GB2468712A

GB2468712A - Decking system for use particularly in the home garden industry

Info

Publication number: GB2468712A
Application number: GB0904798A
Authority: GB
Inventors: Kris Hartley
Original assignee: Individual
Current assignee: Individual
Priority date: 2009-03-20
Filing date: 2009-03-20
Publication date: 2010-09-22
Also published as: GB0904798D0

Abstract

The decking system comprises a frame 12 and at least one decking substrate 20 secured to span at least two spaced locations on the frame. The substrate comprises a deck material 24 and a carrier section having a slot, the deck material being inlaid in the slot and supported by the carrier. The frame may comprise parallel timber joists wherein adjacent joists provide the spaced locations. The deck material may be tiles which do not span the two spaced locations. The carrier may be an elongate tray having a base 26 separating two aluminium L-shaped beams 28, the slot being defined by the space between upwardly protruding peripheral edges 32 of the beams. The deck material may be secured to the carrier by adhesive.

Description

Decking System The present invention relates to a decking system, and in particular, but not exclusively, to a decking system applicable to the home garden industry, and a method of assembling a decking system.

It is known to erect a decking system by creating a raised, level frame from wooden joists, and subsequently laying elongate, wooden planks onto the frame. The frame and planks are normally attached by screws, or nails. In the home garden industry, such arrangements are used to create "patio" areas, particularly as they are easy to lay and are often a less expensive option than laying an area from paving stones that usually requires a foundation such as compacted hard core. However, known decks use wooden planks, which (when untreated) tend to lack weather and erosional resistance, visual appeal, and often become slippery when wet.

It is an objective of the present invention to attempt to overcome at least one of the above, or other disadvantages.

It is a further aim of the present invention to provide a decking system that has improved visual appeal. A further aim of the present invention is to provide a decking system that can be easily laid and that provides improved weather resistance and surface characteristics.

According to a first aspect of the present invention there is provided a decking system comprising a frame and at least one decking substrate that is secured to span at least two spaced locations on the frame, wherein the decking substrate comprises a carrier section for supporting deck material, the carrier section having a slot within which deck material is inlaid.

Advantageously the carrier section provides support to the deck material thereby enabling a wide range of standard materials to be used without modification.

In exemplary embodiments, the slot is formed by two spaced protrusions. Here the protrusions extend upwardly from a base of the carrier section. Thus a slot is formed. Advantageously the slot enables the deck material to be easily aligned and protects the edges of the deck material from wear. Preferably each protrusion is arranged substantially parallel to each other and along a length of the carrier section. Suitably the protruding portion may be provided by a retainer. The retainer may be attached to a base of the carrier. Preferably the deck material is adhered to the carrier. Thus the slot retains adhesive allowing the adhesive to be quickly and easily applied.

According to a second aspect of the present invention there is provided a method of forming a decking system, the method comprising the steps of: creating a frame; securing at least one decking substrate to the frame such that the decking substrate spans at least two spaced locations on the frame; wherein the decking substrate includes a carrier section for supporting a deck material and the step of securing the decking substrate to the frame comprises securing the carrier to the frame; and the method also includes the step of inlaying the deck material into a slot formed in the carrier.

Preferably the method includes forming a decking system according to the first aspect.

According to a further aspect of the present invention, there is provided a decking substrate for being secured to a frame, the decking substrate comprising a carrier section having a slot within which deck material is inlaid.

Further features of the invention are defined in the claims and elsewhere in the specification.

For a better understanding of the invention, and to show how embodiments of the same may be carried into effect, reference will now be made, by way of example, to the accompanying diagrammatic drawings in which: Figure 1 shows a front perspective view of a decking system according to a first embodiment; Figure 2 shows a front perspective view of a decking substrate for use in assembling a decking system; Figure 3 shows an end view of Figure 2; Figure 4 is an exploded front perspective view of the decking substrate shown in Figure 2; Figure 5 is an exploded front perspective view of the decking system shown in Figure 1.

Referring to Figure 1, a decking system 10 is shown. A raised level frame 12 is formed in accordance with known systems. The frame 12 is shown here as a plurality of spaced, parallel joists 14. Secured to the frame 12, transverse to the joists 14, are a plurality of decking substrates 20. Thus adjacent joists provide spaced locations to support the decking substrate.

