PROTECTIVE DECK COVERING DEVICE, SYSTEM, AND METHOD

Abstract

A composite cover configured for use on a deck board is provided. The composite cover can include a top surface and a bottom surface disposed opposite the top surface. The bottom surface can have a plurality of grooves extending along a distance in a direction of the composite cover. A first side can connect the top surface and the bottom surface. The first side can run longitudinally along a length of the composite cover. A second side can be disposed opposite the first side and connect the top surface and the bottom surface. A composite cover system configured for use on a deck board is also provided. The system can include the composite cover and a fastener. The composite covering system is easy to install, cost-effective, and durable requiring minimal maintenance.

Claims

1. A composite cover configured for use on a deck board, comprising: a top surface; a bottom surface disposed opposite the top surface, the bottom surface having a plurality of grooves formed thereon, the plurality of grooves extending along a distance in a direction of the composite cover; a first side connecting the top surface and the bottom surface running longitudinally along a length of the composite cover; and a second side disposed opposite the first side and connecting the top surface and the bottom surface running longitudinally along the length of the composite cover.

2. The composite cover of claim 1, wherein the top surface includes texturing.

3. The composite cover of claim 1, wherein each groove of the plurality of grooves includes a substantially U-shaped cross-section.

4. The composite cover of claim 1, wherein each groove of the plurality of grooves has a width between 1 millimeter and 50 millimeters.

5. The composite cover of claim 1, wherein each groove of the plurality of grooves has a height between 1 millimeter and 7 millimeters.

6. The composite cover of claim 1, wherein each groove of the plurality of grooves are uniformly spaced apart from one another.

7. The composite cover of claim 1, wherein the distance includes an entirety of the length of the composite cover.

8. The composite cover of claim 1, wherein the direction is along a longitudinal axis of the composite cover.

9. The composite cover of claim 1, wherein the composite cover is formed of a composite material comprising: between 20% and 40% of a thermoplastic polymer; between 40% and 80% of a wood material; between 1% and 6% of a coupling agent; between 0.5% and 2% of an ultra-violet stabilizer; between 0.1% and 1.5% of an antioxidant; between 1% and 3% of a process aid; between 1% and 3% of a pigment; and between 0% and 5% of a filler additive.

10. The composite cover of claim 1, wherein the composite cover comprises one or more of the following materials: high-density polyethylene; wood flour; maleic anhydride grafted polyethylene; bis(2,2,6,6-tetramethyl-4-piperidinyl) sebacate; pentaerythritol tetrakis(3-(3,5-di-tert-butyl-4-hydroxyphenyl) propionate); and paraffin wax.

11. A fastener for securing a composite cover to a deck board, comprising: a fastener body, including: a fastener head disposed at a first end; a conical tip disposed at a second end; a first section disposed adjacent the conical tip, the first section threaded in a first direction; and a second section disposed between the fastener head and the first section, the second section threaded in a second direction, different than the first direction.

12. The fastener of claim 11, wherein the first section includes a first length and the second section includes a second length, the first length is greater than the second length.

13. A composite cover system configured for use on a deck board, comprising: a composite cover including: a top surface; a bottom surface disposed opposite the top surface, the bottom surface having a plurality of grooves formed thereon, the plurality of grooves extending along a longitudinal direction of the composite cover; a first side connecting the top surface and the bottom surface running longitudinally along a length of the composite cover; and a second side disposed opposite the first side and connecting the top surface and the bottom surface running longitudinally along the length of the composite cover; and the fastener of claim 11.

14. A composite cover configured for use on a deck board, comprising: a top surface; a bottom surface disposed opposite the top surface, the bottom surface having a plurality of grooves formed thereon, the plurality of grooves extending along a distance in a direction of the composite cover; a first end; a second end opposing the first end; a first side extending from the first end; and a second side extending from the second end, wherein: the first side and the second side are oriented substantially perpendicular to the top surface and the first side includes a first lip and the second side includes a second lip, the first lip and the second lip each have an inside edge facing one another and define a retaining region below the bottom surface.

15. The composite cover of claim 14, wherein the composite cover is formed of a composite material comprising: between 20% and 40% of a thermoplastic polymer; between 40% and 80% of a wood material; between 1% and 6% of a coupling agent; between 0.5% and 2% of an ultra-violet stabilizer; between 0.1% and 1.5% of an antioxidant; between 1% and 3% of a process aid; between 1% and 3% of a pigment; and between 0% and 5% of a filler additive.

16. The composite cover of claim 14, wherein the top surface includes texturing.

17. A method of installing a composite cover system on a board of a deck, comprising: providing the composite cover of claim 1; providing a fastener, the fastener including: a fastener body, including: a fastener head disposed at a first end; a conical tip disposed at a second end; a first section disposed adjacent the conical tip, the first section threaded in a first direction; and a second section disposed between the fastener head and the first section, the second section threaded in a second direction, different than the first direction; positioning the composite cover on the board of the deck; and securing the composite cover to the board of the deck with the fastener, whereby the composite cover is installed on the board.

18. The method of claim 17, wherein prior to the positioning of the composite cover on the board of the deck, the method further comprises: removing a portion of the board to receive a portion of the composite cover; positioning the composite cover on the board of the deck; and securing the composite cover to the board of the deck with the fastener, whereby the composite cover is installed on the board.

19. The method of claim 18, wherein removing the portion of the board includes removing a top surface corner running along a longitudinal axis of the board.

20. The method of claim 19, wherein the portion of the composite cover substantially conforms to the removed portion of the board.

