Permanent outdoor stage for home use

Abstract

The disclosed invention is a permanent, low-profile outdoor stage that resulted from achievement of objectives to build a home-based site for developing performing artists to practice their art. The stage's performance floor simulates floor-features on which users normally carry out training, recitals and competitions. Between practice sessions the stage can be left uncovered and unattended without being damaged by environmental elements while still retaining its desired original structural and functional qualities. The stage's novelty pertains to composition of its performance floor that is made of matte-finished high-density polyethylene, and the process by which this surface is anchored to the stage's rigid base. The stage is functionally spacious, strong and safe. This stage's novel performance floor, its potential extended utility, its durability against outdoor environmental conditions, and its carefree maintenance combine to make the invention unique in its field.

Claims

1. A stage for permanent outdoor use comprising: a performance surface, defining a floor, consisting of high density polyethylene (HDPE) that inherently is weather- and insect resistant, and a base that is rigid and consisting of weather- and insect resistant material, with the said performance floor being anchored (permanently attached) to the said base.

2. A process, serving to anchor said HDPE performance floor of claim 1, wherein said performance floor of claim 1 is permanently attached to said base of claim 1 using trim screws.

3. A process of claim 2 serving to anchor said HDPE performance floor of claim 1, wherein each said trim screw of claim 2 is inserted through a two-tiered pilot hole drilled vertically through said HDPE performance floor of claim 1, with the upper half of said pilot hole being of greater diameter than the lower half.

4. A process of claim 2 serving to anchor said HDPE performance floor of claim 1, wherein said pilot hole of claim 3 is created by drilling a hole, equal in diameter to that of the threaded part of said trim screw of claim 2, through the entire thickness of said HDPE performance floor of claim 1, and then reaming the upper half of the said drilled hole by superimposed drilling from the upper plane of said performance floor with a bevel-tipped bit equal in diameter to the head-width of said trim screw of claim 2 and to a depth of one-fourth inch below the upper plane of said performance floor of claim 1.

5. A process of claim 2 serving to anchor said HDPE performance floor of claim 1, wherein the tips of said trim screws of claim 2 are inserted through the tops of two-tiered pilot holes drilled of claim 4 and screwed securely (being unable to be withdrawn without use of tools) into the base of claim 1 until tops of screw-heads of said trim screws stop below the upper plane of said performance floor of claim 1, that is in a countersunk position.

6. A process of claim 2 serving to anchor said HDPE performance floor of claim 1, wherein the fixed, final depth of the head of said trim screw of claim 2, when countersunk as of claim 5, is determined by the underside of said trim screw head coming to rest on the shoulder formed at the juncture of the upper and lower tiers of said two-tiered pilot hole drilled as of claim 4.

7. A process of claim 2 serving to anchor said HDPE performance floor of claim 1, wherein use of a specified distribution pattern on the surface of said performance floor of said two-tiered pilot holes of claim 3, drilled as of claim 4 in said HDPE performance floor of claim 1 and used for insertion of said trim screws of claim 5, and driving (screwing) said trim screws into said base of claim 1, achieves permanent attachment of said performance floor of claim 1 to said base of claim 1.

Description

BRIEF DESCRIPTION OF THE DRAWING

[0028] Three drawings (FIGS. 1-3) show essential features of the invention, a performance stage, and how it is constructed. The relevance of the performance floor's structure and qualities in providing sought functions, and the novel process by which this floor is anchored (permanently attached) to the stage's base will become better understood by reading the accompanying description and claims.

[0029] FIG. 1 illustrates the invention, as viewed from an above angle. Emphasized is the stage's HDPE performance floor 1 and two of its four similar sides. Evident on the performance floor is a pattern of pilot holes 2, represented by dots and through which screws are inserted to attach the performance floor to the base of the stage. Also evident is the single seam 3. The bordering trim 4, also comprised of HDPE, protects the performance floor. Bordering trim 4 is pocked with pilot holes along its length through which trim screws are inserted to attach it to side ribs 5. Side ribs 5 are attached to outer base boards 6. Ventilation holes 7 are drilled in base boards 6, three on each side. Lower edges of base boards 6 contact the ground and upper edges support base cross boards. Cross boards (hidden by the performance floor) and bordering trim on two sides are not shown, omitted to simplify reader interpretation of FIG. 1.

[0030] FIG. 2 illustrates the invention's base as viewed from the top. Outer base boards 6 form the periphery of the base, and, along with four inner base boards 8, support the base cross boards 9, four of which are shown. Upper edges of outer 6 and inner 8 base boards are visible, and the opposite, lower edges are positioned on the ground, the stance assumed when the stage is completed. At six points along the length of the cross boards, paired dots illustrate the position of deck screws 10 that attach cross boards 9 to inner 8 and outer 6 base boards. A small triangular section of the performance floor 1, with nine pilot holes (dots) 2, is included to illustrate the spatial relationship of the performance floor 1 to the base cross boards 9 to which the performance floor is directly connected.

