|
|
United States Patent
|
7,617,791 |
|
Gribble |
November 17, 2009
|
Simulated wood surface covering
for decks and floors
Abstract
The present invention relates to
a simulated wood surface covering which is particularly useful
in decking and flooring applications, said simulated wood
surface covering being comprised of strips adapted to be
interconnected aside of each other thereby forming an assembled
simulated wood surface covering of desired dimensions to cover a
substrate, wherein the strips are adapted to be interconnected
through shiplaps having tongues and rabbets, wherein the rabbets
have an included angle which is within the range of 70.degree.
to 89.degree., wherein the strips are comprised of a plastic
composition which is comprised of polyvinyl chloride, a
non-migrating plasticizer, and a coloring agent, wherein the
strips have sufficient flexibility to conform to curved surfaces
and to surface irregularities, wherein the upper surface of the
strips are roughened to imitate the grain structure of wooden
material.
|
Inventors: |
Gribble; William R.
(Bath, OH) |
|
Assignee: |
Plasteak, Inc.
(Copley, OH)
|
|
Appl. No.: |
12/017,089 |
|
Filed: |
January 21, 2008 |
|
Current U.S. Class: |
114/85
; 114/357; 52/309.16; 52/592.1 |
|
Current International Class:
|
B63B 5/08 (20060101) |
|
Field of Search:
|
52/578,590.2,591.2,592.2,592.6,582.1,586.1,589.1,309.16,177
114/85,357 523/171 521/131 156/78 |
References
Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
| |
|
|
|
|
|
| |
988022 |
|
Apr., 1976 |
|
CA |
| |
2365880 |
|
Feb., 2002 |
|
GB |
| |
WO2006/102101 |
|
Sep., 2006 |
|
WO |
| |
Other References
Sales literature from Marinedeck.RTM. 2000 Exterior
synthetic marine flooring. cited by other. |
Primary Examiner: Chilcot, Jr.; Richard E
Assistant Examiner: Nguyen; Chi Q
Attorney, Agent or Firm:
Rockhill; Alvin T.
Claims
What is claimed is:
1. A simulated wood surface covering which is particularly
useful in decking and flooring applications, said simulated wood
surface covering being comprised of strips adapted to be
interconnected aside of each other thereby forming an assembled
simulated wood surface covering of desired dimensions to cover a
substrate, wherein the strips are adapted to be interconnected
through shiplaps having tongues and rabbets, wherein there is an
interstices between the tongues and rabbets, wherein the rabbets
have an included angle which is within the range of 70.degree.
to 89.degree., wherein the strips are comprised of a plastic
composition which is comprised of polyvinyl chloride, a
non-migrating plasticizer, and a coloring agent, wherein the
strips have sufficient flexibility to conform to curved surfaces
and to surface irregularities, wherein an upper surface of the
strips are roughened to imitate a grain structure of wooden
material.
2. The simulated wood surface covering as specified in claim 1
wherein the strips do not include longitudinal slots.
3. The simulated wood surface covering as specified in claim 1
wherein the non-migrating plasticizer is a powdered nitrile
rubber.
4. The simulated wood surface covering as specified in claim 1
wherein the non-migrating plasticizer is present at a level
which is within the range of about 5 to about 60 parts by weight
per 100 parts by weight of plastic.
5. The simulated wood surface covering as specified in claim 1
wherein the non-migrating plasticizer is a liquid copolymer of
acrylonitrile and 1,3-butadiene.
6. The simulated wood surface covering as specified in claim 1
wherein a fabric is bonded to an underside of the strips.
7. The simulated wood surface covering as specified in claim 1
wherein the strips are glued together.
8. The simulated wood surface covering as specified in claim 7
wherein glue is utilized to interconnected the tongues and
rabbets of the strips.
9. The simulated wood surface covering as specified in claim 7
wherein glue is present in the interstices between the tongues
and rabbets of the strips.
10. The simulated wood surface covering as specified in claim 1
wherein the plastic composition is further comprised of a
streaking agent.
11. The simulated wood surface covering as specified in claim 1
wherein the upper surface of the strips are roughened by sanding
with a sandpaper of 40 grit or lower.
12. The simulated wood surface covering as specified in claim 1
wherein an upper surface of the strips are roughened by sanding
with a sandpaper of 35 grit or lower.
13. The simulated wood surface covering as specified in claim 1
wherein the upper surface of the strips are roughened by sanding
with 36 grit sandpaper.
14. The simulated wood surface covering as specified in claim 1
wherein the plastic composition is further comprised of an
anti-fungal agent.
15. The simulated wood surface covering as specified in claim 1
wherein the plastic composition is further comprised of an ultra
violet light stabilizer.
16. The simulated wood surface covering as specified in claim 1
wherein the non-migrating plasticizer is present at a level
which is within the range of about 10 to about 30 parts by
weight per 100 parts by weight of plastic.
17. The simulated wood surface covering as specified in claim 1
wherein the simulated wood surface covering is glued to the deck
of a boat.
18. The simulated wood surface covering as specified in claim 1
wherein the rabbets have an included angle which is within the
range of 80.degree. to 89.degree..
19. The simulated wood surface covering as specified in claim 1
wherein the rabbets have an included angle which is within the
range of 85.degree. to 88.degree..