Description

DRAWINGS

[0016] The drawings described herein are for illustrative purposes only of selected embodiments and not all possible implementations, and are not intended to limit the scope of the present disclosure.

[0017] FIG. 1 is a perspective schematic illustration of a deck system;

[0018] FIG. 2 is a top perspective view of a composite cover for use with a deck, according to an embodiment of the present disclosure;

[0019] FIG. 3A is a cross-sectional view of the composite cover, according to the embodiment shown in FIG. 2;

[0020] FIG. 3B is an enlarged cross-sectional view of the composite cover, according to the embodiment shown in FIG. 2;

[0021] FIG. 4 is a bottom perspective view of the composite cover, according to an embodiment shown in FIG. 2;

[0022] FIG. 5 is a bottom plan view of the composite cover, according to an embodiment shown in FIG. 2;

[0023] FIG. 6 is a cross-sectional view of a composite cover, according to an embodiment of the present disclosure;

[0024] FIG. 7 is a cross-sectional view of a composite cover, according to an embodiment of the present disclosure;

[0025] FIG. 8 is a bottom perspective view of a composite cover, according to an embodiment of the present disclosure;

[0026] FIG. 9 is a bottom plan view of the composite cover, according to an embodiment shown in FIG. 8;

[0027] FIG. 10 is a side elevational view of a fastener, according to an embodiment of the present disclosure;

[0028] FIG. 11 is a top plan view of the fastener, according to the embodiment shown in FIG. 10;

[0029] FIG. 12A is a top perspective view of a composite cover for use with a deck, according to an embodiment of the present disclosure;

[0030] FIG. 12B is a bottom perspective view of a composite cover for use with a deck, according to an embodiment of the present disclosure;

[0031] FIG. 13 is a cross-sectional view of the composite cover, according to the embodiment shown in FIG. 12;

[0032] FIG. 14 is a cross-sectional view of a deck board with a top surface corner removed;

[0033] FIG. 15 is a cross-sectional view of the composite cover of FIG. 12 installed on the deck board of FIG. 14;

[0034] FIG. 16 is top perspective view of the composite cover of FIG. 12 installed on a portion of the deck board of FIG. 14;

[0035] FIG. 17 is a top perspective view of a composite cover system, according to an embodiment of the present disclosure;

[0036] FIGS. 18-19 are a flow chart illustrating a method of installing a composite cover system on a board of a deck, according to an embodiment of the present disclosure; and

[0037] FIGS. 20-21 are a flow chart illustrating a method of installing a composite cover system on a concrete surface, according to an embodiment of the present disclosure.

DETAILED DESCRIPTION

[0038] The following description of technology is merely exemplary in nature of the subject matter, manufacture and use of one or more inventions, and is not intended to limit the scope, application, or uses of any specific invention claimed in this application or in such other applications as may be filed claiming priority to this application, or patents issuing therefrom. Regarding methods disclosed, the order of the steps presented is exemplary in nature, and thus, the order of the steps can be different in various embodiments, including where certain steps can be simultaneously performed, unless expressly stated otherwise. A and an as used herein indicate at least one of the item is present; a plurality of such items may be present, when possible. Except where otherwise expressly indicated, all numerical quantities in this description are to be understood as modified by the word about and all geometric and spatial descriptors are to be understood as modified by the word substantially in describing the broadest scope of the technology. About when applied to numerical values indicates that the calculation or the measurement allows some slight imprecision in the value (with some approach to exactness in the value; approximately or reasonably close to the value; nearly). If, for some reason, the imprecision provided by about and/or substantially is not otherwise understood in the art with this ordinary meaning, then about and/or substantially as used herein indicates at least variations that may arise from ordinary methods of measuring or using such parameters.

[0039] Although the open-ended term comprising, as a synonym of non-restrictive terms such as including, containing, or having, is used herein to describe and claim embodiments of the present technology, embodiments may alternatively be described using more limiting terms such as consisting of or consisting essentially of. Thus, for any given embodiment reciting materials, components, or process steps, the present technology also specifically includes embodiments consisting of, or consisting essentially of, such materials, components, or process steps excluding additional materials, components or processes (for consisting of) and excluding additional materials, components or processes affecting the significant properties of the embodiment (for consisting essentially of), even though such additional materials, components or processes are not explicitly recited in this application. For example, recitation of a composition or process reciting elements A, B and C specifically envisions embodiments consisting of, and consisting essentially of, A, B and C, excluding an element D that may be recited in the art, even though element D is not explicitly described as being excluded herein.

[0040] As referred to herein, all compositional percentages are by weight of the total composition, unless otherwise specified. Disclosures of ranges are, unless specified otherwise, inclusive of endpoints and include all distinct values and further divided ranges within the entire range. Thus, for example, a range of from A to B or from about A to about B is inclusive of A and of B. Disclosure of values and ranges of values for specific parameters (such as amounts, weight percentages, etc.) are not exclusive of other values and ranges of values useful herein. It is envisioned that two or more specific exemplified values for a given parameter may define endpoints for a range of values that may be claimed for the parameter. For example, if Parameter X is exemplified herein to have value A and also exemplified to have value Z, it is envisioned that Parameter X may have a range of values from about A to about Z. Similarly, it is envisioned that disclosure of two or more ranges of values for a parameter (whether such ranges are nested, overlapping or distinct) subsume all possible combination of ranges for the value that might be claimed using endpoints of the disclosed ranges. For example, if Parameter X is exemplified herein to have values in the range of 1-10, or 2-9, or 3-8, it is also envisioned that Parameter X may have other ranges of values including 1-9, 1-8, 1-3, 1-2, 2-10, 2-8, 2-3, 3-10, 3-9, and so on.

