DECK BOARD ASSEMBLY AND COMPONENTS THEREOF, AND METHODS OF MANUFACTURING AND USING THE SAME

FIELD

This disclosure relates to support surface structures and components thereof, particularly, composite deck board assemblies for deck structures, outdoor structures, docks, and boats, designed for quick and efficient assembly, environmental resistive functionality, and appealing aesthetics.

BACKGROUND

A deck refers to a horizontal platform or support surface that is elevated above the underlying ground or water. Decks are commonly found on various types of vessels, such as boats and ships, as well as on land-based structures like piers, docks, bridges, patios, and other elevated platforms for commercial and residential use.

On boats, the deck is the uppermost surface of the hull, providing a stable and flat area for people to walk on and perform various activities. It typically extends from the bow (front) to the stern (rear) of the vessel, covering the entire top portion of the hull. The deck may have different sections or levels, such as the foredeck (at the front), the main deck, and the aft deck (at the rear). Depending on the type of boat or ship, there may be multiple decks stacked vertically as floors.

Decks on boats and ships serve multiple purposes, including providing structural support (e.g., decks contribute to the overall strength and stability of the vessel's hull, distributing the weight and loads from various components), safety and accessibility (e.g., the deck provides a secure surface for crew members, passengers, or cargo, allowing them to move around the vessel safely; moreover, rails or bulwarks may be present along the edges of the deck for added safety), functional areas (e.g., different areas of the deck may be designated for specific functions, such as the helm station, seating areas, storage compartments, equipment installations, or recreational spaces), and mooring and equipment handling (e.g., decks often have cleats, bollards, or other fittings for securing ropes, lines, and anchorages). Decks also provide space for handling equipment, such as cranes, winches, or davits, used for loading/unloading cargo or launching/retrieving smaller boats.

In the context of land-based structures, decks are elevated platforms constructed adjacent to buildings or as standalone structures. They are usually made of wood, composite materials, or concrete, and serve as outdoor living areas, extensions of indoor spaces, or recreational spaces. Land-based decks are commonly found in residential settings, restaurants, hotels, and other venues where people gather for leisure activities.

Traditional decks are commonly assembled using wooden materials such as teak, mahogany, or water-resistant, water-proof, or marine-grade plywood. This method involves securing wooden planks or boards to a structural framework using stainless steel screws, nails, or specialized fasteners designed for marine applications. The planks are typically treated with sealants or varnishes to enhance durability and protect against moisture. However, traditional wood construction is often labor-intensive, requiring precise measurements, cutting, and fitting of each plank. Additionally, wood is susceptible to rot, decay, and warping over time, especially when exposed to moisture and harsh marine environments. Regular maintenance, including sanding, resealing, and refinishing, is necessary to preserve the structural integrity and appearance of the wood.

Fiberglass Reinforced Plastic (FRP) panels are a popular alternative to traditional wood construction. These panels consist of layers of fiberglass and polyester or epoxy resin, providing strength, durability, and resistance to corrosion. To assemble decks with FRP panels, the panels are typically cut to size and then attached to a boat's framework using either adhesive bonding, mechanical fasteners, or a combination of both. Adhesives such as epoxy or polyurethane-based formulations are commonly used for bonding FRP panels to the framework. Mechanical fasteners, such as stainless steel screws or bolts, may be employed as additional reinforcement. Proper surface preparation, including cleaning and sanding, is crucial for ensuring a strong bond between the panels and the framework. Despite the improved strength and longevity offered by FRP panels, improper installation, inadequate bonding, or insufficient maintenance can lead to delamination and reduced structural integrity over time.

Decking systems have gained popularity in recent years due to their ease of installation and versatility. These systems consist of pre-made deck boards, slats, tiles, or panels that interlock to create a seamless surface. The tiles or panels are typically made from composite materials (e.g., wood-plastic composites), PVC, or aluminum. Composite materials offer enhanced durability, resistance to moisture, UV rays, and fading, which makes them suitable for marine environments. These solutions are often made for residential use, and are subject to fatigue and stress fractures from any large bearing capacity.

Further, the installation of decking systems usually involves laying a grid-like framework or support structure over the boat's existing deck. The pre-made boards, slats, tiles, or panels are then placed and interlocked on top of the framework. Some decking systems employ specialized clips or connectors to ensure secure attachment. Often times, these systems demand professional expertise and an understanding of the methods and/or specialized tools needed for installing the system.

Often times the solutions require virgin materials, or materials that do not include regrind or other foreign materials. Namely, the addition of certain materials may weaken the integrity or may provide warping or other unwanted side effects.

Thus, there is a long sought need for a pre-made solution that may comprise recycled materials, weight bear large capacities, maintain resistance to the environmental damage, and be infinitely recyclable. The disclosure herein, and the various embodiments, provide for a solution that can meet the challenges of fatigue, longevity, recyclability, and are resistant to environmental damage.

SUMMARY

According to its major aspects and briefly recited, herein is disclosed a deck board assembly for assembling a deck board, including: (i) a plurality of deck board panels including a first deck board panel and a second deck board panel; (ii) a finishing feature; and (iii) a plurality of mechanical fasteners. The first deck board panel and the second deck board panel each include an extruded or pultruded panel body and a chemically bonded use surface. The extruded or pultruded panel body includes an internal screw boss and defines a side including an overhang and an opposite side including a ledge. The plurality of mechanical fasteners includes mechanical fasteners for use with the ledge and mechanical fasteners for use with the finishing feature, for assembling the deck board. The overhang is configured to engage with an adjacent deck board panel of the deck board. Moreover, the finishing feature is configured to engage with the overhang. Furthermore, the finishing feature is configured to straddle at least the first deck board panel and the second deck board panel of the deck board.

