U.S. patent application number 11/335370 was filed with the patent office on 2006-07-20 for synthetic boards for exterior water-resistant applications.
Invention is credited to Francis J. Caufield.
Application Number | 20060156666 11/335370 |
Document ID | / |
Family ID | 36682392 |
Filed Date | 2006-07-20 |
United States Patent
Application |
20060156666 |
Kind Code |
A1 |
Caufield; Francis J. |
July 20, 2006 |
Synthetic boards for exterior water-resistant applications
Abstract
Specially configured synthetic boards are provided for use with
conventional carpentry tools and techniques to form flat,
water-tight surfaces such as decks, roofs, walls, boat decks,
hulls, and the like. The boards are formed to their desired shape
and scale by extruding mixtures of wood particles and thermoplastic
materials through appropriate converging dies. In one
configuration, the edges of the boards have complementary
configured outwardly facing recesses that permit them to be joined
to form the watertight surfaces, and in another configuration the
boards have features that interact with separate plastic structures
to provide water tightness.
Inventors: |
Caufield; Francis J.;
(Lexington, MA) |
Correspondence
Address: |
FRANCIS J. CAUFIELD
6 APOLLO CIRCLE
LEXINGTON
MA
02421-7025
US
|
Family ID: |
36682392 |
Appl. No.: |
11/335370 |
Filed: |
January 19, 2006 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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60593505 |
Jan 20, 2005 |
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Current U.S.
Class: |
52/483.1 |
Current CPC
Class: |
E04F 2201/023 20130101;
E04F 2201/05 20130101; E04F 15/10 20130101; E04F 13/16 20130101;
E04F 2201/026 20130101; E04F 2201/0138 20130101 |
Class at
Publication: |
052/483.1 |
International
Class: |
E04B 2/30 20060101
E04B002/30 |
Claims
1. A substantially planar surface comprising corresponding and
interconnected water proof pieces that form water resistant
channels between them for directing liquid away from the surface,
said water proof pieces having opposed surfaces and edges with at
least one lengthwise recess formed in a surface thereof adjacent
one edge, said recess facing outwardly from said surface and
configured and arranged to engage corresponding complementary
shaped recesses in other like water proof pieces to provide
surfaces with liquid channeling, leak resistant joints formed
between adjoining water proof pieces.
2. A board for use with other like boards to construct surfaces,
said board having opposed surfaces and edges with at least one
lengthwise recess formed in a surface thereof adjacent one edge,
said recess facing outwardly from said surface and configured and
arranged to engage corresponding complementary shaped recesses in
other like boards to provide surfaces with liquid channeling, leak
resistant joints formed between adjoining boards.
3. The board of claim 2 wherein the cross-sectional shape of said
recess comprises one concave section and one convex section
arranged aside of one another.
4. The board of claim 3 wherein said concave section resides
further inboard of said edge than does said convex section and is
larger than said convex section.
5. The board of claim 4 wherein at least a portion of said concave
section includes lengthwise sealing means to further assure that a
leak resistant joint is formed between adjoining boards.
6. The board of claim 5 wherein said sealing means comprises a
lengthwise meniscus of flexible sealing material.
7. The board of claim 6 wherein said flexible sealing material is
selected from the group of materials consisting of elastomers,
silicon, RTV, caulking compound, rubber, latex, and O-ring.
8. The board of claim 5 wherein said sealing means comprises a
lengthwise groove formed in the bottom of said concave section and
filled with a sealing material that sits proud of said surface of
said concave section.
9. The board of claim 2 wherein said recess further includes a
section for engaging adjoining boards along at least one common
edge.
10. The board of claim 5 wherein said recess is configured and
arranged as a snap fit joint, said joint having a widened and
substantially planar surface at the base of said recess so that
fasteners may attach said board to a surface beneath said board
through said widened and substantially planar surface.
11. The board of claim 10 wherein said recess further comprises: a
fastener at the base of said recess sufficiently small so that said
board and said complimentary board are flush and so that said
fastener is hidden from the top surface of said board; and a
lengthwise seal adjacent said hidden fastener to further assure
that a leak resistant joint is formed between adjoining boards.
12. The board of claim 2, wherein said board is comprised of
composite materials selected from the group consisting of wood
particles and plastic so that the appearance of said board is
wood-like, said board being pliabile for use with common carpentry
tools and fasteners and strengthened strength for common
construction purposes selected from the group comprising decks,
roofing, siding, boat decks, and boat hulls.