[0041] When an element or layer is referred to as being on, engaged to, connected to, or coupled to another element or layer, it may be directly on, engaged, connected or coupled to the other element or layer, or intervening elements or layers may be present. In contrast, when an element is referred to as being directly on, directly engaged to, directly connected to or directly coupled to another element or layer, there may be no intervening elements or layers present. Other words used to describe the relationship between elements should be interpreted in a like fashion (e.g., between versus directly between, adjacent versus directly adjacent, etc.). As used herein, the term and/or includes any and all combinations of one or more of the associated listed items.

[0042] Although the terms first, second, third, etc. may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not be limited by these terms. These terms may be only used to distinguish one element, component, region, layer or section from another region, layer or section. Terms such as first, second, and other numerical terms when used herein do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the example embodiments.

[0043] Spatially relative terms, such as inner, outer, beneath, below, lower, above, upper, and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. Spatially relative terms may be intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as below or beneath other elements or features would then be oriented above the other elements or features. Thus, the example term below can encompass both an orientation of above and below. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.

[0044] In accordance with the illustrated embodiments of the present disclosure, a composite cover 100, a fastener 200, a composite cover system 300, another composite cover 400, and a method 500 of installing the composite cover system 300 are provided. Advantageously, the present disclosure addresses shortcomings in outdoor living spaces by providing a composite cover 100 and composite cover system 300 for use on a deck 10 that enhances durability and incorporates effective liquid and vapor management features to militate liquid and vapor accumulation and associated problems. The present disclosure minimizes the need for maintenance by providing a composite cover 100 that resists fading, splintering, and warping, eliminating the need for pressure washing, sanding, staining, or sealing, while shielding against UV rays, moisture, and harsh weather.

[0045] Referring now to the drawings, illustrated in FIG. 1 is a diagrammatic and simplified view of aspects used in construction of a deck 10. The deck 10 can be constructed in various ways, as known to one skilled in the art. The deck 10 can include a plurality of support-posts 12 (or more simply posts or individually a post), a plurality of joists 14 (individually a joist), a bridging 16, and a plurality of deck boards 18 (individually a deck board or board). The plurality of joists 14 extend between the plurality of support-posts 12, a bridging 16 is positioned between the joists 14 for added stability, and a plurality of deck boards 18 supported by the plurality of joists 14 form a deck surface 20. It should be appreciated that the deck 10 can vary in design, material, and construction without departing from the scope of the present disclosure. For example, the dimensions, spacing, and arrangement of the support-posts 12, joists 14, bridging 16, and deck boards 18 can be modified to accommodate different load requirements, environmental conditions, or aesthetic preferences such as overall design or shape. Additionally, while the deck 10 is illustrated in a simplified form, it may include additional structural or decorative elements, such as railings, stairs, or fasteners, as used in the art.

[0046] In certain embodiments, and with reference to FIGS. 2-5, a composite cover 100 for use on a deck board 18 can include a top surface 102 and a bottom surface 104 disposed opposite the top surface 102. The bottom surface 104 can include one or more grooves 106 formed thereon. The grooves 106 can extend along a distance 108 in a direction 110 of the composite cover 100. The grooves 106 will be discussed in more detail below. The composite cover 100 can include a first side 112. The first side 112 can connect the top surface 102 and the bottom surface 104 and can run longitudinally along a length 114 of the composite cover 100. The composite cover 100 can include a second side 116 disposed opposite the first side 112. The second side 116 can connect the top surface 102 to the bottom surface 104 and can run longitudinally along the length 114 of the composite cover 100.

[0047] With reference to FIGS. 2-4, the composite cover 100 can include a transition 118a formed at a junction 120a of the top surface 102 and the first side 112. The composite cover 100 can include another transition 118b formed at a junction 120b of the top surface 102 and the second side 116. Similarly, the composite cover 100 can include a transition 118c formed at a junction 120c of the bottom surface 104 and the first side 112, and another transition 118d formed at a junction 120d of the bottom surface 104 and the second side 116. The transitions 118a, 118b, 118c, 118d can include a smooth, curved profile, such as a fillet or a radius, or can include a chamfer or a beveled edge. The transitions 118a, 118b, 118c, 118d can help shed liquid more efficiently, reducing liquid and moisture retention, and minimizing the risk of rotting or warping over time. Additionally, the transitions 118a, 118b, 118c, 118d can be less prone to chipping or splitting compared to sharp corners, as the curved profile can distribute impact forces more evenly, enhancing the composite cover's durability. Furthermore, the transitions 118a, 118b, 118c, 118d can accommodate slight expansion and contraction due to temperature and humidity changes, helping to maintain the composite cover's 100 structural integrity while militating against excessive wear.

[0048] The top surface 102 and the bottom surface 104 can include texturing 122. The texturing 122 can provide several advantages, including increased friction, masking scratches, dents, and signs of wear while helping to hide dirt and stains, reducing maintenance efforts. Additionally, texturing 122 can minimize glare by diffusing light. There are several types of texturing 122, each serving different functional and aesthetic purposes. A wood grain texture can mimic the natural patterns and ridges of real wood, offering a traditional, authentic appearance. Wood grain textures can contribute to durability by reducing the visibility of surface wear while maintaining a natural and inviting look without the maintenance demands of traditional wood. Brushed finishes feature fine streaks for a subtle, modern look, while grooved or ribbed surfaces incorporate linear patterns to enhance traction and improve liquid drainage. The texturing 122 will be discussed in more detail below.

