# US 2014/0190103 A1 · Underlayment Panel Having Drainage Channels

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- Number: US 2014/0190103 A1
- Document ID: US20140190103A1
- Status: Published application
- Kind: A1
- Application number: 14/204,700
- Filed: 2014-03-11
- Published: 2014-07-10
- Earliest claimed: 2008-01-22
- Assignees: Brock USA, LLC
- Applicants: Brock USA, LLC
- Inventors: Steven L. Sawyer
- Web page: https://patentgrep.com/patent/US20140190103A1

## CPC

- E01C 13/045: {the prefabricated single units consisting of or including bitumen, rubber or plastics}
- E01C 3/06: Methods or arrangements for protecting foundations from destructive influences of moisture, frost or vibration {(heating devices E01C11/26; draining the subbase of roads E01F5/00)}
- E01C 5/001: {on prefabricated supporting structures or prefabricated foundation elements except coverings made of layers of similar elements}
- E01C 5/003: {characterised by material or composition used for beds or joints; characterised by the way of laying}
- E01C 5/18: made of rubber units {(of units made from other material and having a rubber upper layer E01C5/226)}
- E01C 5/20: made of units of plastics, {e.g. concrete with plastics, linoleum}(E01C5/18 takes precedence; {of textiles made of synthetic fibres E01C5/008})
- E01C 5/226: {having an upper layer of rubber, with or without inserts of other materials; with rubber inserts}
- E01C 9/00: Special pavings (specially adapted for playgrounds or sports grounds E01C13/00, for footpaths, sidewalks or cycle tracks E01C15/00); Pavings for special parts of roads or airfields (pavement lights E01C17/00; manholes or like covers or frames E02D29/14)
- E01C 11/02: Arrangement or construction of joints {(for pavings consisting of prefabricated units E01C5/00)}; Methods of making joints {(machines therefor E01C23/02, E01C23/09; removable joint shutterings E01C23/021)}; Packing for joints (sealing joints not restricted to road or airfield paving E04B1/68)
- E01C 11/225: {Paving specially adapted for through-the-surfacing drainage, e.g. perforated, porous; Preformed paving elements comprising, or adapted to form, passageways for carrying off drainage (E01C9/004, E01C9/008, E01C9/08, E01C9/10, E01C11/228, E01C13/00 take precedence)}
- E01C 13/02: Foundations, e.g. with drainage or heating arrangements {(E01C13/003, E01C13/083, E01C13/10 take precedence; drainage of soil E02B11/00)}
- E01C 13/04: Pavings made of prefabricated single units ({E01C13/003, E01C13/06} , E01C13/08, E01C13/10 take precedence)
- E04B 5/48: Special adaptations of floors for incorporating ducts, e.g. for heating or ventilating (in block-shaped elements E04C1/39; in slab- or sheet-shaped elements E04C2/52)
- E04F 15/02194: {Flooring consisting of a number of elements carried by a non-rollable common support plate or grid (E04F15/022 takes precedence)}
- E04F 15/102: {of fibrous or chipped materials, e.g. bonded with synthetic resins}
- E04F 15/105: {of organic plastics with or without reinforcements or filling materials}
- E04F 15/107: {composed of several layers, e.g. sandwich panels (layered products in general B32B; producing decorative panels or veneers B44C5/04)}
- E04F 15/225: {Shock absorber members therefor}
- E01C 2201/10: having build-in shock absorbing devices
- E01C 2201/12: vertically interlocking
- E01C 2201/14: Puzzle-like connections
- E01C 2201/207: channels on the bottom
- Y10T 428/192: Sheets or webs coplanar
- Y10T 428/24273: including aperture
- E01C: CONSTRUCTION OF, OR SURFACES FOR, ROADS, SPORTS GROUNDS, OR THE LIKE; MACHINES OR AUXILIARY TOOLS FOR CONSTRUCTION OR REPAIR (forming roads or like surfaces by compacting or grading snow or ice E01H)
- E04B: GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS (border constructions of opening in walls, floors or ceilings E06B1/00; {electromagnetic shielding H05K9/0001})
- E04F: FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS (windows, doors E06B)
- Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

## Abstract

An underlayment panel includes a top surface and a bottom surface. A plurality of projections define drainage channels. A plurality of drain holes arranged through the panel provide fluid communication between the top surface and the bottom surface.

## Claims

### Claim 1

An underlayment panel having a top surface, a bottom surface, and edges, the top surface having a plurality of projections that define top drainage channels, the bottom surface having a plurality of bottom projections that define drainage channels, the edges having at least one standout spacer arranged to form a gap with an adjacent panel, the gap being configured to provide fluid communication with the bottom side drainage channels, the panel further having a plurality of drain holes arranged on the panel, the plurality of drain holes providing fluid communication between the top surface and the drainage channels of the bottom surface.

