WO2007002442A1 - Système de surface modulaire - Google Patents

Système de surface modulaire Download PDF

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Publication number
WO2007002442A1
WO2007002442A1 PCT/US2006/024540 US2006024540W WO2007002442A1 WO 2007002442 A1 WO2007002442 A1 WO 2007002442A1 US 2006024540 W US2006024540 W US 2006024540W WO 2007002442 A1 WO2007002442 A1 WO 2007002442A1
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WO
WIPO (PCT)
Prior art keywords
mat
modular
surfacing
mats
base
Prior art date
Application number
PCT/US2006/024540
Other languages
English (en)
Inventor
Neil E. Kruschke
Thomas Siebert
Original Assignee
Kruschke Neil E
Thomas Siebert
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Kruschke Neil E, Thomas Siebert filed Critical Kruschke Neil E
Publication of WO2007002442A1 publication Critical patent/WO2007002442A1/fr

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Classifications

    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00—Flooring
    • E04F15/02—Flooring or floor layers composed of a number of similar elements
    • E04F15/10—Flooring or floor layers composed of a number of similar elements of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard, or with a top layer of other materials
    • E04F15/107—Flooring or floor layers composed of a number of similar elements of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard, or with a top layer of other materials composed of several layers, e.g. sandwich panels
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B25/00—Layered products comprising a layer of natural or synthetic rubber
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B25/00—Layered products comprising a layer of natural or synthetic rubber
    • B32B25/04—Layered products comprising a layer of natural or synthetic rubber comprising rubber as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B25/08—Layered products comprising a layer of natural or synthetic rubber comprising rubber as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/32—Layered products comprising a layer of synthetic resin comprising polyolefins
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/40—Layered products comprising a layer of synthetic resin comprising polyurethanes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/18—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material
    • E—FIXED CONSTRUCTIONS
    • E01—CONSTRUCTION OF ROADS, RAILWAYS, OR BRIDGES
    • E01C—CONSTRUCTION OF, OR SURFACES FOR, ROADS, SPORTS GROUNDS, OR THE LIKE; MACHINES OR AUXILIARY TOOLS FOR CONSTRUCTION OR REPAIR
    • E01C13/00—Pavings or foundations specially adapted for playgrounds or sports grounds; Drainage, irrigation or heating of sports grounds
    • E01C13/08—Surfaces simulating grass ; Grass-grown sports grounds
    • E—FIXED CONSTRUCTIONS
    • E01—CONSTRUCTION OF ROADS, RAILWAYS, OR BRIDGES
    • E01C—CONSTRUCTION OF, OR SURFACES FOR, ROADS, SPORTS GROUNDS, OR THE LIKE; MACHINES OR AUXILIARY TOOLS FOR CONSTRUCTION OR REPAIR
    • E01C5/00—Pavings made of prefabricated single units
    • E01C5/22—Pavings made of prefabricated single units made of units composed of a mixture of materials covered by two or more of groups E01C5/008, E01C5/02 - E01C5/20 except embedded reinforcing materials
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00—Flooring
    • E04F15/02—Flooring or floor layers composed of a number of similar elements
    • E04F15/02194—Flooring consisting of a number of elements carried by a non-rollable common support plate or grid
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00—Flooring
    • E04F15/02—Flooring or floor layers composed of a number of similar elements
    • E04F15/10—Flooring or floor layers composed of a number of similar elements of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard, or with a top layer of other materials
    • E04F15/105—Flooring or floor layers composed of a number of similar elements of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard, or with a top layer of other materials of organic plastics with or without reinforcements or filling materials
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2272/00—Resin or rubber layer comprising scrap, waste or recycling material
    • E—FIXED CONSTRUCTIONS
    • E01—CONSTRUCTION OF ROADS, RAILWAYS, OR BRIDGES
    • E01C—CONSTRUCTION OF, OR SURFACES FOR, ROADS, SPORTS GROUNDS, OR THE LIKE; MACHINES OR AUXILIARY TOOLS FOR CONSTRUCTION OR REPAIR
    • E01C2201/00—Paving elements
    • E01C2201/14—Puzzle-like connections
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F2201/00—Joining sheets or plates or panels
    • E04F2201/09—Puzzle-type connections for interlocking male and female panel edge-parts
    • E04F2201/091—Puzzle-type connections for interlocking male and female panel edge-parts with the edge-parts forming part of the panel body
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F2201/00—Joining sheets or plates or panels
    • E04F2201/09—Puzzle-type connections for interlocking male and female panel edge-parts
    • E04F2201/095—Puzzle-type connections for interlocking male and female panel edge-parts with both connection parts, i.e. male and female connection parts alternating on one edge
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F2201/00—Joining sheets or plates or panels
    • E04F2201/09—Puzzle-type connections for interlocking male and female panel edge-parts
    • E04F2201/096—Puzzle-type connections for interlocking male and female panel edge-parts with only one type of connection parts, i.e. with male or female on one edge
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F2201/00—Joining sheets or plates or panels
    • E04F2201/09—Puzzle-type connections for interlocking male and female panel edge-parts
    • E04F2201/098—Puzzle-type connections for interlocking male and female panel edge-parts wherein the interlocking male and female edge-parts have a dovetail, mushroom or similar shape