[0049] With reference to FIGS. 2-9, incorporating one or more grooves 106 on the bottom surface 104 of the composite cover can help manage liquid and vapor, thereby enhancing the longevity of the underlying deck 10. The grooves 106 can include a cross-section designed for liquid and vapor management, directing rainwater, spilled liquids, or moisture condensation away from a surface of the deck. The grooves 106 can help militate against water pooling, which can lead to mold or mildew growth, while also promoting airflow to facilitate drying and reduce warping and/or decay of the deck. Additionally, the grooves 106 can allow vapor to escape, minimizing the moisture being trapped between the composite cover 100 and the deck surface 20. The grooves 106 can each have various cross-sectional shapes, including a U-shape, a V-shape, a trapezoidal shape, a right trapezium shape, or combinations thereof.

[0050] The shape and spacing of the grooves 106 can also contribute to weight reduction of the composite cover 100. By incorporating grooves 106 into the design of the composite cover 100, less material can be used when manufacturing, which directly reduces the overall weight of the composite cover 100. This lighter weight can help make the composite cover 100 easier to handle, transport, and install, especially when placing it on top of the deck 10. While reducing the material volume, the grooves 106 can be designed to maintain the composite cover's 100 structural integrity. The placement and shape of the grooves 106 can help ensure that the composite cover 100 remains strong and capable of supporting loads without warping, cracking, or bending. For example, using grooves 106 can remove material in a way that preserves the composite cover's 100 strength, allowing it to withstand the stresses it will encounter during use. The reduced weight can be achieved without compromising the composite cover's 100 ability to provide the necessary performance characteristics, such as load-bearing capacity and resistance to wear, ensuring that the composite cover 100 performs reliably over time.

[0051] The grooves 106 can each have a width 124 and a height 126. The width 124 can be between 1 millimeter and 50 millimeters. The height 126 can be between 1 millimeter and 7 millimeters. The width 124 and height 126 of the grooves 106 can be chosen such that the remaining solid areas of the composite cover 100 can continue to bear load, ensuring that the composite cover 100 is capable of supporting weight and resisting deformation under stress. Furthermore, the grooves 106 can be uniformly spaced apart between 1 millimeter and 50 millimeters to ensure even liquid distribution and optimized airflow. This spacing of the grooves 106 not only helps with functional aspects like drainage and ventilation but also contributes to maintaining the structural integrity of the composite cover 100. The distribution of grooves 106 can help ensure that the forces exerted on the composite cover 100, whether from foot traffic, furniture, or environmental pressures, are spread out, maintaining the composite cover's 100 overall strength, rigidity, and durability.

[0052] With reference to FIGS. 4-5 and 8-9, the grooves 106 can extend along a distance 108 in a direction 110 of the composite cover 100. The direction 110 can align with either a longitudinal axis 128 or a lateral axis 130 of the composite cover 100. The orientation of the grooves 106 can be chosen to optimize liquid drainage and airflow Additionally, the grooves 106 can extend along the distance 108 across the composite cover 100, which can encompass the entire length 114 of the composite cover 100 or only a portion of it.

[0053] The composite cover 100 can be characterized by a length 132, a width 134, and a height 136. The length 132 of the composite cover 100 can vary to accommodate different decking or structural applications, with options ranging from 6, 8, 12, 16 to 20 feet. The width 134 of the composite cover 100 can range from 4 to 7 inches. A narrower width 134 may be suited for more intricate or compact designs, while a wider width 134 allows for broader coverage, reducing the number of boards required for a particular surface area. The height 136 can range from 5 to 20 millimeters. This variation in height 136 accommodates different thicknesses for the composite cover 100, providing options for strength, durability, and performance. Thicker composite covers 100 may be more suitable for high-traffic areas or environments with extreme weather conditions, while thinner composite covers 100 offer lighter weight and ease of installation without sacrificing structural integrity. By offering a range of dimensions for length 132, width 134, and height 136, the composite cover 100 can meet both functional and aesthetic requirements. It should be understood that one having ordinary skill in the art can select a suitable length, width, and height of the composite cover 100 within the scope of the present disclosure.

[0054] In certain embodiments, and with refence to FIGS. 10 and 11, a fastener 200 for securing a composite cover 100 to a deck board 18 is provided. The fastener 200 can include a fastener body 202. The fastener body 202 can include a fastener head 204 disposed at a first end 206 and a conical tip 208 disposed at a second end 210. A first section 212 can be disposed adjacent the conical tip 208 and can be threaded in a first direction 214. A second section 216 can be disposed between the fastener head 204 and the first section 212 and can be threaded in a second direction 218. The second direction 218 can be different from the first direction 214. The fastener 200 can reduce the risk of cracking or deformation in the composite cover 100, improving the fastener's 200 ability to securely anchor in various substrates with minimal effort.

[0055] The fastener head 204 can be equipped with a drive cavity 220 for secure engagement with a driving tool. The drive cavity 220 can be a T15 Torx drive, which can optimize torque tolerance and minimize the risk of stripping during installation. The drive cavity's 220 dimensions can include a diameter of 5.50.1 mm and a depth of 2.80.1 mm, which can help driving tool engagement and minimize slippage. To further enhance the fastener's 200 durability and color matching with the composite cover 100, the fastener head 204 can be treated with a baked enamel color coating, which can provide corrosion resistance. It should be understood that one having ordinary skill in the art can select a suitable type of drive cavity 220 within the scope of the present disclosure. Examples can include Hex, Torx, TR Torx, Phillips and Slotted Bit.