20. A method of affixing a simulated wood surface covering to a
substrate which comprises providing (1) a simulated wood surface
covering which is comprised of a simulated wood surface covering
which is particularly useful in decking and flooring
applications, said simulated wood surface covering being
comprised of strips adapted to be interconnected aside of each
other thereby forming an assembled simulated wood surface
covering having the dimensions of the substrate, wherein the
strips are adapted to be interconnected through shiplaps having
tongues and rabbets, wherein the rabbets have an included angle
which is within the range of 70.degree. to 89.degree., wherein
there is a joint between the tongues and rabbets of the strips
of the assembled simulated wood surface, wherein the strips are
comprised of a plastic composition which is comprised of
polyvinyl chloride, a non-migrating plasticizer, and a coloring
agent, wherein the strips have sufficient flexibility to conform
to curved surfaces and to surface irregularities, wherein an
upper surface of the strips are roughened to imitate a grain
structure of wooden material; (2) applying glue to the substrate
and to the joint between the tongues and rabbets of
interconnected strips; (3) laying the simulated wood surface
onto the substrate; and (4) pushing the simulated wood surface
covering into the deck so that the glue firmly adheres the
simulated wood surface covering to the substrate.
21. A simulated wood surface covering which is particularly
useful in decking and flooring applications, said simulated wood
surface covering being comprised of strips adapted to be
interconnected aside of each other thereby forming an assembled
simulated wood surface covering of desired dimensions to cover a
substrate, wherein the strips are adapted to be interconnected
through shiplaps having tongues and rabbets, wherein there is an
interstices between the tongues and rabbets, wherein the rabbets
have an included angle which is within the range of 70.degree.
to 89.degree., wherein the strips do not include longitudinal
slots, wherein the strips are comprised of a plastic composition
which is comprised of polyvinyl chloride, a non-migrating
plasticizer, and a coloring agent, wherein the non-migrating
plasticizer is present at a level of at least about 5 php to
provide the strips with sufficient flexibility to bend around
curved surfaces and to conform to irregular surfaces, wherein an
upper surface of the strips are roughened to imitate a grain
structure of wooden material, and wherein a bottom surface of
the strips have a smooth surface.
Description
FIELD OF THE INVENTION
The present invention relates to a shape conforming simulated
wood surface covering useful for covering a floor surface, such
as a boat or yacht deck, floor boards in boats and yachts, bath
and shower room floors, or swimming pool surroundings. The
simulated wood surface coverings of this invention are formed of
strips of a plastic composition which is comprised of polyvinyl
chloride, a non-migrating plasticizer, and a coloring agent,
wherein the strips have sufficient flexibility to conform to
curved surfaces and to surface irregularities. The upper surface
of the simulated wood surface is roughened to imitate the grain
structure of wooden material, such as a deck made of teak,
mahogany, or Oregon pine (wood of the Douglas fir).
BACKGROUND OF THE INVENTION
The decks of boats and yachts are frequently covered with wood,
such as teak, mahogany, or Oregon pine. Teak wood is the most
commonly used wood on pleasure boats for this purpose because it
can typically be bent to conform to curved deck surfaces and to
cover surface defects. Teak wood also provides a beautiful
surface having relatively good anti-slip characteristics under
both dry and wet conditions. Teak further offers the advantage
of containing natural oils which help prevent it from rotting
under the conditions of a marine environment, such as frequent
exposure to water.
The naturally occurring oils in teak unfortunately cause it to
turn grey or black over time. This is because mold and mildew
feed upon the very oils that protect the teak wood from
deterioration. A high level of maintenance is accordingly
required to keep teak decks from discoloring due to the growth
of mold and mildew. This optimally involves cleaning the teak
wood to remove any mold or mildew causing discoloration at its
first appearance and killing any remaining mold or mildew spores
to inhibit further growth of the mold and mildew.
The most effective technique for cleaning teak wood is a three
step process. The first step of the cleaning process normally
involves the application of a relatively strong acid to remove
the mold/mildew and to kill the spores associated with the
therewith. Then, a neutralizer is applied and finally the teak
is rinsed with clean water. This cleaning technique relies upon
the use of a harsh acid that can damage the teak by raising the
wood grain and making the surface of the wood rougher.
Accordingly, the use of this technique normally reduces the
service life of the teak deck.
A two step process can also be used to clean discolored teak
wood decks. In this two-step technique a mild cleaner is worked
into the teak wood with a bristle brush. The mild cleaner is
then allowed to stand on the surface of the teak wood deck for a
few minutes and then it is rinsed off. It is necessary to rub
the surface of the teak deck with steel wool or a metal brush in
the direction of the grain as the cleaner is being rinsed off.
It is necessary to repeat this process on areas of the deck
where stubborn discoloration persists. This two step process
relies upon a tremendous amount of physical labor and can
accurately be depicted as brutal work. It also can lead to
deterioration of the teak due to the repeated rubbing action
that is relied upon to adequately clean the wood.
After teak decks have been cleaned to remove mold and mildew
they should be oiled and sealed to further improve their
appearance. Organic oils are typically used for this purpose and
replenish the oil lost to the environment and during the
cleaning process. The oil will penetrate into the wood to help
restore its original satiny finish. However, this oil provides
more nutrients for the mold and mildew that caused the
discoloration in the first place. In other words, the process of
cleaning and oiling a teak deck develops into a never ending
vicious cycle. To make matters worse teak decks require major
work or replacement on the average of every four to six years.
