Decking planks and / or decking systems

Abstract

A decking plank having a rectangular shape with the length of the plank extending between a first extremity and a second extremity opposite to the first extremity; the width of the plank being provided between a first lateral edge and a second lateral edge opposite to the first lateral edge; the decking plank comprising a composite of largely polymeric material and filler; the upper surface of the decking plank being formed with a first region (4) extending from the first lateral edge to the second lateral edge and the second region (7) extending from the first lateral edge to the second lateral edge wherein the first region comprises a relatively smooth surface and the second region comprises a surface which is coarser than the relatively smooth surface of the first region; the first region and the second region being separated by a rib (5, 6) which extends between the first lateral edge and the second lateral edge; whereby, in use, water falling on the upper surface of the plank drains substantially laterally towards lateral edges of the plank.

Description

[0001]

[0002] Decking Planks and / or Decking Systems

[0003] Field of the Invention

[0004] The invention relates to planks and in particular decking planks. Furthermore, the invention concerns decking systems.

[0005] Background to the Invention and Prior Art Known to the Applicant(s)

[0006] The Applicant has developed over the years decking planks. In particular one of its founding members published WO 2007060392 in 2007 which is principally focused on polymer based decking planks in a very large number of embodiments. The Applicant has over the years improved the formulation for these polymeric moulded decking planks. One of the aspects which neither polymeric nor natural wood decking planks have been particularly able to solve or particularly improve is providing anti-slip characteristics for the decking planks. In particular there has been a need to improve not only the Applicant’s own decking planks but in any of the other prior art proposals since their initial submission, to provide a decking plank which not only as a polymeric board appears to be wholly of natural wood but to also provide a decking plank which is able to more rapidly drain water away and further improve not only the comfort underfoot when walking on the plank but provide a surface which reduces the risk of individuals slipping during wet conditions when walking along the plank.

[0007] In particular, the invention seeks to overcome the traditional risk of slippage on these prior art planks by improving the configuration of the plank and also facilitate a plank which drains water away more rapidly than prior art proposals.

[0008] Summary of the Invention

[0009] In a first broad independent aspect, the invention provides a decking plank having a rectangular shape with the length of the plank extending between a first extremity and a second extremity opposite to the first extremity; the width of the plank being provided between a first lateral edge and a second lateral edge opposite to the first lateral edge; the decking plank comprising a composite of largely polymeric material and filler; the upper surface of the decking plank being formed with a first region extending from the first lateral edge to the second lateral edge and a second region extending from the first lateral edge to the second lateral edge; wherein the first region comprises a relatively smooth surface and the second region comprises a surface which is coarser (or rougher) than the relatively smooth surface of the first region; the first region and the second region being separated by a rib which extends between the first lateral edge and the second lateral edge; whereby, in use, water falling on the upper surface of the plank drains substantially laterally towards lateral edges of the plank.

[0010] The term rib may form a line of separation which is effective to direct the flow of liquid lateral towards the lateral edges. The rib may be a recessed trough, a segmented line formed from a plurality of points or mounts of separation. The rib may also be a recessed line, an edge or a perceptible change in relief capable of distinguishing relatively coarse and relatively smooth zones or areas. This configuration reverses conventional thinking in the art of decking planks where the natural grain of the wood whether in the Applicant’s own prior art embodiments or traditional wood-based decking planks extend length wise from the first extremity or proximal extremity of the plank to the second extremity or distal extremity of the plank. Thus, in the prior art, drainage of surface water on a plank occurs principally along the length of the plank which can result in extended periods of water sitting on the upper surface until it dries away or eventually slowly dripping off the edges at the extremities of the decking plank. In practise, the decking planks are often substantially laid flat or with an almost imperceptible gradient, the water tends to sit on the upper surface in order to produce a potential hazard to those walking on the deck for an extended period after rain has fallen on it. The present configuration provides an advantageous structure which facilitates the flow of fluid laterally off these often very long pieces of decking plank. The presence of the two regions improves the friction offered on the upper surface of the deck which minimises the risk of a fall when surface water has been deposited on the upper surface of the plank. Furthermore, the perceptible change in structure between the smooth region and a relatively coarse region provides this advantageous direction of flow laterally which capitalises on the relatively short distance of flow required as opposed to the full length of a decking plank which may therefore only require a flow of several centimetres as opposed to the several metres in the prior art channels provided along the length of the boards.

[0011] In a further subsidiary aspect, the decking plank comprises at least a third region which is also coarser (or rougher) than the first region; the first region being located between the second and third regions; the first region having a further rib between the first region and the third region; whereby the first region forms a trough to allow, in use, water falling on the upper surface of the plank to drain towards the lateral edge of the plank.

[0012] In a further subsidiary aspect, the second region comprises closely contiguous repeating peaks and troughs. This configuration is particularly advantageous in terms of not only providing enhanced grip underfoot but to break up the surface to increase its water drainage off from the second region. In a further subsidiary aspect, the second region comprises a density of greater than 10 peaks per square centimetre of the region. This configuration is particularly advantageous and marks a complete departure from prior art relatively smooth natural wood finishes which largely fail to break-up the surface tension of the deposited water. This further encourages the flow of fluid off the plank.

