Patent Document

CROSS REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims priority to U.S. Provisional Application Ser. No. 61/956,557 filed on Jun. 11, 2013 which is incorporated herein in its entirety. 
     
    
     TECHNICAL FIELD 
       [0002]    The present invention relates to a system for applying a protective cap to the top and sides of deck boards to shield the boards from weather and traffic. 
       BACKGROUND OF THE INVENTION 
       [0003]    Decks and porches are a common addition to houses, pools and patios and are especially prevalent because of the availability of inexpensive treated lumber. Lumber treating processes are even more improved over the years. However, even with chemical preservatives, years of sunshine, rain, snow and normal use will cause treated deck boards to look weakened, cracked and discolored. Moreover the chemicals and preservatives utilized in treatment of the boards are often toxic or include environment contaminants. 
         [0004]    Composite lumber is a relatively recent entry into the field of deck boards. Composite boards are made from a mixture of wood fibers or particles, plastic fibers or particles, and a binder to hold the mixture together formed under high pressure. Composite boards can be made from virgin plastic and/or rubber materials and or recycled plastic, rubber, or rubber and plastic, or a composite with plastic or rubber and wood materials or can be up to 100% recycled materials and can be made to be more than twice as dense and strong as wood. A major advantage achieved with the use of composite boards is that very little or no maintenance is necessary. No sealing, painting, or refinishing is required. 
         [0005]    Conventional composite decking is often made from (low-density or high-density) polyvinyl chloride or polypropylene, virgin or recycled thermoplastics including HDPE (high-density polyethylene), LDPE (low-density polyethylene), ABS (acrylonitrile butadiene styrene), PS (polystyrene), polyvinylchloride, or PLA (polylactic acid or polylactide) added to wood particles, a binder, and other additives that stabilize the plastic and protect the deck from damaging UV rays. The most common method of production is to extrude the material into the desired shape, though injection molding is also used. Additives such as colorants, coupling agents, UV stabilizers, blowing agents, foaming agents, and lubricants help tailor the end product to the specific application. Extruded composite boards are formed into both solid and hollow profiles. Composite boards do not absorb or give off moisture, so they don&#39;t shrink or swell like wood. As a result, composite decking does not crack, warp or separate due to varying weather cycles. Composite decking resists insects, does not need water repellant or stain and will perform well in extreme weather conditions for decades. 
         [0006]    A more recently introduced composite decking includes a different formulation on the exterior surface of the top and sides of the board which is both protective and more attractive. This outside layer is generally 0.010 to 0.050 inch thick and comes in a variety of colors. 
         [0007]    In some manufacturing facilities, the wood particles and selected synthetics are combined and processed in a pelletizing extruder, which produces pellets of the new material. The pellets are then re-melted and formed into the final shape. Other manufacturers complete the finished part in a single step of mixing and extrusion. 
         [0008]    The main disadvantage with composite boards is the high initial cost. However, a savings is realized in the long run because a composite board deck will outlast a wooden deck and does not need to be painted and sealed as wood does. 
       SUMMARY OF THE INVENTION 
       [0009]    In accordance with the present invention, there is provided a synthetic board cap comprising, consisting of, or consisting essentially of a U-shaped synthetic cap selected from the rubber, plastic, wood materials set forth heretofore, or combinations thereof. Moreover, the boards may have a coextruded material wherein the surface is smooth and the cross-sectional view shows a granular appearance or cellular structure filled with voids or porous material with air spaces forming a matrix. 
         [0010]    The caps may also comprise virgin plastic and/or rubber materials and or recycled plastic, rubber, or rubber and plastic. The caps are composed of Low-density or high-density polyvinyl chloride or polypropylene, virgin or recycled thermoplastics are preferable, however, ABS (acrylonitrile butadiene styrene), PS (polystyrene), polyvinylchloride, or PLA (polylactic acid or polylactide), including HDPE (high-density polyethylene), LDPE (low-density polyethylene). A major advantage achieved with the use of composite boards is that very little or no maintenance is necessary. No sealing, painting, or refinishing is required. The cap may be of a selected size, thickness, width, length, or color. 
