WO2024006513A1

WO2024006513A1 - Modular floor tile

Info

Publication number: WO2024006513A1
Application number: PCT/US2023/026705
Authority: WO
Inventors: Gerald SALUTI; Michael Potempa; Brian Potempa
Original assignee: Saluti Gerald
Priority date: 2022-06-30
Filing date: 2023-06-30
Publication date: 2024-01-04
Also published as: WO2024006513A4

Abstract

A modular floor tile for indoor and outdoor, residential, commercial and sporting applications includes a top surface, an upper bladder and a lower bladder. The upper bladder and lower bladder have a plurality of truncated pyramids for impact absorption. Further, the bottom bladder has a system of channels to assist in draining water from the area where the tiles are installed. The tiles are suitable to be laid directly on the ground or other subfloor surface. The modular floor tile is suitable for sport playing areas, playgrounds and other outdoor or indoor areas. The modular tile is shock-absorbing and durable. It is less expensive and easier to install than other flooring systems.

Description

MODULAR FLOOR TILE

BACKGROUND

[001] As used herein, the term “playground” refers to play areas, sports areas, sports courts, and similar areas, as well as the traditional playgrounds.

[002] Playground surfaces are critical. Due to the physical activity associated with playgrounds, a reduction of injuries to users can be achieved by decreasing impact forces. There is also a defined need for such surfaces to be easily installed. As always, such surfaces should be economical to manufacture and maintain.

[003] The use of modular surfaces made of synthetic materials has increased for playgrounds. Modular synthetic surfaces are advantageous for several reasons. Such a modular surface may be more easily installed. The modular surfaces tend to be more easily replaced if a portion of the modular surface is damaged.

[004] A second reason for the popularity of modular synthetic surfaces is that they are long- lasting. Unlike other alternatives, such as asphalt and concrete, modular surfaces generally absorb impacts better, resulting in less risk of injury if a person falls on the elastomer or rubber material. Additionally, the modular surface requires little maintenance.

[005] While various modular surfaces are available for playgrounds, there are problems. Installation is complicated by the need to secure the modular surface to the existing subsurface. Bolts are sometimes required to fasten the modular surface to the subsurface, which may increase the cost of installation. Suppose an adhesive is used to secure the modular surface to the subsurface. In that case, workers installing the modular surface might inadvertently track the adhesive across the modular surface.

[006] Current modular surfaces used on playgrounds have uniform impact absorption properties across the installed modular surface. However, areas of the playground may have different requirement for impact absorption. For example, a maze may not need the same impact absorption characteristics as the area under a climbing wall. Additionally, the top of the modular surface may need different characteristics dependent upon the function of an area of the modular surface.

[007] Current modular surfaces for playgrounds come in a variety of colors and patterns. However, the colors or patterns are integral with the entire tile rather than only the surface of the tile, thereby increases the cost of a tile.

SUMMARY OF THE INVENTION

[008] The invention hereinafter described is for a modular tile for use in creating a modular surface for a play ground. The modular tile separates the top layer design and manufacture from the bottom impact absorption assembly. The top layer could be thermoformed.

Alternatively, the top layer could be extruded using an embossing roll so the surface will be extruded with a top layer design formed in.

[009] Thus, the lower impact absorption assembly can be optimized for fall height safety as defined by the particular use for the modular tile, while the top layer can have a material with non-skid properties as well as a more pleasing feel. Additionally, the top layer can be made of different colors, thus making the playground more aesthetically pleasing.

[0010] The invention further provides for injection molding of the bottom impact absorption assembly while thermoforming the top layer, lowering tool costs and reducing manufacturing costs.

[0011] The impact absorption layer may be composed of two injection molded one-foot squares. The two one-foot squares could be heat bonded together, one on top of the other. Thus, the design of the impact absorption structure could provide for maximum energy absorption in case of surface impact with the modular tile. This also allows for lower cost tooling and fast injection cycles compared to other manufacturing techniques for modular surfaces, thereby providing lower-cost manufacturing.

