US20060210753A1

US20060210753A1 - Disposable protective sheeting for decks and floors

Info

Publication number: US20060210753A1
Application number: US11/384,573
Authority: US
Inventors: Gary Kadlec
Original assignee: Individual
Current assignee: Individual
Priority date: 2005-03-21
Filing date: 2006-03-20
Publication date: 2006-09-21
Also published as: EP1868782A2; AU2006227296A1; CA2601883C; WO2006102190A3; CA2601883A1; WO2006102190A2; MX2007011429A; US9631380B2; US20160289983A1; EP1868782A4; KR20070120548A

Abstract

Disposable protective sheeting for covering decks and floors during construction and the like. The protective sheeting includes a first layer of a barrier material impervious to liquid and pervious to vapor and a second layer of an overlay material providing a slip-resistant upper surface that is bonded to the first layer. Alternatively, the sheeting can be a single layer of barrier material treated to be slip resistant. The sheeting can be provided in rolls and temporarily secured to the decks and floors at the construction site or pre-installed onto decking materials off-site. When construction is complete, the disposable protective sheeting is removed to expose a contamination and damage free surface.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority benefit of U.S. Provisional Patent Application No. 60/663,830 filed on Mar. 21, 2005, the disclosure of which is expressly incorporated herein in its entirety.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH

Not Applicable

REFERENCE TO MICROFICHE APPENDIX

Not Applicable

FIELD OF THE INVENTION

The present invention generally relates to materials and methods for building construction and, more particularly, to materials and methods for protecting decks and floors during building construction.

BACKGROUND OF THE INVENTION

In building construction, after either a basement or a crawl space has been completed, floor joists are installed and decking material is nailed to the floor joists to form a deck. The decking material is typically plywood, oriented strand board, composite particle board, or the like. Once the deck is formed, external and internal walls are constructed and nailed to the deck. If the building is multilevel, another set of floor joists is secured on top of load bearing walls and decking material is nailed into place onto the additional set of floor joists to form another deck. This process is repeated until all of the levels of the building are complete and a roof is constructed onto load bearing walls of the top level. The upper surface of these decks is typically the surface upon which flooring materials, such as carpet, tile, linoleum, wood, stone, or the like, is directly laid and/or secured. During new construction, remodeling or rebuilding, it is frequently necessary to replace or overlay damaged or contaminated decking material with new decking material.
Construction projects typically take at least several months to complete, during this time the upper surface of the deck is exposed to rain, snow, tracked-in mud, joint compound, dust, saw dust, paint, and other materials. Thus, the decking material often absorbs moisture causing edge swelling, raises-up, warps, and delaminates The decking material can also become caked with these materials and the decking material is virtually impossible to clean effectively because it has rough surfaces. From a cosmetic standpoint, the decking material looks very bad when covered with this contamination. Additionally, the adhesive used to secure certain flooring materials may not adhere effectively to the decking material because of this contamination and work loose prematurely. Furthermore, there are environmental issues as dust and other materials remaining on the decking material after construction are trapped below the flooring material and may eventually work their way out from under the flooring material to create problems for occupants with allergies to such materials. When damage and/or contamination are severe, it is necessary for the builder to incur significant costs to sand, treat or seal the existing decking material or to replace the existing decking material with new decking material before the final flooring is installed.
It is noted that other types of decks and floors can also be damaged and/or contaminated such as, for example, decks and floors of modular and manufactured housing during construction, decks and floors of trucks, trailers, storage facilities, storage containers, and the like during transportation and/or storage of messy or dirty materials, and new or existing floors whether wood, carpet, tile, linoleum, cement, stone, vinyl, or terrazzo, and the like.
Additionally, builders frequently incur significant costs installing neutral colored carpeting, wood floors, tile and the like in “spec” properties simply to cover up the contamination so they look presentable to prospects. This is obviously very expensive and often may need to be removed and replaced to satisfy a buyer, incurring further unanticipated expense. Accordingly, there is a need in the art for improved materials and methods for protecting decks and/or floors.

