US20060137265A1

US20060137265A1 - Cover, a board assembly and a method for protecting a board

Info

Publication number: US20060137265A1
Application number: US11/008,875
Authority: US
Inventors: Thomas Schulner; Alkiviadis Dimakis
Original assignee: Individual
Current assignee: Weyerhaeuser Co
Priority date: 2004-12-09
Filing date: 2004-12-09
Publication date: 2006-06-29

Abstract

A cover, a board assembly and a method for protecting a board are provided. In an embodiment, one or more boards are adjacent lengthwise, as in a floor of a deck or wall. A top portion of each of the boards is trimmed proximate to lengthwise edges. In an alternate embodiment, the boards are trimmed prior to assembly of the deck to create a groove along each of the edges. A cover, constructed from a wood/plastic composite, is placed on each of the boards. The cover extends across each of the boards' top surface and into the grooves created by trimming of the board. The cover may be secured to the board via an adhesive and/or a fastener and limits direct contact between the board and, for example, ultra-violet rays and/or precipitation. Accordingly, a deck utilizing one or more covers may be used for a prolonged period of time.

Description

FIELD OF THE INVENTION

This invention relates generally to protection of a board of, for example, a deck or wall via installation of a cover on the board. More specifically, the board may be trimmed at edges to allow placement of the cover on the board. The cover prevents the board from the effects of elements and enables prolonged use of the deck or wall.

BACKGROUND OF THE INVENTION

A typical deck floor or wall consists of two or more boards placed adjacent to one another lengthwise. Adjacent edges of the boards are placed at a close distance to one another to prevent objects from falling between the boards. In the case of a deck, each of the boards has a top surface upon which a user, for example, stands, walks, or the like. The top surface of the deck is susceptible to precipitation as well as other weather conditions. For example, exposure to heat and/or solar radiation can cause the boards to shrink. Exposure to moisture can cause warping of boards. In addition, moisture causes expansion of the boards such that the boards expand into the space between one another. As a result, debris and other contaminants can become caught between the boards. These particles can cause structural deterioration of the deck. Removing these particles can be a labor-intensive task and one which can be damaging to the deck depending on a type of method chosen for removal.
When a deck surface or wall is damaged, an owner is forced to repair the deck or wall, or, as a more costly alternative, replace the deck or wall. A factor in the high cost of replacing a deck or wall is the cost of natural woods, such as pine, fir, cedar or the like. Composite or engineered woods are desirable for deck construction due to their strength. However, these types of woods are treated with preservatives which typically wash away, or dissipate, when exposed to precipitation. A need exists, therefore, to protect a surface of boards of a deck floor or a wall from damages caused by weather-related effects and/or other conditions. A further need exists to utilize boards constructed from engineered woods for manufacturing of a deck wherein preservatives associated with the engineered woods are not at risk of contact with precipitation.

