BOARD COVER AND BOARD COVERING SYSTEM

Abstract

A cover for a board is disclosed and comprises a sheet. The sheet has a pair of sides and a pair of ends. The sheet, in use, is disposed lengthwise upon said board. For and extending from each side of the sheet is provided a flange, the flange being either fixed at about 90 degrees to or pivotably attached to the sheet. The flanges, in use, extend in a common direction from the sheet, on opposite sides of said board.

Description

FIELD OF THE INVENTION

The present invention relates to building products.

BACKGROUND TO THE INVENTION

The deleterious effects of moisture upon structures constructed from wooden boards, such as decks, docks and walkways, are well known. Moisture can progressively deteriorate wood. There are other problems associated with the deterioration of wooden structures. Such structures can be extremely costly, especially in a climate of increasing costs for natural resources. In view of these factors, innovations to prevent wood deterioration, such as pressure treating have become prevalent.

SUMMARY OF THE INVENTION

Forming one aspect of the invention is a cover for a board. The cover comprises: a sheet having a pair of sides and a pair of ends, the sheet, in use, being disposed lengthwise upon said board; and for and extending from each side of the sheet, a flange, the flange being either fixed at about 90 degrees to or pivotably attached to the sheet. The flanges, in use, extend in a common direction from the sheet, on opposite sides of said board.

According to another aspect of the invention, the flanges can each be movable between an extended position, whereat the flanges extend from the sheet in substantially coplanar relation to the sheet, and a use position, whereat the flanges extend in the common direction in substantially perpendicular relation to the sheet.

According to another aspect of the invention, the flanges can be sized and dimensioned such that, in use, the flanges substantially cover the sides of the board.

According to another aspect of the invention, the cover can further comprises at least one protrusion projecting from the sheet such that, in use, the protrusion and the flanges all extend in the common direction.

According to another aspect of the invention, the cover can further comprise a plurality of protrusions projecting from the sheet such that, in use, the protrusions and the flanges all extend in the common direction, the protrusions, in use, supporting the sheet above the board for foot traffic while permitting air flow beneath the sheet and board as well as drainage.

According to another aspect of the invention, the flanges can be shaped such that, if a pair of covers are disposed in side by side relation on adjacent boards, with the adjacent flanges thereof abutting, voids are defined between the abutting flanges to permit drainage.

According to another aspect of the invention, the sheet and flanges can be injection-molded as a single unit.

According to another aspect of the invention, each side of the sheet can have a single flange.

According to another aspect of the invention, the one end of the cover can be adapted to be mechanically secured to the board by screws.

According to another aspect of the invention, the sheet can be substantially rectangular.

According to another aspect of the invention, the cover can have ends that correspond with the ends of the sheet; one end of the cover can be adapted to be mechanically secured to said board in use; and the ends of the cover can be adapted such that, if a pair of the covers are disposed in use with one of the pair of covers secured to said board by the one end thereof, and the other of the pair of covers is disposed adjacent the one end of the one of the pair such that the sheets of the pair are in end to end close fitting relation, the abutting end of the other of the pair of covers is secured held against said board by the one end of the one of the pair of covers.

According to other aspects of the invention: the ends of the cover can be provided with a locking arrangement such that, if a pair of the covers are disposed in spaced end to end relation on a board and urged together, the proximal ends engage one another in snap fit relation; and the snap fit relation can provides for spaced, close-fitting relation between the adjacent sheets, the spaced relation allowing for the covers to expand lengthwise without buckling in normal hot weather conditions.

A system for covering a plurality of boards forms another aspect of the invention. The system comprises covers and strip foam material. Each cover includes: a substantially rectangular sheet having a pair of sides and a pair of ends; and, for and extending from each side of the sheet, a flange, the flange being either fixed at about 90 degrees to or pivotably attached to the sheet. The covers are deployed in use such that, on each of said plurality of boards, a plurality of covers is disposed with the sheets thereof in close fitting end-to-end relation and the flanges thereof extending from the sheets and between the boards. The foam material is wider than the board width and deployed in use such that, on each of said plurality of boards, foam material is fitted between the boards and the covers so as to cover the surface of the board on which the sheets are positioned and to extend at least partially along each side of the board beneath the flanges.

