WO2013011192A1 - A decking board and a method and a system for manufacturing a decking board - Google Patents

A decking board and a method and a system for manufacturing a decking board Download PDF

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Publication number
WO2013011192A1
WO2013011192A1 PCT/FI2012/050708 FI2012050708W WO2013011192A1 WO 2013011192 A1 WO2013011192 A1 WO 2013011192A1 FI 2012050708 W FI2012050708 W FI 2012050708W WO 2013011192 A1 WO2013011192 A1 WO 2013011192A1
Authority
WO
WIPO (PCT)
Prior art keywords
decking board
decking
distance
corners
corner
Prior art date
Application number
PCT/FI2012/050708
Other languages
French (fr)
Inventor
Harri Latikka
Piia Peltola
Liisa Lehtinen
Sami Kirvesoja
Original Assignee
Upm-Kymmene Corporation
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Upm-Kymmene Corporation filed Critical Upm-Kymmene Corporation
Priority to DE212012000126.3U priority Critical patent/DE212012000126U1/en
Publication of WO2013011192A1 publication Critical patent/WO2013011192A1/en

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
    • B29C48/09—Articles with cross-sections having partially or fully enclosed cavities, e.g. pipes or channels
    • B29C48/11—Articles with cross-sections having partially or fully enclosed cavities, e.g. pipes or channels comprising two or more partially or fully enclosed cavities, e.g. honeycomb-shaped
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00—Flooring
    • E04F15/02—Flooring or floor layers composed of a number of similar elements
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
    • B29C48/07—Flat, e.g. panels
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/003—Balconies; Decks

