Patent Grant
12065840
The disclosure generally relates to flooring and decking. More specifically, the disclosure relates to a set of decking boards provided with a connecting system comprising a connecting device, such as a clip. The disclosure also relates to the connecting device and a method of demounting a set of interlocked decking boards.
Decking is typically utilized as outdoor floor constructions in the vicinity or in connection to a building. Decking panels are usually arranged at an elevated level above a ground. The decking panels may be made of treated or composite lumber, aluminium, or other materials. The decking panels may be installed by means of separate clamps that are attached to a joist structure. The clamps hold the decking panels in place and may define a uniform gap between the decking panels. Adjacent decking panels may comprise overlapping lips, thereby concealing the joist structure provided below the panels.
However, the decking panels in the prior art suffer from several drawbacks, especially in the case when they are made of a relatively soft material, a low-quality material, a cheap material, or a low-density material. Known panels utilizing separate clamps and overlapping lips are hard or even impossible to demount without damaging one or several panels. Indeed, in order to remove a panel, a portion of the panel ordinarily has to be cut in order to be able to access the clamp. One reason for this disadvantage is because the panels are arranged to be installed sequentially in one row after another. According to methods in the state of the art, there is no possibility to remove a panel in the middle of the sequence of panels without removing all of the panels that have been installed subsequently in the sequence of panels.
As a consequence, a new panel that will replace a removed panel cannot be installed in the same manner as the previous ones, since they require a sequential arrangement. Thus, the new panel has to be installed by a different method, for example by cutting it appropriately and fixing it by screwing or by gluing it to the joist structure in an ad hoc manner. The first example may result in a less attractive appearance of the panel, since screws may become visible, and the second example may result in a panel which is not attached to the joist structure properly, since glue may provide less fixation than screws.
Additionally, known panels utilizing separate clamps and overlapping lips typically run the risk of being damaged when they are installed, since they are provided with a rather weak groove and lip structure that are arranged to house the clamp. During installation, a screw is screwed through parts of the weak structure and is provided through the clamp. As a result, the weak structure may become deformed or even damaged.
Finally, panels installed according to known principles may become deformed due to environmental conditions, such as temperature changes and humidity variations, whereby the panels become displaced from their initial positions, and may as a result also be damaged.
It is therefore an objective of the present inventive concept to provide a set of decking boards provided with a connecting system comprising a connecting device that allows for an improved procedure of replacing individual decking boards in the set of decking boards.
Another object is to provide a set of decking boards that are more resistant to damage during demounting and installation of decking boards.
It is also an object to provide a corresponding method of demounting a set of interlocked decking boards.
It is a further object to provide a connecting device for connecting decking boards.
According to a first aspect of the inventive concept, there is provided set of decking boards provided with a connecting system comprising a connecting device. The set of decking boards comprises a first decking board comprising a first side portion and a second decking board comprising a second side portion, each side portion extending along a longitudinal direction of the decking board. Each of the first and second side portions comprises a first lip and a second lip, wherein an extension of the second lip in a transverse direction of the decking board is larger than an extension of the first lip in the transverse direction of the decking board. The first decking board is configured to be connected to a support element. The second decking board is configured to assume a vertically locked state with respect to the first decking board, wherein in the vertically locked state: the connecting device cooperates with the first decking board and with the second decking board; preferably, the first lip of the first decking board and the second lip of the second decking board are provided in a first horizontal plane, and the second lip of the first decking board and the first lip of the second decking board are provided in a second horizontal plane, the first and second horizontal planes each being parallel with a surface member of the first and/or the second decking board; there is a vertical gap between a portion of the second lip of the first decking board and a portion of the second lip of the second decking board; and there is a horizontal space between the first lip of the first decking board and the second lip of the second decking board.
Thus, at least a portion of the first lip of the first board and at least a portion of the second lip of the second board may be provided at the same distance from a surface member of the first and/or the second board. Moreover, at least a portion of the second lip of the first board and at least a portion of the first lip of the second board may be provided at the same distance from a surface member of the first and/or the second board.
The transverse direction of the board is a horizontal direction perpendicular to the longitudinal direction of the board. The transverse direction is also perpendicular to a surface normal of a surface member of the board.
The connection of a board to the support element may be a horizontal and/or a vertical connection, preferably a fixation.
An “installed state” of a board is a state in which the board is connected to the support element, and/or vertically locked with respect to an adjacent board. By a first board being “adjacent” to a second board is meant that the first board is arranged next to the second board and the first side portion of the first board preferably is facing the second side portion of the second board.
In the present disclosure, by a “vertically locked state” of a board with respect to an adjacent board, such as the second board assuming a vertically locked state with respect to the first board, may be that the board, preferably a side portion of the board, is locked with respect to the adjacent board at least in a direction perpendicular to the front side and/or rear side of the board, and/or in a direction perpendicular to a horizontal plane provided in top portions of the support element. Optionally, the board, preferably the side portion of the board, may also be partially or even completely locked in a horizontal direction with respect to the adjacent board, preferably an adjacent side portion, such as in the transverse and/or the longitudinal direction of the board. The vertically locked state may be a vertically locked position.
The surface member of each board has an extension along the longitudinal direction and along the transverse direction of the board. The extension along the longitudinal direction preferably is larger than the extension along the transverse direction. The surface member of each board may be one of a first and a second surface member of the board. Preferably, the first and second surface members are parallel to each other. Moreover, the first and second surface members preferably are planar or substantially planar. The first and second surface members may nevertheless comprise portions that are non-planar and/or having a structure, such as an ornamental design, a wood surface, a wood imitation, an embossing, a debossing, bevels, ridges, grooves, cavities, or similar.
The first surface member may correspond to a front side, or visible side, of the board and the second surface member may correspond to a rear side of the board in an installed state of the board, or vice versa.
In an installed state of the first and second boards, the front sides of the first and second boards are preferably arranged in the same, or essentially the same, horizontal plane.
