GB2512100A - Improvements in and relating to a synthetic surface covering - Google Patents

Abstract

An extruded elongate plank section 10 for use in forming a surface covering together with other similar plank sections has a main plank portion 16 made of a relatively flexible polymeric material and a co-extruded stiffening member 28 made of a relatively rigid polymeric material, extending longitudinally along at least one side of the plank section. The plank section may also have a co-extruded jointing region 20 extending along at least one longitudinal edge above a respective stiffening member. At least part of an upper surface of the jointing region slopes downwardly in a lateral direction of the plank section so that when two plank sections (10A, 10B, Fig 3) are aligned side by side, adjacent jointing regions (20A, 20B, Fig 3) define a groove in which weld (38, Fig 3) is formed to join the plank sections together. Co-extruded stiffening sections and jointing regions can be provided along both sides of the plank section and may be configured to form a coupling arrangement for aligning adjacent plank sections during assembly.

Description

Improvements in and Relatjn. to a Synthetic Surface Coverjn

Technical Field of the Invention

The present invention relates to a synthetic slLrth.ce covering and in particular to synthetic surthce covering for marine vessel decks. The invention also relates to a S method of lbrming a synthetic surlkce covering, especially for marine vessel decks.

Background to the Invention

Traditionally, marine vessel decks have been formed using Doden planks that are laid over beams. Joints between adjacent planks are caulked to form a watertight seal. In modern marine vessel constriction, the dcc]c itself may be solid and could be nioulded, say from fibreglass or composite materials, or formed from sheet material such as metal. A surface covering is applied to the deck to give it an attractive appearance and to provide a non-slip surface. Known surface coverings include wooden planks. often teak, which are affixed to the deck with a small gap between adjacent planks that are filled with a caulking material of contrasting colour to imitate the appearance of a traditional marine vessel deck. More recently, synthetic surface coverings for decks have been developed that are cheaper to produce and which require less maintenance than surface coverings made from natural wood.

The term "marine vessel" is used herein to encompass boats, yachts, ships and the like.

WO 011(10948 A Idiscloses a shape conforming synthetic surthee covering for boat and yacht decks made up of plank sections and caulking strip sections extruded from flexible polyvinyl chloride (PVC). The plank sections are coloured and textured to imitate the appearance of wooden planks, in particular teak, whilst the caulking strip sections are of a. differeuit, usually darker, colour so that thc resulting surface imitates the appearance of a traditional caulked wooden deck. In one embodiment, the surface covering is made up of co-extruded sections, each comprising a wood imitating plank portion with an integral cauJking strip portion of a contrasting colour along one longitudinal edge. The extruded sections may have tongtte and groove connectors along their longitudinal ends so that they can he assembled together to form the surf' cc covering.

Synthetic surface coverings are a]so known in which extruded planks sections made of flexible PVC. are welded together to form pre-assembled panels for subsequent mounting to a surface, such as a deck, using an adhesive. For covering large surface areas, a number of panels are constructed and assembled on the st.jrfa.ce in modular fbrni. with each panel being bonded to the surface using an adhesive and adjacent panels wclded together. Typically, a Lemplate of the area to be covered is produced and the panel or panels made to the template remotely and subsequently transported to the vessel for fitting.

Whilst the known synthetic surface coverings are cheaper to produce and require less maintenance than traditional wooden deck coverings, they can be difficult to lay. A particular problem arises when laying a surface covering on larger marine vessels where it can he difficult to ensure that elongate extruded sections lie in straight lines along the deck. Where the synthetic surface covering is provided in the form of pre-assembled panels, the panels can be unwieldy and very heavy and so difficult to handle, particularly when being taken aboard a marine vessel with limited access. The panels arc subject to damage caused by deck fittings when trying to manoeuvre them into position and often the plank sections in the various panels will not match when the panels jointed in position on the deck. A particular problem in fitting large paElcls in position is tile difficulty in getting the adhesive spread over the surface area quickly enough so that it doesn't part cure before the panel is laid in position. A further issue with known synthetic surface coverings made from flexible Pvc is that the material tends to expand and contract appreciably a.s a result of temperature fluctuations.

There is a need then for an alternative synthetic surface covering suitable for use on a marine vessel deck which overcomes, or at least mitigates, some or all of the limititation of the known synthetic surface coverings.

