WO2015028796A2

WO2015028796A2 - Decking system

Info

Publication number: WO2015028796A2
Application number: PCT/GB2014/052602
Authority: WO
Inventors: Michael Nicholson
Original assignee: Gripsure (Uk) Limited
Priority date: 2013-08-30
Filing date: 2014-08-28
Publication date: 2015-03-05
Also published as: GB2510006A; GB2510006B; WO2015028796A3; GB201315526D0

Abstract

A decking system is provided, the decking system comprising an elongate base member having a base face and an upper face, the base member having a channel formed in its upper face and extending into the body of the base member; a non-slip member disposed within the channel in the base member; wherein the channel has a bottom face, at least a portion of the bottom face extending laterally across the channel at an angle to the base face of the base member.

Description

DECKING SYSTEM

The present invention relates to a decking system, in particular to components for forming a deck.

Decking is constructed in a variety of situations, to provide a stable, level surface, for example for gardens, balconies, walkways, and the like. It is known to construct decking from a plurality of planks, typically wooden planks, laid side by side. A known problem with such decking is that the surface of the decking can become slippery, in particular when wet. A number of attempts have been made to address this problem and a variety of decking products have been made available on a commercial scale. GB 2 339 437 relates to a wooden decking element. The element comprises a non-slip insert located within a groove formed in the upper surface of the element. The groove has side walls tapered outwardly towards the base of the element. WO 2006/1 14586 discloses decking comprising artificial grass. The decking may provided in the form of a strip or plank, with the artificial grass disposed on its upper surface, in particular in a rectangular channel formed in the decking. Both KR 200445649 and JP 200319803 disclose decking units comprising a non-slip insert.

Perhaps most recently, EP 2,210,997 provides a flooring system having a gripping material disposed in a channel in the flooring system. The channel and the gripping material both have a substantially rectangular cross- section. Decking systems of the aforementioned kind have found significant commercial success. However, a particular problem remains with the known and commercially available decking systems, in particular those comprising a gripping material disposed in a channel formed in the decking. Generally, the gripping material is permeable to water. As a result, water collects and remains in the gripping material. This can lead to the decking becoming and remaining slippery for extended periods of time, until the gripping material dries. In addition, cycles of freezing and thawing can lead to degradation of the decking. Finally, algae tend to accumulate, in particular, in the porous gripping material.

Accordingly, there is a need for an improved decking system. In a first aspect, the present invention provides a decking system comprising:

an elongate base member having a base face and an upper face, the base member having a channel formed in its upper face and extending into the body of the base member;

a non-slip member disposed within the channel in the base member; wherein the channel has a bottom face, at least a portion of the bottom face extending laterally across the channel at an angle to the base face of the base member.

The decking system of the present invention comprises an elongate base member. The base member is typically in the form of a strip or plank of material, that is a generally planar member having a length many times the width of the member, while the width of the member is several times the thickness. It is common practice to provide strips or planks of material for forming decks in standard sizes. For example, planks of decking material may be provided with a nominal width of 100 mm, 125 mm, 150 mm or 175 mm. Larger widths may be employed, as required. Planks of decking material may have a thickness of 32 mm, 38 mm or 50 mm. Other

thicknesses may also be provided, as required. Typically the material is provided in cut lengths of several metres, for example lengths of 3.6 m or 4.8 m. Again, the material may be provided in other lengths or cut to length, as required.

The base member may be formed from any suitable material, most conveniently wood. Suitable woods for forming the base member are known in the art. Generally, woods are selected that exhibit resistance to damp or wet conditions and to rotting and fungal infestation. One particularly preferred wood is Redwood, especially Scandinavian Redwood. The wood may be treated with a preservative. Suitable preservatives and treatment methods are well known in the art.