13. The board of claim 12 wherein said plastic is comprised of
polyethylene.
14. The board of claim 13 wherein said board is formed by
extrusion.
15. The board of claim 14 having additional structural features
formed during extrusion including wire and rod stiffeners.
16. The board of claim 5 wherein said sealing means is co-extruded
or contemporaneously applied.
17. A method for producing a wood-plastic composite for a board
having opposed surfaces and edges with at least one lengthwise
recess formed in a surface thereof adjacent one edge with the
recess facing outwardly from the surface and configured and
arranged to engage corresponding complementary shaped recesses in
other like boards to provide surfaces with leak resistant joints
formed between adjoining boards, said method comprising the steps
of: a) providing particles of wood component; b) providing a
thermoplastic component; c) proportioning the wood component and
thermoplastic components in a mixing ratio from about 65/35 to
about 40/60; d) heating the mixture; and, e) extruding the mixture
through a die shaped according to the board's desired dimensions
and profile.
18. The method of claim 17, further including the step of
co-extruding an elastomeric strip along said grooves.
19. The method of claim 17, further including the step of
laminating said board with a PVC layer.
20. A leak-resistant planar surface which channels water away from
an underlying area comprising: a plurality of boards aligned
adjacent to one another with two lengthwise grooves along the
downward face of each board; channel strips placed underneath the
lengthwise boundaries between said boards wherein said strips
comprise protruding tongues that insert in a complimentary manner
into said grooves of said boards so that said channel strips form
channels for directing liquid away from said surface.
21. The leak-resistant planar surface of claim 20 wherein said
channel strips are formed as an integrated sheet of periodically
repeating such channel strips with flat areas spanning and
underneath them.
Description
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of priority from U.S.
Provisional Patent Application Ser. No. 60/593,505 filed on Jan.
20, 2005, the entire contents of which are incorporated herein by
reference.
FIELD OF THE INVENTION
[0002] This invention generally relates to construction materials
and, more particularly, to specially configured synthetic boards
for providing water-tight exterior surfaces such as for decks,
roofs, siding, and boat applications.
BACKGROUND OF THE INVENTION
[0003] In the construction of outdoor surfaces, such as decks and
porches, it is common to use flat materials that are
weather-resistant. Typically, these are pressure-treated wood,
cedar or teak planks, mahogany planks and, more recently, synthetic
boards which are extruded wood/plastic composites.
[0004] In normal construction, boards of the above types are spaced
apart to provide gaps, allowing moisture to drain through the crack
fromed between the butt joint as from a deck to the area below.
Problems arise when it is required that the area below be more or
less protected from rain and snow as, e.g., when a patio is placed
below an elevated deck.
[0005] Solutions for this problem are available on the market
today, but all have certain limitations. Interlocking aluminum
planks (e.g., U.S. Pat. No. 5,816,010) are effective in providing
leak-resistant lower levels. Various underlayments, covered with
rubber or plastic sheet goods, are generally available. These are
also effective.
[0006] However, there are two drawbacks with the above. First is
appearance; many prefer the look of a traditional wooden floor. A
second is related to construction techniques in that the
above-cited existing systems require non-standard carpentry, e.g.,
pre-drilling and sawing of aluminum extrusions and cementing of
large areas of sheet goods.
[0007] Consequently, one primary object of the present invention is
to provide construction materials in the form of leak-resistant
boards which are both attractive, i.e., wood-like in appearance and
that are amenable to being worked with ordinary carpentry tools,
techniques, and fasteners.
[0008] An additional object of the invention is to provide a
low-cost and environmentally friendly means for producing
wood-composite materials with the desired leak-resistant properties
since the use of various products such as pure wood or plywood is
presently expensive and accelerates forest depletion.
[0009] Materials that come in various compositions of wood
particles and plastic have been available for many years. Their
advantages over natural wood include greater durability and
resistance to weathering. They are also often less expensive to
manufacture than traditional wood or aluminum products and have the
benefit of being producible from recycled plastic and wood
products. In addition to these manufacturing benefits, wood-plastic
composites have the same workability as wood with respect to the
use of traditional carpentry tools and fasteners, and conventional
methods for their fabrication have been well established.
