U.S. patent application number 13/295896 was filed with the patent office on 2012-03-29 for planks and/or boards.
Invention is credited to James Edward Douglass.
Application Number | 20120073225 13/295896 |
Document ID | / |
Family ID | 45869222 |
Filed Date | 2012-03-29 |
United States Patent
Application |
20120073225 |
Kind Code |
A1 |
Douglass; James Edward |
March 29, 2012 |
PLANKS AND/OR BOARDS
Abstract
A board comprises a front, a back, a first longitudinal side;
and a second longitudinal side; at least one of said longitudinal
sides comprising a groove to facilitate the junction to another
such board; wherein said board incorporates a backing layer of
primarily rigid plastics material and a further layer located over
said backing layer on said front being primarily of an elastomer;
said elastomer extending only over said front.
Inventors: |
Douglass; James Edward;
(Warwickshire, GB) |
Family ID: |
45869222 |
Appl. No.: |
13/295896 |
Filed: |
November 14, 2011 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
12094106 |
May 16, 2008 |
8065849 |
|
|
PCT/GB2006/004250 |
Nov 15, 2006 |
|
|
|
13295896 |
|
|
|
|
Current U.S.
Class: |
52/309.4 ;
52/309.1; 52/309.13; 52/588.1 |
Current CPC
Class: |
E04F 13/0878 20130101;
E04F 2203/04 20130101; E04F 15/105 20130101; E04C 3/29 20130101;
E04F 15/107 20130101; E04F 2201/0505 20130101; E04F 13/18
20130101 |
Class at
Publication: |
52/309.4 ;
52/588.1; 52/309.13; 52/309.1 |
International
Class: |
E04C 2/38 20060101
E04C002/38; E04C 2/02 20060101 E04C002/02; E04C 2/22 20060101
E04C002/22; E04C 2/20 20060101 E04C002/20 |
Foreign Application Data
Date |
Code |
Application Number |
Nov 24, 2005 |
GB |
0523912.4 |
Mar 25, 2006 |
GB |
0606030.5 |
Jul 13, 2011 |
GB |
1111994.8 |
Sep 29, 2011 |
GB |
1116785.5 |
Claims
1. A board comprising: a front, a back, a first longitudinal side;
and a second longitudinal side; at least one of said longitudinal
sides comprising a groove to facilitate the junction to another
such board; wherein said board incorporates a backing layer of
primarily rigid plastics material and a further layer located over
said backing layer on said front being primarily of an elastomer;
said elastomer extending only over said front.
2. A board according to claim 1, wherein said rigid plastics
material of said backing material is a rigid foam.
3. A board according to claim 1, wherein said groove exposes rigid
foamed plastics material.
4. A board according to claim 2, wherein said layer of primarily
rigid foamed plastics material has a shore D hardness of 35 to
75.
5. A board according to claim 1, wherein said further layer has a
shore A hardness of 20 to 90.
6. A board according to claim 1, wherein said further layer has a
shore A hardness of more than 35 and less than 90.
7. A board according to claim 1, wherein said further layer is an
inherently flexible layer.
8. A board according to claim 2, wherein said layer of primarily
rigid foamed plastics material is primarily polyurethane.
9. A board according to claim 8, wherein said layer of primarily
rigid foamed plastics material incorporates 20 to 50% fillers by
weight.
10. A board according to claim 9, wherein said fillers comprise one
or more from the group consisting of: ground glass, pulverised fuel
ash (PFA), and fibres.
11. A board according to claim 2, wherein said layer of primarily
rigid foamed plastics material incorporates reinforcing fibres.
12. A board according to claim 11, wherein said layer of primarily
rigid foamed plastics material incorporates glass reinforcing
fibres.
13. A board according to claim 11, wherein said layer of primarily
rigid foamed plastics material incorporates a rice based fibre.
14. A board according to claim 2, wherein said layer of primarily
rigid foamed plastics material incorporates 30 to 60% air by
volume.
15. A board according to claim 1, wherein said further layer is
primarily of polyurethane elastomer.
16. A board according to claim 1, where said further layer is
primarily of polyurea.
17. A board according to claim 15, wherein said polyurethane
elastomer incorporates no air bubbles.
18. A board according to claim 15, wherein said polyurethane
elastomer incorporates at least one filler selected from the group
comprising ground glass, water scavengers, liquid fire retardants,
powder fire retardants, recycled rubber, minerals and pulverised
fuel ash (PFA).
19. A board according to claim 1, further comprising a coating
provided over said further layer; said coating being at least in
part an aliphatic isocyanate.
20. A board according to claim 1, wherein said backing layer and
said further layer are chemically cross-linked; thereby no separate
adhesive links one layer to the other.
21. A board according to claim 19, wherein said coating and said
further layer are chemically cross-linked; thereby no separate
adhesive links one layer to the other.
22. A board according to claim 1, wherein at least said further
layer is homogeneous.
23. A board according to claim 1, wherein said backing layer and
said further layer act as an adhesive to one another.
24. A board according to claim 1, further comprising multiple
lateral projections on at least one longitudinal side of the board
and recesses on at least one opposite longitudinal side of the
board for mating engagement with the lateral projections of another
board.
25. A board according to claim 1, wherein said board is a cladding
board.
26. A moulding process of producing a board, comprising the steps
of selecting a mould for forming a board with a side with a groove
to facilitate the attachment of the board to another such board;
forming a layer which is primarily of an elastomer; forming a
backing layer which is primarily of rigid foamed plastics material;
and preventing said groove from being covered by said
elastomer.