Summary of the Invention

In accordance with a first aspect of the invention there is provided an extruded plank section in accordance with claim I. Further optiona.1 features of the first aspect of the invention are set out in the claims dcpendant on claim 1.

In accordance with a second aspect of the invention there is provided a kit of parts in accordance with claim 15.

Further optional features of the second aspect of the invention are set out in the claims dependant on claim 15.

In accordance with a third aspect of the invention there is provided a surface covering in accordance with claim 20.

Further optional features of thc third aspect of the invention are set out in the claims dependant on eaim 20.

In accordance with a fourth aspect of the invention there is provided a method of foirning a surthee covering in accordance with claim 24.

Further optional features of the fourth aspect of the invention are set out in the claims clependant on claim 24 S Detailed scription of the Invention An embodiment of the invention will now be described, by way of example only, with reference to the accompanying drawings iii which: Figure 1 is an end view of an extruded plank section for use in forming a.

surface covering in accordance with an embodiment of the invention; Figures 2 to 5 are a sequence of views illustrating how two plank sections as shown in Figure 1 are joined together to form part of a surface covering.

An embodiment of an extruded plank section 10 in accordance wilh the invention is illustrated in Figure 1. The plank section 10 is adapted to be assembled together in-situ with other similar plank sections 10 to form a surface covering 12 of any desired size and shape. When assembled to form a surftce covering 12, each plank section 10 is bonded to a supporting surface by means of an adhesive and is welded to adjacent plank sections 10 longitudinal edge to longitudinal edge.

Figure 1 shows an end view of the plank section 10, which is an elongate member. Plank sections 10 in accordance with the invention will typically be produced in a range of standard lengths and cut to size as required for any specific application. It is expected that plank sections 10 in accordance with the invention will be produced in lengths raging from 1 meter up to 10 meIci-s or more. It wil! he

S

appreciated, however, that the precise length of the plank sections 10 is not essential to the invention and that the range indicated above is intended as a non-limiting example. Plank sections 10 in accordance with the invention can also be produced iii a range of different widths.

S The plank section 10 ha.s a. main plank portion 14 comprising a relatively flexible plastics material. In one embodiment, the main plank portion 14 comprises a flexible PVC plastics material. The main plailk portion 14 has a central region 16 with general]y planar tipper surface 18 and tapered jointing regions 20 extending along cithcr longitudinal edge. Ihe planar upper surface 18 of die central region 16 may be textured so as to provide a non-slip surface. In one embodiment, the central region 16 of each plank section 10 is coloured and textured so as to imitate the appearance of wood, such as teak, oak, or beech etc. Thejointing regions 20 may be the same colour as the central region or they may he ola different colour. Whilst the jointing regions may be of a different colour to the central region, they are otherwise formed of a similar or identical material, such as a flexible PVC material. The jointing regions 20 do not extend over the frill depth or thickness X of the plank section 10. The upper surface 22 of the jointing regions 20 is angled downwardly and is shaped so that when two similar plank sections 10 are laid side by side, the jointing regions 20A, 20B on the opposing edges of the two plank sections ahnt one another and define a groove 24 in which a weld can he formed to permanently joint the plank sections together in a watertight manner.

A series of grooves 26 are provided in the lower surface of the main plank portion 14. The grooves 26 are configured to allow the adhesive used to fix the plank section 10 to a supporting surface to be keyed between the surface and the plank section 10. When assembling the plank section 10 to a surface, the plank section is pressed onto a bed of adhesive laid on the surface so that the adhesive enters grooves 26 before it sets. in the embodiment as shown, the grooves 26 have a dovetail shape in lateral cross-section. ilowever, the grooves 26 can be of any suitable shape and could, for example, be curved in lateral cross-section. Preferably the grooves 26 are undercut or re-entrant so that once the adhesive sets, it forms a. strong mechanical as well as chemical bond beccn the surface and the plank section 10.

