Patent Abstract:
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.

Full Description:
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&#39;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. 
     Other arrangements, apparatuses, methods, features, and advantages of the present disclosure will be or become apparent to one with skill in the art upon examination of the following drawings and detailed description. It is intended that all such additional systems, methods, features, and advantages be included within this description, be within the scope of the present disclosure, and be protected by the accompanying claims. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Many aspects of the present disclosure can be better understood with reference to the following drawings. The components in the drawings are not necessarily to scale, emphasis instead being placed upon clearly illustrating the principles of the present disclosure. Moreover, in the drawings, like reference numerals designate corresponding parts throughout the several views. 
         FIG. 1  is a diagram of one embodiment, among others, of the safety surfacing tile or mat from a top-view. 
         FIG. 2  is a diagram showing a side view of the safety surfacing tile of  FIG. 1 . 
         FIGS. 3-4  are diagrams showing a process of interlocking safety surfacing tiles, such as the safety surfacing tile of  FIG. 1 . 
         FIG. 5  is a diagram showing a bottom view of the safety surfacing tile of  FIG. 1 . 
         FIG. 6  is a diagram depicting a grid of voids from bottom of the safety surfacing tile of  FIG. 1 . 
         FIG. 7  are diagrams depicting an embodiment of a lock support member that may be used with the surfacing tile of  FIG. 1 . 
         FIGS. 8-10  are diagrams showing embodiments of a process of attaching the lock support member of  FIG. 7  to the surfacing tile of  FIG. 1 . 
     
    
    
     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. 1  is a diagram of one embodiment, among others, of the safety surfacing tile or mat  100  from a top-view. Dimensions of the safety surfacing tile have a width W and a length L. The top surface  110  of the safety surfacing tile  100  has a flat surface. 
     On the edge of the top surface  110 , locking member or mechanism  105  having interlocking tabs  120 ,  130 ,  140 ,  150  is shown. Two adjacent tabs  120 ,  130  at the top surface  110  extend away from a side of the top surface  110  and have a portion or groove  125 ,  135  extending the length of the side and also extending downwards towards the bottom of the tile  100 . Two opposing adjacent tabs  140 ,  150  extend from the bottom surface of the tile  100  the length of a respective side and have a portion or groove  145 ,  155  extending upwards towards the top of the tile  100 . 
       FIG. 2  is a diagram of an embodiment of the safety surfacing tile  100  from a side view showing the interlocking tab  130  of  FIG. 1  extending downward and the interlocking tab  150  of  FIG. 1  extending upward. In addition to dimensions W and L, the safety surfacing tile has a thickness T. Underneath the safety surfacing tile  100 , shown are support members  210  which help provide structural integrity to the safety surfacing tile  100  as potential forces are applied downward from the top surface and from the side from adjacent interlocked tiles  100 . Further, a plurality of voids  220  are shown underneath the tile  100 . It is noted that as thickness of the tile T increases, in some embodiments, the shape of the void  220  may become more round and less flat since the depth or height of the void increases. 
     As depicted in  FIG. 3 , in placing the safety surfacing tiles to cover a hard surface, a first safety surfacing tile  1  may be positioned on a floor or underlying surface and a second safety surfacing tile  2  may be placed to interlock with the first tile  1  by aligning a tab  140  of the first safety surfacing tile that extends upward with a tab  120  of the a second safety surfacing tile  2  that 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 tile  3  may be interlocked with the second safety surfacing tile  2  by aligning a tab  130  extending downward of the third safety surfacing tile with a tab  140  extending upwards of the second safety surfacing tile  2  such that the cooperating surfaces of the tabs match and lock and three safety surfacing tiles  1 ,  2 ,  3  are now interlocked. 
     Accordingly, an embodiment of the safety surfacing tile or mat  100  is fastened to another safety surfacing tile/mat by receiving the outer edge of the tile  100  within an upwardly directed groove of the locking member  105 . The grooves serve to hold the edges of the tiles against one another. 
