CA2982780A1 - Densified foam core (dfc) board for use as a backing surface - Google Patents
Densified foam core (dfc) board for use as a backing surface Download PDFInfo
- Publication number
- CA2982780A1 CA2982780A1 CA2982780A CA2982780A CA2982780A1 CA 2982780 A1 CA2982780 A1 CA 2982780A1 CA 2982780 A CA2982780 A CA 2982780A CA 2982780 A CA2982780 A CA 2982780A CA 2982780 A1 CA2982780 A1 CA 2982780A1
- Authority
- CA
- Canada
- Prior art keywords
- board
- core layer
- recited
- face
- sound
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
- 239000006260 foam Substances 0.000 title claims description 7
- 239000012792 core layer Substances 0.000 claims abstract description 48
- 239000010410 layer Substances 0.000 claims abstract description 38
- 239000006261 foam material Substances 0.000 claims abstract description 21
- 239000000463 material Substances 0.000 claims abstract description 18
- 238000004078 waterproofing Methods 0.000 claims abstract description 4
- 238000009434 installation Methods 0.000 claims description 11
- 239000004800 polyvinyl chloride Substances 0.000 claims description 8
- OYPRJOBELJOOCE-UHFFFAOYSA-N Calcium Chemical compound [Ca] OYPRJOBELJOOCE-UHFFFAOYSA-N 0.000 claims description 6
- 239000011575 calcium Substances 0.000 claims description 6
- 229910052791 calcium Inorganic materials 0.000 claims description 6
- 239000004088 foaming agent Substances 0.000 claims description 6
- 239000000843 powder Substances 0.000 claims description 6
- 229920000915 polyvinyl chloride Polymers 0.000 claims description 4
- 239000007799 cork Substances 0.000 claims description 3
- BFMKFCLXZSUVPI-UHFFFAOYSA-N ethyl but-3-enoate Chemical compound CCOC(=O)CC=C BFMKFCLXZSUVPI-UHFFFAOYSA-N 0.000 claims description 3
- 239000005060 rubber Substances 0.000 claims description 3
- 239000003381 stabilizer Substances 0.000 claims description 3
- 239000000203 mixture Substances 0.000 abstract description 12
- 102100035353 Cyclin-dependent kinase 2-associated protein 1 Human genes 0.000 description 15
- 239000004568 cement Substances 0.000 description 8
- 238000009408 flooring Methods 0.000 description 5
- 239000011120 plywood Substances 0.000 description 5
- 239000004579 marble Substances 0.000 description 4
- 239000004575 stone Substances 0.000 description 4
- 229920002554 vinyl polymer Polymers 0.000 description 4
- 239000000853 adhesive Substances 0.000 description 3
- 230000001070 adhesive effect Effects 0.000 description 3
- 239000004567 concrete Substances 0.000 description 3
- 238000011161 development Methods 0.000 description 3
- 230000018109 developmental process Effects 0.000 description 3
- 239000004570 mortar (masonry) Substances 0.000 description 3
- -1 travertine Substances 0.000 description 3
- 239000002023 wood Substances 0.000 description 3
- 230000004888 barrier function Effects 0.000 description 2
- 230000005540 biological transmission Effects 0.000 description 2
- 239000000919 ceramic Substances 0.000 description 2
- 239000003795 chemical substances by application Substances 0.000 description 2
- 239000003086 colorant Substances 0.000 description 2
- 239000002131 composite material Substances 0.000 description 2
- 150000001875 compounds Chemical class 0.000 description 2
- 239000011888 foil Substances 0.000 description 2
- 239000010438 granite Substances 0.000 description 2
- 239000011810 insulating material Substances 0.000 description 2
- 238000000034 method Methods 0.000 description 2
- 239000002985 plastic film Substances 0.000 description 2
- 229920006255 plastic film Polymers 0.000 description 2
- 229920002994 synthetic fiber Polymers 0.000 description 2
- 125000000391 vinyl group Chemical group [H]C([*])=C([H])[H] 0.000 description 2
- VEXZGXHMUGYJMC-UHFFFAOYSA-M Chloride anion Chemical compound [Cl-] VEXZGXHMUGYJMC-UHFFFAOYSA-M 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 238000010276 construction Methods 0.000 description 1
- 239000013013 elastic material Substances 0.000 description 1
- 230000002349 favourable effect Effects 0.000 description 1
- 238000009472 formulation Methods 0.000 description 1
- 239000011507 gypsum plaster Substances 0.000 description 1
- 238000011900 installation process Methods 0.000 description 1
- 230000007246 mechanism Effects 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000005192 partition Methods 0.000 description 1
- 230000000149 penetrating effect Effects 0.000 description 1
- 229920003023 plastic Polymers 0.000 description 1
- 239000004033 plastic Substances 0.000 description 1
- 229920000642 polymer Polymers 0.000 description 1
- 229910052573 porcelain Inorganic materials 0.000 description 1
- 230000008569 process Effects 0.000 description 1
- 230000009467 reduction Effects 0.000 description 1
- 239000002689 soil Substances 0.000 description 1
- 230000000087 stabilizing effect Effects 0.000 description 1
- 239000000758 substrate Substances 0.000 description 1
- 239000002699 waste material Substances 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
Classifications
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
- E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
- E04C2/10—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products
- E04C2/20—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products of plastics
- E04C2/205—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products of plastics of foamed plastics, or of plastics and foamed plastics, optionally reinforced
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
- E04B1/62—Insulation or other protection; Elements or use of specified material therefor
- E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
- E04B1/82—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to sound only
- E04B1/84—Sound-absorbing elements
- E04B1/8409—Sound-absorbing elements sheet-shaped
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
- E04C2/44—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the purpose
- E04C2/52—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the purpose with special adaptations for auxiliary purposes, e.g. serving for locating conduits
- E04C2/526—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the purpose with special adaptations for auxiliary purposes, e.g. serving for locating conduits with adaptations not otherwise provided for, for connecting, transport; for making impervious or hermetic, e.g. sealings
- E04C2/528—Impervious or hermetic panels not otherwise provided for
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
- E04F13/00—Coverings or linings, e.g. for walls or ceilings
- E04F13/07—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
- E04F13/08—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements
- E04F13/0875—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements having a basic insulating layer and at least one covering layer
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2031/00—Other particular articles
- B29L2031/10—Building elements, e.g. bricks, blocks, tiles, panels, posts, beams
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
- E04B1/62—Insulation or other protection; Elements or use of specified material therefor
- E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
- E04B1/82—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to sound only
- E04B1/84—Sound-absorbing elements
- E04B1/86—Sound-absorbing elements slab-shaped
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
- E04B1/62—Insulation or other protection; Elements or use of specified material therefor
- E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
- E04B1/82—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to sound only
- E04B1/84—Sound-absorbing elements
- E04B2001/8457—Solid slabs or blocks
- E04B2001/8461—Solid slabs or blocks layered
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
- E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
- E04C2/10—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products
- E04C2/20—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products of plastics
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
- E04C2/44—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the purpose
- E04C2/52—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the purpose with special adaptations for auxiliary purposes, e.g. serving for locating conduits
- E04C2/526—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the purpose with special adaptations for auxiliary purposes, e.g. serving for locating conduits with adaptations not otherwise provided for, for connecting, transport; for making impervious or hermetic, e.g. sealings
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
- E04C2002/005—Appearance of panels
Landscapes
- Engineering & Computer Science (AREA)
- Architecture (AREA)
- Civil Engineering (AREA)
- Structural Engineering (AREA)
- Physics & Mathematics (AREA)
- Acoustics & Sound (AREA)
- Electromagnetism (AREA)
- Life Sciences & Earth Sciences (AREA)
- Wood Science & Technology (AREA)
- Laminated Bodies (AREA)
- Floor Finish (AREA)
Abstract
A waterproof board for use as a backing surface comprising a top face, a bottom face, a plurality of sides, a core layer having a thickness of about 5 millimeters, and a sound layer having a thickness of about 2 millimeters. The sound layer is generally interconnected to the core layer. The core layer may comprises at least two faces, either of which may comprise a textured surface.