SUMMARY OF THE INVENTION

The present invention provides improved materials and methods for protecting decks and floors which overcomes at least some of the above-noted problems of the related art. According to the present invention, disposable protective sheeting for covering decks and floors comprises, in combination, a first layer of a barrier material impervious to liquid and pervious to vapor and a second layer of an overlay material providing a slip-resistant upper surface. A bottom surface of the second layer is secured to a top surface of the first layer with adhesive.
According to another aspect of the present invention, decking material with disposable protective sheeting comprises, in combination, a panel of decking material having an upper surface and a disposable protective sheeting temporarily secured to the upper surface of the panel. The disposable protective sheeting includes a first layer of a barrier material impervious to liquid and pervious to vapor and a layer of adhesive at a bottom surface of the barrier layer and temporarily securing the disposable protective sheeting to the upper surface of the panel.
According to yet another aspect of the present invention, a method of protecting decks and floors comprises steps of, in combination, providing disposable protective sheeting having a barrier layer of a barrier material impervious to liquid and pervious to vapor, temporarily securing the disposable protective sheeting to an upper surface of one of the deck and the floor, and removing the disposable protective sheeting at an appropriate time near completion of the project.
According to even yet another aspect of the present invention, disposable protective sheeting for covering decks and floors comprises, in combination, a first layer of a barrier material impervious to liquid and tear resistant, a second layer of an cushioning material. A bottom surface of the first layer is secured to a top surface of the second layer with adhesive.
From the foregoing disclosure and the following more detailed description of various preferred embodiments it will be apparent to those skilled in the art that the present invention provides a significant advance in the technology and art of materials and methods for protecting decks and floors. Particularly significant in this regard is the potential the invention affords for providing a high quality, reliable, efficient, and low cost material and method. Additional features and advantages of various preferred embodiments will be better understood in view of the detailed description provided below.

BRIEF DESCRIPTION OF THE DRAWINGS

These and further features of the present invention will be apparent with reference to the following description and drawings, wherein:
FIG. 1 is a top plan view of disposable protective sheeting according to a first embodiment of the present invention;
FIG. 2 is a cross-section view taken along line 2-2 of FIG. 1;
FIG. 3 is a cross-sectional view similar to FIG. 2 but showing a variation of the protective sheeting wherein an upper surface of the protective sheeting is treated to provide a non-slip surface rather than being laminated with a layer of paper;
FIG. 4 is a cross-sectional view similar to FIG. 2 but showing another variation of the protective sheeting wherein it does not have an overlap portion for adjoining panels;
FIG. 5 is a top plan view of disposable protective sheeting according to a second embodiment of the present invention;
FIG. 6 is a cross-section view taken along line 6-6 of FIG. 5;
FIG. 7 is a cross-sectional view similar to FIG. 6 but showing a variation of the protective sheeting wherein an upper surface of the protective sheeting is treated to provide a non-slip surface rather than being laminated with a layer of paper;
FIG. 8 is a cross-sectional view similar to FIG. 6 but showing another variation of the protective sheeting wherein the sheeting does not have an overlap portion for adjoining panels;
FIG. 9 is a cross-sectional view showing the disposable protective covering of FIGS. 1 and 2 installed on a deck of adjoining panels;
FIG. 10 is a cross-sectional view showing the disposable protective covering of FIG. 4 installed on a deck of adjoining panels;
FIG. 11 is a cross-sectional view showing the disposable protective covering of FIGS. 5 and 6 installed on a deck of adjoining panels;
FIG. 12 is a cross-sectional view showing the disposable protective covering of FIG. 4 installed on a deck of adjoining panels;
FIG. 13 is a top plan view of disposable protective sheeting according to a third embodiment of the present invention;
FIG. 14 is a cross-section view taken along line 14-14 of FIG. 13; and
FIG. 15 is a cross-sectional view similar to FIG. 14 but showing a variation of the protective sheeting wherein an under layer is omitted.
It should be understood that the appended drawings are not necessarily to scale, presenting a somewhat simplified representation of various preferred features illustrative of the basic principles of the invention. The specific design features of materials and methods for protecting decks and floors as disclosed herein, including, for example, specific dimensions, orientations, locations, and shapes will be determined in part by the particular intended application and use environment. Certain features of the illustrated embodiments have been enlarged or distorted relative to others to facilitate visualization and clear understanding. In particular, thin features may be thickened, for example, for clarity or illustration. All references to direction and position, unless otherwise indicated, refer to the orientation of the disposable protective sheeting illustrated in the drawings. In general, up or upward refers to an upward direction out of the plane of the paper in FIGS. 1 and 5 and down or downward refers to a downward direction into the plane of the paper in FIG. 1 and 5.