The base member has a base face and an upper face. The base face and the upper face are preferably parallel to one another. The outer side faces of the base member extending between the upper face and the base face are preferably parallel to each other, more preferably extending perpendicular to both the upper face and the base face. In use, when the decking has been assembled, the base face is disposed lowermost and the upper face uppermost. References herein to 'upper' and 'uppermost' are to be interpreted accordingly and understood to refer to the orientation of the base member when installed. The upper face is thus generally the exposed face and the face upon which the decking is stood or walked by users and on which items, such as tables, chairs and the like, are placed. In use, the base member is generally secured to a support structure, such a one or more beams or other support members. The base member is generally secured such that the base face is substantially horizontal. The upper and/or lower edges of the base member may be chamfered or bevelled, as is known in the art.

The base member is provided with a channel in its upper face. A non- slip member is disposed in the channel. The channel extends across a portion of the width of the upper face of the base member, that is the width of the channel is less than that of the upper face of the base member. The base member may comprise a single channel formed in the upper surface thereof. Alternatively, a plurality of channels may be provided in the upper surface of the base member, with each channel being provided with a non-slip member therein. For example, the upper surface of the base member may be provided with two, three or four channels therein.

The width of the channel may be selected according to such factors as the extent to which the upper surface of the base member is to be provided with the non-slip member. The total width of the one or more channels formed in the upper surface of the base member may be at least 50% of the width of the upper surface of the base member, preferably at least 60%, more preferably at least 70%, still more preferably at least 80%. For example, the width of the channel may be from 50 to 90% of the width of the upper surface of the base member, more preferably from 60 to 80%, still more preferably from 65 to 75%.

The channel extends into the body of the base member from the upper face. The channel has opposing side faces and a bottom face. The side faces may extend along the length of the base member parallel to one another. One or both side faces may extend along the base member parallel to their respective outer side face of the base member. In a preferred embodiment, the side faces of the channel are perpendicular to the upper face. The ends of the channel preferably open into the end faces of the base member, that is the channel extends the full length of the base member. This arrangement allows for the base member to be easily formed, for example by known machining and milling techniques. However, the channel may, if desired, extend only a portion of the length of the base member. In such embodiments, the base member may comprise a single channel extending lengthwise in its upper face. Alternatively, the base member may comprise a plurality of channels extending lengthwise in its upper face and arranged in an end-to-end relationship.

The portion of the upper surface of the base member that is not occupied by a channel may be plain. Alternatively, the said portion may be provided with contours or relief, for example longitudinal grooves, to provide increased grip for users and/or for decorative purposes.

The base member is provided with a non-slip member disposed in the channel in its upper surface. The non-slip member provides increased friction to the upper face of the base member in the portion of the upper face occupied by the channel. In particular, the non-slip member provides increased grip for a user walking or standing on the decking system.

The non-slip member is disposed in the channel. Preferably, the non- slip member substantially fills the channel, with the exposed surface of the non-slip member being level with the upper face of the base member. The non-slip member may extend from the channel beyond the upper face of the base member, such that the upper surface of the non-slip member is proud of the upper face of the base member.

The non-slip member may be formed from any suitable material that provides increased friction to the upper surface of the base member. Suitable materials are known in the art and are commercially available. The non-slip material may comprise natural or synthetic rubber. Preferred materials are elastomers and elastomeric composites. Suitable elastomers include polymers formed from ethylene and propylene monomers. One preferred elastomer is ethylene propylene diene monomer (EPDM) rubber.

In a preferred embodiment, the non-slip member comprises elastomer granules, more preferably EPDM granules, dispersed in a resin matrix, more preferably a polyurethane resin. The granules may be provided in a range of sizes. The elastomer/resin mixture may be formed in the channel and then allowed to cure. The cured elastomer/resin composition provides a surface having a high friction. The composition is porous to water.

The channel has a bottom face. At least a portion of the bottom face of the channel extends laterally across the channel at an angle to the base face of the base member. In the preferred embodiment, in which the upper face and base face of the base member are parallel, the bottom face of the channel extends at the same angle to the upper face of the base member.