U.S. Pat. No. 6,811,628 discloses a method of finishing a wood
surface, such as teak or mahogany, for exterior exposure of the
wood using a finishing film material in the form of a sheet. The
finishing film comprises a flexible polymeric sheet material
having a first major surface and a second major surface and a
pressure sensitive adhesive layer covering at least a portion of
the first major surface of the sheet material. The finishing
film is adhered to the surface to the wood surface by the
adhesive layer. This method is reported to be particularly
suitable for the finishing of brightwork on boats, for example,
teak or mahogany brightwork. The method of U.S. Pat. No.
6,811,628 is also reported to be particularly suitable for
finishing curved and/or compound curved surfaces due to the
flexibility and elongation of the finishing film.
U.S. Pat. No. 6,895,881 discloses a shape conforming surface
covering useful for covering any type of surfaces, characterized
in that the surface covering comprises planks or sheet of a
flexible material adapted to be interconnected aside of each
other thereby forming an assembled surface covering of optional
length and width, and which planks are of a material that can be
laid in curved formations, and which at the upper surface of the
covering is roughened so as to imitate any unique grain effect
of wooden material, further characterized in that the planks or
sheet are formed with longitudinal slots at the underside
thereof for facilitating forming of curved coverings and for
acting as a base for a glue or adhesive material by means of
which the surface covering is mounted on a surface recipient.
U.S. Pat. No. 6,895,881 indicates that the planks can be made of
a plastic or resin material, such as polyvinyl chloride, and can
be made to imitate the color and grain structure of wooden
material, such as teak, mahogany, pine, or redwood.
SUMMARY OF THE INVENTION
The simulated wood surface covering of this invention offers
numerous advantages over conventional wooden coverings for
utilization in covering the decks of boats and yachts. For
instance, it is highly water resistant, easily washable (even
with high pressure jet washers that damage conventional wood
surfaces), stain resistant; mar and scuff resistant, easy to
assemble; easy to lay on curved or irregular surfaces, and
offers excellent anti-slip characteristics under both dry and
wet conditions. It also offers a very low maintenance
alternative to wood surfaces, such as teak wood. The simulated
wood surface coverings of this invention can also be installed
on the deck of a boat much more easily and with lower labor
requirements than can the plastic surface coverings of the prior
art. The installation of the simulated wood surface coverings of
this invention on a curved or irregular surface is also a much
more forgiving process.
The present invention more specifically discloses a simulated
wood surface covering which is particularly useful in decking
and flooring applications, said simulated wood surface covering
being comprised of strips (planks) adapted to be interconnected
aside of each other thereby forming an assembled simulated wood
surface covering of desired dimensions to cover a substrate,
wherein the strips are comprised of a plastic composition which
is comprised of polyvinyl chloride, a non-migrating plasticizer,
and a coloring agent, wherein the strips have sufficient
flexibility to conform to curved surfaces and to surface
irregularities, wherein the upper surface of the strips are
roughened to imitate the grain structure of wooden material,
wherein a pressure sensitive adhesive covers the underside of
the strips, and wherein the pressure sensitive adhesive is
covered by a backing so that the pressure sensitive adhesive is
sandwiched between the strips and the backing.
The present invention further reveals a simulated wood surface
covering which is particularly useful in decking and flooring
applications, said simulated wood surface covering being
comprised of strips adapted to be interconnected aside of each
other thereby forming an assembled simulated wood surface
covering of desired dimensions to cover a substrate, wherein the
strips are comprised of a plastic composition which is comprised
of polyvinyl chloride, a non-migrating plasticizer, and a
coloring agent, wherein the strips have sufficient flexibility
to conform to curved surfaces and to surface irregularities,
wherein the upper surface of the strips are roughened to imitate
the grain structure of wooden material, and wherein a fabric is
bonded to the underside of the strips.
The subject invention also discloses a method of affixing a
simulated wood surface covering to a deck of a boat which
comprises providing (1) a simulated wood surface covering which
is comprised of a simulated wood surface covering which is
particularly useful in decking and flooring applications, said
simulated wood surface covering being comprised of strips
adapted to be interconnected aside of each other thereby forming
an assembled simulated wood surface covering having the
dimensions of the substrate, wherein the strips are comprised of
a plastic composition which is comprised of polyvinyl chloride,
a non-migrating plasticizer, and a coloring agent, wherein the
strips have sufficient flexibility to conform to curved surfaces
and to surface irregularities, wherein the upper surface of the
planks are roughened to imitate the grain structure of wooden
material, wherein a pressure sensitive adhesive covers the
underside of the strips, and wherein the pressure sensitive
adhesive is covered by a backing so that the pressure sensitive
adhesive is sandwiched between the strips and the backing; (2)
removing the backing from the underside of the strips; (3)
laying the simulated wood surface onto the deck; and (4) pushing
the simulated wood surface covering (which is typically in the
form of a sheet) into the deck so that the pressure sensitive
adhesive firmly adheres the simulated wood surface covering to
the substrate.
The subject invention further reveals a simulated wood surface
covering which is particularly useful in decking and flooring
applications, said simulated wood surface covering being
comprised of strips adapted to be interconnected aside of each
other thereby forming an assembled simulated wood surface
covering of desired dimensions to cover a substrate, wherein the
strips are adapted to be interconnected through shiplaps having
tongues and rabbets, wherein the rabbets have an included angle
which is within the range of 70.degree. to 89.degree., wherein
the strips are comprised of a plastic composition which is
comprised of polyvinyl chloride, a non-migrating plasticizer,
and a coloring agent, wherein the strips have sufficient
flexibility to conform to curved surfaces and to surface
irregularities, wherein the upper surface of the strips are
roughened to imitate the grain structure of wooden material.