In some aspects, a deck board is disclosed. The deck board includes: (i) a frame; and (ii) a deck board assembly. The deck board assembly includes a plurality of modular deck board panels each including an extruded or pultruded panel body and a chemically bonded use surface, a finishing feature; and a plurality of mechanical fasteners. The extruded or pultruded panel body includes an internal screw boss and defines a side including an overhang configured to engage with an adjacent deck board panel, and an opposite side including a ledge. The plurality of mechanical fasteners includes: (i) a mechanical fastener fastening at least one of the plurality of modular deck board panels, via the ledge, to the frame; and (ii) a mechanical fastener fastening the finishing feature, via the internal screw boss, to the extruded or pultruded panel body of at least one of the plurality of modular deck board panels. Moreover, the finishing feature is positioned along the extruded or pultruded panel body of at least one of the plurality of modular deck board panels.

In some aspects, a method of assembling a deck board is disclosed. The method includes: (i) providing a frame; (ii) providing a deck board assembly as described herein; (iii) fastening at least one of the plurality of modular deck board panels, via the ledge, to the frame with a mechanical fastener of the plurality of mechanical fasteners; (iv) positioning the finishing feature along the extruded or pultruded panel body of at least one of the plurality of modular deck board panels; and (v) fastening the finishing feature, via the internal screw boss, to the extruded or pultruded panel body of at least one of the plurality of modular deck board panels with another mechanical fastener of the plurality of mechanical fasteners.

These and other advantages will be apparent to those skilled in the art based on the following disclosure.

BRIEF DESCRIPTION OF THE DRAWINGS

Many aspects of the present disclosure will be better understood with reference to the following drawings. The components in the drawings are not necessarily to scale, with emphasis instead being placed upon clearly illustrating the principles of the disclosure. Moreover, in the drawings, like reference numerals designate corresponding parts throughout the several views. It should be recognized that these implementations and embodiments are merely illustrative of the principles of the present disclosure. Therefore, in the drawings:

FIG. 1 is a perspective view of an illustration of an example deck board assembly according to the present disclosure;

FIG. 2 is a perspective view of an illustration of an example deck board assembly according to the present disclosure;

FIG. 3 is a perspective view of an illustration of an example deck board assembly according to the present disclosure;

FIG. 4 is a perspective view of an illustration of an example deck board assembly according to the present disclosure;

FIG. 5 is a perspective view of an illustration of an example deck board assembly according to the present disclosure;

FIG. 6 is a perspective view of an illustration of an example deck board assembly according to the present disclosure;

FIG. 7 is a perspective view of an illustration of an example deck board assembly according to the present disclosure;

FIG. 8 is a perspective view of an illustration of an example deck board assembly according to the present disclosure;

FIG. 9 is a perspective view of an illustration of an example deck board assembly according to the present disclosure;

FIG. 10 is a perspective view of an illustration of an example deck board assembly according to the present disclosure;

FIG. 11 is a perspective view of an illustration of an example deck board assembly according to the present disclosure;

FIG. 12 is a perspective view of an illustration of an example deck board assembly according to the present disclosure; and

FIG. 13 is a perspective view of an illustration of an example deck board assembly according to the present disclosure.

DETAILED DESCRIPTION

The presently disclosed subject matter now will be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all embodiments of the presently disclosed subject matter are shown. Like numbers refer to like elements throughout. The presently disclosed subject matter may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. Indeed, many modifications and other embodiments of the presently disclosed subject matter set forth herein will come to mind to one skilled in the art to which the presently disclosed subject matter pertains having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is to be understood that the presently disclosed subject matter is not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims.

Throughout this specification and the claims, the terms “comprise,” “comprises,” and “comprising” are used in a non-exclusive sense, except where the context requires otherwise. Likewise, the term “includes” and its grammatical variants are intended to be non-limiting, such that recitation of items in a list is not to the exclusion of other like items that can be substituted or added to the listed items.

The present application references PCT Appl. No. US2022/42159, a previous filed and pending application by Applicant, and said reference is incorporated herein in the entirety.

I. EXAMPLE USE CASE SCENARIOS

Decks fabricated with conventional wood construction are susceptible to rot, decay, and warping over time, especially when exposed to moisture and/or harsh marine environments. Proper maintenance, including regular inspections, sealing, and refinishing, is necessary to mitigate these issues. Similarly, improper installation or inadequate maintenance of FRP panels can result in delamination, which reduces the overall structural strength and integrity of the deck components. Regular inspections, repairs, and adherence to manufacturer guidelines are essential to maintain the structural integrity of FRP assemblies.

In either case, traditional wood construction and FRP panels add significant weight to land-based decks or boats. Consequently, decking systems have gained popularity in recent years due to their ease of installation, relative low cost, and versatility. Decking systems are available in a range of materials, including wood-plastic composites, PVC, and aluminum. Wood-plastic composites offer the aesthetic appeal of wood while providing enhanced durability, moisture resistance, and resistance to solar radiation and fading. PVC and aluminum panels may also be used and incorporated into the systems as these components are known for their lightweight properties, corrosion resistance, and low maintenance requirements.

The installation of decking systems typically involves laying a grid-like framework or support structure. This framework provides stability and ensures proper load distribution. The pre-made boards, slats, tiles, or panels of the decking system are then placed and interlocked on top of the framework.

While conventional decking systems offer the above stated benefits, they have limitations when it comes to customization and ease of installation (especially when it comes to at-home users and lay people). As such, in at least one aspect, the disclosure herein is directed to improved support surface structures, in particular, to modular deck board assemblies and decking system components, and to improved methods of producing and assembling the same. In the same vein, the lessons and techniques disclosed herein are applicable to any support structure or surface.

II. Systems and Methods

In one aspect, the support surface structure or deck board according to the present disclosure is a multi-component system that allows for easy assembly, use, and/or disassembly of the structure. The support surface structure or deck board, in one aspect, includes a plurality of molded, extruded, or pultruded components, although other manufacturing methods are envisioned. These components can be easily transported (stacked or nested, for example) and installed/assembled on site. In another aspect, the support surface structure includes a modular deck board assembly of the panel variety, although other modular and non-modular types are envisioned. In particular, in another aspect, the deck board assembly yields a sturdy and rigid deck board that appears, aesthetically, as if made from a plurality of single-piece lineal boards or lineal slats, instead of deck board panels. In another aspect, the deck board produced from the installed deck board assembly appears to be made from conventionally installed wooden or teak deck boards or slats.

