OUTDOOR DECKING MATERIAL
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.
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 INVENTIONThe 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.
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 INVENTIONThe 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.
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.
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
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
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.
By arranging units 1 in a side-by-side fashion, one can create an entire deck surface as shown in
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 3½ 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 ¾ of an inch.
In an alternative embodiment, the individual boards 11-14 (and 15 as illustrated in
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
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.
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.
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 (
As illustrated in
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 36×48 inch pallet.
In an alternative embodiment deck surface unit 1′″ (
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.
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.
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.
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 ¾ 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 ¾ 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.
Type: Application
Filed: Nov 30, 2006
Publication Date: Aug 23, 2007
Inventor: Charles Wheatley (Cincinnati, OH)
Application Number: 11/565,070
International Classification: E04B 7/00 (20060101); E04B 5/00 (20060101);