Definitions

  • This invention relates to a decking board. This invention further relates to a method and a system for manufacturing a decking board.
  • a decking board is an element that may be used, for example, for terraces, rooms and ceilings.
  • the decking boards may consist of wood material. They may comprise, for example, pre-cut timber materials. It is also possible to manufacture decking boards that comprise plastic as a raw material.
  • the present invention discloses a novel decking board.
  • the present invention discloses a solution for manufacturing a decking board.
  • the structure of the decking board having, among other things, large radii of curvature of the corners of a second side of the decking board may have very good strength properties. This effect can be increased if also corners of a first side have large radii of curvature.
  • the inventors of the present invention have surprisingly found a way to manufacture a novel decking board. Due to the structure of the novel decking board, it is possible, among other things, to increase the strength properties of the manufactured decking board and/or production efficiency of the decking board even while using recycled material as a raw material.
  • the amount of the recycled raw materials may need to be increased due to environmental reasons.
  • strength properties of a manufactured decking board may be decreased along with an addition of recycled materials, such as recycled fibers and fillers. Due to the good strength properties of the novel decking board, it is possible to use more recycled material as a raw material than with conventional decking boards, i.e. the novel product may be more environmentally friendly than conventional decking boards.
  • the decking board comprises recycled cellulose fibers and recycled plastic polymers.
  • the raw material of the decking board comprises adhesive label waste material.
  • the decking board may comprise at least one kind of virgin polymer, such as polyolefin, preferably polypropylene.
  • used raw materials are preferably treated in an extruder in order to form the new decking board.
  • the decking board has preferably only one installation side, i.e. the decking board is not symmetrical in the vertical direction, but, on the contrary, a second side of the decking board and a first side of the decking board differ from each other.
  • the new decking board and/or the manufacturing process may make it possible
  • the manufactured decking board may be recycled or re-ground and converted to a new product; - to install the manufactured decking board with conventional woodworking tools,
  • FIG. 1 shows an example embodiment of the decking board according to the invention
  • Fig. 2 shows a first side of the decking board presented in the figure 1 ,
  • Fig. 3 shows a second side of the decking board presented in the figure 1 .
  • Figs 4, 5 and 9 show an end side of the decking board presented in the figure 1 .
  • Fig. 6 shows a height of the groove of the second side
  • Figs 7 and 8 show a part of the end side of the decking board presented in the figure 5, and
  • Fig. 10 shows an example embodiment of three decking boards that are fastened by a fastening member.
  • a first distance i.e. a distance between an oval hole and a second side
  • R1 a radius of outer curvature of the corner of the second side
  • R3 radius of curvature of the groove 12 on the first side.
  • the decking board is preferably a part of a floor, most preferably a part of a terrace floor.
  • the decking board may also be a part of a ceiling or a wall.
  • first side 3 and “first surface 3" refer to a side that is in view when the decking board is installed, i.e. an installation side of a decking board 1 . If the decking board (when installed) is part of a floor (such as a terrace), the first side 3 is a top side of the decking board 1 .
  • the term "corner of the first side” refers to a corner of the first side of the decking board. If the decking board is part of a floor, the corner of the first side is an upper corner of the decking board.
  • second side 2 and “second surface 2" refer to a side that is not usually in view when the decking board is installed. If the decking board (when installed) is a part of a floor (such as a terrace), the second side 2 is a bottom side of the decking board 1 .
  • corner of the second side refers to a corner of the second side of the decking board. If the decking board is part of a floor, the corner of the second side is a bottom corner of the decking board.
  • the decking board has a first side 3, also called as an installation side, and a second side 2.
  • the first side 3 has preferably good strength properties without appearance defects.
  • the second side 2 has preferably a structure that is compatible with a fastening member 20 of the decking board 1 in order to achieve good fastening of the decking board. Therefore, there are advantageously different structures on the first side 3 and the second side 2 of the decking board 1 .
  • the decking board 1 is preferably symmetrical in the width direction 15, i.e. the first transversal side FS of the decking board is preferably substantially a mirror image of the second transversal side SS of the decking board. Therefore, the properties of the decking board 1 presented in this application relate to both sides, i.e.
  • the properties of a corner of the second side presented in this application relate to both corners of the second side, i.e. the corners of the first transversal side FS and the second transversal side SS of the decking board.
  • the properties of a corner of the first side presented in this application relate to both corners of the first side, i.e. the corners of the first transversal side FS and the second transversal side SS of the decking board 1 .
  • the corners of the first transversal side FS and the area between them preferably form a groove 22.
  • the corners of the second transversal side SS and the area between them preferably form a groove 23.
  • the width 15 of the decking board is preferably at least 100 mm, more preferably the width 15 is between 100 and 140 mm. According to an advantageous embodiment of the invention the width 15 of the decking board is approximately 120 mm.
  • the height 14 of the decking board 1 is preferably at least 15 mm, more preferably at least 20 mm or at least 25 mm.
  • the height of the decking board is preferably 50 mm at the most or 40 mm at the most, more preferably 35 mm at the most or 30 mm at the most.
  • the height 14 of the decking board is between 25 and 31 mm, for example 28 mm.
  • the weight of the decking board 1 is preferably between 650 and 830 kg/m 3 , more preferably between 680 and 800 kg/m 3 .
  • the decking board 1 is manufactured in such a way that the weight of the decking board is between 2.2 and 2.8 kg/m, preferably between 2.3 and 2.7 kg/m.
  • the decking board 1 may comprise oval holes 1 1 .