DETAILED DESCRIPTION OF CERTAIN PREFERRED EMBODIMENTS

It will be apparent to those skilled in the art, that is, to those who have knowledge or experience in this area of technology, that many uses and design variations are possible for the improved materials and methods for protecting decks and floors disclosed herein. The following detailed discussion of various alternative and preferred embodiments will illustrate the general principles of the invention with reference to a preferred embodiment for protecting decks during commercial or residential building construction, remodeling, or rebuilding such as, for example homes, condos, apartments, offices, restaurants, clinics, institutional and industrial projects and the like. It is noted that the term “deck” or “decks” as used in this specification and claims means any generally horizontal support surface for walking on and/ or supporting furniture, equipment and the like and formed of materials such as, for example, plywood, oriented strand board (OSB), composite particle board, other engineered materials, concrete, concrete slab, and the like. Other embodiments suitable for other applications will be apparent to those skilled in the art given the benefit of this disclosure such as, for example, protecting decks and floors of modular and manufactured housing during construction, decks and floors of trucks, trailers, storage facilities, storage containers, and the like during transportation and/or storage of messy or dirty materials, and the protection of new or existing floors whether wood, carpet, tile, cement, stone, vinyl, linoleum, or terrazzo, and the like during construction, remodeling, or rebuilding.
Referring now to the drawings, FIGS. 1 and 2 show disposable protective sheeting 10 according to a first preferred embodiment of the present invention. The illustrated disposable protective sheeting 10 is a multi-layer laminate that includes a first layer or sheet 12 of underlay or barrier material, a second layer or sheet 14 of overlay or non-skid material, adhesive 16 permanently bonding the second layer 14 to the top surface of the first layer 12, and a layer of adhesive 18 at the bottom surface of the first layer 12 for removably or temporarily securing the protective sheeting 10 to a deck 20 to be protected. The illustrated protective sheeting 10 is pre-applied to a panel of decking material 22 at off site and pre job installation at a factory, assembly plant, or any other suitable off construction-site location. The decking material can be, for example, plywood, oriented strand board (OSB), composite particle board, other engineered materials, or the like. The illustrated panel of decking material 22 is a standard-size panel of about 4 feet by about 8 feet but it is noted that any other suitable size can be utilized. It is noted that the sheeting 10 and/or the panel 22 can be treated with a fungicide to help prevent any mold from forming between or on the protective sheeting 10 and the panel 22.
The underlay or barrier material of the first layer 12 can preferably be any suitable material that provides a barrier that is permeable to water vapor, impermeable to liquids, and tear resistant. The underlay material protects the top surface of the deck 20 from contamination and permanent damage from spilled and tracked liquids and wet as well as dry substances, while at the same time preferably providing breathability to avoid condensation on the underside which can cause damage to the deck 20. The underlay material can be, for example, nonwoven spunbonded olefin available from E.I. DuPont known as TYVEK. Other suitable underlay materials are believed to be TYPAR available from BBA Fiberweb, R-WRAP and BARICADE available from Ludlow, RUFCOWRAP available from Raven Industries, AMOCOWRAP available from Propex Fabrics, PINKWRAP available from Owens Coming, and CHOICEWRAP available from Weyerhauser. The barrier material of the first layer 12 can alternatively be a polyethylene sheet including “Visqueen” which is waterproof but is not breathable or tear resistant.
The overlay material of the second layer 14 can be any suitable material that provides a non-skid upper surface without detrimentally affecting the breathability of the first layer 12. The overlay material can be a paper sheet such as, for example, kraft paper. It is believed that some absorption of liquid by a paper overlay layer will aid non-skid properties. The paper sheet also provides an upper surface that is easy to write on and mark during construction, remodeling, or rebuilding. The overlay material may be treated with a fire retardant if desired. The upper surface of the overlay material can also have printed indicia 24 such as, for example, the name and/or logo of a volume builder using the protective sheeting 10 in order to promote the company.
