Abstract:
A system for utilizing a hazardous apparatus with a pad of fibrous fabric embedded in cement to shield a protectable surface from hazards produced by the hazardous apparatus.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a division of application Ser. No. 09/343,816, filed Jun. 30, 1999, now abandoned, which is relied on and incorporated herein by reference. 
    
    
     TECHNICAL FIELD 
     The present invention relates to a protective layer of a fire resistant material used on decks, patios, and other surfaces, and more particularly relates to a fire resistant fiber-cement composite mat. 
     BACKGROUND OF THE INVENTION 
     Barbecuing or grilling in the backyard has always been a popular past time. Many households have a grill, a hibachi, a smoker, or other types of outdoor cooking devices. These devices may burn gas, charcoal, wood, or other types of combustible fuels. These devices may be set up in the backyard, on a patio, a deck, a balcony, or anywhere outside. Also popular are various types of outdoor candles. These candles are used for decorative purposes, for lighting, and also to drive away insects. For example, various types of citronella products, such as pots or torches, may be placed outside on the patio, the deck, or elsewhere. Finally, wood burning warming devices also are becoming popular. For example, devices such as clay or ceramic firepots are used outside on the patio, the deck, or elsewhere. 
     One of the main attractions and one of the main drawbacks with these outdoor devices is that they generally use an open flame. The use of the open flame can cause problems ranging from a mere nuisance to a tragedy. For example, flames, ashes, or grease may escape from the outdoor device and stain or scorch a patio or a deck, particularly a wooden deck. Further, the flame, ashes, or grease also can set the wooden deck or even the backyard grass on fire. Likewise, the citronella pots and torches, as well as the firepots, also can scorch a deck or even set the deck on fire if accidentally tipped over. 
     Various types of deck and patio protectors have been used in the past. These known devices generally have been made from stamped metal or from some type of plastic and formed into a shallow box of some sort. The problems with these devices include the fact that the box often retains rain water and may be difficult to clean. The metal devices also tend to rust quickly. Further, the metal or the plastic material generally does not breathe such that any water located between the device and the deck remains trapped. This trapped water also will deteriorate or stain a wooden deck. Finally, it is often difficult to position the cooking device within the box. 
     What is needed, therefore, is an improved protection device for decks, patios, and other outdoor areas for use with an outdoor cooking device or other outdoor product having an open flame. The device must be fire resistant while also being aesthetically pleasing. Further, the device should protect the deck, the patio, or other surface while also resisting deterioration of the deck because of trapped moisture. Finally, the device should be relatively inexpensive, easy to clean, and easy to move. 
     SUMMARY OF THE INVENTION 
     The present invention provides a pad for protecting a surface from a container with a combustion source. The pad includes a cementitious slurry with a fibrous fabric embedded therein. The pad has a thickness of about 0.0625 to about 1.0 inches, with less than about 0.5 inches preferred. 
     Specific embodiments of the pad include having a periphery with a recess therein such that the recess functions as a handle. The cementitious slurry may include a mixture of portland cement, microsilica, fine sand, water, and water reducing super plastisizer. The fibrous fabric may include polypropylene, specifically a needle-punched non-woven material such as a three dimensional web of lofty, discreet fibers. The fibrous fabric may have a fiber volume of approximately three (3) to twenty percent (20%). Recycled fibers may be used. The fibrous fabric may have a weight of about three (3) to about twelve (12) ounces per square yard and a loft of about 0.050 to about 0.250 inches. A single ten (10) ounce per square yard layer of the fibrous fabric may be used as well as a double five (5) ounce per square yard layer. 
     The pad may have a weight of about one (1) to about three (3) pounds per square foot with sufficient flexibility to be rolled up into a tube with a diameter of about six (6) inches. The cementitious slurry and the fibrous fabric provide a water vapor permeable and liquid impermeable material. Specifically, the pad may have water vapor permeability of about one (1) to about three (3) grams per hour per square meter. The cementitious slurry and the fibrous fabric provide fire resistance, heat resistance, and scorch resistance. The pad also may have a sand blasted texture or a plurality of channels formed therein. 
     A further embodiment of the present invention provides for an outdoor surface protection system. The system includes a container with a combustion source and a pad positioned between the outdoor surface and the container. The pad includes a cementitious slurry and a fibrous fabric embedded in the cementitious slurry. The outdoor surface may be a deck or a patio. The container may be a cooking device such as a grill, a barbecue, a hibachi, or a smoker. The container also may include a candle, such as a citronella pot; a firepot; or a fire starter. The pad also may take the shape of a skirt. 
     A further embodiment of the present invention provides for a deck protection system. The system includes a grill and a pad positioned between the grill and the container. The pad includes a cementitious slurry and a fibrous fabric embedded in the cementitious slurry such that the pad provides flame and heat resistance. 
     Other objects, features, and advantages of the present invention will become apparent upon review of the following detailed description of the preferred embodiments of the invention, when taken in conjunction with the drawings and the appended claims. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a plan view of the protective pad of the present invention. 
