IP Library Granted Patent US 9,394,651
Granted Patent B2
US 9,394,651 · App. 14/636,719 · Granted Jul 19, 2016

Underlayment panel having drainage channels

Inventor: Steven L. Sawyer (Huntington Beach, CA)
Assignee: Brock USA, LLC
E01C11/225E01C3/06E01C11/02E01C13/04E01C13/045E04B5/48E04F15/02194E04F15/102E04F15/105E04F15/107E04F15/225E01C2201/14Y10T428/192Y10T428/24273
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Quick Facts
Patent No.
US 9,394,651
App. No.
14/636,719
Granted
Jul 19, 2016
Kind
B2
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 (13)

1. 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.

2. The underlayment panel of claim 1 wherein the panel is made of a material that provides for deflection under load, thereby imparting impact absorption to the panel.

3. The underlayment panel of claim 1 wherein the top surface includes a three dimensional surface texture that creates friction to retain the loose infill material or a covering layer.

4. The underlayment panel of claim 1 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.

5. The underlayment panel of claim 1 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.

6. 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.

7. The underlayment panel of claim 6 including a locking projection to secure the panel together with an adjacent panel when the panel abuts a similar panel.

8. The underlayment panel of claim 6 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.

9. The underlayment panel of claim 6 wherein the flanges are configured to overlap a flange on an adjacent panel when the panel abuts a similar panel.

10. The underlayment panel of claim 9 wherein the panel is made of a material that provides for deflection under load, thereby imparting impact absorption to the panel.

Assignments (9)
FIRST LIEN PATENT SECURITY AGREEMENT SUPPLEMENT Recorded Dec 9, 2025
From: BROCK USA, LLC
To: GOLDMAN SACHS BANK USA, AS COLLATERAL AGENT
Reel/Frame 073891/0555 →
ABL PATENT SECURITY AGREEMENT SUPPLEMENT Recorded Dec 9, 2025
From: BROCK USA, LLC
To: GOLDMAN SACHS BANK USA, AS COLLATERAL AGENT
Reel/Frame 073899/0540 →
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Jun 26, 2025
From: BROCK USA, LLC
To: PLAYCORE ACQUISITION SUB XVI, LLC
Reel/Frame 071536/0896 →
CHANGE OF NAME Recorded Jun 26, 2025
From: PLAYCORE ACQUISITION SUB XVI, LLC
To: BROCK USA, LLC
Reel/Frame 071751/0203 →
RELEASE OF SECURITY INTEREST Recorded Oct 26, 2018
From: JSP SPECIALTY FOAMS LLC; JSP INTERNATIONAL LLC
To: BROCK USA, LLC
Reel/Frame 047330/0734 →
RELEASE OF SECURITY INTEREST Recorded Oct 26, 2018
From: MIDFIRST BANK
To: BROCK USA, LLC
Reel/Frame 047327/0764 →
SECURITY INTEREST Recorded Aug 9, 2017
From: BROCK USA, LLC
To: MIDFIRST BANK
Reel/Frame 043249/0961 →
SECURITY INTEREST Recorded Jul 6, 2017
From: BROCK USA, LLC
To: JSP SPECIALTY FOAMS, LLC; JSP INTERNATIONAL LLC
Reel/Frame 043100/0027 →
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Mar 3, 2015
From: SAWYER, STEVEN L., MR
To: BROCK USA, LLC
Reel/Frame 035121/0552 →
Continuity (7)
Division 14204700 · Mar 11, 2014
Continuation 13741953 · Jan 15, 2013
Continuation 13025745 · Feb 11, 2011
Continuation In Part 12009835 · Jan 22, 2008
Continuation In Part 12830902 · Jul 6, 2010
Provisional Application 61303350 · Feb 11, 2010
Related Publication 20150176225A1 · Jun 25, 2015