  • the decking board 1 has preferably at least two oval holes 1 1 , more preferably at least three oval holes 1 1 .
  • the number of the oval holes may be, for example, between 2 and 6 or between 3 and 5.
  • the decking board comprises three oval holes 1 1 .
  • the weight of the product 1 and the amount of the needed raw material decrease due to the holes 1 1 . Thanks to the decreased weight of the decking board 1 , the installation of the decking boards 1 may be easier and, moreover, the transportation of said decking boards 1 may be cheaper than with conventional decking boards, which do not comprises any kind of holes.
  • not only oval shaped holes, but also holes of other shape may be used in the decking board.
  • Holes of other shape may comprise, for example, symmetrically rounded (circled) holes or tetragon shaped holes, such as square shaped holes. Even these kinds of holes will cause decreased weight of the product, typically even more than the oval shaped holes, and, hence, decrease the transportation costs. Even so, the oval holes are preferably used in the invention, because the strength of the decking board 1 comprising oval holes 1 1 may be much better than the strength of a decking board comprising tetragon shaped holes, and even better than the strength of a decking board comprising symmetrically rounded (circled) holes. In other words, the shape of the oval hole 1 1 is better than a shape of many other kinds of holes in order to achieve better strength properties.
  • the oval holes 1 1 may increase the production efficiency by increasing the runnability of the manufacturing process, because the oval shaped holes may be used in order to achieve small friction during the manufacturing process.
  • there should not be too many oval holes 1 1 in the decking board because too many oval holes 1 1 may decrease the strength properties of the decking board 1 . This should be considered at least when the amount of the used recycled raw material is at least 70%.
  • a first distance 8 between an oval hole 1 1 and the second side 2 of the decking board is preferably substantially the same as the second distance 9, i.e. the first distance 8 differs from the second distance 9 preferably 20% at the most (i.e.
  • the second distance 9 between two oval holes 1 1 is preferably substantially the same as a third distance 18 between an oval hole 1 1 and a surface 3 of the decking board.
  • the difference between the second distance 9 and the third distance 18 is preferably 20% at the most (i.e. between 0.8 and 1 .2), preferably 15% at the most.
  • the first distance 8, the second distance 9 and the third distance 18 are between 3 and 10 mm, preferably between 4 and 7 mm.
  • Shapes and dimensions of the oval holes are preferably selected in such a way that it is possible to achieve very good runnability properties for the decking board to be manufactured.
  • the width 16 of the oval hole 1 1 is preferably about 25 mm, for example between 20 and 30 mm.
  • the height 17 of the oval hole 1 1 is predetermined in such a way that the third distance 18 between the oval hole 1 1 and the first side 3 and the first distance 8 between an oval hole 1 1 and a second side 2 are both at least 3 mm, more preferably between 5 and 7 mm.
  • the height 17 of the oval hole 1 1 is approximately 16 mm, for example between 14 and 18 mm.
  • the height 10 of the corner of the second side 5 of the decking board 1 is preferably between 5 and 7 mm. According to an advantageous embodiment of the invention, the height 10 of the corner of the second side 5 is approximately 6 mm.
  • a length of the corner of the second side 5, i.e. the length of the inner surface 5b of the corner of the second side (shown in fig. 8), is preferably at least 5 mm or at least 6 mm, more preferably at least 8 mm or 10 mm.
  • the length of corner of the second side 5 i.e. the inner surface 5b of the corner of the second side, is preferably 25 mm at the most or 20 mm at the most, more preferably 15 mm at the most or 12 mm at the most.
  • the radius of the curvature R1 a, R1 b of the corner of the second side 5 is preferably limited by the height 10 of the corner of the second side 5 and/or a space needed for fastening means 20 used for the fastening of the decking boards 1 .
  • the radii of the curvature (R1 a, R1 b) of the corner of the second side 5 are preferably both between 0.5 * height 10 of the corner of the second side and 0.25 * height 10 of the corner of the second side.
  • the radii of curvature (R1 a, R1 b) of the corner of the second side 5 may be, for example, between 0.8 and 1 .2 times 0.4 times the height 10 of the corner of the second side, i.e.
  • the radius of the curvature (R1 a, R1 b) of the corner of the second side 5 is between 1 .5 and 3 mm.
  • the structure of the corner of the second side 5 is such that a fastening member 20, preferably a so called T-clip manufactured by UPM Corporation, can be used with the new decking board 1 .
  • a fastening member 20 preferably a so called T-clip manufactured by UPM Corporation
  • the above mentioned definition may be used for the radius of curvature of the corner of the second side.
  • a radius of curvature R2 of the corner of the first side 4 is preferably quite large in order to increase the runnability of the manufacturing process.
  • the radius of curvature R2 is usually limited by the height 13 of the corner of the first side 4, i.e. the radius of curvature R2 of the corner of the first side 4 is preferably 0.6 or 0.5 times the height 13 of the corner of the first side at the most.
  • the large radius of the curvature R2 also increases the strength properties of the decking board 1 .
  • the strength properties may be important because, in the end use, there may be, among other things, quite heavy furniture and, in addition, persons with high-heeled shoes walking on the decking board 1 .
  • the radius of curvature R2 of the corner of the first side 4 is advantageously at least the same as the radius of curvature R1 , R1 a, R1 b of the corner of the second side 5, more preferably R2 > R1 .
  • the radius of curvature R2 of the corner of the first side 4 is between 3 and 5 mm.
  • the above mentioned definition may be used for the radius of curvature of the corner of the second side.
  • the decking board 1 may have a supporting structure 7 within the corner of the first side 4. Thanks to the supporting structure 7, the strength of the corner of the first side 4 of the decking board 1 and, therefore, the strength of the whole decking board 1 may be substantially increased. In addition, the runnability of the manufacturing process may be increased thanks to the supporting structure 7.
  • the supporting structure 7 of the corner of the first side 4 extends to a first end point 25 of the supporting structure 7, which is preferably at least 6 mm above of the inner surface 5b of the corner of the second side 5, more preferably at least 7 mm or at least 8 mm above of the inner surface 5b of the corner of the second side 5.