Each board preferably further comprises an opposed side portion extending along the longitudinal direction of the board. The opposed side portion is provided opposite to the side portion in the transverse direction. The opposed side portion of the first and second board may be a second and a first side portion, respectively. A second side portion of a third board may be installed adjacent to the first side portion of the second board. The second side portion of the first board may be installed adjacent to a first side portion of a previously installed board. Each installation may be the same as for the first and second boards in accordance with the above.
Preferably, the first and/or second side portions of a board extend along the entire longitudinal direction of the board.
The first and second side portions of a board may comprise, or may be, a first and a second longitudinal side edge of the board, respectively.
Each opposed side portion may comprise a first lip and a second lip, wherein an extension of the second lip in a transverse direction of the board is larger than an extension of the first lip in the transverse direction of the board. The transverse extensions of the first and/or second lips may be the same, or substantially the same, on the side portion and on the opposed side portion. Thereby, at least a portion of each board may be substantially symmetric under a 180 degrees rotation around a longitudinal axis of the board. In particular, the entire first and second side portions may be substantially symmetric in accordance with the above. By being substantially symmetric the board may assume the same vertically locked state before and after rotation of the board. Another advantage of having a symmetric board is that the orientation of the board in the installed state may be chosen depending on the curvature of the board, especially along the longitudinal and/or the transverse direction. As a result of the above, the board also may become easier to manufacture.
In accordance with the inventive concept, the first and/or the second boards may be demounted after installation with little or even no damage of any board, in particular when installed in conjunction with an plurality of other boards provided next to the first and the second boards and installed in the same way as the first and second boards. The boards may be removed by disconnecting the connecting device and by angling and/or displacing one or both of the boards away from the support element. Moreover, new boards, replacing any removed board, may be installed in a simple way by reversing the angling and/or displacing action. Thereby, individual boards may be replaced in an improved manner.
The boards may be installed sequentially, e.g. one row at a time, while at the same time allowing for individual boards being removed without having to remove the entire row of installed boards between that individual board and a board installed in an end row or a start row.
Another advantage compared to the teachings in the prior art is that the first and second lips of the may be made thicker which makes the boards more robust. Since the board is not damaged as easily, the board may be re-used.
By decking board or deck board is meant a board, panel, tile or plank or similarly that is configured to be provided on a support element. Throughout the disclosure, the short-hand notation “board” will often be used. The board may be installed indoors and/or outdoors. The board may comprise at least one of softwood, hardwood, lumber, a plastic material, such as PVC, PP, PE, wood fibres or metal(s), such as aluminium. The board may comprise a mix of one or several of these materials. In a first example, the board is made of softwood, such as cedar, larch, fir, redwood or pine. In a second example, the board is composite lumber or a Wood-Plastic Composite (WPC) decking board, comprising wood fibres or wood flour and plastics, preferably a thermoplastic, and optionally a filler and/or a binding agent. In a third example, the board is made of hardwood, such as Ipe, Yellow Balau, or Teak. In a fourth example, the board comprises bamboo or eucalyptus. The board may comprise a protective layer for protecting the board against one or several of wear, moist, heat, sunlight, etc. Any of the boards above may be pressure treated.
The set of boards may comprise further boards, such as a third decking board, a fourth decking board, etc. In particular, there may be a plurality of decking boards. Throughout the present disclosure, when referring simply to a board, it is understood that it may refer to any board in the set of boards.
The boards in the set of boards preferably have one or several essentially identical characteristics, such as shape, material, weight, dimensions, colours, designs, protective layers, etc. The boards may be substantially identical. However, it is conceivable that some boards in the set of boards have different characteristics, such as different designs.
Preferably, the connecting device is a separate connecting device and preferably is mounted to the boards during their installation.
The connecting device may be a clip, a clamp, a clasp, a catch, a hook, a spring clip, etc. The connecting device may comprise a metal, such as stainless steel or aluminium, an alloy, such as an aluminium alloy, e.g. a 6060 aluminium alloy, such as 6060-T6, or a plastic, such as thermoplastic, e.g. polypropylene, nylon, acrylonitrile butadiene styrene (ABS) or acrylonitrile styrene acrylate (ASA), or a combination of any of these materials. The connecting device, e.g. comprising thermoplastic, may comprise a glass-fibre material for reinforcement. The connecting device may comprise a plastic or a metal, e.g. aluminium, that may be injection moulded or extruded.
The connecting device may be provided on or connected to the support element by means of an attaching element. The attaching element may be a screw, nail, bolt, rivet, stapler, flange, tape, adhesive, such as glue, or another fastener known to a person skilled in the art.
Moreover, the connecting device may be provided on or connected to the support element by means of flanges provided on the connecting device. For example, the flanges may be snapped or bended onto the support element, e.g. a joist.
The connecting device may be horizontally connected relative to the first board in an installed state, transversely and/or longitudinally.
The connecting device may comprise a first and a second engagement portion configured to engage with the first and second board, respectively, in an installed state. There may be an intermediate portion connecting the first and second engagement portion. The second engagement portion may comprise a bevel or a rounded portion for simplifying an insertion of the connecting device into a groove of the second board. The first and second engagement portions may be configured to be provided at different levels, preferably vertical levels, from the support member in an installed state.
A shape of the connecting device may be such that, when it is placed on the inner wall of the second lip, it has a balanced torsional moment. In particular, this means that it does not fall off the second lip when placed there, thereby giving rise to a simplified installation of the connecting device.
The connecting device may comprise a positioning portion being configured to position the connecting device with respect to the first board in the transverse direction. Thereby, a uniform distance between adjacent boards may be provided and it may be easier to position the connecting device with respect to a guiding means for an attaching element, such as a notch, or a hole, such as a blind hole or a through hole, in the board where or through which an attaching element is configured to be provided.
The connecting device may be a first connecting device. The set of boards may comprise a second connecting device configured to cooperate with the second board and a third board. In particular, the set of boards may comprise a plurality of connecting devices, preferably along the longitudinal direction of the boards, each cooperating with a pair of adjacent boards.
The connecting device preferably extends only along a portion of the board in a longitudinal direction in an installed state. Thereby, a strong connecting system may be provided while keeping a material consumption small. In non-limiting embodiments, the connecting device may have a horizontal extension 20 mm-60 mm, a vertical extension 20 mm-40 mm, and an extension 10 mm-60 mm in a direction perpendicular to the horizontal and vertical directions.