[0031] FIG. 3 illustrates, through an exploded cross-sectional view, a trim screw 11 in fixed position within one of the pilot holes (see FIG. 1 for pilot hole distribution pattern on the performance floor) drilled in the stage's performance floor 1. Depicted is the pilot hole's two-tiered structure, with the upper tier of greater diameter than the lower tier. The underside of the trim screw 11 head comes to rest at the juncture of the upper and lower tiers of the pilot hole. That is, in a countersunk position. The threaded part of the trim screw traverses the entire thickness of the base cross board 9.

DETAILED DESCRIPTION OF THE INVENTION

[0032] A detailed description is presented so that a person skilled in the art of the field can understand all structural components in relation to intended functions, and a craftsman skilled in the art of building could replicate the invention. The stage's performance floor is crafted from two sheets of HDPE. The rigid base, in the preferred embodiment, is constructed of pressure-treated lumber. Critical is that the HDPE performance floor and base are both weather- and insect-resistant. The type of HDPE used is a black half-inch thick sheet, with a matte finish. The HDPE is a marine grade plastic that does not warp, rot, or deteriorate when exposed to constant humidity or rain. Neither is the HDPE performance floor damaged by UV light, changes in outside temperature, or insects. It is compliant, shrinking slightly in cold- and expanding in hot weather. The HDPE surface layer and wooden base are held together with screws that, in addition to being compatible with treated wood, are rustproof. A critical characteristic is that screws must be long-lasting and ductile.

[0033] FIGS. 1-2 illustrate how the invention's pertinent parts, its performance floor 1, bordering trim 4, side ribs 5, outer base boards 6, inner base boards 8, and base cross boards 9 are spatially related. They illustrate the distribution of pilot holes 2 on the surface, the position of the performance floor's only seam 3, the location of ventilation holes 7 in base boards, and how cross boards are rigidly attached with screws 10 to outer 6 and inner 8 base boards. FIG. 3 illustrates the two-tiered nature of pilot holes and resting position of a trim screws 11 that are functionally and structurally critical in anchoring the invention's performance floor 1 to base cross boards 9.

[0034] In the preferred embodiment, the base is made using treated lumber [YellaWood (Great Southern Wood Preserving, Inc., Abbeville, Ala.)]. Key to building the base is that it is square so that the HDPE surface sheets fit snuggly and precisely on top. Outer base boards 6 are standard eight feet long 2-inch6-inch lumber. To build the square box for the base, two eight-foot long base boards, shortened by cutting off appropriate end pieces (equal to twice the board thickness), are laid in parallel and level on the ground. The other two base boards, are laid perpendicular to and overlap the ends of their grounded counterparts. The two longer, overlapping boards are connected to the two shorter ones with 3.5-inch, star flat-head deck screws (Deck Mate, distributed by The Home Depot, 2455 Paces Ferry Rd. NW, Atlanta, Ga. 30339) inserted from the outer overlapping boards. Three screws are inserted at each overlap. Assembled, these four boards represent the outer base boards 6 that form the square periphery of the stage's base. Four additional boards, inner base boards 8, each cut on its end to remove a section from its length equal to twice the board thickness, are inserted into the square base, parallel to the two previously cut outer boards, and attached with three 3.5-inch deck screws to opposing outer base boards 6. The base boards 6 and 8 visually separate the base into five similar rectangular compartments, evident in FIG. 2.

[0035] Screwed to the top of the compartmentalized square base component, perpendicular to the inner base boards 8, are eight-foot long 1-inch thick6-inch wide boards. These cross boards 9, as illustrated in FIG. 2, are butted together and screwed to the base boards with a pair of 2-inch star flat-head deck screws (Deck Mate) 10 at the six contact points each cross board makes with base boards. Thus, each overlying 1-inch6-inch cross board is secured to the base with twelve screws. The edges of attached cross boards coincide with the perpendicular plane of outer edges of the outer base boards on all four sides. Upon completing attachment of cross boards 9, this component is the stage's wooden base.

[0036] On top of the base are laid two sheets of HDPE plastic (54-inch96-inch and -inch thick; manufactured by VYCOM Olefin and PVC Solutions, Scranton, Pa. 18505), comprising the performance floor 1. Each sheet of HDPE weighs 90 pounds. Because the HDPE sheets are 54 inches wide, a 12-inch section is cut off the length of one panel that overlaps the edge of the base, leaving the performance floor 8-feet8-feet square. This 12-inch surplus piece is used to cut the 1-inch bordering trim strips 4 (see FIG. 1) that frame the 8-foot8-foot HDPE performance floor. The HDPE sheets can be cut easily with saws or blades used to cut regular plywood and can be drilled with regular wood bits. The inner edges of the two surface sheets, when butted together, produce the only seam 3 on the stage's performance floor.