The decking substrates 20 comprise hybrid assemblies that can be easily secured to the joists 14 whilst providing a predominant surface area from a material having desirable surface characteristics.

As shown in Figures 2-4 the decking substrate 20 comprises a carrier section 22 for supporting deck material 24. The decking substrate 20 may have a nominal thickness of approximately 25mm. Each of the carrier section 22 and deck material 24 may be substantially between 5 and 15mm thick and in particular may be around 10mm thick.

The carrier section 22 comprises a base 26 and retainers 28. The base 26 is generally elongate so that it may extend along two or more joists 14. Thus the base 26 provides support, either continuously or in a plurality of discrete places, for the overlaying deck material 24. The deck material 24 is attached to the base 26 by an adhesive layer 29, or any other suitable fixture. The base 26 may be either wood, composite, metal, plastic or any other material suitable to provide a support to the deck material 24. The base 26 may be partially flexible enabling stress relief when in use, thus reducing the risk of cracking in the deck material 24 and adhesive 29.

Suitably the carrier 22 includes two said retainers 28, each fixed to either edge of the base 26 and substantially along the length of the base 26. Here the retainers 28 are each an L' sectioned strip that is either pre-formed, or manipulated from flat panels. Thus the retainers 28 have an attachment portion 30 and a protruding portion 32. The attachment portion 30 is secured to the base 26 such that the protruding portion 32 protrudes upward from the base 26.

Thus a slot is provided between the protruding portions 32 of each retainer 28 and on top of the base. The slot allows the deck material 24 to be easily located on the base 22 and prevents the adhesive of the adhesive layer 29 from spreading. Moreover, the protruding portions 32 provide a straight edge to align the deck material 24 and may also improve the visual appeal of the decking substrate 20. The attachment portion 30 of the retainers 28 is connected to the base 26 in any suitable manner. For example, they may be connected by means of adhesive, screws, nails, rivets, bolts or any other suitable means. Suitably, the retainers 28 are shown attached to a bottom of the base 26. However, it will be appreciated that the protruding portions 32 are designed to give rise to the advantage of providing a slot for receiving decking material to be located. Thus, as an alternative, the retainers 28 may be secured to a top surface of the base 26. Here the decking material 24 may be fixed to the retainers 28 in addition to, or instead of, the base 26. Furthermore, the retainers may be flat strips secured to the side of the base 26 or the protruding portion 32 may be integral to the base 26.

As an alternative, the decking substrate 20 may be pre-assembled. Here the decking substrate 20 is supplied with the deck material 24 pre-inlaid into the slot of the carrier section 22. In this case, fixings may be secured at an angle through the sides of the carrier section 22. Alternatively, the carrier section may include spaced flanges through which fixings are secured.

The carrier 22 has been shown so that, when the decking material 24 is secured to the base 26 and within the slot formed between the two retainers 28, in use the upper edge of the protruding portion 32 of the retainers 28 are flush with a top surface of the decking material 24.

It will be appreciated that should the retainers 28 extend beyond the top surface of the decking material 24, an advantageous non-slip feature may be incorporated. Further, the part of the protruding portion 32 that extends above the top of the decking material 24 may help reduce wear and erosion of the deck material 24. These features may be particularly useful when erecting stairs using the decking system 10, The retainers 28 are preferably fabricated from a metal such as an erosion resistance material like Aluminium. In this case, the retainers 28 provide additional strength to the carrier 22.

The deck material 24 may comprise tiles or panels made from stone, ceramic, wood or any other material having desirable surface characteristics. As can be seen in Figure 1, the deck material 20 comprises a plurality of deck material units 25 inlaid into the single slot. Thus each deck material unit 25 extends substantially less than the length of the carrier section 22. As shown in Figure 1, each deck material unit 25 does not span two joists. Preferably, the deck material units 25 are standard paving materials in that the paving material has not needed to be modified for the decking assembly application. Standard paving material can be used as no particular reinforcement is required because the carrier section 22 provides the support and strength.