The adhesive 16 securing the second layer 14 to the first layer 12 can be any suitable adhesive that permanently bonds the second layer 14 to the first layer 12 without detrimentally affecting the breathability of the first layer 12. The adhesive 16 can be, for example, hot melt or any other suitable adhesive. The adhesive 16 can be applied as a continuous sheet or layer or can be applied on only a portion of the surfaces of the first and second layers 12, 14. Preferably, the adhesive 16 is applied to only about 10% to about 25% of the surfaces so that passage of vapor through the protective sheeting 10 is not overly impeded.
The layer of adhesive 18 that removably secures first layer 12 to the panel of decking material 22 can be any suitable material that temporarily bonds the first layer 12 to the panel of decking material 22 without detrimentally affecting the breathability of the first layer 12. The layer of adhesive 18 should allow the protective sheeting 10 to be peeled-back to nail or screw the panel of decking material 22 in place, such as to floor joists 26, to form the deck 20 and then adhered back in place to protect the constructed deck. The layer of adhesive 18 should also allow easy removal of the protective sheeting 10 from the panel of decking material 22 for disposal once the protective sheeting 10 is no longer needed, without leaving any significant residue. The layer of adhesive 18 preferably enables the protective sheeting 10 to behave like a large “Post-It Note”. It is noted that additionally or alternatively the upper surface of the panel of decking material 22 can be treated with a release coating prior to the application of the protective sheeting 10 to facilitate easy removal of the protective sheeting 10 at the appropriate time in the construction, remodeling, or rebuilding process.
The illustrated protective sheeting 10 is sized and located on the panel of decking material 22 to provide overlap or overhanging portions or strips 28 along two adjacent edges of the panel of decking material 22. The overlap portions 28 extend beyond the edges of the panel 22 and are utilized to overlap joints between adjacent panels of decking material 22 once the panels 22 are installed to provide a continuous protective surface as described in more detail hereinafter. A bottom surface of the overlay portions 28 are provided with a layer pressure-sensitive adhesive 30 to secure the overlap portions 28 to the protection sheeting 10 of an adjacent panel 22 at installation of the panels 22. A release layer or liner 32 is provided on the layer of pressure-sensitive adhesive 30 to protect the layer of adhesive 30 until installation of the panels 22. The illustrated overlap portions 28 each have a width of about four inches but any other suitable width can alternatively be utilized. The illustrated protective sheeting 10 is sized and located on the panel of decking material 22 to provide open strips 34 that are free of the protective sheeting 10 along the two adjacent edges of the panel 22 that do not have the overlap portions 28. The open strips 34 are utilized to initially nail or screw the panel of decking material 22 in place before peeling back the protective sheeting 10 to complete installing the fasteners into the rest of the floor joists. This avoids installing the fasteners 36 through the protective sheeting 10 which would make it more difficult to later remove the protective sheeting. Once installation of the panel 22 is complete, the protective sheeting 10 is then placed back in its original position on the panel 22. The illustrated open strips 34 have a width of about one inch but any other suitable width can alternatively be utilized. It is noted that the illustrated protective sheeting 10 is about eight feet and three inches by about four feet and three inches to obtain the illustrated overlap portions 28 and open strips 34 with the illustrated standard-size panel of decking material 22 but it is noted that any other suitable size can alternatively be utilized.
FIG. 9 shows the protective sheeting 10 on installed adjoining panels 22. The panels 22 are installed by installing the fasteners 36 along each edge of the panels 22. On two sides the fasteners 36 are installed along the open strips 34. On the other two sides, the protective sheeting 10 is temporarily peeled back so that the fasteners 36 for the deck panel 22 can be installed under the protective sheeting 10 and then is placed back onto the deck panel 22. As adjacent deck panels 22 are installed, the release liners 32 of the overlap portions 28 are removed and the overlap portions 28 are adhered onto the top surface of the protective sheeting 10 of the adjoining panel 22 so that the gaps or joints are covered to form a continuous protective covering. When applied to the deck 20 in this temporary manner, the protective sheeting 10 allows for easy removal at the end of construction to facilitate easy cleanup of the jobsite and to provide a clean surface for the installation of flooring material onto the deck surface. Once construction is complete and/or the property is ready for cleanup, the protective sheeting 10 is simply pulled up and discarded. The entire deck surface is vacuumed leaving the deck 20 in virtually new condition.
