend downwardly from lower surface 64 of plate
55. Central ribs 69 extend between opposite pairs of
inner side members 67. Additionally, central portions of
ribs 69 are molded to each other, wherever they cross each
other, as at intersections 70, in addition to being molded
at their outer ends with side members 67. The upper edges
of ribs 69 are molded integrally with the lower surface 64
of plate 62. Thus, ribs 69 rigidize both plate 62 and
side members 67. Ribs 69 are analogous to ribs 35 of the
embodiment of FIG. 2 and they function in the same manner.
Outer side members or outer flanges 71 extend
downwardly from the outer edges of plate 62 and are molded
integrally therewith. They are also molded integrally
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with blocks 58 (FIG. 18) at corners 72. Outer side
members 71 are all of the same height so that the tile 55
can be oriented in any position when installed on joists
13. Ribs 73 are molded integrally with the lower surface
64 of plate 62, and they are molded integrally with and
extend between outer side members 71 and side members 67
to thereby stabilize them. Inner flanges or inner side
members 67 have a greater vertical height than outer side
members 71, and outer side members 71 rest on the tops of
joists 13 when tiles 55 are in their installed position.
Also inner side members 67 abut the sides of joists 13, as
shown in FIG. 25. Each inner side member 67 has slots 74
which function in the same manner as slots 43 of the
embodiment of FIGS. 1-9 when tiles 55 are used in
conjunction with channels 12 described relative to the
previous embodiment or with nails extending outwardly from
the joists. However, if desired, channels need not be
used with tiles 55 because the tiles are fastened to the
joists by screws or nails which extend through apertures
59 at the corners thereof.
Edge tiles 57 are analogous to edge tiles 17 of
FIGS. 1-9. Edge tiles 57 have the same outer dimensions
as inner tiles 55 except that the configuration of their
ribs 75 and their inner side members 77 are slightly
different. The slightly different structure of tile 57
includes longer ribs 79 between two adjacent sides of the
tile. Ribs 79 extend between inner side members or
flanges 77 and outer side members or flanges 80. Ribs 79
are molded integrally with side members 77 and 80 and with
the lower surface 78 of plate 76. The ribs 73' which
extend between the other two pairs of adjacent inner and
outer side members are of the same dimension as ribs 73 of
FIGS. 18-20. Ribs 73' are molded integrally with the
lower surface 78 of plate 76 and with side members 77 and
80. The dimensioning of ribs 79 and 73' of FIGS. 21, 22
and 23 permits positioning tiles 57 the outer edges of the
deck to lie only slightly inwardly of the outer edges of
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the supporting members, thereby eliminating the necessity
for trim on the outer edges of tiles 57. This was fully
explained relative to the embodiment of FIGS. 1-9, and is
shown in FIG. 8.
The tiles 55 and 57 are analogous in all
respects to tiles 11 and 17, respectively, of FIGS. 2 and
3 , respectively, except for the fact that tiles 55 and 57
have bores 59 and 60, respectively, in the corner blocks
58 and 66, respectively, for securing them to the joists
on which they are mounted. Enlarged bores 82 (FIG. 25)
are located above bores 59 of tile 55. Bores 82 receive
plastic plugs 83 with an interference fit, and they
conceal and protect screws 61. Tile 57 (FIGS. 21 and 23)
also has enlarged bores 84 at all four corners above
screw-receiving bores 60. The inner side members 77
include slots 81 for mounting tiles 57 on channels, such
as 12 , or on nails extending outwardly from joists 13 , if
desired. Slots 81 are identical to slots 43 of the
embodiment of FIGS. 1-9. However, the slots are not used
if channels or outwardly extending nails are not used,
when only nails are used to secure the tiles to the joists
and edge-supporting members.
Inner tile 55' (FIG. 26) is a variation of inner
tile 55 (FIGS. 18, 19, 24 and 25) in that the holes 87 for
receiving screws or nails are in the side edge portions 89
between inner side members or flanges 67 and outer side
members or flanges 71. Otherwise the structure of tile
55' is identical to the structure of tile 55 of FIG. 18
which was described above with the use of identical
numerals, and such description will not be repeated here.
Enlarged bores 90 are associated with bores 87 for
receiving plastic plugs, such as 83, with an interference
fit to conceal and protect the screws or nails which are
present in those holes 87 which overlie the joists and for
closing those holes 87 which do not overlie the joists.
As noted above, the bores 87 and 90 are located in plastic
blocks 92 which are molded integrally with the inner and
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outer flanges 67 and 71 and the lower surface 96 of the
top of the tile. The plastic blocks 92 are of the same
depth as ribs 73. An embodiment such as 55', by having
holes 87 in all four side edge portions 89 can be oriented
5 between the joists with either pair of the two opposite
side edge portions 89 overlying the joists. This permits
patterns of identical adjacent tiles to be oriented
perpendicularly to each other. However, it will be
appreciated that the holes 87 and enlarged bores 90 need
10 be placed in only one pair of opposed side edge portions
89 so that the other pair of side edge portions 89 which
lie between the joists will not have holes 87 and two
bores 90 therein. Also, it will be appreciated that while
there are shown two holes 87 and bores 90 in the side edge
15 portions 89, there may be more or less than two. However,
the preferred hole and bore location is as shown in FIGS.
18 and 21 where the holes and bores are at the corners.
Also while FIG. 26 shows a modification of FIG. 18, it
will be appreciated that an analogous modification can be
made of edge tile 57 of FIG. 21.
While the above description has been directed to
a deck, it will be appreciated that the floor system can
be used for animal pens, dock surfaces and platforms for
air conditioners and garbage cans.
While preferred embodiments of the present
invention have been disclosed, it will be appreciated that
it is not limited thereto but may be otherwise embodied
within the scope of the following claims.
C-2504.SPC