Figure 5 shows an example of the assembly of the decking substrate 20 to the joists 14. Here fixings 40, which may be nails, screws, rivets, bolts or any other suitable device, secure the carrier section 22 to span two or more joists. For example the decking substrate may span at least four joists as shown in Figure 5.

The carrier section 22 is first attached to the joists 14 by the fixings 40. The fixings 40 extend through the base 26, for example through pre-drilled holes or by driving the fixing 40 through the base 26. Thus the heads of the fixings 40 are hidden by the deck material 26. This improves the visual appeal and also protects the fixings 40 from the weather and erosion. The adhesive layer 29 is then applied or spread in the slot and decking material inlaid thereon.

The adhesive secures the decking material 24 to the carrier 22. Depending on the type of decking material 24 used, grout may then be applied.

In the embodiment shown in the figures, the carrier section 22 has been shown to support a single row of deck material 24. However, the carrier section 22 may be sized so as to also support a number of equally or unequally sized deck material in two or more rows. Moreover, the carrier section 22 may include one or more intermediate retainers, positioned between the two retainers 28 attached to the side of the carrier section 22. Thus the intermediate retainers protrude upwardly from the base in order to provide individual slots where two or more rows of deck material are supported. Retainers may also be provided along all edges of the carrier section.

Attention is directed to all papers and documents which are filed concurrently with or previous to this specification in connection with this application and which are open to public inspection with this specification, and the contents of all such papers and documents are incorporated herein by reference.

All of the features disclosed in this specification (including any accompanying claims, abstract and drawings), and/or all of the steps of any method or process so disclosed, may be combined in any combination, except combinations where at least some of such features and/or steps are mutually exclusive.

Each feature disclosed in this specification (including any accompanying claims, abstract and drawings) may be replaced by alternative features serving the same, equivalent or similar purpose, unless expressly stated otherwise. Thus, unless expressly stated otherwise, each feature disclosed is one example only of a generic series of equivalent or similar features.

The invention is not restricted to the details of the foregoing embodiment(s). The invention extends to any novel one, or any novel combination, of the features disclosed in this specification (including any accompanying claims, abstract and drawings), or to any novel one, or any novel combination, of the steps of any method or process so disclosed.

Claims

Claims 1. A decking system comprising a frame and at least one decking substrate that is secured to span at least two spaced locations on the frame, wherein the decking substrate comprises a carrier section and a deck material, the carrier section having a slot within which the deck material is inlaid and being adopted for supporting the deck material.
2. The decking system of claim 1, wherein the deck material inlaid within the slot of the carrier section does not span two spaced locations on the frame.
3. The decking system of claim 1 or 2, wherein the frame comprises a plurality of spaced frame members and a location on one frame member provides a first of the spaced locations and a location on another frame member provides a second of the spaced locations.
4. The decking system of any preceding claim, wherein the slot is formed by two spaced protrusions that protrude upwardly from a base of the carrier section and are arranged substantially parallel to each other and along a length of the carrier section.
5. The decking system of claim 4, wherein the carrier section includes two retainers and each protrusion is provided by a protruding portion of the retainer.
6. The decking system of claim 5, wherein each carrier system is elongate and a said retainer is attached to each elongate edge.
7. The decking substrate of any preceding claim wherein the deck material is secured to the carrier by adhesive.
8. A method of forming a decking system, the method comprising the steps of: creating a frame; securing at least one decking substrate to the frame such that the decking substrate spans at least two spaced locations on the frame; wherein the decking substrate includes a carrier section for supporting a deck material and the step of securing the decking substrate to the frame comprises securing the carrier section to the frame; and the method also includes the step of inlaying the deck material into a slot formed in the carrier.
9. The method of claim 8, including the step of adhesively securing the deck material to the carrier.
10. The method of claim 8 or 9 wherein the method comprises securing a decking substrate as claimed in claim 11.
11. A decking substrate for being secured to a frame, the decking substrate comprising a carrier section and deck material, the carrier section having a slot within which deck material is inlaid such that the carrier section supports the deck material.
12. The decking substrate of claim 11, wherein the carrier section is elongate.
13. The decking substrate of claim 11 or claim 12 including the features of any of claims 2 to 7.