Method of forming a self-leveling underlayment for a countertop

Details Method of forming a self-leveling underlayment for a countertop Method of forming a self-leveling underlayment for a countertop

1991-09-20

1993-11-09

Aftergut, Karen

Plastic and nonmetallic article shaping or treating: processes

Forming structural installations in situ

Uniting preform member with molding material

264138, 264219, 264257, 264258, 264259, 264261, 264263, 264264, 264273, 264275, 264279, 2642791, B32B 3104, E04B 116

Patent

active

052600076

ABSTRACT:
A self-leveling underlayment for a tile countertop, and a method and kit for forming same, is disclosed. In practicing the method on the top deck of a cabinet, a protective paper sling is hung in an interior deck opening and a protective shroud is hung over front cabinet faces. The deck is covered with roofing felt and a flashing strip is fitted along the seam where the deck meets walls, masking tape being used to bind these together. A styrofoam punch-out is fixed in place over the sink opening. Metal lath is laid over the felt, and rebar is laid along edges of the deck. Lengths of backer board are placed along walls adjacent the deck to support backsplash tile, and a dam is affixed along the deck's front edge, thus defining a mold for an underlayment. A self-leveling, water-based, cementitious underlayment mix is poured into the mold to form a surface, once set-up, for supporting tile. Leveling of the surface over adjacent areas is aided by driving nails part-way into those areas and setting their heads at the same level, then assuring that the height of the underlayment's surface matches the height of the nail head in each of those areas. The underlayment produced by the method herein includes the foregoing elements, and a kit including those elements is also disclosed.

REFERENCES:
patent: 1656422 (1928-01-01), Copeman
patent: 3616076 (1971-10-01), Gepkens
patent: 4221441 (1980-09-01), Bain
patent: 4397798 (1983-09-01), Parten
patent: 4771488 (1988-09-01), Markham

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