[0056] The first section 212 can have a first length 222 that can be greater than a second length 224 of the second section 216. The first section 212 can include a self-tapping triangular split thread, which can allow the fastener 200 to cut into the composite cover 100 and deck 10 as it is driven in. This self-tapping feature can enable the fastener 200 to engage in the composite cover 100 securely without the need for pre-drilling. The second section 216, positioned between the fastener head 204 and the first section 212, can include a self-tapping reverse thread, which can provide additional stability during installation and facilitate easier driving into harder materials. The second section 216 of the fastener 200 can include a self-tapping reverse-threaded ST4.5 thread, which can transition to a self-tapping ST4.0 triangular split thread in the first section 212. The fastener 200 can reduce driving resistance, balance grip force, and minimize installation torque.

[0057] When securing the composite cover 100 to an underlying board 18, the fastener 200 can be positioned at a predetermined position with the conical tip 208 on the composite cover 100. A driving tool, such as a drill or screwdriver, can be used to rotate the fastener 200, advancing it through the composite cover 100, and into the underlying board 18. As the fastener 200 is driven in, the first section having the self-taping triangular split threads continues from the composite cover 100 into the underlying board 18. As the fastener 200 is further driven in, the second section 216 having the self-tapping reverse-threads can engage with the composite cover 100. The reverse threads can create a secure grip within the composite cover 100, anchoring the fastener 200 and militating against any tendency for the fastener 200 to loosen or back out over time.

[0058] The combination of self-taping triangular split threads and the self-tapping reverse-threads can increase the holding strength of the fastener 200. The reverse threads can prevent the fastener 200 from backing out by counteracting forces that might otherwise loosen it due to environmental factors or structural movement. As a result, the composite cover 100 can remain securely affixed to the board 18, ensuring long-term stability and durability.

[0059] In certain embodiments, and with reference to FIG. 17, a composite cover system 300 for use on a deck 10 is provided. The composite cover system 300 can include a composite cover 100 and a fastener 200. The composite cover 100 can be the composite cover 100 as described hereinabove. The fastener can be any fastener, or the fastener 200 as described hereinabove.

[0060] In certain embodiments, with reference to FIGS. 12-13 and 15-16, a composite cover 400 for use on a deck board 18 can include a top surface 402 and a bottom surface 404 disposed opposite the top surface 402. The bottom surface 404 can have a groove 406 formed thereon. The groove 406 can extend along a distance 408 in a direction 410 of the composite cover 400.

[0061] The composite cover 400 can include a first end 412, a second end 414 opposing the first end 412, a first side 416 extending from the first end 412, and a second side 418 extending from the second end 414. The first side 416 and the second side 418 can be oriented substantially perpendicular to the top surface 402 and the first side 416 can include a first lip 420 and the second side 418 can include a second lip 422. The first lip 420 and the second lip can each include inside edges 423a, 432b. The inside edges 423a, 432b can face one another and define a retaining region 424 below the bottom surface 404.

[0062] With reference to FIG. 13, the composite cover 400 can include a transition 426a formed at a junction 428a of the top surface 402 and the first side 416. The composite cover 400 can include another transition 426b formed at a junction 428b of the top surface 402 and the second side 418. The transitions 426a, 426b can have a smooth, curved profile, such as a fillet or a radius, or include a chamfer or a beveled edge. The transitions 426a, 426b can help shed liquid more efficiently, reducing liquid and moisture retention, and minimizing the risk of rotting or warping over time. Additionally, the transitions 426a, 426b can be less prone to chipping or splitting compared to sharp corners, as the curved profile can distribute impact forces more evenly, enhancing the composite cover's 400 durability. Furthermore, the transitions 426a, 426b can accommodate slight expansion and contraction due to temperature and humidity changes, helping to maintain the composite cover's 400 structural integrity while militating against excessive wear.

[0063] With reference to FIG. 12A, the top surface 402 can include texturing 430. The texturing 430 can provide several advantages, including increased friction, masking scratches, dents, and signs of wear while helping to hide dirt and stains, reducing maintenance efforts. Additionally, the texturing 430 can minimize glare by diffusing light. There are several types of texturing, each serving different functional and aesthetic purposes. A wood grain texture can mimic the natural patterns and ridges of real wood, offering a traditional, authentic appearance. Wood grain textures can contribute to durability by reducing the visibility of surface wear while maintaining a natural and inviting look without the maintenance demands of traditional wood. Brushed finishes feature fine streaks for a subtle, modern look, while grooved or ribbed surfaces incorporate linear patterns to enhance traction and improve liquid drainage. The texturing 430 will be discussed in more detail below.

[0064] With reference to FIGS. 12-13 and 15-16, incorporating one or more grooves 406 on the bottom surface 404 of the composite cover 400 can help manage liquid and vapor, thereby enhancing the longevity of the underlying deck 10. The grooves 406 can include a cross-section designed for liquid and vapor management, directing rainwater, spilled liquids, or moisture condensation away from the deck surface 20. The grooves 406 can help militate against water pooling, which can lead to mold or mildew growth, while also promoting airflow to facilitate drying and reduce warping and/or decay of the deck 10. Additionally, the grooves 406 can allow vapor to escape, minimizing the moisture being trapped between the composite cover 400 and the deck surface 20. The grooves 406 can each have various cross-sectional shapes, including but not limited to, a U-shape, a V-shape, a trapezoidal shape, a right trapezium shape, or combinations thereof.