         [0011]    The cap may be extruded having a top surface and connecting leading side edges forming lips extending downward therefrom a selected length forming side edges which may extend therefrom at right Angeles or The cap typically includes vertical lateral panels connecting at their top edge to a horizontal panel which may be smooth or textured. The U-shaped synthetic cap has a rectangular void formed therein between the two lateral panels sized to receive a wooden deck board trimmed to a selected width. The two lateral panels and the horizontal panel are the same length. 
         [0012]    A system for placing protecting deck boards by covering them with caps made from a wear resistant synthetic material, polymer such as polypropylene, or a wood/polymer composite. The deck boards are trimmed to reduce the overall width of the boards which allows the U-shaped caps to be installed over the trimmed deck board with adhesive. With the U-shaped cap installed, the top surface and both side surfaces of the deck boards are covered and protected from sunlight and weather. The system includes a board trimming and shaping rotary saw tool. The protective board caps are fastened to the deck boards in one of three ways. Preferably countersunk screws with gaskets are used to fasten the caps to the boards. Alternatively, the protective caps include laterally extending barbs or teeth which snap by the bottom lateral edges of the trimmed deck boards and catch on the edges. Another means of fastening the caps to the deck boards is the application of adhesive to the top of the deck board prior to fitting the cap. Yet another method involves the use of a friction fit wherein the leading side edges of the cap are biased inward slightly permitting a slight spreading in order to be fitted over a board of a selected width. 
         [0013]    It is an object of this invention to provide a system for extending the life of a deck or deck boards well beyond the normal lifetime of pre-treated wood decks including a protective deck board cap, a tool for preparing a deck board to receive a cap and a process for applying the cap to the deck board. 
         [0014]    It is an object of this invention to provide a deck board cap and a process for extending the life of a deck or deck boards well beyond the normal lifetime of pre-treated wood decks while improving the appearance of the deck. 
         [0015]    It is an object of this invention to provide a deck board cap and a process for extending the life of a deck or deck boards well beyond the normal lifetime of pre-treated wood decks without refinishing, sealing, painting or using any other treatment. 
         [0016]    It is an object of this invention to provide a deck board cap and a process for extending the life of a deck or deck boards well beyond the normal lifetime of pre-treated wood decks which also removes the necessity of any future protection, refinishing, painting or chemical treatments. 
         [0017]    It is an object of this invention to provide a deck board cap and a process for extending the life of a deck or deck boards well beyond the normal lifetime of pre-treated wood decks wherein a wood shaper is used to widen the gap between exiting deck boards, a U-shaped cap is applied and fastened to the top of the deck boards. 
         [0018]    It is an object of this invention to provide a deck board cap and a process for extending the life of a deck or deck boards well beyond the normal lifetime of pre-treated wood decks which is less expensive than the cost of a complete composite deck and requires less labor than demolishing the old deck and building a new deck. 
         [0019]    Other objects, features, and advantages of the invention will be apparent with the following detailed description taken in conjunction with the accompanying drawings showing a preferred embodiment of the invention. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0020]    A better understanding of the present invention will be had upon reference to the following description in conjunction with the accompanying drawings in which like numerals refer to like parts throughout the views wherein: 
           [0021]      FIG. 1  is a perspective view of a portion of a deck made of wooden boards. 
           [0022]      FIG. 2  is a perspective view of the deck of  FIG. 1  wherein the boards have been trimmed to accept deck board caps. 
           [0023]      FIG. 3  is a perspective view of a deck board cap and a wooden board which has been trimmed to receive a deck board cap prepared with adhesive. 
           [0024]      FIG. 4  is a perspective view of a wooden board and deck board cap assembly. 
           [0025]      FIG. 5  is a close-up view of a deck board cap including an extra protective exterior layer. 
           [0026]      FIG. 6  is a circular saw including an adjustable rip-fence. 
           [0027]      FIG. 7  is a portion of a deck which has been covered with the deck board caps of the present invention. 