Definitions

  • the present invention relates generally to surfacing systems, and more particularly to a modular surfacing system for use in recreational, institutional and other applications.
  • engineered wood fiber One of the least expensive methods for surfacing ground under playground equipment is known as “engineered wood fiber,” or “EWF.”
  • An engineered wood fiber surface traditionally is comprised of specialty shredded virgin wood or recycled pallets, wood chips or other cushioning materials scattered like mulch on the ground under the playground equipment.
  • engineered wood fiber can shift and become uneven due to weather and or kick-out by children, providing less protection in one spot than in another spot. If a person was to fall onto a less-protected spot, they could suffer injuries that would have been avoided had the engineered wood fiber been more evenly distributed.
  • Loose fill is similar to engineered wood fiber in that it is scattered on the ground under the playground equipment, but loose fill is traditionally made of rubber chips or other cushioning material. Some loose fill is made of shredded tires or other recycled materials. Like engineered wood fiber, loose fill can shift and become uneven, providing less protection in one spot than in another spot. Loose fill is also unlikely to meet the ASTM standard Fl 951. Consequently, playgrounds covered with loose fill are unlikely to be certified as wheelchair accessible.
  • a third prevalent method for surfacing ground under playground equipment is called unitary surfacing, such as a rubber mat or a "pour-in-place" surface (described below). Many commercially-available rubber mats are adequate to protect children from falls of 3 to 6 feet. Rubber mats may be purchased as separate interlocking pieces of rubber mat. For example, rubber mats are available in 2-ft by 2ft, 3 -ft by 3 -ft, or 3 -ft by 4-ft, sections that can be locked together.
  • Rubber mats can be very heavy to ship. To cover an entire playground, a very large number of separate interlocking pieces may be needed, and each piece may be required have a thickness adequate to protect children from at least a moderate fall. Also, rubber mats can be very expensive and can be easily vandalized. Due to the cost and the weight, rubber mats are not appropriate for all playgrounds. "Pour-in-place,” surfaces are more common than rubber mats. A pour-in-place surface is a unitary surface that is manufactured on the playground itself. First, a shock- absorbing material such as fine rubber crumbs, small rubber chunks, and/or rubber slivers are dumped into a mixer that is similar to a portable cement mixer. This mixture may be, for example, shredded recycled tires.
  • a suitable liquid that subsequently can form a polymer upon exposure to moisture in the air such as a polyurethane, is then poured into the mixer and mixed with the shock absorbing material to create a slurry.
  • the slurry subsequently is transported, generally in a wheelbarrow or in several buckets, to a site that is to be protected. Laborers then trowel the slurry over the site and allow the slurry to set for at least a day. A guard might be posted to prevent children from playing on the surface during the day that is necessary for the slurry to set. Later, a second slurry composed of colored rubber particles in the same polymeric liquid precursor is poured and troweled over the previously prepared site to form a finished consolidated colored rubber surface.
  • pour-in-place method is very labor intensive. Covering a typical 2000 square- foot playground may require three laborers two full work days to install. If the liquid precursor polyurethane is not mixed thoroughly enough with the fine rubber crumbs, the entire surface might have to be torn up and the site resurfaced so that the fine rubber crumbs can be distributed or mixed more evenly. Up to thirty percent of all pour-in-place surfaces fail during the first year, primarily due to improper temperature and humidity conditions. Pour-in-place surfaces are typically porous, allowing water and environmental wastes to seep into cracks and pores, possibly lowering the Head Impact Criteria within a short time. These porous surfaces can act like a giant filter, trapping dirt, pollen and waste.
  • the present invention provides modular surfacing mats and a modular surfacing system that is applicable for use useable outdoors (e.g., on playgrounds) as well as indoors (e.g., for institutional settings such as nursing homes).
  • the invention provides a modular surfacing mat that includes a base mat or shock absorbing mat, a top mat secured to the base mat with an adhesive, and a top coat applied to the top of the top mat to form a protective finish.
  • the top coat may be any coating that provides a protective top finish on the mat, and is preferably a polyurea or polyurethane.
  • the top coat may include a colorant.
  • the top mat is preferably at least partially made from rubber. For example, recycled rubber may be used.
  • the adhesive that bonds the top mat to the base mat is preferably a polyurethane or a polyurea, but any adhesive may be used.
  • the base mat is preferably made from a closed cell foam.
  • the closed cell foam may be closed cell polyethylene foam nuggets fused together in a crosslinked matrix.
  • the closed cell foam may also be made of expanded polypropylene, expanded polyethylene, or expanded polystyrene.
