Structural interlocking exterior deck tile system

Abstract

A structural deck tile system comprising an interlocking deck tile made of a plywood (or similar material) section coated with a mixture of sawdust and polymers such as recycled plastic. Designs and patterns may be embossed or molded into the top surface of the deck tile. The deck tiles have a cut-out notch at each corner and a plurality of interlocking members fit into the notches between adjoining decking tiles to secure them together at the corners. The interlocking members are screwed to the underlying deck joist infrastructure to secure the tiles as one unitary deck tile system, providing structural capacity, and resulting in an economical, aesthetically pleasing, and structurally sound deck with an easier and faster installation. The reduced weight and interlocking fastener system improves the installation process. The endless variety of designs available for the tiles permits individual creative expression in designing exterior decks.

1 . A structural exterior deck tiling system, comprising: 
 a plurality of composite deck tiles each formed from a mixture of sawdust and plastic, each of said deck tiles having a composite surface layer atop a sub frame layer, said sub frame layer comprising a matrix of intersecting ribs with a substantially rectilinear outer boundary, each corner of said outer boundary being defined by a recess having a lateral groove therein;    a plurality interlocking members adapted to fit within the outer boundary corners of said tiles when said tiles are laid side-to-side, said interlocking members comprising upper cruciform arms for insertion into the lateral groove of said recess, and lower cruciform arms; and    a plurality of screws for securing one of said interlocking members to an underlying deck joist infrastructure,    whereby said deck tiles and interlocking members provide vertical and lateral stability atop said underlying deck joist infrastructure and an aesthetically pleasing appearance.    
   
   
       2 . The structural deck tile system according to  claim 1 , wherein said composite surface layer is compression molded or embossed with an ornamental design.  
   
   
       3 . The structural deck tile system according to  claim 1 , wherein said layer of composite is injection molded.  
   
   
       5 . The structural deck tile system according to  claim 1 , wherein said interlocking members are injection molded of high density polyethylene.  
   
   
       6 . The structural deck tile system according to  claim 1 , wherein the dimensions of said deck tiles are sixteen (15⅞″) inches by sixteen (15⅞″) inches.  
   
   
       7 . A structural exterior deck tiling system, comprising: 
 a plurality of composite deck tiles each formed from a mixture of sawdust and plastic, each of said deck tiles having a surface layer atop an integrally-molded sub frame, said sub frame comprising a plurality of parallel ribs inside a rectilinear outer boundary, and each corner of said boundary being defined by a recess having a groove therein;    a plurality interlocking members each adapted to secure a quadrangle of said tiles together corner-to-corner, and to secure said quadrangle of tiles to a deck foundation, said interlocking members comprising a lower section adapted to fit within the recesses at the corners of said quadrangle of tiles and an upper section adapted for insertion into the lateral grooves within the recesses at the corners of said quadrangle of tiles;    a plurality of screws for securing each interlocking member to an underlying deck joist infrastructure by said base section;    whereby said deck tiles and interlocking members provide vertical and lateral stability atop said underlying deck joist infrastructure and an aesthetically pleasing appearance.    
   
   
       8 . The structural deck tile system according to  claim 7 , wherein said composite surface layer is compression molded or embossed with an ornamental design.  
   
   
       9 . The structural deck tile system according to  claim 7 , wherein said layer of composite is injection molded.  
   
   
       10 . The structural deck tile system according to  claim 7 , wherein said interlocking members are injection molded of high density polyethylene.  
   
   
       11 . The structural deck tile system according to  claim 7 , wherein the dimensions of each deck tile is approximately sixteen inches by sixteen inches.  
   
   
       12 . The structural deck tile system according to  claim 7 , wherein said interlocking member further comprises a lower base section, an intermediate section, and a raised section.  
   
   
       13 . The structural deck tile system according to  claim 12 , wherein the lower base section is in the shape of a cruciform.  
   
   
       14 . The structural deck tile system according to  claim 13 , wherein the raised section is in the shape of a cruciform.  
   
   
       15 . A structural exterior deck tiling system, comprising: 
 a plurality of composite deck tiles each formed from a mixture of sawdust and plastic, each of said deck tiles having a surface layer atop an integrally-molded sub frame, said sub frame comprising a plurality of reinforcing ribs;    a plurality interlocking members each adapted to secure a quadrangle of said tiles together corner-to-corner, and to secure said quadrangle of tiles to a deck foundation; and    a plurality of screws for securing each interlocking member to an underlying deck joist infrastructure;    whereby said deck tiles and interlocking members provide vertical and lateral stability atop said underlying deck joist infrastructure and an aesthetically pleasing appearance.    
   
   
       15 . The structural deck tile system according to  claim 15 , wherein each of said deck tiles has a surface layer embossed with an ornamental design.  
   
   
       16 . The structural deck tile system according to  claim 15 , wherein each of said deck tiles has a surface layer bearing an integrally-molded ornamental design.