The present invention also discloses a method of affixing a
simulated wood surface covering to a substrate which comprises
providing (1) a simulated wood surface covering which is
comprised of a simulated wood surface covering which is
particularly useful in decking and flooring applications, said
simulated wood surface covering being comprised of strips
adapted to be interconnected aside of each other thereby forming
an assembled simulated wood surface covering having the
dimensions of the substrate, wherein the strips are adapted to
be interconnected through shiplaps having tongues and rabbets,
wherein the rabbets have an included angle which is within the
range of 70.degree. to 89.degree., wherein there is a joint
between the tongues and rabbets of the strips of the assembled
simulated wood surface, wherein the strips are comprised of a
plastic composition which is comprised of polyvinyl chloride, a
non-migrating plasticizer, and a coloring agent, wherein the
strips have sufficient flexibility to conform to curved surfaces
and to surface irregularities, wherein the upper surface of the
strips are roughened to imitate the grain structure of wooden
material; (2) applying glue to the substrate and to the joint
between the tongues and rabbets of interconnected strips; (3)
laying the simulated wood surface onto the substrate; and (4)
pushing the simulated wood surface covering into the deck so
that the glue firmly adheres the simulated wood surface covering
to the substrate. In such applications the substrate will
commonly be the deck of a boat or flooring in proximity to a
swimming pool.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a fragmentary perspective view of a strip of simulated
wood surface covering which is affixed to a substrate, such as
the deck of a boat, with a pressure sensitive adhesive.
FIG. 2 is a fragmentary perspective view of a strip of simulated
wood surface covering which is affixed to a substrate, and which
shows the pressure sensitive adhesive which is sandwiched
between the strip and the substrate to affix the strip to the
substrate.
FIG. 3 is a fragmentary perspective view of a strip of simulated
wood surface covering which is affixed to a substrate wherein a
fabric layer is sandwiched between the strip and the substrate
to compensate for surface irregularities on the substrate.
FIG. 4 is a fragmentary perspective view of a strip of simulated
wood surface covering which is affixed to a substrate and which
shows a fabric layer that is sandwiched between the strip and
the substrate to compensate for surface irregularities on the
substrate.
FIG. 5 is a cross-sectional view of a simulated wood surface
covering having a carrier layer for the adhesive used therein.
FIG. 6 is a perspective end view of two strips of simulated wood
surface covering of a preferred shiplap design that are oriented
for interconnection to form an assembled simulated wood surface
covering on a substrate, such as the deck of a boat.
FIG. 7 is a perspective end view of a strip of simulated wood
surface covering of a preferred design showing the angle
.theta., at which the grooves of the shiplaps project into the
body of the simulated wood strips. The angle .theta. has been
exaggerated in FIGS. 6 and 7 for ease of illustration.
FIG. 8 is a perspective end view of two strips of simulated wood
surface covering of a preferred shiplap design that are
interconnected to form an assembled simulated wood surface
covering on a substrate.
DETAILED DESCRIPTION OF THE INVENTION
The simulated wood surface coverings of the present invention
can be utilized as coverings in virtually any decking or
flooring application. However, the simulated wood surface
coverings of this invention are of particular value in decking
and flooring applications where frequent exposure to water is
contemplated. For instance, the simulated wood surface coverings
of this invention can beneficially be utilized as the floor
covering for bathrooms, shower rooms, swimming pool
surroundings, and outdoor decks. The simulated wood surface
coverings of the present invention are of particular value for
covering the decks of boats. These simulated wood surface
coverings can be used in covering deck surfaces on the exterior
or in the interior of the boat. For instance, they can be used
on the aft deck, forward deck, fly bridge deck, and cockpit
deck, side deck walkways, interiorly on the floors in the salon
and galley, and on any other exterior or interior deck surfaces.
The simulated wood surface covering is comprised of strips that
are adapted to be interconnected at their sides to form an
assembled simulated wood surface covering of the desired
dimensions to cover a substrate such as a deck of a boat. The
strips can be designed to include tongues and grooves to
facilitate their interconnection in a side by side manner. Such
a strip 1 is shown in FIG. 1 wherein the strip includes a tongue
2 and a groove 3. The strips can also be adapted to allow for
them to be welded together through the application of heat. In
any case, the strips are adapted to be connected edge to edge in
any desired combination to form the desired size and shape of
the surface to be covered. These strips have sufficient
flexibility to allow for them to bend and conform to curved
substrate surfaces. In some cases it is desirable to heat the
strips to an elevated temperature so that they are more
malleable in cases where the strips need to be bent
significantly. Since the strips of this invention provide
excellent flexibility, it is typically not necessary to include
seams for caulking to attain a relatively stress free surface.
Accordingly, the simulated wood surface coatings of this
invention normally have simulated caulking strips for aesthetic
purposes. These strips can be designed to be of a different
color imitating seams of the type used in applying wooden decks
on a boat. The color of such stripes will typically be black or
some other color which can be easily controlled through the use
of a pigment or colorant such as carbon black or titanium
dioxide.
The strips will typically be manufactured by the extrusion of a
plastic composition. These strips will preferably include a
matching locking means along the longitudinal edges thereof,
preferably a groove (mortise) and tenon means. Such a design is
typically preferable in "do it yourself" applications. However,
in professional operations it is typically preferred to weld the
individual strips together in forming the simulated wood surface
covering of the desired size and shape.
