Note: Descriptions are shown in the official language in which they were submitted.
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
6
119(e) to a currently pending U.S. provisional patent application
7
having Serial No. 62/409,654 and a filing date of October 18, 2016,
8 which is incorporated herein by reference in its entirety.
9
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
17
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.
21
22 DESCRIPTION OF THE RELATED ART
23
During the construction of a home, building or other
24
structure, there will almost always be an unfinished wall surface
such as concrete block, a wood structure or the like, which needs
1
CA 2982780 2017-10-18
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.
17
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
22
areas of a building structure where water and mositure occur, such
23 as in kitchens and bathrooms, and are commonly used as wall
24
surfaces in bathrooms due to their ability to withstand relatiely
high levels of humidity and to serve as a backing support against
2
CA 2982780 2017-10-18
, 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,"
3
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.
8
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
11
difficulty associated with shipment, delivery and installation, as
12 well as attendant higher labor costs. Another disadvantage
13
associated with such boards is that there is often a considerable
14
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
24
capable of being secured to a surface without causing any damage to
the backing support itself, while also capable of supporting a
3
CA 2982780 2017-10-18
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.
8
9 SUMMARY OF THE INVENTION
The present invention is intended to present a solution to
11 these and other needs which remain in this field of art, and as
12
such, is directed to a panel or board made of synthetic materials,
13
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
18
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
23
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
4
CA 2982780 2017-10-18
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.
8
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
17
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
22
substantially smooth finish on the other, which may be desirable in
23 other instances.
24
In addition, the panel or board of the present invention has a
core layer comprising a densified foam material having an optimal
5
CA 2982780 2017-10-18
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
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,
6
CA 2982780 2017-10-18
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.
4
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
13
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.
16
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.
19
BRIEF DESCRIPTION OF THE DRAWINGS
21
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
7
CA 2982780 2017-10-18
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.
2
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.
8
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.
11
Figure 4 is a perspective view of one embodiment of a board
12
according to the present invention comprising a core layer having a
13 textured surface that is substantially smooth.
14
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.
17
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.
8
CA 2982780 2017-10-18
M:\1-PAT\PAT 2016\APP\1653-16 cAiickstyle\PT0\05
PA\2017_06_13_Nonprovisional_Patent Appl_Filed_1653.doc
1 DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
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
6
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
11
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
9
CA 2982780 2017-10-18
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
7
(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.
11
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
14
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
17
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
21
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
24
surface formed at least substantially across one of these faces or
surfaces. Also
in most embodiments, a textured surface can be
CA 2982780 2017-10-18
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.
12
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
18
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
21
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
11
CA 2982780 2017-10-18
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.
12
CA 2982780 2017-10-18
M:\l-PAT\PAT 2016\APP\1653-16 Quickstyle\PT0\05 PA\2017_06_13_Nonprovisiona1
Patent_Appl_FIled_1653.doc
1
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
6
chloride (PVC), calcium powder, and foaming agent. In at least one
7
embodiment, the material composition of the densified foam material
8
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.
19 A
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
23
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
13
CA 2982780 2017-10-18
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.
24
As previously mentioned, yet additional features of the
present invention include providing a board 10 with sound
14
CA 2982780 2017-10-18
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
CA 2982780 2017-10-18
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
12
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
18 40
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
22
coordinate with a particular color scheme for the surrounding area.
23 In other embodiments, however, the inventive board can itself be
24
directly painted, so that in some instances, the present invention
can be used to finish a building floor, wall or other surface, and
16
CA 2982780 2017-10-18
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,
17
CA 2982780 2017-10-18