FIG. 3 shows a variation of the first preferred embodiment of disposable protection sheeting 10 wherein the second layer 14 is eliminated and a suitable non-skid or slip-resistant surface 38 is provided directly onto the top surface of the first layer 12. The non-skid or slip-resistant surface 38 can be obtained by any suitable application, abrasion, coating, or the like in a manner that will not detrimentally affect the breathability of the first layer 12. This variation of the disposable protective sheeting 10 is preferably installed as discussed above.
FIG. 4 shows another variation of the first preferred embodiment of disposable protective sheeting 10 wherein the overlap portions 28 are eliminated and replaced with additional open strips 34. The panels of decking material 22 are initially secured by inserting the fasteners 36 through the panel 22 at the open strips 34. The protective sheeting 10 is peeled back about half way to install fasteners in the exposed portion of the panel 22. That side of the protective sheeting 10 is placed back to its original position and the other half of the protective sheeting is peeled back and the process is repeated. Once installation of the panel 22 is complete and the protective sheeting 10 is in its original position, a thin strip or tape 40 of the protective sheeting 10 much like the overlap portions 28 is applied over the joints or seams between panels 22 to provide a continuous protective surface as described in more detail hereinafter. The illustrated tape 40 has a width of about four inches but any other suitable size can alternatively be utilized. It is believed that this variation may be more easily stored and shipped (as well as more easily installed because the protective sheeting 10 does not need to be initially peeled back to install the fasteners 36). It is noted that the illustrated protective sheeting 10 is about seven feet and ten inches by about three feet and ten inches to obtain the illustrated open strips 34 with the illustrated standard-size panel of decking material 22 but it is noted that any other suitable size can alternatively be utilized.
FIG. 10 shows the variation of the protective sheeting 10 on installed adjoining panels 22. The panels 22 are installed by installing the fasteners 36 along each edge of the panels 22. The fasteners 36 are initially installed along the open strips 34 along the edges of the panels 22. Then the protective sheeting 10 is peeled back so that the panel 22 can be fastened under the protective sheeting 10 and the protective sheeting 10 is returned to its original position. Once adjacent panels 22 are installed. The tape 40 is installed over the joints or seams. The release liner 32 of the tape 40 is removed and the tape 40 is adhered onto the top surface of the protective sheeting 10 of the adjoining panels 22 so that the gaps or joints are covered to form a continuous protective covering. When applied to the deck 20 in this temporary manner, the protective sheeting 10 allows for easy removal at the end of construction to facilitate easy cleanup of the jobsite and to provide a clean surface for the installation of flooring material onto the deck 20. Once construction is complete and/or the property is ready for cleanup, the protective sheeting 10 and the tape 40 is simply pulled up and discarded. The entire deck surface is vacuumed leaving the deck 20 in virtually new condition.
FIGS. 5 and 6 show disposable protective sheeting 100 according to a second preferred embodiment of the present invention wherein like reference numbers are utilized to indicate like structure. The illustrated disposable protective sheeting 100 is a multi-layer laminate similar to that described above but it is sized and shaped as a continuous web so that it can be stored and shipped in roll form and cut to length and attached to the panels of decking material 22 at the construction site after the panels 22 of decking material have been installed to the floor joists 26. The rolls are preferably “reverse rolled” so the materials lay flat. Accordingly, the layer of adhesive 18 at the bottom surface of the first layer 12 as described above has been eliminated. The top surface of the illustrated protective sheeting 100 is printed with lines 42 to facilitate alignment of the protective sheeting across the deck 22, cutting to length, as well as overlapping adjoining pieces of the protective sheeting 100. The illustrated top surface can also be printed with designated places 44 for tacking and/or stapling the protective sheeting 100 to the deck 22 to facilitate easy installation and removal. It is noted that this protective sheeting 100 can also be used to cover surfaces that are difficult to cover like stairs or any areas where protective sheeting becomes damaged while it is protecting the deck 20. In this application the protective sheeting 10 is taped along both edges with tape that would leave no residue. It is noted that the illustrated protective sheeting 100 has a width of about four feet and four inches to obtain the illustrated overlap portions 28 with the illustrated standard-size panels of decking material 22 but it is noted that any other suitable size can alternatively be utilized. It is also noted that the protective sheeting 100 can be treated with a fungicide to help prevent any mold from forming between or on the protective sheeting 100 and the panels 22.