  • the supporting structure 7 of the corner of the first side 4 extends from the first end point 25 of the supporting structure 7 to the second end point 26 of the supporting structure, which second point 26 is at the inner side of the corner of the first side.
  • the length 27 of the supporting structure 7 is preferably at least 8 mm, more preferably between 8 and 10 mm. Thanks to the above mentioned dimensions, the strength properties of the decking board may be increased.
  • a fastening member 20 may be used in order to fasten the manufactured decking board.
  • the fastening member 20 may need a space of about 5 mm above the corner of the second side. There may also be some thermal expansion in the decking board that need to be taken into account.
  • the first side 3 of the decking board 1 has preferably many very tiny grooves 12 in order to achieve high-friction surface.
  • the width 19a between the grooves 12 may be between 5 and 20 mm, more preferably between 10 and 14 mm.
  • the height 19b of the groove 12 on the first side 3 may be between 1 and 2 mm.
  • a radius of curvature R3 of the groove 12 is preferably between 1 and 2 mm. Thanks to the tiny grooves 12, the friction of the first side 3 of the decking board 1 may be increased resulting in good anti-slip properties even when the first side 3 is wet. Moreover, the first side 3 may be easy to clean due to the very tiny size and rounded corners of the grooves.
  • the second side 2 of the decking board 1 has preferably some grooves 6.
  • the grooves 6 are added to the second side 2 in order to prevent possible problems caused by drying shrinkage. Due to the grooves 6, a blistering effect may be prevented.
  • the grooves 6 are preferably small in size.
  • the height 21 of the grooves 6 is preferably between 0.2 and 3.0 mm or between
  • the amount of the grooves 6 on the second side 2 is preferably one less than the amount of the oval holes 1 1 in the decking board
  • the grooves 6 on the second side are preferably placed at a location which is between the oval holes 1 1 in the vertical direction of the decking board 1 in such a way that there is always one groove 6 on the second side of the decking board at a location which is between the holes 1 1 in the vertical direction of the decking board 1 .
  • a distance between two grooves 6 is between 38 and 50 mm, preferably between 42 and 46 mm.
  • the decking board 1 is advantageously cellulose fiber plastic composite, for example, wood plastic composite.
  • Cellulose fibers used in this invention can come from any plant material that contains cellulose, for example wood material.
  • the wood material can be from softwood trees, such as spruce, pine, fir, larch, douglas-fir or hemlock, or from hardwood trees, such as birch, aspen, poplar, alder, eucalyptus or acacia, or from a mixture of softwoods and hardwoods.
  • Non-wood material can be from agricultural residues, grasses or other plant substances such as straw, leaves, bark, seeds, hulls, flowers, vegetables or fruits from cotton, corn, wheat, oat, rye, barley, rice, flax, hemp, manila hemp, sisal hemp, jute, ramie, kenaf, bagasse, bamboo or reed.
  • the decking board advantageously comprises 20 - 60 w-% cellulose fibers, preferably 20- 50 w-% cellulose fibers.
  • the cellulose fibers used for the decking board comprise at least 60 % chemically treated cellulose fibers (i.e. lignin free cellulose fibers), preferably the fibers used for the decking board comprise at least 70 % or at least 80 %, preferably at least 90 % or at least 95 % chemically treated lignin free cellulose fibers.
  • the decking board advantageously comprises from 20 to 80 w-% plastic polymers, preferably from 20 to 60 w-%.
  • the plastic polymer may be virgin or recycled.
  • the amount of the added plastic polymer, such as polypropylene, depends on the other raw material used. For example, if recycled material is used, the amount of added polymer depends on the amount of the different raw materials coming along the recycled material.
  • the decking board 1 preferably comprises at least 70 w-% recycled raw material and, for example, the only added not recycled plastic may be polypropylene. Additionally the decking board may comprise fillers.
  • the decking board 1 may also comprise other compounds, such as colours and waxes.
  • the recycled raw material comprises preferably paper and plastic, most preferably the recycled material comprises paper and plastic polymers which fall as surplus in self-adhesive label production.
  • the proportion of the recycled paper and recycled plastic may vary depending on the product application.
  • the recycled label material may comprise surplus paper and plastic left over from the production of self-adhesive label materials.
  • the adhesive label laminate waste originates from adhesive label laminate production, which primarily produces production reject waste, edge cuttings from rolls and roll ends; from adhesive label laminate printing stations, producing primarily roll ends and label material left over from the die cutting of stickers and labels as well as reject; and/or from the end user clients of the adhesive label laminate, who paste the printed stickers and labels or the like onto their products.
  • the waste coming from the end users is primarily release material, roll ends, and waste from the finished product.
  • the adhesive label laminate waste is typically formed of label material, an adhesive layer, and release material.
  • the liner of the label is usually a paper having a silicone coating or a plastic coating.
  • the plastic polymer is preferably polypropylene.
  • the plastic polymer may also be PVC, polyethylene, polypropylene, polystyrene or polyester.
  • the amount of the adhesive label laminate waste in the decking board 1 is preferably between 50-85 w-%.
  • the adhesive label laminate waste may comprise, for example, adhesives 0 - 5 w-% or 1 - 4 w-% silicone 0-10 w-% or 1 - 9 w-%, cellulose fibers 20-100 w-%, and polymers 0-100 w-% or 5 - 95 w-%.
  • the amount of additionally dosed plastic polymers is advantageously 15-50 w-% from the decking board 1 .
  • Inorganic fillers may be added in order to increase the stiffness properties of the product.
  • the amount of the fillers in the decking board is preferably between 0 and 25 w-%.
  • the fillers preferably consist mostly of talc and/or calcium carbonate and/or fly ash and/or mica and/or glass-filler (i.e. at least 50 w-% from the fillers).
  • the decking board may be coloured, for example, by using pigments. Therefore, the decking board 1 may comprise colours.
  • the manufactured decking board is preferably a wood plastic composite, for example a paper plastic composite.
  • the decking board 1 may be manufactured, for example, by extrusion or by injection moulding process.
  • the decking board 1 is manufactured in an extrusion process using an extruder.