[0037] At this point in construction, an 8-foot8-foot wood base with HDPE performance floor is produced that is sturdy and immobile. Now, ventilation holes 7, one-inch in diameter, are drilled along the outer base boards 6, two inches above the ground and two feet apart. Three ventilation holes 7 on each side of the base allow ground moisture to evaporate and ventilating air to enter behind the baseboards to help keep hidden elements of the base dry. Also, the 2-inch2-inch side ribs 5, previously cut from lengths of treated 2-inch4-inch lumber, are attached to outer base boards 6, with their upper surface of the ribs 5 level with the tops of cross boards 9. Attachment is with 3-inch deck screws. As evident in FIG. 1, the side ribs 5 surround the base and serve as the attachment site for the bordering trim 4 that frames the four sides of the performance floor 1. Side ribs 5, designed to support the bordering trim 4, represent the outer most horizontal extensions of the stage (see FIG. 1).

[0038] In the preferred embodiment, the two sheets of HDPE comprising the performance floor 1 and the bordering trim 4 are anchored (permanently attached) to the wooden base and ribs 5, respectively, with stainless steel trim screws. FIG. 3 helps understand details of the anchoring process. Anchoring involves drilling two-tiered pilot holes in the HDPE performance floor 1, to insert and position No. 71 trim head stainless-steel square drive screws 11 (Rockier Woodworking and Hardware, Medina, Minn. 55340).

[0039] For screw insertion, pilot holes, equal in diameter to the diameter of the threaded portion of the screw, are drilled through the entire thickness of the HDPE sheets (performance floor). The top part of each pilot hole is reamed (enlarged) by drilling from the exposed surface with a bevel-tipped bit equal in diameter to the diameter of the trim screw head. Multiple pilot holes are used in the anchoring process and consistency in drilling the wider tier of the two-tier pilot hole is accomplished by using a device made by the current inventor for this purpose. The device is made using two cylindrical tubes, assembled into an adjustable-length, single cylinder. One piece is a 2-inch long hollow brass cylinder threaded on its outer surface (-inch OD and 5/16-inch ID). The second piece is a -inch long brass collar (-inch ID and 7/16-inch OD), threaded on the inside, that is screwed over the longer cylinder. Assembled, the result is a cylindrical device, with an adjustable collar on one end and the other end being neat.

[0040] The reaming drill bit, attached to a drill gun, is inserted into the neat end of the two-piece cylinder and is advanced until stopped by the forward end of the drill gun chuck contacting the neat end of the device. The device's length is then adjusted by hand-twisting the collar on the longer tube until only a -inch of drill bit extends below the collar. At this point a piece of duct tape is wrapped around the juncture of the device's two parts to hold the adjusted position. Then, when used to drill the upper tier of the pilot hole, the bit is stopped from going deeper into the HDPE performance floor 1 than the exposed part of the bit due to the end of the collar contacting the HDPE surface, serving as a stop. Using the device in this disclosed fashion, prevents the bit from going more than half way through the HDPE performance floor 1, providing uniformity in producing multiple two-tiered pilot holes. The shoulder produced where the wider upper tier of the pilot hole meets the smaller diameter lower tier, as illustrated in FIG. 3, is where the ventral surface or underside of the head of the trim screw comes to rest, setting the trim screw's fixed position. This leaves a -inch distance from top of the trim screw head to the surface plane, effectively countersinking the trim screw. The gap between the trim screw head and the top plane of the performance floor is left open.

[0041] The pattern of drilled pilot holes, and subsequently the pattern of trim screws, on the stage performance floor is illustrated in FIG. 1. Pilot holes are inserted 10 inches apart along the periphery of the performance floor 1 and on both sides of the seam 3. Pilot holes are placed an inch inside the outer edge of the HDPE performance floor 1, with one exception. The exception is that four corners of each HDPE sheet are attached with three trim screws guided by pilot holes placed one inch apart in a triangular pattern, as evident in FIG. 1. Once peripheral screws are in place, other screws are inserted through pilot holes drilled over the inner portion of the performance floor, but spaced 20 inches apart in the longitudinal pattern shown in FIG. 1. Trim screws inserted through the pilot holes in the pattern disclosed anchor the HDPE performance floor 1 firmly in place on top of the base cross boards 9 (FIGS. 2 and 3). Once in place, the tops of all trim screw 11 heads lie below the stage's performing surface (FIG. 3). The upper diameter of pilot holes is small enough to present no user-perceptible depressions on the surface.