  • one or more modular surfacing mats may be combined to form a modular surfacing system.
  • the base mat and top mat of each modular mat have substantially symmetric horizontal cross sections and three or more sides.
  • Each of these may be straight or have tab and slot features of interlocking two or more mats together.
  • Straight side mats allow for easier customization by the end user, while mats with slot and tab features allow for improved locking of a plurality of mats together.
  • the slot and tab features may be of any shape that allows for mats to interlock, such as mortise and tenon, dovetail, or generally shaped like a puzzle piece.
  • a modular surfacing system may include two or more modular surfacing mats that include a first group of modular surfacing mats and a second group of modular surfacing mats.
  • the first group of modular surfacing mats has a base mat with a first density of closed cell foam and the second group of modular surfacing mats has a base mat with a second density of closed cell foam.
  • the first and second groups of modular surfacing mats have the substantially the same thicknesses. In this way, mats of differing densities, and as such different fall height characteristics, may be used on the same playground as they have the same thickness.
  • an adhesive sealant may also be used to bond one or more base mats to a substrate that underlies the modular surfacing mats.
  • substrates include concrete, cement, asphalt, crushed limestone, tile, linoleum, wood, and existing pour-in-place surfaces.
  • the modular surfacing mats may be configured as a multi-layer arrangement having a plurality of layers, each of the plurality of layers being at least one of a base mat and a top mat with an adhesive as both the topcoat and adhesive between the layers.
  • the modular surfacing mats may be configured with a plurality of layers that include a first seam having a first direction and a second seam having a second direction, the first seam having a relationship to the second seam, the relationship being one of substantially parallel, substantially perpendicular, and substantially diagonal.
  • the first layer may overlap the second layer.
  • Figure 1 is a vertical cross-sectional view of a modular surfacing mat in accordance with one embodiment of the invention.
  • Figure 2 is a vertical cross-sectional view of a modular surfacing mat with a carpeted top mat in accordance with one embodiment of the invention.
  • Figure 3 is a vertical cross-sectional view of a modular surfacing mat with an artificial turf top mat in accordance with one embodiment of the invention
  • Figure 4 shows examples of shapes of modular surfacing mats according to various aspects of the invention.
  • Figure 5 shows vertical cross-sectional views of modular surfacing mats with differing base mat densities in accordance with one embodiment of the invention.
  • Figure 6 shows the arrangement of modular surfacing mats in a modular surfacing system according to one embodiment of the invention.
  • Figure 7 shows a vertical cross-section of a multiple layer mat according to one embodiment of the invention.
  • a surfacing systems and more particularly, a modular surfacing system for use in recreational, institutional and other applications is described.
  • FIG. 1 is a vertical cross-sectional view of a modular surfacing mat in accordance with one embodiment of the invention.
  • Modular surfacing mat 100 includes a base mat 101, an adhesive 102, a top mat 103, and a top coat 104.
  • the top mat is bonded to the base mat with adhesive 102.
  • Top coat 104 provides a protective finish to top mat 103.
  • Base mat 101 is preferably made from a cellular foam structure.
  • Cellular foam structures may be formed from various densities of expanded polymers including polyethylene, polypropylene, poly(ethylene-co-propylene), and other expanded polymers such as polystyrene, crosslinked polyurethanes, thermoplastic elastomers, etc.
  • the base mat is formed from a closed cell foam structure.
  • Closed cell foam is a cellular foam structure material that includes millions of tiny, air-filled bubbles or closed cells, which contribute to its cushioning characteristics.
  • the closed cell foam utilized may be formed from closed cell polyethylene foam nuggets fused together in a crosslinked matrix.
  • the base mat may be formed from a plurality of recycled closed cell polyethylene foam nuggets.
  • the mat also may contain other recycled materials comprised of polyurethanes, linear rubbers, vulcanized rubbers, EPDM rubbers (both linear and crosslinked), polymers used in the automotive industry or other deformable materials or combinations thereof permanently fused together in a crosslinked matrix. Depending on their original source, these recycled materials may or may not exist in a foamed state.
  • the base mat is therefore shock and impact absorbent, capable of helping prevent injury by absorbing shock and dissipating the G-forces associated with a fall and impact.
