United States Patent (19)
`Grace
`
`Patent Number:
`11
`(45) Date of Patent:
`
`4,849,269
`Jul. 18, 1989
`
`54
`(75)
`(73)
`21
`22
`51
`(52)
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`58)
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`56)
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`SUBFLOORING COMPOSITE
`Ronald R. Grace, Hamilton, Ohio
`Inventor:
`Assignee:
`Nifty Products, Inc., Hamilton, Ohio
`Appl. No.: 219,359
`Filed:
`Jul. 15, 1988
`Int. Cl."................................................ B32B 3/00
`U.S. Cl. ...................................... 428/81; 428/116;
`428/119; 428/166; 428/178; 428/188; 428/213;
`428/220; 428/316.6
`Field of Search ............... 428/116, 166, 167, 178,
`428/188, 80, 81, 19, 120, 213, 220, 316.6
`References Cited
`U.S. PATENT DOCUMENTS
`2,064,132 12/1936 Upson ................................. 428/282
`2,980,575 4/1961 Petry .....
`... 428/282
`4,091,149 5/1978 Oxendine .............................. 428/81
`
`4,170,674 10/1979 Matsuki ................................. 428/90
`4,172,917 10/1979 Angelle et al. .
`... 428/95
`4,569,872 2/1986 Miller .................................. 428/178
`Primary Examiner-William J. Van Balen
`Attorney, Agent, or Firm-Charles R. Wilson
`57
`ABSTRACT
`A subflooring composite is especially useful in a van.
`The composite comprises a plastic core having a thin
`planar bottom surface layer, a thin planar top surface
`layer and a series of substantially equi-spaced and gener
`ally vertically extending support walls connecting the
`bottom and top surface layers. A foam underlay is ad
`hered to the plastic core's underside. The subflooring
`composite has good structural strength, insulation prop
`erties, and acoustic qualities. It is readily precut to abut
`against the interior vertical walls of the van.
`
`26 Claims, 2 Drawing Sheets
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`MacNeil Exhibit 2069
`Yita v. MacNeil IP, IPR2020-01139
`Page 1
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`U.S. Patent Jul.18, 1989
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`MacNeil Exhibit 2069
`Yita v. MacNeil IP, IPR2020-01139
`Page 2
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`

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`U.S. Patent Jul.18, 1989
`27
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`Sheet 2 of 2
`27
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`4,849,269
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`FIG 4
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`MacNeil Exhibit 2069
`Yita v. MacNeil IP, IPR2020-01139
`Page 3
`
`

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`1.
`
`SUBFLOORING COMPOSITE
`
`4,849,269
`2
`FIG. 2 is a side view of the subflooring composite of
`F.G. 1.
`FIG. 3 is a side view of another subflooring compos
`ite of the invention.
`FIG. 4 is a top view of the subflooring composite of
`FIG. 3 precut to fit the interior floor surface of a van.
`DETALED DESCRIPTION OF THE
`INVENTION
`The invention is described with particular reference
`to the drawings. FIGS. 1, 2 and 3 illustrate the materials
`used in the construction of subflooring composites
`while FIG. 4 illustrates a subflooring composite which
`has been precut according to the interior dimensions of
`a particular van. It is to be understood that recreational
`vehicles and other motor vehicles having a generally
`flat interior space can utilize the subflooring of this
`invention. The description which follows will be with
`reference to vans, though the other vehicles can as well
`utilize the subflooring of the invention.
`With reference to FIGS. 1 and 2, there is shown a
`subflooring composite 10 comprised of a plastic core 1i
`and a foam underlay 12. The core and underlay are
`adhered together sufficiently to withstand lateral forces
`as normally experienced in the installation of the sub
`flooring in a van as well as normal use once installed.
`Preferably, an adhesive is applied to one side of the
`plastic core and a sheet of foam laminated to it. A
`contact adhesive is optimumly used, though other adhe
`sives can as well be used.
`The plastic core 11 comprises a thin planar bottom
`surface layer 13 and a thin planar top surface layer 14
`which are joined together by support walls 15. The
`support walls 15 are equi-spaced and extend in a gener
`ally vertical direction from the bottom surface layer to
`the top surface layer. The bottom surface layer, top
`surface layer and support walls are formed from a plas
`tic material and in effect form a unitary structure. A
`substantial amount of dead air space occupies the areas
`between the support walls and contributes to the physi
`cal properties of the composite as further discussed in
`following paragraphs. From three to ten, preferably
`four to six, support walls per linear inch are used. The
`support walls extend at an angle of from about thirty
`five degrees to about ninety degrees from the horizon
`tal.
