Convex Wood Boards for Outdoor Decking to Reduce Cupping
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Solution Overview
Problem
Conventional wood boards for outdoor decking are prone to cupping, leading to uneven surfaces and reduced durability, especially when installed with the bark side upwards, and non-professionals struggle to select suitable boards, resulting in time-consuming and costly efforts.
Innovation Solution
The wood boards are sawn near the bark side with a convex profile, treated with a chemical preservation method, and have dimensions and curvature adapted for easy installation, ensuring rapid water drainage and reduced cupping risk.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If wood boards are flat sawn near the bark side (sapwood), then more of the log can be used and material waste is reduced, but the boards become unstable with larger growth rings leading to increased cupping and unpredictable forms
Solution Approach 1:
The wood boards are pre-profiled with a convex shape before installation. This preliminary action compensates for the expected cupping that will occur as the bark-side-up boards dry and shrink, ensuring the top surface remains convex and functional throughout the board's service life
Solution Approach 2:
The invention changes the geometric parameter of the board from flat to convex by pre-profiling. This parameter change counteracts the natural shrinkage and cupping tendency of sapwood boards, maintaining the desired surface geometry despite the inherent instability of using bark-side lumber
2Ease of operation
If wood boards are mounted with the bark side upwards, then installation is simpler, but the upper side becomes concave causing water accumulation and uneven walking surfaces
Solution Approach 1:
The boards are pre-profiled with a convex shape before installation, so that when installed bark-side up, the convex profile ensures the top surface remains convex after drying and cupping occurs, preventing water accumulation while maintaining simple installation procedures
Solution Approach 2:
The convex pre-profiling creates an opposing geometric condition that counteracts the expected concave deformation from cupping. This preliminary anti-action ensures that even though the board will cup and shrink, the top surface remains convex and functional
3Adaptability or versatility
If non-professionals select wood boards for decking, then installation flexibility is increased, but selection errors lead to incorrect board orientation and reduced deck lifetime
Solution Approach 1:
The convex pre-profiling creates an asymmetric shape where only one orientation (bark side up) will result in a convex top surface after drying. This asymmetric geometry provides a self-checking mechanism that guides correct installation even for non-professionals, as installing the board incorrectly would result in an obvious concave top surface
Solution Approach 2:
The pre-profiled convex shape enables the board to self-correct and self-verify its orientation. The board's geometry itself provides the information needed for correct installation, eliminating the need for external expertise in selecting or orienting the boards
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 convex profile reduces the risk of incorrect installation, increases durability, and ensures uniform quality, reducing environmental impact and extending the deck's lifetime.
Implementation Method 1
The wood boards are prefabricated in various dimensions and has preferably been treated by a chemical preservation method, often using a pressure treatment including the copper preservative technology, that extends the durability when exposed for water.
Implementation Method 2
Thanks to the prefabricated convex profile, rapid water draining from the surface of the board is ensured.
Data Source
AI summary
The present invention relates to a wood board (1) for outdoor decking (8) use, which board has been sawn from lumber close to bark side of the lumber, with a thickness in the range from about 10 mm up to about 32 mm, the wood board (1) comprises a first side (2) and an opposing second side (4), the first side (2) can be arranged as an upper side of the wood board (1) and the second side (4) can be arranged as a lower side of the wood board (1), or vice versa, between the first side (2) and the second side (4) the board (1) has two opposite short sides (9, 11). The wood board (1) is provided with a convex first side (2) and a convex second side (4).