Extending along each longitudinal edge of the plank section 10 is a stiffening member 28. Each stiffening member 28 is made of a material that is relatively rigid in comparison to the material of the main plank portion 14. In one embodiment, the stiffening members 28 are formed of a rigid acrylonitrile butadiene styrene (ABS) plastic. Each stiffening member 28 is En the form of an elongate strip having a generally rectangular shape in lateral cross-section. being wider than it is deep. Each stiffening member 28 is located below the jointing region 20 on their respective side of the plank section 10 and projects laterally beyond the jointing region so that each jointing region 20 only partially overlaps its respective stiffening member 28. On one side of the plank sect ion 10, the stiffening member 28A is located immediately below its respective jointing member 20A. This stiffening member 28A will be referred to as an upper stiffening member. The stiffening member 28E on the other side of the plank section is spaced downwardly from the jointing region 2GB on. that side by a distance Y, approximately equal to the thickness of the upper stiffening member 28A.

This stiffening member 28B will be referred Lu as a lower stiffening member.

The space between the lower stiffening member 28B and its jointing region 20B defines an elongate slot 30 in which Ilie tipper stiffening member 28A of a further plank section 1.0 is received when the two are interconnected side by side to form part of a surface covering. The outer longitudinal edge 32 of the upper stiffening member 28A is rounded so that it can be initially inserted into the opening of the slot of an adjacent plank section 10 with the plane of the upper stiffening member 2RA inclined at an angle to the plane of the slot 30. as illustrated in Figure 2. The upper stiffening member 28A is then pivoted about the curved end 32 to align the plane of the upper stiftbning member 28A with the plane of the slot as the upper stiffening member is inserted further into the slot. The curved outer edge 32 of the upper stiffening member 2A and slot 30 thus act in the manner of a ball and socket joint to make engagement of the upper stiffening member 28A in the slot 30 easier to initiate and control.

Thc plank SectiOn 10 iS pEOdLLced using co-extrusion techniques. Where the jointing regions 20 are of a. different colour to the remainder of the main plank portion 14, the plank sectLon 10 is produced as a tn-extrusion.

A method of assembling two of the plank sections bA, 1011 together to form part ola surface covering 12 will now be described in detail with reference to Figures 2 to 5.

When forming a surfhce covering, individual plank sections IOA, lOB are sequentially laid in-situ onto a bed of wet adhesive 34 applied to a surface 36 and adjacent plank sections bA, 1GB subsequently joined together by welding from above. Figures 2 to 5 illustrate the steps in laying two adjacent planks sections bA, JOB A first plank section 1 (IA is laid onto the bed of adhesive 34, so that the adhesive enters the grooves 26. The next plank section lOB to be added is held above the bed of adhesive and s tilted about its longitudinal axis at an angle of about 45 degrees so as to extend upwardly and away from the first plank section IOA. The outer edge 32 of the upper stiffening member 28A of the further plank section lOB is introduced into the slot 30 of the already laid plank section bA. The further plank section lOB is then gradually pivoted downwardly in a hinge like manner about the curved edge 32 of its upper stiffening member 28A, as the stiffening member 28A is moved Ilirther into the slot 30. This movement continues until the further plank section lOB is brought into alignment with the already laid plank section 1OA and is bedded into the adhesive 34 with its upper stiffening member 28A fully engaged in the slot, as illusuated in Figure 1 The upper stiffening member 28A and the slot 30 may be configured to allow the further plank section to be tilted through an angle a in the range of 30 to 60 degrees, more preferably in the range of 40 to 50 degrees, and even more preferably at an angle of about 45 degrees, when initially inserting the upper stiffening member in the slot 30.

Tilting a plank section lOB in this way as it is coupled with an already laid plank section lOA means that it can he laid without unduly disturbing the adhesive bed 34 onto which it. is being positioned. The ability to tilt each further plank section lOB as it is added to [he surface coveting also makes it easier to lay plank sections 10 in otherwise confined spaces. This might be usefil when laying a surface covering 12 close to a wall or other edging member. Thi.s arrangement conta-asts with plank sections having a conventional tongue and groove arrangement tbr inter-engagement that would require each tUrLher plank section to be slid in a predomnani1y lateral direction when being engaged with an already laid plank section. Such lateral movement would tend to disturb the adhesive bed 34 and may be difficult in confined spaces.

