US20080038508A1

US20080038508A1 - Deck system

Info

Publication number: US20080038508A1
Application number: US11/823,676
Authority: US
Inventors: William Zell; John-Paul Braaten
Original assignee: Individual
Current assignee: Westech Building Products Inc
Priority date: 2006-06-28
Filing date: 2007-06-28
Publication date: 2008-02-14

Abstract

A deck board and a deck system include a deck board having at least one groove only appearing on either the top or the bottom of the deck board.

Description

RELATED APPLICATIONS

This application claims the benefit, and priority benefit, of U.S. Patent Application Ser. No. 60/817,004, filed Jun. 28, 2006, entitled “Deck System”.

BACKGROUND OF THE INVENTION

1. Field of the Invention
Certain embodiments of the invention relate to deck systems, in particular those which are formed of a plastic material, such as a vinyl plastic material, polyvinyl chloride (“PVC”), or polyethylene plastic.
2. Description of the Related Art
Deck systems have been proposed in the past.

SUMMARY OF THE INVENTION

In accordance with the embodiments hereinafter described, it is believed that advantages are achieved from the deck system of the present invention.

BRIEF DESCRIPTION OF THE DRAWING

In the drawing
FIG. 1 is a cross-sectional view of a deck board in accordance with an embodiment of the present invention;
FIG. 2 are perspective views of a portion of a length of deck board, the deck board being reversed, or flipped over, in one of the views, in accordance with an embodiment of the present invention;
FIG. 3 is a perspective view of a completed deck in accordance with an embodiment of the present invention;
FIG. 4 is a perspective view of a portion of a length of a J-channel member in accordance with an embodiment of the present invention;
FIG. 5 is a perspective view of a portion of a length of an I-channel member in accordance with an embodiment of the present invention;
FIG. 6 is a perspective view of a portion of a length of an undersill trim member in accordance with an embodiment of the present invention;
FIG. 7 is a perspective view of a portion of a length of a C-channel member in accordance with an embodiment of the present invention;
FIG. 8 is a perspective view of a portion of a length of an L-channel member in accordance with an embodiment of the present invention;
FIG. 9 is a perspective view of a portion of a length of a fascia member in accordance with an embodiment of the present invention;
FIG. 10 is a perspective view of a substructure for a deck and a partially completed deck in accordance with an embodiment of the present invention;
FIG. 10 a is an enlargement of a portion of FIG. 10 showing a perspective view of portions of a substructure, a J-channel member, and a deck board in accordance with an embodiment of the present invention;
FIG. 10 b is an enlargement of a portion of FIG. 10 showing a perspective view of portions of a substructure and a deck board in accordance with an embodiment of the present invention;
FIG. 11 is a perspective view of a partially completed deck in accordance with an embodiment of the present invention;
FIG. 11 a is an enlargement of a portion of FIG. 11 showing a perspective view of portions of two deck boards in accordance with an embodiment of the present invention;
FIG. 12 a is a perspective view of portions of a substructure and a deck board in accordance with an embodiment of the present invention;
FIG. 12 b is a perspective view of portions of a substructure and a deck board in accordance with an embodiment of the present invention; and
FIG. 12 c is a perspective view of portions of a substructure and a deck board in accordance with an embodiment of the present invention.
While certain embodiments of the invention will be described in connection with certain preferred embodiments shown herein, it will be understood that it is not intended to limit the invention to those embodiments. On the contrary, it is intended to cover all alternatives, modifications, and equivalents, as may be included within the spirit and scope of the invention as to be defined by the appended claims.