Other advantages, features and characteristics of the present invention, as well as methods of operation and functions of the related elements of the structure, and the combination of parts and economies of manufacture, will become more apparent upon consideration of the following detailed description and the appended claims with reference to the accompanying drawings, the latter being briefly described hereinafter.

BRIEF DESCRIPTION OF THE DRAWINGS

The embodiments of the present invention will now be described by reference to the following drawings, which illustrate by way of example only preferred embodiments of the invention:

FIG. 1 is a top perspective view of the cover with the flanges in a first extended position;

FIG. 2 is a top perspective view of the cover with the flanges in a second use position;

FIG. 3 is a bottom perspective view of the cover with the flanges in a first extended position;

FIG. 4 is a top plan view of the cover;

FIG. 5 is a bottom plan view of the cover;

FIG. 6 is a side plan view of the cover;

FIG. 7 is a front plan view of the cover;

FIG. 8 is a cross-sectional view along line A-A of FIG. 4;

FIG. 9 is a cross-sectional view of the cover along section B-B of FIG. 4;

FIG. 10 is a top perspective view of a plurality of covers covering a plurality of boards;

FIG. 11 is a further top perspective view of a plurality of covers covering a plurality of boards;

FIG. 12 is a top plan view of a plurality of covers covering a plurality of boards;

FIG. 13 is a front plan view of a plurality of covers covering a plurality of boards; and

FIG. 14 is a side plan view of a plurality of covers covering a plurality of boards.

FIG. 15 is a top perspective view of a board cover according to another exemplary embodiment of the invention;

FIG. 16 is a bottom perspective view of the cover of FIG. 15;

FIG. 17 is a top plan view of the board cover of FIG. 15;

FIG. 18 is a bottom plan view of the board cover of FIG. 15;

FIG. 19 is a side view of the board cover of FIG. 15;

FIG. 20 is a view along 20-20 of FIG. 17;

FIG. 21 is an end view of the board cover of FIG. 15;

FIG. 22 is a view along 22-22 of FIG. 17;

FIG. 23 is a perspective view of the structure of FIG. 15, configured for use;

FIG. 24 is a top plan view of a plurality of the covers of FIG. 23, in use;

FIG. 25 is a side view of the structure of FIG. 24; and

FIG. 26 is an end view of the structures of FIG. 24.

DETAILED DESCRIPTION OF THE EXEMPLARY EMBODIMENTS

The present invention will now described for the purposes of illustration only in connection with certain embodiments. However, it is to be understood that other objects and advantages of the present invention will be made apparent by the following description of the drawings according to the present invention. While an exemplary embodiment is disclosed, this is not intended to be limiting. Rather, the general principles set forth herein are considered to be merely illustrative of the scope of the present invention and it is to be further understood that numerous changes may be made without straying from the scope of the present invention.

Referring to FIG. 1, there is shown in perspective view an exemplary embodiment of a cover 100 according to the present invention.

The cover 100 is manufactured from a rigid yet pliable material. The material comprising the cover 100 is also preferably water-resistant or waterproof. Examples of the material from which the cover 100 is manufactured include plastic, non corrosive sheet metal, and rubber. The cover 100 may also be manufactured from a combination of materials, for example by co-molding rubber over plastic, or rubber over formed sheet metal.

The cover 100 has a sheet 110. FIG. 1 depicts the sheet 110 as having a rectangular shape so as to correspond with a board (not shown) having substantially straight edges. Those having ordinary skill in the art will appreciate that the sheet 110 could be shaped in any manner to correspond with the shape of a board beneath the sheet 110.

