GB2628171A - Decking components for use with decking boards, decking systems and methods for the installation of decking boards - Google Patents

Abstract

A decking system having support components e.g. structural supporting rails 200 spaced apart in a longitudinal direction by a span distance, decking boards 100 supported on the rails extending perpendicularly to the rails and arranged adjacent each other in a transverse direction, perpendicular to the longitudinal direction, the system including board-to-board support components or connectors 20 located at a longitudinal position intermediate the rails, sandwiched between and connecting adjacent decking boards to each other in the transverse direction. The board-to-board connectors join adjacent decking boards together mid span between supporting rails, such that adjacent decking boards do not flex independently when loaded between supporting rails, minimising bending of individual boards by sharing loads between boards through the connectors. Decking boards may have transversely extending edge lips 120,122 on their underside which interference fit into matching cooperating grooves or slots 22,24 in the connector such that in use the top surface of the connector is below the upper surface of decking and has limited visibility.

Description

DECKING COMPONENTS FOR USE WITH DECKING BOARDS, DECKING SYSTEMS AND

METHODS FOR THE INSTALLATION OF DECKING BOARDS

Field of the Invention

The present invention relates to decking components for use with decking boards, decking systems and to methods for the installation of decking boards. Such components and boards are of interest for installation on balconies for buildings and/or for other external areas for buildings such as rooftop decks and garden decks.

Background

It is known to produce decking boards from wood, engineered wood or plastics. However, at least in the context of the use of such materials in mid-rise or high-rise buildings, the fire performance of such decking boards may not be acceptable.

It is therefore also known to produce decking boards using other materials with suitable fire performance, such as mineral-based composites. Suitable decking boards may for example be formed by moulding.

An advantage of such decking boards is their aesthetic appeal, particularly where the upper surface of the board is configured to have an appearance similar to natural wood.

An example of a known extruded aluminium decking board is the lnnova TM aluminium decking board of MyDek Limited (UK) for example as shown at https://wwicrnydek.conilproduellinnoval [accessed 24 February 2023] and further described below with reference to Figs. 1 and 2. Another relevant example of a known extruded aluminium decking board is the Delta20 aluminium decking board as shown at hitps.TheAvvv.rnyciek.comfproducticielta:20/ [accessed 24 February 2023]. Such decking boards have several advantages.

An example of a known mineral-based composite decking board is the Luxura® Deck mineral composite non-combustible decking board of MyDek Limited for example shown at Nipsilwww.inyclek.comiproductiuxura-deckl 50/ [accessed 9 March 2023]. This is formed from a calcium silicate and mineral fibre composite. A further product, formed from a similar material, is the Luxura® Pave paving panel for example as shown at https://vkivv-vv.rnydek.corniprodudAuxura-pave6001 [accessed 9 March 2023].

However, the present inventors have realised that further developments of such decking elements are possible in order to improve performance and versatility.

The present invention has been devised in the light of the above considerations.

Summary of the Invention

The present inventors in particular have noted that a significant feature of the perceived performance of a decking board is affected by the deflection of an individual board when loaded, relative to a neighbouring unloaded board. As will be understood, decking boards are generally laid in a parallel arrangement and are supported by joists or rails arranged underneath and typically running in a perpendicular direction to a longitudinal direction of the decking boards. The distance between the rails can be termed the longitudinal span distance of the decking board. At a point half-way between the rails, a vertical load applied to the board will cause a deflection of the board in the vertical direction. Assuming that the adjacent board is not loaded, there will therefore be an unwanted height difference between the loaded board and the unloaded board. This presents a trip hazard. It also gives a perception of flimsiness to the decking that may be unwarranted in view of the actual strength performance of the decking.

Accordingly, in a first aspect, the present invention provides a decking system comprising substructure components supporting an arrangement of decking boards, the decking boards being disposed next to each other in a transverse direction and wherein the substructure components are spaced apart from each other in a longitudinal direction by a longitudinal span distance, wherein the decking boards are arranged to extend in the longitudinal direction and to be supported by the substructure components across the longitudinal span distance, and wherein, at a longitudinal position intermediate between the substructure components, adjacent decking boards are connected to each other in the transverse direction by a board-to-board support component.