`Plastic core 11 has a thickness of from about 0.1
`inches to about 0.4 inches, preferably from about 0.2
`inches to about 0.3 inches. It has sufficient structural
`strength to withstand vertical forces as normally found
`in a van without crushing and to withstand lateral
`forces without wrinkling. Both characteristics are
`needed because of the use to which the composite sub
`flooring is subjected. Preferably, the plastic core is ca
`pable of withstanding at least about 80 pounds per
`square inch without crushing. Such plastic cores are
`commercially available in various widths, thicknesses,
`and strengths. They are made from high impact poly
`propylene/polyethylene copolymers or other poly
`meric resins.
`The foam underlay 12 provides a cushioning effect
`and serves as a means to even out ridges normally built
`into a van's interior floor surface by the manufacturer.
`Thus, the foam underlay accommodates or absorbs the
`floor's uneven floor surface without affecting the plastic
`core's lay or top surface area. Various foams of open
`cell and closed-cell nature are commercially available
`and usable herein. A foam thickness of at least about 0.1
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`10
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`Invention relates to a lightweight subflooring com
`posite. More particularly, the invention relates to a
`subflooring composite useful in the interior floor area of
`3 V8,
`Vans are originally equipped by the manufacturer
`with a basic open rear interior area. A significant indus
`try has been created by the desires of van owners to
`convert their van's interior area into a more liveable or
`luxurious space. Oftentimes, swivel chairs, cabinets, wet
`bars, etc are installed.
`The van converter will initially strip the van's rear
`15
`interior area of carpet and any other factory installed
`component to unveil a substantially flat open area. The
`floor of the van is normally made of metal with ridges
`extending length-wise. The surface is made smooth by
`the installation of furring strips bolted to the floor and
`20
`Mor the installation of a thick plywood or wafer board.
`A substantial number of cuts must be made in the ply
`wood or wafer board to accommodate the vehicle's
`irregular interior shape. This subflooring is needed to
`present a smooth surface not only for comfort purposes,
`but also for ease of installation of new components such
`as chairs, etc. Self-tapping screws or bolts and nuts are
`used to hold the subflooring in place.
`The installation of the plywood or wafer board sub
`flooring is difficult due to its weight. The need to cut it
`30
`in an irregular shape also presents special problems. Still
`another drawback to the conventionally used subfloor
`ing is its stability. It does tend to swell or contract due
`to humidity and temperature fluctuations. Because the
`subflooring is normally pieced together from sections,
`there is a tendency for the subflooring to occasionally
`break at its seams or pull loose from the van's metal
`floor. The subflooring is also subject to deterioration
`due to inadvertent liquid spills or rain water exposure.
`There is a need for a subflooring material will can be
`readily installed in a van without all the disadvantages
`of that currently used. The subflooring ideally would be
`lightweight, easily cut or shaped and strong enough to
`withstand weight forces normally encountered. Of
`course, the subflooring must also be cost effective and
`45
`have all the qualities normally expected of such a prod
`uct, e.g. capable of presenting a smooth upper surface,
`good insulation properties and good acoustic qualities.
`In accord with this invention, there has been developed
`such a product.
`SUMMARY OF THE INVENTION
`A subflooring composite of at least two layers is
`especially useful in vans. The composite comprises a
`core of a plastic material having a thin planar bottom
`55
`surface layer and a thin planar top surface layer with a
`series of substantially equi-spaced and generally verti
`cally extending support walls connecting the bottom
`surface and top surface layers to form a unitary core
`structure. A foam underlay is adhered to one side of the
`core and, in a preferred embodiment, a fibrous overlay
`is adhered to the other side of the core. The subflooring
`composite can be precut to fit the interior floor space of
`a van and readily installed as a single piece of goods.
`BRIEF DESCRIPTION OF THE DRAWINGS
`FIG. It is a view in perspective of the subflooring
`composite of this invention.
`
`MacNeil Exhibit 2069
`Yita v. MacNeil IP, IPR2020-01139
`Page 4
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`4,849,269
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`layer with a series of substantially equi-spaced and
`inches is needed to achieve the benefits of the foam
`generally vertically extending support walls con
`while the upper foam thickness is dictated more by cost
`considerations and feel. Preferably, the foam underlay
`necting the bottom surface and top surface layers in
`a manner to form a unitary core structure with
`has a thickness of from about 0.1 inches to about 0.4
`inches and a density of from about two pounds per
`substantial dead air space, said plastic material fur
`cubic foot to about four pounds per cubic foot. A pre
`ther characterized in having a thickness of from
`ferred foam is an open-cell polyurethane foam. Such
`about 0.1 inches to about 0.4 inches, sufficient
`foams possess the ability to be readily adhered to the
`structural strength to withstand vertical and lateral
`plastic core and to the vehicle's metal floor surface.