The width of the sheet 110 is at least the width of the board being covered. Thus, for structures constructed from four inch wide boards, the sheet 110 is at least four inches wide. For structures constructed from five and one half inch wide boards, the sheet 110 is at least five and one half inches wide.

As may be better appreciated from a consideration of FIG. 13, the width of the sheet 110 may be slightly greater than the width of a top surface a board 120 covered by the cover 100.

In this exemplary embodiment of the cover 100, the sheet 110 includes a means for creating friction on an outer surface 144 of the sheet 110. The means for creating friction shown in FIG. 1 is a series of protuberances 150 formed in the outer surface 144 of the sheet 110. It will be recognized by a person skilled in the art that other means for creating friction could be utilized, such as a series of alternating grooves and ridges.

The protuberances 150 are equally distributed upon the outer surface 144 of the sheet 110 in a grid pattern. Further, as may be better appreciated from consideration of FIGS. 6 and 7, the protuberances 150 are bevelled.

FIG. 3 shows an inner surface 156 of the sheet 110. The inner surface 156 of the sheet 110 includes at least one protrusion for engaging the top surface 124 of the board 120. It will be appreciated by one skilled in the art that the purposes of the invention may be achieved if one employs any number of protrusions shaped and arrayed so as to separate the inner surface 156 of the sheet 110 and the top surface 124 of the board 120. As shown in FIG. 3, the protrusions are a plurality of ribs 160. These ribs 160 are orientated parallel to one another and in two series 164 and 168 that define a channel 170.

Near a first end 180 of the cover 100, four short ribs 162 are orientated across the width of the sheet 110 and parallel to the ribs 160. The ribs 160 and the short ribs 162 are formed in the inner surface 156 of the sheet 110.

The first end 180 of the sheet 110 and a second end 190 of the sheet 110 are adapted to include attachment means. It will be appreciated by a person skilled in the art that the purposes of the invention may be achieved by employing any attachment means including hooks, clasps, or the like. In the embodiment described herein, the attachment means consist of two outer female tabs 200 and two inner female tabs 206 situated at the first end 180 of the sheet 110 and two outer male tabs 210 and an inner male tab 216 situated at the second end 190 of the sheet 110. The female tabs 200 and 206 and the male tabs 210 and 216 are formed in the inner surface 156 of the sheet 110.

The distance between the inner female tabs 206 is equal to the distance between each inner female tab 206 and an adjacent outer female tab 200. The outer female tabs 200 are slightly wider than the inner female tabs 206. Each of the female tabs 200 and 206 correspond with a short rib 162 such that the distances between adjacent female tabs 200 and 206 match corresponding distances between short ribs 162.

The distance between the inner male tab 216 and each outer male tab 210 is at least equal to the width of inner female tabs 206. The distance between each outer male tab 210 and the closest of the first edge 130 of the sheet 110 and the opposing edge 136 of the sheet 110 is at least equal to the width of the outer female tabs 200.

Each male tab 210 and 216 defines an aperture 220 sized so as to receive a fastener (not shown) such as a screw, a nail or the like.

The cover 110 includes a plurality of flanges. In the preferred embodiment depicted herein, the cover 110 has two flanges. It will be appreciated by a person skilled in the art that the purposes of the invention can be achieved by incorporating two or more flanges.

A first flange 300 is attached adjacent to the first edge 130 of the sheet 110 and a second flange 310 is attached to the sheet 110 adjacent to the second edge 136 of the sheet 110. The length of the flanges 300 and 310 is equal to the length of the sheet 110. The height of the flanges 300 and 310 is preferably equal to or greater than the height of sides 124 and 126 of board 120.

The flanges 300 and 310 are either fixed at about 90 degrees as in FIG. 2 (for sheet metal and plastic made parts without fold line-live hinge) or pivotably attachable to the sheet 110 (for plastic parts with fold line-live hinge). It will be appreciated by a person skilled in the art that the purposes of the invention may be achieved employing any conventional means for pivotably attaching the flanges 300 and 310 to the sheet 110. A top edge of each flange is bevelled as demonstrated by top edge 304 of flange 300 shown in FIG. 7.