[0012] Utilizing thermoplastic raw materials for both top and the impact absorption assembly would make the modular tiles of the instant invention completely recyclable. Modular tiles, when retired from a playground, could be ground up and used to produce new modular tiles, thus resulting in 100% recovery and reuse of old tiles.

[0013] Utilizing thermoplastic materials creates a modular tile that will not shrink or change in shape in long term use. Compression molded cross-linked natural rubber or EPDM (ethylene propylene diene monomer) cross-linked rubber parts will shrink and distort over time when exposed to heat and cold in use.

[0014] The modular tiles of this invention utilize interlocks such as fingers at the top and bottom of each modular tile. The finger interlock is designed for easily locking in place the modular tiles during installation. When the modular tiles are engaged on all four sides, the modular tile will be firmly interlocked, and will stay firmly interlocked for a long time after installation.

[0015] The top facet and the bottom facet of the energy absorption assembly of the modular tile have flat contours. The flat contour of the bottom facet of the energy absorption assembly allows a significant portion of the energy absorption assembly to be in contact with the subsurface. If the subsurface is asphalt, concrete or other similar material, the modular tile may be affixed to the subsurface by the use of adhesives such as, for example, poly acrylic, polyether, epoxy or polyurethane adhesives. The design of the bottom facet of the modular tile allows adhesive to be rolled onto the bottom facet, but need not be applied to the subsurface. The ability to bond the thermoplastic tile to the subsurface in this manner eliminates the need to attach the tile to the asphalt or concrete using bolts, thus increasing the functional and aesthetic properties of the modular tile. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] FIG. 1 shows a modular tile.

[0017] FIG. 2 is a side view of the modular tile of FIG 1.

[0018] FIG. 3 shows an exploded view of the modular tile shown in FIG. 1.

[0019] FIG. 4 is top view of a bladder of the modular tile of FIG. 1

[0020] FIG. 5 is the bottom view of the bladder.

[0021] FIG. 6 is a side view of the bladder.

[0022] FIG. 7 is a top view of a four-cell cluster of the bladder.

[0023] FIG. 8 is a bottom view of the four-cell cluster.

[0024] FIG. 9 is a side view of the four-cell cluster.

[0025] FIG. 10 is a side view of an energy absorption assembly used in the modular tile of FIG. 1.

[0026] FIG. 11 is an exploded view of a different configuration for the modular tile of FIG.

1.

[0027] FIG. 12 is a second embodiment for a modular tile.

[0028] FIG. 13 shows a side exploded view of the modular tile of FIG. 12.

[0029] FIG. 14 shows a perspective view of the upper bladder and the lower bladder of the modular tile shown in FIG. 13.

[0030] FIG. 16 shows a bottom view of the upper bladder of the modular tile shown in FIG.

13.

[0031] FIG. 17 shows a perspective view of a portion of the upper bladder of the modular tile shown in FIG. 13.

[0032] FIG. 18 is a side view of the lower bladder of the modular tile shown in FIG. 13.

[0033] FIG. 19 is a top view of the lower bladder of the modular tile shown in FIG. 13.

[0034] FIG. 20 is the bottom view of the lower bladder of the modular tile shown in FIG. 13. DESCRIPTION OF EMBODIMENTS

[0035] FIG. 1 shows a modular tile 10. The modular tile 10 could be used for the surface for playgrounds or other areas where a cushioned surface is desired. FIG. 2 is a side view of the modular tile 10.

[0036] The modular tile 10 has a top surface 12, a first bladder 14 and a second bladder 16. The first bladder 14 and the second bladder 16 are identical in construction. However, the second bladder 16 is inverted when attached to the first bladder 14. When the first bladder 14 and the second bladder 16 are attached, they form an energy absorption assembly 15 (See. FIG. 10)

[0037] The top surface 12 could be made by injection molding and composed of a suitable thermoplastic. The upper side 18 of the top surface 12 could have an anti-skid texture. A design could also be imprinted in the upper side 18 of the top surface 12.