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  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
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Abstract

The invention relates to a decking board comprising two corners (4) on the first side (3) and two corners (5) on the second side (2). The decking board further comprises at least two oval holes (1 1 ) between the first side (3) and the second side (2). Also, there is a first distance (8) between one of the at least two oval holes (1 1 ) and the second side (2), a second distance (9) between the oval holes (1 1 ) and a third distance (18) between one of the at least two oval holes (1 1 ) and the first side (3). This invention further relates to a method and a system for manufacturing the decking board.

Description

A DECKING BOARD AND A METHOD AND A SYSTEM FOR MANUFACTURING A DECKING BOARD
Field of the Invention
This invention relates to a decking board. This invention further relates to a method and a system for manufacturing a decking board.
Background of the Invention
A decking board is an element that may be used, for example, for terraces, rooms and ceilings. The decking boards may consist of wood material. They may comprise, for example, pre-cut timber materials. It is also possible to manufacture decking boards that comprise plastic as a raw material.
However, there is still a need for a new decking board and for a method and a system for manufacturing a decking board.
Summary of the Invention
The present invention discloses a novel decking board. In addition, the present invention discloses a solution for manufacturing a decking board.
The structure of the decking board having, among other things, large radii of curvature of the corners of a second side of the decking board may have very good strength properties. This effect can be increased if also corners of a first side have large radii of curvature.
The inventors of the present invention have surprisingly found a way to manufacture a novel decking board. Due to the structure of the novel decking board, it is possible, among other things, to increase the strength properties of the manufactured decking board and/or production efficiency of the decking board even while using recycled material as a raw material.
The amount of the recycled raw materials may need to be increased due to environmental reasons. However, it has been observed that strength properties of a manufactured decking board may be decreased along with an addition of recycled materials, such as recycled fibers and fillers. Due to the good strength properties of the novel decking board, it is possible to use more recycled material as a raw material than with conventional decking boards, i.e. the novel product may be more environmentally friendly than conventional decking boards. Thus, according to an advantageous embodiment of the invention, the decking board comprises recycled cellulose fibers and recycled plastic polymers. In addition, it is possible to add oval holes into the structure of the decking board in order to decrease the weight of the product.
According to an advantageous embodiment of the invention, the raw material of the decking board comprises adhesive label waste material. In addition, the decking board may comprise at least one kind of virgin polymer, such as polyolefin, preferably polypropylene. In the method for manufacturing a decking board, used raw materials are preferably treated in an extruder in order to form the new decking board.
The decking board has preferably only one installation side, i.e. the decking board is not symmetrical in the vertical direction, but, on the contrary, a second side of the decking board and a first side of the decking board differ from each other.
The new decking board and/or the manufacturing process may make it possible
- to manufacture the decking board more efficiently,
- to manufacture the decking board mainly from recycled materials,
- to manufacture the decking board with good runnability,
- to manufacture a decking board not containing any harmful chemicals,
- to manufacture an environmentally friend decking board,
- to manufacture the decking board without any PVC,
- to manufacture a fully recyclable decking board; for example, the manufactured decking board may be recycled or re-ground and converted to a new product; - to install the manufactured decking board with conventional woodworking tools,
- to fasten the decking board with known fastening members,
- to show a good solution for waste off-cuts and trimmings from self- adhesive labels.
Aspects of the invention are characterized by what is stated in the independent claims 1 , 17, 18 and 19. Various embodiments of the invention are disclosed in the dependent claims.
Description of the Drawings
In the following, the invention will be illustrated by drawings in which Fig. 1 shows an example embodiment of the decking board according to the invention,
Fig. 2 shows a first side of the decking board presented in the figure 1 ,
Fig. 3 shows a second side of the decking board presented in the figure 1 ,
Figs 4, 5 and 9 show an end side of the decking board presented in the figure 1 ,
Fig. 6 shows a height of the groove of the second side,
Figs 7 and 8 show a part of the end side of the decking board presented in the figure 5, and
Fig. 10 shows an example embodiment of three decking boards that are fastened by a fastening member. Detailed Description of the Invention
The following reference numbers are used in this application:
1 a decking board,
2 second side of the decking board, i.e. second surface of the decking board,
3 first side of the decking board, i.e. first surface of the decking board,
4 a corner of the first side of the decking board,
4b inner surface of the corner of the first side,
5 a corner of the second side of the decking board,
5b inner surface of the corner of the second side,
6 a groove on the second side of the decking board,
7 a supporting structure of the corner 4 of the first side,
8 a first distance, i.e. a distance between an oval hole and a second side,
9 a second distance, i.e. a distance between two oval holes,
10 height of the corner of the second side,
1 1 an oval hole,
12 a groove on the first side of the decking board,
13 height of the corner of the first side,
14 height of the decking board, i.e. a vertical direction of the decking board,
15 width of the decking board,
16 width of the oval hole,
17 height of the oval hole,
18 a third distance, i.e. a distance between an oval hole and a first side, 19a width between the grooves on the first side 3, i.e. length between two nearest grooves 12,
19b height of the groove on the first side 3,
20 a fastening member,
21 height of the second side's groove,
22 a groove formed by the corners of a first transversal side FS and a first area between them,
23 a groove formed by the corners of a second transversal side SS and a second are between them, 25 a first end point of the supporting structure 7,
26 a second end point of the supporting structure,
27 length of the supporting structure 7,
FS a first transversal side of the decking board,
SS a second transversal side of the decking board,
R1 radius of curvature of the corner of the second side,
R1 a radius of outer curvature of the corner of the second side,
R1 b radius of inner curvature of the corner of the second side,
R2 radius of curvature of the corner of the first side, and
R3 radius of curvature of the groove 12 on the first side.
The decking board is preferably a part of a floor, most preferably a part of a terrace floor. The decking board may also be a part of a ceiling or a wall. The terms "first side 3" and "first surface 3" refer to a side that is in view when the decking board is installed, i.e. an installation side of a decking board 1 . If the decking board (when installed) is part of a floor (such as a terrace), the first side 3 is a top side of the decking board 1 . The term "corner of the first side" refers to a corner of the first side of the decking board. If the decking board is part of a floor, the corner of the first side is an upper corner of the decking board.
The terms "second side 2" and "second surface 2" refer to a side that is not usually in view when the decking board is installed. If the decking board (when installed) is a part of a floor (such as a terrace), the second side 2 is a bottom side of the decking board 1 .
The term "corner of the second side" refers to a corner of the second side of the decking board. If the decking board is part of a floor, the corner of the second side is a bottom corner of the decking board.