According to one embodiment, the connecting device is operable and/or accessible, and optionally visible, through the horizontally space. Thereby, an arbitrary board in the set of boards may be removed without any substantial damage to any board. In another embodiment, the connecting device is partly or completely concealed.
Alternatively, the connecting device may comprise a covering layer, such as a paint, preferably for increasing its corrosion resistance. The connecting device may comprise an anodic layer, such as aluminium oxide, for increasing its corrosion resistance. In non-limiting examples, the anodic layer has a thickness of 5-25 μm, preferably 10-20 μm.
Next, characteristics of lips, including the first and second lips, are described. It is emphasized that the embodiments below may be applied to any or all of the first and second lips in the first and second side portions of any board. By lip is meant a portion of a board protruding in the transverse direction and having a longitudinal extension. The transverse direction is preferably directed outwards, away from the board. Preferably, the lip has a constant transverse cross-section along the longitudinal direction of the side portion.
The first lip and the second lip of each of the first and the second boards may extend at least along a portion of a longitudinal side edge of each board, preferably side by side and preferably along the entire longitudinal side edge of each board.
According to a preferred embodiment, the second lip protrudes beyond the first lip along the entire longitudinal extension of the board. A maximal extension of the second lip in the transverse direction may be larger than a maximal extension of the first lip in the transverse direction of the board.
The lip may comprise an inner wall, an outer wall, and a side wall. According to one embodiment, at least one of the inner wall, the outer wall, and the side wall is flat. According to one embodiment, at least one of the inner wall, the outer wall, and the side wall is curved.
The first lip of the second board may comprise a bevel or rounded portion for simplifying the insertion of the connecting device.
A thickness, preferably a maximal thickness, of the second lip may be larger than a thickness, preferably a maximal thickness, of the first lip.
A thickness, preferably a maximal thickness, of the second lip may be at least 45%, preferably at least 60%, of a thickness, preferably a maximal thickness, of the board. The first lip of the second board preferably engages with the support element in the installed state, possibly via an elevation element arranged in between.
The first lip of the first board and the second lip of the second board may be provided at a first vertical level, and the second lip of the first board and the first lip of the second board may be provided at a second vertical level, wherein the first and second vertical levels are perpendicular distances from the support element. By way of example, a transversely outer portion, or a vertical centre portion, of each of the first and second lips above may be provided at the first or second vertical level.
In accordance with the first aspect of the inventive concept, there is a vertical gap in the vertically locked state. The portion of the second lip of the first board and the second board may be an upper and transversely outer portion of the second lip and a lower and transversely outer portion of the second lip, respectively.
In an installed state, there may be a horizontal space between the second lip of the first board and the first lip of the second board. This horizontal space may be the same as the horizontal space between the first lip of the first board and the second lip of the second board, especially when the boards are rotationally symmetric by 180 degrees as described above and below. By having the horizontal spaces and the vertical gap, there may be a continuous path between the boards, from a top part to a bottom part of the boards, which may be advantageous for ventilation purposes.
The vertical gap may be provided at least in a region between a first and a second vertical plane. In a first example, the first vertical plane is provided in the side wall of the second lip of the first board and the second vertical plane is provided in the side wall of the second lip of the second board. In a second example, the first vertical plane is provided in the side wall of the first lip of the first board and the second vertical plane is provided in the side wall of the first lip of the second board. The vertical gap may be provided at least in a vertical plane located between the first vertical plane and the second vertical plane, e.g. in the middle. The vertical gap preferably also extends in the horizontal directions.
Transversely outer portions of the first and second lips of the first and second boards, respectively, may be horizontally separated by a space. The horizontal space may be provided in the first horizontal plane.
Optionally, in an installed state, there may be provided an elevation element under at least a portion of the second board for vertically elevating the second board to a vertical level of the first board. Thereby, the front sides of the first and second board may be provided at the same vertical level. This may also be achieved by providing a depression in the first board at the location of the connecting device.
According to one embodiment, at least a portion of each of the first and the second decking boards is symmetric under a 180 degrees rotation around a longitudinal axis of the decking board. The portion may be a portion of the board configured to engage with the connecting device, e.g. provided in the first and/or second lip(s). An advantage of this embodiment is that any of the first and second surface members may be used as a visible surface member. In particular, the surface member having the most attractive properties, such as aesthetics or physical characteristics, may be chosen—during installation or after a period of time.
Additionally, individual boards may be more easily handled during installation. Indeed, only a single rotation around the longitudinal axis is needed for changing the visible surface member of the board, without any further rotation. This is particularly advantageous when the board has a large longitudinal extension when it may be cumbersome to rotate the board around a transverse axis, such as in a small space.
The entire first and second boards may be symmetric, or substantially symmetric, under the 180 degrees rotation around the longitudinal axis.
According to one embodiment, an inner wall of the second lip of the first decking board is inclined with respect to the surface member of the first decking board or curved. An advantage of this embodiment is that fluids, such as water, and moist may be efficiently drained off from the board. The second lip may be tapering along the transverse direction outwards. The inclined inner wall may be planar. The curvature of the curved inner wall may be convex or concave.
An inner wall of the second lip of each of the first and second boards may be inclined with respect to the respective surface members.
An inner wall of the second lip in the second side portion of the first board may be inclined with respect to the surface member of the first board. The inclination may be the same as for the inner wall of the second lip in the first side portion. Thereby, the first board may be made symmetric under a 180 degrees rotation around its longitudinal axis while keeping the drainage advantage described above.
According to one embodiment, the connecting device is provided in a first groove of the first decking board in the vertically locked state and/or the connecting device is provided in a second groove of the second decking board in the vertically locked state. By this embodiments, the connecting device may be more firmly connected to the first and/or second board. The first groove may be provided between the first and second lip of the first board. The first groove may be provided substantially halfway between the first and the second surface member. The second groove may be provided between the first and second lip of the second board. The second groove may be provided substantially halfway between the first and the second surface member.
