Several embodiments of this disclosure relate to articles of manufacture and methods for providing a surface underlayment system with interlocking resilient anti-slip shock tiles or modules.
To reduce injury in sporting events, a playing surface is sometimes provided with an underlayment system that absorbs and redistributes energy, thereby cushioning the blow when for example a player falls to the ground after being tackled. In an industrial setting, flooring systems are sometimes provided that absorb forces generated by repeated footfalls. Playground systems also require some means of absorbing energy to reduce the risk of serious injury when a child falls on the surfaces beneath and around playground structures.
Against this background, it would be desirable to provide an article of manufacture and its method of making that includes a surface underlayment system with interlocking resilient anti-slip shock tiles or modules that accommodate thermal expansion or contraction and can be usefully deployed indoors or outdoors in all weather conditions.
Ideally the tiles could be economically nested or stacked before transportation to a job site, would have a minimal installed cost; be compatible with a lower foundation and an upper surface between which they are interposed; and require little to no maintenance.
One aspect of this disclosure involves a first embodiment of a modular surface underlayment system 10 (
In more detail, at least some of the modules 16 have an array of preferably frustoconical energy absorbing support structures 15. Optionally, ribs (not shown) connect at least some of the frustoconical structures 15. As used herein the term “frustoconical” includes a generally conical structure, the end of which has been truncated, perhaps by a planar or undulating surface (bottom surface 18,
The bottom surface 18 of the frustoconical energy absorbing support structures 15 may or may not be circular. It could for example be oval, elliptical, square, rectangular, triangular, hexagonal or generally polygonal. Effectively the structures 15 serve as support pillars with sidewalls 24 (
It will be appreciated that the terms “top”, “bottom”, “upper” and “lower” should be construed as non-limiting. For example any of the modules 10 could be inverted. In that case the bottom surface 18 could become juxtaposed with and lie below the upper surface 12.
In a preferred embodiment, the top surfaces 20 of the frustoconical structures 15 interface with the upper surface 12, such as an artificial turf or a hard playing surface. The top surfaces 20 are generally planar and are roughly parallel to the bottom surfaces 18. Where the frustoconical structure 15 has a bottom surface 18 that resembles a rook with crenellations, the crenellations have upper edges that are generally co-planar (see,
In one preferred embodiment (see, e.g.,
If desired, lugs 50 and grooves 52 (
The modular energy absorbing system 10 may include a number (n) of modules 10 (where 1<n<1,000,000) depending on the desired footprint on the lower foundational surface 14 over which the system 10 is installed.
One feature of the disclosed structure is that when the upper surface 12 overlies the modules 10, a firm feel under foot is experienced that is relatively uniform over the middle region of a module 10 and over its edges or peripheral flanges that overlap with those of adjacent modules 10. Preferably, the weight of for example, a pedestrian or player is distributed evenly over multiple frustoconical structures 15 associated with one or more modules.
In some cases, (e.g.,
Once the complete modular system 10 has been installed, it may be covered with an upper surface 12, such as a basketball arena or gymnasium floor or layers of permeable materials like synthetic turf, natural grass, sedum, geotextiles, and the like to create a finished surface that is both functional and aesthetically pleasing. A preferred embodiment has a geo textile both above and beneath the underlayment system 10. The lower geotextile prevents the system 10 from settling into the lower foundation 14 and fine particulates from migrating upward. The upper geotextile prevents the migration of infill materials such as sand and crumb rubber through the carpet and into underlying recesses. Filled, or partially filled recesses, have a reduced ability to attenuate impacts. If desired, the system can utilize green products in the upper surface 12. As used herein the term “green product” includes products that have these among other attributes:
See, http://www.isustainableearth.com/green-products/what-is-a-green-product
It will be appreciated that the upper surface 12 can be laid across or secured to one or more modules 10. Optionally, a flooring surface 12 can be laminated to the underlayment system 10. In this embodiment, the cone array 15 and male members 46 are covered by the flooring surface 12 and the female members 44 exposed. When the laminated system is snapped together, the sides of the flooring surface butt together, thereby creating a continuous surface. Optionally, anti-friction lugs 23 (
This disclosure now turns to other embodiments (
It will be appreciated that the disclosed underlayment system may not only underlie artificial turf but also other flooring systems. The drainage holes 19 are optional. In some applications, for example where the upper impact-receiving surface includes an impermeable surface such as a running track, gym floor, floor tile, etc., there may or may not be a benefit from having the rook top 18. These include turf underlayment, playground underlayment, and other systems where the underlayment lies between a wear surface and a drainage system.
One aspect of the system disclosed is that interaction between plastic and a flat surface may be noisy. For example, the system may flutter when displaced relative to the surface above or below and generate sound at a decibel level that may be objectionable. Therefore, alternate embodiments include a thin foam or felt layer interposed between the upper surface 12 and the disclosed energy absorbing system. For instance, most turf systems are installed over a compacted stone base. In such applications, a permeable non-woven or woven PP geo textile not only deadens the noise but also prevents the disclosed system from settling substantially into the stone base or the stone base from migrating up between the frustoconical structures 15. This thin layer promotes drainage but also prevents relative movement or migration of adjacent layers. In an indoor environment, placement of a foam or felt pad underneath the energy absorbing system would tend to deaden that noise.
It will be appreciated that the underlayment systems may or may not be recoverable. For example, a non-recoverable polypropylene or thermoplastic urethane or other thermoplastic may be suitable for use in basements when moisture and mildew could otherwise be an issue. In such applications, the energy absorber 10 would not crush significantly, let alone recover to or toward an undeflected state. Instead of cushioning the blow by deformation, resistance to impact would be relatively inelastic. Then in the absence of drainage holes, the disclosed system would constitute a reservoir or vapor barrier. As used herein the term “thermoplastic” means “a polymer material that becomes pliable with heat, and with sufficient temperature, a liquid. When cooled, thermoplastics return to solid.” See, http://lookup.computerlanguage.com/host_app/search?cid=C999999&term=thermoplastic&lookup.x=0&lookup.y=0
Besides injection molding, one method by which to manufacture the disclosed system is thermoforming. Such approaches enable easy performance tuning by changing sheet thickness and material type that is thermoformed over the tool. It will be appreciated that thermoforming lends itself to rapid high volume manufacturing and low manufacturing costs. Ideally, a polyolefin thermoplastic, such as a polypropylene copolymer, offers an optimal balance of cost and performance. Additional materials may be compounded into the thermoplastic, such as flame retardant packages, to meet customer building codes or performance criteria.
The system can be easily and economically be transported to the job site due to the high packaging density (nesting) of the modules 10. Besides the above advantages, the system is light in weight and low in cost to manufacture.
In summary, the disclosed system offers at least these benefits: minimal installed costs; compatibility with existing foundations; and little to no maintenance.
As required, detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention that may be embodied in various and alternative forms. The Figures are not necessarily to scale; some features may be exaggerated or minimized to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ the present invention.
While exemplary embodiments are described above, it is not intended that these embodiments describe all possible forms of the invention. Rather, the words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the invention. Additionally, the features of various implementing embodiments may be combined to form further embodiments of the invention.
This application is a Continuation-In-Part of U.S. Ser. No. 14/533,438 filed on Nov. 5, 2014 and Ser. No. 13/865,483 filed on Apr. 18, 2013, the disclosures of which are incorporated herein by reference in their entirety
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Number | Date | Country | |
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20160138275 A1 | May 2016 | US |
Number | Date | Country | |
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Parent | 14533438 | Nov 2014 | US |
Child | 15006458 | US | |
Parent | 13865483 | Apr 2013 | US |
Child | 14533438 | US |