SUMMARY OF THE INVENTION

The present invention provides a cover, a board assembly and a method for protecting a board wherein a protective cover is placed on a surface of the board to prevent damage to the board from elements, such as, for example, solar radiation or moisture. In an embodiment, a plurality of boards may be utilized in construction of a deck. The boards are arranged adjacent to one another, each having a top surface and a bottom surface. Opposing edges of the boards may be trimmed in an area proximate to the top surface to create grooves along the board. In an alternate embodiment, the opposing edges may be trimmed prior to arranging of the boards in a floor-type formation. In a further embodiment, the cover is placed on the board without trimming of the board prior to placement. In yet another embodiment, the cover is placed on boards of a wall.
A cover, or sheet, is placed along the top surface of each of the boards. The cover may be constructed from a composite of wood and plastic wherein the cover is approximately 25-75% wood and 25-75% plastic. The cover extends along the top surface. Ends of the cover are positioned adjacent to the grooves in the opposing edges. The protective cover may be secured to the board via an adhesive and/or a fastener, such as a screw. The fasteners may be sized to secure each of the boards to joists. The cover prevents direct contact of the board by elements, such as solar radiation or precipitation. As a result, the top surface of the board may be maintained while the cover provides an aesthetic appearance. Accordingly, the deck may be used for a prolonged period of time.
In an embodiment, a deck or wall is comprised of one or more board assemblies. Each board assembly has a board having a first surface and a second surface opposite the first surface. The board also has edges on opposing sides. The edges define a height between the first surface and the second surface. A width between the edges adjacent to the first surface may not be equal to a width between the edges adjacent to the second surface. A cover, or sheet, is provided on the first surface of the board. The sheet has a width substantially similar to a width for the first surface of the board. The sheet extends along at least one of the edges and is constructed from a wood and plastic composition. A space exists between the sheet and the first surface of the board.
It is, therefore, an advantage of the present invention to provide a cover, a board assembly and a method for protecting a board wherein a cover is placed along a board to prevent direct contact between weather-related elements and a top surface of the board; wherein the cover prevents deterioration of the board; and wherein the board may be used for a prolonged period of time.
Additional features and advantages of the present invention are described in, and will be apparent from, the detailed description of the present embodiments and from the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The embodiments of the present invention are described in detail below with reference to the following drawings.
FIG. 1 is a cross-sectional view of two boards utilized in a deck;
FIG. 2 is a cross-sectional view of the boards of FIG. 1 which are trimmed in accordance with the present invention;
FIG. 3 is a cross-sectional view of a cover secured to the boards of FIG. 2 in accordance with the present invention;
FIG. 4 is a cross-sectional view of a cover secured to a board in another embodiment of the present invention;
FIG. 5 is a cross-sectional view of a cover secured to a board in another embodiment of the present invention; and
FIG. 6 is a cross-sectional view of a cover secured to a board in another embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

