PROTECTIVE GROUND COVER SYSTEM

Abstract

A protective ground cover system for reducing the impact of a fall onto a surface, said system including a first layer of loose fill material placed on or in the ground at an impact zone; at least one supporting layer, wherein each layer has open channels adapted to be filled by loose fill material and to enable fluid to pass there through, the at least one supporting layer positioned over the first layer; a second layer of loose fill material having a thickness less than the first layer and being placed on the at least one supporting layer, wherein the protective ground cover system substantially prevents displacement of the loose fill material away from the impact zone.

Description

BACKGROUND OF THE INVENTION

The present invention relates to protective ground coverings and, more particularly, to a protective ground cover system for impact zones.

The protective ground cover under and around playground equipment (impact zones) is one of the most important factors in reducing the likelihood of serious injuries from a fall. Such areas include underneath swings, monkey bars and slides, particularly at the base of the slide. Either unitary protective mats or loose fill can be used as supportive surfacing to provide such a safe environment for children. Critically, the support surfacing has to be at a particular depth and maintained at that depth for a given critical height that a child may accidently fall from while playing on any playground equipment. However, maintaining such impact zone's ground cover can be challenging because playground surfaces frequently become worn in a short period of time because of the high traffic and the nature of the activity. Over time, children's feet displace or kick out particulate or loose fill material, such as wood chips, originally set in place to provide additional protection for the child's fall. Similarly such high traffic and activities tend to degrade unitary protective mats currently used in impact zones.

Unitary protective mats are much more expensive than loose fill material because of the material used and the effort required in the former's construction and installation. Notably, the unitary mats, because of the necessities of construction and installation, may be used to cover even non-impact zones, further heightening their overall cost. The problem with the less expensive loose fill material, as mentioned above, is that it can quickly be displaced over time and so becomes costly to maintain (the required depth) and replace the loose fill material.

As can be seen, there is a need for a system that combines the low cost of installing loose fill material while preventing its maintenance costs.

SUMMARY OF THE INVENTION

In one aspect of the present invention, a protective ground cover system for reducing the impact of a fall onto a surface defined by an impact zone, comprises: a first layer of loose fill material having a predetermined first thickness, wherein the first layer is placed on the surface; at least one supporting layer, each supporting layer comprising: a substantially flat sheet having a plurality of open channels, each channel having an upper opening at an upper surface of the sheet and a corresponding lower opening at a lower surface of the sheet, thereby enabling loose fill material to be retained therein and enabling fluid to flow there through, wherein the at least one supporting layer lays over the first layer; and a second layer of loose fill material having a predetermined second thickness, wherein the second layer is placed on the at least one supporting layer, whereby the protective ground cover system substantially prevents displacement of the loose fill material away from the impact zone.

In another aspect of the present invention, method of forming a protective ground surface for reducing the impact of a fall onto a surface defined by an impact zone, comprises the steps of: forming a first layer of loose fill material on or in the surface; placing at least one supporting layer over the first layer, each supporting comprising: a substantially flat sheet having a plurality of open channels, each channel having an upper opening at an upper surface of the sheet and a corresponding lower opening at a lower surface of the sheet, thereby enabling loose fill material to be retained therein and enabling fluid to flow there through, wherein the at least one supporting layer lays over the first layer; and forming a second layer of loose fill material of a predetermined thickness over the at least one supporting layer, whereby the placement of the protective ground surface substantially prevents displacement of the loose fill material away from the impact zone.

In yet another aspect of the present invention, a supporting layer for substantially preventing displacement of the loose fill material away from a surface, comprises: a substantially flat sheet having a plurality of open channel, each channel having an upper opening at an upper surface of the sheet and a corresponding lower opening at a lower surface of the sheet, thereby enabling loose fill material to be retained therein and enabling fluid to flow there through, and wherein the spacing of the channels and the area of the upper openings thereof result in the upper surface comprising a plurality of ridges extending along the support layer in at least two directions thereby forming a grid, whereby the plurality of ridges provide a non-skid surface for retaining loose fill material engaging the plurality of ridges.

These and other features, aspects and advantages of the present invention will become better understood with reference to the following drawings, description and claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an exemplary playground, illustrating the impact zones where an exemplary embodiment of the present invention may be cost effectively utilized, as compared to providing a unitary protective mat to substantially cover the playground;

FIG. 2 is a plan view of an exemplary embodiment of the present invention;

FIG. 3 is a detailed perspective view of an exemplary embodiment of a at least one supporting layer of the present invention;

FIG. 4 is a side view of an exemplary embodiment of the at least one supporting layer of the present invention; and

FIG. 5 is a plan view of an exemplary embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

The following detailed description is of the best currently contemplated modes of carrying out exemplary embodiments of the invention. The description is not to be taken in a limiting sense, but is made merely for the purpose of illustrating the general principles of the invention, since the scope of the invention is best defined by the appended claims.

