IMPACT ABSORBING SAFETY UNIT
The present invention concerns the field of impact absorbing units, particularly for use in the construction or building trade in which health and safety requirements dictate that exposure to uncushioned falls of greater than 2 metres or so must be prevented.
UK Patent GB 2367877 discloses an impact absorbing unit which has a generally rectilinear configuration in the form of an elongate block which has four long surfaces and two short end faces. The blocks are formed from sewn panels of flexible web material. These panels form a rectilinear envelope which is filled with flexible filler material such as polystyrene granules. These impact units provide a cushioning and deceleration effect which limits injury to a person falling onto a floor surface covered by these units. By virtue of the rectilinear configuration, a floor surface may be covered with a coterminous and coherent plurality of the units, effectively forming a false cushioned floor.
A problem with the known impact absorbing units is the cost of manufacture involved in attaching seams of several panels to form each unit. The units are also subject to wear at the seams due to the rough manner in which they are handled in the building trade. The seams are particularly vulnerable as they are sewn and therefore tend to detach. Furthermore, laying out the units must be done in a methodical manner as replacement or insertion of single units in a pre-laid
plurality is difficult because of the tight tolerances conferred by the rectilinear configuration.
It is an object of the present invention to provide an impact protection safety unit which is more economic to manufacture. It is a further object to provide a unit which is easier to lay down to cover a floor surface, while still providing adequate safety cushioning as required in service.
According to the present invention there is provided an impact-absorbing safety unit comprising a flexible web envelope containing resilient impact absorbing material, which envelope is configured to adopt an elongate and generally cylindrical shape on filling with said resilient material. The units are intended to be placed side by side over floor surfaces, so as to provide protection against falling for workmen or builders working at height. The envelope web may be a heavy duty plastics film, a woven material or a felt. Preferably the web is made from heavy duty woven plastics material, such as polypropylene. Other materials or heavy duty textiles may be employed. Preferably, the polypropylene has a density of approximately 200g/m2.
The cylindrical shape makes the units easy to lay down and to pick-up even when juxtaposed other neighbouring units. Furthermore, when the units are packed together they tend to deform locally so as to form a flat vertical or side contact surface, whilst maintaining curved edges which reduce exposure to wear and tear.
Thus they are capable of covering a floor surface in a reasonably uniform and continuous manner without leaving gaps at the interfaces between units, and without losing useful cushioning in the region of the interface. Furthermore, a further layer of units stacked over the first is particularly stable as it is may be accommodated in the slight troughs formed at the interface between adjacent underlying units.
Furthermore, upon impact from a falling object, the cylindrical unit is squashed and deforms to take up a flatter configuration. Hence, the falling object initially impacts against a slightly convex surface. Upon impact by the falling object the unit forms a substantially horizontal flat surface. This deformation of the unit upon impact increases the time taken for the falling object to be fully decelerated. Hence, the falling object experiences lower g-forces than it would falling onto a rectilinear impact absorbing unit. In the case of a falling person, this obviously reduces the chance or severity of any injuries occurring.
Said envelope may be formed from a single web panel having a cylindrical sleeve configuration. Said web panel may be formed from a sheet of web material, said web having opposing long sides, which long sides are joined to form the cylindrical sleeve configuration. The use of a single panel and a single seam considerably simplifies manufacture and reduces costs as compared to a rectilinear unit having multiple seams or welds.
Alternatively, the cylindrical sleeve could be formed without a seam. This is possible when using a tubular sleeve of material.
The impact absorbing material may be a particulate expanded foam polymer material, such as polystyrene fillers, or closed cell foam such as polyethylene. Conveniently, the filler may be provided in one or more loosely packed bags, which bags are placed inside the web envelope before closure of the end portions. The absorbing particulate material in each unit may be held in two elongate bags.
The absorbing particulate material may comprise two or more types of material. The different types of material may be separated within the unit. Such separation could involve holding the different types of material in separate bags within the unit. For example, the unit may comprise a central bag containing polystyrene and two end bags containing polyethylene. Alternatively, the different particulate material may be separated by the use of flaps inside the unit. For example, the unit may comprise a central portion containing polystyrene and two end portions containing polyethylene and the portions may be separated by flaps inside the unit. Polyethylene is heavier than polystyrene and retains its shape better than polystyrene. However, it is more expensive than polystyrene. The use of polyethylene only at the ends of the units reduces the cost from using polyethylene throughout the unit. However, it helps the units to retain their shape after impact. This means the ends of the units do not become squashed and deformed after use. This is particularly advantageous as the ends of the units
generally provide a particular weak area where two units meet. Furthermore, having polyethylene at the ends of units allows the end of the units to deform to match the shape of an adjacent unit. Hence, the units can fit closer together.
