U.S. patent application number 11/565070 was filed with the patent office on 2007-08-23 for outdoor decking material.
Invention is credited to Charles E. Wheatley.
Application Number | 20070193145 11/565070 |
Document ID | / |
Family ID | 38227652 |
Filed Date | 2007-08-23 |
United States Patent
Application |
20070193145 |
Kind Code |
A1 |
Wheatley; Charles E. |
August 23, 2007 |
OUTDOOR DECKING MATERIAL
Abstract
An outdoor deck surface unit comprising a substrate support
member and a plurality of separate boards, with the plurality of
boards being unitized by being secured to the substrate in a
desired pattern. The deck surface unit is sufficiently large that
an entire deck surface is created relatively quickly, but being
sufficiently small that a deck surface unit is capable of being
readily lifted, moved, placed and handled by a single individual.
The substrate support member comprises plastic coated polyester and
is stapled to the separate boards.
Inventors: |
Wheatley; Charles E.;
(Cincinnati, OH) |
Correspondence
Address: |
PRICE HENEVELD COOPER DEWITT & LITTON, LLP
695 KENMOOR, S.E.
P O BOX 2567
GRAND RAPIDS
MI
49501
US
|
Family ID: |
38227652 |
Appl. No.: |
11/565070 |
Filed: |
November 30, 2006 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60754113 |
Dec 27, 2005 |
|
|
|
Current U.S.
Class: |
52/263 ;
52/311.2 |
Current CPC
Class: |
B29C 65/76 20130101;
B29K 2105/04 20130101; B29C 65/562 20130101; E04F 2201/0511
20130101; B29C 66/723 20130101; B29K 2309/08 20130101; E04D 11/005
20130101; B29C 66/71 20130101; B29C 66/727 20130101; B29C 66/71
20130101; E01C 5/001 20130101; B29K 2023/06 20130101; B29K 2023/12
20130101; B29C 66/71 20130101; B29C 66/71 20130101; B29C 66/71
20130101; B29C 66/71 20130101; B29K 2055/02 20130101; E04F 15/04
20130101; B29C 65/56 20130101; B29K 2049/00 20130101; B29K 2023/06
20130101; B29K 2067/00 20130101; B29K 2055/02 20130101; B29K
2023/12 20130101 |
Class at
Publication: |
052/263 ;
052/311.2 |
International
Class: |
E04B 7/00 20060101
E04B007/00; E04B 5/00 20060101 E04B005/00 |
Claims
1. An outdoor deck surface unit comprising: a substrate support
member; and a plurality of separate boards, the plurality of boards
being unitized by being secured to the substrate in a desired
pattern; the deck surface unit being sufficiently large that an
entire deck surface is created relatively quickly, but being
sufficiently small that a deck surface unit is capable of being
readily lifted, moved, placed and handled by a single individual;
the substrate support member is stapled to the separate boards.
2. The deck surface unit of claim 1, wherein: the plurality of
separate boards are sufficiently small in area to minimize the
effects of warpage on any individual board.
3. The deck surface unit of claim 2, wherein: the plurality of
separate boards are made of lumber of sufficient thickness to
resist warpage.
4. The deck surface unit of claim 3, wherein: the lumber is treated
to be resistant to outdoor conditions.
5. The deck surface unit of claim 1, wherein: the unit has the
shape of a hexagon.
6. The deck surface unit of claim 5, wherein: the boards include a
hexagonally-shaped center piece and trapezoidally-shaped boards
arranged in rows and extending parallel to the side edges of the
center piece.
7. The deck surface unit of claim 5, wherein: the boards are shaped
to define trapezoids of equal dimensions.
8. The deck surface unit of claim 7, wherein: the unit comprises
six sections, with three trapezoidally-shaped boards per
section.
9. The deck surface unit of claim 1, wherein: the substrate support
member is a flexible member.
10. The deck surface unit of claim 9, wherein: the substrate
support member is plastic coated polyester.
11. The deck surface unit of claim 1 which covers an area of from
about 2 square feet to about 6 square feet.
12. The deck surface unit of claim 11, wherein: each of the boards
is at least about 3/4 inch thick.
13. A deck system comprising a plurality of deck surface units in
accordance with claim 1.
14. The deck system of claim 13, wherein: the plurality of deck
surface units are held in position by a trim member extending
around the perimeter edge of the plurality of units.
