Patents by Inventor Robert N. Clausi
Robert N. Clausi has filed for patents to protect the following inventions. This listing includes patent applications that are pending as well as patents that have already been granted by the United States Patent and Trademark Office (USPTO).
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Publication number: 20240011284Abstract: Sound absorbing or attenuating laminate flooring materials are provided, which are directed to be used in the production of floor covering, floor panels, furniture panels, cabinets, counter-tops and wall panels. As well, the method for producing such products are provided. In particular, abrasion resistant panels, with a laminated structure, created by forming an assembly which consists of laminating a heat-activated resin impregnated paper wear layer, a decorative layer with printed graphics or a wood veneer decorative layer, a medium density (MDF) or high-density (HDF) natural fiber-based core and a resin impregnated paper balancing layer. To achieve sound absorbing and/or attenuating properties, any or all paper layers may be pre coated with an additional flexible elastomeric coating, film or material prior to assembly of the panel, or the natural fiber core panel may be coated with a flexible elastomeric coating, film or material prior to assembly with the papers.Type: ApplicationFiled: August 19, 2023Publication date: January 11, 2024Inventors: Robert N. Clausi, Salvatore Anthony Diloreto
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Patent number: 11732468Abstract: Sound absorbing or attenuating laminate flooring materials are provided, which are directed to be used in the production of floor covering, floor panels, furniture panels, cabinets, counter-tops and wall panels. As well, the methods for producing such products are provided. In particular, abrasion resistant panels, with a laminated structure, created by forming an assembly which consists of laminating a heat-activated resin impregnated paper wear layer, a decorative layer with printed graphics or a wood veneer decorative layer, a medium density (MDF) or high-density (HDF) natural fiber-based core and a resin impregnated paper balancing layer. To achieve sound absorbing and/or attenuating properties, any or all paper layers may be pre coated with an additional flexible elastomeric coating, film or material prior to assembly of the panel, or the natural fiber core panel may be coated with a flexible elastomeric coating, film or material prior to assembly with the papers.Type: GrantFiled: March 10, 2021Date of Patent: August 22, 2023Inventors: Robert N. Clausi, Salvatore Anthony Diloreto
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Patent number: 11673384Abstract: A membrane covered panel and a membrane covered panel production method are provided wherein an elastomeric membrane, and preferably, an aqueous elastomeric resin-based membrane, is applied to a finished panel construct, prior to pressing of the membrane covered panel. The method is used to produce panels which can be used in the production of flooring materials, wall panels, furniture, countertops, and the like. The membrane is applied to a transfer film, which transfer film can be removed at any time prior to, or after the pressing operation. The panels produced have a durable but elastic surface which can protect the surfaces of the panel construct. The elastomeric covering on the panel construct also preferably provides a surface which is abrasion resistant, and provides better acoustical properties while providing a soft touch haptic surface.Type: GrantFiled: March 26, 2018Date of Patent: June 13, 2023Inventors: Robert N. Clausi, Salvatore A. Diloreto
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Publication number: 20220289980Abstract: The present invention describes the production of wood panel boards, or the like, in which a surface modifying agent is mixed with a polyol to prepare a stable surface modifying agent polyol composition. The resultant composition is reacted with an isocyanate, and in particular, a polymeric di-isocyanate resin, in the presence of wood chips, fibers or the like, for the production of lignocellulosic based panels, such as oriented strand board (OSB), MDF, HDF and particle board panel products. In use, the surface modifying agent polyol composition is mixed with the polymeric di-isocyanate resin and the resultant mixture is applied to a lignocellulosic material, such as wood chips or fibers, immediately prior to hot pressing of the mixture to produce the panels. Sticking of the panels to the metal press belts or press plates typically used during production, is reduced or eliminated.Type: ApplicationFiled: May 31, 2022Publication date: September 15, 2022Inventors: Robert N. Clausi, Salvatore Diloreto
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Publication number: 20210207367Abstract: Sound absorbing or attenuating laminate flooring materials are provided, which are directed to be used in the production of floor covering, floor panels, furniture panels, cabinets, counter-tops and wall panels. As well, the methods for producing such products are provided. In particular, abrasion resistant panels, with a laminated structure, created by forming an assembly which consists of laminating a heat-activated resin impregnated paper wear layer, a decorative layer with printed graphics or a wood veneer decorative layer, a medium density (MDF) or high-density (HDF) natural fiber-based core and a resin impregnated paper balancing layer. To achieve sound absorbing and/or attenuating properties, any or all paper layers may be pre coated with an additional flexible elastomeric coating, film or material prior to assembly of the panel, or the natural fiber core panel may be coated with a flexible elastomeric coating, film or material prior to assembly with the papers.Type: ApplicationFiled: March 10, 2021Publication date: July 8, 2021Inventors: Robert N. Clausi, Salvatore Anthony Diloreto