By having at least a portion of the bottom face of the channel extend at an angle to the base face of the base member, the bottom face of the channel extends at an angle to the horizontal when the base member is installed, typically with the base face of the base member substantially horizontal. In this way, water collected in non-slip material within the channel is caused to flow down the angled bottom of the face of the channel and collect in one region of the channel. This in turn significantly improves the drainage of water from the non-slip material and the channel, in turn increasing the friction of the non-slip material in wet or damp conditions, thereby increasing the grip offered to a user by the non-slip portion. The portion of the bottom face of the channel that extends at an angle to the base face preferably extends the full length of the channel, more preferably the full length of the base member. The portion of the width of the bottom face of the channel that extends at an angle to the base face of the base member is preferably at least 30%, more preferably at least 40%, still more preferably at least 50% of the bottom face. In more preferred embodiments, at least 60% of the width of the bottom face extends at an angle to the base face of the base member, more preferably at least 70%, still more preferably at least 80%, especially at least 90% of the width. In a preferred arrangement, the entire bottom face of the channel is angled in the lateral direction to the base face of the base member.

The angled portion of the bottom face of the channel may extend at any suitable angle to the base face of the base member so as to provide adequate drainage of water from the non-slip material when the decking system is installed and in use. For example, the angled portion of the bottom face may extend at an angle to the base face of the The bottom face of the channel may comprise a single portion that extends at an angle to the base face of the base member. For example, the entire bottom face of the channel may extend laterally across the channel at an angle to the base member from a first side of the channel to a second side. In this way, water will drain across the channel in the direction from the first side to the second side and will collect in the region of the second side of the channel. Means for removing accumulated water may be provided, as described hereinafter.

In one preferred embodiment, the bottom face of the channel comprises a first angled portion and a second angled portion, in particular the first and second angled portions extending parallel to each other lengthwise in the channel. The first angled portion extends in the direction away from a first side of the channel towards the opposing second side. The second angled portion extends in the direction away from the second side of the channel towards the opposing first side. In a preferred arrangement, the first angled portion extends from the first side of the channel and/or the second angled portion extends from the second side of the channel.

The first and second angled portions of the bottom face of the channel are preferably contiguous and share a common edge or border.

The angles at which the first and second portions extend to the base face of the base member may be the same or different. In one preferred embodiment, the angles at which the first and second angled portions extend to the base face of the base member are preferably supplementary angles. In this respect, when the channel comprises a plurality of angled portions, references to the angles of the portions are to the angles at which the portions extend to the base face of the base member in the same direction.

The first and second angled portions may extend across the bottom face of the channel such that the edge closest to the base face of the base member is at or towards a side face of the channel, for example in an inverted V-shape, when viewed in cross-section. The first and second angled portions preferably extend across the bottom face of the channel such that the edge closest to the base face of the base member is at or towards the longitudinal centre line of the channel, for example in a V-shape, when viewed in cross- section.

The first and second angled portions of the bottom face are preferably arranged symmetrically about the longitudinal centre line of the channel. The width of the first and second angled portions may be the same or different, most preferably the same.

In a particularly preferred embodiment, the first angled portion extends from the first side of the channel, the second angled portion extends from the second side of the channel, and the first and second angled portions have substantially the same width, such that they form a symmetrical V-shape when viewed in cross-section. The angled portion of the bottom face of the channel may extend at any suitable angle to the base face of the base member, for example from 5° to 40°, preferably from 7.5° to 30°, more preferably from 10° to 25°. An angle of from 10 to 20° is preferred, for example about 15°. As discussed above, the action of the angled portion of the bottom face of the channel is to cause water collecting in the channel to flow across the bottom face and collect in a region of the channel. Typically, the water will collect in the region of the edge of the angled portion that is closest to the base surface of the base member. In one preferred embodiment, the base member is provided with a drainage channel into which water collecting on the angled portion flows, to be directed away from the channel. The drainage channel preferably extends longitudinally along the bottom face of the channel. The angled portion is preferably provided with a single drainage channel. The drainage channel is preferably located along the edge of the angled portion that is closest to the base surface of the base member. In this way, water collecting in the region of the said edge flows into the drainage channel, from which the water can be removed or caused to leave the channel. In embodiments in which the bottom surface of the channel is provided with a plurality of angled portions, each angled portion may be provided with a drainage channel. In a preferred embodiment discussed above, in which the bottom face comprises a pair of angled portions arranged to form a V-shape cross-section, the drainage channel is preferably provided along the contiguous edges of the angled portions. In a particular preferred

embodiment, the drainage channel is disposed substantially centrally in the bottom face of the channel and extends along the longitudinal centre line of the channel.