As may be appreciated by considering FIGS. 7 and 9, the flanges 300 and 310 are each attached to the sheet 110 by a hinge 320. In this embodiment, the hinge 320 extends along the entire length of the sheet 110 so as to create an integral attachment.

The first edges 324 of each hinge 320 are bevelled so as to permit the hinge 320 to pivot downward from a first extended position wherein the hinge flares away from the sheet 110 to a second use position where, upon rotation of the hinge 320 about a point where the hinge 320 attaches to the sheet 110, the hinge 320 is orientated more proximate to the sheet 110. Similarly, a second edge 328 of each hinge 320 is bevelled so as to permit, for example, the first flange 300 to rotate about a point at which the hinge 320 attaches to the first flange 300 from a first position wherein the first flange 300 is parallel to the plane of the sheet 110 to a second position wherein the first flange 300 is perpendicular to the plane of the sheet 110.

Each flange may have a series of bosses 330 on an outer surface 304 of the flange. Each boss 330 is integrally formed in the flange. The bosses 330 can be equally spaced along the length of each flange. Further, as seen in FIG. 1, the bosses 330 may be equally sized. If necessary, narrow bosses 334 at ends of the flanges may be smaller sized than bosses 330 so as to preserve the uniform spacing between the bosses.

FIGS. 11 to 14 depict the cover 100 in operation with other covers 100. Multiple covers 100 may be attached to create a system for covering the board 120. Alternatively or additionally, one or more covers 100 may be positioned upon adjacent boards 120 to create a system for covering multiple boards.

Before affixing the cover 100 upon the board 120 the flanges 300 and 310 are pivoted about hinges 320 from the first position to the second position so that the flanges 300 and 310 are orientated perpendicular to the plane of the sheet 110 and the hinges 320 are orientated so as to permit the cover 100 to fit snugly upon the board 120. The cover 100 is then placed upon the board 120. The cover 100 can be placed upon the board 120 in a snug fit as best depicted in FIG. 13 such that each flange engages a side 126 or 128 of the board 120 and the ribs 160 engage the top surface 124 of the board 120. Accordingly, the cover 100 is centered upon the board 120.

The cover 100 is then fastened to the board 120. Fasteners (not shown) are placed within apertures 220 of male tabs 210 and 216 and attached to the board 120.

A second cover 104 is then attached to the first cover 100. The flanges of the second cover 104 are pivoted to the second position wherein the flanges are perpendicular to the plane of the sheet of the second cover 104. The second cover 104 is then slidably placed upon the board 120 such that the female tabs 200 and 206 of the cover 100 receive the male tabs of the second cover 104.

As seen in FIGS. 12 and 14, preferably, a second end 184 of the second cover 104 is placed slightly distal from the first end 180 of the sheet 110 of the cover 100 so as to define a space 340 between a second end 184 of the second cover 104 and the first end 180 of the sheet 110 of the cover 100 and a first end 180 of the second cover 104. The width of the space 340 may be 0.1 inches to permit thermal expansion of the cover 100 and the second cover 104 without causing damage to the covers or deterioration of the board 120.

Similarly, further covers may be affixed to the board 120 to cover a desired length of the board 120.

As best shown in FIG. 13, adjacent cover 108 may be affixed to an adjacent board 122 to create a system for covering multiple boards. The flanges 314 and 318 of the adjacent cover 108 are pivoted to the second position so that the flanges 314 and 318 of the adjacent cover 108 are perpendicular to the sheet 114 of the adjacent cover 108. The adjacent cover 108 is then slidably placed upon the adjacent board 122 and positioned such that adjacent bosses 336 of the flange 314 of the adjacent cover 108 are adjacent to the corresponding bosses 330 of the flange 310 of cover 100, as depicted in FIG. 12. The adjacent cover 108 is then fastened to the adjacent board 122 in a manner similar to that described above in respect of the fastening of the cover 100 to the board 120. The flange 314 of the adjacent cover 108 and the flange 310 of the cover 100 define a gap 350. One or more additional covers may be placed upon adjacent board 120 and fastened. One or more additional covers may be affixed to further adjacent boards.