FIG. 11 shows the protective sheeting 100 on an installed deck 20 of adjoining panels 22. The panels 22 are installed by installing the fasteners 36 along each edge of the panels 22 and into the floor joists. The protective sheeting 100 is rolled out onto the upper surfaces of the panels 22, aligned using the printed lines 42, and cut to length. If desired, the protective sheeting 100 can be tacked and/or stapled in place with fasteners 46 at the designated locations. As adjacent pieces of the protective sheeting 100 are installed, the release liners 32 of the overlap portions 28 are removed and the overlap portions 28 are adhered onto the top surfaces of the adjacent pieces of the protective sheeting 100 so that the gaps or joints are covered to form a continuous protective covering. When installed onto the deck 20 in this temporary manner, the protective sheeting 100 allows for easy removal at the end of construction to facilitate easy cleanup of the jobsite and to provide a clean surface for the installation of flooring material onto the deck 20. Once construction is complete and/or the property is ready for cleanup, the protective sheeting 100 is simply pulled up and discarded. Any tacks and/or staples 46 used to hold the protective sheeting 100 are pulled out and the entire deck surface is vacuumed leaving the deck 20 in virtually new condition.
When the protective sheeting 100 is installed after construction of the deck 20 is complete but before any interior or exterior walls are constructed, the protective sheeting 100 is stretched across the deck 20 and fast tacked to band board around the perimeter of the deck 20. In the case of concrete floors, after the pouring and curing, the protective sheet is then installed on the floor, taped along the outside edge and all subsequent portions are overlapped and taped together. The overlap portions 28 are then adhered to ensure continuity of coverage. The protective sheeting 100 can then be tacked or stapled at varying points across the deck 20 to help keep the protective sheeting 100 in place. The walls are then erected over the protective sheeting 100. Once construction is complete and/or the property is ready for cleanup, a sharp blade can be run along the perimeter of all rooms to cut the protective sheeting 100 and the protective sheeting 100 is pulled up and discarded. Any tacks and/or staples 46 used to hold the protective sheeting 100 are pulled out and the entire deck surface is vacuumed leaving the deck 20 in virtually new condition.
FIG. 7 shows a variation of the second preferred embodiment of disposable protection sheeting 100 wherein the second layer 14 is eliminated and a suitable non-skid or slip-resistant surface 38 is provided directly onto the top surface of the first layer 12. The non-skid surface 38 can be obtained by any suitable application, abrasion, coating, or the like that doesn't detrimentally affect breathability of the first layer 12. This variation of the disposable protective sheeting 100 is preferably installed as discussed above.
FIG. 8 shows another variation of the second preferred embodiment of disposable protection sheeting 100 wherein the overlap portion 28 is eliminated. A thin strip or tape 40 of the protective sheeting 100 much like the overlap portion 28 is applied over the joints or seams at both sides to provide a continuous protective surface as described in more detail hereinafter. It is noted that the illustrated protective sheeting 100 has a width of about four feet to cover the illustrated standard-size panels of decking material 22 but it is noted that any other suitable size can alternatively be utilized.
FIG. 12 shows the variation of the protective sheeting 100 installed onto a deck 22 of adjoining panels 22. The panels 22 are installed by installing the fasteners 36 along each edge of the panels 22 and into the floor joists. The protective sheeting 100 is rolled out onto the top surface of the panels 22, aligned, and cut to length. If desired, the protective sheeting 100 can be tacked and/or stapled in place with fasteners 46 at the designated locations 44. Once adjacent pieces of the protective sheeting 100 are down, the release liner 32 of the tape 40 is removed and the tape 40 is adhered onto the top surface of the protective sheeting 100 of the adjoining panels 22 at the joints and seams so that the gaps or joints are covered to form a continuous protective covering. When applied to the deck 20 in this temporary manner, the protective sheeting 100 allows for easy removal at the end of construction to facilitate easy cleanup of the jobsite and to provide a clean surface for the installation of flooring material onto the deck surface. Once construction is complete and/or the property is ready for cleanup, the protective sheeting 100 and the tape 40 is simply pulled up and discarded. Any tacks and/or staples 46 used to hold the protective sheeting 100 are pulled out and the entire deck surface is vacuumed leaving the deck 20 in virtually new condition.