27. A method according to claim 26, comprising the step of starting
the moulding process with an in-mould coating of aliphatic
isocyanate based medium.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part of U.S.
application Ser. No. 12/094,106, filed May 16, 2008, which is a
nationalization of PCT Application No. PCT/GB2006/004250, filed
Nov. 15, 2006, which claims priority to United Kingdom Application
Nos. 0523912.4, filed Nov. 24, 2005 and 0606030.5, filed Mar. 25,
2006, and also claims priority to United Kingdom Application Nos.
111994.8, filed Jul. 13, 2011 and 116785.5, filed Sep. 29, 2011,
all of the foregoing being incorporated herein by specific
reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The invention relates to decking planks and/or boards.
[0004] 2. Background to the Invention and Prior Art Known to the
Applicant
[0005] The following prior art documents are acknowledged:
JP10193962; JP09100615; GB1423146; EP1104830; GB2382598;
JP04228767; U.S. Pat. No. 6,427,395; U.S. Pat. No. 6,044,598;
WO98/26140; U.S. Pat. No. 5,713,165; U.S. Pat. No. 5,660,016; and
CA2370583.
SUMMARY OF THE INVENTION
[0006] In a broad independent aspect, the invention provides a
board comprising a front, a back, a first longitudinal side; and
second longitudinal side; at least one of said longitudinal sides
comprising a groove to facilitate the junction to another such
board; wherein said board incorporates a backing layer of primarily
rigid plastics material and a further layer located over said
backing layer on said front being primarily of an elastomer; said
elastomer extending only over said front.
[0007] In a further broad independent aspect, the invention
provides a cladding board comprising a side with a tongue and a
side with a groove or cut-out portion to facilitate the attachment
of the cladding board to another such cladding board; wherein said
board incorporates a backing layer of primarily rigid foamed
plastics material; and a further layer located over said backing
layer being primarily of an elastomer or polyurea; said groove
being of exposed rigid foamed plastics material without any
elastomer or polyurea covering being provided in said groove or
cut-out portion.
[0008] The provision of the rigid foamed plastics material layer
provides enhanced insulation for buildings or other structures
which are clad by this board. This would assist in retaining the
heat in a building during the colder months whilst retaining the
coolth during the warmer months. The provision of the foamed rigid
layer may also increase the rigidity of a building. The provision
of the elastomer located over the backing layer improves the
weather resistance. If the rigid foamed plastics material layer
were simply left exposed, the weather would erode the surface. It
also allows the layer which is most exposed to the weather
conditions to withstand cycles of expansion and contraction which
might arise even though they would arise at a much lower level than
a prior art wood-based cladding board. This configuration is also
particularly advantageous in terms of the inter-connection between
adjacent cladding boards.
[0009] In a subsidiary aspect, said layer of primarily rigid foamed
plastics material has a shore D hardness of 35 to 75. In this
range, the cladding board rigidity achieves optimal constructional
strength. It can for example be used as a conventional wood-based
cladding board, i.e., it can be cut or trimmed using carpenter's
tools.
[0010] In a further subsidiary aspect, said further layer is an
inherently flexible layer. In a further subsidiary aspect, said
further layer has a cushioning effect. In a further subsidiary
aspect, the inherent flexibility of said further layer is higher
than that of the rigid backing layer. This aspect particularly
improves its weather resistance properties due to for example the
impact of hail stones.
[0011] In a further subsidiary aspect, said further layer has a
shore A hardness of 35 to 90. This allows the layer to absorb
impacts and to weather in an improved manner. The likelihood of the
outer layer peeling back due to several cycles of differing weather
conditions is substantially reduced.
[0012] In a further subsidiary aspect, said layer of primarily
rigid foamed plastics material is primarily polyurethane. This
material is particularly suited for retaining its configuration and
has improved thermal properties. Furthermore, it allows the use of
a variety of fillers.
[0013] The cladding board may be further improved if the layer of
primarily rigid foamed plastics material incorporates 20% to 50%
fillers by weight. This reduces the percentage of plastics material
used whilst by selecting the appropriate filler improvements with
regards to the board's fire retarding properties, structural
strength and weather resistance are improved.
[0014] In a further subsidiary aspect, said fillers comprise one or
more from the group consisting of: ground glass, ground limestone,
mineral filler, flour, pulverised fuel ash (PFA), and fibres. The
provision of fibres is particularly advantageous in terms of
providing improved structural strength and since the further layer
may be provided without the use of any fibres, the risk of an
operator accidentally interacting with a fibre is almost entirely
done away with.
[0015] In a further subsidiary aspect, said layer of primarily
rigid foamed plastics material incorporates glass fibres. These
substantially improve the rigidity of the cladding board whilst an
operator can still cut or trim the board using carpenter's
tools.
[0016] In a further subsidiary aspect, the layer of primarily rigid
foamed plastics material incorporates a rice-based fibre. The use
of a natural product of this kind provides a product which is not
only of improved strength but with reduced negative environmental
impact.
[0017] In a further subsidiary aspect, said layer of primarily
rigid foamed plastics material incorporates 30% to 60% air by
volume. This allows the cladding board to appear relatively bulky
whilst being of sufficient strength. It also substantially improves
the thermal insulation properties of the board.
[0018] In a further subsidiary aspect, said further layer is
primarily of a polyurethane elastomer. This is particularly
advantageous in order to create a chemical bond between the backing
layer and the further layer. This does away with any requirement
for employing adhesives between the several layers.