`forces as normally encountered by a floor in the
`The composite of the plastic core 11 and foam under
`van without crushing and without wrinkling, and
`lay 12 is produced in widths and lengths sufficient to
`good insulation properties;
`cover the van's floor surface, e.g. from about five feet to
`(b) a foam underlay adhered to the plastic core, said
`about eight feet wide and from about five feet to about
`foam underlay capable of being adhesively at
`twelve feet long. The composite has excellent insulating
`tached to the floor of the van; and
`qualities due to the dead air space in the plastic core and
`(c) a fibrous overlay adhered to the plastic core for
`the foam underlay. Additionally, the composite has
`added comfort, acoustic and insulation properties.
`good acoustic qualities in reducing road noise from
`2. The subflooring composite of claim 1 wherein the
`outside the van and within the van. More importantly,
`plastic core is further characterized in having from
`the subflooring composite is easy to cut to a desired
`three to ten support walls per linear inch.
`shape and install. Its lightweight makes it easy to handle
`20
`3. The subflooring of claim 2 wherein the support
`by a single worker.
`walls extend from the bottom surface layer at an angle
`Subflooring composite 20 illustrated in FIG.3 has an
`of from about thirty-five degrees to about ninety de
`optional fibrous overlay 21 adhered to the top surface of
`grees from the horizontal.
`plastic core 11. The overlay is preferably a felted fi
`4. The subflooring composite of claim 3 wherein the
`brous sheet adhesively secured to the plastic core. Vari
`25
`plastic core has a vertical structural strength of at least
`ous woven and non-woven sheets and mattings of fi
`about 80 pounds per square inch.
`brous materials can as well be used. The fibrous overlay
`5. The subflooring composite of claim 4 wherein the
`adds additional cushioning, insulation and acoustic
`plastic core has a thickness ranging from about 0.2
`qualities to the subflooring composite. An overlay
`inches to about 0.3 inches.
`thickness of from about 0.3 inches to about 0.6 inches
`6. The subflooring composite of claim 1 wherein the
`provides an optimum balance of performance and cost.
`foam underlay is a polyurethane foam.
`Vans typically have a generally rectangular-shaped
`7. The subflooring composite of claim 6 wherein the
`interiors, though the exact dimensions and shapes will
`foam underlay has a thickness of from about 0.1 inches
`vary widely depending on the vehicle make and model.
`to about 0.4 inches and a density of from about two
`However, the physical characteristics of the composite
`35
`pounds per cubic foot to about four pounds per cubic
`allow it to be cut, preferably die-cut, according to need.
`foot.
`As shown in FIG. 4, the subflooring composite 20 has
`8. The subflooring composite of claim 1 wherein the
`wheel well cut-outs 25, step cut-outs 26 and seat cut
`fibrous overlay is a felted fibrous sheet.
`outs 27 as well as contoured edges. As can be well
`9. The subflooring composite of claim 8 wherein the
`imagined, other shapes are needed depending on the
`felted fibrous sheet has a thickness of from about 0.3
`van being equipped. Such shapes are readily produced
`inches to about 0.6 inches.
`from the aforedescribed subflooring composite.
`10. A van subflooring composite precut to fit onto a
`In accord with this invention, the subflooring com
`van's rear interior floor area to cover the floor and abut
`posite is produced by applying an adhesive to one side
`against vertical interior walls of the van so as to prevent
`of the plastic core and/or the foam underlay and lami
`45
`lateral movement, said subflooring comprising a com
`nating them together. If needed, the fibrous overlay is
`posite of:
`next adhesively adhered to the other side of the plastic
`(a) a core of a plastic material having a thin planar
`core. The composite is then cut to exact specifications,
`bottom surface layer and a thin planar top surface
`which preferably gives a one piece unit which can be
`layer with a series of substantially equi-spaced and
`laid directly onto the interior floor surface of a van.
`50
`generally vertically extending support walls con
`Because of the rigidity of the plastic core and the verti
`necting the bottom surface and top surface layers in
`cal walls of the van, the subflooring will remain in
`a manner to form a unitary core structure with
`place. For further assurance of non-slippage during use,
`substantial dead air space, said plastic material fur
`the subflooring composite can be adhesively adhered to
`ther characterized in having a thickness of from
`the metal floor surface of the van. The installed sub
`55
`about 0.1 inches to about 0.4 inches, sufficient
`flooring can receive a carpet. Any fixture such as swivel
`structural strength to withstand vertical and lateral
`chairs, cabinets, etc. are bolted through the subflooring
`forces as normally encountered by a floor in the
`composite and, if needed, into the van's metal floor.
