Not Applicable
Not Applicable
I. Field of the Present Invention
This application relates to the creation of prefabricated modular accessories and platforms that can be placed in a tile deck or on any flat surface.
II. Description and Examples of Prior Art
Floor systems have been developed and are widely used which elevate, connect and support individual tiles or pavers above a base floor or sub-floor to create a new level floor. The tiles or pavers are supported at the corners by adjustable height pedestals or along the edges by beams which run above and parallel to the base floor. The beams may also be supported by adjustable height pedestals. These raised floor systems are used on level, sloping or uneven sub-floors both inside and outside buildings. Outside installations include level pedestrian decks on roof tops. Tiles are 2 ft×2 ft in size but other sizes such as 4 ft×2 ft, 60 cm×60 cm or 50 cm×50 cm are also used.
Outside installations, over roofs and uneven or sloping ground, utilize wood or stone tiles or concrete pavers. The installations provide a level deck which allows rainwater to drain between or through the tiles to the base surface below. Water drains away on the sub floor. Utilities can be run in the space between the deck and the sub-floor. Tiles or pavers can be temporarily removed for maintenance of the roof and utility services.
Rubber tiled floor systems for plazas, decks, sports and equine areas involve the use of tiles recovered from recycled automobile tires. These tiles are often 2 ft×2 ft in size. The rubber tiles come in different thicknesses and resilience levels, and may have interlocking edges. An adhesive may or may not be used to stick the tiles to a concrete or other surface below.
Methods for incorporating furniture, storage units and planters into raised flooring systems inside buildings have been proposed, for example in U.S. Pat. No. 4,296,574 to Stephens (1981) which describes how furniture supports can be built into a floor panel. Stephens proposes the use of one or more of these special floor panels each of which incorporates an above floor pedestal or leg to allow an item of furniture to be supported. The special panels can be weighted to provide stability. The above floor pedestals or legs can be hollow to allow utilities to be run up from below. Items of furniture then become integral to the floor and its support system rather than sitting separately on top of the floor. The accessories are movable since the special panels, including the integral pedestals, rest freely on the supports and can be lifted off and relocated. Stephens discloses desks, seats, tables and lamps supported by one or more variously configured special panels and a filing cabinet that is sized to replace a floor panel.
Another example, in German patent DE003742558A1, to Brueckner (1989) describes how a planter box can be incorporated into a paneled floor to avoid the pressure points and discoloration on a carpeted panel where a conventional planter might be placed. Brueckner describes the use of a plant box that replaces a floor panel and is supported along its edges on the floor panel support system or fastened in place with clips. The planter is integrated with and is essentially flush with the floor and extends down into the cavity under the floor.
Specially designed panels, planters and furniture as described by Stephens and Bruekner, or which are similar to those described, have not been widely used, if at all. The special products are disadvantaged by having to compete in terms of cost, convenience and availability with large volume lower cost conventional accessories which are simply placed on top of false floors. Planters on a false floor can simply be placed in a tray to avoid the pressure points and discoloration described by Brueckner.
Outside tiled decks often have benches, seats, planters and other features built into the deck or onto the edge of the deck by carpenters during construction. These accessories may be built of the same material as the deck floor to create a uniform appearance, for example by using, teak, Ipê, cedar or composite planks for both the deck floor and the accessories. The built-in features are permanent and custom carpentry is costly.
Pedestal supported decks can be installed with more than one level with a step up from one level to the next. A typical step up is between 5 inches and 7¾ inches in height, the same as a riser in a staircase. The lower deck level might use pedestals adjusted to a four inch height with the upper level pedestals adjusted to an eleven inch height to create a difference of seven inches between the deck levels. The vertical gap between the levels can be closed with a riser made by fixing a vertical plank to the top level pedestals which are modified to allow the attachment. This built-in transition between levels has to be customized for each installation. The same technique could be used to raise an area of the deck consisting of just a few tiles but this is permanent and also costly.
Japanese Patent JP 2009219454, to Hata et al (2009) describes a modular system for the installation of planters, storage boxes and steps on wooden decks by stacking interlocking square box shaped frames, rims, lids and partitions in an up-and-down direction and placing the assembled units side-by-side. The lid and partition components are specially fabricated to fit on or in the square box shaped frames. The box shaped frames are not locked to each other in the side-by-side configurations and the system does not use unmodified standard tiles as used for pedestal supported decks, paving or flooring.
