Patent Publication Number: US-2012042594-A1

Title: Board cover and board covering system

Description:
CROSS REFERENCE TO RELATED APPLICATION 
     This application claims priority of U.S. Provisional Application Ser. No. 61/366,990 filed Jul. 23, 2010, which is incorporated herein by reference. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates to building products. 
     BACKGROUND TO THE INVENTION 
     The deleterious effects of moisture upon structures constructed from wooden boards, such as decks, docks and walkways, are well known. Moisture can progressively deteriorate wood. There are other problems associated with the deterioration of wooden structures. Such structures can be extremely costly, especially in a climate of increasing costs for natural resources. In view of these factors, innovations to prevent wood deterioration, such as pressure treating have become prevalent. 
     SUMMARY OF THE INVENTION 
     Forming one aspect of the invention is a cover for a board. The cover comprises: a sheet having a pair of sides and a pair of ends, the sheet, in use, being disposed lengthwise upon said board; and for and extending from each side of the sheet, a flange, the flange being either fixed at about 90 degrees to or pivotably attached to the sheet. The flanges, in use, extend in a common direction from the sheet, on opposite sides of said board. 
     According to another aspect of the invention, the flanges can each be movable between an extended position, whereat the flanges extend from the sheet in substantially coplanar relation to the sheet, and a use position, whereat the flanges extend in the common direction in substantially perpendicular relation to the sheet. 
     According to another aspect of the invention, the flanges can be sized and dimensioned such that, in use, the flanges substantially cover the sides of the board. 
     According to another aspect of the invention, the cover can further comprises at least one protrusion projecting from the sheet such that, in use, the protrusion and the flanges all extend in the common direction. 
     According to another aspect of the invention, the cover can further comprise a plurality of protrusions projecting from the sheet such that, in use, the protrusions and the flanges all extend in the common direction, the protrusions, in use, supporting the sheet above the board for foot traffic while permitting air flow beneath the sheet and board as well as drainage. 
     According to another aspect of the invention, the flanges can be shaped such that, if a pair of covers are disposed in side by side relation on adjacent boards, with the adjacent flanges thereof abutting, voids are defined between the abutting flanges to permit drainage. 
     According to another aspect of the invention, the sheet and flanges can be injection-molded as a single unit. 
     According to another aspect of the invention, each side of the sheet can have a single flange. 
     According to another aspect of the invention, the one end of the cover can be adapted to be mechanically secured to the board by screws. 
     According to another aspect of the invention, the sheet can be substantially rectangular. 
     According to another aspect of the invention, the cover can have ends that correspond with the ends of the sheet; one end of the cover can be adapted to be mechanically secured to said board in use; and the ends of the cover can be adapted such that, if a pair of the covers are disposed in use with one of the pair of covers secured to said board by the one end thereof, and the other of the pair of covers is disposed adjacent the one end of the one of the pair such that the sheets of the pair are in end to end close fitting relation, the abutting end of the other of the pair of covers is secured held against said board by the one end of the one of the pair of covers. 
     According to other aspects of the invention: the ends of the cover can be provided with a locking arrangement such that, if a pair of the covers are disposed in spaced end to end relation on a board and urged together, the proximal ends engage one another in snap fit relation; and the snap fit relation can provides for spaced, close-fitting relation between the adjacent sheets, the spaced relation allowing for the covers to expand lengthwise without buckling in normal hot weather conditions. 
     A system for covering a plurality of boards forms another aspect of the invention. The system comprises covers and strip foam material. Each cover includes: a substantially rectangular sheet having a pair of sides and a pair of ends; and, for and extending from each side of the sheet, a flange, the flange being either fixed at about 90 degrees to or pivotably attached to the sheet. The covers are deployed in use such that, on each of said plurality of boards, a plurality of covers is disposed with the sheets thereof in close fitting end-to-end relation and the flanges thereof extending from the sheets and between the boards. The foam material is wider than the board width and deployed in use such that, on each of said plurality of boards, foam material is fitted between the boards and the covers so as to cover the surface of the board on which the sheets are positioned and to extend at least partially along each side of the board beneath the flanges. 