The connecting device may engage with a lower groove wall of the first groove. The lower groove wall may be the same wall as the inner wall of the second lip. The connecting device may engage with a lower groove wall of the first groove. The lower groove wall may be the same wall as the inner wall of the first lip of the second board.
The first and second grooves, in particular portions of the grooves configured to engage with the connecting device, may be provided at different vertical levels.
According to one embodiment, the connecting device engages with the second lip of the first decking board and with the first lip of the second decking board in the vertically locked state. By engaging with the second lip, such as an inclined second lip, a tilting or twisting of the connecting device may be counteracted. The connecting device may engage with at least one of the inner wall, the side wall, and the outer wall of the second lip of the first board. Moreover, the connecting device may engage with at least one of the inner wall, the side wall, and the outer wall of the first lip of the second board.
According to one embodiment, the connecting device is further configured to engage with the support element in the vertically locked state. A portion of the connecting device may be provided between the first board and the support element. Thereby, a tilting or displacement of the connecting device may be counteracted.
The connecting device may be configured to be connected, preferably releasably connected, to the support element, preferably to a joist. Thereby, the first board may be connected to the support element by engaging with the connecting device. By way of example, the first board may engage with the connecting device by means of a press fit, a snap fit, or an attaching element.
The connecting device may at least partially enclose the second lip of the first board while being connected to the support element, preferably enclosing the outer wall and side wall and, optionally, also the inner wall.
The connecting device may be connected to the first and/or the second board in the vertically locked state. The first board may be horizontally locked relative to the connecting device at least in a first transverse direction, optionally also in an opposite second transverse direction.
In one example, the connecting device is fixed to the support element. In another example, the connecting device is displaceable relative to the support element, preferably in a longitudinal horizontal direction of the support element, such as a joist.
The connecting device may comprise at least one tooth configured to engage with the second lip of the first decking board. By means of the at least one tooth, an improved connection of the connecting device to the first board, and hence of the first board to the support element, may be provided. The at least one tooth may be configured to engage with the second lip by means of a snapping engagement. The second lip of the first board may comprise a notch configured to engage with a tooth in the vertically locked state. The at least one tooth may be configured to be pressed into the material of the second lip. The tooth may be a barb.
According to one embodiment, the connecting device is configured to cooperate with the support element via an attaching element. Thereby, the attaching element may connect the first side portion vertically and/or horizontally to the support element. The connecting device may comprise an opening through which the attaching element may be provided in the installed state.
The connecting device may be accessible and/or operable through the horizontal space so that it may be disconnected from the support element, it may disengage from the boards, etc. Preferably, the horizontal space between the first lip of the first board and the second lip of the second board is at least 1 mm, more preferably at least 5 mm, most preferably at least 10 mm. The space may be such that the attaching element is accessible by a tool from a visible side of the first and second boards in the vertically locked state, in particular by means of a linear displacement of the tool. Thereby, the first and/or second boards may be removed or replaced from above. By way of example, the tool may be a screw driver, a magnet, or similar tools.
According to one embodiment, the attaching element is provided through the second lip of the first decking board and through the connecting device. Thereby, displacements of the first board caused by temperature and/or moisture variations may be counteracted. For example, a displacement of the board along its horizontal transverse direction may be counteracted. Typically, a wood-based board expands or contracts along the horizontal transverse direction under the influence of moisture variations. Also, longitudinal displacements of the board may be counteracted. Typically, a WPC board expands or contracts in the horizontal transverse direction as well as in the longitudinal direction under the influence of temperature variations.
The connecting device may engage with the second lip of the first board and/or the first lip of the second board with pretension in the installed state.
In an installed state, there may be an inner horizontal separation between the connecting device and a third wall of a groove connecting the lower and upper groove walls. Thereby, the connecting device may be displaced in the groove under temperature and/or moisture variations. In non-limiting examples, the inner separation may be 0.1-2 mm for WPC boards and 2-8 mm, preferably more than 6 mm, for boards made of softwood.
The second side portion may be displaceable in the horizontal longitudinal and/or transverse direction in the vertically locked state. As a result, stress forces on the connecting system caused by various displacements of the boards may be reduced. The displacements may be induced by local or global strains of the boards, temperature fluctuations, moisture or humidity variations, etc.
In one embodiment, the connecting device and boards are arranged to connect the first board transversely relative to the connecting device by a first retaining force, and to connect the second board transversely relative to the connecting device by a second retaining force. The first retaining force may be larger than the second retaining force. Thereby, the second side portion may be horizontally displaced more easily than the first side portion and may reduce stress forces during temperature and/or moisture variations. Alternatively, the second retaining force may be larger than the first retaining force. In non-restrictive examples, the larger retaining force may be between 0.5 and 2.0 kN/m and the smaller retaining force may be between 0.25 and 1.0 kN/m.
In one embodiment, the attaching element is provided through the second lip of the first board and a portion of the connecting device is arranged between the second lip of the first board and the support element in the vertically locked state. Here, an exact alignment of the connecting device between the board and the support element may not be needed, since the attaching element may be provided outside of, or next to, the connecting device. Moreover, in the vertically locked state the connecting device may be horizontally connected relative to the board by means of pressure of the board from above and/or pressure of the support element from below. Optionally, the connecting device may comprise a fixing portion for further fixation of the connecting device.
According to one embodiment, the connecting device is arranged to lock the first side portion or the second side portion vertically and at least in a first transverse direction, optionally also in an opposite second transverse direction, preferably allowing a displacement of the first and/or second board relative the support element along a longitudinal direction of each board. The connecting device may comprise at least one flange, or similarly, functioning as an attaching element. The connecting device may be arranged to cooperate, preferably engage, with the second lip of the first board and the first lip of the second board. The engagement may be pretensioned. The at least one tooth may be provided on the flange being an attaching element.
According to one embodiment, the set of decking boards further comprises the attaching element, wherein a maximal transverse extension of the attaching element is essentially the same or smaller than the horizontal space. A longitudinal extension of the attaching element preferably is larger than the transverse extension. By means of this embodiment, the attaching element may be removed, even in the installed state of the set and, thereby, a board may be removed and replaced. The maximal transverse extension may be a width of the attaching element, such as a width of a head of a screw. By being “essentially the same”, the attaching element may be removed even when the maximal transverse extension is larger than the horizontal space, e.g. by tilting the attaching element with respect to the side walls of the lips or by compressing the material of the lips and forcing out the attaching element.
