Safety surfacing tile support

One embodiment of a safety surfacing tile comprises a top surface; a plurality of series of first members supporting the top surface and extending across a transverse length of the safety surfacing tile; a plurality of series of second members supporting the top surface and extending across a length of the safety surfacing tile perpendicular to the transverse length; and a grid of voids formed by the intersecting first and second members on an underside of the top surface, wherein the grid of voids absorbs impact energy from an object impacting the top surface.

TECHNICAL FIELD

The present disclosure is generally related to impact absorbing protective surfaces.

BACKGROUND

To protect against injuries from falls, a cushioned surface overlying a hard surface, such as the ground or a hard floor, is often used. Cushioned surfaces have been used for floor coverings in indoor facilities, such as gymnasiums, industrial warehouses, nursing homes, hospitals, and rehabilitation centers, and with outdoor athletic and recreational areas such as children's playgrounds.

SUMMARY

Embodiments of the present disclosure provide safety surfacing tiles, apparatus, and related methods. Briefly described, one embodiment of a safety surfacing tile comprises a top surface; a plurality of series of first members supporting the top surface and extending across a transverse length of the safety surfacing tile, a first member being separated from an adjacent first member by a predetermined distance, the plurality of series of first members contacting an underlying surface when the safety surfacing tile is positioned on the underlying surface; a plurality of series of second members supporting the top surface and extending across a length of the safety surfacing tile perpendicular to the transverse length, the plurality of series of the second members contacting the underlying surface when the safety surfacing tile is positioned on the underlying surface, the plurality of series of second members connecting with the plurality of rows of horizontal members; and a grid of voids formed by the connecting first and second members on an underside of the top surface, wherein the grid of voids absorbs impact energy from an object impacting the top surface. The grid of voids comprise at least a first plurality of voids having shape defined by a first polygon base situated next to the underlying surface and a second polygon base parallel to the first polygon base that is situated next to the surfacing tile, the first polygon base joined with the second polygon base by first and second curved side surfaces, wherein a width of the first polygon base is wider than the width of the second polygon base.

DETAILED DESCRIPTION

Embodiments of a safety surfacing tile or mat that may be used around playground equipment, as a non-limiting example, are described in the following text and accompanying diagrams/images. It should be emphasized that the following described embodiments of the present disclosure are merely possible examples of implementations, merely set forth for a clear understanding of the principles of embodiments of the disclosure. Many variations and modifications may be made to the above-described embodiments of the disclosure without departing substantially from the spirit and principles of the disclosure. All such modifications and variations are intended to be included herein within the scope of this disclosure.

FIG. 1is a diagram of one embodiment, among others, of the safety surfacing tile or mat100from a top-view. Dimensions of the safety surfacing tile have a width W and a length L. The top surface110of the safety surfacing tile100has a flat surface.

On the edge of the top surface110, locking member or mechanism105having interlocking tabs120,130,140,150is shown. Two adjacent tabs120,130at the top surface110extend away from a side of the top surface110and have a portion or groove125,135extending the length of the side and also extending downwards towards the bottom of the tile100. Two opposing adjacent tabs140,150extend from the bottom surface of the tile100the length of a respective side and have a portion or groove145,155extending upwards towards the top of the tile100.

FIG. 2is a diagram of an embodiment of the safety surfacing tile100from a side view showing the interlocking tab130ofFIG. 1extending downward and the interlocking tab150ofFIG. 1extending upward. In addition to dimensions W and L, the safety surfacing tile has a thickness T. Underneath the safety surfacing tile100, shown are support members210which help provide structural integrity to the safety surfacing tile100as potential forces are applied downward from the top surface and from the side from adjacent interlocked tiles100. Further, a plurality of voids220are shown underneath the tile100. It is noted that as thickness of the tile T increases, in some embodiments, the shape of the void220may become more round and less flat since the depth or height of the void increases.

As depicted inFIG. 3, in placing the safety surfacing tiles to cover a hard surface, a first safety surfacing tile1may be positioned on a floor or underlying surface and a second safety surfacing tile2may be placed to interlock with the first tile1by aligning a tab140of the first safety surfacing tile that extends upward with a tab120of the a second safety surfacing tile2that extends downwards such that the cooperating surfaces of the tabs match and lock. Accordingly, each tile has formations on the locking member for cooperating with formations on the other tiles for interlocking the tiles together, where the interlocking of the tiles reduces relative movement between the tiles, in use. Similarly, a third safety surfacing tile3may be interlocked with the second safety surfacing tile2by aligning a tab130extending downward of the third safety surfacing tile with a tab140extending upwards of the second safety surfacing tile2such that the cooperating surfaces of the tabs match and lock and three safety surfacing tiles1,2,3are now interlocked.