Broadly, an embodiment of the present invention provides a protective ground cover system for reducing the impact of a fall onto a surface, said system including a first layer of loose fill material placed on or in the ground at an impact zone; at least one supporting layer, wherein each layer has open channels adapted to be filled by loose fill material and to enable fluid to pass there through, the at least one supporting layer positioned over the first layer; a second layer of loose fill material having a thickness less than the first layer and being placed on the at least one supporting layer, wherein the protective ground cover system substantially prevents displacement of the loose fill material away from the impact zone.

Referring to FIGS. 1 through 5, the present invention may include protective ground cover system 100 for impact zones. The ground cover system 100 may include at least one supporting layer 15, a first layer of fill material 32 and a second layer of fill material 33.

Impact zones of a playground 11 may be disposed under and around playground equipment, such as but not limited to a swing set 12, a climbing frame 13 (monkey bars) and a slide 14, as illustrated in FIG. 1. Impact zones typically provide surfacing comprising loose fill material, such as wood chips, wood mulch, wood fiber, sand, shredded rubber mulch, pine bark and the like, over the top of a harder ground 31. The loose fill material is designed to cushion any impact of a child's fall. However, impact zones not only circumscribe falling hazards but may also be areas of heavy wear, such that particulate material is kicked out and dispersed. For example, underneath the swing sets 12, underneath the climbing frame 13 and underneath the slide 14 particularly at the ladder end and at the bottom of the slide. In impact zones where the loose fill material may be kicked out, resulting in its diminished depth, the risk of serious injury to a fallen child increases.

Each supporting layer 15 may be a substantially flat sheet providing a plurality of first channels 20 and smaller second channels 25 there through. Each channel 20, 25 may have an upper opening at the upper surface of the at least one supporting layer 15 and a lower opening at the lower surface of the at least one supporting layer 15. The upper openings and lower openings can be substantially, oval, square, circular or other geometric shapes. Each upper opening has an area greater than the area of its complementary lower opening. The difference in area restricts the flow of loose fill material through each first channel 20, 25. Each channel 20, 25 may form a seat 21, 26 bounded by a sidewall 22, wherein the seat 21, 26 defines the lower opening and the sidewall 22 defines the upper opening, both defining a hollow space or cavity 28 there between. The cavities 28 are designed to house some of the particulate material from the surface of the playground and prevent or substantially reduce the movement of the particulate material when it has heavy use around playground equipment. The presence of the seat 21, 26 bearing the weight of loose fill material in their complementary cavity 28 generally prevents the support layer 15 from moving, especially when the loose fill material about its upper layer may be significantly diminished.

Arrangement of channels 20, 25 on a two-dimensional lattice pattern sufficiently close together results in the upper surface of the at least one supporting layer 15 comprising a plurality of elongated ridges 24 formed within walls 23 separating adjoining channels 20, 25. The two-dimensional lattice pattern results in these ridges 24 extending along the at least one supporting layer 15 in at least two directions to form a grid. The grid also provides a non-slip or non-skid surface for foot traffic and/or as a means to retain loose fill material. The arrangement of the fluid channels 20, 25 or ridges 24 may be altered in any suitable way so as to achieve desired non-skid, retention of other frictional properties for the upper surface of the at least one supporting layer 15. Adjacent ridges 24 may define a small recess 29 between their lengths. The channels 20, 25 may be arranged on the at least one supporting layer 15 in any suitable way. The complementary openings in concert with the ridges 24 are adapted to substantially eliminate accumulation of fluid on the upper surface of the supporting surface 15. Such alterations or adaptations shall fall within the scope of the present disclosure or appended claims.

The at least one supporting layer 15 may be made from EPDM rubber, SBR rubber, other geo textile material, energy-absorbing material, or any combination thereof. The at least one supporting layer 15 may be formed in any suitable way, including but not limited to molding, casting, stamping, extrusion, milling, 3D-printing or the like. In certain embodiments, the at least one supporting layer 15 may have a layer thickness of between about 20 mm/1″ and 30-mm/1¼″. The thickness can be 300 mm/12″ or more if children are playing on something that is very high. The impact absorbance for 200 mm is about 8″ so if the play equipment is 4.57 meters/15 feet or higher than the thickness needs to be expanded to keep them safe. In other embodiments, the layer thickness may be any suitable thickness.

Referring to FIG. 4, the protective ground cover system 100 may be mounted in the ground 31 in a playground area 11 or any other area in which there is potential for a person to fall from a height onto the ground. A series of metal rods or poles 34 are hooked onto a respective cable tie 35 through a hook 36 near a corner of the at least one supporting layer 15. Each of the rods 34 may be made of steel or other suitable material, and can be any suitable length.