In one embodiment, the connecting device is configured to be rotated for vertically locking the second board with respect to the first board. An advantage of this embodiment is that the connecting device may be removed in a simpler manner. The connecting device, preferably the first engagement portion, may comprise a retaining element. The retaining element may be configured to counteract twisting of the connecting device during installation, in particular when an attaching element is driven or turned into the support element through the second lip. The retaining element may also improve the connection of the connecting device to the second lip. The retaining element may be provided inside or outside of the opening or hole in the longitudinal direction of the first engagement portion. In a non-limiting example, the retaining element is a sharp retaining element, such as a jag or a spike. The sharp retaining element may be configured to be inserted or pressed into a portion of the second lip, e.g. the inner wall.
An underside of the second engagement portion may be rounded. Thereby, the installation of the connecting device may be simplified and the second board may be displaced more easily, especially along a longitudinal direction.
According to one embodiment, the second board further comprises a first side portion being opposite to the second side portion of the second board and extending along the longitudinal direction of the second board, wherein the first side portion comprises: a first lip and a second lip, wherein an extension of the second lip in a transverse direction of the second board is larger than an extension of the first lip in the transverse direction of the second board, wherein the second board is configured to be connected to the support element, and wherein a third board is configured to assume a vertically locked state with respect to the second board in which a second connecting device cooperates with the second and third boards. By means of this embodiment, the second connecting device may vertically lock a third board to the second board in complete analogy with the discussion above.
A shape of the side wall of the first lip of the first board may be the same as or complementary to a shape of the side wall of the second lip of the second board. By a complementary shape of a first wall and a second wall is here meant that a protruding or convex portion of the first wall has a corresponding recess or concave portion of the second wall, and vice versa. Moreover, a shape of the side wall of the second lip of the first board may be same as or complementary to a shape of the side wall of the first lip of the second board. In a first example, the side walls are vertical. In a second example, the side walls are inclined with respect to a perpendicular direction of a surface member. Thereby, the connecting device may be more easily accessed and manipulated when the inner wall of the second lip of the first board is inclined. In a third example, the side walls are curved.
Corresponding same or complementary shapes as above may be provided for the side wall of the second lip of the first board and the side wall of the first lip of the second board. It is also clear that these shapes may be provided on an individual board, i.e. the side wall of the first and second lip of the opposed side portion may be the same as or may be complementary to the side wall of the second and first lip, respectively, of the side portion.
In a non-limiting example, at least a portion of the side wall of the first lip of the first board is perpendicular to at least a portion of the, preferably inclined, inner wall of the second lip of the first board.
According to one embodiment, the portion of the second lip of the second decking board is provided above the portion of the second lip of the first decking board in the vertically locked state such that they form a horizontal overlap. By means of the horizontal overlap, at least a portion of the second lip may be concealed in an installed state. Also the connecting device and/or attaching element may be partly or even completely concealed.
The horizontal overlap may be an overlap between a projection of the portion of the second lip of the second board and a projection of the portion of the second lip of the first board onto a horizontal plane, such as, the first or the second horizontal plane.
The connecting device may comprise a protrusion configured to be pressed into, or to be disposed in a notch of, the second lip of the first decking board in an installed state.
A portion of the connecting device may be configured to be provided in a recess, preferably in an inner wall and/or a side wall, of the second lip of the first decking board in an installed state.
Preferably, the boards are installed in a condition such that the level of deformation of the boards over time is kept low or at a minimum. Preferably, the boards are sufficiently dried and/or adapted to the installation environment, e.g. regarding temperature, before installing them. According to one embodiment, however, the boards are configured to be installed with the first lip of the first board and the second lip of the second board being in abutment with each other, whereby the horizontal space between them is formed over time as the material of the boards changes volume, in particular decreases, e.g. due to shrinkage. The material may be a hygroscopic material and/or a material being susceptible to thermal expansion/contraction. Moreover, the material may be an impregnated and/or pressure-treated material. For example, the boards may comprise softwood or may be WPC boards.
According to a second aspect of the inventive concept, there is provided a connecting device for connecting decking boards comprising: a first engagement portion configured to engage with a second lip of a first decking board, optionally comprising a hole for connecting the connecting device to a support element with an attaching element through the hole and the second lip, a second engagement portion configured to engage with a first lip of a second decking board, optionally comprising an end section being curved or forming an angle with respect to an overall lengthwise extension of the second engagement portion.
The connecting device may further comprise a third segment configured to engage with a side wall of the second lip and preferably arranged at an angle with respect to the second engagement portion, such as 45°-135°, preferably 90°.
A portion, preferably an inner section, of the first engagement portion may be inclined with respect to a portion, preferably an inner section, of the second engagement portion.
An end section of the first engagement portion may be parallel to the portion of the second engagement portion.
The hole may be provided in the portion of the first engagement portion.
The first engagement portion and the second engagement portion may be provided asymmetrically with respect to the third segment.
A support surface of the first engagement portion may be vertically displaced from a support surface of the second engagement portion. The support surface of the first engagement portion may be vertically displaced farther away from an end point of a third segment than the support surface of the second engagement portion is, the third segment being configured to engage with a side wall of the second lip.
The connecting device may further comprise a protrusion configured to be disposed in a notch of the second lip of the first decking board in an installed state.
The connecting device may further comprise a protrusion configured to be pressed into the second lip of the first decking board in an installed state.
The hole may be circular.
One or several of a support surface of the first engagement portion, an inner section of the first engagement portion, and a third segment of the connecting device, may be configured to guide the connecting device into position and/or to counteract twisting or tilting of the connecting device during installation
The set of decking boards in accordance with the first aspect may comprise the connecting device in accordance any of the embodiments of the second aspect.