Persons of ordinary skill will appreciate that the foregoing arrangement has substantial advantage:

the covers can be injection molded as a single piece

the pivotable nature of the flanges allow the covers to be densely flat packed

the bosses ensure that, in use, drainage passages remain between the covers

the upper protuberances provide stable footing to foot traffic, even when wet

the ribs ensure airflow between the cover and board, to resist rot

FIGS. 15-26 show a cover according to another exemplary embodiment of the invention, which cover is designated with general reference numeral 400. This cover 400 has functionality substantially similar to the covers previously disclosed. For simplicity, to the extent that this cover 400 is similar to the previously-described covers, a detailed description is neither required nor provided: reference is simply made at this time to the reference numerals on FIGS. 15-26 which correspond to those found in the previous description, and it is hereby confirmed that structures on FIGS. 15-26 which share reference numerals with structures on FIGS. 1-14 operate in an identical or substantially similar fashion. The structure of FIGS. 15-26 does differ somewhat from the structure of FIGS. 1-14, and these differences are described hereinbelow.

Locking Arrangement

As best seen in FIGS. 15-16, this cover 400 includes a locking arrangement, which is defined by, on one end of the cover [the end which includes outer male tabs 210], a pair of resilient locking fingers 502 provided with notches 504 and, on the other end of the cover, a pair of locking detents 506. The fingers 502 are arranged to slide along the female tabs 206, ride up over the detents 506 and then snap back into their original positions once the detents 506 can occupy the notches 504. This snap-fit engagement spaces the longitudinally-adjacent sheets slightly apart from one another to permit thermal expansion without buckling, as discussed earlier.

Pilot Holes

As best seen in FIGS. 15 and 20, the cover 400 includes a plurality of pilot holes 508 on the upper surface which align with stud protuberances 510 that extend from the lower surface of the cover. The stud protuberances 510 function in a manner analogous to ribs 164, but have a girth that is sufficient to allow a finishing nail to pass therethrough. This arrangement allows, inter alia, the cover to be cut to length and secured in place.

Flange Insets

As illustrated in FIG. 15, this cover 400 has flange insets 512 which are shaped and dimensioned such that, when another cover is disposed upon the same board in longitudinally end to end close fitting relation, the flanges of the adjacent cover are received in and overlap the flange insets 512.

System

The cover of this embodiment can be used in a manner similar to that shown in FIG. 10, as evidenced by FIGS. 24-26. However, as a yet further embodiment, this cover, as well as the cover of FIGS. 1-14, can be used as part of a system which includes strip foam material strip foam material, the foam material being wider than the board width and deployed in use such that, on each of said plurality of boards, foam material is fitted between the boards and the covers so as to cover the surface of the board on which the sheets are positioned and to extend at least partially along each side of the board beneath the flanges. This system provides even better protection for the boards from the elements, in that the entire upper surface of the board is shielded from precipitation. This system also has advantage, in that it provides a cushion for the covers, which reduces noise production in use.

Variants

In a yet further alternative embodiment, not shown, the strip foam material can be omitted, and the stud protuberances and ribs can be faced on their lower surface with foam material. This increases cost but increases airflow beneath the covers. This also allows water infiltration at the junction of the longitudinally adjacent covers, but this can be ameliorated, for example, by foam tape at the joints.

In a yet further alternative embodiment, not shown, the ribs can be removed and the stud protuberances can be pointed, lengthened and made more plentiful. The reduced contact area, coupled with the potential for slight penetration of the protuberances into the wood surface, will reduce noise production, but will slightly damage the wood, which may not be desirable in all situations.

