Patent Application
20240426112
The present disclosure relates generally to an outdoor deck, such as a deck that may be attached to or adjacent to a residential building. The outdoor deck may be made of materials including wood, composite or other materials.
An aspect of the present disclosure is directed to a deck system. In some embodiments, the deck system comprises a first flooring board having an upper surface, a first side, and a second side opposite the first side; a second flooring board having an upper surface, a third side, and a fourth side opposite the third side, the third side of the second flooring board being in spaced apart facing relation with the second side of the first flooring board; and a water-resistant strip having a first edge and a second edge, the first edge of the strip being secured to the second side of the first flooring board, and the second edge of the strip being secured to the third side of the second.
In some embodiments, the second side of the first flooring board includes a first recess and the third side of the second flooring board includes a second recess, the first edge of the strip being received within the first recess of the first flooring board, and the second edge of the strip being received within the second recess of the second flooring board.
In some embodiments, the first recess of the first flooring board is near a middle portion of a side wall of the first flooring board and the second recess of the second flooring board is in a middle portion of a side wall of the second flooring board.
In some embodiments, the strip is secured to the first flooring board by a first fastener and the strip is secured to the second flooring board by a second fastener.
In some embodiments, at least one of the first fastener and the second fastener includes an adhesive or another material that makes a watertight seal.
In some embodiments, the first recess is at an upper edge of a side wall of the first flooring board and the second recess is at an upper edge of a side wall of the second flooring board.
In some embodiments, an upper surface of the first edge of the strip is flush with the upper surface of the first flooring board and an upper surface of the second edge of the strip is flush with the upper surface of the second flooring board, wherein hidden fasteners secure the water-resistant strip to a support structure beneath the deck system.
In some embodiments, the strip is secured to the first flooring board by a first fastener and the strip is secured to the second flooring board by a second fastener.
In some embodiments, at least one of the first fastener and the second fastener includes an adhesive or another material that makes a watertight seal.
In some embodiments, the strip has a U-shaped cross when viewed from an end.
In some embodiments, the water-resistant strip is made of plastic, metal, rubber, or a combination thereof or any other material.
In some embodiments, the water-resistant strip is water-impermeable.
In some embodiments, at least one of the first flooring board and the second flooring board is made of wood or composite material or any other material.
Another aspect of the present disclosure is directed to a deck according to any of the embodiments of the present disclosure.
Another aspect of the present disclosure is directed to a method of forming a deck. In some embodiments, the method comprises positioning a first flooring board having an upper surface, a first side, and a second side opposite the first side; positioning a second flooring board having an upper surface, a third side, and a fourth side opposite the third side, the third side of the second flooring board being in spaced apart facing relation with the second side of the first flooring board; positioning a water-resistant strip having a first edge and a second edge between the first flooring board and the second flooring board; and securing the first edge of the strip to the second side of the first flooring board, and securing the second edge of the strip to the third side of the second flooring board.
The accompanying drawings are not intended to be drawn to scale. In the drawings, each identical or nearly identical component that is illustrated in various figures is represented by a like numeral. For purposes of clarity, not every component may be labeled in every drawing. In the drawings:
This disclosure is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the drawings. The disclosure is capable of other embodiments and of being practiced or of being carried out in various ways. Also, the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of “including,” “comprising,” “having,” “containing,” “involving,” and variations thereof herein, is meant to encompass the items listed thereafter and equivalents thereof as well as additional items.
An aspect of the present disclosure is directed to a deck system, particularly a deck system that is attached to or built near a residential structure, such as a house.
Generally, a deck system of the present disclosure includes a post and beam support structure and a plurality of flooring boards that extend crosswise with respect to beams. The flooring boards may be secured to the beams of the support structure that is secured to the ground or another surface, e.g., a joist of a house. The support structure supports the flooring boards in spaced apart relation above the ground or other surface. The beams support the flooring boards, which together constitute a deck surface on which users may walk or stand and on which users may position furniture or appliances. The deck surface may be positioned adjacent to a building, such as a residential building.
