SECTIONAL SPORTS ARENA WALL PAD

A sports arena pad with beveled sides to create overlapping beveled joints when the pads are releasably attached to an arena wall in a linear side-by-side configuration. The inner padding is made of two layers of foam. The first layer is a low-density foam panel attached to and covering a front surface of a substantially rigid backing panel. The second layer is a high-density foam panel attached to and covering a front surface of the low-density foam panel. The padding and much of the backing panel is covered with a weather-resistant fabric, preferably by wrapping. Releasable fasteners are attached to the rear of the backing panel for attaching to complimentary fasteners on the arena wall. Special pads with one beveled edge may be provided for end pieces.

DETAILED DESCRIPTION OF THE INVENTION

The term “sports arena wall pad” as defined and used herein refers to a pad for absorbing impacts from athletes in a sports arena. It should be understood that the present invention involves pads that are used in adjacent series to protect a larger expanse of wall than can conveniently be protected with one pad. Words describing orientation and position are referenced to the installed position of the sectional sports arena wall pad with the viewer facing the player-impact surface as the front surface of the sectional sports arena wall pad.

FIG. 1is a diagrammatic horizontal cross-sectional view illustrating a prior art sports arena wall pad100. The prior art sports pad consists of a rectangular plywood backing102to which a rectangular foam pad104is adhesively attached. A typical thickness110for the foam pad104is five inches. The combined foam pad104and plywood backing102are wrapped in a vinyl wrapping106that rounds the corners114and118of the foam pad104. Sides112and116are intended to abut adjacent prior art sports arena wall pads100when installed in a series. Each prior art sports arena wall pad100has one or more (two illustrated) Z-clips108for mounting the prior art sports arena wall pad100to an arena wall204(seeFIG. 2). Z-clips108are secured to plywood backing102using screws120, which are shown partially extended for visibility in the drawing.

FIG. 2is a diagrammatic top view illustrating a plurality200of prior art sports arena wall pads in a linear, side-by-side configuration. The prior art pads100are hung on arena wall204via Z-clip-receiving channel206that is attached to the arena wall204. Seams202between prior art sports arena wall pads100result in reduced thickness208relative to thickness101(seeFIG. 1), creating a danger for athletes impacting the plurality200of prior art sports arena wall pads100at seams202. In addition, seams202enable sideways compression of the prior art sports arena wall pads100, which opens the seams202, further endangering the athletes.

FIG. 3is a diagrammatic horizontal cross-sectional view illustrating an exemplary embodiment of an improved sports arena wall pad300, according to a preferred embodiment of the present invention. Improved sports arena wall pad300has a rigid, preferably plywood, backing302on which the remainder of sports arena wall pad300is mounted. First and second bevel angles α and β, respectively, are illustrated as equally forty-five degrees, which is preferred, but the invention is not so limited. In particular embodiments in which bevel angles a and β are not equal, a and β must be complimentary angles. For example, α+β=90°.

Plywood backing panel302is preferably thick enough to support the improved sports arena wall pad300during storage, transport, installation, and in the particular use for the improved sports arena wall pad300. For non-limiting example, a plywood backing panel302for an improved sports arena wall pad300in a professional baseball arena is ¾ of an inch thick.

For a smaller improved sports arena wall pad300, a plywood backing panel that is five-eighths of an inch thick may suffice. The thickness of the plywood backing panel302must be sufficient to engage screws320and large enough to secure the Z-clips308that support the weight of the improved sports arena wall pad300and other forces (e.g., outfielders “climbing” the wall to catch a would-be home run, wind, baseball fans, etc.) acting on the improved sports arena wall pad300when installed. APA grade B-C exterior plywood with a coating of paint on the rear (arena wall-engaging side) surface332that matches the color of the vinyl wrapping306is preferred for use as plywood backing panel302. In particular embodiments, backing panels made of other materials and having equivalent functionality may be substituted for plywood backing panel302.

First foam panel304is adhesively attached to plywood backing panel302, as shown, using a high-adhesive glue that remains stable in hot or cold weather. First foam pad304is preferably a high-impact foam having a thickness of at least three inches. For example, the Flexfoam product 1233 from Flexfoam of 617 N. 21st Ave., Phoenix, Ariz. 85009 is useful as first foam panel304. The thickness of first foam panel304may vary with the particular application for which the improved sports arena wall pad300will be used. First foam pad304has oppositely beveled opposing first and second sides324and326with first and second bevel angles α and β, respectively, as previously described. Preferably, first foam panel304covers a front surface of backing panel302, as shown.