The plastic composition utilized in manufacturing the strips is
comprised of polyvinyl chloride (PVC), a non-migrating
plasticizer, and a coloring agent (an organic compound or an
inorganic pigment). A streaking agent can also be added to the
plastic composition to provide the simulated wood surface with a
more realistic appearance. The non-migrating plasticizer can be
selected from an array of suitable materials. For instance, the
non-migrating plasticizer can be a polymer prepared by reacting
one or more dicarboxylic acids with one or more glycols. Such
polymeric plasticizers can be synthesized by reacting a
dicarboxylic acid containing from about 5 to about 10 carbon
atoms with a glycol containing from 2 to about 4 carbon atoms.
For instance, suitable polymeric plasticizers can be made by
reacting phthalic acid, isophthalic acid, terephthalic acid,
glutaric acid, adipic acid, azelaic acid or sebacic acid with
ethylene glycol or propylene glycol. These polymeric
non-migrating plasticizers will typically have a viscosity which
is within the range of about 1,000 cps to about 160,000 cps.
Liquid copolymers of acrylonitrile and 1,3-butadiene (liquid NBR)
can also be beneficially utilized as non-migrating plasticizers
in the practice of this invention. Tri(ethylhexyl)trimellitate (TEHTM)
is another representative example of a non-migrating plasticizer
that can be used in the practice of this invention. It is
typically preferred to utilize a powdered nitrile rubber as the
non-migrating plasticizer.
The non-migrating plasticizer will typically be present in the
plastic composition at a level which is within the range of
about 5 php to about 60 php (parts per hundred parts by weight
of plastic). At levels of less than about 5 php, strips of the
simulated wood do not have sufficient flexibility to bend around
curved surfaces or to conform to irregular surfaces. On the
other side of the coin, at levels of greater than about 60 php
the composition becomes too soft and is not durable enough for
utilization as a flooring material. It is typically preferred
for the non-migrating plasticizer to be present in the plastic
composition at a level which is within the range of about 10 php
to about 30 php.
The plastic composition will also typically contain at least one
antifungal agent (fungicide). Some representative types of
anti-fungal agents that can be utilized include organo-copper
compounds, organo-tin compounds, chlorinated phenols, and
pentachlorophenol esters. Some specific examples of fungicides
that can be used include copper naphthenate,
copper-8-hydroxyquinolinate and pentachlorophenyl laurate.
Irgaguard.RTM. F 3000 organic fungicide from Ciba Specialty
Chemicals is specifically designed for inhibiting the growth of
mold and mildew on polymer surfaces, such as PVC surfaces. The
anti-fungal agent will typically be utilized in the plastic
composition at a level which is within the range of about 0.5
php to about 2 php.
One or more thermal stabilizers can also be added to the plastic
composition in an amount which is typically within the range of
about 0.1 php to about 1 php to prevent thermal degradation
during processing and throughout the service life of the
simulated wood surface covering. The thermal stabilizer will
typically be an organometallic salt of tin, lead, barium,
cadmium, calcium or zinc. Since the simulated wood surface may
be exposed to prolonged periods of harsh sunlight, an
ultraviolet light stabilizer can also beneficially be utilized
in the plastic composition. Benzophenones, benzotriazoles and
substituted acrylonitriles are suitable for utilization as
ultraviolet light stabilizers in polyvinyl chloride-based
plastic compositions.
After being extruded a pressure sensitive adhesive and adhesive
backing is applied to the underside of the strips. Accordingly,
the pressure sensitive adhesive is sandwiched between the
underside of the simulated wood surface covering and the
backing. The backing keeps the adhesive from sticking to any
surfaces or articles before the time that it is desired to affix
the simulated wood surface covering to a substrate. This allows
for the surface covering to be stored and transported without it
sticking to unintended objects. This peel and stick adhesive
system eliminates the need for applying an adhesive to the
underside of the simulated wood surface covering at the point of
installation to a substrate, such as a boat deck. This in turn
reduces labor requirements and the cost of applying the
simulated wood surface covering to a deck. The use of such a
peel and stick pressure sensitive adhesive system is of
particular benefit in the manufacture of new boats and yachts
having uniform and consistent deck surfaces.
It is highly desirable for the adhesive to be applied to the
back of the simulated wood surface covering as a composite which
is comprised of the backing, the adhesive, and a carrier layer.
Typically a second layer of adhesive will be applied to the
opposite side of the carrier layer to enable it to be bonded to
the back of the simulated wood surface covering. Such a
composite adhesive structure offers the advantage of being able
to reposition the surface covering after it is initially
positioned on a substrate for a short period of time. This is
because the adhesive composite is initially bonded much more
strongly to the simulated wood surface covering than it is to
the substrate (boat deck surface) to which it is being applied.
It normally takes about 24 hours for the adhesive to fully cure
to the substrate onto which it is being applied.
As illustrated in FIG. 5 the simulated wood strip 1 has a first
layer of an adhesive 5, a carrier layer 6, a second layer of
adhesive 5', and a layer of backing 7 bonded to the underside
thereof. Typically, the carrier layer will be comprised of a
thin film of a polymeric material, such as a polyester. The
first layer of adhesive 5 will typically be about 0.1 mils to
about 5 mil thick, the carrier layer will be about 0.1 mils to 1
mil thick, and the second layer of adhesive 5' will be about 1
mil to about 10 mils thick. It is typically preferred for the
first layer of adhesive 5 to be about 0.3 mils to about 2 mils
thick, for the carrier layer will be about 0.3 mils to 0.7 mils
thick, and for the second layer of adhesive will be about 2 mils
to about 5 mils thick.
