Patents Assigned to Brock USA, LLC
  • Publication number: 20240130525
    Abstract: A support platform for a furniture unit includes a plurality of support arms that each terminate in a corner pocket. The corner pocket supports a furniture leg end and contains the leg end within the platform perimeter. The platform defines a foundation support surface that may include cleats or anti-skid cushion pads to enhance friction with the foundation surface.
    Type: Application
    Filed: October 19, 2023
    Publication date: April 25, 2024
    Applicant: Brock USA, LLC
    Inventors: Daniel C. Sawyer, John Shaffer, Daniel J. Dodd
  • Publication number: 20240117572
    Abstract: An underlayment layer is configured to support an artificial turf assembly. The underlayment layer comprises a core with a top side and a bottom side. The top side has a plurality of spaced apart, upwardly oriented projections that define channels suitable for fluid flow along the top side of the core when the underlayment layer is positioned beneath an overlying artificial turf assembly.
    Type: Application
    Filed: December 19, 2023
    Publication date: April 11, 2024
    Applicant: Brock USA, LLC
    Inventors: Steven Lee Sawyer, Daniel C. Sawyer, Richard R. Runkles
  • Publication number: 20240035237
    Abstract: An underlayment layer is configured to support an artificial turf assembly. The underlayment layer comprises plurality of panels, each panel comprising a core with a top side and a bottom side. The top side has a plurality of top projections. The top projections form top side water drainage channels. The panels have edges, with the edges of one panel abutting the edges of adjacent panels, thereby forming a drainage path between adjacent panels. The panel edges have vertical support extensions that extend into the drainage paths between adjacent panels. The vertical support extensions have an upper surface for supporting an artificial turf assembly overlying the turf underlayment layer, and the panel edges having one or more complementary indentations corresponding to vertical support extensions of adjacent panels. When the panels move toward each other, thereby closing drainage paths between adjacent panels, the vertical support extensions are received in the corresponding indentations.
    Type: Application
    Filed: October 10, 2023
    Publication date: February 1, 2024
    Applicant: Brock USA, LLC
    Inventors: Daniel C. Sawyer, Richard R. Runkles, James M. Koerlin
  • Publication number: 20240003100
    Abstract: An impact-absorbing assembly includes a covering layer being one or more of artificial turf, rubber mats, polymer mats, short pile carpeting, particulate infill, wood chips, and ground rubber chips. Also included is a layer of underlayment panels positioned beneath the covering layer. The panels have a panel section with a plurality of drain holes formed therethrough. A top surface of the panels is configured to support the covering layer. A bottom surface of the panels has a plurality of bottom projections that cooperate to define bottom channels suitable to permit water flow across the bottom surface, the bottom channels being in fluid communication with the panel drain holes. The bottom 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.
    Type: Application
    Filed: September 19, 2023
    Publication date: January 4, 2024
    Applicant: Brock USA, LLC
    Inventor: Steven Lee Sawyer
  • Patent number: 11846075
    Abstract: An underlayment layer is configured to support an artificial turf assembly. The underlayment layer comprises a core with a top side and a bottom side. The top side has a plurality of spaced apart, upwardly oriented projections that define channels suitable for fluid flow along the top side of the core when the underlayment layer is positioned beneath an overlying artificial turf assembly.
    Type: Grant
    Filed: April 20, 2021
    Date of Patent: December 19, 2023
    Assignee: Brock USA, LLC
    Inventors: Steven Lee Sawyer, Daniel C. Sawyer, Richard R. Runkles
  • Publication number: 20230382023
    Abstract: A steam chest mold includes two mold sections defining a mold cavity and a plurality of steam tubes having steam ports positioned within the mold cavity. The mold cavity is closable to contain and compress a plurality of beads such as expanded polyolefin beads. The steam tubes pass through the beads such that steam is injected through the steam ports into the beads to facilitate localized melting and bonding o the bead interfaces to produce a water-impervious panel or billet form. The steam tubes permit bonding of interior beads in thick section billets and panels that cannot be accessed by perimeter steam sources.
    Type: Application
    Filed: October 12, 2021
    Publication date: November 30, 2023
    Applicant: Brock USA, LLC
    Inventors: Stephen Keyser, John Shaffer
  • Patent number: 11781272
    Abstract: An underlayment layer is configured to support an artificial turf assembly. The underlayment layer comprises plurality of panels, each panel comprising a core with a top side and a bottom side. The top side has a plurality of top projections. The top projections form top side water drainage channels. The panels have edges, with the edges of one panel abutting the edges of adjacent panels, thereby forming a drainage path between adjacent panels. The panel edges have vertical support extensions that extend into the drainage paths between adjacent panels. The vertical support extensions have an upper surface for supporting an artificial turf assembly overlying the turf underlayment layer, and the panel edges having one or more complementary indentations corresponding to vertical support extensions of adjacent panels. When the panels move toward each other, thereby closing drainage paths between adjacent panels, the vertical support extensions are received in the corresponding indentations.