  • the base mat may be formed from crosslinked rubber particles such as natural rubber, styrene butadiene rubber, or EPDM (Ethylene Propylene Diene Rubber). This material is manufactured to a crumb like consistency in a variety of colors. In these cases, the rubber may be either linear or crosslinked. Closed cell foams are made when poly resins are combined with other ingredients and extruded pellets expand to become consistently shaped beads of expanded foam. Closed cell structure foams provide sufficient protection to prevent or minimize the effects of physical abuse, corrosion, temperature extremes, chemical attack, aging, and other adverse conditions. Its softness, resilience, impact strength, anti- abrasion, and strain recovery characteristics make it ideal for continued impact protection even after repeated impacts. Any thickness of base mat may be used, but preferably has a thickness between substantially 50mm (2") and substantially 12mm (1/2"), depending on the required fall height of the project.
  • EPDM Ethylene Propylene Diene Rubber
  • Top mat 103 is preferably made at least partially from rubber, and most preferably from recycled rubber.
  • the top mat may be manufactured from recycled rubber, primarily scrap tires that are ground up to produce a crumb rubber material that is consolidated into a solid surfacing.
  • Other types of top mats such as PVC, carpeting, and synthetic turf (e.g., Astro Turf) may also be used. Any thickness of top mat may be used, but it is preferably 12 mm (1/2") thick.
  • An adhesive 102 is used to secure top mat 103 to base mat 101.
  • adhesive 102 is used to secure top mat 103 to base mat 101.
  • adhesive 102 is used to secure top mat 103 to base mat 101.
  • adhesive 102 is used to secure top mat 103 to base mat 101.
  • adhesive 102 is used to secure top mat 103 to base mat 101.
  • adhesive 102 is used to secure top mat 103 to base mat 101.
  • adhesive 102 is used to secure top mat 103 to base mat 101.
  • adhesive 102 is used to secure top
  • top mat 103 is a polyurethane or polyurea.
  • any adhesive capable of bonding top mat 103 to base mat 102 may be used.
  • Top coat 104 may be any material that provides a protective and/or decorative finish to top mat 104.
  • top coat 104 is a polyurethane or polyurea.
  • Polyurethane (which may be water-based) or polyurea top coats form very wear-resistant barriers and may be water-resistant such that water or environmental wastes do not penetrate.
  • the top-layer coating may be applied in such as a manner that water and environmental wastes are allowed to drain through the surface.
  • the polyurethane or polyurea coating can be cut, for example, with a circular saw, so if there were somehow some damage to a portion of the modular surfacing system, the damage could be cut out and replaced with another section of like material.
  • the topcoat sealant (which may be an adhesive sealant) provides a colorful protective barrier against at least one of: deterioration due to moisture, weathering, UV degradation, and normal wear and tear.
  • the topcoat sealant also has pigments that produce a variety of colors in the adhesive sealant. If desired, a logo or other design may be painted onto the top mat before the topcoat sealant coating is applied, and will be visible after the topcoat sealant coating cures.
  • the polyurea or polyurethane top coat can be applied at room temperature, with a brush, roller, or sprayer, and cures in approximately 45 minutes. If desired, the polyurea, polyurethane, or other sealant can be applied at ambient or an elevated temperature by either spraying, rolling (with a roller), brushing or squeegeeing, and bonds the two surfaces together and produces a durable top coat.
  • the sealant adhesive used between the various layers of the modular surfacing system may or may not be a polyurea or polyurethane.
  • the polyurea used as a topcoat may be an aromatic polyurea, an aliphatic polyurea, an aromatic aliphatic polyurea, a polyurea containing cycloaliphatic structures or combinations thereof.
  • the polyurea When used as an adhesive between the various layers of the modular surfacing system, the polyurea may or may not be the same chemical composition as the polyurea used in the topcoat.
  • the compositions of polyurea may be varied widely from diverse groups of monomeric reactants to produce topcoat surface property characteristics tailored to particular end use requirements such as hardness, stiffness, softness/resiliency/elasticity, anti-skid, abrasion resistance, chemical resistance, and gloss/matte appearance.
  • Top coat 104 may also contain one or more pigments or colorants to add color to the modular surfacing mat. Top coat 104 may also be applied in different manners to provide for different textures (e.g., smooth or rough texture). In some situations, top mat 103 may already have a protective finish, and as such, an additional top coat may not be needed. In addition, some top mats may not be suited for application of an additional top coat.
  • Figures 2 and 3 show examples of modular surfacing mats that do not need a top coat.
  • FIG 2 is a vertical cross-sectional view of a modular surfacing mat with a carpeted top mat in accordance with one embodiment of the invention.
  • Modular surfacing mat 200 includes a base mat 101 and an adhesive 102 as described above with reference to Figure 1.
  • modular surfacing mat 200 includes a carpet layer 203.
  • Carpet layer 203 may be any type of carpeting material. This embodiment is preferably used in indoor settings, but may also be used in outdoor settings.
  • FIG 3 is a vertical cross-sectional view of a modular surfacing mat with an artificial turf top mat in accordance with one embodiment of the invention.
  • Modular surfacing mat 300 includes a base mat 101 and an adhesive 102 as described above with reference to Figure 1.