[0013] In a further subsidiary aspect, the second region has a first number of strands with a principal longitudinal axis parallel to the rib; and further strands at an angle from the first number of strands; whereby troughs are formed between the strands. This configuration is particularly advantageous as it advantageously provides the rougher surface which even in wet conditions provides greater grip for those walking on the plank. It further improves the direction of flow towards the lateral edges of the plank. As in previous embodiments, it further breaks up the surface tension which may be present between the water and the surface.

[0014] In a further subsidiary aspect, the strands are perpendicular to one another and the troughs formed there between are rectangular. This configuration is particularly advantageous as it provides relatively high coefficients of friction to facilitate greater grip under foot.

[0015] In a further subsidiary aspect, both the first and the second regions have curved strands; whereby the curved strands in the first region are flatter in relief than the curved strands in the second region. This configuration is also particularly advantageous to facilitate flow whilst at the same time provide improved grip under foot.

[0016] In a further subsidiary aspect, the first region reflects more light than the second region. This is particularly advantageous as the second region will thus absorb more light and tend to more rapidly evaporate any water which might not have immediately drained off in its respective recesses. Whilst the first region due to its relatively smooth surface will tend to facilitate the lateral flow of water with little or no friction compared to the second region, as a consequence of the present subsidiary aspect, both regions will dry out much faster than any prior art proposal. In a further subsidiary aspect, the rib between the first and second regions forms a curved line between the first lateral edge and the second lateral edge of the plank. This configuration is particularly comfortable under foot whilst providing the advantages outlined with respect to preceding aspects.

[0017] In a further subsidiary aspect, the first region and / or the second region are bowed in crosssection with the apex of the bow being at a central portion of the board whereby; in use, water drains from the apex to the lateral edges of the plank.

[0018] In a further subsidiary aspect, the lateral edges of the plank have themselves a plurality of peaks and troughs along the edges or part thereof. This configuration is particularly advantageous to break up any surface tension at the lateral edges of the decking plank.

[0019] In a further broad independent aspect, the invention provides a decking system comprising a plurality of decking planks in accordance with any one of the preceding claims, wherein the first and second regions of a first plank are provided in line with the corresponding first and second regions of the second plank; and a gap is provided between adjacent planks through which water drains.

[0020] This configuration is particularly advantageous as the flow of neighbouring planks are both simultaneously directed towards the lateral edges which can be particularly beneficial to increase the flow away from the decking plank due to the regions meeting at the gap between respective planks.

[0021] In a second broad independent aspect, the invention provides a cladding or siding board with a longitudinal length extending between a first extremity and a second extremity opposite to the first extremity; the width of the board being provided between a first lateral edge and a second lateral edge opposite to the first lateral edge; the cladding board comprising a composite of largely polymeric material and filler; the board having an outermost surface which is exposed when the board is, in use, attached to a wall; the exposed surface being formed with a first region extending from the first lateral edge to the second lateral edge and a second region extending from the first lateral edge to the second lateral edge; wherein the first region comprises a relatively smooth surface and the second region comprises a surface which is coarser (or rougher) than the relatively smooth surface of the first region; the first region and the second region being separated by a rib which extends between the first lateral edge and the second lateral edge; whereby, in use, water falling on the exposed surface of the board drains downwards towards the lower, when installed, of said first and second lateral edges of the board.

[0022] The term rib may form a line of separation which is effective to direct the flow of liquid laterally towards the lateral edges which when installed on a vertical surface leads to downward directional drainage. The rib may be a recessed trough, a segmented line formed from a plurality of points or mounts of separation. The rib may also be a recessed line, an edge or a perceptible change in relief capable of distinguishing relatively coarse and relatively smooth zones or areas.

[0023] In prior art cladding boards, the surface is uninterrupted from an upper lateral edge to a lower lateral edge. Droplets thus drain down to the lower edge where they either drop further down onto neighbouring boards or through capillary effects drain undesirably upwards, between and behind the boards. Dependent on the slope of the cladding boards and the environmental conditions, drops may also flow diagonally down. The provision of the ribs as defined above allows the drops to be in effect channels down from one board to an adjacent board without necessarily requiring a downpipe for a rain water collection system. In effect, this configuration allows the drainage to be achieved more efficiently by employing the surface of the cladding boards themselves which completely reverses conventional thinking in the field of cladding boards and drainage and those arrangements which are formed by virtue of these.

[0024] The presence of the two regions improves the friction offered on the outermost surface of the cladding boards improves the ability for these to be handled by providing multiple areas for the installers to grip the boards. This will minimise the risk of usually very slippery cladding boards slipping out of the grasp of an installer when, for example, on a scaffold. Thus, these improvements not only enhance the flow of liquid down from board to board but also mitigate the risk of accidents during installation. In a subsidiary aspect in accordance with the second broad independent aspect, the cladding board comprises at least a third region which is also coarser (or rougher) than the first region; the first region being located between the second and third regions; the first region having a further rib between the first region and the third region; whereby the first region forms a trough to channel the water towards the lower lateral edge of the two lateral edges of the board.