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Patent number: 11041305Abstract: Sound absorbing or attenuating laminate flooring materials are provided, which are directed to be used in the production of floor covering, floor panels, furniture panels, cabinets, counter-tops and wall panels. As well, the methods for producing such products are provided. In particular, abrasion resistant panels, with a laminated structure, created by forming an assembly which consists of laminating a heat-activated resin impregnated paper wear layer, a decorative layer with printed graphics or a wood veneer decorative layer, a medium density (MDF) or high-density (HDF) natural fiber-based core and a resin impregnated paper balancing layer. To achieve sound absorbing and/or attenuating properties, any or all paper layers may be pre coated with an additional flexible elastomeric coating, film or material prior to assembly of the panel, or the natural fiber core panel may be coated with a flexible elastomeric coating, film or material prior to assembly with the papers.Type: GrantFiled: April 22, 2019Date of Patent: June 22, 2021Inventors: Robert N. Clausi, Salvatore Anthony Diloreto
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Publication number: 20200101710Abstract: A membrane covered panel and a membrane covered panel production method are provided wherein an elastomeric membrane, and preferably, an aqueous elastomeric resin-based membrane, is applied to a finished panel construct, prior to pressing of the membrane covered panel. The method is used to produce panels which can be used in the production of flooring materials, wall panels, furniture, countertops, and the like. The membrane is applied to a transfer film, which transfer film can be removed at any time prior to, or after the pressing operation. The panels produced have a durable but elastic surface which can protect the surfaces of the panel construct. The elastomeric covering on the panel construct also preferably provides a surface which is abrasion resistant, and provides better acoustical properties while providing a soft touch haptic surface.Type: ApplicationFiled: March 26, 2018Publication date: April 2, 2020Inventors: Robert N. Clausi, Salvatore A. Diloreto
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Publication number: 20200071928Abstract: Sound absorbing or attenuating laminate flooring materials are provided, which are directed to be used in the production of floor covering, floor panels, furniture panels, cabinets, counter-tops and wall panels. As well, the methods for producing such products are provided. In particular, abrasion resistant panels, with a laminated structure, created by forming an assembly which consists of laminating a heat-activated resin impregnated paper wear layer, a decorative layer with printed graphics or a wood veneer decorative layer, a medium density (MDF) or high-density (HDF) natural fiber-based core and a resin impregnated paper balancing layer. To achieve sound absorbing and/or attenuating properties, any or all paper layers may be pre coated with an additional flexible elastomeric coating, film or material prior to assembly of the panel, or the natural fiber core panel may be coated with a flexible elastomeric coating, film or material prior to assembly with the papers.Type: ApplicationFiled: April 22, 2019Publication date: March 5, 2020Inventors: Robert N. Clausi, Salvatore Anthony Diloreto
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Publication number: 20200030846Abstract: A panel and a panel production method are provided wherein an elastomeric coating, and preferably, a water-based elastomeric polyurethane coating, is applied to a pre-existing, finished panel construct, by pressing the coating onto the panel construct, and thereby bond the coating to the surface of the panel construct. The method is used to produce enhanced panels which can be used in the production of flooring materials, wall panels, furniture, countertops, and the like. The resultant panels typically have an enhanced surface that protects the surface layer of the panel construct. The coated panel can also be made abrasion resistant, and can also be enhanced so as to provide better acoustical properties while providing a soft touch, haptic surface.Type: ApplicationFiled: March 26, 2018Publication date: January 30, 2020Inventors: Robert N. Clausi, Salvatore A. Diloreto