[0038] FIG. 3 shows an exploded view of the modular tile 10

[0039] FIGs. 4, 5 and 6 show a bladder 20. (FIG 6 is shown on the same page as FIG. 4). Bladder 20 is representative of both the first bladder 14 and the second bladder 16. FIG. 4 is top view of the bladder 20. FIG. 5 is the bottom view of the bladder 20. FIG. 6 is a side view of the bladder 20. As can be easily seen, the bladder 20 is composed of a plurality of cells. [0040] FIGs. 7, 8, and 9 show a four-cell cluster 30. FIG. 7 is a top view of the four-cell cluster 30. FIG. 8 is a bottom view of the four-cell cluster 30. FIG. 9 is a side view of the four-cell cluster 30.

[0041] The description that follows makes reference to FIGs. 7, 8, and 9. Each cell 31 has a generally truncated trapezoidal pyramid 32. The base of the truncated trapezoidal pyramid 32 has a pair of holes 34. The exterior of the truncated trapezoidal pyramid 32 additionally has a pair of pegs 36 extending in a generally perpendicular direction from the base of the truncated trapezoidal pyramid 32. For each cell, the pair of pegs 36 are aligned such that a line passing through both pegs 36 for that cell are perpendicular to a line passing through both holes 34 for that cell. The pegs 36 are tapered at the end, while the body of the pegs 36 is slightly larger than that of the holes 34.

[0042] At assembly, the second bladder 16 is inverted such that the top of the truncated trapezoidal pyramid 34 is up. The first bladder 14 is rotated and set on top of the second bladder 16 such that the pegs 36 of the first bladder 14 are aligned with the holes 34 of the second bladder 16. Similarly, the pegs 36 of the second bladder 16 are aligned with the holes 34 of the first bladder 14. When pressure is applied, the pegs 36 are inserted into the holes 34 and become fixed within the holes 34.

[0043] As stated previously, when the first bladder 14 and the second bladder 16 are connected, they form an energy absorption assembly 15. The energy absorption assembly 15 can be connected to other bladder assemblies by using a plurality of fingers 50.

[0044] Returning to FIGs. 4, 5, and 6, the bladder 20 has a plurality of fingers 40 extending from two edges of the bladder 20. While the drawings show the fingers 40 extending from consecutive edges of the bladder 20, it is understood that different configurations would be possible. The fingers 40 are flexible and bendable. The fingers 40 extend from the cells 31 located on the two edges of the bladder 20. The cells 31 located on the edge of the bladder 20 have one or more sides adjacent to the edge of the bladder 20 but do not have a finger have an indentation 50. The indentations 50 are of such size and configuration that they can receive a finger 40.

[0045] When it is desired to connect two energy absorption assemblies 15 together, the fingers 40 of a first energy absorption assembly are aligned with the indentations 50 of a second energy absorption assembly. When pressure is applied, the fingers 40 deform and are urged into the indentations 50. The fingers thus become sturdily fixed within the indentations [0046] This interlocking mechanism of the fingers 40 and the indentations 50 allows easy installation. When a modular tile 10 is to be installed next to a second modular tile 10, the edge of one energy absorption assembly 15 is placed at a slight angle to the juxtaposing edge of the second energy absorption assembly 15. The second bladders 16 of the two energy absorption assemblies 15 interlock by way of fingers 40. Then, by pushing dow n on the first bladder 14, the top fingers 40 interlock and the two bladder assemblies 15 are firmly connected. With the energy absorption assemblies 15 thus connected, it is very difficult to separate the energy absorption assemblies 15, and thereby the modular tiles 10.

[0047] The fingers 40 and indentations 50 can be designed into edge pieces and ramps so that there are no points of potential separation over the entire surface.