The means by which standard tiles and other components can be used in a flexible, modular system for creating benches, planters, seats and tables for pedestal supported decks with low labor installation costs has been addressed in the inventors U.S. patent application Ser. No. 12/925051 “Three Dimensional Deck Accessories”. That application describes a modular system for creating multi-level areas on pedestal supported tiled decks for use as platforms, plinths, benches, seats, tables, planters and other accessories utilizing standard floor tiles for the visible horizontal surfaces. Standard floor tiles are used through the use of a new enabling component referred to as a “frame”. Tiles fit in the frames. The system also uses square or rectangular box shaped modules which can fit under or in the new frames. A frame holds the modules together in a horizontal plane and supports additional modules in a vertical plane. The completed accessories appear to be built-in and to be a part of the deck but they can be easily relocated or expanded both horizontally and vertically. The accessories can be used on any deck, patio, rooftop or recreational surface.
U.S. patent application Ser. No. 12/925051 discloses the use of special frames for creating accessories, including small platforms, that are one tile or two tiles wide and several tiles long. However, there is a need to create larger multi level accessories from modular prefabricated components for installation in decks or on flat surfaces, for example in the middle of a plaza. The means for accomplishing this is the subject of this invention and patent application.
An improved modular system for creating multi-level areas on pedestal supported tiled decks or any flat surface which utilizes standard floor tiles, including wood or rubber tiles, for the visible horizontal surfaces. Accessories that exceed the area of six tiles can be created. Standard floor tiles are used through the use of an enabling component referred to as a “ledge frame”. Tiles and tile shaped panels fit in the ledge frames. The system also uses square or rectangular box shaped modules which can fit under or in the ledge frames. A ledge frame holds the modules together in a horizontal plane and supports additional modules in a vertical plane. Ledge frames, of four basic shapes, are described herein which have features enabling the perimeter of a large accessory to be assembled. These ledge frames are combined with conventional deck support pedestals and the frames previously disclosed to create new accessories. The accessories can be used on any deck, patio, rooftop or recreational surface. The system uses prefabricated parts and avoids the need for on-site custom carpentry. The products are economical with respect to materials and installation costs. These and other aspects and advantages of the new system will become apparent after reading the descriptions of the preferred embodiments in conjunction with the drawings.
FIG. 1—a prior art example of a pedestal supported deck with wooden tiles.
FIG. 2—a prior art example of the components for a three unit bench in a deck.
FIG. 3—a prior art example showing two single unit accessories.
FIG. 4—a prior art example showing a three unit width frame.
FIG. 5—a prior art example showing a cross section of a frame, tile and box shaped module.
FIG. 6—a prior art example of a top view of two abutting frames for a six unit accessory.
FIG. 7—four novel frames according to this invention.
FIG. 8—frame assembly for a nine unit accessory connected with dowels.
FIG. 9—frame assembly connected with eyes, wires and turnbuckles.
FIG. 10—assembly with the vertical elements attached and two wood tiles in place.
FIG. 11—box shaped modules in place for a twenty-four unit accessory.
FIG. 12—the first level of a twenty-four unit accessory.
FIG. 13—the second level box shaped modules in place on a twenty-four unit accessory.
FIG. 14—the completed twenty-four unit accessory.
FIG. 15—a twenty-four unit accessory on a frame assembly on a flat surface.
FIG. 16—bottom frame assembly for a flat surface.
FIG. 17—frames and pedestals for a thirty-six unit assembly.
FIG. 18—a three level thirty-six unit assembly set in a deck.
1. standard wood tile—prior art
2. adjustable height pedestal—prior art
3. frame for three units—prior art
4. marine board box shaped three unit module—prior art
5. a single unit frame—prior art
6. a liner for a single unit module—prior art
7. a single unit box shaped module—prior art
8. horizontal frame element—prior art
9. vertical side element—prior art
10. dowel—prior art
11. an assembly of two prior art frames for six units
12. single unit ledge frame
13. double unit ledge frame
14. triple unit double corner ledge frame
15. triple unit single corner ledge frame
16. inside of single unit ledge frame 12
17. inside of triple unit double corner ledge frame 14
18. inside of double unit ledge frame 13
19. inside of triple unit single corner ledge frame 15
20. dowels connecting frames
21. vertical side element
22. eyelets, wires and turnbuckles connector
23. box shaped module 23 with a closed bottom
24. Elevator® deck pedestal
25. box shaped module 25 with a closed bottom
26. vertical side element for bottom frame assembly
27. module retaining element for ledge of bottom frame assembly
28. ⅛″ support shim from the Elevator® system
In the following descriptions and illustrations like reference numbers designate like parts throughout the figures.
Prior art is first described so that the new features and novel results from this invention are more readily understood.
Module 4 is fabricated from four panels of 12″×½″ thick Sandstone Marine Board supplied by Interstate Plastics of Sacramento, Calif. Marine board is formulated to withstand harsh marine environments and is very suitable for exterior deck applications. Marine board comes in different colors and can be machined using standard wood working tools. Module 4 is open at the top and the bottom. The external dimensions of module 4 are 6 feet×2 feet so as to fit on the pedestals in place of the three tiles. Module 4 could be closed at the bottom with an additional panel of marine board and closed at the top also.
