Static structures (e.g. – buildings) – With synthetic resinous component
Reexamination Certificate
1998-11-03
2002-08-06
Stephan, Beth A. (Department: 3635)
Static structures (e.g., buildings)
With synthetic resinous component
C052S299000, C052S263000
Reexamination Certificate
active
06427403
ABSTRACT:
BACKGROUND OF THE INVENTION
This invention to a decking system for use as a residential or commercial deck is manufactured from an extruded fiber reinforced plastic (FRP) material known as pultruded FRP and assembled using a combination of corrosion resistant hardware and/or adhesives. The invention is assembled from FRP pultruded components comprising several systems which included a weight bearing support system, flooring system, safety system, roofing system, and decorative system. The systems described herein can be used to assemble not only decks but also docks, boardwalks, walkways, gazebos, spa and hot tub decks. The FRP material is pultruded from a choice of resin systems with UV inhibitors such as isophtalic polyester flame-retardant, vinyl ester flame-retardant, or the like, such that the decking material is maintenance-free, strong, light in weight, resistant to rotting, corrosion and weathering. However, many other resin systems are available and, therefore, this invention shall not be limited to a specific resin system. The FRP material is pultruded from a choice of fiber reinforcement systems, the most common of which is fiberglass, however many other fiber types are available and, therefore, this invention shall not be limited to a specific type. In this disclosure, it will be understood that the FRP pultrusion decking system of this invention may have many uses such as a decks, docks, walkways, boardwalks, gazebos, hot tub decks, spa decks, etc. and can be extended. However, for the sake of simplicity, the primary applications discussed herein will be in the context of a deck, dock, and boardwalk, and shall not be limited by this disclosure.
1. Field of Invention
This invention pertains generally to the art of deck, dock, and boardwalk construction for residential and commercial applications such as those attached to the wall of a home, constructed on property, freestanding, or extending out from the edge of land property into a waterway or body of water.
2. Description of the Related Art
Most decks, docks, boardwalks, gazebos, and spa decks found in residential and commercial applications are manufactured or constructed from traditional building materials including pressure-treated (CCA: copper-chromated arsenic) wood using screws, nails, and bolts to provide structural attachment. These wooden decks are typically attached to an existing structure, freestanding, or extend out from property into water in the case of a dock. A smaller number of these products are manufactured from aluminum or steel. Conventional design methods have traditionally utilized treated wood for all of the structural potions of decks and docks. These structures are assembled using vertical posts (also know as piles in the case of a dock), beams, joists, deck planking. Typically, a horizontal frame is constructed using wood, pressure-treated lumber 2×8 or 2×10 joists, or the like and attached at one end to the wall of a structure usually with joist hangers. Horizontal, wooden deck planking is secured using nails or screws to the top of the joist frame, forming the decking surface upon which persons may walk. Supporting the decking frame are wood vertical support posts, typically 4×4 or 6×6 or the like made from pressure treated lumber. These posts are anchored either into the ground or on top of a concrete or block pad. Depending on local building codes and customer preferences, a wooden railing may be attached to the perimeter of the deck. Stairs, again commonly constructed from wood, extend from the edge of the deck and are attached to the perimeter of the deck, providing access to ground level. The construction of a dock is similar in that the structure, typically fabricated from pressure-treated lumber, is supported by wood vertical posts or pilings. Wood deck planking boards are attached to the joists, forming the walking surface of the dock.
Wood structures have several disadvantages including but not limited to deterioration resulting from exposure to the weather and water. Wood structures deteriorate with exposure to the elements, even those constructed with treated lumber, and are susceptible to rotting, nail popping, splitting and warping. In addition they require costly and time-consuming maintenance such as replacing rotted or warped planks, painting (which can be difficult with CCA treated wood), staining, power washing, scraping, or the reapplication of chemical treatments (water sealants). The leeching of the copper-chromated arsenic treatment into the ground or water is also of some concern amongst environmental advocates.
There are also disadvantages in constructing decks and docks from PVC (vinyl), aluminum or steel. Metal docks are vulnerable to corrosion, high maintenance and are usually much warmer when contacting with skin; while vinyl decking products require structural supports typically wood or metal bracing and framing. Docks made from vinyl products such as those manufactured by Brock Docks U.S. Pat. No. 5,613,339 to Pollock are not fabricated entirely from polyvinyl chloride material. These dock systems still require either wood or metal members to provide structural support. U.S. Pat. No. 5,048,448 to Misener discloses a boat dock with plastic resin horizontal planking which are slideably engaged into tube-shaped metal supporting members.
Decks and docks manufactured from fiber reinforced plastic (FRP) using pultruded structural shapes offer several advantages. Metal or wood decking and docks are vulnerable to rotting or corrosion and high maintenance and vinyl decking products lack structural integrity and require wood or metal reinforcement support and bracing. Other plastic lumber exhibits dimensional temperature instability. FRP docks and decks made entirely of high strength composite material are maintenance free, do not require painting or staining and will never rust. FRP composite decks and docks are non-corrosive and non-decaying, insect resistant, strong (no need for extra structural reinforcement components), light-weight, and colors can be molded into the product with ultra violet (UV) inhibitors. Further, they are dimensionally stable with regard to temperature fluctuations, allow for concealed installation of auxiliary lighting and power, and do not contain chromated copper arsenic (CCA) as do structures made with pressure treated lumber. Sections or entire structures can be pre-manufactured for easy transportation, assembly and rapid installation. FRP composite decks and docks stay cool to the touch, are warp resistant, will not produce popped nails or wood splinters, and are available with a skid-resistant surface.
Efforts by others to address the challenges raised by using plastic as a building material include U.S. Pat. No. 5,623,803 to Willis, which discloses a decking, made of plastic along with a securement system and method of installation. The deck structure utilizes recycled plastic lumber planks which have T-shaped slots and slide onto a rigid frame. The rigid frame incorporates protruding connectors, which fit into the slots on the bottom side of the decking planks. Willis incorporates the T-slotted feature to account for the thermal dimensionally instability of his plastic. However, Willis does not address the problems of high maintenance, rotting, corrosion and the structural frame, supports and posts which are still made from wood lumber or metal.
U.S. Pat. No. 5,706,620 to De Zen discloses a thermoplastic structural system and components for a structural building system. The material utilizes PVC as the thermoplastic and chopped glass fiber as the reinforcement. However, De Zen does not address the inherent strength limitations of chopped, random reinforcement fibers in contradistinction to the present invention, which utilizes continuous fiber reinforcement. De Zen also does not address the tendency of PVC to sag and the low strength material properties of the matrix material (PVC thermoplastic). De Zen does not address the issue of providing weight-bearing support as the present invention does in the us
Burdett James R.
Daebeler Paul F.
Stephan Beth A.
Venable
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