[0025] In a further subsidiary aspect in accordance with the second broad independent aspect, the second region comprises closely contiguous repeating peaks and troughs. This configuration is particularly advantageous in terms of not only providing enhanced grip underfoot but to break up the surface to increase its water drainage off from the second region.

[0026] In a further subsidiary aspect in accordance with the second broad independent aspect, the second region comprises a density of greater than 10 peaks per square centimetre of the region. This configuration is particularly advantageous and marks a complete departure from prior art relatively smooth natural wood finishes which largely fail to break-up the surface tension of water falling on the surface. This further encourages the drainage flow of fluid off from the board configured in this manner to an adjacent similarly configured further board.

[0027] In a further subsidiary aspect in accordance with the second broad independent aspect, the second region has a first number of strands with a principal longitudinal axis parallel to the rib; and further strands at an angle from the first number of strands; whereby troughs are formed between the strands. This configuration is particularly advantageous as it advantageously provides the rougher surface which even in wet conditions provides greater grip for installers when handling the board. It further improves the direction of flow towards the lower lateral edges of boards. As in previous embodiments, it further breaks up the surface tension which may be present between the water and the surface. In a further subsidiary aspect in accordance with the second broad independent aspect, the strands are perpendicular to one another and the troughs formed there between are rectangular. This configuration is particularly advantageous as it provides relatively high coefficients of friction to facilitate greater grip when handled by an installer.

[0028] In a further subsidiary aspect in accordance with the second broad independent aspect, both the first and the second regions have curved strands; whereby the curved strands in the first region are flatter in relief than the curved strands in the second region. This configuration is also particularly advantageous to facilitate flow whilst at the same time provide improved grip for the installers of the boards as they handle them during installation.

[0029] In a further subsidiary aspect in accordance with the second broad independent aspect, the first region reflects more light than the second region. This is particularly advantageous as the second region will thus absorb more light and tend to more rapidly evaporate any water which might not have immediately drained off in its respective recesses. Whilst the first region due to its relatively smooth surface will tend to facilitate the downward drainage flow of water with little or no friction compared to the second region, as a consequence of the present subsidiary aspect, both regions will dry out much faster than any prior art proposal.

[0030] In a further subsidiary aspect in accordance with the second broad independent aspect, the rib between the first and second regions forms a curved line between the first lateral edge and the second lateral edge of the board. This configuration is particularly comfortable for installers to handle as it minimise any sharp edges whilst providing the advantages outlined with respect to preceding aspects.

[0031] In a further subsidiary aspect in accordance with the second broad independent aspect, the first region and / or the second region are sloped from the uppermost lateral edge to the lowermost lateral edge. In a further subsidiary aspect in accordance with the second broad independent aspect, the lateral edges of the board have themselves a plurality of peaks and troughs along the edges or part thereof. This configuration is particularly advantageous to break up any surface tension at the lateral edges of the cladding board.

[0032] In a further broad independent aspect, the invention provides a cladding system comprising a plurality of cladding boards in accordance with any one of the preceding aspects relating to the second broad independent aspect, wherein the first and second regions of a first board are provided in line with the corresponding first and second regions of the second board; and the lower edge of one board overlaps the upper edge of another board.

[0033] This configuration is particularly advantageous as the flow in the drainage channels of one board may flow into the drainage channel of an adjacent board as these may be aligned thus potentially obviate the need for a separate roof drainage downpipe.

[0034] Figure 1 shows a perspective view of an embodiment of the invention which may be in accordance with the first or the second broad independent aspect.

[0035] Figure 2 shows a perspective view of the edge region in an embodiment of the invention which may be in accordance with the first or the second broad independent aspect.

[0036] Figure 3 shows a plan view of an embodiment of the invention which may be in accordance with the first or the second broad independent aspect.

[0037] Figure 4 shows a cross-sectional view along axis AA which may be in accordance with the first or the second broad independent aspect.

[0038] Figure 5 shows a cross-sectional view along axis BB which may be in accordance with the first or the second broad independent aspect. Figure 6 shows a perspective view of a further embodiment of the upper surface of a decking plank or cladding board which may be in accordance with the first or the second broad independent aspect.

[0039] Figure 7 shows a perspective view of a further embodiment of a decking plank or cladding board which may be in accordance with the first or the second broad independent aspect.

[0040] Figure 8 shows a perspective close-up view of the upper surface of two adjacent decking planks or cladding board which may be in accordance with the first or the second broad independent aspect.

[0041] Figure 9 shows a close up view of a further embodiment of a decking plank or cladding board which may be in accordance with the first or the second broad independent aspect.

[0042] Figure 10 show a close up view of a further embodiment of a decking plank or cladding board which may be in accordance with the first or the second broad independent aspect.

[0043] Figure 11 shows a further embodiment of a decking plank or cladding board which may be in accordance with the first or the second broad independent aspect.

[0044] Figure 12 shows a further embodiment of a decking plank or cladding board which may be in accordance with the first or the second broad independent aspect.

[0045] Figure 13 shows a further embodiment of a cladding arrangement formed by a plurality of adjacent cladding boards.