In one aspect, the deck board assembly according to the present disclosure is part of a decking system including a frame. The frame is configured to hold one or more support surfaces or deck board floors/levels. Each deck board floor or level, in one aspect, is made of a deck board assembly having a plurality of side-by-side deck board panels. The deck board panels, in another aspect, are configured to interconnect to create a contiguous, seemingly-flush support surface. Moreover, the deck board assembly or the deck board components may be manufactured to include internal structures (embedded or removable/replaceable) that are the same or a different material than the deck board assembly or the deck board components. In another aspect, the internal structures may be formed using a different manufacturing method than the deck board assembly or the deck board components. Furthermore, the deck board assembly components or panels, in another aspect, may be further processed (e.g., cut, sheared, sawed, etched, chamfered, notched, bent, drilled, bored, built-up, chemically prepared, etc.) as need.

In one aspect, each deck board panel of a deck board assembly according to the present disclosure is configured to be held and supported directly by a different portion of a frame. The deck board panel(s) of the deck board assembly include a use surface, and a panel body configured to touch and/or interlock with an adjacent deck board panel body of the deck board assembly and configured to be rigidly engaged to the frame. The panel body of each deck board panel, in one aspect, includes internal structures that provide structural integrity to the panel body such that the deck board panel can withstand loads placed on it during use. In another aspect, the panel body of the deck board panels may include an embedded internal reinforcement(s).

In one aspect, the use surface of each deck board panel according to the present disclosure is a flexible PVC that is mechanically engaged to and/or chemically bonded to the panel body of each deck board panel. In particular, in another aspect, the use surface may be enhanced or altered by scuffing, scarring, and other processes that add texture and surface area adhesion. The use surface, in another aspect, may be further processed or finished (e.g., cut, sheared, sawed, etched, chamfered, notched, bent, drilled, bored, built-up, sanded, worn, chemically prepared, etc.) as needed. In this way, for example, the use surface may appear, aesthetically, as if made from a plurality of single-piece lineal boards or lineal slats, although other aesthetic surface finishes are envisioned including surface finishes that look like stone, concrete, marble, monolithic wood, parquet, tile, resin, etc.

In one aspect, the use surface may be configured as a flat or generally planar surface. As such, the use surface is supported and held directly by the panel body of the deck board panel, and as such the use surface is configured to provide a stable support surface for an assembled deck board.

In one aspect, the panel body of each deck board panel according to the present disclosure serves to receive and hold the use surface for each deck board panel, and serves to receive and hold the only mechanical fasteners demanded by the deck board assembly (for securably attaching the deck board panels to a frame). In another aspect, the deck board assembly may call for mechanical fasteners (friction-fit, snap-fit, screws, etc.) for securing the use surface to the panel body and/or for securing any other component of the assembly (e.g., any other lineal members or finishing features as described herein). In another aspect, the panel body defines a surface feature or recess for receiving and holding the use surface, or for receiving the material for the use surface.

In particular, in one aspect, the panel body includes a screw boss(es) to receive the assembly screws. In one aspect, the screw boss(es) help to securably attach (via mechanical fasteners, for example) other components of the deck board assembly to the panel body and/or the use surface. Importantly, assembly screws may be driven into the screw boss(es) that are exposed at the ends of the panel body. In another aspect, the assembly screws also may be driven (e.g., from the side(s) or from within at any point along the length of the panel body, for example, into the internal screw boss (the entire screw boss extending along a length of the panel body, for example).

In one aspect, the deck board panel body is a lineal member produced from an extrusion or pultrusion manufacturing process. Other components of the deck board assembly may be produced from an extrusion or pultrusion manufacturing process as well. The components for the deck board assembly in the form of lineal members, in on aspect, may be made at least in part of polymeric materials or equivalent, e.g., low-density polyethylene (LDPE) (a chemically inert, flexible, insulator), high-density polyethylene (HDPE) (inert, thermally stable, tough and high tensile strength); polypropylene (resistant to acids and alkalis, high tensile strength); polyvinyl chloride (PVC) (insulator, flame retardant, chemically inert); polychlorotrifluoroethylene (PCTFE) (stable to heat and thermal, high tensile strength and non-wetting); polyamide (Nylon) (high melting point, excellent abrasion resistance); polyethylene terephthalate (PET) & (PETG) (High strength and stiffness, broad range of use temperatures, low gas permeability), etc. In another aspect, the components for the deck board assembly also may be made of recycled materials or may incorporate embedded internal reinforcement such as embedded reinforcement fibers (glass fibers, carbon fibers, bast fibers) as is understood in the art or reinforcement strips as described herein. The components for the deck board assembly, in another aspect, may be formed of “color-blend” recycled plastics or polymers as is known in the art. The components for the deck board assembly, in another aspect, may be formed of scrap carbon fiber, and fiber glass and glass fibers, as well as any other polymers and/or any other natural (e.g., plant-based or plant derived) or non-natural fiber(s).

In one aspect, the deck board assembly and/or the deck board component(s) incorporate or is made of a non-homogeneous composition of matter having both compressive strength and stiffness which enables it to be used as a substitute for wood in a wide variety of applications. In another aspect, the structural composite for the deck board component(s) according to the present disclosure can be substituted with other materials having a higher strength modulus than wood, such as aluminum.

In particular, in one aspect, the deck board assembly and/or the deck board panel component(s) are engineered, meaning that its exterior shape and the choice of its external or internal features or components (e.g., screw boss(es)) and their locations and shapes are based at least in part on the demands as specified herein. The deck board assembly and/or the deck board panel component(s) may be extruded or pultruded lineal composite structures produced with embedded reinforcement(s) that are spaced away from the neutral axis, analogous to the flanges on and I-beam, or asymmetrically situated, in order to provide increased strength and stiffness in one or both axes perpendicular to the cross-section.