In another alternative, one type of material may be contained in an inner cylindrical bag extending the length of the unit and surrounded by an outer layer of another type of material. The inner cylindrical bag may be held in a central location of the unit by the use of hanging loops connecting the inner cylindrical bag to the inside of the unit. For example, the inner cylindrical bag may contain polyethylene and the outer layer may comprise polystyrene.
The bags may be made from a thin, rupturable polyethylene material. Alternatively, the loosely packed bags may be placed inside the web envelope and the impact absorbing material emptied from the bags. The empty bags could then be removed before closure of the end portions of the web envelope. Alternatively, the bags may be left open inside the web envelope to allow the impact absorbing material to freely move within the closed web envelope. In yet another alternative, the web envelope may be filled directly with impact absorbing material for example, directly from a storage silo. The density of the particulate foam is preferably between 4.0 to 5.2 Kg per cubic metre.
In a convenient arrangement, opposite end portions of the cylindrical sleeve are gathered and fastened to form closures at each end. Thus end seams are avoided
and manufacture is simplified. The gathered end portions may be fastened by crimping or any suitable securing means, such as use of a draw string or cord, metal or plastic clamps, gluing etc. The gathered end portions are preferably tucked inwardly back into the envelope so as to provide a generally flat end face at each end of the envelope and reduce potential wear and damage.
The use of a drawstring to fasten the ends of the units is especially advantageous. The drawstring may be threaded through hems at the edges of the cylindrical sleeves. Alternatively, a sleeve with a drawstring pre-threaded through it may be stitched around each edge of the cylindrical sleeve. When the drawstring is pulled taught the edges of the cylindrical sleeve are gathered towards each other at the ends of the units. Hence the drawstring arrangement does not leave any excess material at the ends of the units that needs to be tucked back into the envelope. Preferably the drawstring is contained within a sleeve of material. The sleeve may have a width of approximately 6cm. This drawstring sleeve material may be a heavy duty plastics film, a woven material or a felt. It may be made from a heavy duty woven plastics material, such as polypropylene. It may be the same material as the envelope web. Most preferably, however, it is made from polypropylene with a density of approximately 100 g/m2. This density is lower than that preferably used for the envelope web. The lower density material is softer and more flexible and allows the drawstring to be pulled tighter without the sleeve material bunching. Hence, the ends of cylindrical sleeves can be gathered closer together to leave a smaller hole at the ends of the units. The drawstring may
comprise tape, string or a plastic tie. The plastic tie may preferably contain a ratchet mechanism (similar to that of a cable tie) to lock it in position once it has been pulled taught and the edges of the sleeve have been sufficiently gathered. Preferably, the ratchet mechanism is capable of being unlocked.
Alternatively, the drawstring may be held taught by one or more lugs. The lugs may comprise a hole through which the drawstring passes. A biased stopping member may be provided on one side of the hole. It may be biased in such a way so as to act to close the hole and hold the drawstring in place between the stopping member and a corresponding surface on the other side of the hole. The biasing force may be provided by a spring.
The units may further comprise one or two inner flaps. These inner flaps are placed inside the web envelope across one or each end of the unit. The inner flaps prevent any impact absorbing material escaping from the web envelopes. It is especially advantageous to use inner flaps when a drawstring arrangement is used to gather the edges of the cylindrical sleeves. The inner flaps prevent impact absorbing material escaping through the hole formed by the gathered material. The hole could be approximately 10 mm in diameter. The inner flaps could be circular. They could be of a diameter greater than the diameter of the hole formed by the gathered material. The inner flaps could alternatively be rectangular. The inner flaps may be attached to the inner surface of the web envelope (for example by stitching along one part of the circumference of the flap) or may be loose
pieces of material placed inside the web envelope. For example, the inner flaps are made from polypropylene with a density of approximately 100 g/m2.
The opposite end portions of the sleeve may each be provided with an overlap flap, which flap is attached at one end to an end region of the sleeve and positioned so as to be capable of being drawn across to overlap and cover the end tucks of the gathered and fastened closures. A free end region of each of the overlap flaps may be provided with fastening means for securing the flaps in their overlapped position. The fastening means may comprise a toggle and loop pairing. However suitable fasteners may be used, such as Velcro™ type or plastic rivets, clips or gluing/welding.