[0065] The specific shape and spacing of the grooves 406 can also contribute to weight reduction of the composite cover 400. By incorporating grooves 406 into the design of the composite cover 400, less material can be used when manufacturing, which directly reduces the overall weight of the composite cover 400. This lighter weight can help make the composite cover 400 easier to handle, transport, and install, especially when placing it on top of the deck 10. While reducing the material volume, the groove configuration is designed to maintain the composite cover's 400 structural integrity. The placement and shape of the grooves 406 can help ensure that the composite cover 400 remains strong and capable of supporting loads without warping, cracking, or bending. For example, using grooves 406 can remove material in a way that preserves the composite cover's 400 strength, allowing it to withstand the stresses it will encounter during use. The reduced weight can be achieved without compromising the composite cover's 400 ability to provide the necessary performance characteristics, such as load-bearing capacity and resistance to wear, ensuring that the composite cover 400 performs reliably over time.

[0066] The grooves 406 can be similar to the grooves 106 shown in FIGS. 2-9. The grooves 406 can have a width 124 and a height 126. The width 124 can be between 1 millimeter and 50 millimeters. The height 126 can be between 1 millimeter and 7 millimeters. The width 124 and the height 126 of the grooves 406 can be chosen such that the remaining solid areas of the composite cover 400 can continue to bear load, ensuring that the composite cover 400 is capable of supporting weight and resisting deformation under stress. Furthermore, the grooves 406 can be uniformly spaced apart between 1 millimeter and 50 millimeters to ensure even liquid distribution and optimized airflow. This spacing of the grooves 406 not only helps with functional aspects like drainage and ventilation but also contributes to maintaining the structural integrity of the composite cover 400. The distribution of grooves 406 can help ensure that the forces exerted on the composite cover 400, whether from foot traffic, furniture, or environmental pressures, are spread out, maintaining the composite cover's 400 overall strength, rigidity, and durability.

[0067] With reference to FIGS. 12A & 12B, the grooves 406, can extend along a distance 408 in a direction 410 of the composite cover 400. The direction 140 can align with either a longitudinal axis 436 or a lateral axis 438 of the composite cover 400, depending on the desired design and functional requirements. The orientation of the grooves 406 can be chosen to optimize liquid drainage, airflow, and aesthetic appearance. Additionally, the grooves 406 can extend along the distance 408 across the composite cover 400, which can encompass the entire length of the composite cover or only a portion of it.

[0068] The composite cover 400 can have a length 440, a width 442, and a height 444. The length 440 of the composite cover 400 can vary to accommodate different decking or structural applications, with options ranging from 6, 8, 12, 16 to 20 feet. The width 442 of the composite cover 400 can range from 4 to 7 inches. A narrower width may be suited for more intricate or compact designs, while a wider width allows for broader coverage, reducing the number of composite covers required for a particular surface area. The height 444 can range from 5 to 20 millimeters. This variation in height 444 can accommodate different thicknesses for the composite cover 400, providing options for strength, durability, and performance. Thicker composite covers 400 may be more suitable for high-traffic areas or environments with extreme weather conditions, while thinner options offer lighter weight and ease of installation without sacrificing structural integrity. By offering a range of dimensions for length 440, width 442, and height 444, the composite cover 400 can be meet both functional and aesthetic requirements. It should be understood that one having ordinary skill in the art can select a suitable length, width, and height of the composite cover 400 within the scope of the present disclosure.

[0069] The composite cover 100, 400 can be manufactured using an extrusion process, which can provide a consistent and efficient method for producing high-quality, dimensionally stable composite covers 100, 400. In the extrusion process, a mixture of thermoplastic polymers, reinforcing fibers, and additives can be heated and blended into a homogeneous material. The heated composite material can then be forced through a die that shapes it into the desired profile, ensuring uniform thickness and surface characteristics.

[0070] During extrusion, additional features can be incorporated on the composite cover 100, 400, such as surface texturing (e.g., wood grain patterns) or co-extruded protective layers, which can enhance the composite cover's 100, 400 resistance to UV exposure, moisture, and surface wear. The extrusion process can also allow for precise control over the material composition, ensuring that the final product meets structural and aesthetic requirements. Furthermore, by using continuous extrusion, long sections of composite covers can be produced efficiently, reducing material waste and improving production scalability. Texturing 122, 430 can be imprinted onto a composite cover 100, 400 using various manufacturing techniques that enhance both its aesthetic appeal and functional performance. One method can include embossing during the extrusion process, where a patterned roller or plate applies pressure to the surface of the heated composite material as it exits the die. This technique can create a consistent texture, such as a wood grain pattern, grooves, or ridges, giving the composite cover 100, 400 a natural look while improving slip resistance. The depth and sharpness of the texture can be controlled by adjusting the pressure and temperature during embossing, ensuring a durable and long-lasting surface.

[0071] Another approach involves co-extrusion, where an additional protective layer is applied to a composite core during manufacturing. This additional protective layer can include an integrated texture, such as a deep-grain wood pattern or a roughened anti-slip surface. Co-extrusion can provide additional scratch resistance, UV protection, and enhanced color retention, making it ideal for outdoor applications where the board is exposed to weathering and foot traffic. The co-extruded layer can also help reduce maintenance by preventing surface fading, staining, and moisture absorption.

[0072] For other textures, press molding or stamping can be used. In these methods, pre-formed molds with the desired texture are pressed onto the composite cover's 100, 400 surface before it fully cools. This technique allows for intricate detailing, making it useful for replicating the complex grain patterns of natural wood or achieving unique, decorative designs.

