Patent Publication Number: US-2019186131-A1

Title: Plank forming systems

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a continuation-in-part of application Ser. No. 15/845,076, filed 18 Dec. 2017. 
    
    
     BACKGROUND 
     An outdoor deck may include planks that run along a top surface of a sub-frame to form a flooring for the outdoor deck. The planks of the outdoor deck may be interconnected to the sub-frame and each other when installed to provide a stable and secure platform for individuals to walk on or place objects on, such as furniture, grills, or decorations. 
     SUMMARY 
     A method, system, or device for creating a plank. The device may include a container with an opening to receive a material. The device may also include a beam extending from a side of the container to a point in an open space of the container. The beam may have a curved shape. A portion of the material may form around the beam. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The present description will be understood more fully from the detailed description given below and from the accompanying drawings of various embodiments of the present embodiment, which is not to be taken to limit the present embodiment to the specific embodiments but are for explanation and understanding. 
         FIG. 1  illustrates a plank forming system for creating a plank with a curved channel or core, according to an embodiment. 
         FIG. 2A  shows the mold device with multiple molding sections, according to an embodiment. 
         FIG. 2B  shows the second mold with one or more beams, according to an embodiment. 
         FIG. 3  shows a side view of a plank created using plank forming system in  FIG. 1 , according to an embodiment. 
         FIG. 4  shows a side view of the plank connector connecting a first plank to a second plank, according to an embodiment. 
         FIG. 5  shows an outdoor platform with planks uniformly spaced apart from each other, according to an embodiment. 
         FIG. 6  shows a flowchart for a method of creating a plank with an hourglass hollow core, according to an embodiment. 
     
    
    
     DETAILED DESCRIPTION 
     The disclosed plank forming systems will become better understood through a review of the following detailed description in conjunction with the figures. The detailed description and figures provide merely examples of the various embodiments described herein. Those skilled in the art will understand that the disclosed examples may be varied, modified, and altered and not depart from the scope of the embodiments described herein. Many variations are contemplated for different applications and design considerations; however, for the sake of brevity, the contemplated variations may not be individually described in the following detailed description. 
     Throughout the following detailed description, examples of various plank forming systems are provided. Related features in the examples may be identical, similar, or dissimilar in different examples. For the sake of brevity, related features will not be redundantly explained in multiple examples. Instead, the use of related feature names will cue the reader that the feature with a related feature name may be similar to the related feature in an example explained previously. Features specific to a given example will be described in that particular example. The reader is to understand that a given feature need not be the same or similar to the specific portrayal of a related feature in any given figure or example. 
     Planks may be long, thin, flat pieces of material used in building a flooring of a building or an exterior platform. The exterior platform may be a deck, a patio, and so forth. Conventionally, the planks may be formed by shaping a board to the shape and size desired for the exterior platform. For example, the board may be a wood board that is milled, planed, and cut to a desired shape and size. When multiple boards have been shaped and sized, the boards may then be attached to a surface or sub-frame of a floor or exterior platform in rows or columns to form the flooring. Conventionally, the boards may be solid materials that are planed, milled, and cut into planks with desired lengths, widths, and thicknesses. As the conventional boards may be solid material, the boards may be relatively heavy. The heavy material may require that the frame and sub-frame of the exterior platform include more support structures and/or include sturdier material to support the weight of the planks. Additionally, the relatively heavy planks may be relatively costly to transport due to the weight of the material. Furthermore, the relatively heavy planks may be difficult for a builder of the flooring or exterior platform to carry and maneuver. 
     Conventionally, to reduce a weight of a plank, the plank may include channels or hollow cores that extend along an X-axis or a Y-axis of the plank. For example, a drilling device may drill a channel or core into the plank to remove a portion of the material of the plank to reduce a weight of the plank. As the drilling device removes the material to form one or more channels or hollow cores in the plank, the channels or hollow cores may be circular like a drill bit. However, the circular channels or cores may be a weak point in the plank that is prone to breaking. For example, as weight is applied to the plank at a circular channel or core, the plank may begin to flex and break at the circular channel or core because the circular channel or core may not be able to hold the weight being applied to the plank. 