           [0028]      FIG. 8  is a perspective view of a deck board cap including barbs. 
           [0029]      FIG. 9  is a right front perspective view of a preferred deck board trimming tool. 
           [0030]      FIG. 10  is a left front perspective view of a preferred deck board trimming tool. 
           [0031]      FIG. 11  is a left rear perspective view of a preferred deck board trimming tool. 
           [0032]      FIG. 12  is a perspective view of a deck board cap attached to a trimmed deck board with screws. 
           [0033]      FIG. 13  is a front view of a wood screw with an elastomeric gasket. 
           [0034]      FIG. 14  is a right front side view of the preferred dual bladed deck board trimming unit. 
           [0035]      FIG. 15  is a left front side view of the preferred dual bladed deck board trimming unit. 
           [0036]      FIG. 16  is another right front downward perspective of the preferred dual bladed deck board trimming unit. 
           [0037]      FIG. 17  is a rear view of the preferred dual bladed deck board trimming unit. 
       
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0038]    In accordance with the present invention, there is provided a system for extending the life of a treated lumber deck.  FIG. 1  shows a small deck including treated boards  12 . Each treated board  12  has a width  14  and a thickness  16 . It is desired to cover the boards  12  with the deck board caps  20 . The deck board caps  20 , shown in  FIG. 3 , are U-shaped and include a void  21  which is intended to receive a treated board. 
         [0039]    The deck board cap  20  preferably comprises polypropylene and is extruded or molded. Other preferred embodiments of deck board cap  20  are made of synthetics such as ABS, polystyrene or polylactide. Still other preferred embodiments are composite wood made from a mixture of wood particles, a binder and one of the following synthetics: low-density or high-density polyvinyl chloride or polypropylene, virgin or recycled thermoplastics including HDPE (high-density polyethylene), LDPE (low-density polyethylene), ABS (acrylonitrile butadiene styrene), PS (polystyrene), or PLA (polylactic acid or polylactide). Additives such as colorants, coupling agents, UV stabilizers, blowing agents, foaming agents, and lubricants are added to tailor the end product to the specific application. 
         [0040]    The U-shaped deck board cap  20  includes a horizontal rectangular panel  40  connected to the top edges of two vertical rectangular panels  44 , where the three connected panels define a void  21  which is sized to receive a trimmed wooden deck board  22 . The three rectangular panels  40 ,  42  and  44  are all of the same selected length. 
         [0041]    The treated boards  12  must be trimmed, or in other words, resized to receive the caps  20 . A circular saw  30  with an adjustable rip fence  32  is used to remove material from the left side  13  and the right side  15  of each treated board  12  so that the final width  18  of the trimmed board  22  is equal to the width  19  of the channel  21  in the U-shaped deck board cap  20 . The trimmed boards  22  now have the correct width  18  so that the deck board caps  20  just fit. Because the original treated boards  12  are fastened with nails or screws with the heads near or flush with the top surface of the boards, it is not recommended that material be removed from the top of the board  22 . IF the caps are to be fastened with adhesive, it is recommended that the tops of the boards  22  are sanded to encourage better adhesion of the adhesive  24 . Therefore, the depth  17  of the U-channels  20  should be equal to the thickness  16  of the treated boards  12 . 
         [0042]    A preferred tool  40  for trimming deck boards  12  is shown in  FIGS. 9-11 . The resizing tool  40  includes an electric motor unit  44  with a horizontal shaft  45  extending from one end onto which is attached a circular saw blade unit  46 . The motor unit  44  is rotatably attached to a planar platform  48  at pivot points  49  so that the height of the blade with respect to the bottom of the platform  48  is adjustable by sliding the locking pin  61  on the rear of the motor unit  44  up and down within the bracket  60  and then tightening the locking pin  61  to hold the motor unit in place. Blade unit  46  is a dado set. The motor unit  44  includes a forward extending lug  56  which reaches forward beyond the front edge of the blade unit  46 . The lug  56  acts as a stop to prevent the rotating blades from cutting into a vertical surface such as a wall or post adjacent to the deck boards being trimmed. 