The textured surface may comprise either a substantially smooth finish or a substantially abrasive finish. The core layer comprises a densified foam material having a density of 490 kg/m3 to about 520 kg/m3, and a specific material composition, both of which enhance waterproofing and attain an optimal balance between rigidity and severability.
The textured surface may comprise either a substantially smooth finish or a substantially abrasive finish. The core layer comprises a densified foam material having a density of 490 kg/m3 to about 520 kg/m3, and a specific material composition, both of which enhance waterproofing and attain an optimal balance between rigidity and severability.
Description
M:\1-PAT\PAT 2016\APP\1653-16 Quickstyle\PT0\05 PA\2017_06_13_Nonprovisiona1_Patent_App1 Flled_1653.doc 1 DENSIFIED FOAM CORE (DFC) BOARD FOR USE AS A BACKING SURFACE
2
3 BACKGROUND OF THE INVENTION
4 Claim of Priority The present invention claims priority under 35 U.S.C. Section 119(e) to a currently pending U.S. provisional patent application having Serial No. 62/409,654 and a filing date of October 18, 2016, 8 which is incorporated herein by reference in its entirety.
Field of the Invention 11 The present invention is directed to a rigid panel or board 12 made from synthetic materials and which is suitable for use as a 13 backing support against which a variety of coverings may be 14 installed. The inventive board comprises at least a core layer made from a densified foam material having a predetermined 16 structural integrity with sufficient rigidity suitable for installation and the attachment of a variety of coverings thereon.
18 In addition, the densified foam material of the core layer has a 19 predetermined structural integrity to allow a user to make a score line on the board and sever it into smaller pieces.
During the construction of a home, building or other structure, there will almost always be an unfinished wall surface such as concrete block, a wood structure or the like, which needs M:\1-PAT\PAT 2016\APP\1653-16 Quickstyle\PT0\05 PA\2017_06_13_Nonprovisional Patent Appl_Ftled_1653.doc 1 to be finished to offer a more appealing and/or polished 2 appearance. This is also true of most unfinished floor surfaces.
3 Traditionally, various cement based products, such as mortar or 4 "thin-set" have been used to treat such unfinished surfaces and aid in making them more even or level, and often times, tiles of 6 marble, stone, ceramic, and the like are also applied as part of 7 the process. Other products used to treat unfinished surfaces, such 8 as uneven floors or slabs, include plywood underlayment products 9 that may come in sheets or planks having a thickness of about 6 millimeters. Because plywood underlayment products are not 11 waterproof, their application is generally limited to horizontal 12 surfaces. Additionally, the installation of plywood underlayment 13 products and/or cement based products is often tedious, labor 14 intensive and time consuming.
For example, plywood sheets and cement based mixtures are often heavy and cumbersome, plus cement 16 based mixtures and related products need time to cure or harden.
As a result, it has become relatively common to use pre-formed 18 boards made of cementitious materials and attach them to such 19 surfaces in order to provide a backing support that is substantially level, and against which a covering or finish product 21 may be installed. Some known "cement boards" are useful in those areas of a building structure where water and mositure occur, such 23 as in kitchens and bathrooms, and are commonly used as wall surfaces in bathrooms due to their ability to withstand relatiely high levels of humidity and to serve as a backing support against , r . M:\1-PAT\PAT 2016\APP\1653-16 Quickstyle\PT0\05 PA\2017 06 13_Nonprovisional_Patent_Appl Filed_1653.doc 1 which tiles of marble, stone and the like can be applied.
In 2 contrast, however, other pre-formed boards known as "drywall,"
which are made of gypsum plaster and also used on interior walls of 4 a building structure, do not typically serve as a backing support for tiles, and also, are very succeptible to moisture and/or 6 humidity and therefore, are not suitable for wet environments such 7 as in a bathroom, near a shower, etc.
There are several disadvatages associated with both known 9 drywall and cement boards, which include a relatively high cost of the material, the heavy weight of the material and the resulting difficulty associated with shipment, delivery and installation, as 12 well as attendant higher labor costs. Another disadvantage associated with such boards is that there is often a considerable amount of waste generated. Additionally, cement boards tend to be thicker than other types of boards used as wall surfaces, and add 16 difficulty to the installation process as well as spatial 17 constraints, which can be problematic particularly in in small 18 areas or tight spaces.
19 As such, it would be beneficial if a new backing support product could be made out of a material that is relatively thin, 21 relatively lightweight, not cementitious, and which also offers 22 waterproofing properties. If any such improved backing support 23 were developed, it should also be sufficiently rigid so as to be capable of being secured to a surface without causing any damage to the backing support itself, while also capable of supporting a M.\1-PAT\PAT 2016\1PP\1653-16 Quickstyle\PT0\05 PA\2017_06_13_Nonprovisiona1_Patent_App1_Fi1ed_1653.doc 1 covering without being damaged. Further, if any such improved 2 backing support were developed, it should also have an ability to 3 be readily modified or cut into any desired sizes or shape upon 4 installation. Ideally, if any such improved backing support were developed, it would be capable of offering certain sound proofing 6 or sound attenuation properties, which is desirable for use in 7 multi-story developments such as condominiums, hotels, etc.
The present invention is intended to present a solution to 11 these and other needs which remain in this field of art, and as such, is directed to a panel or board made of synthetic materials, and having a structural integrity and sufficient rigidity to permit 14 installation on a surface and to support a variety of coverings thereon. The inventive board overcomes some of the drawbacks of 16 existing plywood underlayment and cement based products as the 17 inventive board is waterproof and can therefore be used on both horizontal and vertical surfaces, and also in different areas of a 19 building such as bathrooms, other areas likely to be exposed to moisture or humidity, as well as with many desired types of 21 flooring surface(s).
The coverings, which may be installed in 22 overlying supported relation to the inventive panel or board, may include tiles made of stone, marble, granite, and the like but also 24 others such as, but not limited to, laminate flooring, vinyl composite tiles (VCT), wood planks and other flooring products. In M:\1-PAT\PAT 2016\1PP\1653-16 Quickstyle\PT0\05 PA\2017_06_13_Nonprovisiona1_Patent_App1 Filed_1653.doc 1 at least one embodiment of the present invention, however, the 2 panel or board can be formed to include a dye or colorant(s) in 3 order to coordinate with a particular color scheme for the 4 surrounding area, and in other embodiments can itself be directly painted, so that in some instances, the present invention can be 6 used to finish a building floor, wall or other surface, and its use 7 with other coverings is not necessary.
The panel or board of the present invention, which can be 9 formed to offer various sizes and dimensions, comprises a core layer having a first or top surface, an oppositely disposed second 11 or bottom surface, and a substantially uniform thickness that in 12 some embodiments is within a range of generally about 4 millimeters 13 to about 6 millimeters, and ideally about 5 millimeters. Also, a 14 textured surface is formed on at least a portion of either the first top surface or the second bottom surface. The textured 16 surface comprises, in at least one embodiment, an abrasive finish formed at least partially, if not entirely, on either the first or 18 second surface, to facilitate use with an adhesive or other 19 material such as "thin-set" or mortar. In some embodiments, both surfaces may include a textured surface, such as but not limited 21 to, a substantially abrasive finish on one of these surfaces and a substantially smooth finish on the other, which may be desirable in 23 other instances.