     The embodiments described herein may address the above-noted deficiencies by providing a plank forming system to form a plank with one or more curved channels or cores from a material. The plank forming system may include a mold device with a container and a beam. As a material is received into the container, a portion of the material may form around the beam to form a plank with a curved channel or core. The plank with the curved channel or core may reduce a weight of the plank and while maintaining a relatively high weight/load distribution ratio. 
       FIG. 1  illustrates a plank forming system  100  for creating a plank with a curved channel or core, according to an embodiment. The plank forming system  100  may include a first container  102 . In one example, the first container  102  may be a hopper of an extrusion machine. The first container  102  may include a first opening to a first opening to receive a material. In one embodiment, the material may be may be a granulated material. In one example, the material may be a granulated wood material, such as a granulated bamboo material, a granulated redwood material, a granulated cedar material, and so forth. In another embodiment, the granulated wood material may be granulated wood fiber material, such as a granulated bamboo fiber material, a granulated redwood fiber material, a granulated cedar fiber material, and so forth. In another embodiment, the material may be a granulated composite material, such as a granulated vinyl material, a granulated fiber material, a granulated fiberglass material, a granulated ceramic material, and so forth. 
     The first container  102  may include a second opening  106 . In one example, the first container  102  may be connected to a second container  108  (also referred to as an extruder) and the second opening  106  in the first container  102  may provide or convey the material into a third opening  110  of the second container  108 . The third opening  110  may be a first end of the second container  108  to receive the material from the second opening  106  of the first container  102 . The second container  108  may include a fourth opening  112  at a second end of the second container  108 . The second container  108  may also include a driver  114  to move the material from the third opening  110  to the fourth opening  112 . In one example, the driver  114  may be a screw connected to a motor. The motor may rotate the screw and as the screw rotates, the screw may grab the material from the first end of the second container  108  and move the material to the second end of the second container  108 . 
     The plank forming system  100  may include a heater  116  to heat up the material while the material is in the second container  108 . In one example, the heater  116  may be integrated into the second container  108 . In another example, the heater  116  may be a separate device that is attached to the second container  108 . In another example, the heater  116  may be approximate or near the second container  108  and may apply heat to the second container  108  and increase a temperature of the material. The heater  116  may increase a temperature of the material to a melting point where the material may transform from a solid granulated material to a liquid material. 
     When the material has become a liquid material, the driver  114  may propel the liquid material out of the fourth opening  112  into a fifth opening  120  at a first end of a mold device  118 . For example, the first end of the mold device  118  may be connected to the second end of the second container  108  and may receive the liquid material from the second container  108 . 
     The mold device  118  may include a form with walls to shape the liquid material into a plank with a defined shape and size. In one example, the form may include walls to shape an exterior shape of the plank. In one embodiment, the defined shape may be a rectangular shape, a square shape, or another polygonal shape. In another example, the plank may have rounded edges or square edges. 
     As the liquid material cools in the mold device  118 , the liquid material may solidify back into a solid material that is in the form of a plank. The mold device may include a sixth opening  122  at a second end of the mold device  118 . The material may be pushed out of the sixth opening  122  of the mold device  118  into a cooling tank  124  (also referred to as a cooling bath). The cooling tank  124  may include a cooling agent. As the material is placed in the cooling tank  124 , the cooling agent may reduce a temperature of the material to further solidify the material into a solid plank. In one example, the cooling agent may be water. In another example, the cooling agent may be ammonia, oil, minerals, and so forth. 
     When the material has cooled in the cooling tank  124  and fully formed into a plank, a cutting device may be used to cut the plank to a desired length. In one example, the cutting device may be a saw that may cut the plank to a standard length for a plank used for flooring or an exterior platform. 
       FIG. 2A  shows the mold device  118  with multiple molding sections, according to an embodiment. Some of the features in  FIG. 2A  are the same or similar to some of the features in  FIG. 1  as noted by same reference numbers, unless expressly described otherwise. The mold device  118  may include a mold head  226 . The mold head  226  may connect to the second end of the second container  108 . The mold head  226  may receive the material from the second container  108  and begin to form the material into a plank. 