In a second aspect, the present invention provides a balcony for a building, the balcony having decking comprising a decking system according to the first aspect.

In a third aspect, the present invention provides a terrace, deck or patio, having decking comprising a decking system according to the first aspect.

In a fourth aspect, the present invention provides a method of installation of a decking system according to the first aspect, including the step of arranging the decking boards to extend in the longitudinal direction and to be supported by the substructure components across the longitudinal span distance and connecting adjacent decking boards to each other in the transverse direction by the board-to-board support component.

Optional features of feature of the invention are now set out. These may be applied singly or in any combination to any aspect of the invention, unless the context demands otherwise.

In some embodiments, the substructure components may be rails. Rails may be formed of any suitable material and may alternatively be referred to as joists or rafters. Typically, rails are transversely extending support components that each support a plurality of decking boards. Alternatively, the substructure components may be pedestals and/or pads. In such embodiments, each substructure component may support only one or two decking boards. However, the inventors have realised that similar principles apply to such embodiments as to the rails-type embodiments and therefore the present invention may also apply to such arrangements.

The board-to-board support component may connect to the decking boards via an interference fit. For example, the component may be attached to the board by a movement in a single relative direction, e.g. transversely. This allows for a simple installation. This may also allow for repositioning of the board-toboard support component as necessary.

When connected between the adjacent decking boards, an uppermost surface of the board-to-board support component is disposed below an upper surface of the decking boards. This allows the component to have only limited visibility to the user of the board, which may be aesthetically significant. Furthermore this may ensure that the component does not itself represent a trip hazard.

In some embodiments, when connected between the adjacent decking boards, a lowermost surface of the board-to-board support component is disposed above a lowermost surface of the decking boards. In other embodiments, when connected between the adjacent decking boards, a lowermost surface of the board-to-board support component is disposed below a lowermost surface of the decking boards.

In some embodiments, a lateral side of the decking boards comprises a lip and a corresponding lateral side of the board-to-board support component comprises a cooperating groove. In other embodiments, a lateral side of the decking boards comprises a groove and a corresponding lateral side of the board-toboard support component comprises a cooperating lip. The board-to-board support component may be configured to be connected to the lateral side of the decking board by an interference fit between the lip and groove. This may for example allow the position of the component relative to the board to be adjusted in the longitudinal direction.

Conveniently, each lateral side of the board-to-board support component may comprise a matching cooperating groove or a matching cooperating lip. For example, the component may be symmetrical. This allows the component to be reversible, ensuring ease of installation.

The board-to-board support component may be configured to have a uniform cross sectional shape in the longitudinal direction. This may allow it to be positioned at any longitudinal position between the adjacent decking boards in the longitudinal span distance between the rails.

For example, the board-to-board support component may have a depth that is smaller than the depth of the adjacent decking boards and/or a transverse width that is greater than its depth and/or a longitudinal length that is at least three times its transverse width. These relative dimensions are found to be mechanically suitable.

In the field of floorboards (typically for indoor use) it is well known to have a tongue-and-groove arrangement so that each board has a tongue (lip) extending transversely from one transverse side of the board and a groove in the other transverse side of the board. The tongue of one board then forms an interference fit with the groove of the adjacent board during installation, thereby ensuring load sharing across the boards during use. However, in the context of decking boards for exterior use (as is preferred in the present invention), such an arrangement can have disadvantages in terms of reducing the possibility of rainwater draining through gaps between the decking boards. Furthermore, such a format for the boards means that they must be installed only one way around so that the tongues and grooves align.

Accordingly, it is convenient to use the board-to-board support components and decking boards as explained above. In order to provide rainwater drainage gaps, the proportion of the longitudinal span taken up by the board-to-board support components may for example be at most 20%, more preferably at most 10%. This therefore leaves the remainder of the longitudinal span to be available as a rainwater drainage gap.