         [0043]    There is one wheel at each corner of the platform  48 . Front wheels  50  and rear wheels  51 , extend below the bottom surface of the platform  48  and carry the weight of the resizing tool  40  as cutting is done. The two front wheels  50  are coaxial with one another and the two rear wheels  51  are coaxial with one another. The axis of both pairs of wheels are parallel so that the wheels  51  follow the wheels  51  as the tool is used. An adjustable fence  54  runs along the edge of a board to guide the tool  40  and guarantee the proper amount is removed from the deck board being resized. The fence is set by loosening the thumb screw  52 , sliding the fence to the desired position and then re-tightening the thumb nut  52 . 
         [0044]    The preferred method of trimming the deck boards is to is accomplished by using the preferred tool trimming tool  40  and by setting the fence  54  so that an approximately equal amount of material is removed from the board at the right of the blade unit  46  and the board at the left of the blade unit  46 . It is preferable that fresh wood is exposed on each side of the board. Another way of accomplishing this task is to use the tool  30  in  FIG. 6  to trim both sides of each board. However, this requires one pass of the tool  30  down each side of each board. Also, the fence must be adjusted for each pass. 
         [0045]    An alternative but less preferred method of using tool  30  involves removing material from only one side of each board. The fence on tool  30  needs to be set only once. However, this process leaves a weathered side remaining on the deck board which is allowable but not preferred. 
         [0046]    Another alternative tool for resizing the board comprises a router having a straight bit and an adjustable fence. 
         [0047]    The most preferred deck board trimming unit is the dual bladed unit  70  shown in  FIGS. 14-17 . The dual bladed trimming unit  70  includes a sliding base  72  with a drive unit  74  which drives a belt  78  which in turn drives a blade shaft  80 . The blade shaft  80  is rotatably held rigidly and adjustably in place by two saddle block bearings which are in turn held to the base  72  by bolts. Attached to the blade shaft  80  are two circular saw blades  82  and  84 . The belt  78 , pulley  76  and shaft  80  are preferably a toothed design to provide a more positive transfer of rotational force to the saw blades  82  and  84 . Also, the saw blades  82  and  84  are preferably carbide tipped. 
         [0048]    In the preferred embodiment, the base plate  72  includes a separately adjustable plate  86  with adjusting screws  88  to provide depth control for the blades  82  and  84 . Further, the base plate  72  includes at least one guide  90  located in front of the blades which slides along the outer side of the deck board to be trimmed to ensure that the board trimming unit  70  is well controlled to provide two straight parallel edges on the trimmed deck board. Preferably, a second guide  92  near the rear end of the base  72  gives further guidance to help keep the board trimming unit  70  well controlled during trimming. It is contemplated that a third guide  93  may be used together with or instead of the guides  90 ,  92  to control the level of the blades. As shown in  FIG. 15 , blade covers or guards  95  will cover the carbide tip rotary blades. The guards may also be spring loaded to bias them against the workpiece. 
         [0049]    It can be seen that the apart saw blades  82  and  84  are spaced apart by exactly the preferred width of a trimmed deck board ready to be capped. Two valuable advantages are realized with this design. With one pass, both sides of the deck board are trimmed and the result is a trimmed board which is the perfect width for the caps which are provided. 
         [0050]    The preferred attachment means, shown in  FIG. 12 , uses countersunk screws  64  to connect the deck board caps  20  to the trimmed deck boards  22 . The deck board caps  20  are pre-drilled with a countersink bit.  FIG. 13  shows an elastomeric washer  68  applied to the screw  64  before screwing the screw into the pre-drilled hole and into the trimmed board  20 . 