     In one example, the driver  114  of the second container  108  in  FIG. 1  may push the material into the mold device  118  at a defined pressure so that the mold device  118  forms the material into a plank at the defined pressure. For example, as the material is pushed into the mold device  118 , the material may be pushed through the molding sections of the mold device  118  to form the plank. 
     The material may be a liquid material that cools to a defined temperature and solidifies into a plank around walls, beams, indents, and other shapes of the mold device  118 . In one example, the mold device  118  may include a vacuum to remove bubbles in the liquid material. For example, as the mold device  118  receives the liquid material, the liquid material may have air bubbles that form in the liquid. The air bubbles may cause pockets in the material that may weaken a structure of a plank. To remove the air bubbles, the vacuum may suck the air bubble out of the liquid so that only the liquid is with the mold device  118 . 
     In one example, the mold device  118  may include a first mold  227  with an opening that has an initial width and height. The first mold may begin to form the material into a plank with a defined width and thickness. For example, the opening of the first mold  227  may be approximately 140 millimeters (mm) wide and 26 mm tall to form a plank that is approximately 140 mm wide and 26 mm thick. The mold head  226  may include a second mold  228 . The second mold  228  may include an opening with one or more beams  229  that extend from a middle portion of the second mold  228  toward an open space of the second mold  228  or the mold device  118 , as further discussed and shown in  FIG. 2B . As the material is pressed through the opening of the second mold  228 , the material may be compacted or shaped around by the beams  229  to form channels or hollow cores within a middle portion of the plank. In one example, the channels or hollow cores may be approximately 13 mm in diameter. 
     The channels or hollow cores may be tunnels or passages that extend from a first end of the plank to a second end of the plank. The channels or hollow cores may reduce an overall amount of material used to form the plank and reduce a weight of the plank. As discussed below, the beams  229  may also have one or more defined shapes that define the corresponding shapes of the channels or hollow cores. 
     The mold device  118  may also include a third mold  230  with one or more beams  232  that extend from an edge or side of the third mold  230 . In one example, a first one of the beams  232  may extend from a first side of an inner cavity of the third mold  230  to form a first indent or channel along a corresponding first side of the plank. In another example, a second one of the beams  232  may extend from a second side of an inner cavity of the third mold  230  to form a second indent or channel along a corresponding second side of the plank. The first indent or channel and the second indent or channel may provide indents or channels for fasteners to be inserted to connect the planks to a sub-frame of an exterior platform or flooring surface. In one example, the first indent or channel may have a height of approximately 6 mm and a depth of approximately 9 mm. 
     The mold device  118  may also include a fourth mold  234  with one or more hoses  236  that extend from a top or bottom of an inner cavity of the fourth mold  234 . In one example, the hoses may be air hoses or vacuum hoses to remove air bubbles from the material. For example, the hoses  236  may be connected to a vacuum that sucks out any air within the material to remove the air bubbles. 
     The mold device  118  may also include a fifth mold  238  with one or more beams  240  that extend from a top surface and/or a bottom surface of an inner cavity of the fifth mold  238 . In one embodiment, the beams  240  may extend from the top of the inner cavity of the fifth mold  238  to form indents or channels into a top surface of the plank. In one example, the indents or channels along the top surface of the plank may provide a texture to the top surface of the plank. The texture may provide an anti-slip gripping surface for the plank. In another example, the indents or channels along the top surface of the plank may provide passageways for water or other fluids to drain off the top of the plank. 
     In another embodiment, the beams  240  may extend from the bottom surface of the inner cavity of the fifth mold  238  to form indents or channels into a bottom surface of the plank. In one example, the indents or channels along the bottom surface of the plank may provide a texture to the bottom surface of the plank. The texture may provide an anti-slip gripping surface for the plank. In another example, the indents or channels along the bottom surface of the plank may provide passageways for water or other fluids to drain off the bottom of the plank. In one example, the indents or channels along the top surface and/or the bottom surface of the plank may have a width of approximately 2.9 mm and a depth of approximately 2.2 mm. 