The present invention relates to a cover, a board assembly and a method for protecting a board. More specifically, the present invention provides one or more boards which are adjacent, as in a floor of a deck or a wall. In an embodiment, a top portion of the boards is trimmed proximate to lengthwise edges. In an alternate embodiment, the boards are trimmed prior to assembly of the deck. A space is created between each board due to trimming of the edges. A cover having a substantially planar shape is placed on each of the boards. The cover may be constructed from a wood/plastic composite and extends across a width of each of the boards into the space created by trimming of the boards. The cover may be secured to the board via an adhesive and prevents direct contact and deterioration due to weather-related elements. As a result, a deck utilizing one or more covers can be used for a prolonged period of time.
Referring now to the drawings wherein like numerals refer to like parts, FIG. 1 illustrates an isolated portion of a conventional deck 2 which has adjacent boards 4, 6 shown in cross-section. The boards 4, 6 may be constructed from any type of wood suitable for assembly of a deck. It is contemplated that, in other embodiments, the boards 4, 6 may be part of a wall. The boards may, in some embodiments, be constructed from engineered strand lumber. The boards 4, 6 may have dimensions, such as, for example, 2 inches by 4 inches, 2 inches by 6 inches, or any other dimension suitable for construction of a deck utilizing a plurality of boards. Board 4 has edges 8, 10 and board 6 has edges 12, 14. In an embodiment, the edges 8, 10, 12, 14 have a height 11 in a range from ½ inch to 6 inches. The edge 10 is adjacent to the edge 12 and is separated by a distance 16 which may be in a range from 1/16 inch to 1 inch.
The board 4 may have a top surface 22 having a width 23 and a bottom surface 24 having a width 25. The board 6 may have a top surface 26 having a width 27 and a bottom surface 28 having a width 29. The widths 23, 25, 27, 29, in various embodiments, are in a range from 2 inches to 8 inches. In an embodiment, the width 23 of the top surface 22 is equal to the width 25 for the bottom surface 24. Similarly, the width 27 of the top surface 26 is equal to the width 29 of the bottom surface 28. It is appreciated, however, that any width may be prescribed for the top surfaces 22, 26 and/or the bottom surfaces 24, 28 wherein the top surfaces 22, 26 and the bottom surfaces 24, 28 are equal or unequal in width. For example, in an embodiment, the top surfaces 22, 26 have a greater width 23, 27 than the bottom surfaces 24, 28 thereby providing a trapezoidal shape, as illustrated in FIGS. 4 and 5 and described in further detail below. It is further appreciated that additional boards may be adjacent to the boards 4, 6 based on a desired size for the deck. These additional boards may or may not have dimensions similar to the boards 4, 6.
The deck 2 is susceptible to effects of sun-related damage, such as heat, ultraviolet rays, or moisture. While these elements may not affect an interior area 18, 20 of each board 4, 6, the top surfaces 22, 26 may become damaged and may provide an unaesthetic appearance to the deck 2. Accordingly, in an embodiment of the present invention, the boards 4, 6 are trimmed at the edges 8, 10, 12, 14 adjacent to the top surfaces 22, 26 of each board 4, 6, respectively to enable placement of covers 54, 54′ on the boards 4, 6. The trimming may be conducted using, for example, one or more tools 200, 300 described in further detail below. The trimming, in essence, leaves grooves in areas where the edges 8, 10 meet the top surface 22 and where the edges 12, 14 meet the top surface 26 along a length (not shown) of each board 4, 6.
As illustrated in FIG. 2, the trimmed edges 8, 10, 12, 14 of the boards 4, 6 have a new width 34, 34′ between sections 36, 36′ and sections 38, 38′. The width 34, 34′ is less than the width 32 and provides a new distance 40 between edges 10, 12. The edges 8, 10, 12, 14 may be beveled along sections 42, 42′, 44, 44′ wherein the width of the boards 4, 6 increases to the width 32 along sections 46, 46′, 48, 48′. In an embodiment, sections 36, 36′, 38, 38′ have a height 50 which is less than a height 52 for sections 46, 46′, 48, 48′. However, it is contemplated that in other embodiments the heights 50, 52 may be equal or may be unequal. It is further contemplated that, in some embodiments, the height 50 is greater than the height 52.
FIG. 3 illustrates the isolated portion of the deck 2 wherein the covers 54, 54′ are provided on the top surfaces 22, 26, respectively. The covers 54, 54′ may be constructed from a wood/plastic composite in a composition ratio of 1:1. In other embodiments, the composition of wood is in a range from 25-75% and the composition of plastic is in a range from 25-75%. Moreover, a wood particle size may range from wood flour (i.e., 20 microns to 0.25 inches) to small wood strands (i.e., 0.05 inches to 0.375 inches). In an embodiment, the plastic may be a thermoplastic, such as, for example, polypropylene, high density polyethylene (HDPE), or other thermoplastic suitable for use in a wood/plastic composite.
The covers 54, 54′ have a width 56, 56′, respectively, which is greater than the width 34, 34′. Ends 58, 58′ of the cover 54 extend adjacent to sections 36, 36′. Ends 60, 60′ of the cover 54′ extend adjacent to the sections 38, 38′. Each of the covers 54, 54′ have a thickness 62, 62′ which, in an embodiment, is in a range of 3/16 inch to ⅜ inch. Members 64, 64′ extend from the cover 54 and members 66, 66′ extend from the cover 54′. The members 64, 64′ and the members 66, 66′ have a height 67, 67′, respectively, in a range from 3/32 inch to 9/16 inch. In an embodiment the height 67, 67′ is 1 inch. The members 64, 64′, 66, 66′ provide a spacing 70, 70′ between the covers 54, 54′ and the top surfaces 22, 26, respectively. In an embodiment, the spacing 70, 70′ ranges from 3/32 inch to 9/16 inch. The spacing 70, 70′ may enable the boards 4, 6 to expel moisture in the form of a vapor. Many known deck covers are applied directly onto a surface of a deck and provide no spacing between the cover and the surface. Because wood expels moisture in an upward direction, pressure accumulates between the known covers and the deck surface. Eventually, the covers are displaced/delaminated from the deck surface and/or the deck surface becomes warped. By providing a space 70, 70′, the present invention allows the deck surface to expel moisture and prevents displacement/delamination.
The covers 54, 54′ may be fastened to the boards 4, 6 via an adhesive which may be, for example, an epoxy or phenolic adhesive (not shown). Other adhesives suitable for attaching a wood/plastic composite product to a board are also contemplated. A fastener may be provided to secure the boards 4, 6 to, for example, a joist (not shown). In the embodiment illustrated in FIG. 3, the fastener is one or more galvanized screws 72. The screws 72 may be inserted through the covers 54, 54′ adjacent to the members 64, 64′, 66, 66′ and may penetrate through the interior area 18, 20 of the board 4, 6, respectively. The covers 54, 54′ prevent direct contact of the boards 4, 6 by elements, such as solar radiation or moisture. As a result, the top surfaces 22, 26 may maintain an aesthetic appearance and the deck may be used for a prolonged period of time.