[0019] In a further subsidiary aspect, said polyurethane elastomer
incorporates no air bubbles. This allows the elastomeric layer to
cope with weather fluctuations whilst a relatively smooth finish
can be obtained. Alternatively, the polyurethane elastomer layer
can incorporate in certain embodiments a relief in order for the
cladding board to take the shape and configuration of a wood-based
board, plastics, and/or stone.
[0020] In a further subsidiary aspect, said polyurethane elastomer
incorporates one or more fillers selected from the group comprising
ground glass, water scavengers, liquid fire retardants, recycled
rubber, minerals and pulverised fuel ash (PFA).
[0021] The provision of liquid and powder fire retardants is
particularly beneficial in terms of preventing the spread of a fire
within a structure which has been clad by the cladding board. It
also prevents an external fire from spreading into an enclosure
which has been protected.
[0022] In a further subsidiary aspect, the cladding board further
comprises a coating provided over said further layer, said coating
being at least in part an aliphatic isocyanate. This is
particularly beneficial for improving the aesthetic appeal of the
board but as well providing an extra protective layer.
[0023] In a further subsidiary aspect, said backing layer and said
further layer are chemically cross-linked; thereby no separate
adhesive links one layer to the other. This allows the cladding
board to appear as a single unitary composition despite the various
layers fulfilling different functions.
[0024] In a further broad independent aspect, the invention
provides a moulding process of producing a cladding board,
comprising the steps of selecting a mould for forming a cladding
board with a side with a tongue and a side with a groove to
facilitate the attachment of the cladding board to another such
cladding board; forming a layer which is primarily of an elastomer;
forming a backing layer which is primarily of rigid foamed plastics
material; and preventing said groove from being covered by said
elastomer.
[0025] The advantages achieved in the context of the cladding board
which have already been detailed above are in part due to the
manufacturing process adopted. Furthermore, it allows the
configuration of the board to not only achieve the improvements
mentioned above but it allows the board to be made to more closely
resemble wood-based cladding products.
[0026] In a further subsidiary aspect, the method comprises the
step of starting the moulding process with an in-mould coating of
aliphatic isocyanate based medium.
[0027] In a further broad independent aspect, the invention
provides a decking plank comprising a core which acts as a support
beam; one or more layers bonded to said core without the use of
releasable attachment means and one or the layer being an outer
slip resistant covering layer with a relief; characterised in that
at least one of said layers is relatively soft compared to said
core which is relatively hard; whereby the core acts as a support
beam and said at least one layer has a cushioning effect.
[0028] This configuration reverses conventional thinking in the
field of decking planks as expressed in U.S. Pat. No. 5,660,016
where a relatively hard outer shell protects a relatively soft
inner portion. This configuration is particularly advantageous
because it allows splinter free decking to be produced which may
also be made to resemble real wood or natural stone while
simultaneously being both slip resistant and cushioned in order to
be particularly comfortable and risk free to stand on. It will also
have fewer tendencies of fungi growing on the deck particularly
when the layers are of plastics material. The covering may also
achieve fire resistance when compared to conventional decking which
is often coated with a flammable varnish. The slip resistance of
the plank will be particularly advantageous when the surface is
wet. Whilst the decking plank may resemble real wood it is also
particularly advantageous because it may be configured to resemble
natural stone or clay tiles or the like.
[0029] In a subsidiary aspect, the or each layer is (or are)
homogeneous. This configuration is particularly advantageous
because it avoids the surface being abrasive or uncomfortable at
least underneath the foot of the user as would be the case for the
prior art non-homogeneous mixtures for example, where a mixture of
resin and glass solid spheres were suggested. It also allows the
relief to have natural-looking and soft-feeling depressions and
projections.
[0030] In a further subsidiary aspect, the core of the plank is
reinforced by fibres. This would allow the core to be strengthened
to act as the main support for the decking plank to allow it to
undergo the necessary bending moments when supported between two
joists.
[0031] In a further subsidiary aspect, said core is a support beam.
This would allow the layers to be cast over a pre-existing support
beam. This would avoid for example using particularly weather
resistant support beams since the layers would protect the support
beam against weathering.
[0032] In a further subsidiary aspect, said supporting beam is of
extruded plastics with tunnels through the beam. This would allow
for example electrics to be placed through the beam in
predetermined positions. It would also render the decking plank
relatively light compared to entirely filled planks.
[0033] In a further subsidiary aspect, said plank has at least a
top surface and a side surface which is covered by said one or more
layers. This configuration is particularly advantageous because it
protects not only the top surface but the side surface and
therefore further minimises any risk of slippage on the edges or of
splinters when handling the plank.
[0034] In a further subsidiary aspect, said core is entirely
encapsulated in a layer with cushioning effect. This provides the
advantage of further increasing the versatility of the plank, its
ease of handling and its properties irrespective of which side a
deck installer chooses to install the plank.
[0035] In a further subsidiary aspect, the decking plank further
comprises a plurality of layers; wherein one covering layer is of
so-called "filled elastomer" and an outermost layer is of greater
wear resistance with less filler than said layer or no filler at
all. This configuration is particularly advantageous because it
maximises the wear resistance of the plank, improves its cushioning
effect whilst simultaneously reducing the costs of the material for
production purposes.
[0036] In a further subsidiary aspect, said plurality of layers are
melded together without the use of adhesives. This configuration is
particularly advantageous because it allows the layers to act as
their own adhesives without the use of separate adhesives as the
layers set together during the manufacturing process.