The decking board has a first side 3, also called as an installation side, and a second side 2. The first side 3 has preferably good strength properties without appearance defects. The second side 2 has preferably a structure that is compatible with a fastening member 20 of the decking board 1 in order to achieve good fastening of the decking board. Therefore, there are advantageously different structures on the first side 3 and the second side 2 of the decking board 1 . The decking board 1 is preferably symmetrical in the width direction 15, i.e. the first transversal side FS of the decking board is preferably substantially a mirror image of the second transversal side SS of the decking board. Therefore, the properties of the decking board 1 presented in this application relate to both sides, i.e. to the first transversal side and to the second transversal side. In other words, for example the properties of a corner of the second side presented in this application relate to both corners of the second side, i.e. the corners of the first transversal side FS and the second transversal side SS of the decking board. Similarly, the properties of a corner of the first side presented in this application relate to both corners of the first side, i.e. the corners of the first transversal side FS and the second transversal side SS of the decking board 1 . The corners of the first transversal side FS and the area between them preferably form a groove 22. Similarly, the corners of the second transversal side SS and the area between them preferably form a groove 23.
The width 15 of the decking board is preferably at least 100 mm, more preferably the width 15 is between 100 and 140 mm. According to an advantageous embodiment of the invention the width 15 of the decking board is approximately 120 mm.
The height 14 of the decking board 1 is preferably at least 15 mm, more preferably at least 20 mm or at least 25 mm. In addition, the height of the decking board is preferably 50 mm at the most or 40 mm at the most, more preferably 35 mm at the most or 30 mm at the most. According to an advantageous embodiment of the invention, the height 14 of the decking board is between 25 and 31 mm, for example 28 mm.
The weight of the decking board 1 is preferably between 650 and 830 kg/m3, more preferably between 680 and 800 kg/m3. According to an advantageous embodiment, the decking board 1 is manufactured in such a way that the weight of the decking board is between 2.2 and 2.8 kg/m, preferably between 2.3 and 2.7 kg/m.
The decking board 1 may comprise oval holes 1 1 . The decking board 1 has preferably at least two oval holes 1 1 , more preferably at least three oval holes 1 1 . The number of the oval holes may be, for example, between 2 and 6 or between 3 and 5. According to an advantageous embodiment, the decking board comprises three oval holes 1 1 . The weight of the product 1 and the amount of the needed raw material decrease due to the holes 1 1 . Thanks to the decreased weight of the decking board 1 , the installation of the decking boards 1 may be easier and, moreover, the transportation of said decking boards 1 may be cheaper than with conventional decking boards, which do not comprises any kind of holes. However, not only oval shaped holes, but also holes of other shape may be used in the decking board. Holes of other shape may comprise, for example, symmetrically rounded (circled) holes or tetragon shaped holes, such as square shaped holes. Even these kinds of holes will cause decreased weight of the product, typically even more than the oval shaped holes, and, hence, decrease the transportation costs. Even so, the oval holes are preferably used in the invention, because the strength of the decking board 1 comprising oval holes 1 1 may be much better than the strength of a decking board comprising tetragon shaped holes, and even better than the strength of a decking board comprising symmetrically rounded (circled) holes. In other words, the shape of the oval hole 1 1 is better than a shape of many other kinds of holes in order to achieve better strength properties. Moreover, the oval holes 1 1 may increase the production efficiency by increasing the runnability of the manufacturing process, because the oval shaped holes may be used in order to achieve small friction during the manufacturing process. However, there should not be too many oval holes 1 1 in the decking board because too many oval holes 1 1 may decrease the strength properties of the decking board 1 . This should be considered at least when the amount of the used recycled raw material is at least 70%. In addition, if a mould is used in the manufacturing process, there probably should not be too many holes in the decking board 1 . A first distance 8 between an oval hole 1 1 and the second side 2 of the decking board is preferably substantially the same as the second distance 9, i.e. the first distance 8 differs from the second distance 9 preferably 20% at the most (i.e. between 0.8 and 1 .2), more preferably 15% at the most. In addition, the second distance 9 between two oval holes 1 1 is preferably substantially the same as a third distance 18 between an oval hole 1 1 and a surface 3 of the decking board. In other words, the difference between the second distance 9 and the third distance 18 is preferably 20% at the most (i.e. between 0.8 and 1 .2), preferably 15% at the most. In addition, due to the above mentioned ratio, it is possible to manufacture better board decks comprising lots of fillers and recycled fibers. According to an advantageous embodiment of the invention, the first distance 8, the second distance 9 and the third distance 18 are between 3 and 10 mm, preferably between 4 and 7 mm.
Shapes and dimensions of the oval holes are preferably selected in such a way that it is possible to achieve very good runnability properties for the decking board to be manufactured. The width 16 of the oval hole 1 1 is preferably about 25 mm, for example between 20 and 30 mm. The height 17 of the oval hole 1 1 is predetermined in such a way that the third distance 18 between the oval hole 1 1 and the first side 3 and the first distance 8 between an oval hole 1 1 and a second side 2 are both at least 3 mm, more preferably between 5 and 7 mm. According to an advantageous embodiment of the invention, the height 17 of the oval hole 1 1 is approximately 16 mm, for example between 14 and 18 mm.
The height 10 of the corner of the second side 5 of the decking board 1 is preferably between 5 and 7 mm. According to an advantageous embodiment of the invention, the height 10 of the corner of the second side 5 is approximately 6 mm. A length of the corner of the second side 5, i.e. the length of the inner surface 5b of the corner of the second side (shown in fig. 8), is preferably at least 5 mm or at least 6 mm, more preferably at least 8 mm or 10 mm. The length of corner of the second side 5 (i.e. the inner surface 5b of the corner of the second side, is preferably 25 mm at the most or 20 mm at the most, more preferably 15 mm at the most or 12 mm at the most. The radius of the curvature R1 a, R1 b of the corner of the second side 5 is preferably limited by the height 10 of the corner of the second side 5 and/or a space needed for fastening means 20 used for the fastening of the decking boards 1 . The radii of the curvature (R1 a, R1 b) of the corner of the second side 5 are preferably both between 0.5 * height 10 of the corner of the second side and 0.25 * height 10 of the corner of the second side. The radii of curvature (R1 a, R1 b) of the corner of the second side 5 may be, for example, between 0.8 and 1 .2 times 0.4 times the height 10 of the corner of the second side, i.e. between 0.32 and 0.48 times the height 10 of the corner of the second side. According to an advantageous embodiment of the invention, the radius of the curvature (R1 a, R1 b) of the corner of the second side 5 is between 1 .5 and 3 mm. According to an advantageous embodiment of the invention, the structure of the corner of the second side 5 is such that a fastening member 20, preferably a so called T-clip manufactured by UPM Corporation, can be used with the new decking board 1 . There may also be, for example, only one radius of curvature R1 of the corner of the second side. Despite the number of the radii of the curvature R1 of the corner of the second side, the above mentioned definition may be used for the radius of curvature of the corner of the second side.