Preferably, the flaps are fastened with a combination of Velcro™ strips and straps with buckles, comprising male and female portions. Preferably, the buckles are such that they require a prising action or similar to be released. This ensures the buckles are not accidentally released during use. Preferably, the overlap flaps are made from the same material as the envelope web. Most preferably, or alternatively, the flaps are made from polypropylene with an approximate density of 200 g/m2. Preferably, the overlap flaps have a width sufficient to "close off the ends of the units so that any gathered end portions are contained and/or holes in the ends of the unit are covered. The overlap flaps may have a width of approximately 40 cm. Preferably, the overlap flaps have a length sufficient to
extend over the length of an end of the unit from one side of the unit to the other side. The overlap flaps may have a length of approximately 80 cm.
An exterior surface of the envelope is provided with a plurality of fasteners, each of which is to be engaged with a corresponding fastener of further units which may be juxtaposed the first unit. The fasteners may be positioned so as to permit engagement of multiple units in a side-by-side arrangement to form a coherent covering of a floor surface.
The fasteners are preferably positioned so as to allow the units to be positioned side-by-side and coterminous with each other. In addition, or alternatively, fasteners may be positioned so as to allow a plurality of units to be fastened side- by-side but non-coterminous so that one unit may be fastened on one side to respective end regions of two units arranged end on end and adjacent the first unit, in a brick work fashion. End fasteners may be positioned so as to permit fastening of adjacent units end-on-end, or in a T-configuration in which an end of one unit is fastened to a side of another unit.
The end and side fasteners may be positioned to permit fastening of a plurality of units end-on to the side of another unit. The fasteners may be such that three units can be fastened end-on to the side of another unit. When the units are so fastened, the sides of the outermost end-on units may be coterminous with the ends of the other unit.
In a preferred arrangement, fasteners are provided towards an upper region of the unit in longitudinally spaced positions. The fasteners are engageable with corresponding fasteners of an adjacent unit. Each of the fasteners is sized and positioned to act to draw adjacent units intimately together so that touching circumferential side surfaces of the units are urged together and deform to form parallel flat contact surfaces.
Alternatively, the fasteners may be provided in circumferentially spaced pairs comprising an upper fastener and a lower fastener, the pair being engageable with corresponding upper and lower fasteners of an adjacent unit.
The fasteners are preferably straps with quick-release buckles, comprising male and female portions, one male portion of one unit adapted to engage with a corresponding female portion of an adj acent unit. Other fasteners such as toggle/loop combinations, clamps or equivalents of the same maybe employed as desired.
The size and resilience of the units is such as to provide adequate cushioning and deceleration for a person falling from a height onto a floor covered by the unit units, whilst also being capable of being handled by a single person, or pair of workmen. Thus, the unit typically has a diameter of 45 to 85 cm, preferably 55 to 75 cm, most preferably 65 to 75cms and a length of 200 to 300 cm, preferably
200 to 250 cm, most preferably 205 to 215cms. In one preferred embodiment, the length is about 210cms and the diameter is about 70 cm. The web envelope of such a unit could be made from a piece of material of overall dimensions of approximately 3.08 m length by 2.2 m width. The long sides of the material could then be stitched to form a cylindrical sleeve with a length of approximately 3.08 m and a diameter of approximately 70 cm.
The web envelopes could alternatively be circular woven with two end panels.
Ancillary units of reduced length may also be provided. These are useful for filing gaps where a brick work fashion overlapping side-by side arrangement is employed. Typically these will be a third of the primary unit lengths, but could be made in other lengths such as 1/2 lengths. Two units of one third length could be joined end-on to form a two third length unit. The diameters should be the same. Thus the ancillary units may have a length of 50 to 100 cm, preferably 70cm. Such ancillary could be filled with polyethylene material.
The unit may be provided with a handle. The unit may be provided with a handle towards each end of the unit. The handle or handles may be orientated lengthways along the unit. The handle or handles may be located on a top surface of the unit.
Following is a description, with reference to the figures, and by way of example only, of two modes of putting the present invention into effect.
In the drawings:
Figure l is a perspective view of a panel from which a unit according to a first embodiment of the invention is to be formed.
Figure 2 is a perspective view of the same panel rolled to form a cylindrical sleeve.
Figure 3 shows the unit after packing with filler and crimping of an end.
Figure 4 shows the finished unit according to a first embodiment of the invention.
Figures 5 and 6 show alternative arrangements of units placed together and fastened to allow the formation of a cushioned floor covering.