The invention includes the combination of the aspects and preferred features described except where such a combination is clearly impermissible or expressly avoided.

Summary of the Figures

Embodiments and experiments illustrating the principles of the invention will now be discussed with reference to the accompanying figures in which: Fig. 1 shows a schematic perspective view of a prior art decking board.

Fig. 2 shows an end view of the decking board of Fig. 1.

Fig. 3 shows a schematic perspective view of a prior art decking system based on boards according to Fig. 1, during installation.

Fig. 4 shows an end view of a further prior art decking board during assembly into a decking system including rail and clips.

Fig. 5 shows a schematic perspective view of a prior art decking system based on boards according to Fig. 4, during installation.

Fig. 6 shows a perspective view of a board-to-board support component according to a first embodiment, for use with decking boards according to Fig. 1.

Fig. 7 shows an end view of the board-to-board support component of Fig. 6.

Fig. 8 shows a side view of the board-to-board support component of Fig. 6.

Fig. 9 shows a top view of the board-to-board support component of Fig. 6.

Fig. 10 shows a cross sectional view of part of a decking system using the decking boards of Fig. 1, supported on rails and with the board-to-board support component of Fig. 6 connecting adjacent decking boards.

Fig. 11 shows a perspective view of the lower part of the decking system using the decking boards of Fig. 1, supported on rails and with the board-to-board support component of Fig. 6 connecting adjacent decking boards.

Fig. 12 shows a schematic perspective view from above of a board-to-board support component according to a second embodiment, for use with decking boards according to Fig. 4.

Fig. 13 shows a schematic perspective view from below of the board-to-board support component of Fig. 12.

Fig. 14 shows an end view of the board-to-board support component of Fig. 12. Fig. 15 shows a bottom view of the board-to-board support component of Fig. 12.

Fig. 16 shows a top view of the board-to-board support component of Fig. 12.

Fig. 17 shows a side view of the board-to-board support component of Fig. 12.

Fig. 18 shows a cross sectional view of part of a decking system using the decking boards of Fig. 4 and with the board-to-board support component of Fig. 12 connecting adjacent decking boards.

Fig. 19 shows a balcony for a building including a schematic arrangement of decking according to an embodiment of the invention.

Detailed Description of the Invention

Aspects and embodiments of the present invention will now be discussed with reference to the accompanying figures. Further aspects and embodiments will be apparent to those skilled in the art. All documents mentioned in this text are incorporated herein by reference.

Before discussing embodiments of the invention, it is of use first to consider a prior art decking system such as that shown in Figs. 1 and 2 which relate to the lnnova TM aluminium decking board and associated system referred to above.

Considering Figs. 1, 2 and 3, each decking board 100 is formed from extruded aluminium and has a uniform cross sectional shape. Each board has lower plates 112 for resting on and attachment to a support structure such as the rails 200 indicated in Fig. 3. It will be understood that the references to rails herein is a specific implementation of a substructure and that the decking boards may alternatively be supported on substructure components such as upstands, pedestals and/or pads (e.g. formed of concrete or another suitable construction material). Each board also has an upper plate 114 providing a surface for a user to stand on during use of the decking board. The upper plate 114 has a slight corrugation in order to provide surface grooves 115 to improve visual appearance and available grip to a user standing on the upper plate 114. The upper plate 114 and lower plates 112 each extend longitudinally. The upper plate 114 also extends transversely to a greater extent than the lower plates 112. The upper plate 114 and the lower plates 112 are spaced apart in a height direction of the board. The board further comprises a first support member 116 extending longitudinally and in the height direction and connecting one of the lower plates 112 with the upper plate 114. There is also a second support member 118 extending longitudinally and in the height direction and connecting another of the lower plates 112 with the upper plate 114. The second support member 118 is spaced apart transversely from the first support member 116 to define a transverse span distance for the upper support plate. Note that feature 119 is a screw pipe feature, allowing an end cap (for example) to be fitted to the end of the decking panel.