A radius of curvature R2 of the corner of the first side 4 is preferably quite large in order to increase the runnability of the manufacturing process. The radius of curvature R2 is usually limited by the height 13 of the corner of the first side 4, i.e. the radius of curvature R2 of the corner of the first side 4 is preferably 0.6 or 0.5 times the height 13 of the corner of the first side at the most. The large radius of the curvature R2 also increases the strength properties of the decking board 1 . The strength properties may be important because, in the end use, there may be, among other things, quite heavy furniture and, in addition, persons with high-heeled shoes walking on the decking board 1 . The radius of curvature R2 of the corner of the first side 4 is advantageously at least the same as the radius of curvature R1 , R1 a, R1 b of the corner of the second side 5, more preferably R2 > R1 . According to an advantageous embodiment of the invention, the radius of curvature R2 of the corner of the first side 4 is between 3 and 5 mm. There may be also, for example, two radii of curvature R2 of the corner of the first side. Despite the number of the radii of curvature R2 of the corner of the first side, the above mentioned definition may be used for the radius of curvature of the corner of the second side. Usually, the larger the radii of curvature R1 of the corner of the second side 5 and the radii of curvature R2 of the corner of the first side 4 are, the better is the runnability of the manufacturing machine and, hence, the more efficiently the decking board 1 may be manufactured. The decking board 1 may have a supporting structure 7 within the corner of the first side 4. Thanks to the supporting structure 7, the strength of the corner of the first side 4 of the decking board 1 and, therefore, the strength of the whole decking board 1 may be substantially increased. In addition, the runnability of the manufacturing process may be increased thanks to the supporting structure 7.
The supporting structure 7 of the corner of the first side 4 extends to a first end point 25 of the supporting structure 7, which is preferably at least 6 mm above of the inner surface 5b of the corner of the second side 5, more preferably at least 7 mm or at least 8 mm above of the inner surface 5b of the corner of the second side 5. The supporting structure 7 of the corner of the first side 4 extends from the first end point 25 of the supporting structure 7 to the second end point 26 of the supporting structure, which second point 26 is at the inner side of the corner of the first side. The length 27 of the supporting structure 7 is preferably at least 8 mm, more preferably between 8 and 10 mm. Thanks to the above mentioned dimensions, the strength properties of the decking board may be increased. Moreover, a fastening member 20 may be used in order to fasten the manufactured decking board. The fastening member 20 may need a space of about 5 mm above the corner of the second side. There may also be some thermal expansion in the decking board that need to be taken into account.
The first side 3 of the decking board 1 has preferably many very tiny grooves 12 in order to achieve high-friction surface. The width 19a between the grooves 12 may be between 5 and 20 mm, more preferably between 10 and 14 mm. The height 19b of the groove 12 on the first side 3 may be between 1 and 2 mm. A radius of curvature R3 of the groove 12 is preferably between 1 and 2 mm. Thanks to the tiny grooves 12, the friction of the first side 3 of the decking board 1 may be increased resulting in good anti-slip properties even when the first side 3 is wet. Moreover, the first side 3 may be easy to clean due to the very tiny size and rounded corners of the grooves.
The second side 2 of the decking board 1 has preferably some grooves 6. The grooves 6 are added to the second side 2 in order to prevent possible problems caused by drying shrinkage. Due to the grooves 6, a blistering effect may be prevented. The grooves 6 are preferably small in size. The height 21 of the grooves 6 is preferably between 0.2 and 3.0 mm or between
0.5 and 2.0 mm. The amount of the grooves 6 on the second side 2 is preferably one less than the amount of the oval holes 1 1 in the decking board
1 . For example, if there are three oval holes 1 1 in the decking board 1 , there are preferably two grooves 6 on the second side 2 of the decking board 1 .
The grooves 6 on the second side are preferably placed at a location which is between the oval holes 1 1 in the vertical direction of the decking board 1 in such a way that there is always one groove 6 on the second side of the decking board at a location which is between the holes 1 1 in the vertical direction of the decking board 1 . This can also be seen in the Figure 5. According to an advantageous embodiment of the invention, a distance between two grooves 6 is between 38 and 50 mm, preferably between 42 and 46 mm. The decking board 1 is advantageously cellulose fiber plastic composite, for example, wood plastic composite. Cellulose fibers used in this invention can come from any plant material that contains cellulose, for example wood material. The wood material can be from softwood trees, such as spruce, pine, fir, larch, douglas-fir or hemlock, or from hardwood trees, such as birch, aspen, poplar, alder, eucalyptus or acacia, or from a mixture of softwoods and hardwoods. Non-wood material can be from agricultural residues, grasses or other plant substances such as straw, leaves, bark, seeds, hulls, flowers, vegetables or fruits from cotton, corn, wheat, oat, rye, barley, rice, flax, hemp, manila hemp, sisal hemp, jute, ramie, kenaf, bagasse, bamboo or reed. The decking board advantageously comprises 20 - 60 w-% cellulose fibers, preferably 20- 50 w-% cellulose fibers. According to the invention, the cellulose fibers used for the decking board comprise at least 60 % chemically treated cellulose fibers (i.e. lignin free cellulose fibers), preferably the fibers used for the decking board comprise at least 70 % or at least 80 %, preferably at least 90 % or at least 95 % chemically treated lignin free cellulose fibers.
In addition, the decking board advantageously comprises from 20 to 80 w-% plastic polymers, preferably from 20 to 60 w-%. The plastic polymer may be virgin or recycled. The amount of the added plastic polymer, such as polypropylene, depends on the other raw material used. For example, if recycled material is used, the amount of added polymer depends on the amount of the different raw materials coming along the recycled material. The decking board 1 preferably comprises at least 70 w-% recycled raw material and, for example, the only added not recycled plastic may be polypropylene. Additionally the decking board may comprise fillers. The decking board 1 may also comprise other compounds, such as colours and waxes.
The recycled raw material comprises preferably paper and plastic, most preferably the recycled material comprises paper and plastic polymers which fall as surplus in self-adhesive label production. The proportion of the recycled paper and recycled plastic may vary depending on the product application.
The recycled label material may comprise surplus paper and plastic left over from the production of self-adhesive label materials. In an embodiment, the adhesive label laminate waste originates from adhesive label laminate production, which primarily produces production reject waste, edge cuttings from rolls and roll ends; from adhesive label laminate printing stations, producing primarily roll ends and label material left over from the die cutting of stickers and labels as well as reject; and/or from the end user clients of the adhesive label laminate, who paste the printed stickers and labels or the like onto their products. The waste coming from the end users is primarily release material, roll ends, and waste from the finished product. The adhesive label laminate waste is typically formed of label material, an adhesive layer, and release material. The liner of the label is usually a paper having a silicone coating or a plastic coating. The plastic polymer is preferably polypropylene. The plastic polymer may also be PVC, polyethylene, polypropylene, polystyrene or polyester.
The amount of the adhesive label laminate waste in the decking board 1 is preferably between 50-85 w-%. The adhesive label laminate waste may comprise, for example, adhesives 0 - 5 w-% or 1 - 4 w-% silicone 0-10 w-% or 1 - 9 w-%, cellulose fibers 20-100 w-%, and polymers 0-100 w-% or 5 - 95 w-%. The amount of additionally dosed plastic polymers is advantageously 15-50 w-% from the decking board 1 . Inorganic fillers may be added in order to increase the stiffness properties of the product. The amount of the fillers in the decking board is preferably between 0 and 25 w-%. The fillers preferably consist mostly of talc and/or calcium carbonate and/or fly ash and/or mica and/or glass-filler (i.e. at least 50 w-% from the fillers). The decking board may be coloured, for example, by using pigments. Therefore, the decking board 1 may comprise colours.
The manufactured decking board is preferably a wood plastic composite, for example a paper plastic composite. The decking board 1 may be manufactured, for example, by extrusion or by injection moulding process. Advantageously the decking board 1 is manufactured in an extrusion process using an extruder.
A person skilled in the art readily understands different embodiments of the invention. Therefore, it is obvious that the present invention is not limited solely to the above-presented embodiments, but it can be modified within the scope of the appended claims.