In addition, the panel or board of the present invention has a core layer comprising a densified foam material having an optimal
Field of the Invention 11 The present invention is directed to a rigid panel or board 12 made from synthetic materials and which is suitable for use as a 13 backing support against which a variety of coverings may be 14 installed. The inventive board comprises at least a core layer made from a densified foam material having a predetermined 16 structural integrity with sufficient rigidity suitable for installation and the attachment of a variety of coverings thereon.
18 In addition, the densified foam material of the core layer has a 19 predetermined structural integrity to allow a user to make a score line on the board and sever it into smaller pieces.
During the construction of a home, building or other structure, there will almost always be an unfinished wall surface such as concrete block, a wood structure or the like, which needs M:\1-PAT\PAT 2016\APP\1653-16 Quickstyle\PT0\05 PA\2017_06_13_Nonprovisional Patent Appl_Ftled_1653.doc 1 to be finished to offer a more appealing and/or polished 2 appearance. This is also true of most unfinished floor surfaces.
3 Traditionally, various cement based products, such as mortar or 4 "thin-set" have been used to treat such unfinished surfaces and aid in making them more even or level, and often times, tiles of 6 marble, stone, ceramic, and the like are also applied as part of 7 the process. Other products used to treat unfinished surfaces, such 8 as uneven floors or slabs, include plywood underlayment products 9 that may come in sheets or planks having a thickness of about 6 millimeters. Because plywood underlayment products are not 11 waterproof, their application is generally limited to horizontal 12 surfaces. Additionally, the installation of plywood underlayment 13 products and/or cement based products is often tedious, labor 14 intensive and time consuming.
For example, plywood sheets and cement based mixtures are often heavy and cumbersome, plus cement 16 based mixtures and related products need time to cure or harden.
As a result, it has become relatively common to use pre-formed 18 boards made of cementitious materials and attach them to such 19 surfaces in order to provide a backing support that is substantially level, and against which a covering or finish product 21 may be installed. Some known "cement boards" are useful in those areas of a building structure where water and mositure occur, such 23 as in kitchens and bathrooms, and are commonly used as wall surfaces in bathrooms due to their ability to withstand relatiely high levels of humidity and to serve as a backing support against , r . M:\1-PAT\PAT 2016\APP\1653-16 Quickstyle\PT0\05 PA\2017 06 13_Nonprovisional_Patent_Appl Filed_1653.doc 1 which tiles of marble, stone and the like can be applied.
In 2 contrast, however, other pre-formed boards known as "drywall,"
which are made of gypsum plaster and also used on interior walls of 4 a building structure, do not typically serve as a backing support for tiles, and also, are very succeptible to moisture and/or 6 humidity and therefore, are not suitable for wet environments such 7 as in a bathroom, near a shower, etc.
There are several disadvatages associated with both known 9 drywall and cement boards, which include a relatively high cost of the material, the heavy weight of the material and the resulting difficulty associated with shipment, delivery and installation, as 12 well as attendant higher labor costs. Another disadvantage associated with such boards is that there is often a considerable amount of waste generated. Additionally, cement boards tend to be thicker than other types of boards used as wall surfaces, and add 16 difficulty to the installation process as well as spatial 17 constraints, which can be problematic particularly in in small 18 areas or tight spaces.
19 As such, it would be beneficial if a new backing support product could be made out of a material that is relatively thin, 21 relatively lightweight, not cementitious, and which also offers 22 waterproofing properties. If any such improved backing support 23 were developed, it should also be sufficiently rigid so as to be capable of being secured to a surface without causing any damage to the backing support itself, while also capable of supporting a M.\1-PAT\PAT 2016\1PP\1653-16 Quickstyle\PT0\05 PA\2017_06_13_Nonprovisiona1_Patent_App1_Fi1ed_1653.doc 1 covering without being damaged. Further, if any such improved 2 backing support were developed, it should also have an ability to 3 be readily modified or cut into any desired sizes or shape upon 4 installation. Ideally, if any such improved backing support were developed, it would be capable of offering certain sound proofing 6 or sound attenuation properties, which is desirable for use in 7 multi-story developments such as condominiums, hotels, etc.
The present invention is intended to present a solution to 11 these and other needs which remain in this field of art, and as such, is directed to a panel or board made of synthetic materials, and having a structural integrity and sufficient rigidity to permit 14 installation on a surface and to support a variety of coverings thereon. The inventive board overcomes some of the drawbacks of 16 existing plywood underlayment and cement based products as the 17 inventive board is waterproof and can therefore be used on both horizontal and vertical surfaces, and also in different areas of a 19 building such as bathrooms, other areas likely to be exposed to moisture or humidity, as well as with many desired types of 21 flooring surface(s).
The coverings, which may be installed in 22 overlying supported relation to the inventive panel or board, may include tiles made of stone, marble, granite, and the like but also 24 others such as, but not limited to, laminate flooring, vinyl composite tiles (VCT), wood planks and other flooring products. In M:\1-PAT\PAT 2016\1PP\1653-16 Quickstyle\PT0\05 PA\2017_06_13_Nonprovisiona1_Patent_App1 Filed_1653.doc 1 at least one embodiment of the present invention, however, the 2 panel or board can be formed to include a dye or colorant(s) in 3 order to coordinate with a particular color scheme for the 4 surrounding area, and in other embodiments can itself be directly painted, so that in some instances, the present invention can be 6 used to finish a building floor, wall or other surface, and its use 7 with other coverings is not necessary.
The panel or board of the present invention, which can be 9 formed to offer various sizes and dimensions, comprises a core layer having a first or top surface, an oppositely disposed second 11 or bottom surface, and a substantially uniform thickness that in 12 some embodiments is within a range of generally about 4 millimeters 13 to about 6 millimeters, and ideally about 5 millimeters. Also, a 14 textured surface is formed on at least a portion of either the first top surface or the second bottom surface. The textured 16 surface comprises, in at least one embodiment, an abrasive finish formed at least partially, if not entirely, on either the first or 18 second surface, to facilitate use with an adhesive or other 19 material such as "thin-set" or mortar. In some embodiments, both surfaces may include a textured surface, such as but not limited 21 to, a substantially abrasive finish on one of these surfaces and a substantially smooth finish on the other, which may be desirable in 23 other instances.
In addition, the panel or board of the present invention has a core layer comprising a densified foam material having an optimal
5 M:\1-PAT\PAT 2016\APP\1653-16 Quickstyle\PT0\05 PA\2017_06 13_Nonprovislonal Patent_Appl_Filed_1653.doc 1 density that achieves balance between rigidity and severability.
2 More specifically, the densified foam material has a predetermined 3 structural integrity so as to be sufficiently rigid to permit 4 installation onto a selected surface without causing damage to the panel or board, and also, adequate structural support to one or
2 More specifically, the densified foam material has a predetermined 3 structural integrity so as to be sufficiently rigid to permit 4 installation onto a selected surface without causing damage to the panel or board, and also, adequate structural support to one or
6 more coverings thereon, some of which may be heavy. At the same
7 time, the predetermined structural integrity of the densified foam
8 material is sufficiently severable such that a user can cut or
9 "score" a line on the panel or board with a box-cutter, knife or other cutting tool, and subsequently "snap" the panel or board into 11 smaller pieces. As such, the densified foam material will have a 12 optimal density ranging from generally about 450 kg/m3 to about 550 13 kg/m3, although in one or more preferred embodiments, this will be 14 generally about 500 kg/m3. Additionally, the panel or board of the present invention can be extruded from a foamed high density 16 polyvinyl (PVC) composition comprising in at least one embodiment 17 generally equal amounts of a polyvinyl chloride (PVC) material and 18 calcium powder, as well as stabilizing agents and foaming agents, 19 such as but not limited to a composition of generally about 47% of PVC, and generally about 47% of calcium powder, a stabilizer agent 21 of generally about 3% and a foaming agent of generally about 3%.