15. An outdoor deck surface unit comprising: a substrate support
member; and a plurality of separate boards, the plurality of boards
being unitized by being secured to the substrate in a desired
pattern; the deck surface unit being sufficiently large that an
entire deck surface is created relatively quickly, but being
sufficiently small that a deck surface unit is capable of being
readily lifted, moved, placed and handled by a single individual;
wherein the substrate support member comprises plastic coated
polyester.
16. The deck surface unit of claim 15, wherein: the plurality of
separate boards are sufficiently small in area to minimize the
effects of warpage on any individual board.
17. The deck surface unit of claim 16, wherein: the plurality of
separate boards are made of lumber of sufficient thickness to
resist warpage.
18. The deck surface unit of claim 17, wherein: the lumber is
treated to be resistant to outdoor conditions.
19. The deck surface unit of claim 15, wherein: the unit has the
shape of a hexagon.
20. The deck surface unit of claim 19, wherein: the boards include
a hexagonally-shaped center piece and trapezoidally-shaped boards
arranged in rows and extending parallel to the side edges of the
center piece.
21. The deck surface unit of claim 19, wherein: the boards are
shaped to define trapezoids of equal dimensions.
22. The deck surface unit of claim 21 comprising six sections, and
three trapezoidally-shaped boards per section.
23. The deck surface unit of claim 15 which covers an area of from
about 2 square feet to about 6 square feet.
24. The deck surface unit of claim 23, wherein: each of the boards
is at least about 3/4 inch thick.
25. A deck system comprising a plurality of deck surface units in
accordance with claim 15.
26. The deck surface unit of claim 25 which covers an area of from
about 2 square feet to about 6 square feet.
27. The deck surface unit of claim 15, wherein: the substrate
support member is stapled to the separate boards.
28. A deck system comprising a plurality of deck surface units in
accordance with claim 27.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority to U.S. Provisional Patent
Application No. 60/754,113 filed on Dec. 27, 2005 entitled OUTDOOR
DECKING MATERIAL.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to outdoor decks. It has
become popular to build attractive, outdoor wooden decks. Often
they are attached to a home, but sometimes they are built to stand
alone. They are typically made from lumber which has been treated
to resist weathering.
[0003] While such decks are attractive, they are expensive to
build. One typically must build a supporting framework, and then
nail top boards to the framework. Even a relatively small deck may
cost $1,500-$2,500 to add to a home, if the work is done
professionally. If the work is done as a "do-it-yourself" project,
the lumber is still quite expensive, and the process of building
the deck is very time-consuming.
SUMMARY OF THE PRESENT INVENTION
[0004] The present invention comprises relatively small outdoor
deck surface units, which can be easily handled by a
"do-it-yourselfer," and which can be easily placed on a cement
slab, some other support or even directly on the ground, to create
an attractive outdoor deck, quickly and easily. Each unit comprises
a plurality of boards arranged in a desired pattern and secured to
an underlying substrate. Each unit is sufficiently large that an
entire deck surface can be created relatively quickly, but is
sufficiently small that each unit can readily be handled by a
"do-it-yourself" deck builder without undue hardship.
[0005] As a result of this invention, an unsightly concrete slab, a
prepared layer of sand or dirt or even an old unsightly wooden deck
can instantly be converted into an attractive deck by one simply
placing a plurality of individual decking surface units in an
adjacent fashion onto the unsightly surface.
[0006] These and other objects, advantages and features of the
invention will be more fully understood and appreciated by
reference to the written specification and appended drawings.
BRIEF DESCRIPTION OF DRAWINGS
[0007] FIG. 1 comprises a perspective view of a deck surface unit
made in accordance with the present invention.
[0008] FIG. 2 is a perspective view of the reverse side of the
surface unit from the side shown in FIG. 1 with a single joining
unit also being shown at one corner of the deck surface unity.
[0009] FIG. 3 is a side elevational view of the deck surface
unit.
[0010] FIG. 4 is a perspective view of an assembled deck, bounded
by an edging trim strip.
[0011] FIG. 5 is a perspective view of an alternative embodiment
deck with the individual surface units arranged in a different
manner.
[0012] FIG. 6 is a top perspective view of an alternative
embodiment individual decking unit of a different pattern.
[0013] FIG. 7 is a plan view of yet another alternative embodiment
deck surface unit.
[0014] FIG. 8 is a top plan view of an alternative embodiment deck
surface unit, with fragmentary portions of several adjacent units
also being shown in plan view, and with substrate members shown in
phantom.
[0015] FIG. 9 is a perspective view of an alternative embodiment
joining member.
