Densified foam core (DFC) board for use as a backing surface

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.

Description

CLAIM OF PRIORITY[0001]The present invention claims priority under 35 U.S.C. Section 119(e) to a currently pending U.S. provisional patent application having Ser. No. 62 / 409,654 and a filing date of Oct. 18, 2016, which is incorporated herein by reference in its entirety.BACKGROUND OF THE INVENTIONField of the Invention[0002]The present invention is directed to a rigid panel or board made from synthetic materials and which is suitable for use as a backing support against which a variety of coverings may be installed. The inventive board comprises at least a core layer made from a densified foam material having a predetermined structural integrity with sufficient rigidity suitable for installation and the attachment of a variety of coverings thereon. In addition, the densified foam material of the core layer has a predetermined structural integrity to allow a user to make a score line on the board and sever it into smaller pieces.Description of the Related Art[0003]During the constru...

AI Technical Summary

Benefits of technology

The present invention is a panel or board made of synthetic materials that can be installed on a surface and support various coverings. The panel is waterproof and can be used on both horizontal and vertical surfaces, as well as in different areas of a building like bathrooms and other areas likely to be exposed to moisture or humidity. The coverings can include tiles, marble, granite, laminate flooring, vinyl composite tiles, wood planks, and other flooring products. The panel can also be formed with a dye or colorant to coordinate with the surrounding area or directly painted. Overall, the present invention provides a versatile solution for finishing surfaces in building floors, walls, and other spaces.

Problems solved by technology

Because plywood underlayment products are not waterproof, their application is generally limited to horizontal surfaces.

Additionally, the installation of plywood underlayment products and / or cement based products is often tedious, labor intensive and time consuming.

For example, plywood sheets and cement based mixtures are often heavy and cumbersome, plus cement based mixtures and related products need time to cure or harden.

In contrast, however, other pre-formed boards known as “drywall,” which are made of gypsum plaster and also used on interior walls of a building structure, do not typically serve as a backing support for tiles, and also, are very susceptible to moisture and / or humidity and therefore, are not suitable for wet environments such as in a bathroom, near a shower, etc.

There are several disadvantages associated with both known 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 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 difficulty to the installation process as well as spatial constraints, which can be problematic particularly in small areas or tight spaces.

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