In one aspect, the deck board assembly and/or the deck board panel component(s) incorporate or is made of a structural polymeric composite, which include a polymer and stiffening additivities, typically waste glass fiber, carbon fiber, or bast fibers. In one aspect, the deck board assembly and deck board component(s) incorporate polyvinyl chloride (PVC) and/or recycled PVC. In one aspect, the deck board assembly and deck board panel component(s) incorporate polyamides. In one aspect, the deck board assembly and deck board panel component(s) incorporate a shredded fibrous material, for example, shredded carbon fiber. In one aspect, the deck board assembly and deck board component(s) incorporate a shredded fibrous material, for example, shredded fiberglass in waste, virgin, or blended form (waste+virgin). In one aspect, the deck board assembly and deck board component(s) incorporate a shredded fibrous material, for example, shredded bast fibre. In one aspect, the deck board assembly incorporates a first polymeric layer of PVC and/or recycled PVC, in which an additive is applied.

Referring to methods herein, in one aspect, a method of assembling a deck board with a deck board assembly comprising a plurality of deck board panels is disclosed. In one aspect, the method comprises providing a lineal panel body having a use surface adhered or laminated thereon, and providing mechanical fasteners for installing the deck board panels to a deck frame. The method also comprises, in one aspect, securably fastening each of the plurality of deck board panels onto the frame, starting with a first deck board panel and then proceeding to place and slide a second deck board panel into position, adjacent, to the first deck board panel, and so on and so forth for the remainder of the plurality of deck board panels. In another aspect, the method also comprises interconnecting and/or interlocking each subsequent deck board panel with a previously installed deck board panel to prevent the subsequent deck board panel from shifting and/or moving relative to the previously installed deck board panel.

In one aspect, the component elements allow for circularity in assembly, disassembly, and repair of broken components. Namely, the infinitely recyclable components may be repaired when broken by shredding, reheating, extruding or molding, and replacing the broken part. Thus, aspects of this disclosure allow cradle to cradle use of patents, lowering the costs of making deck boards from virgin materials, and reducing emissions and greenhouse gases associated with creating more virgin material.

In one aspect, a method of using the deck board components is disclosed. In another aspect, the deck board components are stacked or nested and transported in a box. The stacked and/or nested deck board components conserve space and allow for ready and fast assembly on site.

III. With Reference to the Figures

The term “extruded” is used herein for convenience but deck board may be formed in any way customary in the industry, for example, pultruded and co-extruded with other materials. Resin fusion and vacuum fusion methods are also envisioned.

The term “lineal” is used herein to refer to an extruded deck board component having a uniform cross section perpendicular to its major dimension which major dimension is much longer than its other two dimensions; that is, the plane of any cross section perpendicular to the major dimension of the deck board component is defined by a line parallel to the major dimension.

The term “non-homogeneous” as used herein means that at least some of the constituents are concentrated within the structural composite rather than being homogeneously dispersed.

The term “screw boss” is a physical structure that grips the threads of a screw being driven into it so that, once the screw has been inserted into or through the screw boss, the screw boss resists the removal of the screw more when the screw is pulled than when the screw is unscrewed.

A “mechanical fastener” is a mechanism or structure that helps to fasten to items or two components together, and may include but is not limited to screws, nails, bolts, pegs, mating structures, snap or button mechanisms, etc.

Accordingly, a user, a business, and/or a contractor can affectively manufacture, stack/nest, assemble, use, disassemble, store, and/or recycle the deck board assembly and the deck board panel components based on the systems and methods of the present disclosure. The deck board panel components and the resulting deck board assemblies according to the present disclosure are easier to produce, assemble, and customize than conventional decking systems. The deck board panel components and the resulting deck board assemblies according to the present disclosure allow for ready and efficient transport of deck board panel and assembly components on site, as needed, and rapid assembly/disassembly and use of those components and resulting decks.

Referring now to FIG. 1, a perspective view of an illustration of an example deck board assembly according to the present disclosure is shown. In particular, in FIG. 1 there is shown a multi-component, modular type deck board assembly 100 including a plurality of modular deck board panels 110 and a plurality of finishing features 101, in particular, a plurality of rounded edge panels 102. The deck board assembly 100 is assembled and installed on a frame 10 to create a contiguous, seemingly-flush, generally planar support surface that is both sturdy and rigid.

As illustrated in FIG. 1, each of the plurality of modular deck board panels 110 of the deck board assembly 100, in particular, the deck board panel 112a and the deck board panel 112b, has an extruded panel body 120a, 120b, respectively, and a use surface 130a, 130b respectively. More specifically, as illustrated in FIG. 1, the plurality of modular deck board panels 110 are made of recycled PVC and fiber and are manufactured to include one or more internal reinforcements 150 and one or more screw bosses 160. The one or more internal reinforcements 150a, 150b provide structural integrity to the panel body 120a, 120b such that each deck board panel 112a, 112b, respectively, can withstand downward loads (i.e., loads towards the frame) placed thereon. The one or more internal reinforcements may be comprised of several layers for increasing rigidity. For example, the internal reinforcements may comprise a first polymeric layer with a layer height ranging from 0.20 mm to 1.20 mm; a first mesh layer comprised of a fiberglass or other rigid polymer or metal, a composite layer of shredded fibrous material (carbon fiber, bast fibers, glass fibers) and polymeric material, such as PET. In this aspect, the shredded fibrous material may be of an average length between 5.0 mm and 50 mm, and the polymeric material may have a granular size from 50 microns to 2000 microns prior to heating and extruding; a second mesh layer of fiberglass or other polymer or metal, and a second polymeric layer to fully encapsulate and form a sandwich of layers.