  • modular surfacing mat 300 includes an artificial turf layer 303.
  • Artificial turf layer 303 may be any type of artificial turf. This embodiment is suitable for both indoor and outdoor use.
  • each base mat and top mat have substantially symmetric horizontal cross sections. In this way, multiple modular surfacing mats may be installed next to each other to create a continuous surface.
  • the modular surface mats of Figures 1 through may be constructed in any shape that allows for multiple mats to be installed together to form a substantially continuous surface.
  • Figure 4 shows examples of shapes of modular surfacing mats according to various aspects of the invention.
  • Modular surface mats 400 are shown to be in a square shape, however any polygonal shape may be used. By constructing the modular surface mats in a square shape, the end user has the flexibility to install the mats in any configuration by cutting the mats to shape.
  • Modular surface mats 401, 408, and 409 are shown in shapes with interlocking tabs and slots.
  • Modular surfacing mat 401 has generally "puzzle-shaped" slots 402 and tabs 403.
  • Modular surfacing mat 408 has generally square-shaped slots 404 and tabs 405.
  • Modular surfacing mat 409 has dovetail-shaped slots 406 and tabs 47.
  • the shapes the surfacing mats show in Figure 4 are exemplary only.
  • FIG. 5 shows vertical cross-sectional views of modular surfacing mats with differing base mat densities in accordance with one embodiment of the invention.
  • modular surfacing mats 100a and 100b have substantially the same thickness of 1 " to 2.1 /4"
  • the closed cell foam is formed with different densities.
  • the foam density is controlled by the amount of foam beads contained within the tool or form when creating the foam.
  • an end user may efficiently install the higher fall-rated (and often more expensive) high density foam mats (e.g., 101a) in places where needed and/or required.
  • the fall height rating of surfaces surrounding certain playground equipment is mandated by state and/or local government. In general, the taller the piece of playground equipment, the higher the fall rating of surfaces that surround the equipment.
  • FIG. 6 shows the arrangement of modular surfacing mats in a modular surfacing system according to one embodiment of the invention.
  • modular surfacing mats with different densities are shown in a playground setting forming a modular surfacing system 600.
  • Crosshatched modular surfacing mats 101a are installed within a predetermined circle around playground equipment 601.
  • Modular surfacing mats 101b are used outside this circle.
  • modular surfacing mats 101a have a higher density base mat than modular surfacing mats 101b, and thus a higher fall height rating. Additional levels of base mat density (and thus fall height rating) could be used for installations where two or more fall height ratings regions are needed.
  • FIG. 7 shows a vertical cross-section of a multiple layer mat according to one embodiment of the invention.
  • modular surfacing mat 700 may include two base mats 101 and two top mats 103. Each layer is secured to the next with adhesive 102, and a top coat 104 is applied to the top.
  • each base mat and top mat may be comprised of different materials to carry out different functions.
  • modular surfacing mat 700 may utilize a base mat that is useful to prevent water accumulation, a first top mat may that is useful to absorb shock and impact, and an additional top mat that has thermally dissipative properties that allow children to play barefoot regardless of the heat or cold of the ground.
  • each layer may have desirable properties and is also sufficiently light-weight to be carried easily to the site.
  • Installation When a modular surfacing mat or system is desired at a site, such as a playground, modular surfacing mats (or their individual components) are carried to the site.
  • the modular surfacing mats may be pre-constructed or may be assembled on site.
  • the site may already have a covering, such as concrete, cement, asphalt, crushed limestone, tile, or linoleum.
  • a covering may be regarded as a substrate on which the modular surfacing system is constructed.
  • the base mat is adhered to the substrate. In many situations, adhering the base mat to the substrate can be effective to prevent the base mat from slipping out of position. If desired, the base mat is secured to the substrate by either bonding with an adhesive sealant or with anchors. On the other hand, if the modular surfacing system is to be used in-doors, then adhering the base mat to a substrate may not be necessary. For example, in a nursing home or daycare center, adhering the base mat to the substrate may be unnecessary.
  • an adhesive sealant may be used.
  • the adhesive sealant is, for example, polyurethane.
  • the adhesive sealant may cover the entire surface between the substrate and the base mat, or may be used in spots, or may be used only on the periphery. A determination of how the adhesive sealant can best be used to adhere the base mat to the substrate should consider environmental conditions that the base mat may encounter.
  • the adhesive sealant also may be selected from the group consisting of pressure sensitive adhesives, adhesives specially designed for the base mat and particular substrate involved, or commercially available adhesives.