According to a third aspect of the inventive concept, there is provided a method of demounting a set of decking boards comprising a first connecting device cooperating with a first and a second decking board, and a second connecting device cooperating with the second and a third decking board. The method comprises: vertically unlocking the second decking board with respect to the first decking board; disconnecting the second decking board from a support element, preferably by releasing a horizontal relative connection between the second connecting device and the second decking board; and removing the second decking board.
The act of releasing a horizontal relative connection between the first connecting device and the first decking board may comprise removing a first attaching element provided through the second lip of the first decking board, the first attaching element being provided through or outside of the first connecting device.
The act of releasing a horizontal relative connection between the second connecting device and the second decking board may comprise removing a second attaching element provided through the second lip of the second decking board, the second attaching element being provided through or outside of the second connecting device.
The act of vertically unlocking the second decking board with respect to the first decking board may comprise: releasing a horizontal relative connection between the first connecting device and the first decking board, displacing the second decking board horizontally towards the third decking board, or angling the first and second decking boards away from the support element, preferably while releasing a horizontal relative connection between the first connecting device and the first decking board.
The horizontal relative connection between the first connecting device and the first decking board may comprise an engagement between a fixing portion of the first connecting device and the first decking board, and the horizontal relative connection between the second connecting device and the second decking board may comprise an engagement between a fixing portion of the second connecting device and the second decking board.
The horizontal relative connection between the second connecting device and the second board may be released by operating and/or accessing the second connecting device through a horizontal space provided between a first lip of the second board and a second lip of the third board.
The horizontal relative connection between the first connecting device and the first decking board may be released by operating and/or accessing the first connecting device through a horizontal space provided between a first lip of the first decking board and a second lip of the second decking board.
It is clear that the order of the method steps presented in any of the embodiments above are non-limiting and that the steps may be performed in any order, or even simultaneously.
Embodiments of the first, second and third boards and of the connecting device are largely analogous to those of the first and second aspects wherein reference is made to the above.
Other aspects of the inventive concept and embodiments of the first, second and third aspects are provided in an embodiment section below.
The disclosure will in the following be described in connection to exemplary embodiments and in greater detail with reference to the appended exemplary drawings, wherein:
Next, embodiments of decking boards will be described with reference to
For illustrative purposes
For orientation, a right-handed coordinate system spanned by three perpendicular axes (AX, AY, AZ) is indicated in
The first longitudinal side edge 103 comprises a first 110 and a second 120 lip. The second lip protrudes with respect to the first lip so that a maximal extension of the second lip is larger than a maximal extension of the first lip along the transverse axis AY. A first groove 130 is provided between the first and second lip.
The first lip 110 comprises an inner wall 112, a side wall 114, and an outer wall 116. The outer wall 116 is provided as a portion of the first surface member 101. The inner wall 112 is provided as an upper groove wall of the first groove 130. The side wall 114 connects the inner 112 and outer 116 wall. The inner 112 and outer 116 walk are parallel to each other.
The second lip 120 comprises an inner wall 122, a side wall 124, and an outer wall 126. The outer wall 126 is provided as a portion of the second surface member 102. The inner wall 122 is provided as a lower groove wall of the first groove 130. The side wall 124 connects the inner 122 and outer 126 wall. The inner wall 122 is inclined with respect to the outer wall 126. A width of the second lip 120 in a thickness direction along the axis AZ in
The first groove 130 comprises a third wall 132 connecting the inner walls 112 and 122. The third wall 132 is provided perpendicularly to the first 101 and second 102 surface members.
The second longitudinal side edge 104 comprises a first 140 and a second 150 lip. The second lip 150 protrudes with respect to the first lip 140 so that a maximal extension of the second lip 150 is larger than a maximal extension of the first lip 140 along the transverse axis AY. A second groove 160 is provided between the first 140 and second 150 lip.
The first lip 110 and the second lip 150 are provided in a first horizontal plane H1. Moreover, the second lip 120 and the first lip 140 are provided in a second horizontal plane H2. The first horizontal plane H1 and the second horizontal plane H2 are parallel with the first surface member 101 as well as with the second surface member 102.
The first lip 140 comprises an inner wall 142, a side wall 144, and an outer wall 146. The outer wall 146 is provided as a portion of the second surface member 102. The inner wall 142 is provided as a lower groove wall of the second groove 160. The side wall 144 connects the inner 142 and outer 146 wall. The inner 142 and outer 146 walls are parallel to each other.
The second lip 150 comprises an inner wall 152, a side wall 154, and an outer wall 156. The outer wall 156 is provided as a portion of the first surface member 101. The inner wall 152 is provided as an upper groove wall of the second groove 160. The side wall 154 connects the inner 152 and outer 156 wall. The inner wall 152 is inclined with respect to the outer wall 156. A width of the second lip 150 in a thickness direction along the axis AZ in
The second groove 160 comprises a third wall 162 connecting the inner walls 142 and 152. The third wall 162 is provided perpendicularly to the first 101 and second 102 surface members.
The walk 112, 114, 116 and 142, 144, 146 of the first lips and the walls 122, 124, 126 and 152, 154, 156 of the second lips are flat. Preferably, there is a bevel or smooth transition between the walls 114 and 116, between the walls 124 and 126, between the walls 144 and 146, and between the walls 154 and 156. Moreover, the side walls 114, 124, 144 and 154 are arranged perpendicularly to the first surface member 101.
A respective notch 125 and 155 is provided in the second lips 120 and 150, preferably extending along the entire side edges 103, 104. The notches 125, 155 are provided in the inner walls 122, 152.
According to the embodiment in
Due to the discrete rotational symmetry of order two as described above, the board 100 may be installed with either of the first 101 and second 102 surface members facing upwards so that it becomes visible. For sake of clarity, it is assumed that the first surface member 101 is visible after installation of the board 100, i.e. facing upwards, but it is clear that this choice is non-limiting.
In one example, β2 is different from β1 and/or α2 is different from α1. In another example, β2 is the same as β1 and α2 is the same as α1. In the latter example, the board is symmetric under a rotation by 180 degrees around the axis AX (not shown). For example, the positions of the side walls 114 and 144 are interchanged.