[0046] Figure 14 is a cross-sectional vies of a cladding board showing a slope from a first lateral edge to a second lateral edge. Detailed of the

[0047] Figure 1 shows a decking plank generally referenced 1. In this view, the decking plank has a rectangular shape when viewed in plan. Although not visible in Figure 1, the decking plank may have a first extremity and a second extremity opposite to the first extremity and may thus take the form of a plank as shown in figure 7. The decking plank has a width, as shown in Figure 1, between a first lateral edge 2 and a second lateral edge 3 opposite to the first lateral edge. The upper surface of the decking plank has been formed in a moulding process or an extrusion process whereby the upper surface has a number of regions. A first region 4 is provided between lateral edges 2 and 3 and is delimited further by ribs 5 and 6. Thus, first region 4 extends from first lateral edge 2 to second lateral edge 3. By contrast, a further region generally referenced 7 is provided adjacent to the first region. The first and second regions have different textures. In preferred embodiments, both first and second regions are integrally formed in the upper surface of the decking plank. The first region is configured to be relatively smooth compared to the second region which has a much coarser or rougher surface. In other words, region 4 has a relatively low coefficient of friction whilst region 7 has a much higher coefficient of friction. This is achieved by specifically shaping the respective regions during the manufacturing process, for example, by providing a mould which is configured to provide a smooth surface for region 4 and a relatively coarse surface for region 7. Region 7 has a much higher density of peaks and troughs. The peaks are formed by strands such as strand 8 extending at least partially between the lateral edges of the board. In this embodiment, the strands form a substantially crisscross pattern with the peaks being formed by the upper most parts of the strands whilst the troughs are provided between the strands. In this configuration, optionally, strand 8 is substantially parallel to rib 5 in order to define a principal direction of flow for any liquid falling onto the decking plank in the particular direction of the lateral edges. As can be seen in Figure 1, region 4 is not entirely smooth and may also have a number of peaks and recesses such as recesses 9 and 10. These extra recesses further encourage the flow of liquid towards the lateral edge of the plank. In preferred embodiments, the recessed 9 and 10 are sloped towards the lateral edge in order to further encourage drainage. Optionally, ribs 5 and 6 not only define the first region 4 but also provide an edge so that the region 4 may act as a trough to channel the flow of liquid towards the lateral edges of the plank.

[0048] Figure 2 shows in more detail the edge of the plank. For ease of reference, similar numerical references have been employed even though the regions in question are different. In the embodiment of Figure 2, region 4 also has a number of recessed portions towards the edge of the plank such as recess 9. Rib 6 defines one side of region 4 beyond which a further relatively coarse region 11 is provided. As can be seen in the strands of region 11, a crisscross pattern of the kind described with reference to Figure 1 is shown in greater detail. When reaching the edge of the board, the strands direct liquid onto the lateral edge 12. Thus, at the edge itself a high density of peaks and troughs are also provided which serve to break up any potential surface tension in the liquid should the decking plank be, for example, exposed to rain. In this embodiment, the edge extends substantially at 45 degrees from the principal plane of the upper surface before the lateral edge forms a surface at 90 degrees from the principal direction of the upper plane of the decking plank. In this configuration, region 6 and region 7 bound the relatively smooth region 4.

[0049] In practice, a large number of a succession of smooth and coarse regions are provided along the length of the board in order to advantageously cause the flow of liquid to be lateral along the entire length of the board thus minimising the potential amount of sitting water on the upper portion of the board. A view of the entirety of a decking plank is provided by way of illustration in figure 7.

[0050] In preferred embodiments, as illustrated in Figure 3, boards with respective smooth regions and coarse regions may be aligned at their respective edges. In particular, smooth region 4 may be aligned with smooth region 14 whilst coarse region 7 is aligned with coarse region 17. Furthermore, similar alignments may also be provided such as smooth region 13 and smooth region 15. When arranging for this kind of positioning of adjacent decking planks any liquid falling on the top of the respective planks is advantageously drawn through the gap 16 which separates the boards. With respect to the edge of the coarse regions as can be seen the lateral edge of the board is frequently interrupted which will facilitate the breaking up of surface tension to encourage the water to flow down through the gap. Furthermore, the smooth regions form in effect a trough to facilitate the flow of liquid into the gap.

[0051] In order to further improve a configuration of these decking planks, Figures 4 and 5 in particular show how the surfaces have been advantageously formed to further encourage the flow of liquid away from the upper surface of the planks. In particular, Figure 4 which is a cross-sectional view along axis AA whilst not to scale and exaggerated for the purposes of illustration and clarity, the smooth region and optionally the coarse region as well may be bowed so that an apex 18 is provided at a central region of the decking plank in order to further encourage the natural flow of water from a central region towards the lateral edges and into the respective gaps between decking planks. In other words, the upper smooth region may be bowed to progressively diminish in height towards the lateral edge where the edge may incorporate itself a 45 degree angle followed by a 90 degree angle relative to the dashed line illustrated. This bowed configuration may not be visible to the naked eye as the decking plank will appear to all intents and purposes to be substantially flat.

[0052] As further illustrated in Figure 5, by significantly exaggerating the configuration of the coarse region along, for example an axis BB, when referring to Figure 3, the coarse region has in effect a large number of peaks and troughs which collectively encourage the flow of liquid down from the peak towards the lateral edges of the plank. In this illustration, there are at least 10 peaks per square centimetre to provide significantly greater coarseness relative to the smooth region located between the relatively coarse regions.