  • the modular surfacing system may be constructed to divert rainwater to a periphery of the modular surfacing system, and adhering the base mat to the substrate may be useful to prevent water from accumulating under the base mat.
  • the base mat can be easily trimmed and fitted using either a knife, hand saw or reciprocating saw.
  • the top mat may be placed on the base mat.
  • the top mat is also easily transportable to the site on which the modular surfacing system is desired to be assembled. Because the modular surfacing system is comprised of layers, each layer may be easily carried to the site by one or two laborers, without the weight considerations that might be prohibitive if a single rubber mat were to be used. Also, because the top mat need not be composed of the same material as the base mat, mats may be chosen from different suppliers.
  • the top mat typically is shipped in a roll (for situations where modular surfacing mats are not preconstructed) and is secured over the base mat using an adhesive (e.g., polyurea, polyurethane coating other commercially available adhesives).
  • the top mat like the base mat, can easily trimmed by using either a knife, hand or reciprocating saw. Once the top mat is installed and secured to the base mat, a top coat is applied to bond all materials together.
  • an adhesive may be used to adhere the base mat to the substrate. Additionally, an adhesive may be placed, if at all, at the periphery of each modular surfacing mat. Also, a top surface of a top mat is covered with a top coat (which may be a sealant). Any of these adhesives and top coats may be identical to any of the other adhesives and top coats, or a variety of adhesive and top coats (some adhesive, some not) may be used. The top coat that is used to cover the top surface of the top mat need not be adhesive, since no further mats are to be placed on the top surface of the top mat. Any or all of these adhesives and/or top coats may be polyurea. If desired, polyurea need not be present in the modular surfacing system. The top coat provides several advantages including wheelchair accessibility.
  • the modular surfacing system is comprised of layers, each layer being a mat, the modular surfacing system can be both customized and transported easily.
  • the modular surfacing system can be customized easily, since additional mats can be added. For example, under gymnastics equipment, where athletes may fall while in awkward body positions or with additional velocity, additional layers of mats can be added to exceed mandated and/or recommended safety margins by any desired margin.
  • the mats When multiple mats are used, the mats may be stacked and overlapped. The mats may also be placed along side one another to form a layer (i.e., a first layer), and then other mats are stacked on top of the first layer to form an additional layer. When the mats are placed along side one another, a first seam may exist between adjacent mats within the first layer. The additional layer may have a second seam that is parallel, perpendicular, or diagonal with respect to the first seam (i.e., the seam of the first layer).
  • the base mats are assumed to be of an interlocking design, which does not need to be glued together.
  • the sub-base (substrate) should be compacted and smooth. The sub-base should be without ridges, rolls, or depressions, as the base mats are of uniform thickness.
  • a bad seam will not effect the impact attenuation or the accessibility of the surface, but a bad seam can affect the appearance of the final product.
  • the Top Coat will assist in hiding some bad seams, but attention to this step will produce an "invisible" seam. Avoid getting the adhesive on the surface of the top mats. Interlock and install the second mat so the seam is flush. Do not apply adhesive to the edges of the top mat as this will result in visible seams.
  • the top mat can be cut with either a utility knife or 6" Aviation snips.
  • the utility knife have a titanium blade for easier cutting and longer blade life. For each cut, snap a chalk line first to ensure a straight cut. Be sure to change blades often to keep a neat and clean cut.
  • the top coat is applied.
  • the top coat may be a two-party polyurea such as TuffShellTM Topcoat sealant available from SafeStructure LLC of Solon, OH.
  • TuffShellTM Topcoat sealant is a two-part, technically advanced polymer coating designed to add color, UV resistance, and extra durability to your playground surface. It is extremely durable, is applied at ambient temperatures, and is resistant to most water- and petroleum- based chemicals.
  • the surface temperatures of the playground should be above 5O 0 F, and below 130° F. Surfaces must be completely dry, free of moisture, no bubbles, and clean of any debris.
  • TuffShell Top Coat Sealant is humidity sensitive and therefore cure times vary with locale, time of day and time of year. Although play could resume after two to four hours, we recommend considering the weather conditions, and that heavier applications could prolong the drying time 12- to 24-hours.
  • the modular surfacing system may also be used in manufacturing facilities or other locations where heavy fragile items or people are in danger of falling or colliding, such as flooring under baggage handling areas, parcel handling areas, movie theater aisles, and sidewalks.
  • the modular surfacing system may also be installed vertically, such as on a baseball diamond outfield back wall.