The drainage channel may have any suitable cross-section, for example a V-shape, a U-shape or rectangular.

The non-slip member may extend partially or wholly into the drainage channel. Alternatively, the drainage channel is empty and substantially free of the non-slip member, so as to provide increased drainage for water.

To remove water collected in the channel, the base member may be provided with one or more drainage bores therethrough, each drainage bore opening into the channel for water to leave the channel. Preferably, the or each drainage bore opens in the bottom surface of the channel. More preferably, the or each drainage bore opens in the bottom surface of the channel in the region in which water collects, more particularly the region of the angled portion adjacent the edge that is closest to the base face of the base member. In embodiments in which the channel is provided with a drainage channel, the or each drainage bore preferably opens into the drainage channel.

The base member is preferably provided with a plurality of drainage bores arranged in a spaced apart pattern along its length. The drainage bores may be located at any suitable position and spacing along the length of the base member. The number and diameter of the drainage bores is determined by such factors as the volume of water to be removed from the channel. A typical diameter for the drainage bore is from 5 to 20 mm, more preferably from 10 to 15 mm.

In a further aspect, the present invention provides a surface assembly comprising a decking system as hereinbefore described.

In one embodiment, the surface assembly is a deck, path or walkway.

Embodiments of the present invention will now be described, by way of example only, having reference to the accompanying drawings, in which:

Figure 1 is a perspective view of a decking system according to one embodiment of the present invention;

Figure 2 is a cross-sectional view of the system of Figure 1 along the line II - II;

Figure 3 is a cross-sectional view of a decking system according to a second embodiment of the present invention;

Figure 4 is a cross-sectional view of a decking system according to a third embodiment of the present invention; Figure 5 is a cross-sectional view of a decking system according to a fourth embodiment of the present invention;

Figure 6 is a cross-sectional view of a decking system according to a fifth embodiment of the present invention; and Figure 7 is a cross-sectional view of a decking system according to a sixth embodiment of the present invention.

Turning to Figure 1 , there is shown a decking system according to one embodiment of the present invention. The decking system, generally indicated as 2, comprises an elongate wooden base member 4 having an upper face 6, a base face 8, opposing side faces 10 and opposing end faces 12. The upper edges 14 of the side faces 10 of the base member 4 are chamfered, as is known in the art.

The decking system 2 is shown in cross-section in Figure 2. A channel 20 is formed in the upper face 6 of the base member 4 and has a first side face 22, a second side face 24 and a bottom surface 26. A non-slip member 30 is disposed in the channel 20 and is formed from EPDM granules dispersed in a polyurethane matrix.

The non-slip member 30 has an upper surface 32 extending slightly proud of the upper face 6 of the base member 4.

The bottom surface 26 of the channel is provided with an angled portion 40, angled in the lateral direction, that is across the channel 20. The angled portion 40 extends across about 75% of the width of the channel and has an edge 42 closest to the base face 8 of the base member 4 adjacent the first side face 22 of the channel 20. The angled portion 40 extends at an angle a to the base face 8 of the base member 4. In the embodiment shown, the angle a is 15°. In use, the base member 4 is affixed to a support member, such as a beam or the like (not shown for clarity), with the base face 8 lowermost and the upper face 6 uppermost and exposed. Water collecting in the channel 20 is caused to flow across the angled portion 40 and collects in the region of the edge 42 adjacent the first side face 22 of the channel, from where it drains out of the channel 20 through a plurality of drainage bores 50 extending from the channel 20 through the base member 4 to open in the base face 8 of the base member. The drainage bores 50 are disposed in the region adjacent the first side face 22 of the channel.