[0053] Whilst Figures 1 to 3 have shown the peaks and troughs as being formed by strands, the embodiment of Figure 5 shows relief with relatively closely contiguous peaks or mounts with individual upwardly pointing upper portions.

[0054] In a further configuration as shown in Figure 6, the coarse region 19 may comprise a large number of irregular fibre like or filament portions in random directions. Nevertheless, these filaments are separated by respective troughs as in the preceding embodiments. By contrast in adjacent relatively smooth region 20, the filaments are much more dispersed and relatively smooth. As can also be observed the relatively coarse region tends to reflect less light where as the relatively smooth surface of region 20 reflects much more light. This is particularly significant in terms of allowing the coarse region to potentially dry quicker due to light whereas the smooth region 20 would dry faster due to enhanced flow of liquid towards the lateral edges of the planks. Whilst most embodiments detailed above have shown a rib between coarse regions and smooth regions, these are not necessarily in a straight line and may advantageously be arc shaped as in the embodiment of Figure 6 where rib 21 marks a line of segregation between the respective regions. The arcs of separation between neighbouring regions may extend from one lateral edge of the plank to an opposite lateral edge of the plank; whereby surface water flow is encouraged towards the lateral edges of the planks to further improve the rate by which these planks dry. A plurality of a succession of coarse and smooth regions may also be provided in the context of the embodiment of figure 6; whereby each region is separated from an adjacent region by arc shaped lines instead of the straight lines of previous embodiments. Decking systems with a plurality of decking planks each of which having arc shaped lines of separation may also be formed by placing the decking planks next to one another with a minimal gap between them.

[0055] Preferably, in such embodiments, the relatively smooth regions are aligned with the relatively smooth regions of the neighbouring planks whereby enhanced surface water flow may be achieved across the system.

[0056] In other embodiments in accordance with any of the preceding embodiments, the respective neighbouring regions of the planks may be staggered.

[0057] In other embodiments, the coarse regions of neighbouring planks may be aligned with the smooth regions of neighbouring planks.

[0058] In other embodiments, the line or rib separating adjacent regions may comprise a number of zig-zags. In other embodiments, the line or rib separating adjacent regions may form a V when viewed in plan view. In such embodiments, an apex may optionally be provided at the lower most point of the V, whereby flow is further improved in certain decking systems. The angle of the V may be preferably between 30 and 60 degrees.

[0059] The further embodiments of figures 7 to 12 are provided to illustrate in greater detail various advantageous configurations on the upper surface of the boards.

[0060] Figure 7 shows a full length decking plank generally referenced 22. In this view, the decking plank has a rectangular shape when viewed in plan. The decking plank may have a first extremity 23 and a second extremity 24 opposite to the first extremity. The decking plank has a width between a first lateral edge 25 and a second lateral edge 26 opposite to the first lateral edge. The upper surface of the decking plank has been formed in a moulding process or an extrusion process whereby the upper surface has a number of regions. A first region 27 is provided between lateral edges 25 and 26 and is delimited further by ribs 28 and 29. Thus, first region 27 extends from first lateral edge 25 to second lateral edge 26. By contrast, a further region generally referenced 30 is provided adjacent to the first region. The first and second regions have different textures. In preferred embodiments, both first and second regions are integrally formed in the upper surface of the decking plank. The first region is configured to be relatively smooth compared to the second region which has a much coarser or rougher surface. In other words, region 27 has a relatively low coefficient of friction whilst region 30 has a much higher coefficient of friction. This is achieved by specifically shaping the respective regions during the manufacturing process, for example, by providing a mould which is configured to provide a smooth surface for region 27 and a relatively coarse surface for region 30. Region 30 has a much higher density of peaks and troughs. The peaks may be formed by strands extending at least partially between the lateral edges of the board. In this embodiment, the strands form a substantially crisscross pattern with the peaks being formed by the upper most parts of the strands whilst the troughs are provided between the strands. As can be seen in Figure 7, region 27 is not entirely smooth and may also have a number of peaks and recesses. These extra recesses further encourage the flow of liquid towards the lateral edge of the plank. Optionally, ribs 28 and 29 not only define the first region 27 but also provide an edge so that the region 27 may act as a trough to channel the flow of liquid towards the lateral edges of the plank. In the close up view of figure 8, troughs 28 and 29 are provided to delimit the relatively smooth region 27. The neighbouring relatively rough region 30 comprises a crisscross pattern of what appears to be a weave like texture. Both the regions are in preferred embodiments formed entirely with the same chemical compositions.

[0061] In the close up view of figure 9, lines of separation 31 and 32 are shown creating a boundary between smooth region 33 and adjacent rough regions 34 and 35. The darker pigment of this embodiment provides a board which absorbs greater solar energy and thus further improves the achievable rate of drying the upper surface of the board following rain.

[0062] In a further embodiment as shown in the close up view of figure 10, regions may form a V or bend at illustrated by comer 36. In certain embodiments, the central apex of a board may be configured to coincide with the comer thus encourage flow away from the comer.