Second foam panel305is a high-density foam that is adhered to first foam panel304using a high adhesive glue with temperature stability for hot and cold weather conditions. For non-limiting example, Flexible Polyurethane Foam 23/90 from Ureblock S.A. de C.V. of Av. Dr. Angel Leaño No. 480, Fracc. Los Robles, Zapopan-Jalisco.México is a high-density foam suitable for use as second foam panel305. The high density of second foam panel305reduces rounding at the corners314and318from wrapping and provides additional protection for the athlete. Second foam panel305is preferably at least two inches thick to provide a total thickness110for the combined first and second foam panels304and305of at least five inches. Thicker combined first and second foam panels304and305are within the scope of the invention. Second foam panel305has oppositely beveled opposing first and second sides328and330with complimentary bevel angles α and β, respectively, as previously described. Preferably, second foam panel305covers the front surface of first foam panel304, as shown.

Vinyl wrapping306covers first and second foam pads304and305and at least a portion of the rear surface332of the plywood backing panel302. Vinyl wrapping306is shown in exaggerated scale inFIG. 3for clarity of illustration. For non-limiting example, vinyl wrapping306is preferably a sixteen ounce to eighteen ounce 1000 denier laminate vinyl with a weave count of 9×9, UV resistance, a tear strength of 55/60, a tensile strength of 235/210, flame retardant, and with a cold crack of forty degrees below zero Fahrenheit. The portion of the vinyl wrapping306that at least partially covers the rear surface332of plywood backing302is stapled near the edge to the plywood backing302. In a particular embodiment, the vinyl wrapping306is stapled every two inches. Various staples may be used. For non-limiting example, eighteen gauge stainless steel staples are suitable for the purpose. Attaching vinyl wrapping306to the plywood backing302involves some folding of the vinyl wrapping306on the rear surface332of the plywood backing302. Such folding is preferably done in a manner to avoid creating rain catchments in the folds.

Z-clips308are a first part of a two-part wall-hanging system and are designed to be fastened to the plywood backing302, as shown, and to engage a second part206(seeFIG. 4) of the two-part wall hanging system that is fastened to the arena wall204(SeeFIG. 4). For non-limiting example, Z-clips308are extruded aluminum, one-eighth of an inch thick and two and one-half inches wide, and are fastened to the plywood backing302with ¼″×1″ galvanized steel screws320. In various particular embodiments, various types of wall-hanging hardware may be used.

Manufacturing of the improved sports arena wall pads300is similar to manufacturing of prior art sports arena wall pads100, except that the first and second foam pads304and305must be beveled on the sides, and the size of the improved sports arena wall pads300should be economically selected to adapt to commercially available widths of vinyl wrapping306, as the perimeter of the improved sports arena wall pads300is slightly greater than the perimeter of the prior art sports arena wall pads100.

In addition to the improved sports arena wall pad300illustrated, an improved sports arena wall pad may be fashioned with one beveled side316and one non-beveled side112for use in corners of arena walls204.

FIG. 4is a diagrammatic top view illustrating a plurality400of the exemplary embodiments of the improved sports arena wall pads300ofFIG. 3, according to a preferred embodiment of the present invention. When installed in linear sequence, as shown, the oppositely beveled sides312and316of improved sports arena wall pads300form a beveled seam402that does not create an area of reduced thickness208and does not open like seams202in response to impact. Improved sports arena wall pads300install in the same manner and, optionally, with the same hardware308and320as prior art sports arena wall pads100. As a result, improved sports arena wall pads300are easy to manufacture and install. The number of improved sports arena wall pads300illustrated is exemplary, and does not limit the number of improved sports arena wall pads300that can be arranged in linear fashion. Installation along gradually curved walls is also possible.

FIG. 5is a diagrammatic bottom view illustrating the plurality400of the exemplary embodiments of the improved sports arena wall pads300ofFIG. 3, according to a preferred embodiment of the present invention. Bottom surfaces502of improved sports arena wall pads300have weep holes504(one of nine labeled) for venting water that may work its way into the improved sports arena wall pads300. The positioning of weep holes504is exemplary, and not intended to be limiting. Weep holes504may also vent air during impact, and may be sized to provide the best air cushioning affect for the athlete.

FIG. 6is a diagrammatic front view illustrating the plurality400of the exemplary embodiments of the improved sports arena wall pads300ofFIG. 3, according to a preferred embodiment of the present invention. Beveled side312is shown. Any number of improved sports arena wall pads300may be arranged together. The particular rectangular proportions shown are merely exemplary, and are not intended to limit the invention.

FIG. 7is a diagrammatic rear view illustrating the plurality400of the exemplary embodiments of the improved sports arena wall pads300ofFIG. 3, according to a preferred embodiment of the present invention. Placement of Z-clips308(one of six labeled) is exemplary, and is not intended to be limiting. For various embodiments adapted to various installations, more or fewer, larger or smaller Z-clips may be used, and may be positioned as appropriate for the particular installation.