Once the two plank sections bA, lOB are positioned adiacent one another on the surface and bedded in the adhesive, they are hot welded tcgether in-slut Iron-i above. A weld rod 8 of compatiblc filler material is uscd to form a weld fillet 40 in the groove 24 defined by the abutting jointing regions 20A, 20B of the two plank sections. After welding, any excess weld material is cut off, using a sharp pallet knife or other suitable tool, to leave a neat, watertight welded joint 40 between the plank sections. Where the jointing regions 20 je formed of a PVC material, as will usually be the case, the weld rod will also be a PVC material.

If desired, the weld 40 can be formed of a differently coloured material to that of the central region 16 of the main p'ank section 14, so as to form a surface covering with watertight yet decorative (highlighted/contrasting) welded joints 40. For example, the surface covering 12 may be armnged to imitate the appearance of a caulked wooden deck in which the central region 16 of the main plank portions 14 are coloured and texiLtred tO imitate the appearance of wooden planks and the welds 40 formed of a contrasting, usually darker colour, similar to that of conventional caulking. In this case, the jointing regions 20 will be produced in the desired contrasting colour and a weld rod having a matching colour to that of the jointing regions 20 used. The jointing regions 20 create a straight crisp frame for the weld to be applied into. Ihis makes it easier for even a relatively inexperienced installer to produce a weld 40 having perfectly straight sides with no visible scorch marks on the central, wood imitating, regions 16 Further plank sections 10 can he added using the above method to produce a surface covering of the desired width. Lach pair of adjacent plank sections IDA, lOB are welded together in turn as they are laid. Alternatively, three or more plank sections 10 can be laid on a bed of adhesive to cover a region of the surface before all the adjacent pairs of plank sections iDA, lOB in the region are welded together.

Welding can be carried out prior to, or after, the adhesive has seC The stiffening members 28A, 28B of the two plank sections bA, 1MB overlap one another below the jointing regions 20 when they are coupled together. This provides a physical barrier between the deck surface 36 and the groove 24 in which the weld 40 is formed, ibis has a number of advantages. Firstly it prevents the wet adhesive from passing between the plank sections and contaminating the groove 24, which might adversely affect the welding process. Secondly, the overlapping stiffening menihers 28A, 28B act as a heat barrier between the weld groove 24 and the surface of the deck during the welding process. This reduces the risk of the deck surface being damaged as the plank sections are welded. For example, if the deck surface is painted or has some other surface treatment, the stiffening members 28A, 28B act as a heat barrier to reduce the risk of the paint or other surface treatment blistering. Blistering of paint on a steel deck for example could lead to the deck corroding.

In addilion 10 hot welding adjacent plank sections 10 together, an adhesive can also be used to solvent weld them together to provide additional joint strength. In this case the adhesive would usually be applied between the overlapping stiffening members 2K 28B to bond the stiffening members together. The hot weld can then be formed above the solvent weld as described above. A further advantage of using stiffening members 28A, 28B made of ABS plastics is that adhesive wi]l adhere to the ABS material well as there are no fillers that inhibit solvent welding, as is the ease with PVC.

The provision of stiffcning members 28 along either side of the plank section 10 is also advantageous in helping to maintain (lie straightness or the plank section 10.

This is particularly advantageous when tbrming a surface covering on larger marine vessels where long plank sections or bnger runs of plank sections are used and where any lateral curvature will be particularly noticeable. The stiffening members 28 also aid with the overall stability of the plank section 10 during temperature fluctuations.

PVC tends to expand and contract appreciably as a result of temperature changes due, for example, to changes in environmental conditions and/or during welding. The rigid ABS plastic from which the stiffening members 28 are produced is less prone to expansion and contraction and so [he stiffening members act as a reinforcing framework for the plank section 10.

Plank sections 10 as described are particularly suitable for use in forming a main, central region of a surface covering in which other plank sections 10 are connected on either side. However, differently profiled plank sections (not shown) in accordance with the invention can also be used in combination with the plank sections as described above to fonn a complete surface covering. For example, to form a neat edge to a surface covering, it may be advantageous to use a plank section having a curved profile along one longitudinal side edge with a stiffening member 28 and jointing region 20 only along the other longitudinal side edge for connection with a plank section 10 as described above. Two versions might he produced for use on opposite sides of the slLrface covering, one version having an upper stiffening member 28.A and the other version having a lower stiffening member 2811 and longitudinal slot 30. Alternatively, a plank section 10 as described above could be cut longitudinally through the main plank portion 14 and the cut edge shaped to form a suitable edge to a surface covering.