[0037] In a further subsidiary aspect, one or more layers are of a
resilient foam material. This optional feature assists in achieving
a cushioned feel to the decking plank as well as retaining the
advantages discussed above in connection with the previous
aspects.
[0038] In a further subsidiary aspect, said core is a wood-based
support beam which has been treated against damp induced rot. This
is advantageous because it allows the plank to be used for
prolonged periods in a humid environment such as a garden.
[0039] In a further subsidiary aspect, the plank further comprises
multiple lateral projections on at least one side of the plank and
recesses on at least one opposite side of the plank for mating
engagement with the lateral projections of another plank. This
optional configuration is particularly advantageous because it not
only allows neighbouring planks to be secured to one another but it
also allows them to be secured in predetermined relative positions
so that no horizontal adjustment is required.
[0040] In a further subsidiary aspect, said plank further comprises
heating means. This configuration is particularly advantageous
because it allows decking planks which are suitable for use
outdoors (or indoors) to thaw any ice or snow accumulating on the
deck. It also allows the deck to be used in cold temperatures so
that users in the vicinity of the deck may be warmed by the deck
itself. Such decks may become complimentary to gas fired patio
warmers or even render these redundant.
[0041] In a further subsidiary aspect, said supporting core is a
beam whose underside incorporates open troughs separated by
substantially vertical (in use) webs. This configuration is
particularly advantageous because it reduces the overall weight of
the decking plank whilst maintaining its strength. The exposed
troughs also allow electrical wiring to be fitted and effectively
hidden by the plank even after the planks have been installed.
[0042] In a further subsidiary aspect, one or more of the plank's
sides incorporates or incorporate grooves. This would be
particularly advantageous because it would accommodate hidden
fixing.
[0043] In a further subsidiary aspect, the invention provides a
decking plank comprising a support beam, characterised in that said
decking plank further comprises heating means. This combination of
features is particularly advantageous because it allows decking
planks which are suitable for use outdoors (or indoors) to thaw any
ice or snow accumulating on the deck. It also allows the decking to
be used in cold temperatures so that users in the vicinity of the
deck may be warmed by the deck itself.
[0044] In a subsidiary aspect, in accordance with the invention's
second broad independent aspect, said support beam incorporates
grooves in which said heating means are placed so would allow the
heating means to be accurately located within the plank.
[0045] In a further subsidiary aspect, the top portion of the plank
is covered by a layer which is relatively soft compared to the
support beam. This feature is particularly advantageous because it
allows the decking plank to feel softer to a user which will
further increase his/her comfort as well as avoiding the risk of
injury from accidentally rubbing against a hard top or receiving
splinters from a wooden decking plank.
[0046] In a further subsidiary aspect, said encapsulating layer
acts as a cushion. This would also be particularly advantageous in
terms of comfort for a user and would further reduce any risk of
user accidents.
[0047] In a further subsidiary aspect, said heating means are
electrical heating means and the plank incorporates either recessed
or projecting or both recessed and projecting electrical contacts
to allow the location of neighbouring planks and electrical contact
between neighbouring planks.
[0048] In a further subsidiary aspect, the plank comprises a
covering layer and the top surface of the plank incorporates
recessed portions in a covering layer indicating suitable locations
for the insertion of one or more screws or the like.
[0049] This avoids a user inadvertently severing the heating means
during installation of the deck. It also avoids any requirement of
having to use warning stickers indicating where it would not be
suitable to insert screws. Alternatively, a template may be
provided.
[0050] In a further subsidiary aspect, said decking plank
incorporates a covering layer and lighting means embedded into said
covering layer. The covering layer can, for example, serve as a
waterproof barrier to prevent the corrosion of the lighting means.
This configuration can also limit breakage of the lighting
means.
[0051] In a further subsidiary aspect, said decking plank
incorporates a covering layer and alarm components embedded into
said covering layer. This would allow the alarm components to be
protected from corrosion and from breakage whilst adding a
potential invisible extra safety component to a decking plank.
[0052] In a further broad independent aspect, the invention
provides a method of producing a decking plank, comprising the
steps of:
[0053] selecting a support beam and an electrical component;
[0054] placing said support beam and electrical component in a
mould;
[0055] filling said mould in order to cover said electrical
component; and
[0056] removing said cast decking plank from said mould.
[0057] This method is particularly advantageous because it allows
as many electrical components as necessary to be placed and secured
in close proximity to a support beam of a decking plank. It
provides protection for electrical components against corrosion and
accidental damage. It also prevents accidental harm occurring to
users of the deck.
[0058] In a further broad independent aspect, the invention
provides a decking plank comprising a support beam, one or more
electrical components secured to said decking plank, a covering
layer cast onto said support beam and one or more electrical
components; whereby said covering layer secures said electrical
components in position. This configuration also allows a wide
variety of electrical components being placed in a wide variety of
locations. It also allows the electrical components to be protected
whilst avoiding them causing damage to the users of the deck.
BRIEF DESCRIPTION OF THE FIGURES
[0059] Various embodiments of the present invention will now be
discussed with reference to the appended drawings. It is
appreciated that these drawings depict only typical embodiments of
the invention and are therefore not to be considered limiting of
its scope.
