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/m 3 to about 520 kg/m 3 , and a specific material composition, both of which enhance waterproofing and attain an optimal balance between rigidity and severability.

What is claimed is: 
     
         1 . A board intended for use as a backing support comprising:
 a core layer having a first face and an oppositely disposed second face,   said core layer formed of a densified foam material having a predetermined structural integrity;   said predetermined structural integrity of said core layer being sufficiently rigid to support one or more coverings thereon,   said predetermined structural integrity of said core layer also being sufficiently severable so that a user may score and break said board into smaller pieces, and   a textured surface formed on at least a portion of either said first face or said second face.   
     
     
         2 . The board as recited in  claim 1  wherein said predetermined structural integrity is also sufficiently rigid to permit installation of said board without damage. 
     
     
         3 . The board as recited in  claim 1  wherein said core layer comprises waterproofing properties. 
     
     
         4 . The board as recited in  claim 1  wherein said densified foam material is waterproof and comprises polyvinyl chloride and calcium powder in generally equal amounts of between about 45% to 48% each, and generally about 3% to 6% of a stabilizing agent and a foaming agent. 
     
     
         5 . The board as recited in  claim 1  wherein said densified foam material comprises a density of about 450 kg/m 3  to about 550 kg/m 3 . 
     
     
         6 . The board as recited in  claim 5  wherein said densified foam material comprises a density of about 490 kg/m 3  to about 510 kg/m 3 . 
     
     
         7 . The board as recited in  claim 1  wherein said core layer comprises a thickness of generally about 4 millimeters to about 6 millimeters. 
     
     
         8 . The board as recited in  claim 1  wherein said core layer comprises a thickness of about 5 millimeters. 
     
     
         9 . The board as recited in  claim 1  wherein said textured surface comprises a substantially abrasive finish. 
     
     
         10 . The board as recited in  claim 9  wherein said textured surface is formed on substantially all of said first face. 
     
     
         11 . The board as recited in  claim 10  wherein said second face includes a textured surface. 
     
     
         12 . The board as recited in  claim 11  wherein said textured surface on said second face comprises a substantially smooth finish. 
     
     
         13 . The board as recited in  claim 1  wherein said textured surface comprises a substantially smooth finish. 
     
     
         14 . A waterproof panel for use as a backing support for coverings comprising:
 a core layer having a first surface and a second surface,   said first surface including a substantially abrasive texture,   said core layer comprising a densified foam material having a density of between generally about 490 kg/m 3  to about 520 kg/m 3  to provide a structural integrity having sufficient rigidity to support one or more coverings and for installation of the panel without damage, and   a sound layer connected to said core layer and structured to reduce sound.   
     
     
         15 . The panel as recited in  claim 14  wherein said densified foam material is also severable upon being scored by a user and flexed along a score line created by the user. 
     
     
         16 . The panel as recited in  claim 14  wherein said sound layer comprises ethyl vinyl acetate. 
     
     
         17 . The panel as recited in  claim 14  wherein said sound layer comprises at least one material selected from the group consisting of cork, rubber, or foam. 
     
     
         18 . The panel as recited in  claim 14  further comprising a moisture layer disposed in interconnecting relation between said core layer and said sound layer. 
     
     
         19 . The panel as recited in  claim 14  wherein said sound layer comprises a thickness of about 1 millimeter to about 4 millimeters. 
     
     
         20 . A waterproof board having at least one side used as backing support for a plurality of coverings, said board comprising:
 a core layer having a first face and a second face, each having a textured surface formed at least partially thereon;   said core layer having a thickness of generally about 5 millimeters between said first face and said second face, and comprising a densified foam material having a density of between generally about 490 kg/m 3  to about 520 kg/m 3 ;   said core layer also having a predetermined structural integrity so as to be sufficiently rigid to support the coverings and to permit attachment of said board to a surface without damage;   said predetermined structural integrity of said core layer also being sufficiently severable so that a user may score and sever a piece of said board; and   a sound layer comprising a thickness of generally about 2 millimeters and structured to reduce sound.