The one or more screw bosses 160 are configured to receive mechanical fasteners 170 for installing each deck board panel 112 of the deck board assembly 100 to the frame 10. The one or more screw bosses 160 also are configured to receive the mechanical fasteners 170 for installing other components of the deck board assembly 100 to the deck board panels 112a, 112b (best seen in FIGS. 9 and 10).

Depending on the embodiment, additional deck board panels 112 and/or finishing features 101 may be part of the deck board assembly 100 a (i.e., three or more, four or more, etc. deck board panels 112 and a complementary number of rounded edge panels 102). Moreover, the deck board panels 112 and/or the finishing features 101 may be further processed (e.g., cut, sheared, sawed, etched, chamfered, bent, pre-drilled, bored, built-up, chemically prepared, etc.) during manufacturing or on-site during assembly. In some aspects, the deck board panels 112 and/or the finishing features 101 are pre-drilled or pre-bored to allow for ready placement and use of the mechanical fasteners 170 (best in FIG. 8). Furthermore, each of the deck board panels 112 and/or the finishing features 101 may further incorporate embedded reinforcement fibers, strands, or rebar-like lineal structures according to the present disclosure.

Returning to FIG. 1, the extruded panel body 120 of each of the plurality of modular deck board panels 110 according to the present disclosure serves to receive and hold the use surface 130. In particular, as illustrated in FIG. 1, the use surface 130 is chemically bonded to the panel body 120 of each of the plurality of modular deck board panel 110. Moreover, the use surface 130 may be made of flexible PVC and further processed or finished (e.g., scuffed, cut, sheared, sawed, etched, chamfered, notched, bent, drilled, bored, built-up, sanded, worn, chemically prepared, etc.) to appear, aesthetically, as if made from a plurality of single-piece lineal boards or lineal slats. In particular, as illustrated in FIG. 1, the use surface 130 of each of the plurality of modular panels 110 appears to be made from conventionally installed wooden or teak deck boards or slats.

As further illustrated in FIG. 1, the extruded panel body 120 of each of the plurality of modular deck board panels 110 according to the present disclosure serves to receive and hold the mechanical fasteners 170. In particular, as illustrated in FIG. 1, the extruded panel body has edge features 121, in particular, ledge(s) 122 (best seen in FIGS. 5 and 6) through which the mechanical fasteners are screwed and into the frame 10 beneath. Depending on the embodiment, the mechanical fasteners 170 may be screwed through the ledge 122 adjacent to the internal reinforcement 150 and not through the internal reinforcement 150. Furthermore, as illustrated in FIG. 1, the extruded panel body 120 also has an overhang 124 (i.e., an edge feature 121) configured to touch and/or interlock with an adjacent deck board panel 112 of the deck board assembly 100 (best seen in FIGS. 7 and 8). Depending on the embodiment, the extruded panel body 120 of each of the plurality of modular deck board panels 110 may be pre-drilled or pre-bored to allow for easy configuration with mechanical fasteners. Furthermore, the extruded panel body 120 may incorporate embedded reinforcement fibers, strands, or rebar-like lineal structures according to the present disclosure. Depending on the embodiment, the extruded panel body 120 may be formed entirely of rolled metal instead of being an extrusion or pultrusion product. Regardless of the composition the various components may be prepared with pre-drilling, or treated with exterior additives to ensure longevity, such as oils for the rolled steel, or UV protection on the synthetic polymer embodiments.

Referring now to FIG. 2, is a perspective view of an illustration of an example deck board assembly being assembled according to the present disclosure. In particular, in FIG. 2, there is shown a deck board panel 212a of a plurality of modular deck board panels 210 (only partially shown) of a deck board assembly 200 being mechanically fastened onto a frame 10.

As illustrated in FIG. 2, the extruded panel body 220a of the deck board panel 212a already has a use surface 230a thereon. The use surface 230a is chemically bonded to the extruded panel body 220a of the deck board panel 212a. The use surface 230a also is processed or finished to appear to be made from conventionally installed wooden or teak deck boards or slats. Moreover, the use surface 230a and the underlying extruded panel body 220a are processed or finished to have a pre-drilled aperture 226a therethrough. In this way, the extruded panel body 220a can serve to receive and hold a mechanical fastener 270a.

Referring now to FIG. 3, is a perspective view of an illustration of an example deck board assembly being assembled according to the present disclosure. In particular, in FIG. 3, there is shown a deck board panel 312a of a plurality of modular deck board panels 310 (only partially shown) of a deck board assembly 300 being mechanically fastened onto a frame 10. The extruded panel body 320a of the deck board panel 312a has a use surface 330a chemically bonded to the extruded panel body 320a, and is processed/finished to appear to be made from conventionally installed wooden or teak deck boards or slats, and together both are processed/finished to have a pre-drilled aperture 326a. A mechanical fastener 370a has traversed the aperture 326a and is screwed through a side wall 327a of the extruded panel body 320a of the deck board panel 312a adjacent, and not through, an embedded internal reinforcement 350a, and into the underlying frame 10. In particular, as illustrated in FIG. 3, the deck board assembly 300 includes a plug 380a for the aperture 326a defined by the use surface 330a, and the plug 380a is configured to look like the material of the use surface 330a to hide the aperture 326a.

Referring now to FIG. 4, is a perspective view of an illustration of an example deck board assembly being assembled according to the present disclosure. In particular, in FIG. 4, there is shown a deck board panel 412a of a plurality of modular deck board panels 410 (only partially shown) of a deck board assembly 400 being mechanically fastened onto a frame 10. The extruded panel body 420a of the deck board panel 412a has a use surface 430a chemically bonded to the extruded panel body 420a, and is processed/finished to appear to be made from conventionally installed wooden or teak deck boards or slats. A pre-drilled aperture 326a (not shown) is obscured by a plug 480a. As illustrated in FIG. 4, on the end of the extruded panel body 420a opposite the plug 480a, a mechanical fastener 370a′ is positioned for screwing through a side wall 427a of the extruded panel body 420a of the deck board panel 412a adjacent, and not through, an embedded internal reinforcement 450a, and into the underlying frame 10. In particular, as illustrated in FIG. 4, the mechanical fastener 470a′ is positioned at an angle.

