Synthetic boards for exterior water-resistant applications

Abstract

Specially configured synthetic boards are provided for use with conventional carpentry tools and techniques to form flat, water-tight surfaces such as decks, roofs, walls, boat decks, hulls, and the like. The boards are formed to their desired shape and scale by extruding mixtures of wood particles and thermoplastic materials through appropriate converging dies. In one configuration, the edges of the boards have complementary configured outwardly facing recesses that permit them to be joined to form the watertight surfaces, and in another configuration the boards have features that interact with separate plastic structures to provide water tightness.

Description

CROSS REFERENCE TO RELATED APPLICATION[0001] This application claims the benefit of priority from U.S. Provisional Patent Application Ser. No. 60 / 593,505 filed on Jan. 20, 2005, the entire contents of which are incorporated herein by reference.FIELD OF THE INVENTION [0002] This invention generally relates to construction materials and, more particularly, to specially configured synthetic boards for providing water-tight exterior surfaces such as for decks, roofs, siding, and boat applications. BACKGROUND OF THE INVENTION [0003] In the construction of outdoor surfaces, such as decks and porches, it is common to use flat materials that are weather-resistant. Typically, these are pressure-treated wood, cedar or teak planks, mahogany planks and, more recently, synthetic boards which are extruded wood / plastic composites. [0004] In normal construction, boards of the above types are spaced apart to provide gaps, allowing moisture to drain through the crack fromed between the butt joint as ...

AI Technical Summary

Benefits of technology

[0013] The invention relates to channeled, interlocking boards with integral elastomeric or supplemental seals that are effective in constructing extensive, leak-resistant lateral surface, as for a deck, roof, wall or boat application.

[0015] Such boards are wood-like in appearance, extremely rugged and inexpensive. The low cost derives from the fact that the wood content comes from waste sawdust, and the plastic is from recycled goods, such as bags and bottles. Inexpensive processes for producing boards of such material can be adapted for incorporating the desired leak-resistant characteristics.

Problems solved by technology

Problems arise when it is required that the area below be more or less protected from rain and snow as, e.g., when a patio is placed below an elevated deck.

Solutions for this problem are available on the market today, but all have certain limitations.

However, there are two drawbacks with the above.

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