In the arrangement shown in Fig. 1, there are four support members. These can be described as legs 1, 2, 3, and 4 of the decking panel, with the lower ends of the legs terminating in feet corresponding to the lower plates mentioned above.

Fig. 3 shows how an arrangement of these boards can be installed as a decking system 250 and in particular shows how fixing clips 230 are used at the sides of the boards to attach to legs 1 and 4 of the board and folded clips 232 are used to attachment between legs 2 and 3 of the board. The rails 200 are supported on pads 240 via cleats 234.

Such an arrangement is convenient and has good performance. However, it is of interest to further improve the system in order to increase mechanical performance and also their installation efficiency.

As shown in Fig. 2, legs 1 and 4 of the decking board are at the lateral sides of the decking board.

Taking leg 1 as an example, this has a transversely-extending lip 120 that is formed longitudinally continuously along the decking board. Leg 4 similarly has transversely-extending lip 122.

Accordingly, a suitable board-to-board support component 20 for such decking panels 100 is as shown in Figs. 6-9. This board-to-board support component includes cooperating grooves formed in a transverse direction in order each to form an interference fit with a respective transversely-extending lip of adjacent decking boards. In Fig. 6, the longitudinal direction L, transverse direction T and depth (or height) direction D are indicated.

Fig. 10 shows a cross sectional view of part of a decking system using the decking boards 100 of Fig. 1, supported on rails 200 and with the board-to-board support component 20 of Fig. 6 connecting adjacent decking boards 100. The decking boards and the rail are shown in dotted outline. This drawing shows how the board-to-board support component 20 forms an interference fit with the transversely-extending lips 120, 120 of the adjacent decking boards. The addition of the board-to-board support component at a position intermediate between the rails 200 provides the benefit that a load applied to one of the decking boards 100 is supported also by the adjacent decking board 100 via the board-to-board support component 20. This reduces the deflection provided by a particular load and also reduces the formation of an unwanted height difference between the loaded board and the unloaded board, which would otherwise present a trip hazard.

As can be seen in particular from Fig. 10, when the board-to-board support component 20 is connected between the adjacent decking boards 100, an uppermost surface of the board-to-board support component 20 is disposed below an upper surface of the decking boards. In this way, the board-to-board support component 20 is only partially visible to the end user of the decking system. In the case of the present embodiment, a lowermost surface 26 of the board-to-board support component is disposed below a lowermost surface of the decking boards 100. This is acceptable since there is typically space available underneath the decking boards and between the rails for the board-to-board support component to project downwardly.

As can be seen from Figs. 6-11, each lateral side of the board-to-board support component comprises a matching cooperating groove 22, 24. The board-to-board support component has mirror symmetry about a plane extending along a longitudinal direction of the board-to-board support component and extending in a depth direction (i.e. plane L-D in Fig. 6).

Furthermore, the board-to-board support component has a uniform cross sectional shape in the longitudinal direction. This allows it to be positioned at any longitudinal position between the adjacent decking boards in the longitudinal span distance between the rails. The board-to-board support component may for example be formed by extrusion. The board-to-board support component may be formed from a metallic material such as aluminium or an aluminium alloy.

Before discussing further embodiments of the invention, it is of use first to consider a further prior art decking system such as that shown in Figs. 4 and 5 which relate to the Luxura® decking board and associated system referred to above.

Considering Figs. 4 and 5, each decking board 400 is formed from a composite material and has a uniform cross sectional shape. Each board has a lower face 412 for resting on and attachment to a support structure such as the rails 200. Each board also has an upper face 114 providing a surface for a user to stand on during use of the decking board. The upper face 414 and lower face 412 each extend longitudinally and transversely and are parallel, spaced apart in a height direction of the board.

Fig. 3 shows how an arrangement of these boards 400 can be installed as a decking system 450 and in particular shows how fixing clips 430 are used at the sides of the boards to attach to the boards with respect to the rails 200. The rails 200 are supported on pads 240 via cleats 234. Fixing clips fix to the board 400 via grooves 420, 422 formed in the sides of the board.