DETAILED DESCRIPTION OF THE INVENTION AND SPECIFIC EMBODIMENTS

With reference to FIG. 1, a sectional view of a deck board in accordance with an embodiment of the present invention is shown. Deck board 100 is generally an elongated member 101 having a generally rectangular-shaped cross-sectional configuration and includes a first side, top, or top surface, 105 and a second side, bottom, or bottom surface, 110. First side 105 includes a deck groove, or groove, 115, extending into the top surface 105 and extending along and substantially parallel with, its longitudinal axis 116 (FIGS. 2 and 11). When viewed from above, the first side 105 would appear to be formed of two individual boards, separated by groove 115. If second side 110 were to be viewed, it would appear to be formed of one complete board. For example, the width of a deck board 100 may be approximately twelve inches wide, whereby the first side 105 would appear to be two approximately six-inch wide boards laying next to each other with a gap disposed between them resulting from groove 115. Similarly the second side 110 would appear as an approximately twelve inch wide deck board 100. Deck board 100 could have other widths, as well as additional grooves 115 could be disposed in first side 105.
Strengthening webs, or reinforcing members, 120 may extend between first side 105 and second side 110 and may be disposed substantially parallel to the longitudinal axis 116 of deck board 100. Longitudinal ends, or side edges, 125 of deck board 100 extend the length of deck board 100. One end, side edge, or first side edge, 125 may include an end groove or mounting groove, 130. A deck screw 135 may be installed at an angle into end groove 130 to secure deck board 100 to a substructure 170 (FIG. 11). Another end, side edge, or second side edge, 125 may include a tongue, or outwardly extending engagement member, 140, which is adapted to matingly engage groove 130, such as in one embodiment by being frictionally received within a groove 130 of another adjoining deck board 100. Tongue 140 may be disposed substantially parallel to the longitudinal axis of 116 of deck board 100. Other shapes of webs 120 may be used, as well as a greater or fewer number of webs than illustrated may also be used.
In FIG. 2, deck board 100 is shown in the right hand view with second side 110 facing upward displaying what appears to be a single deck board 100, as previously described. Other features of deck board 100, such as end groove 130 and tongue 140, are visible as previously described with relation to FIG. 1. By flipping, turning, or rotating deck board 100 over in the direction of the arrow of the right hand view of FIG. 2, or by flipping, turning, or rotating deck board 100 over about its longitudinal axis 116, deck board 100 is shown with first side 105 facing upward in a second orientation as shown in the left hand view of FIG. 2. Deck groove 115, end groove 130 and tongue 140 are again visible as described with relation to FIG. 1. Thus deck board 100 is reversible and when disposed upon a support structure as shown in FIG. 11, second side 110 is visible if the first orientation is selected and first side 105 is visible if the second orientation is selected.
FIG. 3 is a perspective view of a completed, assembled deck 200 assembled from deck boards 100, previously described, and other deck components as will be hereinafter described. Deck 200 is disposed upon a support structure 170 and deck boards 100 form an upper surface, or floor, 201 of the deck 200. As shown in FIG. 3, deck 200 may include post supports 205 and railings 206 disposed between the post supports. The support structure 170 may include stair risers 210 and stair treads, or stairs, 211, for easy access to deck 200.
With reference to FIGS. 4-9, various components used in the construction and assembly of a deck 200 are shown. In FIG. 4 a portion of a length of J-channel, or J-channel member, 145 is shown. J-channel 145 is sized to mate with, or receive, a deck board 100, as will be hereinafter described. In FIG. 5 a portion of a length of I-channel, or I-channel member, 150 is shown. I-channel 150 is sized to mate with, or receive, the ends 141 (FIG. 10) of two deck boards 100, which are in an end-to-end abutting relationship. In FIG. 6 a portion of a length of undersill trim, or undersill trim member 155 is shown. Undersill trim 155 may be used in a deck 200, including fascia members 167 as hereinafter described. In FIG. 7 a portion of a length of C-channel, or C-channel member, 160 is shown. C-channel 160 may be used in a deck 200 including deck boards 100 as hereinafter described. In FIG. 8 a portion of a length of L-channel, or L-channel member, 165 is shown. L-channel 165 may be used in a deck 200 including deck boards 100 as hereinafter described. In FIG. 9 a portion of a length of fascia, or fascia member 167, is shown. Facia 167 may be used in a deck 200 including deck boards 100 as hereinafter described. All of the foregoing described components, including deck boards 100 may be manufactured, or made, from any suitable plastic material having the requisite strength and durability characteristics to function as parts of a deck 200, such as a thermoplastic material, PVC, or polyethylene plastic. The deck boards 100 and other components may be formed by an extrusion process.
With reference to FIG. 10, substructure 170 provides a support structure for attaching the deck boards to, and may include a plurality of joists, or joist members, 171 disposed on centers, or spaced from each other, no more than approximately 24 inches apart. The joist members 171 may be disposed within outer frame members, or header boards, 172, which are in turn secured to posts, or post supports, 173. Substructure 170 and its components may be made from wood, or plastic materials. As will be hereinafter described, a single deck board 100 may be laid upon the joist members 171 and secured thereto, with the deck board extending between two opposing header boards 172. If the deck 200 to be constructed is longer than the length of a single deck board 100, two deck boards 100 may be laid end-to-end upon the joists 171, and the abutting ends 141 of adjacent deck boards 100 may be connected by a length of I-channel member 150 (FIG. 5).