         [0051]    Another embodiment of the invention, shown in  FIG. 8  includes spaced apart teeth  34  extending downward below the edge of the cap  20 . The spaced apart teeth  34  include an inward pointing barb  35  which catch under the bottom lateral edges of the trimmed deck boards  22 . The deck boards  22  are typically supported by parallel floor joists on edge and which are typically one and one half inches thick and are spaced apart on either 16″ or 24″ centers. The spacing between the teeth is at least four inches and is preferably eight inches or more. Preferably, the tooth spacing should be either four or eight inches because 16 and 24 are multiples of four and eight. With a spacing of eight inches, the likelihood of a tooth  34  contacting a floor joist and preventing the complete seating of a cap  20  onto a deck board  22  is remote. In the event that the teeth  34  do contact the floor joists, however, the cap may be shortened and moved to a position where the teeth  34  do not touch the joist. When the deck board cap  20  is pressed down onto the trimmed board  22 , the barbs  35  will spring outward and slip past the bottom lateral edges of the board and snap back under the board edges, thus trapping the board inside the cap  20  with the board  20  being held in place by the top surface of the barbs  35 . 
         [0052]    Another method of fixing the cap  20  to the deck board  22  involves using adhesive. As seen in  FIG. 3 , when the boards  12  have been trimmed, adhesive  24  is applied to the top of the boards  22  and the caps  20  are then applied to cover the boards and pressed down tightly into place as shown in  FIGS. 4 and 7 . 
         [0053]    It is anticipated that the outer width  23  of the U-shaped caps  20  is about equal to the original width  14  of the treated boards so that the gap between the assembled deck board caps and boards is about equal to the original gaps between the deck boards  12 . However, if it is desired to change the width of the gaps between the deck boards, the caps  20  may have a outer width  23  which is either greater than or less than the width  14  of the original deck boards  12 . 
         [0054]    Another embodiment of the present invention, shown in  FIG. 5  includes a composite deck board cap with an outer layer  26  on the top surface and outer lateral surfaces of the U-shaped deck board cap  20 . The outer layer  26  is preferably a water proof, UV stabilized protective layer which may include decorative features such as a desired color and texture. The outer layer  26  is preferably 0.010 to 0.050 inches thick. The outer layer  26  is either laminated or sprayed onto the top surface and both lateral surfaces of the deck board cap  20 . Another method of applying the outer layer  26  to the deck board cap is an extrusion process wherein the deck board cap  20  is extruded from a first die and the outer layer  26  is extruded onto the deck board cap by a second die in close proximity to the first die. 
         [0055]    It is also contemplated that the cap may be used as a cover for fence rails or post. Moreover, the leading side edges may be extended to cover the side edges of the fence rail or post. A back cover may have side edges extending downward therefrom for cooperative engagement with the side edges of the top cover, or the bottom of the top side edges may include an offset or detent to allow a friction fit, snap-fit, tongue and groove arrangement, or other cooperative engagement with the side edges of a back plate so that the wood rail or post is completely covered with the cap material. 
         [0056]    A method of renewing and protecting a board deck including the steps of providing a board deck structure, a board trimming tool, deck board caps with pre-drilled spaced apart countersunk holes formed therein, a screw driver and countersunk wood screws; selecting a first board within said board deck structure; trimming a first amount of material from a first side of said selected board; trimming a second amount of material from a second side of said selected board, said trimming of said first and said second amounts of material causing said selected board to have a width equal to said rectangular void between said two vertical panels of a deck board cap; pressing a selected deck board cap over said selected board so that said selected board is between said two vertical panels and said cap is pressed tightly against a top surface of said selected board at a selected horizontal position on said selected board; inserting and driving said countersunk wood screws into said pre-drilled countersunk spaced apart holes of said selected board cap and into said selected board; and selecting a next selected board within said board deck structure and performing the four preceding steps with respect to said next selected board until all boards of said board deck structure are capped. 
         [0057]    The foregoing detailed description is given primarily for clearness of understanding and no unnecessary limitations are to be understood therefrom, for modification will become obvious to those skilled in the art upon reading this disclosure and may be made upon departing from the spirit of the invention and scope of the appended claims. Accordingly, this invention is not intended to be limited by the specific exemplification presented herein above. Rather, what is intended to be covered is within the spirit and scope of the appended claims.

Technology Category: 0