Accordingly, an embodiment of the safety surfacing tile or mat100is fastened to another safety surfacing tile/mat by receiving the outer edge of the tile100within an upwardly directed groove of the locking member105. The grooves serve to hold the edges of the tiles against one another.

In one embodiment, the safety surfacing tile100features a locking member105that is extending downwards only on two sides instead of all four sides. This avoids having to lift a safety surfacing tile (that has already been laid on a floor) to lock with an adjacent tile that is being placed into position. Referring to the middle step/stage ofFIG. 3, if tile2had a downward extending tab on the right side instead of an upward extending tab140, then the right side of tile2would have to be lifted in order to position the corresponding tab of tile3so that the two tabs could lock. Accordingly, when a tile100has downward interlocking tabs or grooves120,130on all four sides, a side of the tile100(which has already been laid onto another tile) has to be lifted so it can be matched with a new adjacent tile being placed into position next to the tile100.

In contrast (and referring toFIG. 4), by having downward tabs or grooves120,130on two sides and upward tabs/grooves140,150on the other two sides, the downward tabs120,130of a tile2being placed into position is matched with the upwards tabs140,150of a tile1that has already been positioned, leaving two sets of upward tabs140,150available to be used to lock or connect with a tile3being positioned next to tile2(previously positioned). Similarly, a tile4may be laid onto the upward tab140of tile2into position as shown. Therefore, the most recent tile4placed has two tabs/grooves140,150sticking out and up so that the next tile5can sit on top of the appropriate tabs/grooves150and also sit on the upward tabs/grooves140of tile3and is now in proper position and interlocked with the other tiles1,2,3,4. In a situation where additional upwards tabs140,150are needed, a lock support member (as is later discussed with respect toFIG. 7) may also be used.

In one embodiment, it is noted that the safety surfacing tile features a notch540(seeFIG. 5) that provides a cutting point for slicing a full tile into two half tiles. This allows for greater flexibility in arranging tile patterns and placement.

In addition to the interlocking mechanism, an embodiment of the safety surfacing tile100incorporates a bottom support grid on the underside of the tile, as shown inFIG. 5. In one embodiment of the grid, a series of horizontal members510support the top surface of the tile100and extend continuously from one side of the tile100across a horizontal length of the tile100up to an interlocking tab150that extends upwards (away from the bottom of the tile). The series of horizontal members510contact a floor or underlying surface (e.g., concrete, asphalt, dirt, wood, etc.) when the safety surfacing tile100is positioned on the floor or underlying surface. The safety surfacing tile100also contains a series of vertical members520supporting the top surface and extending across a vertical length of the safety surfacing tile100up from an interlocking tab140upwards to one of the series of horizontal members510. The series of vertical members520contact the floor or underlying surface when the safety surfacing tile100is positioned on the floor or underlying surface. Support foot(s)515,525are features on respective horizontal and vertical members510,520to provide additional supports to help cushion or support a weight placed on the surfacing tile.

It is shown that the series of vertical members520connect with the series of horizontal members510to form a grid of voids530on the underside of the tile100. The grid of voids aids in cushioning impact of an object on the top surface110of the safety surfacing tile100and absorbing impact energy. Upon impact, the upper surface of the safety surfacing tile100is capable of being temporarily deformed into one or more voids530.

FIG. 6is provided to show one embodiment of the grid of voids, where a series of horizontal members510are shown connecting with respective ones of a series of vertical members520forming a grid600. The grid600forms a series of voids530that extend and repeat across the length and width of the grid. In one embodiment, the horizontal and vertical members are arranged to form a series of voids530oriented in a longitudinal direction running vertically at one end of the surfacing tile100. Then, a series of voids are repeated across the width of the grid which are oriented in a lateral direction running horizontally in the middle of the tile. Again, the horizontal and vertical members are arranged to form a series of voids530oriented in a longitudinal direction running vertically at the other end of the surfacing tile100. Each horizontal member is spaced apart from an adjacent horizontal member by a predetermined distance and each vertical member is spaced apart from an adjacent vertical member by a predetermined distance.