[0010] One method of generating wood-plastic materials is by
heating mixtures of the composites and applying an extrusion
process whereby the melted mixture is forcibly passed through a
converging die assembly with the desired cross-sectional shape. For
example, U.S. Pat. Nos. 5,746,958 and 5,851,469 describe methods
for mixing and stabilizing such material and extruding the heated
composite through a die to provide board-shaped products of desired
dimensions. Such a process could be adapted for shaping materials
with novel dimensions and features (i.e., channels) meant for
creating leak-resistant characteristics.
[0011] A further object of the invention is therefore to produce
wood-like and leak-resistant material with an inexpensive and
environmentally-friendly fabrication process.
[0012] Other objects of the invention will, in part, be obvious and
will, in part, appear hereinafter when the detailed description is
read with reference to the drawings.
SUMMARY OF THE INVENTION
[0013] The invention relates to channeled, interlocking boards with
integral elastomeric or supplemental seals that are effective in
constructing extensive, leak-resistant lateral surface, as for a
deck, roof, wall or boat application.
[0014] In material content, the boards are typical of the
composites now used for decking: 50% more or less of wood fibers,
the remainder, of thermoplastic binders, typically high and low
density polyethylenes. Alternatively, more or less plastic can be
used.
[0015] Such boards are wood-like in appearance, extremely rugged
and inexpensive. The low cost derives from the fact that the wood
content comes from waste sawdust, and the plastic is from recycled
goods, such as bags and bottles. Inexpensive processes for
producing boards of such material can be adapted for incorporating
the desired leak-resistant characteristics.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] The structure, operation and methodology of the invention,
together with other objects and advantages thereof, may best be
understood by reading the detailed description in connection with
the drawings in which each part has an assigned label or numeral
that identifies it wherever it appears in the various drawings and
wherein:
[0017] FIG. 1 is a diagrammatic perspective view of a completed
deck structure assembled with boards according to the
invention;
[0018] FIG. 2 is a diagrammatic perspective view of a single basic
board according to the invention;
[0019] FIG. 2A is an enlarged cross-sectional view of part of a
channel of the board of FIG. 2;
[0020] FIG. 3 is a diagrammatic, partially exploded, view of a pair
of basic boards, showing the interlocking features;
[0021] FIG. 4 is a diagrammatic perspective view of a beginning and
finishing board according to the invention;
[0022] FIG. 4A is an elevation of the board of FIG. 4;
[0023] FIG. 5 is an elevational view of an assembly of basic
boards, including beginning and finishing boards according to the
invention;
[0024] FIG. 5A shows an alternative means for sealing a beginning
board against a vertical wall;
[0025] FIG. 6 is a diagrammatic view of boards with an alternative
geometry for outwardly facing channels in accordance with the
snap-fit features of the invention;
[0026] FIG. 6A is an enlarged diagrammatic view of the channels of
FIG. 6;
[0027] FIG. 7 is a diagrammatic, partially exploded view of boards
with an alternative geometry, along with separate channel sheets in
accordance with the invention;
[0028] FIG. 8A is an elevational view of the boards and channel
sheets of FIG. 7;
[0029] FIG. 8B is a blown-up elevation view of the joint and
channel section of the boards of FIG. 7;
[0030] FIG. 9 is a diagrammatic, partially exploded view of the
boards of FIG. 7 with an alternative design for laterally extending
channel sheets;
[0031] FIG. 10 is a diagrammatic perspective view of the boards of
FIG. 7 joined lengthwise along the channel sheets of FIG. 9;
[0032] FIG. 11A is an elevational view, partially exploded, of the
boards of FIG. 9 fastened and sealed to underlying surfaces;
[0033] FIG. 11B is an enlarged elevation view of joint and channel
section of the boards of FIG. 11A;
[0034] FIG. 11C is an elevational view of the boards of FIG. 9 with
alternative means for fastening to an adjoining vertical
surface;
[0035] FIG. 12 is a diagrammatic cross-sectional elevation of an
alternate embodiment of the invention provided with an enlarged
fastening surface; and
[0036] FIG. 13 is a diagrammatic cross-sectional elevation of an
alternate embodiment of another embodiment of the invention having
yet another enlarged fastening surface.
DETAILED DESCRIPTION
[0037] This invention relates to the production and use of
materials suitable to provide extensive generally planar surfaces,
such as a deck roof, or wall, which are water-tight to the areas
enclosed, thus allowing such areas to be useful as protected areas,
e.g., a patio, second deck, porch, storage, or living space.