[0016] FIG. 10 is a bottom plan view of an alternative embodiment
deck surface unit, utilizing a different type of substrate
member.
[0017] FIG. 11 is a cross-sectional, fragmentary view of the
substrate member, taken along plane XI-XI of FIG. 10.
[0018] FIG. 12 is a rear view of a further alternative embodiment
of the deck surface unit.
[0019] FIG. 13 is a close up view of the substrate used with the
further alternative embodiment of the deck surface unit.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0020] For purposes of description herein, the terms "upper,"
"lower," "right," "left," "rear," "front," "vertical,"
"horizontal," and derivatives thereof shall relate to the invention
as orientated in FIG. 1. However, it is to be understood that the
invention may assume various alternative orientations, except where
expressly specified to the contrary. It is also to be understood
that the specific devices and processes illustrated in the attached
drawings, and described in the following specification are simply
exemplary embodiments of the inventive concepts defined in the
appended claims. Hence, specific dimensions and other physical
characteristics relating to the embodiments disclosed herein are
not to be considered as limiting, unless the claims expressly state
otherwise.
[0021] In one embodiment, a plurality of individual weather-treated
boards 11-14, arranged in a predetermined pattern, are secured to
an underlying substrate member 20 to form a unit 1.
[0022] By arranging units 1 in a side-by-side fashion, one can
create an entire deck surface as shown in FIG. 4. Preferably,
adjacent deck units 1 are kept from moving apart either by tacking
a trim strip 40 around the perimeter of the arranged units 1 (FIG.
4), or by underlying each of the adjacent units along adjacent side
edges or corners with a small joining pad or unit 30 (FIGS. 2 and
3), or by underlying several or all of the units with one or more
pieces of double-faced adhesive 80 (FIG. 2) or some combination of
the foregoing. Another option is to underlie at least the perimeter
units with double-faced tape 80. Units, similarly made, of
different configurations, e.g. units 2 and 3 in FIG. 4, are used to
fill in small spaces left by the arrangement of adjacent decking
units.
[0023] Each of the boards 11-14 is preferably weather treated
lumber to be resistant to outdoor conditions. The boards can be
treated during manufacture, but units 1 can also be sold without
treatment, leaving treatment to the purchaser. It is preferably of
sufficient thickness to resist warpage. Each of the individual
boards 11-14 are preferably of sufficiently small area that the
effects of any warpage on individual boards are less likely to be
noticed. Most preferably, the individual boards, other than center
piece 11, are cut from 5/4 inch by 4 inch boards, which, in other
words, have a thickness of about 1 inch and a width of about 31/2
inches. In the pattern shown in deck surface unit 1, center piece
11 has to be cut from a somewhat wider board, but also of 5/4 inch
nominal thickness. If 1 inch thick boards are used, the final
thickness of the boards is about 3/4 of an inch.
[0024] In an alternative embodiment, the individual boards 11-14
(and 15 as illustrated in FIGS. 6-7) can be molded of a weather
resistant polymeric material. Structural foam polyethylene or
polypropylene might be used. UV stabilizers would be incorporated.
ABS and glass fiber reinforced urethanes and/or polyisocyanurates
might also be used. The relatively small size of the individual
boards 11-15 helps to minimize heat shrink and weather warpage
problems. Ceramic or regular or foam concrete might also be used to
make boards 11-15.
[0025] Each deck surface unit 1 is sufficiently large that it
covers a significant area, but is sufficiently small that a unit
can readily be lifted, moved, placed and handled by a single
individual. Preferably, each unit covers an area of at least about
2 square feet and no more than about 6 feet. More preferably, the
area covered by each unit is between 3 and 5 feet. Unit 1 as shown
in FIGS. 1-4 is a hexagon which is 15.5 inches on each side, and
therefore covers approximately 4.36 square feet. Preferred
embodiment unit 1 comprises a hexagonally-shaped center piece 11,
having a trapezoidally-shaped board 12 adjacent each edge of
hexagon 11. Each board 12 has a larger trapezoidally-shaped board
13 adjacent it, and each board 13 has a larger trapezoidally-shaped
board 14 adjacent it.