[0060] FIGS. 1a to 1f show four separate embodiments of a decking
plank in cross-section;
[0061] FIG. 2 shows a cross-sectional view of a further embodiment
of a decking plank;
[0062] FIG. 3 shows a cross-sectional view of a further decking
plank;
[0063] FIG. 4 shows a cross-sectional view of a further decking
plank;
[0064] FIG. 5 shows a cross-sectional view of a further decking
plank;
[0065] FIG. 6 shows a cross-sectional view of a further decking
plank;
[0066] FIG. 7 shows a part cross-sectional view of an arrangement
of decking planks on a joist with an electrical contact projection
and an electrical contact recess to permit location and electrical
contact between neighbouring planks. The planks of FIG. 7 are in
accordance with a further embodiment of the invention.
[0067] FIG. 8 shows an arrangement of neighbouring decking planks
in part cross-sectional view with an exposed cable connector
between neighbouring planks. The decking planks of FIG. 8 are in
accordance with the seventh embodiment of the invention.
[0068] FIG. 9 shows a decking plank in cross-sectional view in
accordance with a further embodiment of the invention;
[0069] FIG. 10 shows a further cross-sectional view of a decking
plank in accordance with a further embodiment of the invention;
[0070] FIG. 11 shows a cross-sectional view of a decking plank in
accordance with a further embodiment of the invention;
[0071] FIGS. 12a, b and c show a schematic plan view of decking
planks equipped with heating wires. The decking planks of FIGS.
12a, b and c respectively show further embodiments of the
invention;
[0072] FIG. 13 shows a cross-sectional view of a decking plank in
accordance with a further embodiment of the invention;
[0073] FIG. 14 shows a cross-sectional view of a decking plank in
accordance with a further embodiment of the invention;
[0074] FIG. 15 shows a cross-sectional view of a decking plank in
accordance with a further embodiment of the invention;
[0075] FIG. 16 shows a cross-sectional view of a decking plank in
accordance with a further embodiment of the invention;
[0076] FIG. 17 shows a cross-sectional view of a decking plank in
accordance with a further embodiment of the invention;
[0077] FIG. 18 show a cross-sectional view of a decking plank in
accordance with a further embodiment of the invention;
[0078] FIG. 19 shows a perspective view of two decking planks
joined together by a T-junction member;
[0079] FIG. 20 shows a cross-sectional view of a decking board with
channels for allowing the circulation of water/air;
[0080] FIG. 21 show two cross-sectional views of a decking plank
with pipes;
[0081] FIG. 22 shows first embodiment of a junction mechanism for
water/air flow decking boards;
[0082] FIG. 23 shows a side elevation view of a threaded collar
used in the junction mechanism of FIG. 22;
[0083] FIG. 24 shows a second embodiment of a junction
mechanism;
[0084] FIG. 25 shows a third embodiment of a junction
mechanism;
[0085] FIG. 26 shows a fourth embodiment of a junction
mechanism;
[0086] FIG. 27 shows a fifth embodiment of a junction
mechanism;
[0087] FIG. 28 shows a cross-sectional view of a cladding
board;
[0088] FIG. 29 shows a perspective view of the end of a cladding
board;
[0089] FIG. 30 shows a perspective view of the end of a cladding
board in accordance with a further embodiment of the invention;
[0090] FIG. 31 shows a perspective view of the end of a cladding
board in accordance with a further embodiment; and
[0091] FIG. 32 shows a cladding board according to a further
embodiment of the invention.
DETAILED DESCRIPTION OF THE FIGURES
[0092] FIG. 1a shows a decking plank 1 in cross-section. This
decking plank has a substantially rectangular cross-section with a
substantially rigid support beam 2, encapsulated in a covering
layer 3. On top of the covering layer 3, a further covering layer 4
is provided which extends only across the top surface of the plank.
The embodiment shown in FIG. 13 shows the further covering layer of
the embodiment of FIG. 1a extending at least partially down the
sides and/or ends of the plank. Alternatively, the further covering
layer may extend all down the sides and/or ends of the plank. The
support beam forms a strong hard core to support foot fall. The
support beam may be of timber, plywood or an extruded material such
as an extruded beam made out of plastics. FIG. 1a shows a support
beam without a hollow core in order to allow the screwing and
retention of a screw into the covering layers and support beam.
Alternatively, as shown in FIG. 14, a hard core may be hollow with
a number of tunnels such as tunnel 201. Layer 202 encapsulates the
hard core as in previous embodiments and an upper layer 203 with a
softer walking surface is provided.
[0093] Returning to the description of FIG. 1a, layer 3 may be a
"filled elastomer". The elastomer may preferably be of
polyurethane. The filler is for example, pulverised fuel ash. It
may also for example include calcium carbonate.
[0094] The upper layer 4 may be of a purer polyurethane material so
as to have a greater resistance to wear. The upper layer of the
decking material may incorporate an array of troughs and peaks
which may also take the shape of the grains of an antique piece of
wood or a natural stone, clay tiles or the like. The shape of the
plastics material of the covering layers may be achieved by using
appropriate moulds into which the plastics material is injected
around the plank of timber for example, and once set, is removed to
reveal the relief of the top surface. The relief of the softer top
surface will also assist in the non-slip properties of the covering
layers. The "filled polyurethane" may be blown.
[0095] As an alternative to the embodiment of FIG. 1a, FIG. 1b
shows a decking plank 5, with a support beam 6 entirely
encapsulated within a single layer of homogeneous covering material
7, which may be of the "blown" type with "filled polyurethane". The
support beam may be of blown "filled polyurethane"; whereby the
density of the support beam is much lower than the density of the
covering layer.
[0096] Side portions 8 and 9 of the plank are covered by the
plastics material. The invention envisages embodiments where only
the top surface of the supporting beam and side portions 8 and 9
are covered by the protective material.