Figures 7 and 8 are perspective views of a flattened sleeve from which a unit according to a second embodiment of the invention is to be formed.
Figure 9 shows an enlarged view of part of a drawstring sleeve of the unit according to a second embodiment of the invention.
Figure 10 is a perspective view of two units according to one embodiment of the invention.
Figure 11 is a schematic plan view of units according to the present invention in a "brickwork" matrix.
Figure 12 is a schematic plan view of units according to the present invention in a "parallel" matrix.
Figure 13 is a schematic plan view of units according to the present invention in a "combination" matrix.
Figure 14 is a perspective view of units according to the present invention fastened together.
Figure 1 shows a precursor panel 10 of a polypropylene textile material of heavy duty grade. An upper surface 11 of the panel is provided with a plurality of straps 12 attached at one end to the panel surface and having a free end provided with either a male 13 or a female 14 buckle portions. Long sides 15 of the panel are joined as shown in Figure 2 and stitched or riveted or welded to form a single elongate seam 16 of sleeve 22. A flap 17 shown in Figure 2 (and not shown in Figure 1 for the sake of clarity) is attached by welding at one end to an end portion 18 of the sleeve. A free end of the flap has a Velcro™ pad 19. An
opposite side of the sleeve carries a corresponding Velcro™ pad which may receive the free end of the flap. Figure 3 shows two cylindrical bags 20, 21 of polystyrene loose fill foam particles, disposed end-on inside the envelope. One end of the sleeve 22 is shown crimped with a metal crimping collar 23. The other end (not shown) is also crimped in the same way. In Figure 4 the crimped end is shown tucked 24 into the envelope. Although not shown in Figure 4, the flap is overlaid the crimped tuck so as to form a flush surface. In Figure 4 the position of various buckle fasteners is also shown. Thus it will be seen that there are end fasteners 25, end/side fasteners 26 and middle portion side fasteners 27. In Figure 5 a plan view is shown of respective end regions of four units laid side-by-side. The units are aligned so that they are end on and coterminous, hi Figure 6 an alternative arrangement is shown in which three units are laid in brick work pattern. In this arrangement middle portion buckles 27 of one unit are attached to side end buckles 26 of the adjacent unit.
Figures 7, 8 and 9 show a second embodiment of the present invention. Like elements to those in the first embodiment are represented by like reference numerals.
Figure 7 shows a sleeve 22 formed from a precursor panel similar to that in Figure 1. The material of the sleeve and panel is a polypropylene material with a density of approximately 200 g/m2. Two rectangular flaps 17 are attached; one to each end portion 18 of the sleeve 22. Each flap 17 is approximately 40cm by 80cm.
The flaps 17 are secured at a location at the end portion 18 of the sleeve 22. This is seen in Figure 7 in the centre of the sleeve. The flaps are located so as to extend over the edge of the sleeve 22. The flap 17 is placed so approximately half its length extends over the edge of the sleeve i.e. one end of the flap 17 is placed 40cm from the edge of the sleeve. The flaps 17 are secured by stitching a line across the width of the flap approximately 5cm from the end of the flap i.e. 35cm from the edge of the sleeve 22. A free end region of each flap has a Velcro™pad (not shown) stitched onto it. As can be seen in Figure 8, an opposite side of the sleeve 22 carries a corresponding Velcro™ pad 30 which may receive the free end region of the flap. The Velcro™ pad 30 is located approximately 40cm from the edge of the sleeve 22 in order to match up with the Velcro™ pad on the free end region of the flap 17.
A buckle 33 may also be used to secure the flap 17. The buckle 33 comprises a male 34 and female 35 portion. In Figures 7 and 8, the male portion 34 of the buckle 33 is attached towards the end of the free end region of flap 17. It is attached at a central location along the width of the flap 17. The corresponding female portion 35 of the buckle 33 is attached in a similar location to the Velcro™ pad 30, approximately 40cm from the edge of the sleeve 22 at an opposite side of the sleeve 22 to the flap 17.
Each end of the sleeve 22 has a drawstring sleeve 31 stitched around the edge of the sleeve 22. The material of the drawstring sleeve is polypropylene with a
density of approximately 100 g/m2. Figure 9 shows part of the drawstring sleeve in more detail. The drawstring sleeve 31 has a width of approximately 6cm. It is formed by folding a length of material of a width of greater than 12cm. The material is then stitched 32 to secure the two folds of material together. The drawstring sleeve 31 can be stitched to the edge of sleeve 22 in the same stitching operation. The length of the drawstring sleeve 31 corresponds to the diameter of the sleeve 22.