The vertical members are shown as a shape resembling a solid having two parallel flat bases of regular or irregular form, joined by flat or curved surfaces where straight lines can be drawn from one parallel face to the other.FIG. 6shows an enlarged view605of two of the vertical members520from the grid600, where the members are in the shape of solids whose bases are parallel polygons having curved surfaces joining the two polygon bases. For the vertical member, a rectangular base connects with two similarly oriented curved sides at an angle (less than 90 degrees). The sides connect with a second rectangular base opposing the first rectangular base, where the width of the first rectangular base is greater than the width of the second rectangular base. The sides and bases connect with respective curved sides. In other embodiments, the bases may connect with non-curved or straight sides. Such solids have been observed to provide exceptional structural integrity. Other forms of the horizontal (and vertical) members could be useful and selected depending on the parameters of performance that are to be provided by the total structure.

In one embodiment, the safety surfacing tile100is made of solid resilient rubber including the horizontal and vertical members510,520. As explained above, the individual vertical members520have a solid shape, where a narrow base of the vertical member520is in contact with the floor or underlying surface during use and the wider base of the vertical member520is adjacent to the upper surface.

The sides of the vertical members520help form the shapes of the voids530adjacent to the vertical members520. Accordingly, in one embodiment, the voids530share a curved or sloped shape at the sides and have opposing flat bases where the base next to the surfacing tile is smaller than the base that will be next to the ground upon which the surfacing tile100is positioned. While the shape of the vertical member520has a wider base at the upper surface (closest to the upper surface of the surfacing tile), the shape of the void530has a narrow base at the upper surface and a wider base at the bottom surface (closest to the ground upon which the tile100may be positioned).

The sides of the horizontal members510are similar in shape to the vertical members in one embodiment. However, in some embodiments, horizontal members may be straight and rectangular or a combination of rectangular and non-rectangular. For example, the horizontal members510may comprise a rectangular cuboid shape having six flat rectangular sides with all right angles, in one embodiment. However, the sides of the horizontal members510may be sloped or curved rather than straight or perpendicular to the top surface in some embodiments. Further, in one embodiment, a horizontal member may be adjacent to one void on side of the horizontal member and another void on the opposite of the horizontal member, where one side of the horizontal member has a straight side adjacent to the first void and the opposite side of the horizontal member has a curved side adjacent to the second void.

The base and lock design of an embodiment of the safety surfacing tile100allow for better surface adhesion preventing curling and separation that may occur with other surfacing tiles. In one embodiment, the safety surfacing tiles100are modular and pre-constructed from a resilient material, such as rubber. For example each tile may be 24 inches square (W=24 inches, L=24 inches). The thickness T of the tiles100may vary depending on desired safety criteria, such as Critical Fall Height, as explained below. In one embodiment, the safety surfacing tile is made of solid rubber structure permeable to water which allows water to drain from a top surface to the voids at the bottom surface and to the underlying floor. Therefore, the permeable surface of an embodiment of the safety surfacing tile100allows water to pass through the tile surface instead of standing on top. For example, typically on playgrounds there is a drainage path where water is designed to travel and drain.

An embodiment of the safety surfacing tile100is designed so that the outer sides of the tile100have escape channels or port(s) in the form of the voids at the outer perimeter that allow water to escape. The horizontal and vertical members510,520also provide conduits or passageways540(seeFIG. 5) through which water may flow from one void530to the next towards the outer perimeter of the tile100. In one embodiment, the conduits540have a prismoid or cuboid shape.

The vertical and horizontal members510,520structurally hold the safety surfacing tile100in a desired form from side to side and achieve horizontal and vertical lines to keep the tile100from shrinking or curling after repeated use and/or exposure. The safety surfacing tile100is structurally sound because all four sides are attached by underlying structural supports510,520that extend the length of the tile in both vertical and horizontal directions and create the shape of the voids530which affect the profile of how energy is dissipated by the supports510,520during an impact. The narrowing projections of the vertical members510have been observed to reduce peak deceleration and lessen the impact during a fall.