The PVC strips initially have a very smooth, somewhat shiny
surface which does not have the appearance or feel of wood.
Accordingly, the upper surface of the extruded strips is
roughened to provide the appearance and feel of real wood. This
can be accomplished by sanding the upper surface of the plastic
strips with coarse sandpaper in a direction which is parallel to
the length of the strips. This provides the strips with a
natural grain appearance that runs in the direction parallel to
the length of the strips. It is preferred to utilize a 36 grit
sandpaper to accomplish this objective. This gives the imitation
wood the texture and appearance of real wood. This rough texture
is not slippery to walk on even with bare feet under dry or wet
conditions. Additionally, it is mar and scuff resistant and
cannot normally be hurt by hard soled shoes or high heels.
In another embodiment of this invention, the simulated wood
surface covering is designed with the replacement of
deteriorated wooden decks on older boats and yachts in mind. In
such applications it is common for the deck of the boat to have
an irregular surface after the deteriorated wood deck covering
has been removed. Such applications optimally call for a more
forgiving simulated wood surface covering. In this embodiment of
the invention a fabric is bonded to the underside of the strips
of the simulated wood surface covering. This can be accomplished
by extruding the molten plastic strips onto the fabric or by
heating the plastic and pushing the fabric into the soft plastic
material while it is at an elevated temperature to attain good
adhesion between the fabric and the plastic strips. In this
embodiment of the invention, an adhesive is applied to the
fabric on the underside of the simulated wood surface coating
and then the surface coating is applied to the desired
substrate. The fabric is typically made from a synthetic polymer
such as polyester or nylon. The fabric can optionally include an
array of small hooks (as is found the on pieces of Velcro fabric
that stick to a corresponding fabric of small loops).
In still another embodiment of this invention which is of
particular value in manufacturing new boats and yachts, a high
pressure laminate is bonded to the underside of the strips of
the simulated wood surface covering. High pressure laminates
prove to be useful in improving installation time of strips of
both the welded and shiplap designs. The high pressure laminate
can be bonded to the strips with glue or pressure sensitive
adhesive. This reduces the time necessary for the simulated wood
surface covering to bond to the substrate on which it is
applied, such as a boat deck. This is beneficial in many
commercial applications because it makes it possible for workers
to walk on the new simulated wood surface covering sooner and to
perform other manufacturing functions at an earlier point in
time than would other wise be possible. In any case, these high
pressure laminates are typically composites of paper or fabric
with a melamine resin. The melamine resin is a hard,
thermosetting plastic made by the polymerization of melamine and
formaldehyde. High pressure laminates that are suitable for use
in the practice of this invention are available from a variety
of commercial sources and are sold as Formica.RTM. laminates and
Arborite.RTM. laminates. The high pressure laminate will
typically have a thickness which is within the range of 0.175
inch to 0.250 inch and will more typically have a thickness
which is within the range of 0.185 inch to 0.200 inch.
FIG. 1 illustrates a simulated wood surface covering of this
invention that includes a strip 1 that is adapted to be
interconnected to additional strips by a tongue 2 and a groove
3. The strips will be cut to a length that matches the length of
the substrate 4 being covered and a sufficient number of strips
will be bonded together to provide a surface having the width of
the substrate 4 being covered. An adhesive 5 is utilized to
securely bond the strips to the substrate 4. FIG. 2 shows the
adhesive 5 which was applied to the underside of the strip 1 of
simulated wood.
FIGS. 3 and 4 illustrates a simulated wood surface covering of
this invention that includes a strip 1 that is adapted to be
interconnected to additional strips by a tongue 2 and a groove
3. The strips will be cut to a length that matches the length of
the substrate 4 being covered and a sufficient number of strips
will be bonded together to provide a surface having the width of
the substrate 4 being covered. A fabric 6 is utilized to make
the simulated wood strip 1 conform to the surface of the
substrate 4. An adhesive is applied to the fabric 6 and then it
is applied to the substrate 4 to attain good adhesion between
the simulated wood strip 1 and the substrate 4.
FIG. 6 illustrates a first strip 1 of the simulated wood surface
covering of this invention that is adapted to be interconnected
to a second strip 8 of simulated wood surface covering by a
rabbet joint to make a shiplap structure. The first strip 1 has
a tongue 2 that overlaps the second strip 8 and extends into the
rabbet 9 of the second strip to form a rabbet joint when the
strips are interconnected. After being interconnected the tongue
of the first strip extends into the rabbet (rebate) of the
second strip to make a flush joint as shown in FIG. 8. The
strips will be cut to a length that matches the length of the
substrate being covered and a sufficient number of strips will
be bonded together to provide a surface having the width of the
substrate being covered. A fabric or high pressure laminate can
optionally be applied to the underside 10 of the strips to allow
for the simulated wood strips to better conform to the surface
of the substrate to which they are being applied. An adhesive is
applied to the underside of the strips or to the fabric on the
underside of the strips to adhere the simulated wood covering to
a substrate, such as the deck of a boat.