It is apparent from the forgoing that the present invention provides improved materials and methods for protecting decks and floors 20 that are relatively inexpensive, are easy to use, and save a considerable amount of time and effort during construction. It is also apparent that multiple layers of the protective sheeting 10, 100 can be utilized if desired. For example, multiple layers of the protective sheeting 10, 100 can be used in long term constructions projects so that a top one of the layers of protective sheeting 10, 1000 can be removed as work progresses. The layers of protective sheeting 10, 100 are preferably oriented ninety degrees to each other.
FIGS. 13 and 14 show disposable protective sheeting 200 according to a third preferred embodiment of the present invention wherein like reference numbers are utilized to indicate like structure. The protective sheeting 200 according to the third embodiment of the present invention includes padding or cushioning to protect finished flooring materials such as, for example, wood, stone, ceramic, other tile materials, and the like. The illustrated disposable protective sheeting 200 is a multi-layer laminate sized and shaped as a sheet or panel so that it can be handled easily and temporarily attached to the finish flooring material at the construction site after the finish material has been installed on the decking material. It is noted however that the protective sheeting could alternatively be provided in roll form. It is noted that the illustrated protective sheeting 200 has a width of about four feet and a length of about four feet but it is noted that any other suitable size can alternatively be utilized.
The illustrated disposable protective sheeting 200 is a multi-layer laminate that includes a first layer or sheet 47 of barrier material, a second layer of cushioning or padding material 48 permanently bonded to the bottom surface of the first layer 47 with adhesive 16, and a third layer or sheet 50 of underlay or non-stick material permanently bonded to the bottom surface of the padding layer 48 with adhesive 16. The barrier material of the first layer 47 can be any suitable material that provides a barrier that is impermeable to liquids and is tear resistant. The barrier material of the first layer 47 protects the top surface of the flooring material from contamination and permanent damage from scratches, spilled and tracked liquids, and wet as well as dry substances. The barrier material of the first layer 47 can be permeable to water vapor but it is not required because at this point the building should be dry. The barrier material of the first layer 47 can be, for example, nonwoven spunbonded olefin available from E.I. DuPont known as TYVEK or any other suitable material. The padding or cushioning material of the second layer 48 protects the flooring material from impact damage due to dropped tools and the like. The padding material of the second layer 48 can be high density foam, fiber fill, bubble cushion, or any other suitable material. Using high density foam would give the sheets good rigidity making them easy to handle. The non-stick material of the third layer 50 is provided to avoid the remote possibility of the padding material sticking to the finished flooring material. The non-stick material of the third layer 50 can be, for example, a polyethylene sheet including “Visqueen”.
Once the final flooring material is installed on the decking material, the sheets of protective sheeting 200 are laid out, cut to span the room or hallway, and taped together. The edges are taped down to the floor with a tape that does not leave any residue. If desired the sheets can be printed with faint lines to facilitate cutting straight lines to fit a room or hallway. After construction was done, or the move in complete, the tape is removed from the floor and the protective sheets can be discarded or kept and reused if not damaged.
FIG. 15 shows a variation of the third preferred embodiment of disposable protection sheeting 200 wherein the third layer 14 is eliminated. Tear resistance and cushioning properties are maintained and the cost is reduced. This variation of the disposable protective sheeting 200 is preferably installed as discussed above.
From the foregoing disclosure and detailed description of certain preferred embodiments, it is also apparent that various modifications, additions and other alternative embodiments are possible without departing from the true scope and spirit of the present invention. The embodiments discussed were chosen and described to provide the best illustration of the principles of the present invention and its practical application to thereby enable one of ordinary skill in the art to utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated. All such modifications and variations are within the scope of the present invention as determined by the appended claims when interpreted in accordance with the benefit to which they are fairly, legally, and equitably entitled.