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Publication number: 20190345338Abstract: The present invention describes the production of wood panel boards, or the like, in which a surface modifying agent is mixed with a polyol to prepare a stable surface modifying agent polyol composition. The resultant composition is reacted with an isocyanate, and in particular, a polymeric di-isocyanate resin, in the presence of wood chips, fibers or the like, for the production of lignocellulosic based panels, such as oriented strand board (OSB), MDF, HDF and particle board panel products. In use, the surface modifying agent polyol composition is mixed with the polymeric di-isocyanate resin and the resultant mixture is applied to a lignocel-lulosic material, such as wood chips or fibers, immediately prior to hot pressing of the mixture to produce the panels. Sticking of the panels to the metal press belts or press plates typically used during production, is reduced or eliminated.Type: ApplicationFiled: September 8, 2017Publication date: November 14, 2019Inventors: Robert N. Clausi, Salvatore Diloreto
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Patent number: 10287771Abstract: Sound absorbing or attenuating laminate flooring materials are provided, which are directed to be used in the production of floor covering, floor panels, furniture panels, cabinets, counter-tops and wall panels. As well, the methods for producing such products are provided. In particular, abrasion resistant panels, with a laminated structure, created by forming an assembly which consists of laminating a heat-activated resin impregnated paper wear layer, a decorative layer with printed graphics or a wood veneer decorative layer, a medium density (MDF) or high-density (HDF) natural fiber-based core and a resin impregnated paper balancing layer. To achieve sound absorbing and/or attenuating properties, any or all paper layers may be pre coated with an additional flexible elastomeric coating, film or material prior to assembly of the panel, or the natural fiber core panel may be coated with a flexible elastomeric coating, film or material prior to assembly with the papers.Type: GrantFiled: April 11, 2017Date of Patent: May 14, 2019Inventors: Robert N. Clausi, Salvatore Anthony Diloreto
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Patent number: 10086531Abstract: A resilient MDF, HDF or particleboard material is prepared by pressing natural fibers, which have been pre-treated with binder which falls within the scope of the present invention, to form a fiber board material. The fiber board is a mixture of fibers, and a resin system comprising an isocyanate, and a polyol component. The resin system is selected so as to provide are resilient material that provides sound attenuating properties.Type: GrantFiled: June 8, 2009Date of Patent: October 2, 2018Inventors: Robert N. Clausi, Savaltore Diloreto
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Publication number: 20170321416Abstract: Sound absorbing or attenuating laminate flooring materials are provided, which are directed to be used in the production of floor covering, floor panels, furniture panels, cabinets, counter-tops and wall panels. As well, the methods for producing such products are provided. In particular, abrasion resistant panels, with a laminated structure, created by forming an assembly which consists of laminating a heat-activated resin impregnated paper wear layer, a decorative layer with printed graphics or a wood veneer decorative layer, a medium density (MDF) or high-density (HDF) natural fiber-based core and a resin impregnated paper balancing layer. To achieve sound absorbing and/or attenuating properties, any or all paper layers may be pre coated with an additional flexible elastomeric coating, film or material prior to assembly of the panel, or the natural fiber core panel may be coated with a flexible elastomeric coating, film or material prior to assembly with the papers.Type: ApplicationFiled: April 11, 2017Publication date: November 9, 2017Inventors: Robert N. Clausi, Salvatore Anthony Diloreto
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Patent number: 9631361Abstract: Sound absorbing or attenuating laminate flooring materials are provided, which are directed to be used in the production of floor covering, floor panels, furniture panels, cabinets, counter-tops and wall panels. As well, the methods for producing such products are provided. In particular, abrasion resistant panels, with a laminated structure, created by forming an assembly which consists of laminating a heat-activated resin impregnated paper wear layer, a decorative layer with printed graphics or a wood veneer decorative layer, a medium density (MDF) or high-density (HDF) natural fiber-based core and a resin impregnated paper balancing layer. To achieve sound absorbing and/or attenuating properties, any or all paper layers may be pre coated with an additional flexible elastomeric coating, film or material prior to assembly of the panel, or the natural fiber core panel may be coated with a flexible elastomeric coating, film or material prior to assembly with the papers.Type: GrantFiled: March 18, 2014Date of Patent: April 25, 2017Inventors: Robert N. Clausi, Salvatore Anthony Diloreto
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Publication number: 20140196982Abstract: Sound absorbing or attenuating laminate flooring materials are provided, which are directed to be used in the production of floor covering, floor panels, furniture panels, cabinets, counter-tops and wall panels. As well, the methods for producing such products are provided. hi particular, abrasion resistant panels, with a laminated structure, created by forming an assembly which consists of laminating a heat-activated resin impregnated paper wear layer, a decorative layer with printed graphics or a wood veneer decorative layer, a medium density (MDF) or high-density (HDF) natural fiber-based core and a resin impregnated paper balancing layer. To achieve sound absorbing and/or attenuating properties, any or all paper layers may be pre coated with an additional flexible elastomeric coating, film or material prior to assembly of the panel, or the natural fiber core panel may be coated with a flexible elastomeric coating, film or material prior to assembly with the papers.Type: ApplicationFiled: March 18, 2014Publication date: July 17, 2014Inventors: Robert N. Clausi, Salvatore Anthony Diloreto