22 Additionally, the densified foam material composition and density 23 thereof contribute to the waterproofing properties of the 24 invention, making it ideal for use in moist environments such as kitchens, bathrooms, and showers. It should be noted, however, M:\1-PAT\PAT 2016\APP\1653-16 Quickstyle\PT0\05 PA\2017_06_13_Nonprovisiona1_Patent_App1_Fi1ed_1653.doc 1 that in other embodiments, the core layer of the inventive panel or 2 board, including the densified foam material may also comprise 3 other materials and/or formulations.
As one example, the panel or board of the present invention may also comprise in some embodiments a sound layer formed from a 6 sound insulating material that can attenuate sound transmission, 7 which is desirable in some environments where sound reduction is 8 important, such as in multi-story developments. The sound layer 9 may be connected to the core layer and may comprise ethyl vinyl acetate or other sound insulating materials including, but not 11 limited to, cork, rubber, or foam.
The thickness of the sound 12 layer may range from about 1 millimeter to about 4 millimeters depending on the desired level of sound attenuation. Additionally, 14 the sound layer may comprise a moisture layer in the form of a plastic film or foil.
These and other objects, features and advantages of the 17 present invention will become clearer when the drawings as well as 18 the detailed description are taken into consideration.
BRIEF DESCRIPTION OF THE DRAWINGS
For a fuller understanding of the nature of the present 22 invention, reference should be had to the following detailed 23 description taken in connection with the accompanying drawings in 24 which:
Figure 1 is a perspective view of one embodiment of a board M:\1-PAT\PAT 2016\APP\1653-16 Quickstyle\PI0\05 PA\2017_06_13_Nonprovisional Patent_Appl_FIled_1653.doc 1 according to the present invention comprising a core layer.
Figure 2 is a perspective view of a board according to the 3 present invention in another embodiment comprising a core layer and 4 a sound layer.
Figure 3A is a perspective exploded view of one embodiment of 6 a board according to the present invention comprising a core layer 7 and a sound layer.
Figure 3B is a perspective exploded view of one embodiment of 9 a board according to the present invention comprising a core layer, and a moisture layer.
Figure 4 is a perspective view of one embodiment of a board according to the present invention comprising a core layer having a 13 textured surface that is substantially smooth.
Figure 5 is a perspective view of one embodiment of a board according to the present invention comprising a core layer having a 16 textured surface that is substantially abrasive.
Figure 6 is a perspective view of another embodiment of a 18 board according to the present invention comprising a core layer 19 having a textured surface that is substantially smooth.
Figure 7 is a perspective view of another embodiment of a 21 board according to the present invention comprising a core layer 22 having a textured surface that is substantially abrasive.
23 Like reference numerals refer to like parts throughout the 24 several views of the drawings.
M:\1-PAT\PAT 2016\APP\1653-16 cAiickstyle\PT0\05 PA\2017_06_13_Nonprovisional_Patent Appl_Filed_1653.doc 2 The present invention is directed towards a panel or board, 3 generally indicated as 10, that may be used as backing support for 4 a variety of different applications. While the present invention is referred to herein primarily as a board or panel, it may also comprise a sheet or other similar structure, and consequently, this 7 terminology should not be deemed a limiting factor.
8 As will be explained in greater detail below, the board 10 of 9 the present invention is intended for installation on an unfinished floor, wall, soffit, ceiling, or other similar surface. By way of example, the board 10 may be secured to an unfinished wall such as 12 a masonry wall or a concrete wall, or against an unfinished floor 13 such as a concrete slab or floor. In most instances, the board 10 14 will typically be nailed, screwed or drilled into place, but may also be secured by other methods. Also, the board 10 of the 16 present invention is well suited to level an otherwise uneven 17 surface, but it may also be used in a variety of other 18 applications. As another example, the board 10, itself, may be 19 used to form a wall, ceiling, soffit, or other similar partition or divider, and to support a covering or finish. In other words, the 21 board 10 may be disposed against or connected to a support 22 structure such as, but not limited to, a frame or a mount.
23 After the inventive board 10 is installed in a desired 24 location, a variety of coverings or finishing products may be installed, applied, or otherwise adhered to the board 10. These M\1-PAT\PAT 2016\APP\1653-16 Quickstyle\PT0\05 PA\2017_06_13_Nonprovislona1_Patent_epp1_Pl1ed_1653.doc 1 covering or finish products generally require a flat surface for 2 installation and may include various types of tiles such as, but 3 not limited to, marble, stone, travertine, granite, mosaics, 4 ceramic, porcelain and the like, some of which may be quite heavy.
Other coverings can also be used with the inventive board 10, such 6 as, but not limited to, laminate flooring, vinyl composite tiles (VCT), wood planks and other flooring products. Moreover, other 8 coverings or finish products which may also require a flat surface 9 for installation are also within the scope of the present invention.
With reference now to Figure 1, the panel or board 10 of the 12 present invention comprises at least a core layer, generally 13 represented as 20. As shown, the core layer 20 comprises a first face 22 that defines a top surface 12 of the board 10 and a second face 24 that is oppositely disposed so as to define a bottom 16 surface 14 of the panel or board 10.
The core layer 20 will preferably have a uniform thickness between its top surface 12 and 18 bottom surface 14 and be in a range of generally about 4 19 millimeters to 6 millimeters, although in a preferred embodiment, this thickness will be generally 5 millimeters. Additionally, at least one of these faces, such as 22, 24 or such as surfaces 12, 14 22 will include a texture formed on at least a portion thereof. In 23 most embodiments, however, the board 10 will have a textured surface formed at least substantially across one of these faces or surfaces. Also in most embodiments, a textured surface can be M:\1-PAT\PAT 2016\APP\1653-16 Quickstyle\PT0\05 PA\2017_06_13_Nonprovisional_Patent_Appl_Filed_1653.doc 1 formed on both of these faces or surfaces. For example, and with 2 reference to Figures 4 through 7, the first face 22 and the second 3 face 24 may respectively comprise a first textured surface 26 and 4 second textured surface 28. The texture surface may comprise a smooth finish, although in at least one embodiment, the textured 6 surface comprises an abrasive finish.
However, the present 7 invention contemplates a board 10 having both a first face 22 8 defined by top surface 12 with a first textured surface 26 that may 9 be smooth, and a second face 24 defined by bottom surface 14 having a second textured surface 28 that offers a partially or 11 substantially abrasive finish.
As represented in the illustrative embodiments of Figures 1-7, 13 the board 10 may comprise a substantially rectangular shape, having 14 a pair of elongated sides or edges 16 and a pair of shorter sides or edges 16'. Other configurations for the panel or board 10 are 16 possible and within the spirit of the present invention, such as 17 but not limited to, substantially square, trapezoid, circular or other shapes. Also, and while the board 10 may be formed to have 19 other dimensions, in the embodiment having a rectangular shape, the board 10 may be manufactured to have dimensions that generally correspond to the spacing commonly found between drywall studs. By 22 way of example only, the dimensions of the board 10 may be 23 approximately thirty six (36") inches wide by approximately sixty 24 (60") inches long.