[0048] FIG. 10 shows the energy absorption assembly 15. As explained previously, the energy absorption assembly 15 is made by firmly attaching the first bladder 14 to the second bladder 16. The energy absorption assembly 15 has an upper facet 70 and a lower facet 72. The top surface 12 is attached to the upper facet 70. Heat bonding or an adhesive could be used to secure the top surface 12 to the upper facet 70.

[0049] The lower facet 72 has a flat contour and, as seen in FIG. 4, has a substantial surface area. Due to the significant surface area of the lower facet 72, the energy absorption assembly 15 may be attached to an asphalt or concrete base surface by using epoxy or polyurethane adhesives. The design of the lower facet 72 allows a sealant to be rolled onto the energy absorption assembly 15 only and not onto the base surface. This provides for efficient and speedy installation, thereby reducing installation costs. Also, there is less tracking of adhesive onto the surfaces.

[0050] The ability to bond the energy absorption assembly 15, and thus the entire modular tile 10, to the base surface eliminates the need to physically attach the tile to the subsurface using bolts. By using adhesives rather than bolts, the labor is considerably reduced because there is no need to drill bolt holes into the modular tile 10, fill the bolt holes with epoxy, and then install the bolts. Consequently, there is no need to mold the modular tile 10 with bolt holes, thus improving the aesthetics and reducing the potential of fall injuries by contact with the bolts.

[0051] Returning to FIGs. 4 and 5, there are a plurality of access holes 60 located on the top surface of the bladder 20. These access holes 60 allow the insertion of heating elements to thermally bond the first bladder 14 and the second bladder 16, thereby forming an energy absorption assembly 15. The thermo bonding of the first bladder 14 and the second bladder 16, along with the hole and peg assembly previously described creates an extremely stable and sturdy structure.

[0052] The access holes 60 serve an additional purpose. In the event of rain, the access holes 60 allow water to drain through the energy' absorption assembly 15. The water then flows into channels 62. The channels 62 then can be used to guide the water out of the modular tile 10.

[0053] The bladder 20 can be manufactured from a thermoplastic rubber such as Santoprene. By choosing different types of thermoplastic rubber, the energy absorption characteristic of the modular tile 10 can be altered. Thus, the modular tile 10 can be manufactured with a unique absorption characteristic for a specific application. E.g., a modular tile 10 for use in a maze could be less energy absorbing than a similar modular tile 10 for use near a climbing tower.

[0054] The separation of top surface 12 from the energy' absorption assembly 15 allows the top surface 12 and the bladder 20 to be separately designed and manufactured. Thus, the bladder 20 can be made of a cushioning layer material that gives maximum energy absorption for fall height safety, while the top surface 12 can use a material that gives better non-skid and soft feel for children. [0055] The bladder 20 can be injection molded, while the top surface 12 can be thermoformed, allowing for lower cost tools and lower manufacturing costs.

[0056] Customers often desire different color top surface 12. Because the bladder 20 cannot be seen in use, the color of the bladder 20 is irrelevant. The same color bladder can be used on all different colored top surfaces 12.

[0057] Because the bladder 20 cannot be seen, the top surfaces 12 can be manufactured and inventoried separately. Different color top surfaces 12 can be maintained in inventory, and the modular tiles 10 can be produced on demand by heat bonding the top surfaces 12 to the bladder 20 or the energy absorption assembly 15. Much lower inventory costs will result in faster turnaround time for orders.

[0058] Because the energy absorption assembly 15 is composed of two bladders 20 which are heat bonded together, low-cost tooling and fast injection cycles can be utilized for manufacture.

[0059] It is possible to use thermoplastic materials for both the energy absorption assembly 15 and the top surface 12. If so, then the tile would be completely recyclable. Thus, the entire modular tile 10 could be ground up and used to produce new modular tiles 10, resulting in 100% recovery and reuse of old modular tiles 10.