Additionally, the materials appropriately sized may be used in boat
applications such as for hulls, decking, interior finishes, and
topside structures.
[0038] Referring to FIG. 1, a diagrammatic perspective view of a
completed deck structure 50 is shown assembled with boards 52
according to the invention. Boards 52 are sealed from moisture and
are otherwise configured to channel water out and away from
sheltered area 54.
[0039] Reference is now made to FIG. 2, which shows an embodiment
of a board 100. Board 100 is shown with opposite outward facing
channels 106, provided with elastomeric strips 102, which are
applied in channels 106 and which seal against moisture when
compressed by opposing tongues 104. Such strips are preferably
co-extruded with the body of boards 100 in a manner to be
described, or may be added in a secondary operation. The boards 100
can alternatively be covered entirely with elastomeric material.
Note that the durometer of the elastomeric strips 102 is low,
typically Shore 40A, to avoid undue stress in the board structure
as the strips are compressed. Note also, that for clarity, the
boards are shown dramatically foreshortened; Width "W" is typically
several inches, Length "L" is typically several feet or more and
can be made in standard lengths as needed. The elastomeric strips
may be from the group of materials consisting of silicon, RTV,
caulking compound, rubber, latex, and any of these in the form of
an O-ring
[0040] Reference is now made to FIG. 2A, which is a magnified view
of the elastomeric strip 102, shown as a thin meniscus, typically
of polyurethane. Circular cross-section seals (O-ring style) laid
into extruded channels are more appropriate in secondary
fabrication operations.
[0041] Reference is now made to FIG. 3, which is a perspective view
of two basic boards 100, slightly separated from their assembled
positions. Here, it can be seen that on every joint formed by
mating the complimentary shaped channels 106, there are two
side-by-side seals 102, providing improved water tightness.
[0042] Reference is now made to FIGS. 4 and 4A, which are,
respectively, perspective and elevational views of a needed
additional board configuration 200, to be used at the beginning and
finishing boundaries of the extensive spans of basic boards 100.
One side presents a rounded nose feature, seen at 208. The other
side, to mate with basic boards 100, features identical channels
206, upwardly extending tongues 204 and elastomeric strips 202. The
use of beginning and finishing boards 200 is best shown in FIG.
5.
[0043] Reference is now made to FIG. 5, which is an elevation of a
typical construction. (Only two basic boards 100 are shown for
clarity. There would typically be many more in the main span.) A
beginning board 200, on the left of the drawing, is shown to be in
proximity with a vertical member 310. Such a member is, for
example, siding on a structure or a riser on a stair, on which the
subject boards are to form the tread.
[0044] The joint between board 200 and vertical member 310 is
sealed with a bead of caulk 302 or alternatively suitable flashing
can be used. The finishing board 200, on the right side of the
drawing, finishes the run of boards 100 in a neat and workmanlike
manner.
[0045] Still referring to FIG. 5, the boards 100 and 200 are
fastened to joists 312 with standard decking screws 308 without
pre-drilling. However, in certain applications, the use of
predrilling may be desired and special screws provided with
self-sealants may be used. Screws 308 are typically stainless
steel, galvanized or ceramic coated for corrosion resistance. As
mentioned, they may also be of the self-sealing variety.
[0046] Reference is now made to FIG. 5A, which shows, in elevation,
the use of a metal flashing strip 306, lead or aluminum, as an
alternative to caulk 302. This is appropriate to lap siding, such
as clapboards or shingles.
[0047] Reference is now made to FIGS. 6 and 6A, which are both
diagrammatic elevational views showing an alternatitive snap-fit
joint configuration for assembling boards 300 in accordance with
the invention. Here, tongues 320 of each channel 330 are configured
and arranged to provide both camming action and flexibility so
that, as the channels 330 are slid toward one another to form a
joint, the camming action causes them to flex about their root
sections. This bending causes their ends to enter a relief area 350
(FIG. 6A) formed in each channel 330. Upon being pushed together
further, the flexed tongues snap back to complete the joint. The
snap-fit mechanism together with hidden nails 310 secure the boards
to the attachment surface. The base of channels 330 provide
sufficient surface area for nails 310 so that the surface areas of
the subject boards are flush at interlocked joints. Elastomeric
strips 202, shown as thin menisci, seal against moisture when
compressed by opposing tongues 320.