Next, various installed states of two or more boards of the types in
For clarity, embodiments of connections of the boards to the support element and vertical locking of the second board 100b to the first board 100a are suppressed in
In
In
In any of the embodiments in
The boards 100 are configured to be connected to each other by means of a connecting device 200.
According to the embodiment in
The second engagement portion comprises a first 232 and a second 234 section. The first section 232 is arranged at an angle with respect to the intermediate portion 220, for example 45°-135°, preferably 70°-85°. The second section 234 is an end section of the second engagement portion that is curved upwards. An underside of the second section comprises a bevel or a rounded portion.
The connecting device 200 in
A shape of at least a portion of the intermediate portion 220 in any of the embodiments of the present disclosure may correspond to a shape of the side wall 124. Thereby, a tight abutment between the intermediate portion and the side wall 124 may be obtained. The intermediate portion may be a flat or a curved surface, for example corresponding to a shape of the side wall 124 in any of the embodiments in
In any of the embodiments of the present disclosure the connecting device 200 may comprise a positioning portion or spacer 203. Thereby, a uniform gap between the boards may be provided. In
The connecting device 200 in
Optionally, the connecting device may comprise a third segment 222 for further connecting and/or positioning it to the first board. For example, the third segment 222 may counteract twisting of the connecting device during installation of the boards. The third segment 222, indicated by a broken line in
The connecting device 200 in
In the installed state, the first lip 110 of the first board and the second lip 150 of the second board are provided in a first horizontal plane H1, and the second lip 120 of the first board and the first lip 140 of the second board are provided in a second horizontal plane H2. The first H1 and second H2 horizontal planes are parallel with the surface members 101, 102 of the first and the second boards. Moreover, there is a transversal horizontal space S between the first lip 110 and the second lip 150. The spaces S may be measured as distances between transversely outer portions of the lips.
In the installed state, a portion of the second lip 120 is vertically separated from a portion of the second lip 150 by a vertical gap G. According to the embodiments in
The second lips 120 and 150 are partially overlapping along the axes AX and AY in
The support element 300 may be any support structure known to a person skilled in the art. It may comprise one or several supporting members. In particular, the support element may be a joist grid system comprising at least one joist, preferably a plurality of joists, such as wood joists or metal joists, e.g. aluminium joists. The support element may also be a sub-flooring, optionally in turn being supported by joists.
The first board is connected to the support element 300 by means of an attaching element 400 in the form of a screw that is provided through the second lip 120 and through the hole 202. Thereby, the connecting device 200 becomes horizontally connected relative to the first board. It is clear that other attaching elements are equally conceivable, such as a nail, a bolt, a rivet, a stapler, a flange, a tape, or an adhesive.
Due to the connecting device being arranged under it, the first board is raised vertically. An elevation element 201 is provided under the first lip 140 for raising the second board to the same vertical level as the first board. It is understood that, in one embodiment, a depression may be provided in the first board at the location of the connecting device 200 so that the first board does not become vertically elevated, or only partly elevated, with respect to the support element.
In one embodiment, there is no elevation element 201 and the boards 100a-b are slightly inclined, preferably unnoticeable for an observer at a distance therefrom, say at 0.5 m or 1 m. Thereby, the boards may have better drainage properties and may dry faster after being exposed to liquids etc.
The embodiment in
The embodiment in
The embodiment in
In
The first board is connected to the support element 300 by means of an attaching element 400, presently in the form of a screw, that is provided through the second lip 120 and through the hole 202 in the first engagement portion 210. Thereby, the connecting device 200 becomes horizontally connected relative to the first board.
The second segment 216 and/or third segment 222 are optional and may be omitted in other embodiments, one of which is illustrated in
Any of the embodiments of the first 210, the intermediate 220 and the second 230 engagement portions, and fixing portions 212 or third segments 222, described above in relation to
An edge portion 213 of the first engagement portion is curved or beveled. Thereby, the first engagement portion may be rotated more easily, especially when the edge portion engages with the third wall 132 in an installed state. A front portion 223 of the second engagement portion also is curved or beveled. As seen in the front view in
In
In any of the embodiments in
The connecting device 200 may be horizontally and/or vertically connected to a board 100 by a rotational movement. According to the embodiment in
As shown in
The second lip increases in thickness outwardly. Moreover, the second flange 291 forms an obtuse angle with respect to the vertical portion 292, e.g. between 90° and 120°, and preferably comprises an outer portion 298 that is curved downwards towards the base portion 294. The outer portion 298 is provided in a notch 145 in the first lip 140. In one example, the board 100b is transversely connected to the connecting device, preferably in two opposite directions, and the board 100a is transversely displaceable relative to the connecting device.
The embodiment in
In any of the embodiments in
In
According to the embodiment in
In
In one embodiment, illustrated in the lowermost row in
Preferably, a ratio X1/X, measured in percentage, between a horizontal extension X1 from a centre of the hole 202 to an end part of the second engagement portion 230 and a total horizontal extension X of the connecting device is 50%-80%, such as around 60% as in
Preferably, any of the connecting devices of the present disclosure, especially that in
In an alternative embodiment (not shown), the end section 233 of the first engagement portion 210 is missing and the first engagement portion only comprises the inner section 238 of the first engagement portion that is inclined with respect to the second engagement portion. Other features of the connecting device may be identical to those described above in relation to
The second board 100b may be replaced by a new second board 100b′ as shown in the embodiment in
In the embodiment in
In the embodiments illustrated in
A new second board 100b′ may be placed between the first 100a and third 100c boards. Then the steps above may be reversed: a first and a second connecting device 200 is provided in engagement with the side walls 114 of the first and second boards, respectively, and with the lips 120, 140 of a respective pair of boards from above; then a first and a second attaching element 400 is provided through the second lips 120 of the first and second board, respectively, and are connected to the support element 300.
In some embodiments, it is preferred—especially in the case when the boards are made of softwood which may shrink over time—that there is a vertical space, such as 0.3-15 mm or more preferably 0.5-1.5 mm, between the support member 300 and the end section 224 of the third segment 222 in the installed state. Here, there is no direct engagement between the connecting device and the support member.