The flooring boards extend parallel to each other and are spaced apart from each other, leaving a gap between a pair of adjacent flooring boards. To seal this gap between the pair of adjacent flooring boards, a strip is positioned between the pair of adjacent flooring boards. The strip forms a water-tight seal between the pair of adjacent flooring boards. Together, the pair of adjacent flooring boards and the strip prevent liquids, such as water, from passing through the gap to the ground or other surface beneath the flooring boards of the deck system. The deck system may be configured to direct water along the strip to an end of the strip, with the strip acting as a gutter between the pair of adjacent flooring boards of the deck system. In some embodiments, the deck system may be configured to direct water away from the residential structure. In some embodiments, the strip is configured such that rainwater drains off the end of the deck system with no pitch required along the deck surface.
According to embodiments of the present disclosure, the deck system helps keep an area underneath the deck system dry during a rainstorm. This allows a user to more freely use the area underneath the deck system both during rainy weather and after rain has ended.
At least some embodiments of the deck system of the present disclosure may be used with an existing deck. At least some embodiments of the deck system of the present disclosure may be installed at the site of the existing deck.
Referring now to
The strips 14 are configured to provide a gutter system along the length of the flooring boards 12 of the deck system 10. Water, such as rainwater, that falls on an upper surface 16 of a flooring board automatically runs off the deck system through the gutter system. The gutter system prevents water from falling from the upper surface 16 onto any joists that support the deck system 10.
The deck system 10 of
The strips 14 may be secured to the flooring boards 12 in various ways.
The relative arrangement of the flooring boards and the strips is best understood by referring to two adjacent flooring boards. The flooring boards 112, 114, 116 include a first flooring board 112 and a second flooring board 114. Each flooring board may be made of one or more materials. In some embodiments, the first flooring board 112 and/or the second flooring board 114 is made of wood. In some embodiments, the first flooring board 112 and/or the second flooring board 114 is made of a composite material including a plastic, thermoplastic, resin, or other material.
The first flooring board 112 has an upper surface, a lower surface opposite the upper surface, a first side, and a second side opposite the first side. In
The second flooring board 114 has an upper surface, a lower surface opposite the upper surface, a first side, and a second side opposite the first side, the first side of the second flooring board 114 being in spaced apart facing relation with the second side of the first flooring board 112. The first side of the second flooring board 114 includes a second recess 124 configured to receive another portion of the strip 118. as with the first recess 122 of the first floor board 112, the second recess 124 is in a middle portion of the first side of the second floor board 114. In some embodiments, the middle portion of the first side may be about halfway between the upper surface and the lower surface of the second floor board 114.
Each strip 118, 120 has a first edge and a second edge. In some embodiments, each strip 118, 120 may be substantially planar. The first edge of the strip 118 is secured within the recess 122 of the first flooring boards 112. The second edge of the strip 118 is secured within the recess 124 of the second flooring boards 114.
Each strip 118, 120 extends to at least substantially seal the gap between the two adjacent floor boards when the deck system is viewed from the top. Each strip 118, 120 has a width that is at least as great as the respective gap. Each strip 118, 120 has a length that is at least substantially the same as the length of the gap between the two adjacent floor boards.
In some embodiments, the length of the strip is the same as the length of the gap between the two adjacent floor boards.
A user may secure each strip 118, 120 between the adjacent floor boards 112, 114, 116 by sliding the strip lengthwise into the recesses of the adjacent flooring boards when the floor boards are secured next to each other.
Once the respective strip is secured between the respective adjacent floor boards, the strip and the floor boards together form a watertight gutter on the deck system.
Each strip may be made of one or more materials. In some embodiments, the strip is a water-resistant strip. In some embodiments, the strip is water-impermeable.
In some embodiments, the strip is made of plastic, metal, rubber, another material, or a combination thereof. In some embodiments, each strip is made of a combination of at least two of the following three materials: plastic, metal, rubber, or another material suitable for making a watertight seal.
Each strip may be fastened to each adjacent flooring board by one or more fasteners.
In
In some embodiments, the first fastener and/or the second fastener includes a nail and/or an adhesive. In some embodiments, the first fastener and/or the second fastener is an adhesive. In some embodiments, the first fastener and/or the second fastener is a nail. In
A coating may be applied over the flooring boards 112, 114, 116 and the strips 118, 120. In some embodiments, the coating may be a water-resistant coating. In some embodiments, the coating may be a resin coating.