In the configuration shown inFIG. 6, as an example, the arrangement of the plurality of the intersecting members510,520significantly affects a Critical Fall Height of the surface of the safety surfacing tile100. In particular, the members510,520are arranged to deform into the voids530to dissipate energy during an impact. It has been found that the combination of features of the above-described embodiment(s) result in the safety surfacing tile having predictable characteristics in relation to absorption of impact energy applied to a top surface including a Critical Fall Height (CFH) of 5 feet for a safety surfacing tile having a 2.25 inch thickness (T) tested in accordance with procedures and standards specified under American Society for Test Methods (ASTM) F1292-09 “Standard Specification for Impact Attenuation of Surface Systems Under and Around Playground Equipment.”

Further, the top surface110maybe non-slip and porous to provide additional safety measures. Particularly, the safety surfacing tiles100may be manufactured with a buffing top or EPDM (Ethylene Propylene Diene Monomer) top wear surface providing a non-slip, soft, porous safety surface.

In one embodiment, the horizontal and vertical members have a height (the vertical distance from a valley between respective members to the apex of the respective members) of approximately 1 inch for a safety surfacing tile having a 2 inch thickness. Correspondingly, the width of the horizontal member responsible for forming an individual void is approximately 1 inch for such an embodiment. Accordingly, a wide base of the void at a perimeter is approximately 10 inches long and 3 inches wide and has a depth of 1 inch. The wide base of the void at the middle is approximately 6.5 inches long and 3 inches wide and has a depth of 1 inch.

As previously mentioned, in some embodiments, a locking support mechanism is also provided.FIG. 7shows one embodiment of the locking support mechanism710, where710A is a top view of the locking support mechanism and710B is a perspective view.

For example, consider a surfacing tile that has a side120,130that features interlocking tabs that extend downwards but is not being interlocked with another surfacing tile (e.g., the tile may be flush against a wall). In this case, this side of the surfacing tile does not have as much structural support as a side that is interlocked with another surfacing tile. However, a locking support mechanism can be used to lock with the side120,130and interlocking tab125,135to provide structural support, as is depicted inFIG. 8.

InFIG. 8, first, a surfacing tile is shown next to locking support mechanism710. The locking support mechanism is placed next to side130of the surfacing tile. Next, the locking support mechanism is locked with the interlocking tab135of the surfacing tile. The interlocking tab135has a male portion that extends downward from the surfacing tile and mates with a female portion of the locking support mechanism710, as shown inFIG. 8and also depicted inFIG. 9. Accordingly, each structure includes cooperative surfaces that function in combination with each other and is configured so as to mate with a corresponding structure when the tile/locking support mechanism is stacked or placed atop one another.

Starting from the top,FIG. 9shows the surfacing tile100next to the locking support structure710. Next (920), the surfacing tile100is shown connected or locked with the locking support structure710where the interlocking tab135of the tile mates with the locking support structure710. The locking support structure710, in one embodiment, is made to extend from the interlocking tile when connected and to provide a female interlocking mechanism for connecting with another structure, such as a ramp (in stage930). In this way, a ramp710or other structure having a male locking structure or member can be connected with a side or end of an interlocking tile having a male member via use of the locking support structure710. In one embodiment, the locking support structure710has the following or substantially the following dimensions: H1= 6/16 inches, W1= 8/16 inches, W2=1 inch, W3=2 inches, H4=1.5 inches. Depending on dimensions of different surfacing tiles, the dimensions of the locking support structure710may change accordingly.

In an arrangement where another structure is not to be connected to the locking support structure410, some embodiments provide cutting grooves1010on the top and bottom surface of the structure410, as shown inFIG. 10. Therefore, the locking support structure410may be split into halves410A,410B by cutting the structure410at the cutting grooves1010and then one half410B is locked with a side of the interlocking tile100in order to provide additional support and a flush abutment or square edge without extending outside the perimeter of the tile.

Aspects of the present disclosure are not limited to the above-described embodiments which may be modified without departing from the scope of the present disclosure or sacrificing all of its advantages. In this regard, the terms in the foregoing description and the following claims, such as “upwards”, “downwards”, “right”, and “left”, have been used only as relative terms to describe the relationships of the various elements of embodiments of safety surfacing tiles and depend upon a perspective of a person in relation to the safety surfacing tile. Many variations and modifications may be made to the above-described embodiment(s) without departing substantially from the spirit and principles of the present disclosure. All such modifications and variations are intended to be included herein within the scope of this disclosure and protected by the following claims.