         FIG. 2  is a side cross sectional view of the pad of the present invention. 
         FIG. 3  is a side cross sectional view of an alternative embodiment of the pad of the present invention. 
         FIG. 4  is a side cross sectional view of the pad of the present invention with a sand blasted surface. 
         FIG. 5  is a side cross sectional view of the pad of the present invention with channels therein. 
         FIG. 6  is a perspective view of the pad of the present invention with a grill on a deck. 
         FIG. 7  is a side view of the pad of the present invention in its rolled up form. 
         FIG. 8  is a perspective view of an alternative embodiment of the present invention showing a firebox. 
         FIG. 9  is a perspective view of an alternative embodiment of the present invention showing a candle pad. 
         FIG. 10  is a plan view of an alternative embodiment of the present invention showing a skirt pad. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Referring now to the drawings, in which like numerals represent like parts throughout the several views,  FIG. 1  shows a protector pad  10  of the present invention. The protector pad  10  may be made in any convenient size or shape. In the example of  FIG. 1 , the pad  10  is in the form of a circle. The pad  10  preferably is big enough for an outdoor device to be placed thereon. The pad  10  may have a recess  15  on one end that acts as a handle. The recess  15  preferably is large enough so as to be grasped by hand. 
     As is shown in  FIGS. 2 and 3 , the pad  10  may be made from a composite mixture  20 . A preferred composite mixture  20  includes a combination of a slurry mixture  25  and one or more fibrous fabrics  30  embedded within the slurry mixture  25 . The fibrous fabric  30  provides continuous and uniform three-dimensional re-enforcement throughout the entire thickness of the slurry mixture  25 . The slurry mixture  25  provides rigidity while the high fiber volume of the fibrous fabric  30  provides toughness, ductility, and crack resistance. 
     The slurry mixture  25  is preferably a cementitious mixture, but can include mixtures of concrete, plaster, epoxy, synthetic resins, polymers, paint, or water proofing compounds. Any type of known cementitious slurry can be used, including a preferred mixture of about ten (10) parts portland cement, about one (1) part microsilica, about five (5) parts fine sand, about four (4) parts water, and about 0.1 parts water reducing super plastisizer. By “portland cement”, we mean a hydraulic cement made by finely pulverizing a mixture of clay and limestone or similar materials. The proportions of the slurry mixture  25  may vary according to the use of the pad  10 , i.e., the proportions described above may be varied according to the desired hardness or size of the pad  10 . 
     The fibrous fabric  30  is preferably a needle-punched polypropylene non-woven material such as a three dimensional web of lofty, discreet polypropylene fibers with a fiber volume of approximately three (3) to twenty percent (20%). Continuous fibers also may be used. Polypropylene is preferred because of its combination of strength, ductility, economy, and chemical resistance. The fibrous fabric  30  may include recycled polypropylene fibers or a combination of virgin and recycled fibers. The fibrous fabric  30  may weigh between about three (3) and about twelve (12) ounces per square yard and may have a loft of about 0.050 and 0.250 inches. Although a three dimensional fabric is preferred, the fibrous fabric  30  can be any type of synthetic or natural fibrous materials, including spunbonded fabrics, mesh, glass mats, or even paper. 
     As is shown in  FIG. 2 , a single layer  35  of the fibrous fabric  30  may be used. In this example, the single layer  35  may weigh about ten (10) ounces per square yard. Further, as is shown in  FIG. 3 , a double layer  40  of the fibrous fabric  30  also may be used. In this case, each layer in the double layer  40  of the fibrous fabric  30  may weigh about five (5) ounces per square yard. The fibrous fabric  30  is embedded into and impregnated by the slurry mixture  25 . The fibrous fabric  30  can be applied by hand or by mechanical pressing to insure that the slurry mixture  25  is uniformly distributed throughout the fibrous fabric  30 . 
     The pad  10  may have a thickness of about 0.0625 of an inch to about an inch, with less than about 0.5 inches preferred. The composite mixture  20  weighs about one (1) to about three (3) pounds per square foot with about two (2) pounds per square foot preferred. In the example of  FIG. 1 , the pad  10  may have a diameter of about three (3) feet and a thickness of about a quarter (0.25) inch. Such a pad  10  would weigh only about twelve (12) pounds. Significantly, such a pad  10  also would have a great amount of flexibility. For example, the pad  10  described herein may have sufficient flexibility to be rolled up into a tube with a diameter of about six (6) inches without breaking or cracking. Further, the pad  10  is useful on uneven surfaces because of its flexibility. 
     The pad  10  not only has a high degree of flexibility, but the use of the composite mixture  20  also allows the pad  10  to breathe. Any moisture that may be trapped underneath the pad  10  can evaporate. For example, the pad  10  described above may allow about one (1.0) to about three (3.0) grams per hour per square meter of water vapor to pass through. The pad  10 , however, is largely water-resistant such that rainwater or other liquids will not pass through the pad  10  to the underlying surface. 