[0060] Using thermoplastic materials, the modular tile 10 will not shrink or change in shape in long-term use. On the other hand, compression molded cross-linked natural rubber or EPDM cross-linked rubber parts will shrink and distort over time when exposed to heat and cold in use.

[0061] FIG. 11 shows an alternative construction where four energy absorption assemblies 15 are used with a larger top surface 80. [0062] Another embodiment of the modular tile is show n in FIG. 12. This configuration may, in some applications, provide an advantage over the previous embodiment. FIG. 13 shows a side-exploded view of the modular tile 100.

[0063] The embodiment in FIG. 12 has a different method of attaching the upper bladder and the lower bladder, which may, in some applications, provide an advantage over the previous embodiment. FIG. 13 shows a side-exploded view of the modular tile 100.

[0064] Referring to FIG. 13, the modular tile 100 includes a top surface 102, an upper bladder 104 and a lower bladder 106. The top surface 102 can be molded with a variety' of different textures or patterns. The top surface 102 could be embossed with a thatch pattern. However, any pattern could be embossed on the top surface 102.

[0065] FIG. 14 shows a perspective view of the upper bladder 104 and the lower bladder 106. FIG. 1 shows a top view of the upper bladder 104. FIG. 16 shows a bottom view of the upper bladder 104. FIG. 17 shows a perspective view of a portion of the upper bladder 104.

[0066] Referring to FIGs. 15, 1 and 17, the upper bladder 104 is comprised of a plurality of interior cells 110 and a plurality of edge cells 112. For clarity in the figures, not all cells are labeled. In FIGs. 16 and 17, there are sixteen interior cells 110 shown, and twenty exterior cells 112 shown. As can be easily understood, different bladders may contain a different number of interior cells 110 and exterior cells 112. The exterior cells 112 are located at the edge of the first bladder 102 while the interior cells 114 are contained within the penmeter formed by the exterior cells 112.

[0067] Each of the exterior cells 112 and the interior cells 114 have a generally truncated trapezoidal pyramidal structure. Each exterior cell 112 and each interior cell 114 have a hole 116 in the center of the cells 112, 114. Each exterior cell 112 and each interior cell 114 have a downwardly extending nipple 118, as shown in FIG. 13. [0068] The exterior cells 112 have a stabilizer 120 within the exterior cells 112. In this particular embodiment, the stabilizer 120 has the general shape of an X, with the hole 116 extending through the center of the stabilizer 120. As is well understood, the stabilizer 120 could have different shapes other than that of an X.

[0069] The exterior cells 112 have either a male attachment means 122 or a female attachment means 124. In the shown embodiment, the male attachment means 122 are configured as tabs. However, other configurations for the male attachment means 122 are possible. Similarly, the female attachment means 124 are slots of suitable size and shape for receiving the male attachment means 122.

[0070] In use, the male attachment means 122 for a first upper bladder 104 are inserted into the female attachment means 124 for a second upper bladder 104. This attachment securely fastens the two upper bladders together. In this manner, a plurality of upper bladders 104 could be secured together, thus allowing the formation of a surface of various shapes and sizes.

[0071] FIGs. 18, 19 and 20 show the lower bladder 106. FIG. 18 is a side view of the lower bladder 106. FIG. 19 is a top view of the lower bladder 106. FIG. 20 is the bottom view of the lower bladder 106.

[0072] The lower bladder 106 is composed of a plurality of lower bladder cells 130. Each of the plurality of lower bladder cells 130 has a generally truncated trapezoidal pyramidal structure. In the center of each of the plurality of lower bladder cells 130 is a hole 132.

[0073] The lower bladder 106 includes a network of channels 134 connecting each of the plurality of the lower bladder cells 130. The channels 134 form a grid on the lower bladder 106. The network of channels 134, along with the holes 132, allows water to drain through the modular tile 100. That is, if there is rain, the water passes through the holes 132 and then through the network of channels 134. If the modular tile 100 is properly position, the water will drain from the modular tile 100.