[0073] The composite cover 100, 400 can be formed from a composite material formulated for durability, weather resistance, and structural integrity. The composite material can include a thermoplastic polymer, to provide flexibility and moisture resistance. It can also include a wood material to enhance strength and reduce thermal expansion. To improve material performance, the composite can incorporate a coupling agent, which can enhance the adhesion between the polymer and wood fibers, increasing overall stability.

[0074] The composite material can include various additives, such as an ultra-violet (UV) stabilizer to reduce degradation from sun exposure, an antioxidant to prevent thermal oxidation, and a processing aid to improve manufacturability. A colorant or a pigment can be added for aesthetic customization, while a filler additive can enhance density and mechanical properties. A blowing agent can be included to create a lightweight, foamed structure, reducing material weight while maintaining strength. Furthermore, the composite material can incorporate an impact modifier to improve resistance to cracking and a scratch-resistant additive to enhance surface durability, reducing wear from foot traffic and environmental factors.

[0075] The thermoplastic polymer can include polypropylene, polyethylene, polyvinyl chloride, styrene-butadiene-styrene (SBS), styrene-ethylene-butylene-styrene (SEBS), thermoplastic polyurethanes (TPUs), natural rubber (NR), nitrile rubber (NBR), chloroprene rubber (CR), carboxyl-terminated butadiene acrylonitrile (CTBN), recycled polypropylene, recycled polyethylene, recycled polyvinyl chloride, rubber granule, recycled rubber granule, and combinations thereof.

[0076] The wood material can include sawdust, wood flour, finely milled hardwood, finely milled softwood, wood fiber, and lignocellulosic fibers, wood chips, microcrystalline cellulose, nanocellulose, torrefied wood particles, bark powder, lignin powder, and combinations thereof.

[0077] The coupling agent can include maleic anhydride-grafted polyethylene/polypropylene (MAPP), maleic anhydride grafted styrene-ethylene-butylene-styrene, silane based such as aminopropyltriethoxysilane and vinyltriethoxysilane, diisocyanate based such as polymeric methylene diphenyl diisocyanate (pMDI), functionalized polyolefins such as epoxidized polypropylene, and combinations thereof.

[0078] The ultra-violet (UV) stabilizer can include hindered amine light stabilizers (HALS), such as Bis(2,2,6,6-tetramethyl-4-piperidyl) sebacate (BTMPS) (Tinuvin 770) and Poly [[6-[(1,1,3,3-tetramethylbutyl)amino]-1,3,5-triazine-2,4-diyl][(2,2,6,6-tetramethyl-4-piperidinyl)imino]-1,6-hexanediyl [(2,2,6,6-tetramethyl-4-piperidinyl)imino]]) (Chimassorb 944), 2,4-Dihydroxybenzophenone (Uvinul 400), Bisoctrizole (Tinosorb M), and combinations thereof.

[0079] The process aid can include polyethylene wax, stearates, stearic acid, metal stearates such as calcium stearate and zinc stearate, amide waxes such as ethylene Bis(Stearamide) (EBS), paraffin wax, and FT-wax, hydrocarbon waxes such as low-molecular-weight polyethylene, polypropylene wax, recycled waxes, ester-based process aids, fatty acid amides such as erucamide and oleamide, and combinations thereof. The process aid can also include a plasticizer including phthalates such as diisononyl phthalate (DINP) and diisodecyl phthalate (DIDP), non-phthalates such as dioctyl adipate (DOA), epoxidized soybean oil, acetyl tributyl citrate (ATBC), and chlorinated paraffin, and combinations thereof.

[0080] The colorant/pigment can include titanium dioxide, iron oxide, carbon black, chromium oxide, ultramarine blue, cobalt blue, cadmium pigment, phthalocyanine blue, phthalocyanine green, azo pigment, quinacridone pigment, carbonized wood, biochar, hematoxylin, tannin-based pigment, aluminum powder, pearlescent mica pigment, and combinations thereof.

[0081] The filler additive can include calcium carbonate, talc, kaolin clay, silica, alumina trihydrate (ATH), magnesium hydroxide, barium sulfate, wollastonite, mica, feldspar, perlite, vermiculite, glass beads, glass fibers, ceramic microspheres, fly ash, basalt fibers, cellulose fibers, lignin, starch, biochar, nanocellulose, carbon black, graphite, montmorillonite, sepiolite, dolomite, zinc oxide, titanium dioxide, iron oxide, and combinations thereof.

[0082] The blowing agent can include azodicarbonamide (ADC), sodium bicarbonate, citric acid, hydrazine derivatives, benzene sulfonyl hydrazide, p-toluene sulfonyl hydrazide, p-toluene sulfonyl semicarbazide, 5-phenyltetrazole, urea-based blowing agents, expandable microspheres, isocyanates, hydrocarbons (butane, pentane, isopentane), carbon dioxide, nitrogen, water, hydrofluorocarbons (HFCs), hydrochlorofluorocarbons (HCFCs), hydrofluoroolefins (HFOs), formic acid, and combinations thereof.

[0083] The impact modifier can include ethylene vinyl acetate (EVA), acrylic impact modifiers such as methyl methacrylate butadiene styrenic (MBS) resins, chlorinated polyethylene (CPE) resins, acrylic resins, acrylonitrile butadiene styrene (ABS), styrene-ethylene-butadiene-styrene (SEBS), styrene-butadiene rubber (SBR), ethylene propylene diene monomer (EPDM), ethylene-methyl acrylate (EMA), ethylene-ethyl acrylate (EEA), maleic anhydride-grafted polymers (e.g., MA-g-PE, MA-g-PP), polyolefin elastomers (POE), thermoplastic polyurethanes (TPU), core-shell rubber particles, ionomers (e.g., Surlyn), polysiloxane-based impact modifiers, and combinations thereof.