Alternatively, the second board 100b in
In some embodiments, a vertical extension, preferably a maximal vertical extension, of the groove 160 is smaller than a thickness, preferably a maximal thickness, of the end section of the second engagement portion of the connecting device. This is particularly advantageous for boards comprising a material whose volume changes, e.g. decreases, over time, for example a hygroscopic material or a material being susceptible to thermal expansion/contraction. The material may be an impregnated and/or pressure-treated material. Hence, by having a smaller vertical extension of the groove 160, a locking capability of the locking system may be substantially maintained over time.
In one embodiment, there is a minimal space S between the boards, given by a thickness of the third segment 222.
When installing the new second board 100b′ the first connecting device 200 may be temporarily or permanently adhered to an underside of the second lip 120 of the first board 100a, e.g. by means of a tape, an adhesive, such as glue, or a nail or the like, see
In the embodiment illustrated in
In the embodiments of
In the embodiment illustrated in
In
The horizontal space S and/or the chamfers between the second surface members 102 and the side walls 114 and 154 are configured so that installation and demounting of the boards by means of angling is admitted.
Eventually, when the first and second board have been angled more than a critical angle, e.g., 25°-50°, and optionally linearly displaced, the connecting devices will disengage from the support element, see
However, in
Moreover, in
In
The inventive concept has mainly been described above with reference to a few embodiments. However, as is readily appreciated by a person skilled in the art, other embodiments than the ones disclosed above are equally possible within the scope of the invention, as defined by the appended patent claims. A majority of the decking board embodiments in the present application have been presented to be rotationally symmetric around a longitudinal axis, and preferably are so, but it is understood that that rotationally asymmetric shapes are equally conceivable. For instance, the transverse extensions of the first lips 110, 140 may differ and/or the extensions of the second lips 120, 150 may differ. Any embodiment of the disclosure is valid for boards made of softwood and WPC boards, but also other materials. Moreover, the orders of the demounting and installation steps above are exemplifying and other orders are equally conceivable.
Further aspects of the inventive concept are provided below. Embodiments of these aspects are largely analogous to the embodiments for the first, second and third aspects, wherein reference is made to the above.
Item 1. A set of decking boards provided with a connecting system comprising a connecting device, the set of decking boards comprising:
a first decking board comprising a first side portion and a second decking board comprising a second side portion, each side portion extending along a longitudinal direction of the decking board, wherein each of said first and second side portions comprises:
a first lip and a second lip, wherein an extension of the second lip in a transverse direction of the decking board is larger than an extension of the first lip in said transverse direction of the decking board,
wherein a first decking board is configured to be connected to a support element,
wherein the second decking board is configured to assume a vertically locked state with respect to the first decking board, wherein in said vertically locked state:
said connecting device cooperates with the first decking board and with the second decking board;
there is a horizontal space between the first lip of the first decking board and the second lip of the second decking board; and
there is a horizontal overlap between a portion of the second lip of the second decking board and a portion of the second lip of the first decking board,
wherein the second decking board is configured to assume a vertically unlocked state with respect to the first decking board so that the second decking board becomes removable.
Item 2. A set of decking boards according to item 1, wherein the connecting device is operable and/or accessible through said horizontal space for assuming said vertically unlocked state, the horizontal space preferably being at least 1 mm, more preferably at least 5 mm, most preferably at least 10 mm.
Item 3. A set of decking boards according item 1 or 2, wherein the second decking board is configured to become removable when the second decking board is disconnected from the support element and/or when a third decking board assumes a vertically unlocked state with respect to the second decking board.
Item 4. A set of decking boards according to any of items 1 to 3, comprising the first and second decking board and/or the connecting device.
Item 5. A set of decking boards according to any of items 1 to 3, comprising the connecting device.
Item 6. A set of decking boards provided with a connecting system comprising a connecting device, the set of decking boards comprising:
a first decking board comprising a first side portion and a second decking board comprising a second side portion, each side portion extending along a longitudinal direction of the decking board, wherein each of said first and second side portions comprises:
a first lip and a second lip, wherein an extension of the second lip in a transverse direction of the decking board is larger than an extension of the first lip in said transverse direction of the decking board,
wherein the first decking board is configured to be connected relative to the connecting device vertically and at least in a first horizontal direction,
wherein the second decking board is configured to be vertically connected relative to the connecting device, and
wherein the connecting device is configured to at least partially enclose the second lip of the first board while being connected to a support element, such as a joist.
Item 7. A set of decking boards according to item 6, wherein the first decking board is configured to be connected relative to the connecting device in a second horizontal direction being opposite to the first horizontal direction.
Item 8. A set of decking boards according to item 6 or 7, wherein the second decking board is configured to be connected relative to the connecting device at least in a first horizontal direction and, optionally, in a second horizontal direction being opposite to the first horizontal direction.
Item 9. A set of decking boards according to any of items 6 to 8, wherein the transverse direction is parallel with the first and/or second horizontal directions.
Item 10. A set of decking boards according to any of items 6 to 9, wherein the connecting device is configured to be displaceable with respect to the support element, preferably in a longitudinal horizontal direction of the support element.
Item 11. A set of decking boards according to any of items 6 to 9, wherein the connecting device is configured to be fixed with respect to the support element.
Item 12. A set of decking boards according to any of items 6 to 11, comprising the first and second decking board and/or the connecting device.
Item 13. A set of decking boards according to any of items 6 to 11, comprising the connecting device.
| Number | Date | Country | Kind |
|---|---|---|---|
| 1651663-5 | Dec 2016 | SE | national |
The present application is a continuation of U.S. application Ser. No. 16/467,062, filed on Jun. 6, 2019, which is a U.S. national stage of International Application No. PCT/SE2017/050384, filed on Apr. 18, 2017, which claims the benefit of Swedish Application No. 1651663-5, filed on Dec. 16, 2016. The entire contents of each of U.S. application Ser. No. 16/467,062, International Application No. PCT/SE2017/050384, Swedish Application No. 1651663-5 are hereby incorporated herein by reference in their entirety.
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| Number | Date | Country | |
|---|---|---|---|
| 20210381258 A1 | Dec 2021 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 16467062 | US | |
| Child | 17407674 | US |