All of the above discussion is prior art according to U.S. patent application Ser. No. 12/925051. The new physical features of this invention and their application are now described in several embodiments.
The four ledge frames share common features. They are rectangular, one or more tiles can be placed within the boundaries of each frame and an inside ledge is created when a tile is placed against the outer edge of the frame. The outer edges of the frames are the edges closest to the identifying numerals 12, 13, 14 and 15. The inside ledges 16, 17, 18, 19 protrude on the inside edge along all or a part of the frame when square tiles or modules are placed on the frames against the outside edges, as illustrated by the dotted line square below frame 15 relative to ledge 19.
These frames are sized for 23.7″ square tiles with a ⅛″ gap between adjoining tiles and between a tile and the inside edge of the frame or a tile and the end edge of the frame.
The four frames shown in
The first step in creating a nine unit accessory in a deck is to place box shaped modules, of the same height, in the deck in place of the tiles at the four corners of the unit and at the planned locations of the two frames 12. The center locations of frames 14 can be left with tiles in the deck. The frames are then placed on top of the six modules.
Once the frame is assembled the vertical side elements 21 are joined to the edges of the frames around the perimeter using dowels. The side elements are predrilled for dowels at the corners and along the inside perimeter matching predrilled holes in the outer edges of the frames. In this embodiment the vertical side elements are 0.75″ thick and 2.7″ wide and are joined to the frames in the manner shown in
Three adjustable height Elevator® deck pedestals 24 supplied by Hanover Architectural Products of Hanover, Pa. are in the center of the assembly. These pedestals sit on the subfloor of the deck, alongside the pedestals that support the deck tiles, and are connected using standard Hanover StayBars™ for added stability. The StayBars™ components are not shown in
In this embodiment,
Each of the frames is placed on circular one-eighth inch or one-quarter inch thick plastic shims, 28 and 29 on the inside and outside edges to hold the frame just off the floor. This prevents rain water from pooling around the accessory edges. Shims can be purchased from Hanover Architectural Products. The circular shims are adhered to the undersurface of the frames using a few dabs of construction adhesive.
The frames are joined together and the outside vertical elements joined to the frames with dowels at the predetermined locations of the predrilled holes on each element.
A new prefabricated component 27 consisting of 2 11/16″ wide, ¾″ thick planks is then joined to the frames on top of the ledge around the inside perimeter. Dowels are used in predrilled holes. Component 27 and vertical edge 26 are one module width apart plus a ⅛″ gap on each side. Twelve modules 24 are then positioned on top of the frame with the layout shown in
The accessory is then built up on top of modules 24 as previously described to create the embodiment illustrated in
In the embodiment of
Many variations of the embodiments are made possible by the prior art of U.S. patent application Ser. No. 12/925051 and the novel features and improvements described herein. The arrangement of planters and benches can be changed by relocating tiles and modules. Table tops, made from marine board, fabricated from reinforced molded fiberglass or anodized aluminum can replace tiles. Table tops can be tile sized or two or more units long and be of different colors and placed in the frames. Modules and frames can be fabricated from molded reinforced fiberglass and other materials creating many opportunities to mix and match components. Accessories can be installed on or in tiled rubber surfaces on plazas or playgrounds. Tile colors and resilience can match the plaza surface. Rubber tiles are supplied by Diamond Safety Concepts, of Olivenhaim, Calif. with dimensions that match a 1.5″ thick wood tile when combined with a PVC support panel.
It is apparent that the enabling concept in the creation of the large multiple unit deck accessories described herein is the use of the novel frames shown in
Standard sized tiles are available in a wide range of materials and surfaces and these tiles can be incorporated into new accessories to create variety. Alternatively, the modules and frames can be fabricated from exactly the same materials as standard tiles or fabricated from the tiles themselves to create a uniform appearance. Manufacturers, marketers and installers of pedestal supported tiled decks and tiles are able to produce accessories that match or compliment their decks using prefabricated parts with no on-site carpentry costs. Landscape architects can create custom installations of benches, planters and tables using computer aided placement of standard components suited to the customer's existing or proposed deck, plaza or garden. Changes to the layouts can be made subsequent to installation at minimum cost.
Having described the invention in terms of the preferred and other embodiments it will be apparent that other tile sizes, parts and component dimensions, modifications and materials can be used. Other arrangements and improvements can be made and other deck accessories produced utilizing the same concept and intrinsic advantages. For the sake of clarity and ease of understanding these have been omitted since it will be evident that they are properly within the scope of the claims.
This application relates to improvements in the accessories disclosed in Ser. No. 12/925051 “Three Dimensional Deck Accessories” by the present inventor and which is incorporated by reference.