[0026] The illustrated substrate member 20 is preferably flexible
and, in one embodiment, slightly cushiony to absorb irregularities
in an underlying surface. It also preferably has a floor engaging
surface which affords some frictional resistance against deck
surface unit slippage during use. In preferred embodiment unit 1,
substrate 20 comprises a hexagonally-shaped piece of outdoor
carpeting having a polymeric backing surface 21 with a nap layer 22
projecting therefrom. The polymeric backing is preferably a rubbery
polymer backing. Boards 11-15 are preferably glued to the
polymeric, preferably rubbery, backing surface 21, with nap 22
facing away from the boards. Any adhesive which will resist the
conditions of outdoor use and adhere wood to a rubbery polymeric
material may be used. It has been found that a polyethylene
hot-melt is a satisfactory adhesive, though a preferred adhesive is
a moisture cured polyurethane adhesive.
[0027] An alternative to using outdoor carpeting for substrate
member 20 is to use "geo fabric" that includes a "fuzzy surface" on
one side. While less cushiony than outdoor carpet, it is
economically less expensive and easier to cut so that individual
units 1 can be cut. Geo fabric is woven from a very strong,
polymeric, narrow ribbon. Some geo fabric is available with a
"fuzzy surface" on one side. This is the type of geo fabric that is
preferred for use as substrate 20 in the present invention. The
individual boards 11-14 are adhered to the smooth side of the geo
fabric, such that the fuzzy surface acts as a friction surface to
prevent the individual decking units 1 from sliding, or at least to
minimize such slippage. A jute mat, polyester mat, polyethylene
mat, polypropylene mat or other flexible weather resistant
substrate, for example of the type used in quality indoor-outdoor
carpet backings might be used. Materials which deteriorate
relatively quickly in the elements, including some foam rubber
carpet backing materials, are preferably avoided, in order to have
a quality product.
[0028] The illustrated joining units 30 are simply small area
circles of a soft, fairly high friction, rubbery material. Each
circle is very thin, and has a relatively small area, just
sufficient to engage a portion of each of two or three adjacent
units 1. Double-faced tape or a bead of adhesive 80 (FIG. 2) can be
used in addition to or in place of units 30. A preferred
double-faced adhesive material is the tacky polyvinylbutyrate bead
material used in the auto industry to seal the perimeter of
windshields. This material comes in a 3/16 inch diameter bead,
rolled up with a silicone release paper tape. It could be applied
at the point of manufacture, but is preferably sold with units 1
for application in situ by the installer so the bead compresses
under unit 1 in conformity with irregularities in the underlying
surface.
[0029] As illustrated in FIG. 4, each deck unit 1 abuts an adjacent
deck unit 1 along a side edge. This leaves two different types of
gaps at the perimeter of an assembled deck surface, as shown in
FIG. 4. One is of a trapezoidal configuration, which can be filled
by a trapezoidally-shaped unit 2. The other is triangular, and can
be filled by a triangular-shaped unit 3. As mentioned above, a trim
strip 40 is then tacked to the perimeter of the assembled deck
surface to help hold it all together. In addition, joining units 30
are located at each corner of the adjacent units 1. The specially
shaped perimeter units 2 and 3 may also be adhered to a rather
stiff, thin plastic substrate which projects from the inside edge
of the perimeter unit underneath adjacent larger units. This helps
prevent the perimeter units from flipping if a person steps on the
outside edge, and it also helps to hold the smaller perimeter units
in place.
[0030] FIG. 5 shows an alternative arrangement of units 1, wherein
some are arranged side-by-side, while others are arranged
point-to-point. This leaves diamond-shaped openings in the interior
of the deck surface, and triangular-shaped openings along each
edge. By providing a plurality of triangular-shaped or "half
diamond" shaped units 4, a pair of such units arranged back-to-back
can take care of the gaps left in the interior of the deck surface,
while one of such units can take care of a triangular opening along
the edge.
[0031] FIG. 6 shows an alternative embodiment hexagonal-shaped
surface unit 1' made up of boards 15 which are all of the same size
and shape. Each board 15 is cut as a trapezoid. When cut from board
which is 31/2 inches wide, each trapezoid can have a top edge which
is 4 inches long and a bottom edge which is 8 inches long. The
diagonal edges are also 4 inches long. A deck surface unit 1' is
comprised of six sections, with three boards 15 in each section.
When each board is 31/2 inches wide, the length of each side of the
resulting hexagon is 12 inches, and the area covered by deck unit
1' is about 2.6 square feet. FIG. 7 shows an alternative embodiment
deck surface unit 1'' which is made out of precisely the same
trapezoidally-shaped unit 15 as is deck surface unit 1' of FIG. 6.