[0063] In a further embodiment as shown in the close up view of figure 11, a further board is provided with a succession of relatively smooth regions such as region 37 and relatively rough regions such as region 38. The relatively smooth region 37 has a number of channels such as channel 39 whose boundaries substantially extend towards the edges of the board. The relatively smooth region 39 is separated from relatively rough regions such as region 38 by virtue of discontinuous lines such as lines 40 and 41 of separation forming nevertheless a rib of separation between two adjacent regions. The relative rough region 38 appears to comprise randomly oriented fibres such as might be associated with biologically derived pulp. Both the smooth and rough regions are however in preferred embodiments formed by exactly the same chemical composition whereby only the texture of the upper surface has been changed in order to provide the technical effects discussed herein.

[0064] In a further embodiment as shown in the close up view of figure 12, a further board may comprise adjacent regions such as regions 42 and 43. Region 42 may be smoother than region 43. The regions have a perceptible curvilinear line of separation between adjacent regions with in preferred embodiments the line extending substantially laterally from a middle portion 44 of the board towards the edges such as edge 45.

[0065] In accordance with a second broad independent aspect, figure 1 shows a cladding or siding board generally referenced 1. In this view, the cladding board has a substantially rectangular shape when viewed in plan. Although not visible in Figure 1, the cladding board may have a first extremity and a second extremity opposite to the first extremity and may thus take the form of a board as shown in figure 7. The cladding board has a width, as shown in Figure 1, between a first lateral edge 2 and a second lateral edge 3 opposite to the first lateral edge. In practice, the depth of the cladding board at the first lateral edge may be lower at the upper lateral edge than its lower lateral edge in order to allow the boards to appropriately fit against each other as in conventional cladding arrangements. These may include a first lateral edge having a recessed portion and a second lateral edge having a tongue shaped and configured to fit against the recessed portion. The outermost exposed surface of the cladding board has been formed in a moulding process or an extrusion process whereby the outermost surface has a number of regions. A first region 4 is provided between lateral edges 2 and 3 and is delimited further by ribs 5 and 6. Thus, first region 4 extends from first lateral edge 2 which is an upper lateral edge to a second lateral edge 3 which may be a lower lateral edge when installed against a substantially vertical wall or upward extending wall. By contrast, a further region generally referenced 7 is provided adjacent to the first region. The first and second regions have different textures. In preferred embodiments, both first and second regions are integrally formed in the upper surface of the cladding board. The first region is configured to be relatively smooth compared to the second region which has a much coarser or rougher surface. In other words, region 4 has a relatively low coefficient of friction whilst region 7 has a much higher coefficient of friction. This is achieved by specifically shaping the respective regions during the manufacturing process, for example, by providing a mould which is configured to provide a smooth surface for region 4 and a relatively coarse surface for region 7. Region 7 has a much higher density of peaks and troughs. The peaks are formed by strands such as strand 8 extending at least partially between the lateral edges of the board. In this embodiment, the strands form a substantially crisscross pattern with the peaks being formed by the upper most parts of the strands whilst the troughs are provided between the strands. In this configuration, optionally, strand 8 is substantially parallel to rib 5 in order to define a principal direction of flow for any liquid to be thus channelled from one cladding board to an adjacent cladding board. As can be seen in Figure 1, region 4 is not entirely smooth and may also have a number of peaks and recesses such as recesses 9 and 10. These extra recesses may be sloped to further encourage the flow of liquid towards the lateral edge of the board. In preferred embodiments, the recessed 9 and 10 are sloped towards the lateral edge in order to further encourage drainage. Optionally, ribs 5 and 6 not only define the first region 4 but also provide an edge so that the region 4 may act as a trough to channel the flow of liquid towards the lateral edges of the board and thus direct the flow of liquid downwards.

[0066] Figure 2 shows in more detail the edge of a cladding board. For ease of reference, similar numerical references have been employed even though the regions in question are different. In the embodiment of Figure 2, region 4 also has a number of recessed portions towards the edge of the board such as recess 9. Rib 6 defines one side of region 4 beyond which a further relatively coarse region 11 is provided. As can be seen in the strands of region 11, a crisscross pattern of the kind described with reference to Figure 1 is shown in greater detail. When reaching the edge of the board, the strands direct liquid onto the lateral edge 12. Thus, at the edge itself a high density of peaks and troughs are also provided which serve to break up any potential surface tension in the liquid should the cladding board be, for example, exposed to rain. In this embodiment, the edge extends substantially at 45 degrees from the principal plane of the outermost exposed surface before the lateral edge forms a surface at 90 degrees from the principal direction of the outermost plane of the cladding board. In this configuration, region 6 and region 7 bound the relatively smooth region 4.

[0067] In practice, a large number of a succession of smooth and coarse regions are provided along the length of the board in order to advantageously cause the flow of liquid to be segmented along the entire length of the board thus providing multiple effective downward flowing channels when boards are secured side by side on a vertical wall. Figure 13 illustrates a cladding board arrangement 46 with cladding boards such as cladding board 47 and the potential interaction of adjacent regions. Cladding board 47 have for example multiple regions 48 which collaborate with adjacent regions such as region 49 in an adjacent board 50. The configuration and the alignment of the various regions may not necessarily be in the form provided in figure 13 as will now be further detailed.