     Other advantages, features and characteristics of the present invention, as well as methods of operation and functions of the related elements of the structure, and the combination of parts and economies of manufacture, will become more apparent upon consideration of the following detailed description and the appended claims with reference to the accompanying drawings, the latter being briefly described hereinafter. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The embodiments of the present invention will now be described by reference to the following drawings, which illustrate by way of example only preferred embodiments of the invention: 
         FIG. 1  is a top perspective view of the cover with the flanges in a first extended position; 
         FIG. 2  is a top perspective view of the cover with the flanges in a second use position; 
         FIG. 3  is a bottom perspective view of the cover with the flanges in a first extended position; 
         FIG. 4  is a top plan view of the cover; 
         FIG. 5  is a bottom plan view of the cover; 
         FIG. 6  is a side plan view of the cover; 
         FIG. 7  is a front plan view of the cover; 
         FIG. 8  is a cross-sectional view along line A-A of  FIG. 4 ; 
         FIG. 9  is a cross-sectional view of the cover along section B-B of  FIG. 4 ; 
         FIG. 10  is a top perspective view of a plurality of covers covering a plurality of boards; 
         FIG. 11  is a further top perspective view of a plurality of covers covering a plurality of boards; 
         FIG. 12  is a top plan view of a plurality of covers covering a plurality of boards; 
         FIG. 13  is a front plan view of a plurality of covers covering a plurality of boards; and 
         FIG. 14  is a side plan view of a plurality of covers covering a plurality of boards. 
         FIG. 15  is a top perspective view of a board cover according to another exemplary embodiment of the invention; 
         FIG. 16  is a bottom perspective view of the cover of  FIG. 15 ; 
         FIG. 17  is a top plan view of the board cover of  FIG. 15 ; 
         FIG. 18  is a bottom plan view of the board cover of  FIG. 15 ; 
         FIG. 19  is a side view of the board cover of  FIG. 15 ; 
         FIG. 20  is a view along  20 - 20  of  FIG. 17 ; 
         FIG. 21  is an end view of the board cover of  FIG. 15 ; 
         FIG. 22  is a view along  22 - 22  of  FIG. 17 ; 
         FIG. 23  is a perspective view of the structure of  FIG. 15 , configured for use; 
         FIG. 24  is a top plan view of a plurality of the covers of  FIG. 23 , in use; 
         FIG. 25  is a side view of the structure of  FIG. 24 ; and 
         FIG. 26  is an end view of the structures of  FIG. 24 . 
     
    
    
     DETAILED DESCRIPTION OF THE EXEMPLARY EMBODIMENTS 
     The present invention will now described for the purposes of illustration only in connection with certain embodiments. However, it is to be understood that other objects and advantages of the present invention will be made apparent by the following description of the drawings according to the present invention. While an exemplary embodiment is disclosed, this is not intended to be limiting. Rather, the general principles set forth herein are considered to be merely illustrative of the scope of the present invention and it is to be further understood that numerous changes may be made without straying from the scope of the present invention. 
     Referring to  FIG. 1 , there is shown in perspective view an exemplary embodiment of a cover  100  according to the present invention. 
     The cover  100  is manufactured from a rigid yet pliable material. The material comprising the cover  100  is also preferably water-resistant or waterproof. Examples of the material from which the cover  100  is manufactured include plastic, non corrosive sheet metal, and rubber. The cover  100  may also be manufactured from a combination of materials, for example by co-molding rubber over plastic, or rubber over formed sheet metal. 
     The cover  100  has a sheet  110 .  FIG. 1  depicts the sheet  110  as having a rectangular shape so as to correspond with a board (not shown) having substantially straight edges. Those having ordinary skill in the art will appreciate that the sheet  110  could be shaped in any manner to correspond with the shape of a board beneath the sheet  110 . 
     The width of the sheet  110  is at least the width of the board being covered. Thus, for structures constructed from four inch wide boards, the sheet  110  is at least four inches wide. For structures constructed from five and one half inch wide boards, the sheet  110  is at least five and one half inches wide. 
     As may be better appreciated from a consideration of  FIG. 13 , the width of the sheet  110  may be slightly greater than the width of a top surface a board  120  covered by the cover  100 . 