     Further, the pad  10  also provides a high degree of fire resistance, heat resistance, and scorch resistance because of the use of the slurry mixture  25 . The concrete within the slurry mixture  25  is of sufficient hardness so as to resist burning when a flame or other type of combustion or other item falls onto the pad  10  for a short amount of time. Although the pad  10  is flame resistant, the pad  10  is not intended as a refractory insulation. In other words, the pad  10  is not intended as a surface on which an open fire should be built directly thereon. 
     Finally, the pad  10  is easy to clean. Grease, dirt, or other items that land thereon usually can be cleaned with soap and water. The composite mixture  20  also may be mixed with paint or various types of dyes so as to produce a pad  10  in any given color. This coloration also may help in hiding scorches or imperfection in the material. Further, the pad  10  can be stained or painted after manufacture. 
     Production of the pads  10  can be done continuously, i.e., the fibrous fabric  30  may be embedded into the slurry mixture  25  to form a pad  10  of infinite length. The pad  10  would then be cut with a flying-type cut off saw (not shown) into pads  10  of predetermined length. Alternatively, the fibrous fabric  30  may be cut to a predetermined size and shape and then the slurry mixture  25  may be added to form the pad  10  with the predetermined size and shape. 
     As is shown in  FIGS. 4 and 5 , the pad  10  has an upper surface  45  and a lower surface  50 . Either or both surfaces  45 ,  50  may be textured in any desired manner. For example, in  FIG. 4 , the upper surface  45  is textured in a sand blasted pattern  55 . This sand blasted pattern  55  may provide traction to the pad  10 . Further,  FIG. 5  shows the upper surface  45  of the pad  10  with a plurality of channels  60  formed therein. The channels  60  may provide drainage or a runway by which to install or to roll the cooking device or other object onto the pad  10 . 
     In use, the pad  10  is placed on a support surface  100 . The support surface  100  may be a deck, a patio, a balcony, the grass, the beach, or any suitable surface. In the example of  FIG. 6 , a deck  105  is shown. A cooking device  110  is then placed on the pad  10 . The cooking device  110  may be a barbecue, a hibachi, a smoker, or any type of device using a flame or heat. In the example of  FIG. 6 , a grill  115  is shown. The pad  10  protects the deck  105  from sparks, flames, grease, or any other hot or burning items that may come from the grill  115 . The composite mixture  20  of the pad  10  is sufficiently fire resistant, heat resistant, and scorch resistant so as to protect the deck  105 . After use, the pad  10  may be rolled up as shown in FIG.  7  and stored. The pad  10  is sufficiently lightweight such that it is easily portable. 
       FIG. 8  shows an alternative embodiment of the present invention.  FIG. 8  shows a grill box  120 . The grill box  120  includes an outer frame  125  and a pad insert  130  using the composite mixture  20  of the present invention. The frame  125  may be made from wood or other suitable materials. The pad insert  130  is inserted within the frame  125 . The grill box  120  is designed to be attached to the grill  115  or to be located nearby. In this example, a fire starter  135  is placed within the grill box  120 . The fire starter  135  may be used to start a fire within the grill  115  and may be extremely hot. Placing the fire starter  135  within the grill box  120  prevents the fire starter  135  from accidentally starting a fire outside the grill  115  or scorching the surrounding area. The grill box  120  also may be used for other holding other types of grill tools and for raw or cooked food. 
       FIG. 9  shows a further alternative embodiment of the present invention.  FIG. 9  shows a candle pad  140 . The candle pad  140  is made from the same composite mixture  20  materials as the pad  10  described above. In this example, a citronella pot  145  is placed on the candle pad  140 . The citronella pot  145  is typically made from a galvanized metal  150 . This galvanized metal  150  may become quite hot as the candle within the citronella pot  145  burns down. This hot galvanized metal  150  also may burn or scorch the deck  105  or other type of supporting surface  100 . The candle pad  140  is placed beneath the citronella pot  145  and protects the supporting surface  100 . The candle pad  140  may have a diameter of only about three (3) or four (4) inches, but can be of any desired size or shape. In addition to the citronella pot  145 , the candle pad  140  also can be used for firepots or any other type of outdoor product using a flame. The pad  140  may be sized to fit the object placed thereon. 
       FIG. 10  shows a further alternative embodiment of the present invention. In this embodiment, a skirt  155  is shown. The skirt  155  is made from the same composite mixture  20  material as the pad  10 . In this embodiment, the skirt  155  may encircle either a permanently attached structure or may be used simply to encircle a device so as to protect the surrounding support surface  110  from flames or other items that may escape. The skirt  155  may have a slit  160  therethrough such that the skirt  155  may be positioned around the device. 
     It should be understood that the foregoing relates only to the preferred embodiments of the present invention and that numerous changes may be made herein without departing from the spirit and scope of the invention as defined by the following appended claims.