[0048] Reference is now made to FIG. 7, which is a diagrammatic
perspective and partially exploded view of an alternative
embodiment of the invention, combining boards 402 with channel
strips 404. Tongues 408 of channel strips 404 fit into
complimentary configured grooves 406. Water flows between boards
402 and into channels 404 which are angled to direct water away
from a sheltered area such as 102 (shown in FIG. 1).
[0049] Reference is now made to FIG. 8A, which shows, in elevation,
the boards 402 of FIG. 7 fastened to a joist 504 with standard
decking screws 502, without pre-drilling. FIG. 8B shows an enlarged
elevational view of boards 402 engaged with channel strip 404. If
desired, the spacing between the upwardly depending tongues may be
dimensioned to provide a tight butt joint between adjacent boards
to reduce the amount of moisture that can reach the channels
404.
[0050] Reference is now made to FIG. 9 which shows a diagrammatic
perspective view of an alternative embodiment for a multi-channel
sheet 606. Channel sheet 606 is extruded to include multiple
channels 602 and 604, and the like, which may be repeated to
sensible lengths. FIG. 10 shows a diagrammatic perspective view of
the boards of FIG. 7 joined lengthwise for extensive spans along
channel sheets 606 of FIG. 9. Water that may flow into a joint 702
is drained outward along channel sheet 606.
[0051] Reference is now made to FIG. 11A where the boards 402 and
802 are fastened to a joist 806 with standard decking screws 502,
with or without pre-drilling. Channel sheet 606 spans across the
bottom side of boards 802 and 402.
[0052] The finishing boards 802, on the left and right side of the
drawing, finish the run of boards 402 in a neat and workmanlike
manner. The joint between board 802 and vertical member 808 is
sealed with a bead of caulk 810.
[0053] Screws 502 are typically stainless steel, galvanized or
ceramic coated for corrosion resistance and may be
self-sealing.
[0054] Reference is now made to FIG. 11B, which shows an enlarged
elevational view of a board 402 with channel sheet 606. Here, the
channel defined between adjacent board edges can be more clearly
seen.
[0055] Reference is now made to FIG. 11C, which shows, in
elevation, the use of a metal flashing strip 804, lead or aluminum,
as an alternative to caulk 810. This is appropriate for lap siding,
such as clapboards or shingles.
[0056] FIG. 12 shows in diagrammatic cross section an elevational
view of boards 700 having an alternate channel configuration shown
generally at 702 that is provided with a flat elongated surface
area 704 to promote ease in fastening operations. A screw fastener,
or the like, may be inserted to underlying attachment structure
along the centerline to form a robust joint.
[0057] FIG. 13 shows a diagrammatic cross section yet another
elevatioinal view of boards 800 having an alternate channel
configuration shown generally at 802 that is provided with a
slightly angled elongated surface area 804 to promote ease in
fastening operations. Elastomeric seals may be provided in either
of the channels of FIGS. 12 and 13 as previously described and may
if sensible be extended over the overlapping fastening flat areas
to provide even more robust sealing joints.
[0058] It is important to note that this construction system is
completely compatible with the customary carpentry of balusters,
railings, skirts and the like.
[0059] The inventive boards can be produced using wood-composite
materials, having the advantage of being inexpensive while
retaining wood-like workability and appearance. One embodiment of
production includes a means for generating an easily transportable
composite mixture of wood particles and thermoplastic materials
(i.e., post-consumer recycled plastics), as illustrated in U.S.
Pat. No. 5,746,958. Such material is shaped with the desired
features (e.g., the channels shown in 206 and rounded edges 208) by
passing it under pressure, in a partially or fully melted state,
through a converging die shaped accordingly. This process is
similar to and may be adapted from an embodiment of U.S. Pat. No.
6,527,532. The extrusion process may also incorporate a means for
laminating the elastomeric layer 202, alternatively covering the
entire board. The layer 202 can alternatively be applied separately
from the extrusion process.
[0060] Such boards may be used to promote water resistant deck
surfaces, roofs, siding, boat decking, and boat hulls. The
dimensions of the boards can be appropriately sized in thickness,
width, and length, according to the particular application.
[0061] Based on the various described embodiments and teachings of
the invention, other variants of it will occur to those skilled in
the art and it is intended that such variants be within the scope
of the invention as claimed.
* * * * *