    Type: Grant
    Filed: September 7, 2021
    Date of Patent: October 10, 2023
    Assignee: Brock USA, LLC
    Inventors: Daniel C. Sawyer, Richard R. Runkles, James M. Koerlin
  • Patent number: 11761154
    Abstract: An impact-absorbing assembly includes a covering layer being one or more of artificial turf, rubber mats, polymer mats, short pile carpeting, particulate infill, wood chips, and ground rubber chips. Also included is a layer of underlayment panels positioned beneath the covering layer. The panels have a panel section with a plurality of drain holes formed therethrough. A top surface of the panels is configured to support the covering layer. A bottom surface of the panels has a plurality of bottom projections that cooperate to define bottom channels suitable to permit water flow across the bottom surface, the bottom channels being in fluid communication with the panel drain holes. The bottom 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.
    Type: Grant
    Filed: April 13, 2021
    Date of Patent: September 19, 2023
    Assignee: Brock USA, LLC
    Inventor: Steven Lee Sawyer
  • Patent number: 11371194
    Abstract: An underlayment layer is configured to support an artificial turf assembly. The underlayment layer comprises a core with a top side and a bottom side. The top side has a plurality of spaced apart, upwardly oriented projections that define channels suitable for fluid flow along the top side of the core when the underlayment layer is positioned beneath an overlying artificial turf assembly.
    Type: Grant
    Filed: December 10, 2021
    Date of Patent: June 28, 2022
    Assignee: Brock USA, LLC
    Inventors: Steven Lee Sawyer, Daniel C. Sawyer, Richard R. Runkles
  • Publication number: 20220098802
    Abstract: An underlayment layer is configured to support an artificial turf assembly. The underlayment layer comprises a core with a top side and a bottom side. The top side has a plurality of spaced apart, upwardly oriented projections that define channels suitable for fluid flow along the top side of the core when the underlayment layer is positioned beneath an overlying artificial turf assembly.
    Type: Application
    Filed: December 10, 2021
    Publication date: March 31, 2022
    Applicant: Brock USA, LLC
    Inventors: Steven Lee Sawyer, Daniel C. Sawyer, Richard R. Runkles
  • Publication number: 20210395956
    Abstract: An underlayment layer is configured to support an artificial turf assembly. The underlayment layer comprises plurality of panels, each panel comprising a core with a top side and a bottom side. The top side has a plurality of top projections. The top projections form top side water drainage channels. The panels have edges, with the edges of one panel abutting the edges of adjacent panels, thereby forming a drainage path between adjacent panels. The panel edges have vertical support extensions that extend into the drainage paths between adjacent panels. The vertical support extensions have an upper surface for supporting an artificial turf assembly overlying the turf underlayment layer, and the panel edges having one or more complementary indentations corresponding to vertical support extensions of adjacent panels. When the panels move toward each other, thereby closing drainage paths between adjacent panels, the vertical support extensions are received in the corresponding indentations.
    Type: Application
    Filed: September 7, 2021
    Publication date: December 23, 2021
    Applicant: Brock USA, LLC
    Inventors: Daniel C. Sawyer, Richard R. Runkles, James M. Koerlin
  • Publication number: 20210285166
    Abstract: An artificial turf system includes a turf assembly having a turf backing and stands of artificial grass blades extending from the turf backing to form an artificial turf layer. Infill material is placed in between the blades of artificial grass and on top of the turf backing. The infill material has a composition of sand in an amount within the range of from about 80 to about 98 percent of the infill by dry bulk weight, and organic particles in an amount within the range of from about 2 to about 20 percent of the infill by dry bulk weight.
    Type: Application
    Filed: June 1, 2021
    Publication date: September 16, 2021
    Applicant: Brock USA, LLC
    Inventors: Daniel C. Sawyer, Stephen Keyser, Steven L. Sawyer, Richard R. Runkles
  • Patent number: 11111636
    Abstract: An underlayment layer is configured to support an artificial turf assembly. The underlayment layer comprises plurality of panels, each panel comprising a core with a top side and a bottom side. The top side has a plurality of top projections. The top projections form top side water drainage channels. The panels have edges, with the edges of one panel abutting the edges of adjacent panels, thereby forming a drainage path between adjacent panels. The panel edges have vertical support extensions that extend into the drainage paths between adjacent panels. The vertical support extensions have an upper surface for supporting an artificial turf assembly overlying the turf underlayment layer, and the panel edges having one or more complementary indentations corresponding to vertical support extensions of adjacent panels. When the panels move toward each other, thereby closing drainage paths between adjacent panels, the vertical support extensions are received in the corresponding indentations.