When fonning a surface covering 12. plank sections 10 may also be joined end to end where the length of the surface covering required is eater than the maximum length of the plank sections 10 available. The plank sections 10 are butted hard against each other end to end and a router, or other suitable tool. is used to cut a grove half the depth ol' the plank sections where the ends meet. The ends of the adjacent plank sections are hot welded together along the g'oove using a weld filler rod, in a manner similar to the process for joining adjacent plank sections along their longitudinal edges as described above. The weld can be formed using weld filler rod having a colour that matches the main central region 1601 the plank section if the join is to be substantially invisible or using a tiller rod having a colour that matches the colour of the longitudinal welds where this is different to the main plank colour to produce a contiasting joint After welding, the weld fillet is cut flat and sanded to produce a neat join.

Whilst the invention has been described with reference to a surface covering for marine vessel decks, it is not limited to this application but can be used to form a surface covering Ibr a wide range of applications such as: pontoon decking, decking in gardens or surroundhig swimming pools and the like. Furthermore, whilst stiffening members are provided along either side of the plank section 10 in the preferred embodiment, many of the advantages of the invention can he obtained by having just a single stiffening member extending longitudinally of the plank section.

The above embodiment is described by way of example onLy. Many variations are possible without departing from the scope of the invention.

Claims (1)

1. Claims 1. An extruded plank section for use in forming a surface covering, the plank section being elongate and including a main plank portion comprising a first polymeric material and a. co-extruded stiffening member comprising a second polymeric material which is relative rigid in comparison to the first material extending longitudinally along Ihe plank section.

   2. An extruded plank section as claimed in claim 1, wherein the first matcrial comprises a flexible PVC plastic and the second material comprises a relatively rigid ABS plastic.

   3. An extruded plank section as claimed in claim I, wherein a first stiffening member extends along a first longitudinal edge of the main plank portion.

   4. An exnded plank section as claimed claim 3, wherein a second stiffening member extends along a second longitudinal edge of the main plank portion opposite from the first.

   5. An extruded plank section as claimed in claim 3 or claim 4. wherein the, or each, stiffening member prolects laterally outwardly from the main plank portion and has an upper surface spaced below an upper surface of the main plank portion.

   5. An extrudcd plank section as claimed in any one of the preceding claims, wherein the main plank portion comprises at least one jointing region extending along a longitudinal edge, wherein at least part of an upper surface of the jointing region slopes downwardly in a lateral direction of the plank section.

   7. An extruded plank section as claimed in claim 6, wherein the upper surfItce of the jointing region is shaped to define at least part of a groove or recess for receiving weld filler material.

   8. An extruded plank section as claimed in claim 6 or claim 7, wherein the material in the jointing region is differently coloured from the material in the remainder of the main plank portion.

   9. An extruded plank section as claimed in any one of claims 6 to 8 when dependant on claim 5, wherein a first jointing region extends along the fiNt longitudinal edge of the main plank portion. partially overlapping the first stiffening member.

   10. An extruded plank section as claimed in claim 9 when dependent on claim 4, wherein a second jointing region extends along the second longitudinal edge of the main plank portion, partially overlapping the second stiffening member.

   11. An extruded plank section as claimed in claim 9 or claim 10, wherein along one longitudinal edge of the plank section the stiffening member is a lower stiffening member and is spaced below the jointing region so that a longitudinal slot is defined between at least part of the lower stiffening member and the jointing member.

   12. An extruded plank section as claimed in claim 11, wherein along the other longitudina.l edge of the plank section, the stiffening member is an upper stiffening member and is aligned coplanar with the longitudinal slot, the upper stiffening member being configured and positioned so that at least an outer longitudinal edge region thereof can be inserted in the longitudinal slot of a further correspondingly constructed plank section when the two plank sections are aligned co-planar.

   13. An extruded plank section as claimed in claim 12, wherein a longitudinal edge of the upper stiffening member is curved.