The core layer 20 of the inventive panel or board 10 M:\1-PAT\PAT 2016\APP\1653-16 QuIckstyle\PT0\05 PA\2017_06_13_Nonprovisional Patent_Appl_Filed_1653.doc 1 additionally comprises a densified foam material having a 2 predetermined structural integrity. This predetermined structural 3 integrity is the result of the specific material composition and 4 density range of the densified foam material, and allows for an optimal balance between rigidity and severability that makes the 6 board 10 ideal for use as a backing support. For example, the 7 inventive board 10 is sufficiently rigid so that the board 10 can 8 be installed and secured to an unfinished wall or floor surface, 9 whether by nails, screws or other fastening mechanism without damaging the board, such as by the head of the screw or nail 11 penetrating the surface of the board 10. In addition, the board 10 12 is sufficiently rigid so as to provide adequate support to one or 13 more tiles, or other coverings disposed thereon. Moreover, the 14 inventive board 10 should at the same time be sufficiently severable, so as to allow a user to expeditiously cut, trim or 16 otherwise form the inventive board 10 into a desired shape by 17 "scoring" a line(s) on the board 10 with a box-cutter, knife or 18 other cutting tool, and subsequently break or snap off a piece of 19 the board 10 along the scoring line. For example, and due to the composition and thickness of the board 10 in some embodiments, a 21 user may use a box-cutter, knife, or other similar instrument to 22 "score" a line(s) on the inventive board 10 at a depth of 23 approximately 2 millimeters to approximately to 3 millimeters below 24 the top surface 12 of the board 10, and thereafter, readily snap or break off the board 10 into smaller pieces along the scoring line.
M:\l-PAT\PAT 2016\APP\1653-16 Quickstyle\PT0\05 PA\2017_06_13_Nonprovisiona1 Patent_Appl_FIled_1653.doc Accordingly, the core layer 20 comprises a densified foam 2 material that is preferably a foamed, high density, polyvinyl 3 chloride (PVC) material. While the specific composition of the 4 densified foam material may vary, it generally comprises a combination of a synthetic plastic polymer such as polyvinyl chloride (PVC), calcium powder, and foaming agent. In at least one embodiment, the material composition of the densified foam material comprises polyvinyl chloride (PVC) and calcium powder in generally 9 equal amounts. For example, the densified foam material may comprise polyvinyl chloride (PVC) in an amount of between generally 11 between about 45% to about 48%, and calcium powder in an amount 12 also generally between 45% to about 48%, as well as stabilizing 13 agent(s) in an amount of approximately 3% and foaming agent(s) in 14 an amount of approximately 3%. The foaming agent may be a mixture of several materials that enhance stability. Additionally, the 16 density of the core layer 20 and its densified foam material may 17 range from about 450 kg/m3 to about 550 kg/m3, with very favorable 18 results attained with a density of 500 kg/m3.
feature of the board 10 of the present invention is that either of the faces 22 or 24 of the core layer 20 may be modified 21 or roughened to facilitate adhesion. As is represented in Figures 22 4 and 7, the board 10 of the present invention, and more specifically the core layer 20, is initially manufactured so that 24 all of its faces, such as 22 and/or 24, comprise a substantially smooth finish. As such, either or both of the first textured M:\1-PAT\PAT 2016\APP\1653-16 Quickstyle\PT0\05 PA\2017_06_13_Nonprovisional_Patent_Appl_Flled_1653.doc 1 surface 26 and/or second textured surface 27 may comprise a 2 substantially smooth finish, generally indicated as 27.
As is 3 represented in Figures 5 and 8, either or both of the first face 22 4 or second face 24 of the core layer, may be modified or roughened to achieve a substantially abrasive finish, generally represented 6 as 29. As such, at least a portion of the core layer 20 may be 7 passed through a light sander to roughen it thereby creating a 8 substantially abrasive finish 29 on either or both of its faces 22 9 or 24. With a substantially abraded finish 29, an adhesive such as thin-set, mortar, or another compound, can better adhere to either 11 face 22 or 24 of the core layer 20.
Providing a board 10 12 comprising a core layer 20 with a substantially abraded finish 29 13 is particularly useful if an adhesive or other compound is required 14 to install the exposed surface. Conversely, a substantially abrasive finish 29 may not always be needed, such as in a face 22 16 of 24 of the core layer 20, against which may not be installed an 17 exposed surface.
Hence, a substantially smooth finish 27 is 18 acceptable on areas that may be intentionally left exposed, such as 19 for example inner portions of walls.
Further, if the board 10 comprises is a sound layer 30, then the face 22 or 24 of the core 21 layer 20, that is connected either face 32 or 34 of the sound 22 layer, may also comprise a substantially smooth finish 27 in lieu 23 of a substantially abraded finish 29.
As previously mentioned, yet additional features of the present invention include providing a board 10 with sound M:\1-PAT\PAT 2016\APP\1653-16 Quickstyle\PT0\05 PA\2017_06_13_Nonprovisional Patent_Appl_FIled_1653.doc 1 attenuation properties. Therefore, and as shown in Figures 2-3A, 2 the inventive board 10 may also comprise a sound layer, generally 3 represented as 30. The sound layer 30 may be structured to lessen 4 sound transmissions in environments where sound attenuation is important. These environments may include, but are not limited to, 6 multi-story developments such as condominiums, apartments, hotels, 7 retail spaces, office towers, hospitals, and several others. The 8 sound layer 30 may comprise ethyl vinyl acetate which is a material 9 that has sound attenuation properties. Other sound attenuating materials, however, are also within the scope of the present 11 invention.
For example, the sound layer 30 may comprise other 12 materials such as, but not limited to, cork, rubber, or foam. The 13 overall thickness of the sound layer 20 may vary, but generally 14 ranges from about 1 millimeter to about 4 millimeters depending on the desired level of sound attenuation and on spatial constrains.
16 This range may also be about 1.5 millimeters to about 3 millimeters 17 as a sound layer 30 having a thickness of about 2 millimeters may 18 be optimal. Additionally, as represented in Figures 2-3B, the sound 19 layer 30 may also comprise a plurality of edges 36. The plurality of edges 36 of the sound layer 30 may substantially overlap or be 21 substantially coincident with the plurality of sides 16 of the 22 board 10. Alternatively, as is represented in Figure 2, the sound 23 layer 30 may be disposed so that the edge(s) 36 are in a 24 substantially offset relation to the side(s) 16 of the board. That is, a substantially offset relation, between the edge(s) 36 of the M:\1-PAT\PAT 2016\APP\1653-16 Quickstyle\PT0\05 PA\2017_06_13_Nonprovisiona1_Patent_App1_FIled_1653.doc 1 sound layer 30 and the side(s) of the board 10, may be desirable so 2 as to provide an area of the board 10 where a user may be able to 3 cut the board 10 without having to cut or otherwise damage any 4 portion of the sound layer 30.
Moreover, as represented in Figure 3B, the board 10 of the 6 present invention may also comprise a moisture layer, indicated as 7 40.
The moisture layer 40 generally comprises an elastic material 8 such as, but not limited to, a plastic film or a foil, and serves 9 as a moisture barrier between the sound layer 30 and the core layer 20. A moisture layer 40 may be appropriate when the inventive 11 board 10 is used as a leveling surface against a slab that is substantially disposed at grade level. There may be excess 13 moisture in a slab, especially due to saturation of the underlying 14 soil or substrate. In such instances, a moisture layer 40 may be desirable to prevent damage to the covering or finish. As is shown 16 in Figure 3B, the moisture layer 40 is generally connected to the 17 core layer 20. When the board 10 is installed, the moisture layer should face the underlying surface such as the slab on grade so 19 as to serve as a moisture barrier.
In at least one embodiment of the present invention, the panel 21 or board can be formed to include a dye or colorant(s) in order to coordinate with a particular color scheme for the surrounding area.