Claims

Claims:
1 . A decking board comprising
a first surface (3), and
- a second surface (2),
the decking board further comprising
at least two corners (4) of the first surface,
at least two corners (5) of the second surface,
at least two oval holes (1 1 ) between the first surface and the second surface,
and
- a first distance (8) between one of the at least two oval holes (1 1 ) and the second surface (2) of the decking board,
- a second distance (9) between the two oval holes (1 1 ), and - a third distance (18) between one of the at least two oval holes
(1 1 ) and the first surface (3).
2. A decking board according to claim 1 , characterized in that a width (16) of the oval holes (1 1 ) is between 20 and 30 mm.
3. A decking board according to claim 1 or 2, characterized in that a height (17) of the oval holes is between 14 and 18 mm.
4. A decking board according to any of the preceding claims, characterized in that the first distance is at least 3 mm, preferably between 3 and 10 mm
5. A decking board according to any of the preceding claims, characterized in that the second distance is between 3 and 10 mm.
6. A decking board according to any of the preceding claims, characterized in the third distance is at least 3 mm, preferably between 3 and 10 mm.
7. A decking board according to any of the preceding claims, characterized in that the first distance (8) differs from the second distance (9) 20 % at the most, preferably 15% at the most.
8. A decking board according to any of the preceding claims, characterized in that the third distance (18) differs from the second distance (9) 20 % at the most, preferably 15% at the most.
9. A decking board according to any of the preceding claims, characterized in that the corners (5) of the second surface have radii of curvature (R1 a, R1 b) between 0.32 and 0.48 times the height (10) of the corners (5) of the second surface.
10. A decking board according to any of the preceding claims, characterized in that the decking board comprises a first transversal side (FS) of the decking board and a second transversal side (SS) of the decking board, and
- the corners in the first transversal side FS comprises one corner of the at least two corners (5) of the second surface (2), and one corner (4) of the at least two corners of the first surface (3), wherein a first area between them forms a first groove (22), and
- the corners in a second transversal side SS comprises one another corner (5) of the at least two corners (5) of the second surface (2), and one another corner (4) of the at least two corners of the first surface (3), wherein a second area between them forms a second groove (23).
1 1 . A decking board according to any of the preceding claims, characterized in that the first surface (3) is an installation side that is visible when the decking board is installed.
12. A decking board according to any of the preceding claims, characterized in that the corners (4) of the first surface (3) have radii of curvatures (R2) between 0.32 and 0.6 times the height (13) of the corners of the first surface.
13. A decking board according to any of the preceding claims, characterized in that the decking board is unsymmetrical in the vertical (14) direction, i.e. outlines of the second surface of the decking board and outlines of the first surface of the decking board differ from each other.
14. A decking board according to any of the preceding claims, characterized in that the corner (4) of the first surface (3) has a supporting structure (7).
15. A decking board according to any of the preceding claims, characterized in that the material of the decking board (1 ) comprises wood plastic composite.
16. A decking board according to any of the preceding claims, characterized in that the decking board (1 ) comprises recycled cellulose fibers and recycled plastic polymers.
17. A method for manufacturing a decking board comprising
- a first surface (3), and
a second surface (2),
the decking board further comprising
- at least two corners (4) of the first surface,
- at least two corners (5) of the second surface,
- at least two oval holes (1 1 ) between the first surface and the second surface,
and
- a first distance (8) between one of the at least two oval holes (1 1 ) and the second surface (2) of the decking board,
- a second distance (9) between the two oval holes (1 1 ), and
- a third distance (18) between one of the at least two oval holes (1 1 ) and the first surface (3),
and the method comprises:
- manufacturing the decking board (1 ) using an extrusion process.
18. A system for manufacturing a decking board comprising a first surface (3), and a second surface (2),
the decking board further comprising
- at least two corners (4) of the first surface,
- at least two corners (5) of the second surface,
- at least two oval holes (1 1 ) between the first surface and the second surface,
and
- a first distance (8) between one of the at least two oval holes (1 1 ) and the second surface (2) of the decking board,
- a second distance (9) between the two oval holes (1 1 ), and
- a third distance (18) between one of the at least two oval holes (1 1 ) and the first surface (3),
and the system comprises an extruder in order to manufacture the decking board.
19. A terrace comprising a decking board according to any of the preceding claims 1 to 16.
PCT/FI2012/050708 2011-07-08 2012-07-05 A decking board and a method and a system for manufacturing a decking board WO2013011192A1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
DE212012000126.3U DE212012000126U1 (en) 2011-07-08 2012-07-05 Decking board and a system for the production of a decking board

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
FI20115741A FI20115741L (en) 2011-07-08 2011-07-08 A cover board and a method and system for making a cover board
FI20115741 2011-07-08

Publications (1)

Publication Number Publication Date
WO2013011192A1 true WO2013011192A1 (en) 2013-01-24

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FI (1) FI20115741L (en)
WO (1) WO2013011192A1 (en)

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Publication number Priority date Publication date Assignee Title
DE102013112360A1 (en) * 2013-08-08 2015-02-12 Hamberger Industriewerke Gmbh baseplate
RU202407U1 (en) * 2020-09-24 2021-02-16 Андрей Витальевич Норкин TERRACE BOARD
RU215307U1 (en) * 2022-10-26 2022-12-08 Александр Александрович Николаенко Terraced board
EP4410511A3 (en) * 2023-01-13 2024-10-16 UPM-Kymmene Corporation Natural fiber plastic composite

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Publication number Priority date Publication date Assignee Title
EP1108529A2 (en) * 1999-12-14 2001-06-20 Mannington Mills, Inc. Thermoplastic planks and methods for making the same
US20030154662A1 (en) * 2000-10-30 2003-08-21 Andersen Corporation Hollow profile decking system comprising plank and anchor using anchor flange construction
EP1808546A1 (en) * 2006-01-13 2007-07-18 Wyco G.C.V. Deck or floor panel and system comprising such panels

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1108529A2 (en) * 1999-12-14 2001-06-20 Mannington Mills, Inc. Thermoplastic planks and methods for making the same
US20030154662A1 (en) * 2000-10-30 2003-08-21 Andersen Corporation Hollow profile decking system comprising plank and anchor using anchor flange construction
EP1808546A1 (en) * 2006-01-13 2007-07-18 Wyco G.C.V. Deck or floor panel and system comprising such panels

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102013112360A1 (en) * 2013-08-08 2015-02-12 Hamberger Industriewerke Gmbh baseplate
RU202407U1 (en) * 2020-09-24 2021-02-16 Андрей Витальевич Норкин TERRACE BOARD
RU215307U1 (en) * 2022-10-26 2022-12-08 Александр Александрович Николаенко Terraced board
RU215542U1 (en) * 2022-10-26 2022-12-16 Александр Александрович Николаенко Terraced board
EP4410511A3 (en) * 2023-01-13 2024-10-16 UPM-Kymmene Corporation Natural fiber plastic composite

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FI20115741A0 (en) 2011-07-08
DE212012000126U1 (en) 2014-03-21

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