FIG. 10 a illustrates an enlarged portion of a corner of FIG. 10 showing portions of substructure 170, a J-channel 145, and a deck board 100. J-channel 145 is first attached to substructure 170, or header board 172, with deck screws 135. Deck screws 135 preferably are made of stainless steel to prevent staining of deck 200. Deck board 100 may be cut as shown to fit around or avoid features of substructure 170, such as post support 173′. As the corner post support 173′ is intended to be used to support railing 206 (FIG. 3), post supports 173′ are longer in length than post supports 173. The side edge 125 (FIG. 1) of a deck board 100 is then inserted into the J-channel 145, and the deck board 100 is secured to the joist members 171, or header boards 172, of substructure 170 with deck screws 135 as shown in FIG. 10 b. Deck screws 135 may be installed at an angle inside end groove 130 of side edge 125. If the side edge 125 having tongue 140 is to be inserted into J-channel 145, the tongue if desired may first be removed from the side edge 125 of deck board 100, as by sawing tongue 140 off. Alternatively, if desired, J-channel 145 may not be used and the first deck board is located in the desired portion upon substructure 170 and secured thereto by screws 135. Other fasteners such as nails, bolts, etc. could be used in lieu of screws 135.
With reference to FIG. 11, a partially completed deck 200 is shown. A plurality of deck boards 100 are matingly positioned and secured to the substructure 170. As shown in FIG. 11 a two deck boards 100 have their ends 141 lined up with each other and end groove 130 of one side edge 125 of one board 100 matingly engages, or receives, tongue 140 of another side edge 125 of an adjacent, abutting board 100. Boards 100 are continued to be placed upon, and secured to, substructure 170, until deck 200 is completed.
With reference to FIG. 12 a, the last deck board 100′ is positioned upon header board 172 of substructure 170, so that end groove 130 generally aligns with the edge of header board 172 of substructure 170. Deck screws 135 may be used to secure deck board 100′ to substructure 170 by installing deck screws 135 in end groove 130. As shown in FIG. 12 b in another embodiment, deck board 100″ has been cut, or sawn, along its length to remove groove 130 or tongue 140 such that neither end groove 130 nor tongue 140 appears on side edge 125 when overlying the header board 172 of substructure 170. Deck board 100″ is positioned so that side edge 125 generally aligns with an edge of the header board 172 of substructure 170. Deck screws 135 may be used to secure deck board 100″ to substructure 170. In another embodiment shown in FIG. 12 c, deck board 100″ has again been cut along its length such that neither end groove 130 nor tongue 140 appears on side edge 125. Deck board 100″ is positioned so that longitudinal end 125 overhangs an edge of header board 172 of substructure 170. A hole 174 may be made in deck board 100″, so that deck screws 135 may be used to secure deck board 100″ to substructure 170. A hole plug 175 may be positioned in hole 174 after deck board 100″ has been secured, to conceal the hole 174.
Deck boards 100, 100′, 100″ may have additional J-channels 145 surrounding the deck boards 100, 100′, 100″ to present a finished appearance to the ends 141 and side edges 125 of the deck boards as shown in FIG. 3. Where there is no overhang, as shown in FIGS. 12 a and 12 b, C-channel members 160 (FIG. 7) or L-channel members 165 (FIG. 8) may be used in place of J-channel members 145. If deck board 100″ is positioned overhanging substructure 170 as shown in FIG. 12 c, J-channels 145 may be miter cut to the correct length and may be trimmed lengthwise so that they may mate fully with the deck board 100″ where the amount of overhand of deck board 100″ over substructure 170 is small. Fascia members 167 (FIG. 9) may surround the deck 200, as by securing them to the header boards 172 to cover them as shown in FIG. 3. If desired, undersill trim members 155, may be attached to substructure 170, as with electro-galvanized roofing nails and may be used to secure fascia members 167 to the header boards 172. Fascia members 167 may be cut to fit substructure 170 and may be punched with a snaplock punch (not shown) to create snaplock tabs which may engage undersill trim members 155 (FIG. 6). Fascia members 167 cooperate with undersill trim members 155 to hold fascia members 167 securely in place by snaplocks engaging undersill trim members 155.
Deck boards 100 may be used for the steps 211 (FIG. 3) and may be secured to the stair risers 210, by use of J-channels 160. Two oppositely dispose J-channels 145 may be secured in a substantially parallel relationship to the stair risers, and a deck board, sized in accordance with the size of the desired stair, may then be slid into the two parallel J-channels 145. The ends of the deck boards used for the stairs 211, may be finished off with J-channel 145 and C-channel 160, or L-channel 165, if desired.
It should be noted that before the first deck board 100 is secured to the substructure 170, the deck installer/assembler must decide whether or not the first side, or top, 105 (FIG. 1) of deck board is to be visible when viewing deck 200, or if the second side, or bottom, 110 of deck boards 100 are to be visible. This selection may be based upon the visual appearance for the deck 200 the installer/assembler or the owner of the deck wants to achieve. Alternatively, a third appearance of the top surface, or floor, 201 of deck 200 may be achieved by varying the orientations of the deck boards 100, whereby some deck boards 100 would be mounted with top 105 displayed and others would have the bottoms 100 displayed to people viewing the floor 201 of deck 200.
The present invention has been described and illustrated with respect to specific embodiments. It will be understood to those skilled in the art that changes and modifications may be made to these embodiments without departing from the spirit and scope of the invention(s) as set forth in the appended claims.

