Composite Deck Board With Artificial Turf and Built-In Drainage
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Solution Overview
Problem
Traditional deck systems face issues with durability, drainage, and customization, particularly in marine environments, and often require virgin materials, lacking recyclability and effective moisture resistance.
Innovation Solution
A deck board system featuring extruded or pultruded panels with internal reinforcement strips, drainage channels, and a chemically bonded artificial turf layer, allowing for modular assembly and easy installation, using recycled materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional wood construction is used, then ease of manufacture and aesthetic appeal are improved, but durability and resistance to rot/decay worsen
Solution Approach 1:
The patent uses composite materials consisting of a core layer (wood fiber, plastic, or metal) surrounded by a protective outer layer. This composite structure combines the ease of manufacture and aesthetic appeal of wood with the durability and rot resistance of synthetic materials, resolving the contradiction between traditional wood construction and modern durability requirements.
2Ease of manufacture
If traditional wood construction is used, then ease of manufacture is improved, but resistance to moisture and environmental damage worsens
Solution Approach 1:
The composite construction with synthetic outer layers provides inherent moisture and environmental resistance while maintaining ease of manufacture. The protective outer layer acts as a barrier against moisture and decay, eliminating the need for continuous sealing and maintenance.
Solution Approach 2:
The patent changes the material parameters from natural wood to synthetic-composite materials, fundamentally altering the moisture absorption and decay resistance properties while preserving manufacturing ease through standardized production processes.
3Reliability
If fiberglass reinforced plastic panels are used, then strength and durability are improved, but ease of installation and bonding complexity worsen
Solution Approach 1:
The patent segments the deck system into modular components including the composite board, support structure, and drainage elements. This segmentation allows for easier installation compared to monolithic FRP panels, as each component can be independently positioned and assembled using standardized connection methods.
Solution Approach 2:
The patent introduces intermediary elements such as support beams, connection brackets, and drainage components that facilitate the installation process. These intermediaries simplify the assembly of the overall structure, making it easier to install while maintaining the strength and durability of the FRP materials.
4Productivity
If rapid install deck solutions are used, then installation speed is improved, but drainage capability and durability worsen
Solution Approach 1:
The patent merges the drainage function directly into the composite board structure by incorporating drainage channels and cavities within the board itself. This integration allows rapid installation of the entire deck system while ensuring effective drainage capability, as the drainage features are built-in rather than requiring separate installation steps.
Solution Approach 2:
The composite board serves multiple functions simultaneously: structural support, aesthetic surface, and drainage system. This multi-functionality eliminates the need for separate drainage components, enabling rapid installation while maintaining reliable drainage capability through the integrated design.
5Strength
If virgin materials are used, then structural integrity is improved, but recyclability and environmental sustainability worsen
Solution Approach 1:
The patent designs the composite deck system with recyclability in mind, allowing components to be disassembled and recovered at the end of their service life. The modular construction enables selective replacement and recycling of materials, reducing waste and environmental impact while maintaining structural integrity during the operational phase.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system provides enhanced durability, effective drainage, and aesthetic customization options while being recyclable, reducing material waste and maintenance needs.
Implementation Method 1
drainage channels, and a chemically bonded artificial turf layer
Implementation Method 2
a chemically bonded artificial turf layer
Data Source
AI summary
A deck board system for integrating artificial turf and drainage features includes a plurality of deck board panels, each with an extruded or pultruded panel body featuring an internal screw boss, an internal reinforcement strip, an overhang, a ledge, drainage openings on the topside, and underside openings. The system further comprises a finishing feature and an artificial turf layer. The overhang engages with adjacent panels, while the finishing feature straddles at least two panels and engages with the overhang. The artificial turf layer covers one or more deck board panels, providing a seamless and functional deck surface with integrated drainage capabilities.