FIG. 7 illustrates a strip 1 for interconnection to other strips
through rabbet joints to make a simulated wood structure of
shiplap design. It should be noted that the rabbet forms an
included angle .theta., wherein .theta. is within the range of
70.degree. to 89.degree.. The angle .theta. will typically be
within the range of 80.degree. to 89.degree. and will more
typically be within the range of 85.degree. to 88.degree.. The
horizontal surface 11 of the rabbet will normally be parallel to
the underside 10 of the strip 1. The tongue 2 of the strips will
normally have a vertical tongue wall 14 that makes an includes
angle, .alpha., with the bottom wall of the underside of the
tongue 15. The included angle, .alpha., will typically be within
the range of 91.degree. to 110.degree.. The angle .alpha. will
more typically be within the range of 91.degree. to 100.degree.
and will preferably be within the range of 92.degree. to
95.degree.. Thus, on being interconnected there will be an
interstice 16 (void space) within the rabbet joint where excess
glue can agglomerate as illustrated in FIG. 8. It should be
noted that in making simulated wood surface coverings that glue
is applied both to the underside of the strips and at the
interface of the rabbet joints.
The simulated wood surface coverings of the present invention
are highly resistant to aqueous fluids. Water and other aqueous
fluids do not normally damage or permanently stain the simulated
wood surface coverings of this invention. However, in some cases
it may be desirable to treat the outer surface of the simulated
wood surface covering with a chemical/oil resistant protective
coating. A water based penetrating sealer can be used for this
purpose. The water based penetrating sealer used for this
purpose can be comprised of water, an aqueous fluorochemical
solution, a fluoropolymer dispersion, and one or more alcohols,
such as 2-butoxyethenol and/or isopropanol.
This invention is illustrated by the following examples that are
merely for the purpose of illustration and are not to be
regarded as limiting the scope of the invention or the manner in
which it can be practiced. Unless specifically indicated
otherwise, parts and percentages are given by weight.
EXAMPLE 1
A plastic composition that contains 200 parts by weight of
polyvinyl chloride resin, about 20 parts by weight of powdered
nitrite rubber (as a non-migrating plasticizer), about 2 parts
by weight of a brown colorant, about 0.2 parts by weight of a
streaking agent, about 1 part by weight of Irgaguard.RTM. F 3000
organic fungicide, and about 1 part by weight of benzotriazole
ultraviolet light stabilizer can be extruded into plastic strips
that are adapted to be interconnected from side to side. As the
strips are being extruded, a pressure sensitive adhesive and
backing are applied to the underside of the strips to produce a
peel and stick type of structure. This allows for the simulated
wood surface covering having the pre-applied pressure sensitive
adhesive to be stored and shipped without sticking to any other
object or surface before being applied to the boat deck.
These plastic strips can then be sanded with 36 grit sandpaper
in the longitudinal direction to attain a surface having the
texture of wood. The desired number of strips of desired length
can then be glued or welded together side by side to attain a
simulated wood surface. This simulated wood surface can then be
cut to the desired dimensions of a boat deck to which it will be
applied.
The simulated wood surface covering is then transported to be
within proximity to the boat deck to which it will be applied.
The backing is then removed from the surface covering to expose
the pressure sensitive adhesive and the simulated wood surface
is carefully positioned above and lowered onto the surface of
the boat deck to which it is being applied.
This technique eliminated the need to apply an adhesive to the
underside of the covering at the site of application to the boat
deck. This greatly reduced labor requirements and can lead to a
more uniform result since the pressure sensitive adhesive is
applied to the simulated wood structure at the factory where it
is produced.
EXAMPLE 2
A plastic composition that contains 100 parts by weight of
polyvinyl chloride resin, about 30 parts by weight of powdered
nitrile rubber (as a non-migrating plasticizer), about 3 parts
by weight of a brown colorant, about 0.4 parts by weight of a
streaking agent, about 1 part by weight of Irgaguard.RTM. F 3000
organic fungicide, and about 1 part by weight of a benzophenone
ultraviolet light stabilizer can be extruded into plastic strips
that are adapted to be interconnected from side to side by a
mortise and tenon means. After being extruded while the plastic
composition is still hot and soft a polyester fabric can be
pushed into the underside of the strips. After the plastic
composition is allowed to cool the polyester fabric is well
bonded into the underside of the plastic strips.
The top side of these plastic strips can then be sanded with 36
grit sandpaper in the longitudinal direction to attain a surface
having the texture of wood. The strips can then be glued side by
side to a boat deck to provide a simulated wood surface. Since
the plastic strips are somewhat flexible they can be easily bent
to conform to curves on the surface of the boat deck. The
polyester fabric on the underside of the strips helps to
compensate for defects and surface irregularities of the deck of
the boat. The polyester fabric also greatly improves the bonding
between the substrate and the simulated wood surface covering.
This technique is extremely forgiving and is designed to be used
by non-professionals in resurfacing the decks of their boats.
The strips of simulated wood offer good flexibility and are easy
to assemble and lay on curved or even irregular surfaces. After
being laid on the deck of a boat the simulated wood surface
covering offers the advantages of being highly water resistant,
easily washable (even with high pressure jet washers that damage
conventional wood surfaces), stain resistant; mar and scuff
resistant, and offers excellent anti-slip characteristics under
both dry and wet conditions. It also requires virtually no
maintenance to maintain and will not rot or deteriorate.