   14. An cxtruded plank section substantially as hereinbefore described, with reference to and as illustrated in the accompanying drawings.iS. A ldt of parts for foniiing a surfaec covering, the kit comprising at least two extruded plank sections in accordance with any one of the preceding claims.1.6. A kit of parts as claimed in claim 15, wherein the kit comprises at lcasL tv plank sections as claimed in claim 6, or any one of claims 7 to 13 when dependent on claim 6, wherein at least two of the extruded plank sections have corresponding longitudinal edges that can be brought into abutment whcn assembling the plank sections to form part of a surface covering, the at least two plank sections each having a corresponding jointing rcgion extending along their corresponding longitudinal edge, in which the corresponding jointing regions are configured to abut one another and have upper surfaces shaped so as to define a longitudinal groove in which a. weld can he formed to join the at least two plank sections whcn the corresponding longitudinal edges of the plank sections are brought into abutment.17. A kiL of parts as claimed in claim 16, wherein the kit comprises a plurality of planks as claimed iii claim 12 or claim 13, wherein at least some of the plurality of plank sections are configured such that the upper stiffening member along one side of each plank section can be received within the longitudinal slot on the other side of another of the plank sections whcn the plank sections are brought mb abutment longitudinal edge to!ongitudinal edge to form a surface covering.18. A kit of parts as claimed in claim 17, wherein at least sonic of the plank sections are configured such that when two of the at least some plank sections are assembled together longitudinal edge to longitudinal edge, the upper stitTening member on one of the assembled planks overlaps the lower stiffening member on the other of the assembled planks.19. A kit of parts as claimed in claim 17 or claim 18, wherein the outer edge of the upper stiffening member is curved such that each plank section can he assembled to a. further of the plank sections by engaging [lie curved longitudinal edge of its upper stiffening member in the longitudinal slot ot'the further plank section whilst it is Lilted about its longitudinal axis at angle of' between 30 to 60 degrees. preferably 40 to 50 degrees, relative to a lateral plane of the further plank section.20. A surface covering comprising a plurality of plank sections in accordance with any one of claims I to 14, or constucted using a kit of parts as claimed in any one of claims 15 to 19, in which a plurality of the plank sections are connected together in abutting relation longitudinal side to longitudinal side, and wherein adjacent planks sections are welded together.21. A surface covering as claimed in claim 20, the surface covering comprising a plurality of plank sections as claimed in claim 6, wherein the weld joining each adjacent pair of plank sections is formed in a groove defined by opposed jointing regions of the pair of plank sections.22. A surface covering as claimed in claim 21, the surface covering comprising a plurality of plank sections as claimed in claim 8, wherein each weld matches the colour of the jointing rcgions.23. A surface covering substantially as hereinbefore described, with reference to and as illustrated in the accompanying drawings.24. A method of forming a surface covering comprising a plurality of plank sections in accordance with any one of claims 1 to 14, the method comprising forming a bed ofadhcsivc on a surface to be covcrcd; laying a fii* plank section in position on the bed of adhesive; positioning a further plank section on the bed of adhesive in abutting relation with the first plank section longitudinal edge to longitudinal edge; and hot welthng the first and flMher plank sections together in-situ from above.25. A method of' fonning a surface covering as claimed in claim 24, in which the plurality of plank sections comprises a plurality of plank sections as defined in claim 6, the method comprising hot welding the fast and further plank sections together along a groove defined by opposed jointing regions of the plank sections using a welding filler rod.26. A method as claimed in claim 25, the method comprising removing excess weld material using a knife or other suitable tool after welding.27. A method as claimed in any one of claims 24 to 26, in which the plurality of plank sections comprises a plurality of plank sections as dcfincd in claim 13, the step of positioning the further plank section on the bed of adhesive in abutting relation with the first plank section longitudinal edge to longitudinal edge comprising: holding the further plank section above the bed of adhesive and tilting it about its longitudinal axis at an angle of between 30 to 60 degrees, preferably between 40 to 50 degrees, relative to a lateral plane of the first plank section upwardly and away from th.e firsi plank section; engaging the curved edge of the upper stiffening member of said further plank section in the longitudinal slot of the first plank; gradually inserting the upper stiffening member on the further plank section further into the longitudinal slot on the IiIsL plank section whilst pivoting the further plank section about the curved edge of its upper stiffening member to bring the fUrther plank section into co-planar alignment with the first plank section and into contact with the bed of adhesive.28. A method of forming a surface covering substantially as hereinbefore described, with reference to and as illustrated in the accompanying drawings.