FIG. 4 illustrates a board assembly 80 in another embodiment of the present invention. The board assembly 80 has a cover 81 which is attached to a board 82. A width 87 of the board adjacent to a top surface 86 is greater than a width 89 adjacent to a bottom surface 91. In an embodiment, a difference between the width 87 and the width 89 is 1 inch. Accordingly, implementation of two or more boards 82 to form, for example, a deck floor, may allow adequate spacing to prevent contaminants and other debris from being trapped between boards 82. Members 84, 84′ of the cover 81 are attached to the top surface 86 of the board 82 via an epoxy or phenolic resin adhesive (not shown) in, for example, a lamination process. Additional types of adhesives capable of forming a wood and wood/plastic composite bond are also contemplated. Recessions 88, 88′ are formed within the top surface 86 to receive the members 84, 84′. Ends 90 of the cover 81 extend to edges 92 of the board 82. The cover 81 may form an apex 93 or crown which enables liquids on the cover 81 to disperse in a downward direction toward the edges 92. The edges 92 may be beveled to enable liquids in contact with the edges 92 to stream downward toward a bottom surface 94. The liquids may then completely disperse from the board 82. The members 84, 84′ may have a height 96 which may provide a space 98 between the cover 81 and the board 82. The space 98 enables the board 82 to expel vapor from the top surface 86. Members 84′ have a greater width 89 than a width 91 of members 84 to enable placement of fasteners (not shown) into the members 84′.
FIG. 5 illustrates a board assembly 100 having a cover 102 displaced on a board 104. The cover 102 has an apex 106 formed at each end 108 which points toward a bottom surface 110 of the board 104. Water or other liquids may accumulate and fall from the apex 106 to prevent the liquids from contacting edges 112 of the board 104. Accordingly, the apex 106 may reduce a rate of deterioration for the edges 112 due to moisture.
The board 104 may have recessions 101 wherein a width 103 at a top end 105 may be less than a width 107 at a bottom end 109. Members 111 may be shaped to correspond to the recessions 101. The members 111 may interlock with the recessions 101 in a manner similar to conventional male-female interlocking mechanisms wherein the members 111 serve as the male member and the recessions 101 serve as the female members. In an embodiment, the members 111 are inserted within the recessions 101 wherein the cover 102 is pressed toward the board 104 to snap the members 111 into the recessions 101. In another embodiment, the cover 102 is aligned wherein the members 111 may be inserted into the recessions 101 in a sliding motion. In this embodiment, the members 111 slide along a bottom surface 113 of each of the recessions 101 across a length (not shown) of the board 104.
FIG. 6 illustrates a board assembly 120 in which a cover 122 is placed on a board 124 which does not require trimming of edges 126 prior to attachment of the cover 122. Ends 128 of the cover 122 have a bottom surface 130 which contacts a top surface 132 of the board 124. The cover 122 may be attached to the board 124 via an epoxy or phenolic resin adhesive. Members 132 create a space 134 between the cover 122 and board 124 which is sufficient for vapor expulsion. Fasteners, such as screws 136, may extend through the members 132 to connect the cover 122 and the board 124 to a joist (not shown). The cover 122 has a width 138 which is sufficient to prevent direct contact between elements and the top surface 132 of the board 124.
A deck featuring board assemblies as described above may be provided to individuals in at least two different scenarios. In a first scenario, a previously constructed deck may be renovated wherein one or more boards of the deck are trimmed. Covers may then be provided for each of the boards. In a second scenario, a cover is attached to a board prior to assembly of a deck. An individual may, for example, obtain several boards having covers and assemble a deck using the prefabricated board assemblies. The prefabricated board assemblies could also be placed adjacent to boards of a pre-existing deck which an individual wishes to expand. Either scenario reduces time and effort associated with repair or replacement of a deck according to known methods. Moreover, either scenario offers a cost-effective solution to repair or replacement of a deck.
FIGS. 1-6 illustrate covers which are aligned in a parallel arrangement to boards, i.e., the length of the cover is aligned with the length of the board. However, it is contemplated that one or more covers may be attached to boards of a deck in a non-parallel arrangement, such as, for example, a 45-degree or 90-degree arrangement with respect to the lengths of the boards and covers. Non-parallel arrangements may provide an individual with an option for additional aesthetic configurations for the board assemblies. In such an embodiment, the cover may be placed directly on the deck surface without trimming of the deck, as non-parallel trimming may reduce strength of the board.
The present invention allows the use of wood composites as a construction material for the boards. Use of wood composites is favorable due to the stiffness, high modulus of elasticity, and low cost of manufacture associated with wood composites. However, wood composites were previously considered materials which could only be used indoors because they are treated with preservatives which dissipate and/or deplete due to a scouring action on the surface of the wood composite when exposed to outdoor elements. For example, zinc borate is a preservative commonly used for engineered strand lumber and borate-treated oriented strand board. Zinc borate leeches or dissipates if contacted by precipitation. However, the cover of the present invention limits contact between precipitation and zinc borate and thereby reduces a rate of dissipation and/or leeching for the preservative.
Typically, wooden decks are provided with joists which are spaced at intervals of 24 inches underneath floorboards to ensure that the floorboards can bear loads. Decks which are constructed from wood/plastic composites are provided with joists which are spaced at intervals of 16 inches or less underneath floorboards. Moreover, wooden decks receiving wood/plastic boards in the replacement process may require extra joists to meet the 16 inch requirement between joists. However, due to the stiffness of wood composites, such as engineered strand lumber or oriented strand board, supporting joists could be placed anywhere from approximately 24 inches to 32 inches apart. Use of fewer joists would result in reduced labor and lower costs to construct a deck.
While the embodiments of the invention have been illustrated and described, as noted above, many changes can be made without departing from the spirit and scope of the invention. Accordingly, the scope of the invention is not limited by the disclosure of the embodiments. Instead, the invention should be determined entirely by reference to the claims that follow.