A second embodiment of the invention uses a board-to-board support component 40 as shown in Figs. 12-17. This is suitable for example for decking boards 400 as shown in Figs. 4 and 5. This board-toboard support component 40 includes cooperating lips 42, 44 formed in a transverse direction in order each to form an interference fit with a respective transversely-extending groove 422, 420 of adjacent decking boards 400. In general terms the cross sectional shape of the board-to-board support component can be described as a lower case Greek letter pi shape.

In Fig. 12, the longitudinal direction L, transverse direction T and depth (or height) direction D are indicated.

Fig. 18 shows a cross sectional view of part of a decking system using the decking boards 400 of Figs. 4 and 5, and with the board-to-board support component 40 of Figs. 12-17 connecting adjacent decking boards. The decking boards are shown in dotted outline. The rails are not shown in this view. This drawing shows how the board-to-board support component 40 forms an interference fit with the transversely-extending grooves 422, 420 of the adjacent decking boards 400. The addition of the board-to-board support component 40 at a position intermediate between the rails provides the benefit that a load applied to one of the decking boards is supported also by the adjacent decking board via the board-to-board support component. This reduces the deflection provided by a particular load and also reduces the formation of an unwanted height difference between the loaded board and the unloaded board, which would otherwise present a trip hazard.

As for the first embodiment, and as can be seen from Fig. 18, when the board-to-board support component 40 is connected between the adjacent decking boards 400, an uppermost surface of the board-to-board support component is disposed below an upper surface of the decking boards. In this way, the board-to-board support component is only partially visible to the end user of the decking system. In the case of the present embodiment, a lowermost surface of the board-to-board support component is disposed above a lowermost surface of the decking boards.

In this embodiment, the board-to-board support component includes transverse facing surfaces 46, 48 disposed below the lips 42, 44. These are provided by legs 50, 52 projecting in the depth direction but could be formed by an integral trunk of the component. As seen in Fig. 18, the transverse facing surfaces abut against corresponding transverse facing surfaces of the decking boards. In addition to the support provided by the fit of the lip in the groove, the transverse facing surfaces further prevent unwanted relative movement in the depth direction between the adjacent decking boards.

It is instructive to consider the effect of the including of such board-to-board support components on a decking system. For a reference arrangement, a rail-to-rail span distance may for example be 500 mm.

With an arrangement of decking boards of a particular construction (e.g. as shown in Fig. 1) attached to the rails but without the inclusion of board-to-board support components, the amount of deflection between adjacent boards may be at the limit of an acceptable range. It is found that when an otherwise identical arrangement has the board-to-board support components included, the rail-to-rail span distance can be increased to 800 mm for the same amount of deflection between adjacent boards. This is considered to be due to the board-to-board support components providing a distribution of the load across adjacent decking boards. In an example decking area of 4 m2, this means that the number of rails can be reduced from 9 to 6. This leads to a significant efficiency in the manufacture of the substructure that supports the decking.

Fig. 19 shows a balcony 300 for a building. The balcony comprises a cassette 302 that provides the structural base for the balcony including structural beams and rails (not shown). Openings 304 are formed in the cassette for allowing attachment of the balcony to the building (not shown). Upstanding from the cassette is a balustrade 306. The balcony has decking 308 comprising an arrangement of decking boards connected by board-to-board connection components as set out above, although the decking is indicated in Fig. 19 only schematically.

The features disclosed in the foregoing description, or in the following claims, or in the accompanying drawings, expressed in their specific forms or in terms of a means for performing the disclosed function, or a method or process for obtaining the disclosed results, as appropriate, may, separately, or in any combination of such features, be utilised for realising the invention in diverse forms thereof.

While the invention has been described in conjunction with the exemplary embodiments described above, many equivalent modifications and variations will be apparent to those skilled in the art when given this disclosure. Accordingly, the exemplary embodiments of the invention set forth above are considered to be illustrative and not limiting. Various changes to the described embodiments may be made without departing from the spirit and scope of the invention.