The first layer of fill material 32 may be formed by placing loose fill material on a ground surface 30 defined by a trench or cavity 37 that may be dug out underneath the play equipment at the impact zone to a predetermined first thickness of between 100 mm (4″) and 200 mm (7″ ⅞″), preferably between 150 mm (6″) and 200 mm (7″ ⅞″) (shown as thickness B in FIG. 4). The predetermined first thickness can be 300 mm/12″ or more if children are playing on something that is very high. The impact absorbance for 200 mm is about 8″ so if the play equipment is 4.57 meters/15 feet or higher than the thickness needs to be expanded to keep them safe. In an alternative embodiment, a trench is not dug out and instead a layer of particulate material is formed of indefinite dimensions.

After the first layer of fill material 32 is formed the at least one supporting layer 15 may be laid over the top of the first layer 32 with each of the rods 34 driven into the ground 31. Sufficient length of each rod 34 exists in the ground 31 (shown as depth C in FIG. 4) and sufficient length is located above the ground surface 30 (slightly less than B), adjusted to the actual thickness of B. The ends of the rods 34 at which the hook 36 is located remains in a location underneath the bottom surface of the at least one supporting layer 15 for safety purposes, whereby a child would not inadvertently be able to touch or be injured by the hook 36 or the rod 34. Each of the cable ties 35 are loosely connected to a nearest channel 20, 25 to near each corner of the at least one supporting layer 15. The rods 34 may therefore keep the at least one supporting layer 15 in its original position despite the movement and pressure applied by high usage areas in the vicinity of the playground equipment.

Once the at least one supporting layer 15 is positioned in place, the second layer of fill material 33 may be formed by placing loose fill material over the top of the at least one supporting layer 15 (shown as thickness A in FIG. 4). The second layer of fill material 33 put on top of the layer 15 may be either kicked off or knits into the openings 27 and cavities 28 created by the channels 25, 20 and this binds the whole loose fill material together and makes it difficult to move or displace the fill material over time amid high usage. Usually a predetermined second thickness of the second layer of fill material 33 is about 2″ as the first layer of fill material 32 under the layer 15 in combination with the the layer 15 itself provides the most protection (impact absorbance) of a fallen child. In an alternative embodiment, the predetermined second thickness may be any suitable thickness.

A method of using the present invention may include the following. A protective ground cover system as disclosed above may be provided. A user may initially dig out a small pit 37, as mentioned previously to a depth of 100 mm (4″) to 200 mm (7″ ⅞″) preferably between 150 mm (6″) to 200 mm (7″ ⅞″) in the desired impact zone around the playground equipment. The rods 34 are then secured near each corner of the at least one supporting layer 15 to the cable ties 35 and the first layer of fill material 32 may be added into the trench 37. The at least one supporting layer 15 may then be placed over the layer 32 and the rods 34 are driven into the ground 31 to sufficient depths. In certain embodiments the sufficient depth may be of 4″ to 6″. The second layer of fill material 33 may then be placed over the top of the at least one supporting layer 15.

FIG. 5 shows two at least one supporting layers 15 that can be joined together by cable ties 35, along adjacent sides, through convenient channels 20 or 25 on adjoining at least one supporting layers 15. A plurality of at least one supporting layers 15 may be required to be tied together in situations, for example, underneath the climbing frame 13 shown in FIG. 1 or underneath swings 12. The plurality of at least one supporting layers 15 may be laid on a generally shared surface in a side-by-side arrangement. As many cable ties 35 as are needed can be used to joint two or more at least one supporting layer 15 together. Typically two to three cable ties are used along the sides of adjoining at least one supporting layer 15.

The supportive ground cover system 100 was tested by TÜV SÜD America and meets the requirements of U.S. Consumer Product Safety Commission standards ASTM F1292-09. According to TÜV SÜD America the test samples exceeded the maximum capabilities of the test equipment and met the requirements specified in ASTM F1292-09 for a 15 foot impact height.

The system 100 has been tested with a depth of 200 mm/8″, with the first layer 32 of 150 mm/6″ of loose fill pine chip material, a rubber at least one supporting layer 15 and the second layer 33 of 50 mm of loose fill pine chip material, the critical fall height (for example from on top of monkey bars or a climbing frame 13) was 3.1 meters. The same critical fall height was achieved without the use of the supporting surface 15, that is, just with a 200 mm/8″ layer of loose fill pine or wood chip material. This shows that the softfall properties of the loose fill material are maintained with the presence of the at least one supporting layer 15, as the at least one supporting layer 15 retains the particulate material in place such that it is lessens the effect of dispersion of the material (particularly in the first layer 32) away from heavy foot traffic areas, and allows recovery of some surface material displacement caused by various impacts due to the elastic recovery response of the at least one supporting layer 15. If for some reason the second layer 33 is moved over time, the at least one supporting layer 15 retains the first layer 32 of particulate material in place to meet the softfall and surfacing requirements. It is also found that the recommended installation depth for the loose fill material is reduced with the addition of the retention at least one supporting layer 15.