Referring now to FIG. 5, is a perspective view of an illustration of an example deck board assembly being assembled according to the present disclosure. In particular, in FIG. 5, there is shown a deck board panel 512a of a plurality of modular deck board panels 510 (only partially shown) of a deck board assembly 500 being mechanically fastened onto a frame 10. The extruded panel body 520a of the deck board panel 512a has a use surface 530a chemically bonded to the extruded panel body 520a, and is processed/finished to appear to be made from conventionally installed wooden or teak deck boards or slats. A pre-drilled aperture 526a (not shown) is obscured by a plug 580a. As illustrated in FIG. 5, on the end of the extruded panel body 520a opposite the plug 580a, a mechanical fastener 570a′ is screwed through a side wall 527a of the extruded panel body 520a of the deck board panel 512a adjacent, and not through, an embedded internal reinforcement 550a, and into the underlying frame 10. In particular, as illustrated in FIG. 4, the mechanical fastener 470a′ is screwed at an angle. Moreover, as illustrated in FIG. 5, on the side of the extruded panel body 520a opposite the mechanical fastener 570a′, a mechanical fastener 570a″ is positioned at an angle for screwing through a ledge 522 of the extruded panel body 520a of the deck board panel 512a adjacent, and not through, an embedded internal reinforcement 550a, and into the underlying frame 10. Furthermore, as illustrated in FIG. 5, on the same end of the extruded panel body 520a but on the side opposite the plug 580a, a mechanical fastener 570a′″ is positioned at an angle for screwing through the ledge 522a adjacent, and not through, the embedded internal reinforcement 550a, and into the underlying frame 10.

Referring now to FIG. 6, is a perspective view of an illustration of an example deck board assembly being assembled according to the present disclosure. In particular, in FIG. 6, there is shown a deck board panel 612a and a deck board panel 612b of a plurality of modular deck board panels 610 of a deck board assembly 600 being mechanically fastened onto a frame 10. The extruded panel body 620a, 620b of the deck board panels 612a, 612b, respectively, each have a use surface 630 chemically bonded to the extruded panel body 620, and each is processed/finished to appear to be made from conventionally installed wooden or teak deck boards or slats. As illustrated in FIG. 6, mechanical fastener 670a are screwed through side walls 627a and/or a ledge 622a of the extruded panel body 620a of the deck board panel 612a and into the underlying frame 10. Moreover, as illustrated in FIG. 6, the deck board panel 612b is positioned on the frame adjacent to the deck board panel 612a.

Referring now to FIG. 7, is a perspective view of an illustration of an example deck board assembly being assembled according to the present disclosure. In particular, in FIG. 7, there is shown a deck board panel 712a and a deck board panel 712b of a plurality of modular deck board panels 710 of a deck board assembly 700 being mechanically fastened onto a frame 10. The extruded panel body 720a, 720b of the deck board panels 712a, 712b, respectively, each have a use surface 730 chemically bonded to the extruded panel body 720, and each is processed/finished to appear to be made from conventionally installed wooden or teak deck boards or slats. As illustrated in FIG. 7, mechanical fastener 770a are screwed through side walls 727a and/or a ledge 722a of the extruded panel body 720a of the deck board panel 712a and into the underlying frame 10. Moreover, as illustrated in FIG. 7, the deck board panel 712b is positioned and slid on the frame 10 adjacent to the deck board panel 712a and into contact with the adjacent deck board panel 712a such that an overhang 724b of the extruded panel body 720b is touching and/or interlocked with the adjacent deck board panel 712a.

Referring now to FIG. 8, is a perspective view of an illustration of an example deck board assembly being assembled according to the present disclosure. In particular, in FIG. 8, there is shown a deck board panel 812a and a deck board panel 812b of a plurality of modular deck board panels 810 of a deck board assembly 800 mechanically fastened to a frame 10. The extruded panel body 820a, 820b of the deck board panels 812a, 812b, respectively, each have a use surface 830 chemically bonded to the extruded panel body 820, and each is processed/finished to appear to be made from conventionally installed wooden or teak deck boards or slats. As illustrated in FIG. 8, mechanical fastener 870a are screwed through side walls 827a and/or a ledge 822a of the extruded panel body 820a of the deck board panel 812a and into the underlying frame 10. Moreover, mechanical fastener 870b are screwed through side walls 827b and/or a ledge 822b of the extruded panel body 820b of the deck board panel 812b and into the underlying frame 10. As illustrated in FIG. 8, an overhang 824b of the extruded panel body 820b is touching and/or interlocked with the adjacent deck board panel 812a.

As illustrated in FIG. 8, the deck board panel 812a and the deck board panel 812b of the plurality of modular deck board panels 810 include a plurality of screw bosses 860 configured to receive mechanical fasteners 870. For example, in FIG. 8, a first rounded edge panel 802 (also known as a bull nose configuration) of the deck board assembly 800 is positioned for being mechanically fastened to the extruded panel body 820a of the deck board panel 812a along an overhang 824a. Moreover, the first rounded edge panel 802 is processed/finished to have pre-drilled apertures 826 therethrough. In this way, the first rounded edge panel 802 can serve to receive and hold mechanical fasteners 870a (best seen in FIG. 9). Additionally, the first rounded edge panel 802, or any of the other edge panels may have an indication line on one side and may not have such a line on the opposite side. Therefore, allowing for reversal of the first rounded edge panel 802 to conform to the teak line of the finishing feature. In this aspect, the installer may easily align the teak markings or indications in the surface by reversing the edge panels to conform to desired aesthetics. In further aspects, the first rounded edge panel serves as a bumper, as it is comprised mainly of flexible PVC, it may be a bolster or bumper for incoming watercraft, or other objects. The structural design of the first rounded edge panel 802 allows for impact and cushioning, by having several air gaps and compression points. These air gaps and compression points serve to resiliently bolster against repeated impact, while allowing the edge panel to maintain integrity.