     The mold device  118  may also include a sixth mold  242  with a smoothing device. The smoothing device may be sandpaper, abrasive material, polishing material, and so forth. The smoothing device may smooth one or more exterior surfaces of the plank and remove any stray debris from the exterior surfaces of the plank. 
     The number, shape, and order of the molds  228 ,  230 ,  234 ,  238 , and  242  of the mold device  118  and/or the beams of the molds  228 ,  230 ,  234 ,  238 , and  242  are not intended to be limiting and may vary based on a desired size and shape of the plank. For example, the mold device  118  may include a single mold to form the plank to a desired shape and size or multiple molds to form different portions of the plank to desired shapes and sized. In another example, the molds  228 ,  230 ,  234 ,  238 , and  242  may not include any beams, may include one beam, or may include multiple beams. In another example, the molds  234  and  238  may sequentially come before the mold  230  to form the plank as it is pushed through the mold device  118 . The sizes of the channels, cores, and indents of the plank formed by the molds  228 ,  230 ,  234 ,  238 , and  242  of the mold device  118  and/or the beams of the molds  228 ,  230 ,  234 ,  238 , and  242  are not intended to be limiting and may vary based on a size and shape of the plank. 
     As discussed above, when the mold device  118  has formed the plank to the desired size and shape, the plank may enter the cooling tank  124  of  FIG. 1  to cool the material of the plank and solidify the material of the plank into a solid plank. In one example, the cooling agent of the cooling tank  124  may cool the material of the plank to a defined temperature to solidify the plank. 
       FIG. 2B  shows the second mold  228  with one or more beams  229 , according to an embodiment. Some of the features in  FIG. 2B  are the same or similar to some of the features in  FIG. 2A  as noted by same reference numbers, unless expressly described otherwise. As discussed above, the second mold  228  may include one or more beams  229 . The beams  229  may extend from a side of the second mold  228  toward an open space of the second mold  228  or the mold device  118  in  FIGS. 1 and 2A . In one example, the beams  229  may include a first beam  229   a , a second beam  229   b , a third beam  229   c , a fourth beam  229   d , a fifth beam  229   e , and a sixth beam  229   f . The beams  229   a - f  may extend from the side of the second mold  228 . The beams  229   a - f  may be separated from each other at defined intervals to form multiple channels or hollow cores into a middle portion of the plank. 
     The beams  229   a - f  may have a defined shape and size. In one example, the beams  229   a - f  may be the same shape and size. In another example, one or more of the beams  229   a - f  may be a first defined shape and size and one or more of the beams  229   a - f  may be a second defined shape and/or size. In one embodiment, the beams  229   a - f  may be curve shaped, where at least a portion the exterior edge of each beam  229  is rounded. In one example, the curved shape may be an oval shape, an oval shape with an indent, a square shape with an indent, or a circle shape with an indent. In another example, the curved shape may be an hourglass shape, where the beam is oval shaped with a first indent on a first side of the oval and a second indent on a second side of the oval. The hourglass shape may distribute a weight applied to a top of the plank relatively evenly and increase a weight to load distribution ratio of the plank. For example, as weight is placed on a top surface of the plank, the weight pushes down on the channels or hollow cores. As the weight pushes down on the channels or hollow cores, the indents of the house glass may flex inwardly to distribute the weight relatively evenly across the arches of the hourglass shaped channel or hollow core. A curved shaped channel or hollow core may support a greater amount of weight than a channel or hollow core with straight edges because the force on the curve squeezes, or compresses, the material in the arch, rather than bending the channel or core. The material of the plank may be stronger when compressed than when bent. 
       FIG. 3  shows a side view of a plank  302  created using plank forming system  100  in  FIG. 1 , according to an embodiment. The plank  302  may include a top surface  304 , a bottom surface  306 , a first side edge  308 , and a second side edge  310 . 