[0068] In preferred embodiments, as illustrated in Figures 3 and 13, boards with respective smooth regions and coarse regions may be aligned at their respective edges. In particular, smooth region 4 may be aligned with smooth region 14 whilst coarse region 7 is aligned with coarse region 17. Furthermore, similar alignments may also be provided such as smooth region 13 and smooth region 15. When arranging for this kind of positioning of adjacent cladding boards any liquid falling on the top of the respective board is advantageously drawn to their lower lateral edge 16 or overlapping portion 16 where adjacent boards meet. With respect to the edge of the coarse regions as can be seen the lateral edge of the board is frequently interrupted which will facilitate the breaking up of surface tension to encourage the water to flow down from the boards rather than potentially being drawn between adjacent boards due to capillary effects which often arise in external cladding arrangements. Furthermore, the smooth regions form in effect a channel to facilitate the flow of liquid down a succession of such channels formed in adjacent boards.

[0069] In order to further improve a configuration of these cladding boards, Figure 5 in particular shows how the surfaces have been advantageously formed to further encourage the flow of liquid down through defined flow channels. As further illustrated in Figure 5, by significantly exaggerating the configuration of the coarse region along, for example an axis BB, when referring to Figure 3, the coarse region has in effect a large number of peaks and troughs which collectively encourage the flow of liquid down from the peak towards the lateral edges of the board. In this illustration, there are at least 10 peaks per square centimetre to provide significantly greater coarseness relative to the smooth region located between the relatively coarse regions. Figure 14 illustrates further how the cladding board can not only comprise the channels described herein with respect to any of the other figures but can also incorporate a slope between a first lateral edge 52 and a second lateral edge 53 of the board. The slope may be selected to further encourage flow in the dedicated channels.

[0070] Whilst Figures 1 to 3 have shown the peaks and troughs as being formed by strands, the embodiment of Figure 5 shows relief with relatively closely contiguous peaks or mounts with individual upwardly pointing upper portions.

[0071] In a further configuration as shown in Figure 6, the coarse region 19 may comprise a large number of irregular fibre like or filament portions in random directions. Nevertheless, these filaments are separated by respective troughs as in the preceding embodiments. By contrast in adjacent relatively smooth region 20, the filaments are much more dispersed and relatively smooth. As can also be observed the relatively coarse region tends to reflect less light whereas the relatively smooth surface of region 20 reflects much more light. This is particularly significant in terms of allowing the coarse region to potentially dry quicker due to light whereas the smooth region 20 would dry faster due to enhanced flow of liquid towards the lateral edges of the boards. Whilst most embodiments detailed above have shown a rib between coarse regions and smooth regions, these are not necessarily in a straight line and may advantageously be arc shaped as in the embodiment of Figure 6 where rib 21 marks a line of segregation between the respective regions. The arcs of separation between neighbouring regions may extend from one lateral edge of the board to an opposite lateral edge of the board; whereby surface water flow is encouraged towards the lateral edges of the boards to further improve the rate by which water drains down from the exposed surface of the cladding boards. A plurality of a succession of coarse and smooth regions may also be provided in the context of the embodiment of figure 6; whereby each region is separated from an adjacent region by arc shaped lines instead of the straight lines of previous embodiments. Cladding systems with a plurality of cladding boards each of which having arc shaped lines of separation may also be formed by placing the cladding boards next to one another with a minimal gap between them. Preferably, in such embodiments, the relatively smooth regions are aligned with the relatively smooth regions of the neighbouring boards whereby enhanced vertical drainage water flow may be achieved across the system.

[0072] In other embodiments in accordance with any of the preceding embodiments, the respective neighbouring regions of the boards may be staggered.

[0073] In other embodiments, the coarse regions of neighbouring boards may be aligned with the smooth regions of neighbouring boards.

[0074] In other embodiments, the line or rib separating adjacent regions may comprise a number of zig-zags. In other embodiments, the line or rib separating adjacent regions may form a V when viewed in plan view. The angle of the V may be preferably between 30 and 60 degrees.

[0075] The further embodiments of figures 7 to 14 are provided to illustrate in greater detail various advantageous configurations on the outer most exposed surface of the boards.

[0076] Figure 7 shows a full length cladding board generally referenced 22. In this view, the cladding board has a rectangular shape when viewed in plan. The cladding board may have a first extremity 23 and a second extremity 24 opposite to the first extremity. The cladding board has a width between a first lateral edge 25 and a second lateral edge 26 opposite to the first lateral edge. The upper surface of the cladding board has been formed in a moulding process or an extrusion process whereby the upper surface has a number of regions. A first region 27 is provided between lateral edges 25 and 26 and is delimited further by ribs 28 and 29. Thus, first region 27 extends from first lateral edge 25 to second lateral edge 26. By contrast, a further region generally referenced 30 is provided adjacent to the first region. The first and second regions have different textures. In preferred embodiments, both first and second regions are integrally formed in the outermost surface of the cladding board. The first region is configured to be relatively smooth compared to the second region which has a much coarser or rougher surface. In other words, region 27 has a relatively low coefficient of friction whilst region 30 has a much higher coefficient of friction. This is achieved by specifically shaping the respective regions during the manufacturing process, for example, by providing a mould which is configured to provide a smooth surface for region 27 and a relatively coarse surface for region 30. Region 30 has a much higher density of peaks and troughs. The peaks may be formed by strands extending at least partially between the lateral edges of the board. In this embodiment, the strands form a substantially crisscross pattern with the peaks being formed by the upper most parts of the strands whilst the troughs are provided between the strands. As can be seen in Figure 7, region 27 is not entirely smooth and may also have a number of peaks and recesses. These extra recesses further encourage the flow of liquid towards the lateral edge of the board. Optionally, ribs 28 and 29 not only define the first region 27 but also provide an edge so that the region 27 may act as a trough to channel the flow of liquid towards the lateral edges of the board.