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Patent number: 8678133Abstract: Sound absorbing or attenuating laminate flooring materials are provided, which are directed to be used in the production of floor covering, floor panels, furniture panels, cabinets, counter-tops and wall panels. As well, the methods for producing such products are provided. In particular, abrasion resistant panels, with a laminated structure, created by forming an assembly which consists of laminating a heat-activated resin impregnated paper wear layer, a decorative layer with printed graphics or a wood veneer decorative layer, a medium density (MDF) or high-density (HDF) natural fiber-based core and a resin impregnated paper balancing layer. To achieve sound absorbing and/or attenuating properties, any or all paper layers may be pre coated with an additional flexible elastomeric coating, film or material prior to assembly of the panel, or the natural fiber core panel may be coated with a flexible elastomeric coating, film or material prior to assembly with the papers.Type: GrantFiled: February 3, 2010Date of Patent: March 25, 2014Inventors: Robert N. Clausi, Salvatore Anthony Diloreto
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Publication number: 20120276348Abstract: Resilient flooring materials made from impregnated papers or foils and core materials are provided. As well, the methods for producing such products are provided. In particular, panels, with a layered structure, created by forming an assembly which consists of laminating a heat-activated resin impregnated decorative layer with printed graphics or a wood veneer decorative layer, a core material made up of one or more heat-activated resin-impregnated papers or other materials including linoleum, natural or synthetic rubber, cork, flexible natural fiber composites or other core materials, and a heat-activated resin impregnated paper backing layer. The heat-activated resin also acts to waterproof each of the layers and abrasion particles may be incorporated to improve wear properties. The panels may also be formed into three-dimensional products.Type: ApplicationFiled: January 7, 2011Publication date: November 1, 2012Inventors: Robert N. Clausi, Salvatore A. Diloreto
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Publication number: 20120103722Abstract: Sound absorbing or attenuating laminate flooring materials are provided, which are directed to be used in the production of floor covering, floor panels, furniture panels, cabinets, counter-tops and wall panels. As well, the methods for producing such products are provided. In particular, abrasion resistant panels, with a laminated structure, created by forming an assembly which consists of laminating a heat-activated resin impregnated paper wear layer, a decorative layer with printed graphics or a wood veneer decorative layer, a medium density (MDF) or high-density (HDF) natural fiber-based core and a resin impregnated paper balancing layer. To achieve sound absorbing and/or attenuating properties, any or all paper layers may be pre coated with an additional flexible elastomeric coating, film or material prior to assembly of the panel, or the natural fiber core panel may be coated with a flexible elastomeric coating, film or material prior to assembly with the papers.Type: ApplicationFiled: February 3, 2010Publication date: May 3, 2012Inventors: Robert N. Clausi, Salvatore Anthony Diloreto
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Publication number: 20110073253Abstract: A resilient MDF, HDF or particleboard material is prepared by pressing natural fibers, which have been pre-treated with binder which falls within the scope of the present invention, to form a fiber board material. The fiber board is a mixture of fibres, and a resin system comprising an isocyanate, and a polyol component. The resin system is selected so as to provide are resilient material that provides sound attenuating properties.Type: ApplicationFiled: June 8, 2009Publication date: March 31, 2011Inventors: Robert N. Clausi, Savaltore Diloreto
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Publication number: 20090078162Abstract: A light-weight gypsum-based composition is provided which is particularly suitable for use in the production of wall panels. The composition comprises: (i) gypsum; (ii) glass, ceramic or polymer microspheres; and (iii) a coupling agent preferably selected from a silane or metal coupling agent. The resultant panel has good strength properties and has good performance with respect to nailability and cutability. Further, the paper backing commonly used on traditional commercial drywall panels can be optionally eliminated. The composition can also be cast into thicker products. A lightweight wall panel material is provided.Type: ApplicationFiled: March 9, 2007Publication date: March 26, 2009Inventors: Robert N. Clausi, Savaltore Diloreto