Decking

Abstract

Decking comprises: a support selected from the group consisting of: polymeric materials; marine engineering polymers, fibre reinforced polymers, polymer metal composites, metal or wood sheets or marine superstructure; an array of strips of polymer treated wood secured to the support by means of an adhesive; the adhesive being selected from the group consisting of: polyurethane adhesives, modified silyl polymer adhesives and epoxy resin adhesives; wherein the polymer treated wood comprises a wood species selected from the group consisting of: maple species impregnated with a wood compatible polymerisable monomer, preferably selected from furfuryl alcohol, bis hydroxymethyl furan and mixtures thereof and subsequently dried and cured.

1 . Decking comprising:
 a support selected from the group consisting of: polymeric materials; marine engineering polymers, fibre reinforced polymers, polymer metal composites, metal or wood sheets or marine superstructure;   an array of strips of polymer treated wood secured to the support by means of an adhesive;   wherein the polymer treated wood comprises a wood species selected from the group consisting of: maple species impregnated with a wood compatible polymerisable monomer, preferably selected from furfuryl alcohol, bis hydroxymethyl furan and mixtures thereof and subsequently dried and cured.   
     
     
         2 . Decking as claimed in  claim 1  wherein the treated wood has a hardness value of about 3 to about 8 on the Brinell scale. 
     
     
         3 . Decking as claimed in  claim 1 , wherein the treated wood has a bending modulus of rupture of between about 100 and about 130 MPa. 
     
     
         4 . Decking as claimed in  claim 1  wherein the wood surface exhibits a hardness of 4 to 7 on the Brinell scale. 
     
     
         5 . Decking as claimed in  claim 1  wherein the wood surface exhibits a hardness of 5 to 6 on the Brinell scale. 
     
     
         6 . Decking as claimed in  claim 1  wherein the monomer is furfuryl alcohol. 
     
     
         7 . Decking as claimed in  claim 1  wherein the support substrate is selected from polyester sheeting, glassfibre, reinforced polyester, epoxy-wood composites, plywood, polyaramid sheet, carbonfibre composites or laminates, and solid wood or metal sheets. 
     
     
         8 . Decking as claimed in  claim 1  wherein the adhesive is selected from the group consisting of: polyurethane adhesives, modified silyl polymer adhesives and epoxy resin adhesives. 
     
     
         9 . Decking as claimed in  claim 1  wherein the species of wood is selected from  Acer macrophyllum; Acer negundo; Acer nigrum; Acer rubrum; Acer saccharinum; Acer saccharum; Acer pseudoplatinus; Acer platanoides; Acer campestre.    
     
     
         10 . Decking or a process of manufacture of decking as claimed in  claim 1  wherein edges of the strips include rebates. 
     
     
         11 . Decking as claimed in  claim 1  wherein a volumetric swelling of the treated wood is about 8 to 10% from oven dry to moisture saturated. 
     
     
         12 . Decking as claimed in  claim 1  having a modulus of elasticity between 10000 and 17000 MPa. 
     
     
         13 . Decking as claimed in  claim 1  wherein the impregnated timber composite has a density of 700 to 1000 kgm −3 . 
     
     
         14 . A process for manufacture of decking, said decking comprising:
 a support selected from the group consisting of: polymeric materials; marine engineering polymers, fibre reinforced polymers, polymer metal composites, metal or wood sheets or marine superstructure;   an array of strips of polymer treated wood secured to the support by means of an adhesive;   wherein the polymer treated wood comprises a wood species selected from the group consisting of: maple species impregnated with a wood compatible polymerisable monomer, preferably selected from furfuryl alcohol, his hydroxymethyl furan and mixtures thereof and subsequently dried and cured;   said process for manufacture comprising the steps of:   assembling a laminate comprising an array of strips of wood secured to a support selected from the group consisting of a sheet of polymeric material selected from the group consisting of: marine engineering polymers, fibre reinforced polymers, polymer metal composites metal or wood sheets or superstructure by means of an adhesive selected from the group consisting of: polyurethane adhesives modified silyl polymer adhesives and epoxy resin adhesives;   applying pressure to the assembly and allowing the adhesive to cure.   
     
     
         15 . A process for manufacture of decking as claimed in  claim 14  comprising the steps of:
 impregnating the wooden strips with a polymerisable composition comprising: 
 (i) one or more wood compatible polymerisable monomers, oligomers or mixture thereof; 
 (ii) a catalyst and; 
 (iii) a solvent selected from the group consisting of: water, C 1 -C 4  alcohols and mixtures thereof; and 
 (iv) optionally one or more stabilisers or other ingredients; 
 
       to produce impregnated decking strips;
 subjecting the impregnated decking strips to a water removal process comprising maintaining the wood in an atmosphere having a pressure of about 0.1 to about 0.5 bar, a temperature of about 50 to about 90° C., for a duration sufficient to cause removal of water from the wood; and maintaining the wood at a higher temperature to form the polymeric material to produce polymer treated decking strips. 
 
     
     
         16 . A process as claimed in  claim 14  wherein the treatment solution comprises furfuryl alcohol 20 to 95 parts and water 100 parts with optional further ingredients. 
     
     
         17 . A process as claimed in  claim 16  wherein the treatment solution comprises 30% to 50% furfuryl alcohol. 
     
     
         18 . A process as claimed in  claim 16  wherein the treatment solution contains 40% to 70% furfuryl alcohol.