     In one embodiment, the safety surfacing tile  100  features a locking member  105  that 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 of  FIG. 3 , if tile  2  had a downward extending tab on the right side instead of an upward extending tab  140 , then the right side of tile  2  would have to be lifted in order to position the corresponding tab of tile  3  so that the two tabs could lock. Accordingly, when a tile  100  has downward interlocking tabs or grooves  120 ,  130  on all four sides, a side of the tile  100  (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 tile  100 . 
     In contrast (and referring to  FIG. 4 ), by having downward tabs or grooves  120 ,  130  on two sides and upward tabs/grooves  140 ,  150  on the other two sides, the downward tabs  120 ,  130  of a tile  2  being placed into position is matched with the upwards tabs  140 ,  150  of a tile  1  that has already been positioned, leaving two sets of upward tabs  140 ,  150  available to be used to lock or connect with a tile  3  being positioned next to tile  2  (previously positioned). Similarly, a tile  4  may be laid onto the upward tab  140  of tile  2  into position as shown. Therefore, the most recent tile  4  placed has two tabs/grooves  140 ,  150  sticking out and up so that the next tile  5  can sit on top of the appropriate tabs/grooves  150  and also sit on the upward tabs/grooves  140  of tile  3  and is now in proper position and interlocked with the other tiles  1 ,  2 ,  3 ,  4 . In a situation where additional upwards tabs  140 ,  150  are needed, a lock support member (as is later discussed with respect to  FIG. 7 ) may also be used. 
     In one embodiment, it is noted that the safety surfacing tile features a notch  540  (see  FIG. 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 tile  100  incorporates a bottom support grid on the underside of the tile, as shown in  FIG. 5 . In one embodiment of the grid, a series of horizontal members  510  support the top surface of the tile  100  and extend continuously from one side of the tile  100  across a horizontal length of the tile  100  up to an interlocking tab  150  that extends upwards (away from the bottom of the tile). The series of horizontal members  510  contact a floor or underlying surface (e.g., concrete, asphalt, dirt, wood, etc.) when the safety surfacing tile  100  is positioned on the floor or underlying surface. The safety surfacing tile  100  also contains a series of vertical members  520  supporting the top surface and extending across a vertical length of the safety surfacing tile  100  up from an interlocking tab  140  upwards to one of the series of horizontal members  510 . The series of vertical members  520  contact the floor or underlying surface when the safety surfacing tile  100  is positioned on the floor or underlying surface. Support foot(s)  515 ,  525  are features on respective horizontal and vertical members  510 ,  520  to provide additional supports to help cushion or support a weight placed on the surfacing tile. 
     It is shown that the series of vertical members  520  connect with the series of horizontal members  510  to form a grid of voids  530  on the underside of the tile  100 . The grid of voids aids in cushioning impact of an object on the top surface  110  of the safety surfacing tile  100  and absorbing impact energy. Upon impact, the upper surface of the safety surfacing tile  100  is capable of being temporarily deformed into one or more voids  530 . 
       FIG. 6  is provided to show one embodiment of the grid of voids, where a series of horizontal members  510  are shown connecting with respective ones of a series of vertical members  520  forming a grid  600 . The grid  600  forms a series of voids  530  that 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 voids  530  oriented in a longitudinal direction running vertically at one end of the surfacing tile  100 . 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 voids  530  oriented in a longitudinal direction running vertically at the other end of the surfacing tile  100 . 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. 6  shows an enlarged view  605  of two of the vertical members  520  from the grid  600 , 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 tile  100  is made of solid resilient rubber including the horizontal and vertical members  510 ,  520 . As explained above, the individual vertical members  520  have a solid shape, where a narrow base of the vertical member  520  is in contact with the floor or underlying surface during use and the wider base of the vertical member  520  is adjacent to the upper surface. 
     The sides of the vertical members  520  help form the shapes of the voids  530  adjacent to the vertical members  520 . Accordingly, in one embodiment, the voids  530  share 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 tile  100  is positioned. While the shape of the vertical member  520  has a wider base at the upper surface (closest to the upper surface of the surfacing tile), the shape of the void  530  has a narrow base at the upper surface and a wider base at the bottom surface (closest to the ground upon which the tile  100  may be positioned). 