Claims

1. A cover comprising:

a substantially planar body having a top surface and a bottom surface wherein the body is constructed from a wood and plastic composition wherein the wood composition is in a range from about 25-75% and the plastic composition is in a range from about 25-75%; and

one or more members extending orthogonally from the bottom surface.

2. The cover of claim 1 wherein at least one of the ends forms an apex which extends from the bottom surface.

3. The cover of claim 1 wherein a wood particle size is in a range from 20 microns to 0.375 inches.

4. The cover of claim 1 wherein each of the members have a height in a range from 3/32 inch to 1 inch.

5. The cover of claim 1 wherein a ratio of wood to plastic with respect to composition is about 1:1.

6. The cover of claim 1 wherein the first end is rounded.

7. A board assembly comprising:

a board having a first surface and a second surface opposite the first surface, the board further having edges on opposing sides wherein the edges define a height between the first surface and the second surface;

a sheet on the first surface of the board wherein the sheet extends along at least one of the edges and wherein the sheet is constructed from a wood and plastic composition wherein a particle size for the wood is in a range from 20 microns to 0.375 inches and further wherein a space exists between the sheet and the first surface of the board; and

an adhesive securing the sheet to the board.

8. The board assembly of claim 7 wherein the board is an engineered lumber product.

9. The board assembly of claim 7 wherein the sheet has one or more members wherein each of the members extends from the sheet in a non-parallel direction between the sheet and the first surface.

10. The board assembly of claim 7 wherein the wood composition is in a range from 25-75% and the plastic composition is in a range from 25-75%.

11. The board assembly of claim 7 wherein the plastic is a thermoplastic.

12. The board assembly of claim 7 wherein a composition ratio between the wood and the plastic is 1:1.

13. The board assembly of claim 7 wherein ends of the sheet are rounded.

14. A method for protecting a board, the method comprising the steps of:

providing a board; and

placing a cover on a top surface of the board wherein the cover has a substantially planar body having a width which extends to edges of the board wherein the cover is constructed from a wood and plastic composition and wherein the cover has one or more members extending from a bottom surface of the cover to the top surface of the board thereby creating a space between the cover and the board.

15. The method of claim 14 wherein the wood composition is in a range from 25-75% and the plastic composition is in a range from 25-75%.