Thermoplastic Deck Covering with Carbon-Black Adhesive
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Solution Overview
Problem
Current deck materials, such as plastic, wood, and composite decks, require frequent and costly maintenance to prevent deterioration and discoloration, and lack materials with adequate permanent adhesion for deck coverings that are fade and rot resistant.
Innovation Solution
The development of deck coverings made from thermoplastic material with a butyl rubber adhesive heavily loaded with carbon black, featuring a 'peel-and-stick' design and textured surfaces for non-slip functionality, which can be easily applied to various deck materials and designed to simulate wood patterns, providing water resistance and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional deck materials (plastic, wood, composite) are used, then initial deck structure is achieved, but frequent maintenance is required to prevent deterioration and discoloration
Solution Approach 1:
The patent uses a composite material system consisting of a thermoplastic polymer layer combined with a pressure-sensitive adhesive layer containing butyl rubber and carbon black. This composite structure provides both durability and weather resistance, eliminating the need for frequent maintenance while maintaining structural integrity.
Solution Approach 2:
The patent modifies the chemical composition parameters of the adhesive layer by incorporating heavily carbon-black-loaded butyl rubber, which changes the adhesive's properties to provide permanent, weather-resistant bonding. This parameter change enables the covering to maintain its bond without degradation over time.
2Reliability
If deck coverings are applied to protect against elements, then protection against water damage and discoloration is achieved, but adequate permanent adhesion was not achievable with known materials
Solution Approach 1:
The patent employs a composite adhesive system combining butyl rubber polymer with heavy carbon black loading. This composite provides both strong initial adhesion and long-term weather resistance, achieving permanent bonding that known materials could not accomplish.
Solution Approach 2:
The patent applies different material properties to different layers: the thermoplastic layer provides weather protection and aesthetic appearance, while the specially formulated adhesive layer provides permanent bonding. This local differentiation of material qualities achieves both protection and permanent adhesion.
3Reliability
If thermoplastic material with butyl rubber adhesive is used, then secure permanent adhesion is achieved, but the covering must be easily applied with peel-and-stick design
Solution Approach 1:
The patent divides the covering into distinct functional layers: a thermoplastic polymer layer for weather resistance and aesthetics, and a separate pressure-sensitive adhesive layer for application. This segmentation allows the adhesive to be applied in a user-friendly peel-and-stick format while maintaining strong bonding performance.
Solution Approach 2:
The patent replaces complex mechanical bonding systems (screws, clips, adhesives requiring mixing or activation) with a pressure-sensitive adhesive system that bonds through simple pressure application. This substitution maintains secure adhesion while dramatically simplifying the application process.
4Reliability
If the top surface is textured for non-slip functionality, then safety is improved, but the manufacturing process becomes more complex
Solution Approach 1:
The patent combines the aesthetic pattern layer and the non-slip textured surface into a single integrated thermoplastic layer. This merging is achieved through co-extrusion or embossing techniques that create both visual patterns and tactile texture in one manufacturing step, maintaining ease of manufacture while providing safety benefits.
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 deck coverings offer long-lasting, low-maintenance solutions that resist fading, warping, and cracking, maintaining a vibrant appearance and functionality with minimal effort, while ensuring secure adhesion and water runoff.
Implementation Method 1
The deck coverings are comprised of a thermoplastic material and a butyl rubber adhesive which has been heavily loaded with carbon black
Implementation Method 2
the top surface is textured to provide a non-slip surface
Implementation Method 3
The coverings have curved longitudinal edges, which allow them to cover the surface of the deck planks in their entirety; thereby providing a more visually appealing deck, and offering a means to direct water away from the underlying deck substrate
Implementation Method 4
The deck coverings of this invention are highly water resistant and can shield the underlying deck from water damage and consequential warping
Data Source
AI summary
The subject invention discloses a deck covering having a top surface, a bottom surface, a front side longitudinal edge and a back side longitudinal edge, wherein the deck covering is comprised of a thermoplastic material, wherein the top surface is textured to provide a non-slip surface, wherein the bottom surface is covered with a peel and stick adhesive, wherein the front side longitudinal edge is curved downwardly, and wherein the back side longitudinal edge is curved downwardly. The peel and stick adhesive is preferably a butyl rubber adhesive which is preferably heavily loaded with carbon black.