Claims

1. A deck board, comprising:

an elongated member having a top surface and a bottom surface, a length, and a longitudinal axis; and

only one of the top or bottom surfaces having at least one groove extending along the longitudinal axis of the elongated member.

2. The deck board of claim 1, wherein the elongated member has a generally rectangular shaped cross-sectional configuration.

3. The deck board of claim 1, wherein the at least one groove extends into the top or bottom surface.

4. The deck board of claim 1, wherein the deck board includes a plurality of reinforcing members extending between the top surface and the bottom surface of the elongated member.

5. The deck board of claim 4, wherein the reinforcing members extend in a direction along the longitudinal axis of the elongated member.

6. The deck board of claim 1, wherein the deck board has first and second side edges, and the first side edge includes a mounting groove and the second side edge includes an engagement member, adapted to mate with a mounting groove of another deck board.

7. The deck board of claim 1, wherein the mounting groove and the engagement member extend the length of the elongated member, substantially parallel to the longitudinal axis of the elongated member.

8. The deck board of claim 1, wherein the deck board is made of a plastic material.

9. A deck system, comprising:

a substructure upon which a deck formed of a plurality of deck boards, may be secured; and

a plurality of deck boards secured to the substructure, with at least one of the deck boards including,

10. The deck system of claim 9, wherein the elongated member has a generally rectangular shaped cross-sectional configuration.

11. The deck board of claim 9, wherein the at least one groove extends into the top or bottom surface.

12. The deck board of claim 9, wherein the deck board includes a plurality of reinforcing members extending between the top surface and the bottom surface of the elongated member.

13. The deck board of claim 12, wherein the reinforcing members extend in a direction along the longitudinal axis of the elongated member.

14. The deck board of claim 9, wherein the deck board has first and second side edges, and the first side edge includes a mounting groove and the second side edge includes an engagement member, adapted to mate with a mounting groove of another deck board.

15. The deck board of claim 9, wherein the mounting groove and the engagement member extend the length of the elongated member, substantially parallel to the longitudinal axis of the elongated member.

16. The deck board of claim 9, wherein the deck board is made of a plastic material.

17. A method of assembling a deck, comprising:

utilizing at least one deck board member which is an elongated member having a top surface and a bottom surface, a length, and a longitudinal axis;

only one of the top or bottom surfaces having at least one groove extending along the longitudinal axis of the elongated member; and

securing the at least one deck board to a substructure in either a first orientation wherein the at least one groove is visible and faces upwardly, or in a second orientation wherein the at least one groove is not visible and faces downwardly.

18. The method of claim 17, including utilizing at least one J-channel member in association with the at least one deck board.

19. The method of claim 17, including utilizing at least one undersill trim member in association with the at least one deck board.

20. The method of claim 17, including utilizing at least one C-channel member in association with the at least one deck board.