As yet further options, the cover can itself be covered with carpeting. In one embodiment, polypropylene outdoor carpet is fused via an overmolding process to the cover, such that the covers function as ‘carpet tiles’. In another embodiment, outdoor carpet can be secured, by self-adhesive backing on the carpet, after the covers have themselves been installed.

It will be apparent to those having ordinary skill in the art that various modifications and variations may be made to the embodiments disclosed herein, consistent with the present invention, without departing from the spirit and scope of the present invention. Accordingly, the specification is to be considered exemplary only, with the true scope and spirit of the invention being disclosed by the following claims, purposively construed.

Claims

1. A cover for a board, the cover comprising: a sheet having a pair of sides and a pair of ends, the sheet, in use, being disposed lengthwise upon said board; andfor and extending from each side of the sheet, a flange, the flange being either fixed at about 90 degrees to or pivotably attached to the sheet, the flanges, in use, extending in a common direction from the sheet, on opposite sides of said board.

2. The cover of claim 1, wherein the flanges are each movable between an extended position, whereat the flanges extend from the sheet in substantially coplanar relation to the sheet, and a use position, whereat the flanges extend in the common direction in substantially perpendicular relation to the sheet.

3. The cover of claim 1, wherein the flanges are sized and dimensioned such that, in use, the flanges substantially cover the sides of the board.

4. The cover of claim 1, further comprising at least one protrusion projecting from the sheet such that, in use, the protrusion and the flanges all extend in the common direction.

5. The cover of claim 1, further comprising a plurality of protrusions projecting from the sheet such that, in use, the protrusion and the flanges all extend in the common direction, the protrusions, in use, supporting the sheet above the board for foot traffic while permitting air flow beneath the sheet and board and drainage.

6. The cover of claim 1, wherein the flanges are shaped such that, if a pair of covers are disposed in side by side relation on adjacent boards, with the adjacent flanges thereof abutting, voids are defined between the abutting flanges to permit drainage.

7. The cover of claim 1, wherein the sheet and flanges are injection-molded as a single unit.

8. The cover of claim 1, wherein each side of the sheet has a single flange.

9. The cover of claim 1, wherein: the cover has ends that correspond with the ends of the sheet;one end of the cover is adapted to be mechanically secured to said board in use; andthe ends of the cover are adapted such that, if a pair of the covers are disposed in use with one of the pair of covers secured to said board by the one end thereof, and the other of the pair of covers is disposed adjacent the one end of the one of the pair such that the sheets of the pair are in end to end close fitting relation, the abutting end of the other of the pair of covers is secured held against said board by the one end of the one of the pair of covers.

10. The cover of claim 9, wherein the one end of the cover is adapted to be mechanically secured to the board by screws.

11. The cover of claim 1, wherein the ends of the cover are provided with a locking arrangement such that, if a pair of the covers are disposed in spaced end to end relation on a board and urged together, the proximal ends engage one another in snap fit relation.

12. The cover of claim 11, wherein the snap fit relation provides for spaced, close-fitting relation between the adjacent sheets, the spaced relation allowing for the covers to expand lengthwise without buckling in normal hot weather conditions.

13. The cover of claim 1, wherein the sheet is substantially rectangular.

14. A system for covering a plurality of boards, the system comprising: covers, each cover including: a substantially rectangular sheet having a pair of sides and a pair of ends; and, for and extending from each side of the sheet, a flange, the flange being either fixed at about 90 degrees to or pivotably attached to the sheet, the covers being deployed in use such that, on each of said plurality of boards, a plurality of covers is disposed with the sheets thereof in close fitting end-to-end relation and the flanges thereof extending from the sheets and between the boards; andstrip foam material, the foam material being wider than the board width and deployed in use such that, on each of said plurality of boards, foam material is fitted between the boards and the covers so as to cover the surface of the board on which the sheets are positioned and to extend at least partially along each side of the board beneath the flanges.