# US 8,769,895 B2 · Subfloor component and method of manufacturing same

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- Number: US 8,769,895 B2
- Document ID: US8769895B2
- Status: Granted
- Kind: B2
- Application number: 14/102,662
- Filed: 2013-12-11
- Published: 2014-04-10
- Granted: 2014-07-08
- Earliest claimed: 2012-03-05
- Applicants: Victor Amend
- Inventors: Victor Amend
- Web page: https://patentgrep.com/patent/US8769895B2

## CPC

- E04F 15/185: {Underlayers in the form of studded or ribbed plates}
- B29C 44/14: the preformed part being a lining {(B29C44/1209 takes precedence)}
- B29C 44/445: {in the form of expandable granules, particles or beads}
- B32B 3/085: {spaced apart pieces on the surface of a layer}
- B32B 13/045: {of foam}
- B32B 15/046: {of foam}
- B32B 21/02: {the layer being formed} of fibres, chips, or particles {, e.g. MDF, HDF, OSB, chipboard, particle board, hardboard}
- B32B 21/047: {of foam}
- B32B 21/14: comprising wood board or veneer
- B32B 27/065: {of foam}
- B32B 27/302: {comprising aromatic vinyl (co)polymers, e.g. styrenic (co)polymers}
- B32B 27/32: comprising polyolefins {(comprising vinyl (co)polymers or acrylic (co)polymers B32B27/30)}
- B32B 2307/558: Impact strength, toughness
- B32B 2307/734: Dimensional stability
- B32B 2471/00: Floor coverings (B32B2419/04 takes precedence)
- E04F: FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS (windows, doors E06B)
- B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00)
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM

## Abstract

A subfloor component comprises an insulating rigid foam panel having first and second opposing faces and a plurality of intersecting grooves to define, in cross-section, a plurality of pedestals having at least one wall extending into the panel from the first face toward the second face; a film of substantially moisture-impervious material attached to the first face of the panel and that conforms to the tops and walls of the pedestals and to the bottoms of the grooves; and a hardboard layer on the second face of the panel.

## Claims

### Claim 1

A subfloor component comprising:
an insulating rigid foam panel having first and second opposing faces and a plurality of intersecting grooves to define, in cross-section, a plurality of pedestals having at least one wall extending into the panel from the first face toward the second face;
a film of substantially moisture-impervious material attached to the first face of the panel and that conforms to the tops and walls of the pedestals and to the bottoms of the grooves; and
a hardboard layer on the second face of the panel.

### Claim 2 (depends on 1)

The subfloor component of claim 1, wherein the film is fused to the panel.

### Claim 3 (depends on 1)

The subfloor component of claim 1, wherein the film comprises material selected from the group comprising plastic or polymer.

### Claim 4 (depends on 3)

The subfloor component of claim 3, wherein the plastic or polymer is selected from the group consisting of: high-impact polystyrene, polyethylene, and ABS (Acrylonitrile Butadiene Styrene).

### Claim 5 (depends on 1)

The subfloor component of claim 1, wherein each of the plurality of pedestals has a single wall.

### Claim 6 (depends on 5)

The subfloor component of claim 5, wherein the pedestals are shaped as circles or ellipses.

### Claim 7 (depends on 1)

The subfloor component of claim 1, wherein the panel comprises expanded polystyrene (EPS).

### Claim 8 (depends on 1)

The subfloor component of claim 1, wherein the hardboard layer and the panel are attached to each other with glue.

### Claim 9 (depends on 1)

The subfloor component of claim 1, wherein the intersecting grooves are rectangular.

### Claim 10 (depends on 1)

The subfloor component of claim 1, wherein the pedestals are shaped as at least one of circles, ellipses, rectangles, diamonds, squares, and hexagons.

### Claim 11 (depends on 1)

The subfloor component of claim 1, wherein the hardboard layer comprises material selected from the group consisting of: OSB (oriented strand board), plywood, fiber cement board, cement board, metal sheeting, and magnesium oxide board.

### Claim 12 (depends on 1)

The subfloor component of claim 1, wherein the subfloor component is shaped to connect to another subfloor component.

### Claim 13 (depends on 12)

The subfloor component of claim 12, wherein the hardboard layer comprises a tongue/groove configuration for connecting to another hardboard layer of another subfloor component.

### Claim 14 (depends on 1)

The subfloor component of claim 1, wherein the pedestals are generally uniformly distributed across the first surface of the panel.

### Claim 15 (depends on 1)

The subfloor component of claim 1, wherein the hardboard layer includes a groove that is open along a side-facing surface of the hardboard layer, further comprising: a connector dimensioned to insert into the groove.

### Claim 16 (depends on 15)

The subfloor component of claim 15, wherein the connector comprises:
a central body; and
tongues extending outwards from the central body, wherein each tongue is dimensioned to be inserted into a respective groove in a hardboard layer of a subfloor component.