23 In other embodiments, however, the inventive board can itself be directly painted, so that in some instances, the present invention can be used to finish a building floor, wall or other surface, and M:\1-PAT\PAT 2016\APP\1653-16 Quicksty1e\PTO\05 PA\2017_06_13_Nonprovisional_Patent_Appl Filed_1653.doc 1 its use with other coverings is not necessary.
2 Since many modifications, variations and changes in detail can 3 be made to the described preferred embodiment of the invention, it 4 is intended that all matters in the foregoing description and shown in the accompanying drawings be interpreted as illustrative and not 6 in a limiting sense. Thus, the scope of the invention should be 7 determined by the appended claims and their legal equivalents.
8 Now that the invention has been described,
22 Additionally, the densified foam material composition and density 23 thereof contribute to the waterproofing properties of the 24 invention, making it ideal for use in moist environments such as kitchens, bathrooms, and showers. It should be noted, however, M:\1-PAT\PAT 2016\APP\1653-16 Quickstyle\PT0\05 PA\2017_06_13_Nonprovisiona1_Patent_App1_Fi1ed_1653.doc 1 that in other embodiments, the core layer of the inventive panel or 2 board, including the densified foam material may also comprise 3 other materials and/or formulations.
As one example, the panel or board of the present invention may also comprise in some embodiments a sound layer formed from a 6 sound insulating material that can attenuate sound transmission, 7 which is desirable in some environments where sound reduction is 8 important, such as in multi-story developments. The sound layer 9 may be connected to the core layer and may comprise ethyl vinyl acetate or other sound insulating materials including, but not 11 limited to, cork, rubber, or foam.
The thickness of the sound 12 layer may range from about 1 millimeter to about 4 millimeters depending on the desired level of sound attenuation. Additionally, 14 the sound layer may comprise a moisture layer in the form of a plastic film or foil.
These and other objects, features and advantages of the 17 present invention will become clearer when the drawings as well as 18 the detailed description are taken into consideration.
BRIEF DESCRIPTION OF THE DRAWINGS
For a fuller understanding of the nature of the present 22 invention, reference should be had to the following detailed 23 description taken in connection with the accompanying drawings in 24 which:
Figure 1 is a perspective view of one embodiment of a board M:\1-PAT\PAT 2016\APP\1653-16 Quickstyle\PI0\05 PA\2017_06_13_Nonprovisional Patent_Appl_FIled_1653.doc 1 according to the present invention comprising a core layer.
Figure 2 is a perspective view of a board according to the 3 present invention in another embodiment comprising a core layer and 4 a sound layer.
Figure 3A is a perspective exploded view of one embodiment of 6 a board according to the present invention comprising a core layer 7 and a sound layer.
Figure 3B is a perspective exploded view of one embodiment of 9 a board according to the present invention comprising a core layer, and a moisture layer.
Figure 4 is a perspective view of one embodiment of a board according to the present invention comprising a core layer having a 13 textured surface that is substantially smooth.
Figure 5 is a perspective view of one embodiment of a board according to the present invention comprising a core layer having a 16 textured surface that is substantially abrasive.
Figure 6 is a perspective view of another embodiment of a 18 board according to the present invention comprising a core layer 19 having a textured surface that is substantially smooth.
Figure 7 is a perspective view of another embodiment of a 21 board according to the present invention comprising a core layer 22 having a textured surface that is substantially abrasive.
23 Like reference numerals refer to like parts throughout the 24 several views of the drawings.
M:\1-PAT\PAT 2016\APP\1653-16 cAiickstyle\PT0\05 PA\2017_06_13_Nonprovisional_Patent Appl_Filed_1653.doc 2 The present invention is directed towards a panel or board, 3 generally indicated as 10, that may be used as backing support for 4 a variety of different applications. While the present invention is referred to herein primarily as a board or panel, it may also comprise a sheet or other similar structure, and consequently, this 7 terminology should not be deemed a limiting factor.
8 As will be explained in greater detail below, the board 10 of 9 the present invention is intended for installation on an unfinished floor, wall, soffit, ceiling, or other similar surface. By way of example, the board 10 may be secured to an unfinished wall such as 12 a masonry wall or a concrete wall, or against an unfinished floor 13 such as a concrete slab or floor. In most instances, the board 10 14 will typically be nailed, screwed or drilled into place, but may also be secured by other methods. Also, the board 10 of the 16 present invention is well suited to level an otherwise uneven 17 surface, but it may also be used in a variety of other 18 applications. As another example, the board 10, itself, may be 19 used to form a wall, ceiling, soffit, or other similar partition or divider, and to support a covering or finish. In other words, the 21 board 10 may be disposed against or connected to a support 22 structure such as, but not limited to, a frame or a mount.
23 After the inventive board 10 is installed in a desired 24 location, a variety of coverings or finishing products may be installed, applied, or otherwise adhered to the board 10. These M\1-PAT\PAT 2016\APP\1653-16 Quickstyle\PT0\05 PA\2017_06_13_Nonprovislona1_Patent_epp1_Pl1ed_1653.doc 1 covering or finish products generally require a flat surface for 2 installation and may include various types of tiles such as, but 3 not limited to, marble, stone, travertine, granite, mosaics, 4 ceramic, porcelain and the like, some of which may be quite heavy.
Other coverings can also be used with the inventive board 10, such 6 as, but not limited to, laminate flooring, vinyl composite tiles (VCT), wood planks and other flooring products. Moreover, other 8 coverings or finish products which may also require a flat surface 9 for installation are also within the scope of the present invention.
With reference now to Figure 1, the panel or board 10 of the 12 present invention comprises at least a core layer, generally 13 represented as 20. As shown, the core layer 20 comprises a first face 22 that defines a top surface 12 of the board 10 and a second face 24 that is oppositely disposed so as to define a bottom 16 surface 14 of the panel or board 10.
The core layer 20 will preferably have a uniform thickness between its top surface 12 and 18 bottom surface 14 and be in a range of generally about 4 19 millimeters to 6 millimeters, although in a preferred embodiment, this thickness will be generally 5 millimeters. Additionally, at least one of these faces, such as 22, 24 or such as surfaces 12, 14 22 will include a texture formed on at least a portion thereof. In 23 most embodiments, however, the board 10 will have a textured surface formed at least substantially across one of these faces or surfaces. Also in most embodiments, a textured surface can be M:\1-PAT\PAT 2016\APP\1653-16 Quickstyle\PT0\05 PA\2017_06_13_Nonprovisional_Patent_Appl_Filed_1653.doc 1 formed on both of these faces or surfaces. For example, and with 2 reference to Figures 4 through 7, the first face 22 and the second 3 face 24 may respectively comprise a first textured surface 26 and 4 second textured surface 28. The texture surface may comprise a smooth finish, although in at least one embodiment, the textured 6 surface comprises an abrasive finish.
However, the present 7 invention contemplates a board 10 having both a first face 22 8 defined by top surface 12 with a first textured surface 26 that may 9 be smooth, and a second face 24 defined by bottom surface 14 having a second textured surface 28 that offers a partially or 11 substantially abrasive finish.
As represented in the illustrative embodiments of Figures 1-7, 13 the board 10 may comprise a substantially rectangular shape, having 14 a pair of elongated sides or edges 16 and a pair of shorter sides or edges 16'. Other configurations for the panel or board 10 are 16 possible and within the spirit of the present invention, such as 17 but not limited to, substantially square, trapezoid, circular or other shapes. Also, and while the board 10 may be formed to have 19 other dimensions, in the embodiment having a rectangular shape, the board 10 may be manufactured to have dimensions that generally correspond to the spacing commonly found between drywall studs. By 22 way of example only, the dimensions of the board 10 may be 23 approximately thirty six (36") inches wide by approximately sixty 24 (60") inches long.