The boards 15 are arranged in a slightly different pattern,
however. Yet, the length of each of the hexagonal edges and the
area covered by deck unit 1'' are the same as for deck unit 1'.
[0032] One advantage to the alternative embodiment deck units 1'
and 1'' is that they can be made from individual boards which have
identical dimensions. This makes the job of cutting and handling
during manufacturing much easier. A second important advantage is
that individual deck units 1' and 1'' can be cut in half, or even
in individual triangular-shaped sections, by simply cutting through
substrate member 20 with a knife (this can also be done with
embodiment 1, if center board 11 is made in two equal halves). This
will be useful when arranging perimeter pieces. Yet another
advantage to deck surface units 1' and 1'' is that their overall
dimensions are such that four of them fit on a standard 36.times.48
inch pallet.
[0033] In an alternative embodiment deck surface unit 1''' (FIG.
8), the individual boards 11-14 are secured to a plurality of
separate substrate members 50, each comprising a separate molded
plastic rib. Each of boards 11-14 are tacked or glued to the ribs
50. In the hexagon shown in FIG. 8, each rib extends radially
outwardly from the center, along the seam between adjacent hex
segments. Each rib 50 includes an open socket 51 at each end, which
receives the upwardly extending post 61 of a triangular-shaped
joining member 60 (FIG. 9). Joining member 60 is preferably molded
of plastic, preferably the same type of plastic used to make molded
ribs 50.
[0034] The illustrated ribs 50 required for a deck surface unit
1''' can also be molded as a single integral unit, rather than as
separate units. FIG. 10 shows an alternative embodiment deck unit
1''' in which the individual boards 11-14 are adhered to an
integrally molded substrate 70. Substrate 70 is vacuum formed or
injection molded of plastic, and includes a center 71, outwardly
radiating arms 72, a joining member receiving aperture 73 at the
end of each arm 72, and a pair of downwardly projecting ribs 74 on
the bottom of each arm 72. The ribs 74 reinforce arms 72 and also
provide a support for deck unit 1''' (FIG. 11).
[0035] FIG. 12 illustrates another substrate 102 used with the
boards 11-15 to form a unit 100. The substrate 102 (FIG. 13) is
preferably formed of strands of polyester scrim 104 coated with
crossing and orthogonal strips of plastic 106 (e.g., vinyl or PVC).
The substrate 102 as described in this application is commercially
available from Markers, Inc. in Avon Lake, Ohio, under the name
Polyester Wind Screen. The substrate 102 is easy to cut, easy to
manufacture and is lighter than the other substrates described
above. Furthermore, the substrate 102 is thin and at least two
layers of material made of the strands of polyester scrim 104
coated with crossing and orthogonal strips of plastic 106 can be
cut on a single cutting step to form two substrates 102. Moreover,
a back lit template allows a person cutting the substrate 102 to
see through the substrate 102 for ease of cutting. Furthermore,
since the substrate 102 is light, the units 100 are easy to handle.
Preferably, the substrate 102 is stapled to the boards 11-15 using
staples 110 to connect the substrate 102 to the boards 11-15 to
form the units 100. In the illustrated embodiment, three staples
110 are used to connect the substrate 102 to each board 11-15.
[0036] Using the deck system of the present invention, any
individual can make a lovely wood surfaced deck in an afternoon. A
plurality of individual surface units can be placed on a concrete
slab. Alternatively, one can dig up a patch of grass and smooth a
dirt or sand surface to which individual deck surface units 1, 1',
1'', 1''' , 1'''', or 100 can be placed. One could also build a
plywood surfaced deck, and then cover the plywood with a plurality
of deck surface units. Joining members 30 or 60 are used to help
keep adjacent deck units from slipping relative to one another. In
addition, a perimeter trim strip can be tacked around the perimeter
of the assembled units to help hold them in place. Nails can be
nailed directly into the exposed side edges of the perimeter deck
units. When outdoor carpet substrate 20 is used, the surface units
can be reversed to provide an outdoor carpet surface instead of the
wood deck surface appearance. Using a flexible substrate,
especially a relatively thin material such as geo fabric or strands
of polyester scrim coated with a plastic, allows the units 1, 1',
1'', or 100 to conform somewhat to surface irregularities, and
allows the units to be cut into partial units with a knife or the
like.
[0037] It is to be understood that variations and modifications can
be made on the aforementioned structure without departing from the
concepts of the present invention, and further it is to be
understood that such concepts are intended to be covered by the
following claims unless these claims by their language expressly
state otherwise.
* * * * *