    Type: Grant
    Filed: October 29, 2019
    Date of Patent: September 7, 2021
    Assignee: Brock USA, LLC
    Inventors: Daniel C. Sawyer, Richard R. Runkles, James M. Koerlin
  • Publication number: 20210238810
    Abstract: An underlayment layer is configured to support an artificial turf assembly. The underlayment layer comprises a core with a top side and a bottom side. The top side has a plurality of spaced apart, upwardly oriented projections that define channels suitable for fluid flow along the top side of the core when the underlayment layer is positioned beneath an overlying artificial turf assembly.
    Type: Application
    Filed: April 20, 2021
    Publication date: August 5, 2021
    Applicant: Brock USA, LLC
    Inventors: Steven Lee Sawyer, Daniel C. Sawyer, Richard R. Runkles
  • Publication number: 20210230812
    Abstract: An impact-absorbing assembly includes a covering layer being one or more of artificial turf, rubber mats, polymer mats, short pile carpeting, particulate infill, wood chips, and ground rubber chips. Also included is a layer of underlayment panels positioned beneath the covering layer. The panels have a panel section with a plurality of drain holes formed therethrough. A top surface of the panels is configured to support the covering layer. A bottom surface of the panels has a plurality of bottom projections that cooperate to define bottom channels suitable to permit water flow across the bottom surface, the bottom channels being in fluid communication with the panel drain holes. The bottom 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.
    Type: Application
    Filed: April 13, 2021
    Publication date: July 29, 2021
    Applicant: Brock USA, LLC
    Inventor: Steven Lee Sawyer
  • Patent number: 11021842
    Abstract: An artificial turf system includes a turf assembly having a turf backing and stands of artificial grass blades extending from the turf backing to form an artificial turf layer. Infill material is placed in between the blades of artificial grass and on top of the turf backing. The infill material has a composition of sand and organic particles. The infill material organic particles includes a plurality of wood particles where at least a portion of the wood particles define a length dimension oriented generally parallel to a grain structure of the wood particles. The length dimension is greater than a width or a thickness dimension and, in one example, may be in a range of about 0.5 mm to about 10 mm. The length dimension and one of the width or thickness dimensions may, in another example, define an aspect ratio within a range of 1:2 to 10:1.
    Type: Grant
    Filed: March 7, 2019
    Date of Patent: June 1, 2021
    Assignee: Brock USA, LLC
    Inventors: Daniel C. Sawyer, Stephen Keyser, Steven L. Sawyer, Richard R. Runkles
  • Patent number: 10982395
    Abstract: An underlayment layer is configured to support an artificial turf assembly. The underlayment layer comprises a core with a top side and a bottom side. The top side has a plurality of spaced apart, upwardly oriented projections that define channels suitable for fluid flow along the top side of the core when the underlayment layer is positioned beneath an overlying artificial turf assembly.
    Type: Grant
    Filed: March 16, 2020
    Date of Patent: April 20, 2021
    Assignee: Brock USA, LLC
    Inventors: Steven Lee Sawyer, Daniel C. Sawyer, Richard R. Runkles
  • Patent number: 10975532
    Abstract: An impact-absorbing assembly includes a covering layer being one or more of artificial turf, rubber mats, polymer mats, short pile carpeting, particulate infill, wood chips, and ground rubber chips. Also included is a layer of underlayment panels positioned beneath the covering layer. The panels have a panel section with a plurality of drain holes formed therethrough. A top surface of the panels is configured to support the covering layer. A bottom surface of the panels has a plurality of bottom projections that cooperate to define bottom channels suitable to permit water flow across the bottom surface, the bottom channels being in fluid communication with the panel drain holes. The bottom 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.
    Type: Grant
    Filed: May 19, 2020
    Date of Patent: April 13, 2021
    Assignee: Brock USA, LLC
    Inventor: Steven Lee Sawyer
  • Publication number: 20200277740
    Abstract: An impact-absorbing assembly includes a covering layer being one or more of artificial turf, rubber mats, polymer mats, short pile carpeting, particulate infill, wood chips, and ground rubber chips. Also included is a layer of underlayment panels positioned beneath the covering layer. The panels have a panel section with a plurality of drain holes formed therethrough. A top surface of the panels is configured to support the covering layer. A bottom surface of the panels has a plurality of bottom projections that cooperate to define bottom channels suitable to permit water flow across the bottom surface, the bottom channels being in fluid communication with the panel drain holes. The bottom 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.
    Type: Application
    Filed: May 19, 2020
    Publication date: September 3, 2020
    Applicant: Brock USA, LLC
    Inventor: Steven Lee Sawyer
  • Publication number: 20200240090
    Abstract: An underlayment layer is configured to support an artificial turf assembly. The underlayment layer comprises a core with a top side and a bottom side. The top side has a plurality of spaced apart, upwardly oriented projections that define channels suitable for fluid flow along the top side of the core when the underlayment layer is positioned beneath an overlying artificial turf assembly.
    Type: Application
    Filed: March 16, 2020
    Publication date: July 30, 2020
    Applicant: Brock USA, LLC
    Inventors: Steven Lee Sawyer, Daniel C. Sawyer, Richard R. Runkles