Landscapes

  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Road Paving Structures (AREA)

Abstract

L’invention concerne une surface modulaire qui comprend un mat de base, un mat supérieur fixé au mat de base au moyen d’un adhésif, et un revêtement supérieur appliqué sur la partie supérieure du mat supérieur permettant de former un fini protecteur. Le revêtement supérieur peut être n’importe quel revêtement qui permet un fini protecteur sur le mat, de préférence un polyuréthane ou une polyurée. Le revêtement supérieur peut comprendre un colorant. Le mat supérieur est de préférence composé, au moins en partie, de caoutchouc. Par exemple, du caoutchouc recyclé peut être utilisé. L’adhésif qui joint le mat supérieur au mat de base est de préférence un polyuréthane ou une polyurée. Le mat de base est composé de préférence d’une structure mousseuse cellulaire comme par exemple, des pépites de mousse de polyéthylène à cellules closes fusionnées dans une matrice réticulée.
PCT/US2006/024540 2005-06-22 2006-06-22 Système de surface modulaire WO2007002442A1 (fr)

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
US69324005P 2005-06-22 2005-06-22
US60/693,240 2005-06-22
US72455505P 2005-10-06 2005-10-06
US60/724,555 2005-10-06

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US (1) US20070042828A1 (fr)
WO (1) WO2007002442A1 (fr)

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EP2298996A3 (fr) * 2007-01-19 2012-05-09 Brock International Base de système de gazon
CN102602064A (zh) * 2012-03-12 2012-07-25 欧阳鹰湘 经济型塑胶跑道卷材
US8353640B2 (en) 2008-01-22 2013-01-15 Brock Usa, Llc Load supporting panel having impact absorbing structure
US8662787B2 (en) 2007-01-19 2014-03-04 Brock Usa, Llc Structural underlayment support system for use with paving and flooring elements
FR3019774A1 (fr) * 2014-04-14 2015-10-16 Astrium Sas Piece polygonale a alveoles pour une ame de panneau, en particulier de reflecteur d'antenne de satellite
EP3022451A4 (fr) * 2013-07-18 2016-07-20 Palziv Ltd Connecteur vertical compressible
US10060082B2 (en) 2016-05-18 2018-08-28 Brock Usa, Llc Base for turf system with vertical support extensions at panel edges
USD866800S1 (en) 2015-10-26 2019-11-12 Brock Usa, Llc Turf underlayment
EP3819117A1 (fr) * 2019-11-11 2021-05-12 Turfs Konstgräs i Sverige AB Protection antichute
WO2021214229A1 (fr) * 2020-04-23 2021-10-28 Basf Se Gazon artificiel
RU208580U1 (ru) * 2021-04-26 2021-12-24 Общество с ограниченной ответственностью "ЗЕВС ТЕХНОЛОГИИ" Двухслойная дорожно-тротуарная плитка
WO2022046856A1 (fr) * 2020-08-27 2022-03-03 Newpark Mats & Integrated Services Llc Tapis multicouche
RU2784849C1 (ru) * 2022-03-04 2022-11-30 Пётр Валерьевич Здендяк Плитка дорожно-тротуарная двухслойная