[0097] In a further embodiment, FIG. 1c shows a support beam 10 and
an upper top surface only covering layer 11 which together form a
decking plank 12. The upper layer 11 may be cast on top of the
support beam or alternatively glued onto the support beam.
[0098] FIG. 1d shows a support beam 13 which may be of a laminate
timber kind covered by a covering layer 14 entirely encapsulating
the support beam. In this embodiment, the upper surface may be a
soft surface when compared to traditional timber. It will
nevertheless retain the looks of real wood and will be classified
as slip-resistant particularly due to the relief. The plastics
material used may be selected to have fire-resistant/fire retardant
properties.
[0099] FIG. 1E shows a decking plank comprising a support beam 15
and a covering layer 16 of cushion material applied to the top,
sides, and end portion of the beam only. This configuration is
particularly advantageous to firstly reduce cost of the overall
item by reducing the amount of covering material used, and secondly
to allow a resilient, and perhaps decorative and non-slip layer to
be used on exposed parts, whilst providing a non-resilient surface
(the "bottom") to allow firm fixing to a sub-structure.
[0100] FIG. 1F illustrates a decking plank wherein the structural
support beam 17 is itself comprised of a filled elastomer, such as
polyurethane, i.e. without a wooden core. One or more surfaces of
the plank have a covering layer, 18, as above.
[0101] The plastics material used may be selected to have
fire-resistant/fire retardant properties.
[0102] FIG. 15 shows a decking plank generally referenced 204 with
a hard core 205 which may be an extruded plastics beam with on its
lower portion a number of longitudinal troughs 206. Over the top
and side surfaces of the hard core, there is provided a softer
walking surface 206. The harder core may be cast into the softer
"face".
[0103] As can be seen in FIG. 16, trough 206 is closed towards the
ends such as end 208. FIG. 16 also shows that top layer 207 also
covers the end as well as the sides in this embodiment.
[0104] The invention also envisages a retro-fittable sheet shaped
and configured to fit over the top surface of a decking plank and
its side surfaces which may be glued or stapled to a support
beam.
[0105] It is also envisaged that an outer colour resistant layer is
provided.
[0106] Furthermore, the invention envisages the incorporation of
both heating and lighting in the same decking board plus optionally
an alarm in the same decking board.
[0107] FIG. 17 shows a further decking plank generally referenced
209 with side grooves 210 and 211. The grooves may be located in
one or both sides to accommodate hidden fixing.
[0108] The decking plank of the invention does not necessarily need
to have a separate wooden or metallic support beam. It may be
sufficient for layer 202 for example, to be strong enough on its
own. In other words, the filled "encapsulating resin" may be
strengthened by, for example, the use of fibres or any other
appropriate strengthening material.
[0109] Furthermore, the covering of the decking plank may
preferably have a Shore factor (A) within the range of around 20 to
around 90 Shore (A).
[0110] FIG. 2 shows a decking plank generally referenced 101 with a
support beam 102 and a covering layer 103. The covering layer 103
may be a "filled elastomer". The elastomer may be of polyurethane.
The filler is for example, pulverised fuel ash. It may, for
example, include or be of calcium carbonate. The upper layer 104
which covers only the top portion of the decking plank may be of a
purer polyurethane material so as to have greater resistance to
wear and to achieve a cushioning feeling when compared to a layer
which would not be of such purity of polyurethane.
[0111] The upper layer of decking material may incorporate an array
of troughs and peaks that may also take the shape of the grains of
an antique piece of wood, or natural stone, or clay tile. The array
of troughs may be designed to avoid the electrical heating wires
105 and 106 so that the user when given instructions to insert
screws only into pre-recessed portions of the decking plank would
avoid any damage occurring to the electrical heating wires. Whilst
electrical heating wires have been illustrated, other forms of heat
exchangers are envisaged such as an arrangement of pipes for
transmitting heat from a circulating fluid. In the summer such a
heating arrangement may also be used as a solar panel.
[0112] The support beam 102 may be devoid of any chemicals which
are typical in decking planks to allow them to be preserved in the
outside environment. This is because the elastomer itself can act
as a barrier and protect the decking plank.
[0113] FIG. 3 shows a decking plank 107 with a support beam 108,
and two electrical wires 109 and 110. The wires 109 and 110 may be
a single wire which loops around the top surface of the support
beam. The covering layer may be a hard plastic layer. The
electrical components are shown on the top half only of the decking
plank in this embodiment.
[0114] FIG. 4 shows a decking plank 112 with a support beam 113 and
an encapsulating covering layer 114 in which a light source 115 is
embedded. The light source is in fact partially within the layer
and partially outside the layer.
[0115] FIG. 5 shows a decking plank 116 with a support beam 117
with a number of grooves such as grooves 118 and 119 in which are
provided recessed electrical components 120 and 121. A covering
layer 122 entirely encapsulates the support beam in order to
provide an environmental barrier between the support beam and the
outside environment. The covering layer also entirely masks the
presence of the electrical components.
[0116] FIG. 6 shows a decking plank 123 with a support beam 124 and
a number of wire portions 125, set within an encapsulating layer
126. The layer incorporates a number of outer recess portions 127
and 128 which mark the location for the insertion for the screws
129 and 130.