A cross-sectional view of a second embodiment of the decking system of the present invention is shown in Figure 3. The decking system, generally indicated as 102 comprises a base member having a channel formed in its upper surface as in the first embodiment. Accordingly, components in common with those of the first embodiment are indicated using the same reference numerals and are as described above.

In the embodiment of Figure 3, the bottom surface 26 of the channel 20 is provided with an angled portion extending across 100% of the width of the bottom surface, that is from the first side face 22 to the second side face 24. A cross-sectional view of a third embodiment of the decking system of the present invention is shown in Figure 4. The decking system, generally indicated as 202 comprises a base member having a channel formed in its upper surface as in the first embodiment. Accordingly, components in common with those of the first embodiment are indicated using the same reference numerals and are as described above.

In the embodiment of Figure 4, the bottom surface 26 of the channel 20 is provided with an angled portion extending across 100% of the width of the bottom surface, that is from the first side face 22 to the second side face 24. The channel 20 is provided with a drainage channel 210 extending

longitudinally along the edge 42 of the angled portion adjacent the first side face 22. The drainage channel has a generally rectangular cross-section. The drainage bores 50 open in the drainage channel 210 and provide a means for water to drain from the drainage channel 210. A cross-sectional view of a fourth embodiment of the decking system of the present invention is shown in Figure 5. The decking system, generally indicated as 302 comprises a base member having a channel formed in its upper surface as in the first embodiment. Accordingly, components in common with those of the first embodiment are indicated using the same reference numerals and are as described above.

In the embodiment of Figure 5, the bottom surface 26 of the channel 20 is provided with a first angled portion 40a extending across the bottom surface from the first side face 22 and a second angled portion 40b extending across the bottom surface from the centre of the channel to the second side face 24. The first and second angled portions 40a, 40b each extend across 50% of the width of the bottom surface of the channel. As shown in Figure 5, each angled portion 40a, 40b extends at an angle a to the base face 8 of the base member 4, with a being 15 °.

Drainage bores 50 are provided in the base member 4 with openings at the edge 42 of each angled portion 40a, 40b.

A cross-sectional view of a fifth embodiment of the decking system of the present invention is shown in Figure 6. The decking system, generally indicated as 402 comprises a base member having a channel formed in its upper surface as in the first embodiment. Accordingly, components in common with those of the first embodiment are indicated using the same reference numerals and are as described above. In the embodiment of Figure 6, the bottom surface 26 of the channel 20 is provided with a first angled portion 40a extending across the bottom surface from the first side face 22 and a second angled portion 40b extending across the bottom surface from the second side face 24. The first and second angled portions 40a, 40b each extend across 50% of the width of the bottom surface of the channel and form a V-shape when viewed in cross-section as in Figure 6. As shown in Figure 6, the first angled portion 40a extends at an angle a to the base face 8 of the base member 4, with a being 15°. The second angled portion 40b extends at an angle β, the supplementary angle of a, that is 165°.

Drainage bores 50 are provided in the base member 4 with openings at the junction between the first and second angled portions 40a, 40b formed by the edges 42, that is along the longitudinal centre line of the channel 20. A cross-sectional view of a sixth embodiment of the decking system of the present invention is shown in Figure 7. The decking system, generally indicated as 502 comprises a base member having a channel formed in its upper surface as in the first embodiment. The bottom surface of the channel is formed with first and second angled portions, as in the fifth embodiment shown in Figure 6. Accordingly, components in common with those of the first embodiment are indicated using the same reference numerals and are as described above.

In the sixth embodiment, shown in Figure 7, a drainage channel 210 is provided at the junction between the first and second angled portions 40a, 40b and extends along the longitudinal centre line of the channel 20.

Drainage bores 50 extend from the channel 20 through the base member 4 from the drainage channel 210. As shown in Figure 7, the material of the non-slip does not extend into the drainage channel 210, leaving the drainage channel free to drain water collected in the channel 20.

Claims

1 . A decking system comprising:

2. The decking system according to claim 1 , wherein the base member is formed from wood.

3. The decking system according to either of claims 1 or 2, wherein the upper and/or lower edges of the base member are chamfered.