It should be understood, of course, that the foregoing relates to exemplary embodiments of the invention and that modifications may be made without departing from the spirit and scope of the invention as set forth in the following claims.

Claims

1. A protective ground cover system for reducing the impact of a fall onto a surface defined by an impact zone, comprising: a first layer of loose fill material having a predetermined first thickness, wherein the first layer is placed on the surface;at least one supporting layer, each supporting layer comprising: a substantially flat sheet having a plurality of open channels, each channel having an upper opening at an upper surface of the sheet and a corresponding lower opening at a lower surface of the sheet, thereby enabling loose fill material to be retained therein and enabling fluid to flow there through, wherein the at least one supporting layer lays over the first layer; anda second layer of loose fill material having a predetermined second thickness, wherein the second layer is placed on the at least one supporting layer,whereby the protective ground cover system substantially prevents displacement of the loose fill material away from the impact zone.

2. The system of claim 1, wherein the predetermined second thickness has a thickness less than the predetermined first thickness.

3. The system of claim 2, wherein the predetermined first thickness is between about 100 mm and about 200 mm.

4. The system of claim 2, wherein the predetermined second thickness is at least 40 mm.

5. The system of claim 1, wherein the spacing of the channels and the area of the upper openings thereof result in the upper surface comprising a plurality of ridges extending along each support layer in at least two directions thereby forming a grid.

6. The system of claim 5, wherein the plurality of ridges provide a non-skid surface.

7. The system of claim 1, further providing a secure attachment between the at least one supporting layer and the impact zone surface.

8. The system of claim 7, wherein the secure attachment includes a plurality of rods, wherein each rod is secured at a first end to a portion of supporting layer and secured at a second end to the surface.

9. The system of claim 7, wherein the second end is driven into the surface a depth ranging from about four to about six inches.

10. The system of claim 7, wherein each rod has a hook at the first end and is positioned below the at least one supporting layer within the first layer of loose fill material.

11. The system of claim 5, wherein the at least one supporting layer has a layer thickness of between about 20 mm and 30 mm.

12. A method of forming a protective ground surface for reducing the impact of a fall onto a surface defined by an impact zone, comprising the steps of: forming a first layer of loose fill material on or in the surface;placing at least one supporting layer over the first layer, each supporting comprising: a substantially flat sheet having a plurality of open channels, each channel having an upper opening at an upper surface of the sheet and a corresponding lower opening at a lower surface of the sheet, thereby enabling loose fill material to be retained therein and enabling fluid to flow there through, wherein the at least one supporting layer lays over the first layer; andforming a second layer of loose fill material of a predetermined thickness over the at least one supporting layer,whereby the placement of the protective ground surface substantially prevents displacement of the loose fill material away from the impact zone.

13. The method of claim 12, wherein the predetermined second thickness has a thickness less than the predetermined first thickness.

14. The method of claim 13, wherein the predetermined first thickness is between about 100 mm and about 200 mm.

15. The method of claim 13, wherein the predetermined second thickness is at least 40 mm.

16. The method of claim 12, wherein the spacing of the channels and the area of the upper openings thereof result in the upper surface comprising a plurality of ridges extending along each support layer in at least two directions thereby forming a grid.

17. The method of claim 16, further including forming a secured attachment between the at least one supporting layer and the impact zone surface.

18. The method of claim 17, wherein the secured attachment includes a plurality of rods, wherein each rod is secured at a first end to a portion of each of the at least one supporting layer and secured at a second end to the surface.

19. The method of claim 18, wherein each rod has a hook at the first end and is positioned below the at least one supporting layer within the first layer of loose fill material.

20. A supporting layer for substantially preventing displacement of the loose fill material away from a surface, comprising: a substantially flat sheet having a plurality of open channel, each channel having an upper opening at an upper surface of the sheet and a corresponding lower opening at a lower surface of the sheet, thereby enabling loose fill material to be retained therein and enabling fluid to flow there through, andwherein the spacing of the channels and the area of the upper openings thereof result in the upper surface comprising a plurality of ridges extending along the support layer in at least two directions thereby forming a grid,whereby the plurality of ridges provide a non-skid surface for retaining loose fill material engaging the plurality of ridges.