The relative arrangement of the floor boards 212, 214, 216 and the strips 218, 220 is best understood by referring to two adjacent floor boards. The floor boards 212, 214, 216 include a first floor board 212 and a second floor board 214. Each floor board may be made of one or more materials. In some embodiments, the first floor board 212 and/or the second floor board 214 is made of wood. In some embodiments, the first floor board 212 and/or the second floor board 214 is made of a composite material including a plastic, thermoplastic, resin, or other material.
The first floor board 212 has an upper surface, a lower surface opposite the upper surface, a first side, and a second side opposite the first side. In
The second floor board 214 has an upper surface, a lower surface opposite the upper surface, a first side, and a second side opposite the first side, the first side of the second floor board 214 being in spaced apart facing relation with the second side of the first floor board 212. The second floor board 214 includes a second recess 224 configured to receive a portion of the strip 218. The second recess is defined in the upper surface of the second flooring board 214 near the first side of the second flooring board.
Each strip 218, 220 has a first edge and a second edge. In some embodiments, each strip 218, 220 may have a shape that is not planar. In
Each strip extends to at least substantially seal the gap between the two adjacent floor boards when the deck system is viewed from the top. Each strip has a width that is at least as great as the respective gap. The strip has a length that is at least substantially the same as the length of the gap between the two adjacent floor boards.
In some embodiments, the length of the strip is the same as the length of the gap between the two adjacent floor boards.
A user may secure the strip between the adjacent floor boards by placing the strip into the recesses on the adjacent floor boards from above, along the direction of arrow A, when the floor boards are secured next to each other when using hidden fasteners.
Once the strip is secured between the adjacent floor boards, the strip and the floor boards together form a watertight gutter on the deck system that has a flush finish.
In
Each strip 218, 220 may be made of one or more materials. In some embodiments, the strip is a water-resistant strip. In some embodiments, the strip is water-impermeable.
In some embodiments, the strip is made of plastic, metal, rubber, another material, or a combination thereof. In some embodiments, each strip is made of a combination of at least two of the following materials: plastic, metal, rubber, and another material suitable for making a watertight seal. In some embodiments, each strip is made of a combination of at least two of the following three materials: plastic, metal, and rubber.
Each strip may be fastened to each adjacent flooring board by one or more fasteners.
In
In some embodiments, the first fastener and/or the second fastener is an adhesive or another material to make a watertight seal. In some embodiments, the first fastener and/or the second fastener is a nail.
A coating may be applied over the flooring board 212, 214, 216 and the strips 218, 220. In some embodiments, the coating may be a water-resistant coating. In some embodiments, the coating may be a resin coating.
An advantage of the embodiment of
Embodiments of the deck system of the present disclosure are less expensive to manufacture and construct than previously available deck systems. Another advantage of the deck system of the present disclosure is that any debris that falls on the deck system may be removed from the surface of the deck system by sweeping the upper surface of the deck system with a broom or by rinsing the upper surface of the deck system with a hose spray.
Another aspect of the present disclosure is directed to a method of forming a deck of the present disclosure.
In one embodiment, a method of forming a deck includes positioning a first flooring board having an upper surface, a first side, and a second side opposite the first side. The method further includes positioning a second flooring board having an upper surface, a third side, and a fourth side opposite the third side, so the third side is in spaced apart facing relation with the second side of the first flooring board.
To form a seal between the first flooring board and the second flooring board, the method further includes positioning a water-resistant strip having a first edge and a second edge between the first flooring board and the second flooring board, securing the first edge of the strip to the second side of the first flooring board, and securing the second edge of the strip to the third side of the second flooring board.
In one embodiment, the deck system may be used for existing decks and is capable of achieving the same results had the deck system been originally installed. Recessing the boards may also be done at the point of manufacture and the gutter system may be installed at a later time and still be flush with the decking.
Having thus described several aspects of at least one embodiment of this disclosure, it is to be appreciated various alterations, modifications, and improvements will readily occur to those skilled in the art. Such alterations, modifications, and improvements are intended to be part of this disclosure, and are intended to be within the spirit and scope of the disclosure. Accordingly, the foregoing description and drawings are by way of example only.
This application claims priority to U.S. Provisional Patent Application No. 63/523,264, filed on Jun. 26, 2023, which is hereby incorporated herein by reference in its entirety.
| Number | Date | Country | |
|---|---|---|---|
| 63523264 | Jun 2023 | US |