[0084] Example formulations of the composite cover 100, 400 are provided in Tables 1-7, shown below, so that this disclosure will be thorough, and will fully convey the scope to those who are skilled in the art. The formulations for the composite cover 100, 400 can be used in various manufacturing processes, such as extrusion and co-extrusion.

TABLE-US-00001 TABLE 1 Formulation 1 Component % By Weight Thermoplastic Polymer 20-50% Wood Material 40-80% Coupling Agent 1-6% Ultra-violet (UV) Stabilizer 0.5-2% Antioxidant 0.1-1.5% Processing Aid 1-3% Colorant/Pigment 1-3% Filler Additive 0-5%

TABLE-US-00002 TABLE 2 Formulation 2 Component % By Weight Thermoplastic Polymer 15-30% Wood Material 40-80% Coupling Agent 1-6% Ultra-violet (UV) Stabilizer 0.5-2% Antioxidant 0.1-1.5% Processing Aid 1-3% Colorant/Pigment 1-3% Filler Additive 0-5% Impact Modifier 5-20%

TABLE-US-00003 TABLE 3 Formulation 3 Component % By Weight Thermoplastic Polymer 20-50% Wood Material 40-80% Coupling Agent 1-6% Ultra-violet (UV) Stabilizer 0.5-2% Antioxidant 0.1-1.5% Processing Aid 1-3% Colorant/Pigment 1-3% Filler Additive 0-5% Blowing Agent 0.1-6%

TABLE-US-00004 TABLE 4 Formulation 4 Component % By Weight Thermoplastic Polymer A 50-70% Thermoplastic Polymer B 0-10% Ultra-violet (UV) Stabilizer 1-3% Antioxidant 0.1-0.5% Processing Aid 0.5-2% Colorant/Pigment 2-20% Scratch Resistive Additive 1-2% Impact Modifier 1-4%

TABLE-US-00005 TABLE 5 Formulation 5 Component % By Weight Thermoplastic Polymer 50-60% Ultra-violet (UV) Stabilizer 1-3% Antioxidant 0.1-0.5% Processing Aid 0.5-2% Colorant/Pigment 10-20% Scratch Resistive Additive 1-2% Impact Modifier 2-5% Filler Additive 5-20%

TABLE-US-00006 TABLE 6 Formulation 6 Component % By Weight Thermoplastic Polymer 50-60% Ultra-violet (UV) Stabilizer 1-3% Antioxidant 0.1-0.5% Processing Aid 0.5-2% Colorant/Pigment 10-20% Scratch Resistive Additive 1-2% Impact Modifier 10-30%

TABLE-US-00007 TABLE 7 Formulation 7 Component % By Weight Thermoplastic Polymer A 20-50% Thermoplastic Polymer B 40-80% Processing Aid 1-3% Filler Additive 0-5%

[0085] With reference to FIGS. 17 and 18, a method 500 of installing a composite cover system 300 on a board 18 of a deck 10 is provided. The method 500 can include a step 502 of providing the composite cover 100, 400 as described hereinabove. The method can include a step 504 of providing a fastener. The fastener can be any fastener or the fastener as described hereinabove. The method can include a step 506 of preparing the deck 10. The method can include a step 508 of positioning the composite cover 100, 400 on the board 18 of the deck 10. The method 500 can include a step 510 of securing the composite cover 100, 400 to the board 18 of the deck 10 with the fastener 200, whereby the composite cover 100, 400 is installed on the board 18.

[0086] In certain embodiments, the method 500 can further include a step 512 of removing a portion 446 of the board 18 to receive a portion 448 of the composite cover 400. The removing of the portion 446 of the board 18 can include removing a top surface corner 450 running along a longitudinal axis of the board 18. The portion 448 of the composite cover 400 can substantially conform to the removed portion 446 of the board 18. The method 500 can further include a step 514 of positioning the composite cover 400 on the board 18 of the deck 10. The method 500 can further include a step 516 of securing the composite cover 400 to the board 18 of the deck 10 with the fastener 200, whereby the composite cover 400 is installed on the board 18.

[0087] With reference to FIGS. 19-20, in certain embodiments, a method 600 of installing a composite cover system 300 on a concrete surface is provided. The method 600 can include a step 602 of providing the composite cover 100 as described hereinabove. The method can include a step 604 of providing a fastener. The fastener can be any fastener or the fastener as described hereinabove. The method 600 can include a step 606 of providing an adhesive. The method 600 can include a step 608 of roughening a bottom surface 104 of the composite cover 100. The method 600 can include a step 610 of preparing the concrete surface. The method 600 can include a step 612 of positioning the composite cover 100 on the concrete surface. The method 600 can include a step 614 of securing the composite cover 100 to the concrete surface with the adhesive and the fastener 200.

[0088] Example embodiments are provided so that this disclosure will be thorough, and will fully convey the scope to those who are skilled in the art. Numerous specific details are set forth such as examples of specific components, devices, and methods, to provide a thorough understanding of embodiments of the present disclosure. It will be apparent to those skilled in the art that specific details need not be employed, that example embodiments may be embodied in many different forms, and that neither should be construed to limit the scope of the disclosure. In some example embodiments, well-known processes, well-known device structures, and well-known technologies are not described in detail. Equivalent changes, modifications and variations of some embodiments, materials, compositions and methods can be made within the scope of the present technology, with substantially similar results.