# US 2021/0340779 A1 · Deck board apparatus and method of making same

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- Number: US 2021/0340779 A1
- Document ID: US20210340779A1
- Status: Published application
- Kind: A1
- Application number: 17/372,991
- Filed: 2021-07-12
- Published: 2021-11-04
- Earliest claimed: 2020-03-27
- Assignees: Strongwell Corporation
- Applicants: Strongwell Corporation
- Inventors: Joe Spanovich; Barry Myers, II
- Web page: https://patentgrep.com/patent/US20210340779A1

## CPC

- E04F 15/02044: {Separate elements for fastening to an underlayer (E04F15/02133, E04F15/0215 take precedence)}
- B29C 70/521: {and impregnating the reinforcement before the die}
- E04B 1/003: {Balconies; Decks}
- E04F 15/02183: {for outdoor use, e.g. in decks, patios, terraces, verandas or the like}
- E04F 15/102: {of fibrous or chipped materials, e.g. bonded with synthetic resins}
- E04F 15/105: {of organic plastics with or without reinforcements or filling materials}
- E04F 15/107: {composed of several layers, e.g. sandwich panels (layered products in general B32B; producing decorative panels or veneers B44C5/04)}
- B29L 2031/10: Building elements, e.g. bricks, blocks, tiles, panels, posts, beams {(frameless domes B29L2025/00, doors B29L2031/724)}
- E04F 2015/02072: {the additional fastening elements extending into the back side of the flooring elements (E04F2015/021 takes precedence)}
- E04F 2015/02111: {not adjustable}
- E04F 2203/00: Specially structured or shaped covering, lining or flooring elements not otherwise provided for
- E04F: FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS (windows, doors E06B)
- B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00)
- E04B: GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS (border constructions of opening in walls, floors or ceilings E06B1/00; {electromagnetic shielding H05K9/0001})
- B29L: INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES

## Abstract

A method of making a pultruded deck board attachment fastened to a substructure to provide a stiffer and stronger deck board than a wood, wood composite, or plastic deck board, wherein the pultruded deck board attachment, along with any fasteners, is covered and protected with a walking surface that is, in examples, snapped in to place.

## Claims

### Claim 1

1) A method of making a decking attachment apparatus comprising the following steps:
pulling fibrous reinforcements off one or more creels or doffs;
pulling the fibrous reinforcements through one or more guide plates to align with one or more thermosetting resin wet-out baths;
pulling the fibrous reinforcements through the one or more thermosetting wet-out baths, wherein the one or more wet-out baths contain a liquid thermosetting resin matrix to create or form saturated fibrous reinforcements;
pulling the saturated fibrous reinforcements through one or more preformers to consolidate, shape, or form the saturated fibrous reinforcements; and
pulling the saturated fibrous reinforcements through one or more heated dies to cure and harden the saturated fibrous reinforcements;
wherein the decking attachment apparatus is capable of being attached to one or more decking joists on a first side and one or more decking surface capping apparatus on a second side.

### Claim 2 (depends on 1)

2) The method of making a decking attachment apparatus according to claim 1, further comprising:
pulling the cured and hardened saturated fibrous reinforcements through one or more pulling system apparatus;
pulling the cured and hardened saturated fibrous reinforcements through or to one or more saws; and
cutting the cured and hardened saturated fibrous reinforcements.

### Claim 3 (depends on 1)

3) The method of making a decking attachment apparatus according to claim 1, wherein the fibrous reinforcements are continuous fibrous reinforcements.

### Claim 4 (depends on 1)

4) The method of making a decking attachment apparatus according to claim 1, wherein the resin matrix comprises polyester, vinylester, epoxy, phenolic, polyurethane, modified acrylic, or a combination thereof.

### Claim 5 (depends on 1)

5) The method of making a decking attachment apparatus according to claim 1, wherein the fibrous reinforcements comprise one or more of fiberglass, carbon fiber, flax, hemp, aramid, basalt, or a combination thereof.

### Claim 6 (depends on 1)

6) The method of making a decking attachment apparatus according to claim 1, wherein the fibrous reinforcements comprise one or more of unidirectional rovings, unidirectional stitched rovings, continuous filament mat, fiber material, chopped fiber material, woven material, point bonded material, or a combination thereof.

### Claim 7 (depends on 1)

7) The method of making a decking attachment apparatus according to claim 1, wherein the fibrous reinforcements are processed in a form of continuous unidirectional rovings, continuous unidirectional stitched rovings, continuous filament mat, continuous woven material, or a combination thereof.