The core layer 20 of the inventive panel or board 10 M:\1-PAT\PAT 2016\APP\1653-16 QuIckstyle\PT0\05 PA\2017_06_13_Nonprovisional Patent_Appl_Filed_1653.doc 1 additionally comprises a densified foam material having a 2 predetermined structural integrity. This predetermined structural 3 integrity is the result of the specific material composition and 4 density range of the densified foam material, and allows for an optimal balance between rigidity and severability that makes the 6 board 10 ideal for use as a backing support. For example, the 7 inventive board 10 is sufficiently rigid so that the board 10 can 8 be installed and secured to an unfinished wall or floor surface, 9 whether by nails, screws or other fastening mechanism without damaging the board, such as by the head of the screw or nail 11 penetrating the surface of the board 10. In addition, the board 10 12 is sufficiently rigid so as to provide adequate support to one or 13 more tiles, or other coverings disposed thereon. Moreover, the 14 inventive board 10 should at the same time be sufficiently severable, so as to allow a user to expeditiously cut, trim or 16 otherwise form the inventive board 10 into a desired shape by 17 "scoring" a line(s) on the board 10 with a box-cutter, knife or 18 other cutting tool, and subsequently break or snap off a piece of 19 the board 10 along the scoring line. For example, and due to the composition and thickness of the board 10 in some embodiments, a 21 user may use a box-cutter, knife, or other similar instrument to 22 "score" a line(s) on the inventive board 10 at a depth of 23 approximately 2 millimeters to approximately to 3 millimeters below 24 the top surface 12 of the board 10, and thereafter, readily snap or break off the board 10 into smaller pieces along the scoring line.
M:\l-PAT\PAT 2016\APP\1653-16 Quickstyle\PT0\05 PA\2017_06_13_Nonprovisiona1 Patent_Appl_FIled_1653.doc Accordingly, the core layer 20 comprises a densified foam 2 material that is preferably a foamed, high density, polyvinyl 3 chloride (PVC) material. While the specific composition of the 4 densified foam material may vary, it generally comprises a combination of a synthetic plastic polymer such as polyvinyl chloride (PVC), calcium powder, and foaming agent. In at least one embodiment, the material composition of the densified foam material comprises polyvinyl chloride (PVC) and calcium powder in generally 9 equal amounts. For example, the densified foam material may comprise polyvinyl chloride (PVC) in an amount of between generally 11 between about 45% to about 48%, and calcium powder in an amount 12 also generally between 45% to about 48%, as well as stabilizing 13 agent(s) in an amount of approximately 3% and foaming agent(s) in 14 an amount of approximately 3%. The foaming agent may be a mixture of several materials that enhance stability. Additionally, the 16 density of the core layer 20 and its densified foam material may 17 range from about 450 kg/m3 to about 550 kg/m3, with very favorable 18 results attained with a density of 500 kg/m3.
feature of the board 10 of the present invention is that either of the faces 22 or 24 of the core layer 20 may be modified 21 or roughened to facilitate adhesion. As is represented in Figures 22 4 and 7, the board 10 of the present invention, and more specifically the core layer 20, is initially manufactured so that 24 all of its faces, such as 22 and/or 24, comprise a substantially smooth finish. As such, either or both of the first textured M:\1-PAT\PAT 2016\APP\1653-16 Quickstyle\PT0\05 PA\2017_06_13_Nonprovisional_Patent_Appl_Flled_1653.doc 1 surface 26 and/or second textured surface 27 may comprise a 2 substantially smooth finish, generally indicated as 27.
As is 3 represented in Figures 5 and 8, either or both of the first face 22 4 or second face 24 of the core layer, may be modified or roughened to achieve a substantially abrasive finish, generally represented 6 as 29. As such, at least a portion of the core layer 20 may be 7 passed through a light sander to roughen it thereby creating a 8 substantially abrasive finish 29 on either or both of its faces 22 9 or 24. With a substantially abraded finish 29, an adhesive such as thin-set, mortar, or another compound, can better adhere to either 11 face 22 or 24 of the core layer 20.
Providing a board 10 12 comprising a core layer 20 with a substantially abraded finish 29 13 is particularly useful if an adhesive or other compound is required 14 to install the exposed surface. Conversely, a substantially abrasive finish 29 may not always be needed, such as in a face 22 16 of 24 of the core layer 20, against which may not be installed an 17 exposed surface.
Hence, a substantially smooth finish 27 is 18 acceptable on areas that may be intentionally left exposed, such as 19 for example inner portions of walls.
Further, if the board 10 comprises is a sound layer 30, then the face 22 or 24 of the core 21 layer 20, that is connected either face 32 or 34 of the sound 22 layer, may also comprise a substantially smooth finish 27 in lieu 23 of a substantially abraded finish 29.
As previously mentioned, yet additional features of the present invention include providing a board 10 with sound M:\1-PAT\PAT 2016\APP\1653-16 Quickstyle\PT0\05 PA\2017_06_13_Nonprovisional Patent_Appl_FIled_1653.doc 1 attenuation properties. Therefore, and as shown in Figures 2-3A, 2 the inventive board 10 may also comprise a sound layer, generally 3 represented as 30. The sound layer 30 may be structured to lessen 4 sound transmissions in environments where sound attenuation is important. These environments may include, but are not limited to, 6 multi-story developments such as condominiums, apartments, hotels, 7 retail spaces, office towers, hospitals, and several others. The 8 sound layer 30 may comprise ethyl vinyl acetate which is a material 9 that has sound attenuation properties. Other sound attenuating materials, however, are also within the scope of the present 11 invention.
For example, the sound layer 30 may comprise other 12 materials such as, but not limited to, cork, rubber, or foam. The 13 overall thickness of the sound layer 20 may vary, but generally 14 ranges from about 1 millimeter to about 4 millimeters depending on the desired level of sound attenuation and on spatial constrains.
16 This range may also be about 1.5 millimeters to about 3 millimeters 17 as a sound layer 30 having a thickness of about 2 millimeters may 18 be optimal. Additionally, as represented in Figures 2-3B, the sound 19 layer 30 may also comprise a plurality of edges 36. The plurality of edges 36 of the sound layer 30 may substantially overlap or be 21 substantially coincident with the plurality of sides 16 of the 22 board 10. Alternatively, as is represented in Figure 2, the sound 23 layer 30 may be disposed so that the edge(s) 36 are in a 24 substantially offset relation to the side(s) 16 of the board. That is, a substantially offset relation, between the edge(s) 36 of the M:\1-PAT\PAT 2016\APP\1653-16 Quickstyle\PT0\05 PA\2017_06_13_Nonprovisiona1_Patent_App1_FIled_1653.doc 1 sound layer 30 and the side(s) of the board 10, may be desirable so 2 as to provide an area of the board 10 where a user may be able to 3 cut the board 10 without having to cut or otherwise damage any 4 portion of the sound layer 30.
Moreover, as represented in Figure 3B, the board 10 of the 6 present invention may also comprise a moisture layer, indicated as 7 40.
The moisture layer 40 generally comprises an elastic material 8 such as, but not limited to, a plastic film or a foil, and serves 9 as a moisture barrier between the sound layer 30 and the core layer 20. A moisture layer 40 may be appropriate when the inventive 11 board 10 is used as a leveling surface against a slab that is substantially disposed at grade level. There may be excess 13 moisture in a slab, especially due to saturation of the underlying 14 soil or substrate. In such instances, a moisture layer 40 may be desirable to prevent damage to the covering or finish. As is shown 16 in Figure 3B, the moisture layer 40 is generally connected to the 17 core layer 20. When the board 10 is installed, the moisture layer should face the underlying surface such as the slab on grade so 19 as to serve as a moisture barrier.