[0117] When the screws 129 and 130 are inserted at these locations,
they avoid accidentally severing the electrical components 125 in
FIG. 7. Two side portions 131 and 132 of neighbouring decking
planks are illustrated which respectively incorporate a projecting
member 133 and a recess 134. Electrical contact means are also
envisaged at appropriate locations of the recess 134 and projection
133 to allow electrical currents to pass across the junction
between neighbouring planks. The projection and recess arrangements
shown also allow neighbouring planks to be securely fitted onto
each other. It is also envisaged to support the planks on joists
such as joist 135.
[0118] FIG. 8 shows neighbouring decking plank portions 136 and 137
supported on joists 138 and 139. Exiting from the underneath
regions of the decking plank portions are wires 140 and 141
allowing an electrical contact to be achieved across neighbouring
planks. A releasable external connector 142 is provided at the end
of wires 140 and 141.
[0119] FIG. 9 shows the decking plank 143 with a support beam 144
and a covering layer 145 which is of translucent plastics material.
The lighting sources 146, 147 and 148 are each entirely located
within the covering layer 145.
[0120] FIG. 10 shows a decking plank 149 with an arrangement of
sensors 150, 151 and 152 located on the top surface of the support
beam 153. The sensors may be suitable to arrange the triggering of
an alarm 154 when, for example, they sense that a certain weight is
placed on the decking plank. This might have a particularly useful
application when the decking plank forms part of a deck located in
the vicinity of the house which would activate an alarm when
would-be intruders stand on the deck.
[0121] FIG. 11 shows a deck 155 with a supporting beam 156 and a
covering layer 157. Within the covering layer there is provided a
radio receiver 158 and a loudspeaker 159.
[0122] The process of manufacture of the previous decking planks
may involve first the selection of an appropriate support beam such
as an untreated wooden plank of decking following this first step,
any appropriate electrical component may be placed onto the support
beam prior to placing into a mould for casting material onto the
support beam to achieve the dual protection of the support beam and
electrical components. The mould may be provided with appropriate
shapes to mimic antique wood, stone or terracotta tiles and to
indicate the locations for inserting screws. Other suitable mould
configurations may be envisaged.
[0123] FIGS. 12a, 12b and 12c show the support beams 160, 161 and
162 respectively on which heating wires 163, 164 and 165 are
respectively placed. The wires may incorporate any number of
undulations of, for example as in FIG. 12a, approximately ten
undulations per metre. FIG. 12b shows two separate wires 164a and
164b extending in a straight line along the length of a relatively
wide support beam. In FIG. 12c the electrical heating means 165
forms a C-shape. The heating means of FIG. 12c is provided in a
parallel electrical configuration whilst the heating means of FIGS.
12a and 12b are provided in a series of electrical
configurations.
[0124] It is also envisaged that a conduit such as a hollow tube
may be cast in with the layers of plastics covering to allow
heating cables to be slid through after the decking plank is
formed.
[0125] FIGS. 18a and 18b show two portions of two decking planks
where the projections of decking plank 212 such as projections 213
and 214, are sized and shaped to fit into corresponding recesses
215 and 216, located on the side of decking plank 217. Projections
such as projection 213 incorporate lateral wings 218 and 219, which
allow the projection to be locked in place when forced into a
recess such as recess 216 where corresponding side cut-outs such as
cut-out 220 are provided. In this embodiment, plank 217
incorporates a covering layer 221 of polyurethane of a thickness
selected within the range 2 to 7 mm.
[0126] FIG. 19 shows two planks of the kind shown in FIG. 18a and a
T-shaped member for insertion into apertures in the sides of the
planks in order to secure them together in a so-called invisible
manner.
[0127] Whilst the previous embodiments envisage in particular the
use of resistance heating, it is also envisaged to use fluid heated
decking such as water heated decking or hot air heated decking. It
is envisaged that the decking boards incorporate pipes or an
extruded hollow support that can not only support the board but act
as a water/air manifold.
[0128] FIG. 20 shows a board 301 with an extruded core region 302
with a number of tunnels to commit the flow of liquid or air so
that the board can act as a heat exchanger. The core region is
encapsulated in resin in region 303 and incorporates a relatively
soft top layer 304.
[0129] FIGS. 21a and b show two further embodiments of a heated
decking board where pipes are cast into resin. The board of FIG.
21a shows round pipes 305 whereas the board of FIG. 21b
incorporates square pipes 306.
[0130] A wide variety of junction mechanisms are envisaged between
neighbouring pipes or boards. For example, FIG. 22 shows two boards
307 and 308 supported on a joist at a junction region where a
threaded collar 309 is incorporated. The threaded collar
incorporates a flange 310 as shown in FIG. 23. It also incorporates
threads on either side of the flange 310. Said threads on each side
of the flange are envisaged to meet with hollow cores of two
neighbouring boards at the same time. The flange may be faceted in
order to allow screwing in with ease by the use of a spanner.
[0131] FIG. 24 shows a further embodiment of the junction mechanism
between two neighbouring boards 311 and 312. Each board
incorporates a cast in connector 313 and 314 which permit a water
tight attachment to a short tube which is slotted between the
connectors.
[0132] FIG. 25 shows a further junction mechanism where
encapsulated pipes or a hollow extruded support is envisaged and
the connector is in the form of a tube 315 with an arrangement of
O-rings such as O-ring 316 which are sized and shaped to provide a
water tight attachment between the two decking boards.
[0133] FIG. 26 shows two neighbouring boards 317 and 318 and a tube
319 which is simply glued into the channels provided in each
decking board.
[0134] FIG. 27 shows the ends of manifold pipes with greater
diameters at their connecting extremities in order to locate a pipe
320 which may be glued into position.