FIG. 8is a diagrammatic horizontal cross-sectional view illustrating another exemplary embodiment of an improved sports arena wall pad800, according to a preferred embodiment of the present invention. Improved sports arena wall pad800has a plywood backing802with oppositely beveled opposing first and second sides820and822. First and second bevel angles α and β, respectively, are illustrated as equally forty-five degrees, which is preferred, but the invention is not so limited. In particular embodiments in which bevel angles α and β are not equal, α and β must be complimentary angles. For example, α+β=90°. In a particular embodiment, the acute corners of the first and second sides820and822may be rounded to reduce wear on the vinyl wrapping306.

Plywood backing802is preferably thick enough to support the improved sports arena wall pad800during storage, transport, installation, and in the particular use for the improved sports arena wall pad800. For non-limiting example, a plywood backing802for an improved sports arena wall pad800in a professional baseball arena is ¾ of an inch thick. For a smaller improved sports arena wall pad800, a plywood backing that is five-eighths of an inch thick may suffice. The thickness of the plywood backing802must be sufficient to engage screws320large enough to secure the Z-clips308that support the weight of the improved sports arena wall pad800and other forces (e.g., outfielders “climbing” the wall to catch a would-be home run, wind, baseball fans, etc.) acting on the improved sports arena wall pad800when installed. APA grade B-C exterior plywood with a coating of paint on the rear (arena wall-engaging side) surface332that matches the color of the vinyl wrapping306is preferred for use as plywood backing802. In particular embodiments, panels made of other materials and having equivalent functionality may be substituted for plywood backing802.

First foam pad304is adhesively attached to plywood backing802, as shown, using a high-adhesive glue that remains stable in hot or cold weather. First foam pad304is preferably a high-impact foam having a thickness of at least three inches. For example, the Flexfoam product 1233 from Flexfoam of 617 N. 21st Ave., Phoenix, Ariz. 85009 is useful as first foam pad304.

The thickness of first foam pad304may vary with the particular application for which the improved sports arena wall pad300will be used. First foam pad304has oppositely beveled opposing first and second sides324and326with first and second complimentary bevel angles α and β, respectively, as previously described.

Second foam pad305is a high-density foam that is adhered to first foam pad304using a high adhesive glue with temperature stability for hot and cold weather conditions. For non-limiting example, Flexible Polyurethane Foam 23/90 from Ureblock S.A. de C.V. of Av. Dr. Angel Leaño No. 480, Fracc. Los Robles, Zapopan-Jalisco.México is a high-density foam suitable for use as second foam pad305. The high density of second foam pad305reduces rounding at the corners314and318and provides additional protection for the athlete. Second foam pad305is preferably at least two inches thick to provide a total thickness110for the combined first and second foam pads304and305of at least five inches. Thicker combined first and second foam pads304and305are within the scope of the invention. Second foam pad305has oppositely beveled opposing first and second sides328and330with complimentary bevel angles α and β, respectively, as previously described.

Vinyl wrapping306covers first and second foam pads304and305and at least a portion of the rear surface332of the plywood backing panel802. Vinyl wrapping306is shown in exaggerated scale inFIG. 3for clarity of illustration. For non-limiting example, vinyl wrapping306is preferably a sixteen ounce to eighteen ounce 1000 denier laminate vinyl with a weave count of 9×9, UV resistance, a tear strength of 55/60, a tensile strength of 235/210, flame retardant, and with a cold crack of forty degrees below zero Fahrenheit. The portion of the vinyl wrapping306that at least partially covers the rear surface332of plywood backing802is stapled near the edge to the plywood backing802. In a particular embodiment, the vinyl wrapping306is stapled every two inches. Various staples may be used. For non-limiting example, eighteen gauge stainless steel staples are suitable for the purpose. Attaching vinyl wrapping306to the plywood backing802involves some folding of the vinyl wrapping306on the rear surface332of the plywood backing802. Such folding is preferably done in a manner to avoid creating rain catchments in the folds.

Z-clips308are a first part of a two-part wall-hanging system and are designed to be fastened to the plywood backing, as shown, and to engage a second part206(seeFIG. 4) of the two-part wall hanging system that is fastened to the arena wall204(SeeFIG. 4). For non-limiting example, Z-clips308are extruded aluminum one-eighth of an inch thick and two and one-half inches wide and are fastened to the plywood backing802with ¼″×1″ galvanized steel screws320. In various particular embodiments, various types of wall-hanging hardware may be used.

Manufacturing of the improved sports arena wall pads800is similar to manufacturing of prior art sports arena wall pads100, except that the plywood backing panel802and the first and second foam pads304and305must be beveled on the sides, and the size of the improved sports arena wall pads800should be economically selected to adapt to commercially available widths of vinyl wrapping, as the perimeter of the improved sports arena wall pads800is slightly greater than the perimeter of the prior art sports arena wall pads100.

Although applicant has described applicant's preferred embodiments of this invention, it will be understood that the broadest scope of this invention includes such modifications as diverse shapes and sizes and materials. Such scope is limited only by the above specification.

Further, many other advantages of applicant's invention will be apparent to those skilled in the art from the above descriptions and the claims below.