     The sides of the horizontal members  510  are 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 members  510  may comprise a rectangular cuboid shape having six flat rectangular sides with all right angles, in one embodiment. However, the sides of the horizontal members  510  may 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 tile  100  allow for better surface adhesion preventing curling and separation that may occur with other surfacing tiles. In one embodiment, the safety surfacing tiles  100  are 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 tiles  100  may 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 tile  100  allows 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 tile  100  is designed so that the outer sides of the tile  100  have escape channels or port(s) in the form of the voids at the outer perimeter that allow water to escape. The horizontal and vertical members  510 ,  520  also provide conduits or passageways  540  (see  FIG. 5 ) through which water may flow from one void  530  to the next towards the outer perimeter of the tile  100 . In one embodiment, the conduits  540  have a prismoid or cuboid shape. 
     The vertical and horizontal members  510 ,  520  structurally hold the safety surfacing tile  100  in a desired form from side to side and achieve horizontal and vertical lines to keep the tile  100  from shrinking or curling after repeated use and/or exposure. The safety surfacing tile  100  is structurally sound because all four sides are attached by underlying structural supports  510 ,  520  that extend the length of the tile in both vertical and horizontal directions and create the shape of the voids  530  which affect the profile of how energy is dissipated by the supports  510 ,  520  during an impact. The narrowing projections of the vertical members  510  have been observed to reduce peak deceleration and lessen the impact during a fall. 
     In the configuration shown in  FIG. 6 , as an example, the arrangement of the plurality of the intersecting members  510 ,  520  significantly affects a Critical Fall Height of the surface of the safety surfacing tile  100 . In particular, the members  510 ,  520  are arranged to deform into the voids  530  to 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.” 
     As previously discussed, one embodiment of safety surfacing tiles  100  are manufactured in 2′×2′ (24 inches×24 inches) squares. Thicknesses may vary depending on CFH requirements. In some embodiments, thicknesses of safety surfacing tiles correspond to 1″, 1.5″, 2″, 2.75″, 3″, 3.25″, 3.5″, 3.75″, 4″. 
     Further, the top surface  110  maybe non-slip and porous to provide additional safety measures. Particularly, the safety surfacing tiles  100  may 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. 7  shows one embodiment of the locking support mechanism  710 , where  710 A is a top view of the locking support mechanism and  710 B is a perspective view. 
     For example, consider a surfacing tile that has a side  120 ,  130  that 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 side  120 ,  130  and interlocking tab  125 ,  135  to provide structural support, as is depicted in  FIG. 8 . 
     In  FIG. 8 , first, a surfacing tile is shown next to locking support mechanism  710 . The locking support mechanism is placed next to side  130  of the surfacing tile. Next, the locking support mechanism is locked with the interlocking tab  135  of the surfacing tile. The interlocking tab  135  has a male portion that extends downward from the surfacing tile and mates with a female portion of the locking support mechanism  710 , as shown in  FIG. 8  and also depicted in  FIG. 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. 9  shows the surfacing tile  100  next to the locking support structure  710 . Next ( 920 ), the surfacing tile  100  is shown connected or locked with the locking support structure  710  where the interlocking tab  135  of the tile mates with the locking support structure  710 . The locking support structure  710 , 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 stage  930 ). In this way, a ramp  710  or 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 structure  710 . In one embodiment, the locking support structure  710  has the following or substantially the following dimensions: H 1 = 6/16 inches, W 1 = 8/16 inches, W 2 =1 inch, W 3 =2 inches, H 4 =1.5 inches. Depending on dimensions of different surfacing tiles, the dimensions of the locking support structure  710  may change accordingly. 
     In an arrangement where another structure is not to be connected to the locking support structure  410 , some embodiments provide cutting grooves  1010  on the top and bottom surface of the structure  410 , as shown in  FIG. 10 . Therefore, the locking support structure  410  may be split into halves  410 A,  410 B by cutting the structure  410  at the cutting grooves  1010  and then one half  410 B is locked with a side of the interlocking tile  100  in 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.

Technology Classification (CPC): 4