[0135] It is envisaged that the connector pipes may or may not be
flexible.
[0136] The invention also envisages that the fluid flowing in the
decking boards may either be heated or cooled in order to act
either as a heater or as a cooler. The invention envisages that
optionally the decking may be located around a swimming pool in the
summer and a pump may be positioned between the decking boards and
the water of the swimming pool so that the decking boards may be
cooled and simultaneously the water of the swimming pool may be
heated by the arrangement.
[0137] Plastic pipes (possibly 2) cast in the covering layer acts
as both a support beam as well as a fluid conduit.
[0138] FIG. 28 shows a section 401 of a typical board which may be
used for cladding according to the invention. It incorporates a
backing layer 402, a further layer 403 and a coating 404. The
backing layer 402 is of filled polyurethane rigid foam. This layer
may itself have a thickness of between 10 mm and 30 mm. It has a
relatively large proportion of air bubbles such as air bubble 405
distributed randomly throughout the layer. The air bubbles or
closed cells of gas are of greater size in the centre of the
backing layer whilst they are compressed in the outer portions of
the backing layer. This allows the material to be denser in the
outer portions compared to the core of the backing layer where the
cells occupy a greater volume. The content of air in this layer may
be between 30% and 70% in volume. In addition to the air bubbles a
number of fibres such as fibres 406 are provided throughout the
layer in order to increase its rigidity. The fibres may be of
chopped glass fibre strands or other appropriate man-made fibrous
material. Alternatively, a natural fibre such as that obtained from
rice husks might be employed to provide the necessary increased
rigidity. In addition to the fibres, other fillers are envisaged.
In this layer of the cladding board 20% to 50% fillers by weight is
envisaged. The fillers may be mineral fillers coupled with ground
glass or pulverised fuel ash (PFA). In addition, the backing layer
which could also be referred to as a core layer may employ fire
retardants.
[0139] Layer 403 is provided to cover the backing layer with
regards to at least its top face. Layer 403 may be either an
unfilled or a filled polyurethane elastomer. This elastomer may be
pigmented. It may also contain fire retardants in either liquid or
powder form along with other fillers such as water scavengers,
recycled rubber, further elastomers, or even minerals. The shore A
of the layer 403 may be selected between 35 and 90.
[0140] Alternatively, layer 403 may be of or incorporate
polyurea.
[0141] The further layer may alternatively have a much higher
inherent flexibility. The shore level may be selected to offer a
cushioning effect. The inherent flexibility of the further layer
may be higher than that of the rigid backing layer. This aspect
particularly improves its weather resistance properties due to for
example the impact of hail stones.
[0142] Due to the selection of materials for both layer 402 and
layer 403 chemical cross-linking arises which creates excellent
adhesion between the core and its topping without any requirement
for a separate adhesive.
[0143] Optionally, a further top layer is provided such as top
layer 404 which provides an improved finish. This top layer may be
based on aliphatic isocyanate. Other materials of a similar
category may be employed in this context. This selection of
material however is particularly suited for cross-linking with
layer 403 in order to provide a layer-wise construction which holds
together as an integral unit without the use of adhesives. The
thickness of layer 404 may be much less than a millimetre and
typically of the order of the thickness of a typical paint. Layer
403 however is preferably of 1 mm to 5 mm in thickness.
[0144] The process which is preferred in the production of the
cladding board is a moulding process. The first step in the process
is to place an in-mould coating consisting of an aliphatic
isocyanate based medium applied in one or more full or partial
layers (each layer having a thickness similar to that of paint).
Layer 403 which might be a hybrid polyurethane is applied to
cross-link with the coating 404 to form a hard or alternatively a
resilient backing to the coating. Once this is applied, another
form of polyurethane is applied. This polyurethane is that of layer
402 and would contain a wide spectrum of fillers. This layer would
also readily cross-link with the previous layer 403 during the
curing process. In order to control the expansion of the foam
polyurethane an encapsulating mould box is employed which
constrains the expansion within the mould itself. The cladding
board lends itself to being cut or trimmed using carpenter's
tools.
[0145] FIG. 29 shows a cladding board 407 with a filled
polyurethane rigid foam layer 408 in which are formed a tongue 409
and a groove 410 in its respective upper and lower side. The groove
410 may either be formed during the moulding process or cut out as
a separate step in the manufacturing process. Directly over the
outer face of layer 408, there is provided a polyurethane elastomer
411 which protects and seals the closed or open cell portions of
layer 408. In this configuration layer 411 covers the outside
portion 412 of tongue 409. This configuration may facilitate an
improved attachment of the tongue into the groove of a
corresponding cladding board.
[0146] FIG. 30 shows a further cladding board generally referenced
413 with a polyurethane elastomer provided on both the outer and
inner surfaces of tongue 414.
[0147] In a further embodiment, as shown in FIG. 31, both the
tongue and the groove can be entirely free of any polyurethane
elastomer. Elastomer 415 of cladding board 416 is limited to the
outer most surface of the board.
[0148] FIG. 32 shows a cladding board with a front face 418 of
polyurethane elastomer 418 and a backing layer 419 of closed-cell
foamed polyurethane. Closed-cell foamed polyurethane is potentially
an inventive option for any of the preceding embodiments. The rear
face 420 of the backing layer is sloped. In a lower portion of the
board, a cut-out portion 421 is provided. A tongue 422 is provided
on one side of the lower portion whilst said cut-out portion 421
fulfils the function of a groove.
* * * * *