     In this exemplary embodiment of the cover  100 , the sheet  110  includes a means for creating friction on an outer surface  144  of the sheet  110 . The means for creating friction shown in  FIG. 1  is a series of protuberances  150  formed in the outer surface  144  of the sheet  110 . It will be recognized by a person skilled in the art that other means for creating friction could be utilized, such as a series of alternating grooves and ridges. 
     The protuberances  150  are equally distributed upon the outer surface  144  of the sheet  110  in a grid pattern. Further, as may be better appreciated from consideration of  FIGS. 6 and 7 , the protuberances  150  are bevelled. 
       FIG. 3  shows an inner surface  156  of the sheet  110 . The inner surface  156  of the sheet  110  includes at least one protrusion for engaging the top surface  124  of the board  120 . It will be appreciated by one skilled in the art that the purposes of the invention may be achieved if one employs any number of protrusions shaped and arrayed so as to separate the inner surface  156  of the sheet  110  and the top surface  124  of the board  120 . As shown in  FIG. 3 , the protrusions are a plurality of ribs  160 . These ribs  160  are orientated parallel to one another and in two series  164  and  168  that define a channel  170 . 
     Near a first end  180  of the cover  100 , four short ribs  162  are orientated across the width of the sheet  110  and parallel to the ribs  160 . The ribs  160  and the short ribs  162  are formed in the inner surface  156  of the sheet  110 . 
     The first end  180  of the sheet  110  and a second end  190  of the sheet  110  are adapted to include attachment means. It will be appreciated by a person skilled in the art that the purposes of the invention may be achieved by employing any attachment means including hooks, clasps, or the like. In the embodiment described herein, the attachment means consist of two outer female tabs  200  and two inner female tabs  206  situated at the first end  180  of the sheet  110  and two outer male tabs  210  and an inner male tab  216  situated at the second end  190  of the sheet  110 . The female tabs  200  and  206  and the male tabs  210  and  216  are formed in the inner surface  156  of the sheet  110 . 
     The distance between the inner female tabs  206  is equal to the distance between each inner female tab  206  and an adjacent outer female tab  200 . The outer female tabs  200  are slightly wider than the inner female tabs  206 . Each of the female tabs  200  and  206  correspond with a short rib  162  such that the distances between adjacent female tabs  200  and  206  match corresponding distances between short ribs  162 . 
     The distance between the inner male tab  216  and each outer male tab  210  is at least equal to the width of inner female tabs  206 . The distance between each outer male tab  210  and the closest of the first edge  130  of the sheet  110  and the opposing edge  136  of the sheet  110  is at least equal to the width of the outer female tabs  200 . 
     Each male tab  210  and  216  defines an aperture  220  sized so as to receive a fastener (not shown) such as a screw, a nail or the like. 
     The cover  110  includes a plurality of flanges. In the preferred embodiment depicted herein, the cover  110  has two flanges. It will be appreciated by a person skilled in the art that the purposes of the invention can be achieved by incorporating two or more flanges. 
     A first flange  300  is attached adjacent to the first edge  130  of the sheet  110  and a second flange  310  is attached to the sheet  110  adjacent to the second edge  136  of the sheet  110 . The length of the flanges  300  and  310  is equal to the length of the sheet  110 . The height of the flanges  300  and  310  is preferably equal to or greater than the height of sides  124  and  126  of board  120 . 
     The flanges  300  and  310  are either fixed at about 90 degrees as in  FIG. 2  (for sheet metal and plastic made parts without fold line-live hinge) or pivotably attachable to the sheet  110  (for plastic parts with fold line-live hinge). It will be appreciated by a person skilled in the art that the purposes of the invention may be achieved employing any conventional means for pivotably attaching the flanges  300  and  310  to the sheet  110 . A top edge of each flange is bevelled as demonstrated by top edge  304  of flange  300  shown in  FIG. 7 . 
     As may be appreciated by considering  FIGS. 7 and 9 , the flanges  300  and  310  are each attached to the sheet  110  by a hinge  320 . In this embodiment, the hinge  320  extends along the entire length of the sheet  110  so as to create an integral attachment. 