Claims

1. Disposable protective sheeting for covering decks and floors comprising, in combination:

a first layer of a barrier material impervious to liquid and pervious to vapor;

a second layer of an overlay material providing a slip-resistant upper surface; and

wherein a bottom surface of the second layer is secured to a top surface of the first layer with adhesive.

2. The disposable protective sheeting according to claim 1, wherein the barrier material comprises polyethylene sheet.

3. The disposable protective sheeting according to claim 1, wherein the barrier material comprises nonwoven spunbonded olefin.

4. The disposable protective sheeting according to claim 1, wherein the overlay material comprises paper sheet.

5. The disposable protective sheeting according to claim 4, wherein the overlay material comprises kraft paper sheet.

6. The disposable protective sheeting according to claim 1, wherein the adhesive between the first and second layers is at about 10% to about 25% of the first and second layers.

7. The disposable protective sheeting according to claim 1, wherein the first and second layers form at and overlap portion along at least one edge and the overlap portion has a pressure-sensitive adhesive layer at a bottom surface of the first layer and a release liner protectively covering the pressure-sensitive adhesive layer.

8. Decking material with disposable protective sheeting comprising, in combination:

a panel of decking material having an upper surface;

disposable protective sheeting temporarily secured to the upper surface of the panel;

wherein the disposable protective sheeting includes a first layer of a barrier material impervious to liquid and pervious to vapor and a layer of adhesive at a bottom surface of the barrier layer and temporarily securing the disposable protective sheeting to the upper surface of the panel.

9. The decking material with disposable protective sheeting according to claim 8, wherein the decking material is one of plywood, oriented strand board (OSB), and composite particle board.

10. The decking material with disposable protective sheeting according to claim 8, wherein the disposable protective sheeting includes a second layer of an overlay material providing a slip-resistant upper surface, and a bottom surface of the second layer is secured to the upper surface of the first layer with adhesive.

11. The decking material with disposable protective sheeting according to claim 10, wherein the overlay material comprises paper sheet.

12. The decking material with disposable protective sheeting according to claim 11, wherein the overlay material comprises kraft paper sheet.

13. The decking material with disposable protective sheeting according to claim 10, wherein the adhesive between the first and second layers is at about 10% to about 25% of the first and second layers so as not to impede breathability.

14. The decking material with disposable protective sheeting according to claim 8, wherein the barrier material comprises polyethylene sheet.

15. The decking material with disposable protective sheeting according to claim 8, wherein the barrier material comprises nonwoven spunbonded olefin.

16. The decking material with disposable protective sheeting according to claim 8, wherein the disposable protective sheeting has overlap portion formed along at least one edge that extends beyond the panel and the overlap portion has a pressure-sensitive adhesive layer at a bottom surface of the first layer and a release liner protectively covering the pressure-sensitive adhesive layer.

17. The decking material with disposable protective sheeting according to claim 8, wherein the disposable protective sheeting does not cover the upper surface of the panel along at least one edge of the panel and the overlap portion to form an open strip.

18. A method of protecting decks and floors comprising steps of, in combination:

providing disposable protective sheeting having a barrier layer of a barrier material impervious to liquid and pervious to vapor;

temporarily securing the disposable protective sheeting to an upper surface of one of the deck and the floor; and

removing the disposable protective sheeting at an appropriate time near completion of a project.

19. The method according to claim 18, further comprising the step of providing the disposable protective sheeting a layer of adhesive at a bottom surface of the barrier layer temporarily securing the disposable protective sheeting to the upper surface of the panel and temporarily securing the disposable protective sheeting with a layer of adhesive.

20. The method according to claim 18, further comprising the step of applying tape to edges of disposable protective sheeting.

21. Disposable protective sheeting for covering decks and floors comprising, in combination:

a first layer of a barrier material impervious to liquid and tear resistant;

a second layer of an cushioning material; and

wherein a bottom surface of the first layer is secured to a top surface of the second layer with adhesive.

22. The disposable protective sheeting according to claim 21, further comprising a third layer of non-stick material, wherein a bottom surface of the second layer is secured to a top surface of the third layer with adhesive.

23. The disposable protective sheeting according to claim 21, wherein the barrier material comprises nonwoven spunbonded olefin.

24. The disposable protective sheeting according to claim 21, wherein the cushioning material comprises high density foam.