Referring now to FIG. 9, is a perspective view of an illustration of an example deck board assembly being assembled according to the present disclosure. In particular, in FIG. 9, there is shown a deck board panel 912a and a deck board panel 912b of a plurality of modular deck board panels 910 of a deck board assembly 900 mechanically fastened to a frame 10. The extruded panel body 920a, 920b of the deck board panels 912a, 912b, respectively, each have a use surface 930 chemically bonded to the extruded panel body 920, and each is processed/finished to appear to be made from conventionally installed wooden or teak deck boards or slats. As illustrated in FIG. 9, a first rounded edge panel 902 of the deck board assembly 900 is positioned for being mechanically fastened to the extruded panel body 920a of the deck board panel 912a along an overhang 924a. Moreover, the first rounded edge panel 902 is processed/finished to have pre-drilled apertures 926 therethrough and mechanical fasteners 970a are positioned for being screwed into the screw boss 960. Furthermore, as illustrated in FIG. 9, the first rounded edge panel 902 also is processed/finished to appear to be made from conventionally installed wooden or teak deck boards or slats and to match the use surface 930a.

Referring now to FIG. 10, is a perspective view of an illustration of an example deck board assembly being assembled according to the present disclosure. In particular, in FIG. 10, there is shown a deck board panel 1012a and a deck board panel 1012b of a plurality of modular deck board panels 1010 of a deck board assembly 1000 mechanically fastened to a frame 10. The extruded panel body 1020a, 1020b of the deck board panels 1012a, 1012b, respectively, each have a use surface 1030 chemically bonded to the extruded panel body 1020, and each is processed/finished to appear to be made from conventionally installed wooden or teak deck boards or slats. As illustrated in FIG. 10, a first rounded edge panel 1002 of the deck board assembly 1000 is positioned and mechanically fastened, via the mechanical fasteners 1070 (not shown) to the extruded panel body 1020a of the deck board panel 1012a. Moreover, the first rounded edge panel 1002 is processed/finished to have pre-drilled apertures 1026 therethrough. Furthermore, as illustrated in FIG. 10, the deck board assembly 1000 also includes plugs 1080 for the apertures 1026 defined by the first rounded edge panel 1002, and plugs 1080 are configured to hide the apertures 1026.

Referring now to FIG. 11, is a perspective view of an illustration of an example deck board assembly being assembled according to the present disclosure. In particular, in FIG. 11, there is shown a deck board panel 1112a and a deck board panel 1112b of a plurality of modular deck board panels 1110 of a deck board assembly 1100 mechanically fastened to a frame 10. The extruded panel body 1120a, 1120b of the deck board panels 1112a, 1112b, respectively, each have a use surface 1130 chemically bonded to the extruded panel body 1120, and each is processed/finished to appear to be made from conventionally installed wooden or teak deck boards or slats.

As illustrated in FIG. 11, a first rounded edge panel 1102 of the deck board assembly 1100 is positioned and mechanically fastened, via the mechanical fasteners 1170 (not shown) to the extruded panel body 1120a of the deck board panel 1112a. Furthermore, as illustrated in FIG. 11, a second rounded edge panel 1102′ of the deck board assembly 1100 is positioned for being mechanically fastened to the extruded panel body 1120a, 1120b of the deck board panels 1112a, 1112b, respectively. Moreover, the second rounded edge panel 1102′ is processed/finished to have pre-drilled apertures 1126′ therethrough. In this way, the second rounded edge panel 1102′ can serve to receive and hold mechanical fasteners 1170′ (best seen in FIG. 12).

Referring now to FIG. 12, is a perspective view of an illustration of an example deck board assembly being assembled according to the present disclosure. In particular, in FIG. 12, there is shown a deck board panel 1212a and a deck board panel 1212b of a plurality of modular deck board panels 1210 of a deck board assembly 1200 mechanically fastened to a frame 10. The extruded panel body 1220a, 1220b of the deck board panels 1212a, 1212b, respectively, each have a use surface 1230 chemically bonded to the extruded panel body 1220, and each is processed/finished to appear to be made from conventionally installed wooden or teak deck boards or slats.

As illustrated in FIG. 12, a first rounded edge panel 1202 of the deck board assembly 1200 is positioned and mechanically fastened, via the mechanical fasteners 1270 (not shown) to the extruded panel body 1220a of the deck board panel 1212a. Furthermore, as illustrated in FIG. 12, a second rounded edge panel 1202′ of the deck board assembly 1200 is positioned for being mechanically fastened to the extruded panel body 1220a, 1220b of the deck board panels 1112a, 1112b, respectively (i.e., the second rounded edge panel 1202′ straddles both the deck board panels 1112a, 1112b). Moreover, the second rounded edge panel 1202′ is processed/finished to have pre-drilled apertures 1226′ therethrough and through which mechanical fasteners 1270′ can be received. In this way, the second rounded edge panel 1202′ meets with and creates a contiguous, continuous edge surface with the first rounded edge panel 1202 and meets with the use surface 1230.

Referring now to FIG. 13, is a perspective view of an illustration of an example deck board assembly being assembled according to the present disclosure. In particular, in FIG. 13, there is shown a deck board panel 1312a and a deck board panel 1312b of a plurality of modular deck board panels 1310 of a deck board assembly 1300 mechanically fastened to a frame 10. The extruded panel body 1320a, 1320b of the deck board panels 1312a, 1312b, respectively, each have a use surface 1330 chemically bonded to the extruded panel body 1320, and each is processed/finished to appear to be made from conventionally installed wooden or teak deck boards or slats. A second rounded edge panel 1302′ is processed/finished to have pre-drilled apertures 1326′ therethrough and through which mechanical fasteners 1370′ can be received. Moreover, as illustrated in FIG. 13, the deck board assembly 1300 also includes plugs 1380′ for the apertures 1326′ defined by the second rounded edge panel 1302′, and plugs 1380 are configured to hide the apertures 1326′.