For the avoidance of any doubt, any theoretical explanations provided herein are provided for the purposes of improving the understanding of a reader. The inventors do not wish to be bound by any of these theoretical explanations.

Any section headings used herein are for organizational purposes only and are not to be construed as limiting the subject matter described.

Throughout this specification, including the claims which follow, unless the context requires otherwise, the word "comprise" and "include", and variations such as "comprises", "comprising", and "including" will be understood to imply the inclusion of a stated integer or step or group of integers or steps but not the exclusion of any other integer or step or group of integers or steps.

It must be noted that, as used in the specification and the appended claims, the singular forms "a," "an," and "the" include plural referents unless the context clearly dictates otherwise. Ranges may be expressed herein as from "about" one particular value, and/or to "about" another particular value. When such a range is expressed, another embodiment includes from the one particular value and/or to the other particular value. Similarly, when values are expressed as approximations, by the use of the antecedent "about," it will be understood that the particular value forms another embodiment. The term "about" in relation to a numerical value is optional and means for example +/-10%.

Claims (15)

1. Claims: 1. A decking system comprising substructure components supporting an arrangement of decking boards, the decking boards being disposed next to each other in a transverse direction and wherein the substructure components are spaced apart from each other in a longitudinal direction by a longitudinal span distance, wherein the decking boards are arranged to extend in the longitudinal direction and to be supported by the substructure components across the longitudinal span distance, and wherein, at a longitudinal position intermediate between the substructure components, adjacent decking boards are connected to each other in the transverse direction by a board-to-board support component.
2. 2. A decking system according to claim 1 wherein the board-to-board support component connects to the decking boards via an interference fit.
3. 3. A decking system according to claim 1 or claim 2 wherein, when connected between the adjacent decking boards, an uppermost surface of the board-to-board support component is disposed below an upper surface of the decking boards.
4. 4. A decking system according to any one of claims 1 to 3 wherein, when connected between the adjacent decking boards, a lowermost surface of the board-to-board support component is disposed above a lowermost surface of the decking boards.
5. 5. A decking system according to any one of claims 1 to 3 wherein, when connected between the adjacent decking boards, a lowermost surface of the board-to-board support component is disposed below a lowermost surface of the decking boards.
6. 6. A decking system according to any one of claims 1 to 5, wherein: (i) a lateral side of the decking boards comprises a lip and a corresponding lateral side of the board-toboard support component comprises a cooperating groove, or (ii) a lateral side of the decking boards comprises a groove and a corresponding lateral side of the boardto-board support component comprises a cooperating lip, and wherein the board-to-board support component is configured to be connected to the lateral side of the decking board by an interference fit between the lip and groove.
7. 7. A decking system according to claim 6 wherein each lateral side of the board-to-board support component comprises a matching cooperating groove or a matching cooperating lip.
8. 8. A decking system according to any one of claims 1 to 7 wherein the board-to-board support component is configured to have a uniform cross sectional shape in the longitudinal direction, allowing it to be positioned at any longitudinal position between the adjacent decking boards in the longitudinal span distance between the substructure components.
9. 9. A decking system according to claim 8 wherein the board-to-board support component has a depth that is smaller than the depth of the adjacent decking boards.
10. 10. A decking system according to claim 9 wherein the board-to-board support component has a transverse width that is greater than its depth.
11. 11. A decking system according to claim 10 wherein the board-to-board support component has a longitudinal length that is at least three times its transverse width.
12. 12. A decking system according to any one of claims 1 to 11 wherein the substructure components are rails that extend in the transverse direction to support a plurality of decking boards.
13. 13. A balcony for a building, the balcony having decking comprising a decking system according to any one of claims 1 to 12.
14. 14. A terrace, deck or patio, having decking comprising a decking system according to any one of claims 1 to 12.
15. 15. A method of installation of a decking system according to any one of claims 1 to 12, including the step of arranging the decking boards to extend in the longitudinal direction and to be supported by the rails across the longitudinal span distance and connecting adjacent decking boards to each other in the transverse direction by the board-to-board support component.