DECK BOARD

Abstract

This invention relates to a deck board and more particularly, to a reduced material deck board. In accordance with this invention there is provided a deck board comprising an operatively upper board section having at least one operatively downwardly depending support leg terminating in at least one flange, an underside of the flange having a concave surface.

Claims

1. A deck board comprising an operatively upper board section having at least one operatively downwardly depending support leg terminating in two flanges that extend transversely away from opposite sides of a lower end of the leg, an underside of the two flanges comprising a concave surface, the deck board being manufactured from a composite material.

2. The deck board of claim 1, wherein an underside of the upper board section comprises a concave surface.

3. The deck board of claim 1, wherein anti-slip formations are located in or on an upper surface of the upper board section.

4. The deck board of claim 3, wherein the anti-slip formations comprise parallel, elongate grooves or parallel elongate protrusions.

5. The deck board of claim 1, wherein the composite material is a filled thermoplastic polymer material.

6. The deck board of claim 5, wherein the composite material is a wood plastic composite material.

7. The deck board of claim 6, wherein the deck board is extruded from the wood plastic composite material.

8. The deck board of claim 1, wherein the deck board is an outdoor deck board.

9. The deck board of claim 1, wherein the deck board has a wall thickness of at least 4 mm.

10. A deck board comprising an elongate body which, in cross section, comprises a number of substantially I-beam shaped sections with operatively horizontal upper or head sections connected to one another and lower operatively horizontally extending foot sections being shorter in length than the head sections so that free ends of the foot sections are spaced apart, the deck board being manufactured from a composite material.

11. The deck board of claim 10, wherein a central connecting section of the I-beam connects the upper and lower sections to complete the I-beam shape.

12. The deck board of claim 10, wherein the underside of the foot section is concave.

13. The deck board of claim 10, wherein an underside of the connected head sections is concave.

14. The deck board of claim 10, wherein upper surfaces of the foot sections are substantially operatively horizontal.

15. The deck board of claim 10, wherein the composite material is a filled thermoplastic polymer material.

16. The deck board of claim 14, wherein the composite material is a wood plastic composite material.

17. The deck board of claim 16, wherein the deck board is extruded from a wood plastic composite material.

18. The deck board of claim 10, wherein the deck board is an outdoor deck board.

19. The deck board of claim 10, wherein the deck board has a wall thickness of at least 4 mm.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0039] One embodiment of the invention is described below, by way of example only, and with reference to the drawings in which:

[0040] FIG. 1 shows an upper perspective view of a deck board in accordance with the invention;

[0041] FIG. 2 shows an underside perspective view of the deck board FIG. 1;

[0042] FIG. 3 shows a plan view of the deck board of FIGS. 1 and 2;

[0043] FIG. 4 shows a bottom view of the deck board of FIGS. 1 to 3;

[0044] FIG. 5 shows a left side view of the deck board of FIGS. 1 to 4;

[0045] FIG. 6 shows a right-side view of the deck board of FIGS. 1 to 5;

[0046] FIG. 7 shows a front-end view of the deck board of FIGS. 1 to 6; and

[0047] FIG. 8 shows a rear end view of the deck board of FIGS. 1 to 7.

DETAILED DESCRIPTION OF THE DRAWINGS

[0048] With reference to the drawings, a deck board is generally indicated by reference numeral 1.

[0049] The deck board 1 includes an elongate body that has an operatively upper board section 4 that has a number of operatively downwardly depending support legs 5 extending downwardly from an underside surface 8 of the upper board section 4.

[0050] Lower ends 6 of each leg terminate in a transversely extending flanged that, in effect, forms two transversely extending flanges 7 extending transversely away from opposite sides of lower ends 6 of the legs 5.

[0051] In cross-sectional profile view, the legs, flanges and upper board section resemble I-beam sections connected side-by-side with their upper or head sections connected to each other and lower foot sections, spaced apart.

[0052] An underside surface 9 of each flange 7, is concave. Underside surfaces 8 of the upper board section 4, between the downwardly depending legs 5, are also concave. Upper surfaces 7a of the flanges are operatively level and, in use, receive parts of fastener clips thereon.

[0053] An upper surface 2 of the upper board section 4 includes anti-slip formations in the form of a series of parallel and elongate grooves, parallel with the main axis of the deck board 1. It will be appreciated by those skilled in the art that any other convenient anti-slip formations may be formed on the upper surface, as may be required.

[0054] The deck board 1 is extruded from a wood plastic composite material. The thickness of the board profile is at least 4 mm (0.15 inches) thick, but a minimum of 7 mm (0.27 inches) thickness is more suitable. At a thickness of less than 7 mm, the brittleness of the composite is so low that the product becomes unusable.

[0055] In use, deck boards are placed side-by-side on joists of a substructure on which an outdoor deck is to be formed. The deck boards are attached with fastener clips as is known in the art. Wings or other parts of the fastener clips locate on part of the upper surfaces 7a of flanges at opposite outer edges of the deck board.

[0056] This invention thus provides a deck board comprising an elongate body which, in cross section, has a number of substantially I-beam shaped sections with operatively horizontal upper or head sections connected to each other and lower operatively horizontally extending foot sections being shorter in length than the head sections so that theft free ends 10 are spaced apart. Space between two free ends 10 may form an opening of a channel 11. The channel 11 may be bounded by the upper board section 4 at a top, the free ends 10 at a bottom, and the legs 5 at the sides.

[0057] A central connecting section of the I-beam connects the upper and lower sections to complete the I-beam shape. An underside of the foot section is concave. An underside of the connected head sections is concave. Upper surfaces of the foot sections are substantially operatively horizontal.

[0058] All corners and edges of the board are rounded and the arched surfaces (8 and 9) adds to the strength of the board and ensures improved load distribution. The spaced apart flanges ensure that water will easily be drained from the board. Even if water collects on the level surfaces 7a, and especially those at the opposite outer edges of the deck board, these surfaces are exposed and will dry relatively quickly. Water will thus not collect, or not collect for an undesired length of time, on or in the board, thereby enhancing its durability. The board is relatively light, as a result of using less material than a solid board. The board, however, remains strong enough and fit for purpose.

[0059] It will be appreciated by those skilled in the art that many other embodiments are possible without departing from the scope of the invention. For example, the board can be manufactured from any material suitable for extrusion. The board may also be used for outdoor decking, indoor floors or covering wall surfaces.

[0060] It is envisaged that the invention herein described is convenient to use in that the decking board does not include any cavities or grooves in which water will be trapped. This makes the board suitable to use for outdoor decking. Furthermore, the profile of the deck board increases load bearing capabilities of the board. The concavity of the underside of the upper head sections of the board optimises material usage with respect to product performance. Where the top element gets thicker, near to the downward leg, it transfers ordinary loading more efficiently.