EXAMPLES 3-6
In this series of experiments simulated wood surface coverings
having different types of surface textures on the bottom surface
thereof were tested to determine the relationship between
surface texture and adhesion to a substrate. The type surface
texture on the bottom surface of the simulated wood surface
coverings evaluated in this series of experiments is depicted in
Table I. In the procedure used the bottom surface of the
simulated wood surfaces was totally covered with an acrylic
adhesive and the then applied to a plywood substrate. In all
cases the adhesive was allowed to fully cure to the plywood
substrate. Then the strength of the adhesion of the simulated
wood surface covering to the plywood substrate was tested. This
was done by measuring the force that needed to be applied to
pull the simulated wood surface covering from the plywood
substrate. The results of this experiment are reported in Table
I.
TABLE-US-00001 TABLE I Example Surface Texture Strength of
Adhesion 3 Dovetail 40-45 pounds 4 Diamond point 20 pounds 5
smooth 50 pounds 6 Sanded Rough 20 pounds
As can be seen from Table I, the simulated wood surface covering
having the smooth surface texture on the bottom thereof
exhibited the highest level of adhesive strength to the plywood
substrate. In fact, the plywood substrate broke apart and
delaminated when a force of about 50 pounds was applied rather
than the simulated wood surface covering being pulled from it.
In other words, the adhesion of the simulated wood surface
covering to the plywood substrate was stronger than the adhesion
between the layers of wood structure in the plywood.
Unexpectedly, the smooth surface provided stronger adhesion than
did the rough surface, the diamond point surface pattern, or the
dovetail design.
EXAMPLE 7
In this experiment a simulated wood surface covering for a boat
deck was fabricated by welding strips of simulated wood sheet
together utilizing PVC welding rod. The simulated wood surface
covering was made of the design and shape needed to cover the
deck of the boat. A pressure sensitive acrylic adhesive having a
backing covering its entire outer surface was applied to the
bottom surface of the simulated wood surface covering. The
simulated wood surface covering having the pressure sensitive
acrylic adhesive backing was then applied to the original deck
surface of a new boat. This was accomplished by removing the
backing from the simulated wood surface covering to expose the
acrylic adhesive. Then, the simulated wood surface covering was
positioned as desired above the boat deck and then lowered into
position onto the boat deck surface. Pressure was applied to the
simulated surface covering to firmly secure it to the boat deck.
The simulated wood surface covering adhered well to the boat
deck and provided the desired aesthetically pleasing simulated
wood surface.
Repositioning was difficult or impossible in cases where the
simulated wood surface was lowered onto the boat deck in a
manner wherein it was initially out of the desired position.
Accordingly, it is important to initially position such
simulated wood surface covering into the exact desired position
on the boat deck surface before the exposed adhesive on the back
of the simulated wood surface covering comes into contact with
the boat deck.
EXAMPLE 8
In this experimental procedure a simulated wood surface covering
was again applied to a boat deck surface as in Example 7.
However, the simulated wood surface covering used in this
procedure was designed so that the pressure sensitive adhesive
was supported by carrier layer with the carrier layer being
positioned between the acrylic adhesive and the simulated wood
structure. The simulated wood structure was of the design
depicted in FIG. 5 wherein the first layer of adhesive 5 was
about 2 mils thick, wherein the carrier 6 was a polyester film
that was about 0.5 mils thick, and wherein the second layer of
adhesive 5' was about 2 mils thick.
In cases where the simulated wood surface covering was initially
positioned inaccurately to the boat deck surface it was possible
to easily remove the simulated wood surface covering from the
boat deck surface and to properly reposition it. This is because
the adhesion between the first layer of adhesive and the carrier
layer was much stronger than the adhesion that was initially
attained between the second layer of adhesive and the boat deck
surface. However, it is still important to reposition the
simulated wood surface covering onto the boat deck surface as
soon as possible after it is initially applied out of the
desired position. It should be noted that it takes about 24
hours for the acrylic adhesive to fully cure (wet out) to attain
essentially full strength. In any case, the utilization of the
polyester carrier layer made the application of the simulated
wood surface to the boat deck a much more forgiving process.
EXAMPLE 9
In this experiment a simulated wood surface covering for a boat
deck was fabricated utilizing simulated wood strips having a
conventional shiplap stricture. The strips were glued together
along their rabbet joints and were further glued to the deck of
the boat. The simulated wood surface covering adhered well to
the boat deck. However, the tongues of the rabbet joints tended
to leave an open gap on the surface between the strips which
resulted in an uneven and aesthetically undesirable surface
appearance. In some cases an uneven surface resulted as a
consequence of this tendency for gaps to occur between the
strips.
EXAMPLE 10
In this experiment a simulated wood surface covering for a boat
deck was fabricated utilizing simulated wood strips having a
modified shiplap structure. In this modified shiplap structure
the rabbets formed an included angle (.theta. in FIG. 7) of
about 87.degree.. The strips were glued together along their
rabbet joints and were further glued to the deck of the boat.
The simulated wood surface covering adhered well to the boat
deck and the tongues of the rabbet joints did fit together
forming uniform seams without gaps forming between the strips.
This resulted in an even deck surface having a smooth and
aesthetically pleasing surface appearance. This can be
contrasted to the undesirable result experienced with the
conventional shiplap structure employed in Example 9 where the
included angle formed by the rabbets was essentially 90.degree..
While certain representative embodiments and details have been
shown for the purpose of illustrating the subject invention, it
will be apparent to those skilled in this art that various
changes and modifications can be made therein without departing
from the scope of the subject invention.
* * * * * |
|