[0042] The insertion of specified stainless steel trim screws into pilot holes arranged in the pattern specified on the stage's performance floor is critical to anchoring the HDPE performance floor to the wooden base. Stainless steel trim screws were chosen in the anchoring process for two primary reasons. These pertain to material characteristics, namely screw length and head diameter, and inherent properties, namely ductile traits, and endurance in harsh weather. Inherently, stainless steel resists corrosion, a factor important in durability outdoors. Considering material characteristics, the length of trim screws is sufficient to securely attach the performance floor 1 to the base by inserting screw shafts through the HDPE performance floor via pilot holes and penetrating the full thickness of the base cross boards 9 (see FIG. 3) with the screws' threaded segments. In their fixed position (FIG. 3) stainless trim screws withstand shear stress (caused by a force acting parallel to the surface) and normal stress (caused by a force acting perpendicular to the surface) resulting from expansion and contraction of the HDPE sheets in response to changes in outside temperature, effectively counteracting stress-related forces tending to detach the performance floor from the stage's base. This stress countermeasure is related to both ductility and head diameter of the stainless trim screws. Stainless steel trim screws coming under pressures of stress, because of ductile properties, are pliable and undergo microscopic deformation (bending) without fracturing. In contrast, carbon steel trim screws, designed specifically for outdoor use and utilized in early iterations of the stage to anchor the performance floor, were brittle and readily fractured under shear stress when the HDPE expanded and contracted. The use of carbon steel trim screws was abandoned and replaced by use of stainless trim screws in the preferred embodiment of the stage. Relative to screw-head diameter, when hot weather caused the HDPE sheets to expand and rise, especially at floor corners, trim screws with relatively small diameter heads, used in early iterations of the stage, pulled through the smaller diameter, lower tier of the pilot holes. Resulting was that the HDPE sheets detached from the base. Use of trim screws with small diameter heads in early iterations of the stage was abandoned in favor of the specified stainless trim screws that have larger diameter heads and are used as specified in the preferred embodiment. The larger-headed trim screws prevent HDPE sheets from rising past the screw-head, maintaining attachment to the base. In the preferred embodiment, when the HPDE does expand there is a faint rise (bowing) in each HDPE sheet between screws on outer edges of the performance floor and the inner row of screws situated parallel to the stage's only seam. This bowing is not perceptible to stage users. Thus, use of specified stainless steel trim screws and the pattern of their installation on the performance floor (FIG. 1) buffer against functionally noticeable changes in the HDPE performance floor caused by shear and normal stresses, and effectively anchor the performance floor to the base component.

[0043] The performance floor 1 edges are protected by the bordering trim 4, which surrounds it like a picture frame. After attaching the bordering trim 4, the HPDE and wood corners of the stage are smoothed with sandpaper to remove exposed sharp edges.

[0044] When construction of this preferred embodiment of the stage is complete the weight of the stage keeps it firmly on the ground, immobile. The performance floor is well secured. The performance floor, having only a single discreet seam 3, is smooth, firm and hard wearing. The matte finished HDPE surface provides traction for safe walking but facilitates easy voluntary foot movement to allow users to execute smooth gliding moves and routines with ease, confidence and full expression. The HDPE surface allows performers to carry out actions in safety and to use a full range of shoes without damage to delicate materials. The stage is enduring outdoors and requires minimal upkeep. Impermeability to water makes the performance floor easy to clean and dry when needed. Cleaning with water and drying is the only expected between-performance user upkeep required.

[0045] The preferred embodiment described is for illustrative purposes and other embodiments are evident, such as increasing or decreasing stage size and shape to change the stage's surface area or height. The rigid wooden base of the stage could be constructed of different woods or man-made simulations, or plastic, such as used for playground equipment. The surface could be made of related HDPE materials of assorted colors and thicknesses. Screws made of different metals and of different configurations could be used to anchor the performance floor. Screws could be inserted in two-tiered pilot holes of sizes different from that disclosed and drilled in different patterns to anchor the HDPE surface. The base of the stage, instead of contacting the ground, could be built on top of a cement slab or paving stones laid on the ground and the HDPE sheets (or partial sheets) could be anchored directly to these grounded structures. Such changes would be evident to those skilled in the craft as obvious modifications and remain within the latitude of the invention's description, scope and claims.

[0046] Although designed primarily for home use by developing performing artists, the stage has greater utility. It can be used by homeowners as a site for outdoor tables and chairs or for an umbrella table at poolside. It can serve as a permanent dance floor for outdoor gatherings or a play site for children. It could also be used as an open pavilion on playgrounds or at parks. Support of performance functions for which it is designed, its potential manifold embodiments, its extended utility, its durability outdoors, and its carefree maintenance combine to make the invention unique in its field.