### Claim 2 (depends on 1)

The underlayment panel of claim 1 wherein the panel has a resilient characteristic that provides for deflection under load sufficient to impart impact absorption to the panel.

### Claim 3 (depends on 1)

The underlayment panel of claim 1 wherein the plurality of projections each have a first spring rate characteristic and a second spring rate characteristic such that the first spring rate characteristic provides for more deflection under load than the second spring rate characteristic.

### Claim 4 (depends on 1)

The underlayment panel of claim 1 wherein the top surface includes a plurality of projections that cooperate to define top surface drainage channels, the top surface channels being directly connected with the bottom surface drainage channels by way of the drain holes.

### Claim 5 (depends on 1)

The underlayment panel of claim 1 wherein the bottom surface drainage channels are configured to hold water for release to a substrate layer.

### Claim 6 (depends on 5)

The underlayment panel of claim 5 wherein the release rate of water to the substrate layer is slower than a rate of lateral drainage across the bottom surface drainage channels to the panel edge.

### Claim 7 (depends on 3)

The underlayment panel of claim 3 wherein the first spring rate characteristic of the projections is part of a first stage and the second spring rate characteristic is part of a second stage, the first stage having a smaller volume of material than the second stage.

### Claim 8 (depends on 3)

The underlayment panel of claim 3 wherein the first and second spring rate characteristics combine to form a general spring rate gradient over the entire projection length between a truncated end of the projection and the bottom surface.

### Claim 9 (depends on 3)

The underlayment panel of claim 3 wherein the first stage is configured to collapse initially when subjected to an impact load, the second stage is configured to provide greater resistance to the impact load than the first stage, and a panel section is defined between the top surface and the bottom surface, the panel section being configured to provide greater resistance to the impact load than the first and second stages.

### Claim 10 (depends on 9)

The underlayment panel of claim 9 wherein the second stage is configured to be dimensionally larger than the first stage such that the first stage can deflect into the second stage during the impact.

### Claim 11

An underlayment panel comprising:
a panel section having a plurality of drain holes formed therethrough;
a top surface configured to support at least a layer of loose infill material, the top side further including a texture that maintains the general position of the loose infill material on the top surface; and
a bottom surface having a plurality of projections that cooperate to define channels suitable to permit water flow across the bottom surface, the channels being in fluid communication with the panel drain holes, the projections having tapered sides such that the bottom side channels will retain up to 25 mm of water for a slower release rate into a substrate than a drainage rate across the channels.

### Claim 12 (depends on 11)

The underlayment panel of claim 11 wherein the panel is made of a material that provides for deflection under load, thereby imparting impact absorption to the panel.

### Claim 13 (depends on 11)

The underlayment panel of claim 11 wherein the top surface includes a three dimensional surface texture that creates friction to retain the loose infill material or a covering layer.

### Claim 14 (depends on 11)

The underlayment panel of claim 11 wherein at least one flange extends from the panel section, the flange being configured to overlap with a mating panel flange such that the top surface and the bottom surface of one panel are generally continuous with the top surface and bottom surface of the adjacent panels.

### Claim 15 (depends on 11)

The underlayment panel of claim 11 wherein at least one flange extends from the panel section, the flange being configured to overlap with a mating panel flange and further configured to compensate for thermal expansion.

### Claim 16

An underlayment panel having a top surface, a bottom surface, and four edges, the edges being configured to abut edges of similar panels, two of the edges having flanges to allow overlapping edges with an adjacent panel when the panel abuts a similar panel, the top surface having a plurality of projections that define top drainage channels, the bottom surface having a plurality of bottom projections that define drainage channels, the panel having a plurality of drain holes connecting the top surface in fluid communication with the bottom surface, the panel being made of a molded polyolefin material, the panel including at least one locking aperture enabling an interlocking connection to secure the panel together with an adjacent panel when the panel abuts a similar panel.

### Claim 17 (depends on 16)

The underlayment panel of claim 16 including a locking projection to secure the panel together with an adjacent panel when the panel abuts a similar panel.

### Claim 18 (depends on 16)

The underlayment panel of claim 16 wherein the projections define a first spring rate characteristic that is part of a first stage and a second spring rate characteristic is part of a second stage, the first stage having a smaller volume of material than the second stage.

### Claim 19 (depends on 16)

The underlayment panel of claim 16 wherein the flanges are configured to overlap a flange on an adjacent panel when the panel abuts a similar panel.

### Claim 20 (depends on 19)

The underlayment panel of claim 19 wherein the panel is made of a material that provides for deflection under load, thereby imparting impact absorption to the panel.