     The first side edge  308  and/or the second side edge  310  may include grooves  312 . In one embodiment, a groove  312  may be located between the top surface  304  and the bottom surface  306  of the first side edge  308  and/or the second side edge  310  of the plank. The grooves  312  may be formed by the beams  232  of the third mold  230 . 
     In one embodiment, the groove  312  may be located at the approximate midpoint between the top surface  304  and the bottom surface  306  of the first side edge  308  and/or the second side edge  310 . In another embodiment, the groove  312  may extend longitudinally along the entire length of the first side edge  308  or the second side edge  310 . In another embodiment, the groove  312  may extend longitudinally along a portion of the length of the first side edge  308  and/or the second side edge  310 . For example, the groove  312  may be formed into the first side edge  308  or the second side edge  310  at one or more portions along the length of the first side edge  308  and/or the second side edge  310 . 
     In another embodiment, the groove  312  may be substantially rectangular shaped in a lateral cross-section. In another embodiment, the groove  312  may be substantially square shaped, circular shaped, or polygonal shaped in the lateral cross-section. 
     In another embodiment, a middle portion  318  of the plank  302  may include one or more channels or hollow cores  316 . In one example, the middle portion  318  may be an area surrounding a center of the plank  302 . The channels or hollow cores  316  may be formed by the beams  229  of the second mold  228 . A size and shape of the channels or hollow cores  316  may correspond to a size and shape of the beams  229  of the second mold  228 . For example, when the beams  229  are hourglass shaped beams, the channels or hollow cores  316  may be hollow hourglass shaped passages that extend a partial length or a full length of the plank  302 . For example, the channels or hollow cores  316  may extend from a first end of the plank  302  to a second end of the plank  302 . 
     In another embodiment, the top surface  304  and/or the bottom surface  306  may include one or more grooves  314 . In one example, the grooves  314  may be formed by the fourth mold  234  or the fifth mold  238 . The grooves  314  may be channels or conduits that control the flow or direction of the fluid. For example, the grooves  314  may extend along the top surface  304  and/or the bottom surface  306  of the plank  302  to direct the fluid to drain between gaps or spaces between multiple planks  302  of an outdoor platform. The plank  302  may include a single groove or multiple grooves that run along the top surface  304  and/or the bottom surface  306  of the plank  302 . 
       FIG. 4  shows a side view of the plank connector  400  connecting a first plank  402  to a second plank  404 , according to an embodiment. The first plank  402  and the second plank  404  may be created using the plank forming system  100 . The first plank  402  may include an opening or first groove  410  at one or more edges of the first plank  402 . The second plank  404  may include an opening or second groove  412  at one or more edges of the second plank  404 . The first groove  410  and/or the second groove  412  may be substantially similar to the groove  312  in  FIG. 3 . The plank connector  400  may include a first wing  416  and a second wing  418 . The first wing  416  of plank connector  400  may be inserted into the first groove  410 . The second wing  418  may be inserted into the second groove  412 . The plank connector  400  may also include an arm  408  that may be located on either side of a body of the plank connector  400 . The arm  408  may be inserted or located between the bodies of the first plank  402  and the second plank  404  to space the first plank  402  and the second plank  404  apart from each other by a defined distance. For example, the arm  408  may be inserted or located between the first plank  402  and the second plank  404  to space the first plank  402  apart from the second plank  404  by approximately a width of the arm  408 . 
     The plank connector  400  may be connected to a joist  414  by inserting a fastener  406  into an opening of the plank connector  400 . The plank connector  400  may connect to the joist  414  and may fasten down the first plank  402  and the second plank  404  to the joist  414 . For example, when the plank connector  400  is fastened to the joist  414 , the first wing  416  may be located within the first groove  410  to hold the first plank  402  against the joist  414  and the second wing  418  may be located within the second groove  412  to hold the second plank  404  against the joist  414 . The order that the plank connector  400  is connected to the joist  414 , the first wing  416  is inserted into the first groove  410 , and the second wing  418  is inserted into the second groove  412  is not intended to be limiting. In one example, the plank connector  400  may be connected to the joist  414  prior to the first wing  416  and the second wing  418  being inserted into the first groove  410  and the second groove  412 , respectively. In another example, the first wing  416  may be inserted into the first groove  410 , the plank connector  400  may be connected to the joist  414  by the fastener  406 , and then the second wing  418  may be inserted into the second groove  412 . Additionally, as discussed above, the design of the plank connector  400  may be symmetrical such that the first wing  416  may be inserted into the second groove  412  and the second wing  418  may be inserted into the first groove  410 . 