     The first edges  324  of each hinge  320  are bevelled so as to permit the hinge  320  to pivot downward from a first extended position wherein the hinge flares away from the sheet  110  to a second use position where, upon rotation of the hinge  320  about a point where the hinge  320  attaches to the sheet  110 , the hinge  320  is orientated more proximate to the sheet  110 . Similarly, a second edge  328  of each hinge  320  is bevelled so as to permit, for example, the first flange  300  to rotate about a point at which the hinge  320  attaches to the first flange  300  from a first position wherein the first flange  300  is parallel to the plane of the sheet  110  to a second position wherein the first flange  300  is perpendicular to the plane of the sheet  110 . 
     Each flange may have a series of bosses  330  on an outer surface  304  of the flange. Each boss  330  is integrally formed in the flange. The bosses  330  can be equally spaced along the length of each flange. Further, as seen in  FIG. 1 , the bosses  330  may be equally sized. If necessary, narrow bosses  334  at ends of the flanges may be smaller sized than bosses  330  so as to preserve the uniform spacing between the bosses. 
       FIGS. 11 to 14  depict the cover  100  in operation with other covers  100 . Multiple covers  100  may be attached to create a system for covering the board  120 . Alternatively or additionally, one or more covers  100  may be positioned upon adjacent boards  120  to create a system for covering multiple boards. 
     Before affixing the cover  100  upon the board  120  the flanges  300  and  310  are pivoted about hinges  320  from the first position to the second position so that the flanges  300  and  310  are orientated perpendicular to the plane of the sheet  110  and the hinges  320  are orientated so as to permit the cover  100  to fit snugly upon the board  120 . The cover  100  is then placed upon the board  120 . The cover  100  can be placed upon the board  120  in a snug fit as best depicted in  FIG. 13  such that each flange engages a side  126  or  128  of the board  120  and the ribs  160  engage the top surface  124  of the board  120 . Accordingly, the cover  100  is centered upon the board  120 . 
     The cover  100  is then fastened to the board  120 . Fasteners (not shown) are placed within apertures  220  of male tabs  210  and  216  and attached to the board  120 . 
     A second cover  104  is then attached to the first cover  100 . The flanges of the second cover  104  are pivoted to the second position wherein the flanges are perpendicular to the plane of the sheet of the second cover  104 . The second cover  104  is then slidably placed upon the board  120  such that the female tabs  200  and  206  of the cover  100  receive the male tabs of the second cover  104 . 
     As seen in  FIGS. 12 and 14 , preferably, a second end  184  of the second cover  104  is placed slightly distal from the first end  180  of the sheet  110  of the cover  100  so as to define a space  340  between a second end  184  of the second cover  104  and the first end  180  of the sheet  110  of the cover  100  and a first end  180  of the second cover  104 . The width of the space  340  may be 0.1 inches to permit thermal expansion of the cover  100  and the second cover  104  without causing damage to the covers or deterioration of the board  120 . 
     Similarly, further covers may be affixed to the board  120  to cover a desired length of the board  120 . 
     As best shown in  FIG. 13 , adjacent cover  108  may be affixed to an adjacent board  122  to create a system for covering multiple boards. The flanges  314  and  318  of the adjacent cover  108  are pivoted to the second position so that the flanges  314  and  318  of the adjacent cover  108  are perpendicular to the sheet  114  of the adjacent cover  108 . The adjacent cover  108  is then slidably placed upon the adjacent board  122  and positioned such that adjacent bosses  336  of the flange  314  of the adjacent cover  108  are adjacent to the corresponding bosses  330  of the flange  310  of cover  100 , as depicted in  FIG. 12 . The adjacent cover  108  is then fastened to the adjacent board  122  in a manner similar to that described above in respect of the fastening of the cover  100  to the board  120 . The flange  314  of the adjacent cover  108  and the flange  310  of the cover  100  define a gap  350 . One or more additional covers may be placed upon adjacent board  120  and fastened. One or more additional covers may be affixed to further adjacent boards. 