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US8967905B2 (en) 2007-01-19 2015-03-03 Brock Usa, Llc Structural underlayment support system and panel for use with paving and flooring elements
EP2298996A3 (fr) * 2007-01-19 2012-05-09 Brock International Base de système de gazon
US9771692B2 (en) 2007-01-19 2017-09-26 Brock Usa, Llc Base for turf system
US9631326B2 (en) 2007-01-19 2017-04-25 Brock Usa, Llc Underlayment panel having drainage channels
US8568840B2 (en) 2007-01-19 2013-10-29 Brock Usa, Llc Base for turf system
US8597754B2 (en) 2007-01-19 2013-12-03 Brock Usa, Llc Base for turf system
US8603601B2 (en) 2007-01-19 2013-12-10 Brock Usa, Llc Base for turf system
US8662787B2 (en) 2007-01-19 2014-03-04 Brock Usa, Llc Structural underlayment support system for use with paving and flooring elements
US9567714B2 (en) 2007-01-19 2017-02-14 Brock Usa, Llc Structural underlayment support system and panel for use with paving and flooring elements
US8827590B2 (en) 2007-01-19 2014-09-09 Brock Usa Structural underlayment support system and panel for use with paving and flooring elements
WO2009042346A1 (fr) * 2007-09-24 2009-04-02 Dow Global Technologies Inc. Piste synthétique avec couche d'absorption de chocs
US9394651B2 (en) 2008-01-22 2016-07-19 Brock Usa, Llc Underlayment panel having drainage channels
US8967906B2 (en) 2008-01-22 2015-03-03 Brock Usa, Llc Underlayment panel having drainage channels
US8668403B2 (en) 2008-01-22 2014-03-11 Brock Usa, Llc Load supporting panel having impact absorbing structure
US8353640B2 (en) 2008-01-22 2013-01-15 Brock Usa, Llc Load supporting panel having impact absorbing structure
CN102602064A (zh) * 2012-03-12 2012-07-25 欧阳鹰湘 经济型塑胶跑道卷材
EP3022451A4 (fr) * 2013-07-18 2016-07-20 Palziv Ltd Connecteur vertical compressible
US9724618B2 (en) 2013-07-18 2017-08-08 Palziv Ltd. Compressible vertical connector
WO2015158966A1 (fr) * 2014-04-14 2015-10-22 Airbus Defense And Space Sas Pièce polygonale à alvéoles pour une âme de panneau, en particulier de réflecteur d'antenne de satellite
FR3019774A1 (fr) * 2014-04-14 2015-10-16 Astrium Sas Piece polygonale a alveoles pour une ame de panneau, en particulier de reflecteur d'antenne de satellite
US10112363B2 (en) 2014-04-14 2018-10-30 Arianegroup Sas Polygonal part having cavities for a panel core, in particular of a satellite antenna reflector
USD866800S1 (en) 2015-10-26 2019-11-12 Brock Usa, Llc Turf underlayment
US10060082B2 (en) 2016-05-18 2018-08-28 Brock Usa, Llc Base for turf system with vertical support extensions at panel edges
EP3819117A1 (fr) * 2019-11-11 2021-05-12 Turfs Konstgräs i Sverige AB Protection antichute
WO2021214229A1 (fr) * 2020-04-23 2021-10-28 Basf Se Gazon artificiel
WO2022046856A1 (fr) * 2020-08-27 2022-03-03 Newpark Mats & Integrated Services Llc Tapis multicouche
US11712869B2 (en) 2020-08-27 2023-08-01 Newpark Mats & Integrated Services Llc Multilayered mat
RU208580U1 (ru) * 2021-04-26 2021-12-24 Общество с ограниченной ответственностью "ЗЕВС ТЕХНОЛОГИИ" Двухслойная дорожно-тротуарная плитка
RU2784849C1 (ru) * 2022-03-04 2022-11-30 Пётр Валерьевич Здендяк Плитка дорожно-тротуарная двухслойная
RU215433U1 (ru) * 2022-05-30 2022-12-13 Общество с ограниченной ответственностью "ЗЕВС ТЕХНОЛОГИИ" Тактильная плитка
RU2801725C1 (ru) * 2023-02-20 2023-08-15 Общество С Ограниченной Ответственностью "Рекро" Покрытие для площадки общего пользования

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