       FIG. 5  shows an outdoor platform  500  with planks  502  uniformly spaced apart from each other, according to an embodiment. The planks  502  may be created using the plank forming system  100  in  FIG. 1 . The outdoor platform  500  may include multiple planks  502  that may be disposed transversely across a sub-frame  504  (referred to hereafter as joists) of a structure, such as a patio or deck of a house. For example, the outdoor platform  500  may be an outside deck that extends from a house. The outside deck may include planks  502  that may be disposed transversely across the joists  504 . For example, the planks  502  may run adjacent to each other and may be spaced apart at a defined distance. The planks  502  may also be referred to as boards or decking. 
     In one embodiment, the planks  502  may be spaced apart by a distance ranging from approximately one-eighth of an inch to approximately a half of an inch. In another embodiment, a spacing of the planks may be based on the environmental conditions that the outdoor platform  500  may be subjected. In one example, the planks  502  may be spaced relatively close together when the outdoor platform is located in a relatively dry environment with low annual rainfall and/or no snow. In another example, the planks  502  may be spaced relatively far apart when the outdoor platform is located in a relatively wet environment with high annual rainfall and/or snow. 
     In one embodiment, a plank  502  may be hardwood material, composite material, synthetic material, and so forth. In another embodiment, the plank  502  may be two inches thick, 4 inches wide and 8 feet long. Each joist  504  may be hardwood material, composite material, synthetic material, and so forth. Each joist  504  may include a top edge, a bottom edge, a front surface, and a rear surface. The top edge, the bottom edge, the front surface, and the rear surface may be substantially flat surfaces. In one example, a portion of the bottom surface of each plank  502  may rest on the top edge of one or more of the joists  504 . In one embodiment, the joists  504  may be successively spaced apart from one another at defined distances. For example, the joists  504  may be spaced apart from each other by a distance of approximately 52 inches to 24 inches. The joists  504  may support one or more planks  502  that are disposed transversely across the top edges of the joists  504 . 
       FIG. 6  shows a flowchart  600  for a method of creating a plank with an hourglass hollow core, according to an embodiment. The method may include receiving a material in a cavity through an opening in a mold head (block  610 ). The method may include forming the material around a curved beam and walls of the cavity (block  620 ). The method may include applying pressure and heat to the material to solidify the material into a plank (block  630 ). In one example, the curved beam may an hourglass shape that creates an hourglass hollow core in the plank. 
     The disclosure above encompasses multiple distinct embodiments with independent utility. While these embodiments have been disclosed in a particular form, the specific embodiments disclosed and illustrated above are not to be considered in a limiting sense as numerous variations are possible. The subject matter of the embodiments includes the novel and non-obvious combinations and sub-combinations of the various elements, features, functions and/or properties disclosed above and inherent to those skilled in the art pertaining to such embodiments. Where the disclosure or subsequently filed claims recite “a” element, “a first” element, or any such equivalent term, the disclosure or claims is to be understood to incorporate one or more such elements, neither requiring nor excluding two or more such elements. 
     Applicant(s) reserves the right to submit claims directed to combinations and sub-combinations of the disclosed embodiments that are believed to be novel and non-obvious. Embodiments embodied in other combinations and sub-combinations of features, functions, elements and/or properties may be claimed through amendment of those claims or presentation of new claims in the present application or in a related application. Such amended or new claims, whether they are directed to the same embodiment or a different embodiment and whether they are different, broader, narrower or equal in scope to the original claims, are to be considered within the subject matter of the embodiments described herein.