     Persons of ordinary skill will appreciate that the foregoing arrangement has substantial advantage: 
     the covers can be injection molded as a single piece 
     the pivotable nature of the flanges allow the covers to be densely flat packed 
     the bosses ensure that, in use, drainage passages remain between the covers 
     the upper protuberances provide stable footing to foot traffic, even when wet 
     the ribs ensure airflow between the cover and board, to resist rot 
       FIGS. 15-26  show a cover according to another exemplary embodiment of the invention, which cover is designated with general reference numeral  400 . This cover  400  has functionality substantially similar to the covers previously disclosed. For simplicity, to the extent that this cover  400  is similar to the previously-described covers, a detailed description is neither required nor provided: reference is simply made at this time to the reference numerals on  FIGS. 15-26  which correspond to those found in the previous description, and it is hereby confirmed that structures on  FIGS. 15-26  which share reference numerals with structures on  FIGS. 1-14  operate in an identical or substantially similar fashion. The structure of  FIGS. 15-26  does differ somewhat from the structure of  FIGS. 1-14 , and these differences are described hereinbelow. 
     Locking Arrangement 
     As best seen in  FIGS. 15-16 , this cover  400  includes a locking arrangement, which is defined by, on one end of the cover [the end which includes outer male tabs  210 ], a pair of resilient locking fingers  502  provided with notches  504  and, on the other end of the cover, a pair of locking detents  506 . The fingers  502  are arranged to slide along the female tabs  206 , ride up over the detents  506  and then snap back into their original positions once the detents  506  can occupy the notches  504 . This snap-fit engagement spaces the longitudinally-adjacent sheets slightly apart from one another to permit thermal expansion without buckling, as discussed earlier. 
     Pilot Holes 
     As best seen in  FIGS. 15 and 20 , the cover  400  includes a plurality of pilot holes  508  on the upper surface which align with stud protuberances  510  that extend from the lower surface of the cover. The stud protuberances  510  function in a manner analogous to ribs  164 , but have a girth that is sufficient to allow a finishing nail to pass therethrough. This arrangement allows, inter alia, the cover to be cut to length and secured in place. 
     Flange Insets 
     As illustrated in  FIG. 15 , this cover  400  has flange insets  512  which are shaped and dimensioned such that, when another cover is disposed upon the same board in longitudinally end to end close fitting relation, the flanges of the adjacent cover are received in and overlap the flange insets  512 . 
     System 
     The cover of this embodiment can be used in a manner similar to that shown in  FIG. 10 , as evidenced by  FIGS. 24-26 . However, as a yet further embodiment, this cover, as well as the cover of  FIGS. 1-14 , can be used as part of a system which includes strip foam material strip foam material, the foam material being wider than the board width and deployed in use such that, on each of said plurality of boards, foam material is fitted between the boards and the covers so as to cover the surface of the board on which the sheets are positioned and to extend at least partially along each side of the board beneath the flanges. This system provides even better protection for the boards from the elements, in that the entire upper surface of the board is shielded from precipitation. This system also has advantage, in that it provides a cushion for the covers, which reduces noise production in use. 
     Variants 
     In a yet further alternative embodiment, not shown, the strip foam material can be omitted, and the stud protuberances and ribs can be faced on their lower surface with foam material. This increases cost but increases airflow beneath the covers. This also allows water infiltration at the junction of the longitudinally adjacent covers, but this can be ameliorated, for example, by foam tape at the joints. 
     In a yet further alternative embodiment, not shown, the ribs can be removed and the stud protuberances can be pointed, lengthened and made more plentiful. The reduced contact area, coupled with the potential for slight penetration of the protuberances into the wood surface, will reduce noise production, but will slightly damage the wood, which may not be desirable in all situations. 
     As yet further options, the cover can itself be covered with carpeting. In one embodiment, polypropylene outdoor carpet is fused via an overmolding process to the cover, such that the covers function as ‘carpet tiles’. In another embodiment, outdoor carpet can be secured, by self-adhesive backing on the carpet, after the covers have themselves been installed. 
     It will be apparent to those having ordinary skill in the art that various modifications and variations may be made to the embodiments disclosed herein, consistent with the present invention, without departing from the spirit and scope of the present invention. Accordingly, the specification is to be considered exemplary only, with the true scope and spirit of the invention being disclosed by the following claims, purposively construed.