4. The decking system according to any preceding claim, wherein the base member comprises a single channel in its upper surface.

5. The decking system according to any of claims 1 to 3, wherein the base member comprises a plurality of channels in its upper surface.

6. The decking system according to claim 5, wherein the upper surface of the base member comprises two, three or four channels therein.

7. The decking system according to any preceding claim, wherein the total width of the channel in the upper surface of the base member is at least 50% of the width of the base member.

8. The decking system according to claim 7, wherein the total width of the channel in the upper surface of the base member is at least 70% of the width of the base member.

9. The decking system according to any preceding claim, wherein the side faces of the channel are parallel to one another.

10. The decking system according to any preceding claim, wherein the channel extends the full length of the base member.

1 1 . The decking system according to any preceding claim, wherein the non-slip member comprises an elastomer.

12. The decking system according to claim 1 1 , wherein the elastomer EPDM.

13. The decking system according to either of claims 1 1 or 12, wherein the elastomer is in the form of granules dispersed in a resin matrix.

14. The decking system according to claim 13, wherein the resin is polyurethane.

15. The decking system according to any preceding claim, wherein the upper surface of the non-slip member is proud of the upper surface of the base member.

16. The decking system according to any preceding claim, wherein the angled portion of the bottom face of the channel extends the full length of the channel.

17. The decking system according to any preceding claim, wherein the width of the angled portion of the bottom face of the channel is at least 50% of the width of the bottom face of the channel.

18. The decking system according to claim 17, wherein the angled portion of the bottom face of the channel extends across the full width of the channel.

19. The decking system according to any preceding claim, wherein the angled portion extends at an angle of from 5 to 40° to the base face of the base member.

20. The decking system according to claim 19, wherein the angled portion extends at an angle of from 10 to 25° to the base face of the base member.

21 . The decking system according to any preceding claim, where bottom face of the channel comprises a single angled portion.

22. The decking system according to any of claims 1 to 20, wherein the bottom face of the channel comprises a first angled portion and a second angled portion.

23. The decking system according to claim 22, wherein the first and second angled portions extend parallel to each other lengthwise in the channel.

24. The decking system according to either of claims 22 and 23, wherein the first angled portion extends from a first side of the channel and/or the second angled portion extends from a second side of the channel.

25. The decking system according to any of claims 22 to 24, wherein the first and second angled portions are contiguous and share a common edge or border.

26. The decking system according to any of claims 22 to 25, wherein the first and second angled portions extend at supplementary angles to the base face of the base member.

27. The decking system according to any of claims 22 to 26, wherein the first and second angled portions are arranged in a V-shape or an inverted V- shape, when viewed in lateral cross-section.

28. The decking system according to any of claims 22 to 25, wherein the first and second angled portions extend at the same angle to the base face of the base member.

29. The decking system according to any of claims 22 to 28, wherein the first and second angled portions have the same width.

30. The decking system according to any preceding claim, further comprising a drainage channel extending in the bottom face of the channel.

31 . The decking system according to claim 30, wherein the drainage channel extends longitudinally along the channel.

32. The decking system according to either of claims 30 or 31 , wherein the drainage channel is located at an edge of the angled portion.

33. The decking system according to claim 32, wherein the drainage channel is located in the edge of the angled portion that is closest to the base face of the base member.

34. The decking system according to any of claims 30 to 33, wherein the drainage channel is V-shaped, U-shaped or rectangular in lateral cross- section.

35. The decking system according to any of claims 30 to 34, wherein the non-slip member extends partially or wholly into the drainage channel.

36. The decking system according to any preceding claim, further comprising one or more drainage bores opening in the channel and extending through the base member.

37. The decking system according to claim 36, wherein the or each drainage bore opens in the bottom surface of the channel.

38. The decking system according to claim 37, wherein the or each drainage bore opens in the region of the angled portion adjacent the edge that is closest to the base face of the base member.

39. A surface assembly comprising a decking system according to any preceding claim.

40. The surface assembly according to claim 39, comprising a deck, path or walkway.