`van without crushing and without wrinkling, and
`While the invention has been described with particu
`good insulation properties;
`lar reference to the drawings, it should be understood
`60
`(b) a foam underlay adhered to the plastic core, said
`various modifications are possible. All obvious modifi
`foam underlay capable of being adhesively at
`cations and changes are within the scope of the follow
`ing claims.
`tached to the floor of the van; and
`(c) a fibrous overlay adhered to the plastic core for
`What is claimed is:
`1. A lightweight subflooring composite for use in a
`added comfort, acoustic and insulation properties.
`65
`van, said composite comprising:
`11. The van subflooring composite of claim 10,
`(a) a core of a plastic material having a thin planar
`wherein the plastic core is further characterized in hav
`ing from three to ten support walls per linear inch.
`bottom surface layer and a thin planar top surface
`
`30
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`MacNeil Exhibit 2069
`Yita v. MacNeil IP, IPR2020-01139
`Page 5
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`4,849,269
`6
`5
`generally vertically extending support walls con
`12. The van subflooring composite of claim 11
`necting the bottom surface and top surface layers in
`wherein the support walls extend from the bottom sur
`face layer at an angle of from about thirty-five degrees
`a manner to form a unitary core structure with
`to about ninety degrees from the horizontal.
`substantial dead air space, said plastic material fur
`13. The van subflooring composite of claim 12
`ther characterized in having a thickness of from
`wherein the plastic core has a vertical structural
`about 0.1 inches to about 0.4 inches, sufficient
`strength of at least about 80 pounds per square inch.
`structural strength to withstand vertical and lateral
`14. The van subflooring composite of claim 13
`forces as normally encountered by a floor in the
`wherein the plastic core has a thickness ranging from
`van without crushing and without wrinkling, and
`about 0.2 inches to about 0.3 inches.
`good insulation properties; and
`15. The van subflooring composite of claim 10
`(b) a foam underlay adhered to the plastic core, said
`wherein the foam underlay has a thickness of from
`foam underlay capable of being adhesively at
`about 0.1 inches to about 0.4 inches and a density of
`tached to the floor of the van.
`from about two pounds per cubic foot to about four
`20. The subflooring of claim 19 wherein the plastic
`pounds per cubic foot.
`core is further characterized in having from three to ten
`16. The van subflooring composite of claim 10
`support walls per linear inch.
`wherein the fibrous overlay is a felted fibrous sheet.
`21. The subflooring of claim 20 wherein the support
`17. The van subflooring composite of claim 16
`walls extend from the bottom surface layer at an angle
`wherein the felted fibrous sheet has a thickness of from
`of from about thirty-five degrees to about ninety de
`about 0.3 inches to about 0.6 inches.
`20
`grees from the horizontal.
`18. The van subflooring composite of claim 10
`22. The subflooring of claim 21 wherein the plastic
`wherein said composite has a generally rectangular
`core has a vertical structural strength of at least about
`shape with cut-out portions at its edges and contoured
`80 pounds per square inch.
`edges to accommodate an irregular shape of the van's
`23. The subflooring of claim 22 wherein the plastic
`interior area.
`core has a thickness ranging from about 0.2 inches to
`19. A subflooring for vans, said subflooring shaped so
`about 0.3 inches.
`as to be generally rectangular with a width of from
`24. The subflooring of claim 19 wherein the foam
`about five feet to about eight feet and a length of from
`underlay has a thickness of from about 0.1 inches to
`about five feet to about twelve feet with cut-out por
`about 0.4 inches and a density of from about two pounds
`tions at its edges and contoured edges so to substantially
`30
`per cubic foot to about four pounds per cubic foot.
`cover the van's rear interior floor area and abut against
`25. The subflooring of claim 24 wherein the foam
`vertical interior walls of the van to prevent lateral
`underlay is an open-cell polyurethane foam.
`movement, said subflooring comprising a composite of:
`26. The subflooring of claim 19 wherein the subfloor
`(a) a core of a plastic material having a thin planar
`ing is a one piece unit.
`bottom surface layer and a thin planar top surface
`layer with a series of substantially equi-spaced and
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`MacNeil Exhibit 2069
`Yita v. MacNeil IP, IPR2020-01139
`Page 6
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