IV. Embodiments

Certain implementations of systems and methods consistent with the present disclosure are provided as follows:

Clause 1. A deck board assembly for assembling a deck board, comprising: (i) a plurality of deck board panels comprising a first deck board panel and a second deck board panel, the first deck board panel and the second deck board panel each comprising an extruded or pultruded panel body and a chemically bonded use surface, the extruded or pultruded panel body comprising an internal screw boss and defining a side comprising an overhang and an opposite side comprising a ledge; (ii) a finishing feature; and (iii) a plurality of mechanical fasteners comprising mechanical fasteners for use with the ledge and mechanical fasteners for use with the finishing feature, for assembling the deck board, wherein the overhang is configured to engage with an adjacent deck board panel of the deck board, wherein the finishing feature is configured to engage with the overhang, and wherein the finishing feature is configured to straddle at least the first deck board panel and the second deck board panel of the deck board.

Clause 2. The deck board assembly of the preceding clause, wherein each of the plurality of deck board panels is modular.

Clause 3. The deck board assembly of any of the preceding clauses, wherein the extruded or pultruded panel body further comprises an internal reinforcement.

Clause 4. The deck board assembly of any of the preceding clauses, wherein the chemically bonded use surface is processed or finished as imitation lineal deck boards or lineal slats.

Clause 5. The deck board assembly of any of the preceding clauses, wherein the finishing feature is a rounded edge panel.

Clause 6. The deck board assembly of the preceding clause, wherein the rounded edge panel is configured to meet with the use surface of the first deck board panel and the second deck board panel of the deck board.

Clause 7. The deck board assembly of any of the preceding clauses, wherein the deck board assembly further comprises a plug for an aperture through the finishing feature.

Clause 8. A deck board, comprising: (i) a frame; and (ii) a deck board assembly, the deck board assembly comprising (a) a plurality of modular deck board panels each comprising an extruded or pultruded panel body and a chemically bonded use surface, the extruded or pultruded panel body comprising an internal screw boss and defining a side comprising an overhang configured to engage with an adjacent deck board panel, and an opposite side comprising a ledge; (b) a finishing feature; and (c) a plurality of mechanical fasteners comprising: (i) a mechanical fastener fastening at least one of the plurality of modular deck board panels, via the ledge, to the frame; and (ii) a mechanical fastener fastening the finishing feature, via the internal screw boss, to the extruded or pultruded panel body of at least one of the plurality of modular deck board panels, wherein the finishing feature is positioned along the extruded or pultruded panel body of at least one of the plurality of modular deck board panels.

Clause 9. The deck board of the preceding clause, wherein the extruded or pultruded panel body of at least one of the plurality of modular deck board panels further comprises an internal reinforcement.

Clause 10. The deck board of any of the preceding clauses, wherein the chemically bonded use surface is processed or finished as imitation lineal deck boards or lineal slats.

Clause 11. The deck board of any of the preceding clauses, wherein the finishing feature is a rounded edge panel.

Clause 12. The deck board of the preceding clause, wherein the rounded edge panel is configured to meet with the use surface of at least one of the plurality of modular deck board panels.

Clause 13. The deck board of any of the preceding clauses, wherein the finishing feature is configured to engage with the overhang feature, and wherein the finishing feature is positioned along the overhang feature of the extruded or pultruded panel body of the least one of the plurality of modular deck board panels.

Clause 14. The deck board assembly of any of the preceding clauses, wherein the deck board assembly further comprises a plug for an aperture through the finishing feature.

Clause 15. A method of assembling a deck board, comprising: (i) providing a frame; (ii) providing a deck board assembly, the deck board assembly comprising (a) a plurality of modular deck board panels each comprising an extruded or pultruded panel body and a chemically bonded use surface, the extruded or pultruded panel body comprising an internal screw boss and defining a side comprising an overhang configured to engage with an adjacent deck board panel, and an opposite side comprising a ledge; (b) a finishing feature; and (c) a plurality of mechanical fasteners for assembling the deck board; (iii) fastening at least one of the plurality of modular deck board panels, via the ledge, to the frame with a mechanical fastener of the plurality of mechanical fasteners; (iv) positioning the finishing feature along the extruded or pultruded panel body of at least one of the plurality of modular deck board panels; and (v) fastening the finishing feature, via the internal screw boss, to the extruded or pultruded panel body of at least one of the plurality of modular deck board panels with another mechanical fastener of the plurality of mechanical fasteners.

Clause 16. The method of the preceding clause, wherein the extruded or pultruded panel body of at least one of the plurality of modular deck board panels further comprises an internal reinforcement.

Clause 17. The method of any of the preceding clauses, wherein the finishing feature is a rounded edge panel.

Clause 18. The method of the preceding clause, wherein the rounded edge panel is configured to meet with the use surface of at least one of the plurality of modular deck board panels.

Clause 19. The method of any of the preceding clauses, wherein positioning the finishing feature along the extruded or pultruded panel body further comprises positioning the finishing feature along the overhang feature of the extruded or pultruded panel body.

Clause 20. The method of any of the preceding clauses, further comprising plugging an aperture through the finishing feature with a plug component of the deck board assembly.

It should be emphasized that the above-described embodiments of the present disclosure are merely possible examples of implementations set forth for a clear understanding of the principles of the disclosure. Many variations and modifications may be made to the above-described embodiment(s) without departing substantially from the spirit and principles of the disclosure. All such modifications and variations are intended to be included herein within the scope of this disclosure and protected by the following claims.

DECK BOARD ASSEMBLY AND COMPONENTS THEREOF, AND METHODS OF MANUFACTURING AND USING THE SAME

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