Construction panel with non-skid surface and method of fabrication

• US 4,109,041 A
• Filed: 11/04/1977
• Issued: 08/22/1978
• Est. Priority Date: 07/26/1976
• Status: Expired due to Term

• Current Assignee: Georgia-Pacific Corporation
• Original Assignee: Champion International Corporation (International Paper Company)
• Inventors: Tellman, Stephen J.
• Primary Examiner(s): Robinson, Ellis
• Application Number:
  US05/848,485
• Time in Patent Office: 291 Days
• Field of Search: 428/327, 428/326, 428/143, 428/147, 428/206, 428/342, 428/511, 428/512, 428/496, 428/334, 428/402, 428/521, 156/62.2, 156/279, 156/280, 427/202, 427/180, 52/181, 264/122, 264/112, 264/113, 16/1
• US Class Current: 428/147
• CPC Class Codes: B32B 2038/0076 Curing, vulcanising, cross-linking
• CPC Class Codes: B32B 21/12 next to a particulate layer
• CPC Class Codes: B32B 2264/0207 Particles made of materials belonging to B32B25/00
• CPC Class Codes: B32B 2307/744 Non-slip, anti-slip
• CPC Class Codes: B32B 2309/105 Thickness
• CPC Class Codes: B32B 2607/00 Walls, panels
• CPC Class Codes: E04D 3/351 at least one of the layers being composed of insulating material, e.g. fibre or foam material
• CPC Class Codes: E04D 3/352 at least one insulating layer being located between non-insulating layers, e.g. double skin slabs or sheets
• CPC Class Codes: E04G 1/151 Platforms made of wood, with or without reinforcements E04G1/152 takes precedence
• CPC Class Codes: Y10T 428/24372 Particulate matter
• CPC Class Codes: Y10T 428/24405 Polymer or resin [e.g., natural or synthetic rubber, etc.]
• CPC Class Codes: Y10T 428/254 Polymeric or resinous material
• CPC Class Codes: Y10T 428/263 Coating layer not in excess of 5 mils thick or equivalent
• CPC Class Codes: Y10T 428/277 Cellulosic substrate
• CPC Class Codes: Y10T 428/31841 Next to cellulosic
• CPC Class Codes: Y10T 428/31931 Polyene monomer-containing

Abstract

Elastomeric particles, e.g., rubber grindings and buffings produced in vehicular tire manufacturing and recapping operations, are incorporated into at least one surface of particle-board panel to increase friction, prevent stacked panels from sliding in echelon, prevent tools from sliding thereon, prevent workmen from slipping thereon, and still allow the panel to be cut and nailed. The particles can be bonded to the panels simultaneously with the panel molding operation or in a separate subsequent operation. In a preferred method of fabricating a non-skid construction panel of the subject invention, rubber particles in the range from below about 10 to above about 20 pounds per one thousand square feet of surface area are distributed over a panel, and the rubber particles and the panels are subsequently subjected to heat and pressure, and the resulting panel has a smooth surface with the elastomeric particles being used somewhat as a light "salting" of the construction panel'"'"'s surface layer. The resulting layer is smooth, but the presence of the elastomeric particles insures the non-slipping features mentioned above, as well as the ability of the panel to be nailed and cut, as required.

Claims

1. An improved construction panel comprising:

a structural sheet of material selected from the group consisting of particleboard, hardboard, plywood, fiberboard, and combinations thereof, said sheet having at least one smooth surface; and

a layer of elastomeric particles generally uniformaly distributed over and bonded to at least one smooth surface of said sheet, said particles being separated to expose a substantial part of said surface and being of a size which effectively preserves the smoothness of said surface while imparting a non-slip characteristic thereto.

2. An improved construction panel according to claim 1 wherein said elastomeric particles comprise the dust produced by grinding tire rubber.

3. The improved construction panel according to claim 1 wherein said elastomeric panels are distributed in an amount in the range of from about 10 to about 20 pounds of particles per one thousand square feet of sheet surface.

4. The improved construction panel according to claim 1 wherein said particles cover approximately 10% of the sheet surface.

5. The improved construction panel according to claim 1 wherein the layer of elastomeric particles is about 4 mils in thickness.

6. The improved construction panel according to claim 3 wherein the layer of elastomeric particles is about 4 mils in thickness.

7. The improved construction panel according to claim 4 wherein the layer of elastomeric particles is about 4 mils in thickness.

8. The method of inhibiting normally slippery surfaced construction panels from sliding in echelon when stacked which comprises providing at least one smooth surface of each of said panels with a thin adherent layer of generally uniformly-distributed elastomeric particles, said particles being separated to expose a substantial part of said surface and being distributed in an amount in the range of from about10 to about 20 pounds of particles per one thousand square feet of panel surface.

9. The method of producing a particleboard panel comprising the steps of generally uniformly distributing elastomeric particles on a caul plate in an amount in the range of from about 10 to about 20 pounds of particles per one thousand square feet of caul plate area, said particles forming a thin layer of spaced particles, depositing wood flakes admixed with a binder over said particles to form a composite mat, and curing said binder to form said particleboard panel while bonding said elastomeric particles to the surface thereof.

11. The method according to claim 9 wherein said binder is cured by applying heat and pressure to said mat.

10. The method of producing a particleboard panel comprising the steps of generally uniformly distributing elastomeric particles on a caul plate in an amount in the range of from about 10 to about 20 pounds of particles per one thousand square feet of caul plate area, said particles forming a thin layer of spaced particles, depositing wood flakes admixed with a binder over said particles to form a composite mat, prepressing said mat to form a surface, generally uniformly distributing elastomeric particles on the mat surface in an amount in the range from about 10 to about 20 pounds of particles per one thousand square feet of mat surface, and curing said binder to form said particleboard panel while bonding said elastomeric particles to both surfaces thereof.

12. The method according to claim 10 wherein said binder is cured by applying heat and pressure to said mat.

13. The method of producing a particleboard panel comprising the steps of depositing wood flakes admixed with a binder on a caul plate to produce a mat, prepressing said mat, generally uniformly distributing elastomeric particles over a surface of the prepressed mat in an amount in the range of from about 10 to about 20 pounds of particles per one thousand square feet of mat surface, said particles forming a thin layer of spaced particles which expose a substantial part of the mat surface, and curing said binder to form said particleboard panel while bonding said elastomeric particles to the surface thereof.

14. The method according to claim 13 wherein said binder is cured by applying heat and pressure.