[0074] The modular tile 100 is assembled by placing the upper bladder 104 onto the lower bladder 106. A heating element is inserted into the holes 116, 132, and the upper bladder 104 is heat welded onto the lower bladder 106. As shown in FIG. 12, the cells of the upper bladder 104 and the lower bladder 106 thus form a series of cushioning elements characterized by a plurality of inverted truncated pyramid resting on a plurality of upright truncated pyramid.

[0075] The placement of a plurality of inverted truncated pyramids provides exceptional shock absorption, thereby reducing the danger to users playing on the tile surface.

[0076] The preceding detailed description describes the embodiment with reference to specific exemplary embodiments. However, it will be appreciated that various modifications and changes can be made without departing from the scope of the present invention. The detailed description and accompanying drawings are to be regarded as illustrative rather than restrictive. All such modifications or changes, if any, are intended to fall within the scope of the present invention as described and set forth herein.

Claims

1. A modular thermoplastic floor tile comprising an upper bladder and a lower bladder.

2. The modular floor tile of claim 1 further comprising a top surface, and where the upper bladder has an upper bladder shock absorption means and the lower bladder has a lower bladder shock absorption means.

3. The modular thermoplastic floor tile of claim 3where the upper bladder shock absorption means has a truncated pyramidal shape and the lower bladder shock absorption means has a truncated pyramidal shape.

4. The modular thermoplastic floor tile of claim 3 where the upper bladder is aligned with the lower bladder such that the upper bladder shock absorption means abut the lower bladder shock absorption means.

5. The modular thermoplastic floor tile of claim 4 where the lower bladder has a network of channels for allowing liquid to drain from underneath the modular tile.

6. The modular thermoplastic floor tile of claim 5 where the upper bladder has at least four sides and a plurality of male attachment means extends from two of the four sides.

7. The modular thermoplastic floor tile of claim 6 where the upper bladder includes a plurality of female attachment means within two sides other than the sides with the male attachment means extending therefrom, the female attachment means being capable of receiving the male attachment means.

8. The modular thermoplastic floor tile of claim 7 where some of the upper bladder cells have a stabilizer within the shock absorption means.

9. A method of manufacturing a modular thermoplastic floor tile comprising extruding an upper surface, injection molding a lower bladder, injection molding an upper bladder, attaching the lower bladder to the upper bladder by heat welding, and attaching the top surface to the upper bladder.

11 . The method of claim 10 where the top surface is attached to the upper bladder by an adhesive.

12. The method of claim 10 where the top surface is attached to the upper bladder by heat bonding.

13. A modular thermoplastic floor tile comprising an upper surface, an upper bladder, and a lower bladder, where the upper bladder has attachment means for securing the thermoplastic floor tile to another thermoplastic floor tile.

14. The thermoplastic floor tile of claim 11 where the attachment means comprises a plurality of tabs and a plurality of slots.

15. The thermoplastic floor tile of claim 12 where the plurality of tabs are located on the perimeter of the thermoplastic floor tile and the plurality of slots are located on the perimeter of the thermoplastic floor tile.

16. The thermoplastic floor tile of claim 11 where the lower bladder has a plurality of channels located at the bottom of the lower bladder.

17. The thermoplastic floor tile of claim 14 where the channels form a grid on the bottom of the lower bladder.

18. The thermoplastic floor tile of claim 15 where the lower bladder has a plurality of channels forming a grid at the bottom of the lower bladder.

19. The thermoplastic floor tile of claim 16 where the upper bladder has an upper bladder shock absorption means and the lower bladder has a lower bladder shock absorption means.

20. The thermoplastic floor tile of claim 17 where the upper bladder shock absorption means has a truncated pyramidal shape and the lower bladder shock absorption means has a truncated pyramidal shape.