Composite Decking Plank With Soft Slip-Resistant Outer Layer
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Solution Overview
Problem
Conventional decking planks either require laying flat for support, are not slip-resistant, or have abrasive surfaces, and may be prone to splintering, fungal growth, and flammability, especially when wet.
Innovation Solution
A decking plank design featuring a hard core with one or more soft, homogeneous layers providing cushioning and slip resistance, potentially resembling real wood or stone, with integrated heating and electrical components, and a design that allows for secure installation without separate adhesives or releasable attachments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a hard outer shell is used to protect a soft inner portion, then structural strength is improved, but slip resistance and comfort deteriorate
Solution Approach 1:
The patent inverts the conventional decking structure by placing a soft cushioning layer on the outer surface that contacts the user, while the hard structural core is positioned inside. This reversal simultaneously provides structural strength from the hard core and slip resistance plus comfort from the soft outer layer, resolving the contradiction between strength and ease of operation.
Solution Approach 2:
The patent employs composite materials by combining a hard structural core material with a soft cushioning layer material. This composite structure allows the decking to exhibit both the strength characteristics of the hard material and the comfort/slip resistance characteristics of the soft material, thereby resolving the contradiction between structural strength and user comfort.
2Ease of operation
If an abrasive surface is used to improve slip resistance, then friction is improved, but comfort and user experience deteriorate
Solution Approach 1:
The patent changes the surface parameter from abrasive to soft and cushioning. By selecting a soft material for the outer layer with appropriate surface properties, the patent achieves slip resistance through increased friction without the harmful abrasiveness of traditional abrasive surfaces, thus improving comfort while maintaining slip resistance.
3Ease of manufacture
If conventional materials are used for decking, then ease of manufacture is improved, but fire resistance and durability deteriorate
Solution Approach 1:
The patent uses composite materials where the hard core can be made from fire-resistant and durable materials such as treated wood, metal, or composite lumber, while the soft outer layer provides additional protection and comfort. This composite approach maintains ease of manufacture through established materials while significantly improving fire resistance and overall durability.
Data Source
AI summary
A decking plank (1) comprising a core (2) which acts as a support beam, one or more layers (3,4) bonded to said core without the use of releasable attachment means and one or the layer being an outer slip resistant covering layer with a relief; characterised in that at least one of said layers (3) is relatively soft compared to said core which is relatively hard; whereby the core acts as a support beam and said at least one layer has a cushioning effect.