In at least one embodiment of the present invention, the panel 21 or board can be formed to include a dye or colorant(s) in order to coordinate with a particular color scheme for the surrounding area.
23 In other embodiments, however, the inventive board can itself be directly painted, so that in some instances, the present invention can be used to finish a building floor, wall or other surface, and M:\1-PAT\PAT 2016\APP\1653-16 Quicksty1e\PTO\05 PA\2017_06_13_Nonprovisional_Patent_Appl Filed_1653.doc 1 its use with other coverings is not necessary.
2 Since many modifications, variations and changes in detail can 3 be made to the described preferred embodiment of the invention, it 4 is intended that all matters in the foregoing description and shown in the accompanying drawings be interpreted as illustrative and not 6 in a limiting sense. Thus, the scope of the invention should be 7 determined by the appended claims and their legal equivalents.
8 Now that the invention has been described,
Claims (20)
1. A board intended for use as a backing support comprising:
a core layer having a first face and an oppositely disposed second face, said core layer formed of a densified foam material having a predetermined structural integrity;
said predetermined structural integrity of said core layer being sufficiently rigid to support one or more coverings thereon, said predetermined structural integrity of said core layer also being sufficiently severable so that a user may score and break said board into smaller pieces, and a textured surface formed on at least a portion of either said first face or said second face.
a core layer having a first face and an oppositely disposed second face, said core layer formed of a densified foam material having a predetermined structural integrity;
said predetermined structural integrity of said core layer being sufficiently rigid to support one or more coverings thereon, said predetermined structural integrity of said core layer also being sufficiently severable so that a user may score and break said board into smaller pieces, and a textured surface formed on at least a portion of either said first face or said second face.
2. The board as recited in claim 1 wherein said predetermined structural integrity is also sufficiently rigid to permit installation of said board without damage.
3. The board as recited in claim 1 wherein said core layer comprises waterproofing properties.
4. The board as recited in claim 1 wherein said densified foam material is waterproof and comprises polyvinyl chloride and calcium powder in generally equal amounts of between about 45% to 48% each, and generally about 3% to 6% of a stabilizing agent and a foaming agent.
5. The board as recited in claim I wherein said densified foam material comprises a density of about 450 kg/m3 to about 550 kg/m3.
6. The board as recited in claim 5 wherein said densified foam material comprises a density of about 490 kg/m3 to about 510 kg/m3.
7. The board as recited in claim 1 wherein said core layer comprises a thickness of generally about 4 millimeters to about 6 millimeters.
8. The board as recited in claim 1 wherein said core layer comprises a thickness of about 5 millimeters.
9. The board as recited in claim 1 wherein said textured surface comprises a substantially abrasive finish.
10. The board as recited in claim 9 wherein said textured surface is formed on substantially all of said first face.
11. The board as recited in claim 10 wherein said second face includes a textured surface.
12. The board as recited in claim 11 wherein said textured surface on said second face comprises a substantially smooth finish.
13. The board as recited in claim 1 wherein said textured surface comprises a substantially smooth finish.
14. A waterproof panel for use as a backing support for coverings comprising:
a core layer having a first surface and a second surface, said first surface including a substantially abrasive texture, said core layer comprising a densified foam material having a density of between generally about 490 kg/m3 to about 520 kg/m3 to provide a structural integrity having sufficient rigidity to support one or more coverings and for installation of the panel without damage, and a sound layer connected to said core layer and structured to reduce sound.
a core layer having a first surface and a second surface, said first surface including a substantially abrasive texture, said core layer comprising a densified foam material having a density of between generally about 490 kg/m3 to about 520 kg/m3 to provide a structural integrity having sufficient rigidity to support one or more coverings and for installation of the panel without damage, and a sound layer connected to said core layer and structured to reduce sound.
15. The panel as recited in claim 14 wherein said densified foam material is also severable upon being scored by a user and flexed along a score line created by the user.
16. The panel as recited in claim 14 wherein said sound layer comprises ethyl vinyl acetate.
17. The panel as recited in claim 14 wherein said sound layer comprises at least one material selected from the group consisting of cork, rubber, or foam.
18. The panel as recited in claim 14 further comprising a moisture layer disposed in interconnecting relation between said core layer and said sound layer.
19. The panel as recited in claim 14 wherein said sound layer comprises a thickness of about 1 millimeter to about 4 millimeters.
20. A waterproof board having at least one side used as backing support for a plurality of coverings, said board comprising:
a core layer having a first face and a second face, each having a textured surface formed at least partially thereon;
said core layer having a thickness of generally about 5 millimeters between said first face and said second face, and comprising a densified foam material having a density of between generally about 490 kg/m3 to about 520 kg/m3;
said core layer also having a predetermined structural integrity so as to be sufficiently rigid to support the coverings and to permit attachment of said board to a surface without damage;
said predetermined structural integrity of said core layer also being sufficiently severable so that a user may score and sever a piece of said board; and a sound layer comprising a thickness of generally about 2 millimeters and structured to reduce sound.
a core layer having a first face and a second face, each having a textured surface formed at least partially thereon;
said core layer having a thickness of generally about 5 millimeters between said first face and said second face, and comprising a densified foam material having a density of between generally about 490 kg/m3 to about 520 kg/m3;
said core layer also having a predetermined structural integrity so as to be sufficiently rigid to support the coverings and to permit attachment of said board to a surface without damage;
said predetermined structural integrity of said core layer also being sufficiently severable so that a user may score and sever a piece of said board; and a sound layer comprising a thickness of generally about 2 millimeters and structured to reduce sound.
Applications Claiming Priority (4)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US201662409654P | 2016-10-18 | 2016-10-18 | |
| US62/409,654 | 2016-10-18 | ||
| US15/621,487 | 2017-06-13 | ||
| US15/621,487 US20180106039A1 (en) | 2016-10-18 | 2017-06-13 | Densified foam core (dfc) board for use as a backing surface |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2982780A1 true CA2982780A1 (en) | 2018-04-18 |
Family
ID=61904366
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA2982780A Abandoned CA2982780A1 (en) | 2016-10-18 | 2017-10-18 | Densified foam core (dfc) board for use as a backing surface |
Country Status (2)
| Country | Link |
|---|---|
| US (1) | US20180106039A1 (en) |
| CA (1) | CA2982780A1 (en) |
Families Citing this family (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US10132088B2 (en) * | 2016-08-26 | 2018-11-20 | Quickstyle Industries Inc. | Stone plastic composite (SPC) tile with imitation grout line |
| US10233656B2 (en) * | 2016-08-26 | 2019-03-19 | Quickstyle Industries Inc. | Densified foam core (DFC) tile with imitation grout line |
| US9938726B2 (en) | 2016-08-26 | 2018-04-10 | Quickstyle Industries Inc. | Densified foam core (DFC) tile with imitation grout line |
| US10544595B2 (en) * | 2016-08-26 | 2020-01-28 | Quickstyle Industries Inc. | Tile with protected imitation grout line |
| USD1028286S1 (en) * | 2022-05-13 | 2024-05-21 | Hercutech, Inc. | Corner track |
-
2017
- 2017-06-13 US US15/621,487 patent/US20180106039A1/en not_active Abandoned
- 2017-10-18 CA CA2982780A patent/CA2982780A1/en not_active Abandoned
Also Published As
| Publication number | Publication date |
|---|---|
| US20180106039A1 (en) | 2018-04-19 |
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| FZDE | Dead |
Effective date: 20201019 |