[0077] In the close up view of figure 8, troughs 28 and 29 are provided to delimit the relatively smooth region 27. The neighbouring relatively rough region 30 comprises a crisscross pattern of what appears to be a weave like texture. Both the regions are in preferred embodiments formed entirely with the same chemical compositions.

[0078] In the close up view of figure 9, lines of separation 31 and 32 are shown creating a boundary between smooth region 33 and adjacent rough regions 34 and 35 of a cladding board. The darker pigment of this embodiment provides a board which absorbs greater solar energy and thus further improves the achievable rate of drying the outermost surface of the board following rain.

[0079] In a further embodiment as shown in the close up view of figure 10, regions may form a V or bend as illustrated by corner 36. In certain embodiments, the central apex of a board may be configured to coincide with the comer thus encourage flow away from the comer.

[0080] In a further embodiment as shown in the close up view of figure 11, a further board is provided with a succession of relatively smooth regions such as region 37 and relatively rough regions such as region 38. The relatively smooth region 37 has a number of channels such as channel 39 whose boundaries substantially extend towards the edges of the board. The relatively smooth region 37 is separated from relatively rough regions such as region 38 by virtue of discontinuous lines such as lines 40 and 41 of separation forming nevertheless a rib of separation between two adjacent regions. The relative rough region 38 appears to comprise randomly oriented fibres such as might be associated with biologically derived pulp. Both the smooth and rough regions are however in preferred embodiments formed by exactly the same chemical composition whereby only the texture of the upper surface has been changed in order to provide the technical effects discussed herein.

[0081] In a further embodiment as shown in the close up view of figure 12, a further board may comprise adjacent regions such as regions 42 and 43. Region 42 may be smoother than region 43. The regions have a perceptible curvilinear line of separation between adjacent regions with in preferred embodiments the line extending substantially laterally from a middle portion 44 of the board towards the edges such as edge 45.

Claims

CLAIMS1. A decking plank having a rectangular shape with the length of the plank extending between a first extremity and a second extremity opposite to the first extremity; the width of the plank being provided between a first lateral edge and a second lateral edge opposite to the first lateral edge; the decking plank comprising a composite of largely polymeric material and filler; the upper surface of the decking plank being formed with a first region extending from the first lateral edge to the second lateral edge and a second region extending from the first lateral edge to the second lateral edge; wherein the first region comprises a relatively smooth surface and the second region comprises a surface which is coarser than the relatively smooth surface of the first region; the first region and the second region being separated by a rib which extends between the first lateral edge and the second lateral edge; whereby, in use, water falling on the upper surface of the plank drains substantially laterally towards lateral edges of the plank.

2. The decking plank according to claim 1, comprising at least a third region which is also coarser than the first region; the first region being located between the second and third regions; the first region having a further rib between the first region and the third region; whereby the first region forms a trough to allow, in use, water falling on the upper surface of the plank to drain towards the lateral edge of the plank.

3. The decking plank according to either claim 1 or claim 2, wherein the second region comprises closely contiguous repeating peaks and troughs.

4. The decking plank according to claim 3, wherein the second region comprises a density of greater than 10 peaks per square centimetre of the region.

5. The decking plank according to any one of the preceding claims, wherein the second region has a first number of strands with a principal longitudinal axis parallel to the rib; and further strands at an angle from the first number of strands; whereby troughs are formed between the strands.

6. The decking plank according to claim 5, wherein strands are perpendicular to one another and the troughs formed therebetween are rectangular.

7. The decking plank according to any one of the preceding claims, wherein both the first and the second region have curved strands; whereby the curved strands in the first region are flatter in relief than the curved strands of the second region.

8. The decking plank according to any one of the preceding claims, wherein the first region reflects more light than the second region.

9. The decking plank according to any one of the preceding claims, wherein the rib between first and second regions forms a curved line between the first lateral edge and the second lateral edge of the plank.

10. The decking plank according to any one of the preceding claims, wherein the first region and / or the second region are bowed in cross- section with the apex of the bow being at a central portion of the board whereby, in use, water drains from the apex to the lateral edges of plank.

11. The decking plank according to any one of the preceding claims, wherein the lateral edges of the plank have themselves a plurality of peaks and troughs along the edges or part thereof.

12. A decking system comprising a plurality of decking planks in accordance with any one of the preceding claims, wherein the first and second regions of a first plank are provided in line with the corresponding first and second regions of the second plank; and a gap is provided between adjacent planks through which water drains.

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