In use, a drawstring (not shown) is threaded through each drawstring sleeve 31. In use, a first drawstring at one end of the unit is pulled taught and secured. This could be by tying the drawstring or by using the plastic lugs, or similar.
Flap 17 is folded over the corresponding end of the unit and held in place by the Velcro™ pads 30 and/or buckles 33. The units are then filled. The second drawstring at the other end of the unit is then pulled taught, secured and the second flap is folded over and held in place.
The drawstrings are generally of a non-elastic nature and could be cord or tape. Polypropylene tape is especially good for use as a drawstring as it has adequate strength.
Figures 7, 8, 10 and 14 show the positioning of the various buckles on the unit. As well as buckles 33, the unit also has one middle buckle 27 with corresponding
male 27a and female 27b parts. The male part 27a is located halfway along the length of the sleeve 22. The female part 27b is also located halfway along the length of the sleeve 22. It is placed behind the male part 27a and facing away from it. A male part 27a will attach to a corresponding female part 27b of an adjacent unit when the units are laid side-by-side. Alternatively, buckles 27 may not be present.
The unit also has two side end buckles 26 with corresponding male 26a and female 26b parts. The male part 26a of one side buckle 26 is located approximately a quarter of the length of the sleeve 22 in from the edge of the sleeve. The corresponding female part 26b is also located approximately a quarter of the length of the sleeve 22 in from the edge of the sleeve. It is placed behind the male part 26a and facing away from it. The other parts of the second side buckle are located in corresponding locations in the other half of the length of the sleeve 22. A male part 26a will attach to a corresponding female part 26b of an adjacent unit when the units are laid side-by-side.
The unit, for example, has a length of 210cms and a diameter of 70cms. In such an example, the buckles 26, 27 are positioned 35cms in from the end of the units and centrally along the unit, respectively. Therefore the buckles 26, 27 are spaced in a row along the unit at 70cms intervals. In this way, three units can be placed perpendicularly (end-on) to another unit with their ends adjacent with the side of the other unit. They can be secured in place attaching an end buckle 25 from each
of the three units to one of the buckles 26, 27 of the other unit. The sides of the outermost end-on units are then aligned with the ends of the other unit.
Alternatively, male 27a and female 27b parts can attach to male 26a and female 26b parts respectively of an adjacent unit when the units are laid in a brick work pattern. In the alternative configuration (where there are no buckles 27) in a brick wall pattern, said buckles 26 attach to corresponding side buckles 26 located towards the opposite end of an adjacent unit.
The unit also has end buckles 25 comprising male 25a and female 25b parts. These are located approximately a quarter of the length of the sleeve 22 in from the edge of the sleeve. Both parts face towards the end of the sleeve. The male part 25a is located on one half of the length of the sleeve, the female part 25b located on the other. A male part 25a will attach to a corresponding female part 25b of an adjacent unit when the units are placed end to end.
As shown in Figure 14, ancillary units 110 have one side buckle part 27a, 27b on each side of the unit and one end buckle part 25a, 25b on each end of the unit.
The material of the precursor panel 10 or the sleeve 22 may be treated with UV protection.
The units of figure 10 are also provided with handles 28. These are provided one towards each end of the unit. They are located on the upper surface of the unit, towards the centre of the upper surface. The handles 28 are orientated lengthways along the length of the unit. They are made of the same material as used for the straps for the buckles. They are stitched at each end of the handle to the unit. Ideally, the handles are provided by having a additional length of strap material associated with the end buckle 25 straps. The strap material is stitched at both ends to the unit, leaving a loose, unattached section between the stitched ends, providing handle means. The additional length of strap material needed to provide a handle is approximately 15-20cm.
Figure 11 shows units 10 in a "brickwork" formation. Two sets of brickwork formation can be joined at a corner. Ancillary units 110 are used to fill the gaps at the corner where the two sets meet. Hence, the entire of the floor surface can be covered by units 10 and ancillary units 110.
Figure 12 shows units 10 in a "parallel" formation. The ends of the units are aligned, as opposed to in the brickwork formation. An ancillary unit 110a is used to align the ends of the units to change from a brickwork formation to the parallel formation. Ancillary units 110 are also used to provide a step- wise formation. This can be used to cover a floor that may be obstructed by objects, such as pillars.
Figure 13 shows a combination of brickworks sets of units 10, 110 and parallel sets of units 10, 110. Ancillary units 110 are used to fill any gaps upon joining the sets at right angles to each other.