Patent Document

RELATED APPLICATIONS 
       [0001]    This application claims the benefit of U.S. provisional patent application 61/679,708 filed Aug. 4, 2012 to the same inventors. 
     
    
     TECHNICAL FIELD 
       [0002]    This invention relates to a cushion or pad for walls within sports arenas for assisting in protecting athletes during collisions with arena walls. More particularly, it relates to providing improved arena wall pads that are easy to manufacture and provide better protection for athletes. 
       BACKGROUND 
       [0003]    Pads are used on walls in sports arenas to assist in protecting athletes during collisions with walls. The pads are sectional and are hung from the wall to be protected. A typical prior art pad is a rectangular foam block with a plywood backing and wrapped in a vinyl covering over the front, two sides, top and bottom edges, and at least part of the rear surface of the plywood panel. During the vinyl wrapping process, the front edges of the rectangular foam block are rounded by pressure from the vinyl wrapping. When the prior art pads are arranged on a wall with sides abutting, the padding on the wall is less thick along the line of abutment, or seam, and so provides less padding. Most of the serious injuries to major league baseball players in the past year due to wall collisions have happened at seams between wall pads. 
         [0004]    An attempt to ameliorate this problem is found in U.S. Pat. No. 7,727,609 to Crasno which uses a lap joint between TEMPER-FOAM™ pads. Crasno does not disclose wrapping in vinyl or providing any other protective coating to defend the foam against abrasion, debris from sports fans, or the weather. The design could not be easy wrapped with vinyl, as the wrapping would bend the narrow portion of the lap into a dysfunctional position. Crasno&#39;s lap joints are coupled with hook and loop fasteners, which adds to the manufacturing and installation cost. 
         [0005]    Therefore, a need exists for an arena wall pad that is inexpensive to manufacture and install and which provides increased protection for athletes during collisions at seams. 
       OBJECTS AND FEATURES OF THE INVENTION 
       [0006]    A primary object and feature of the present invention is to overcome the above-mentioned problems and fulfill the above-mentioned needs. 
         [0007]    Another object and feature of the present invention is to provide an arena wall pad that provides increased protection at the seams. 
         [0008]    It is a further object and feature of the present invention to provide a wall pad that is no more difficult to install than prior art arena wall pads. 
         [0009]    It is a further object and feature of the present invention to provide an arena wall pad that is resistant to the effects of abrasion, impact from athletes, impact from debris launched by sports fans, and weather. 
         [0010]    It is a further object and feature of the present invention to provide a sports arena pad that is economical to manufacture and install. 
         [0011]    It is an additional primary object and feature of the present invention to provide such a system that is replaceable, effective, and handy. Other objects and features of this invention will become apparent with reference to the following descriptions. 
       SUMMARY OF THE INVENTION 
       [0012]    In accordance with a preferred embodiment hereof, this invention provides a sports arena wall pad that provides increased protection at the side abutments, but is economical to manufacture and install and is durable. The sports arena wall pad of the present invention uses a substantially rigid (i.e., plywood) backing panel supporting a two-layer foam, generally rectangular, pad with two opposing oppositely (complimentarily) beveled sides for abutting adjacent sports arena wall pads of the present invention. The beveled sides provide overlapping beveled joints at the seams, which provide superior protection. The outer layer of foam is more dense and resilient than the inner layer of foam. The entire front, four sides and at least part of the back of the plywood backing is wrapped in weather-resistant vinyl. The rear surface of the backing panel has clips for attachment to arena walls. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0013]    The present invention will hereinafter be described in conjunction with the following drawing figures, wherein like numerals denote like elements, and 
           [0014]      FIG. 1  is a diagrammatic horizontal cross-sectional view illustrating a prior art sports arena wall pad; 
           [0015]      FIG. 2  is a diagrammatic top view illustrating a plurality of prior art sports arena wall pads in a linear, side-by-side configuration; 
           [0016]      FIG. 3  is a diagrammatic horizontal cross-sectional view illustrating an exemplary embodiment of an improved sports arena wall pad, according to a preferred embodiment of the present invention; 
           [0017]      FIG. 4  is a diagrammatic top view illustrating a plurality of the exemplary embodiments of the improved sports arena wall pads of  FIG. 3 , according to a preferred embodiment of the present invention; 
           [0018]      FIG. 5  is a diagrammatic bottom view illustrating the plurality of the exemplary embodiments of the improved sports arena wall pads of  FIG. 3 , according to a preferred embodiment of the present invention; 
           [0019]      FIG. 6  is a diagrammatic front view illustrating the plurality of the exemplary embodiments of the improved sports arena wall pads of  FIG. 3 , according to a preferred embodiment of the present invention; 
           [0020]      FIG. 7  is a diagrammatic rear view illustrating the plurality of the exemplary embodiments of the improved sports arena wall pads of  FIG. 3 , according to a preferred embodiment of the present invention; and 
           [0021]      FIG. 8  is a diagrammatic horizontal cross-sectional view illustrating another exemplary embodiment of an improved sports arena wall pad, according to a preferred embodiment of the present invention. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0022]    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. 
         [0023]      FIG. 1  is a diagrammatic horizontal cross-sectional view illustrating a prior art sports arena wall pad  100 . The prior art sports pad consists of a rectangular plywood backing  102  to which a rectangular foam pad  104  is adhesively attached. A typical thickness  110  for the foam pad  104  is five inches. The combined foam pad  104  and plywood backing  102  are wrapped in a vinyl wrapping  106  that rounds the corners  114  and  118  of the foam pad  104 . Sides  112  and  116  are intended to abut adjacent prior art sports arena wall pads  100  when installed in a series. Each prior art sports arena wall pad  100  has one or more (two illustrated) Z-clips  108  for mounting the prior art sports arena wall pad  100  to an arena wall  204  (see  FIG. 2 ). Z-clips  108  are secured to plywood backing  102  using screws  120 , which are shown partially extended for visibility in the drawing. 
         [0024]      FIG. 2  is a diagrammatic top view illustrating a plurality  200  of prior art sports arena wall pads in a linear, side-by-side configuration. The prior art pads  100  are hung on arena wall  204  via Z-clip-receiving channel  206  that is attached to the arena wall  204 . Seams  202  between prior art sports arena wall pads  100  result in reduced thickness  208  relative to thickness  101  (see  FIG. 1 ), creating a danger for athletes impacting the plurality  200  of prior art sports arena wall pads  100  at seams  202 . In addition, seams  202  enable sideways compression of the prior art sports arena wall pads  100 , which opens the seams  202 , further endangering the athletes. 
         [0025]      FIG. 3  is a diagrammatic horizontal cross-sectional view illustrating an exemplary embodiment of an improved sports arena wall pad  300 , according to a preferred embodiment of the present invention. Improved sports arena wall pad  300  has a rigid, preferably plywood, backing  302  on which the remainder of sports arena wall pad  300  is 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°. 
         [0026]    Plywood backing panel  302  is preferably thick enough to support the improved sports arena wall pad  300  during storage, transport, installation, and in the particular use for the improved sports arena wall pad  300 . For non-limiting example, a plywood backing panel  302  for an improved sports arena wall pad  300  in a professional baseball arena is ¾ of an inch thick. 
         [0027]    For a smaller improved sports arena wall pad  300 , a plywood backing panel that is five-eighths of an inch thick may suffice. The thickness of the plywood backing panel  302  must be sufficient to engage screws  320  and large enough to secure the Z-clips  308  that support the weight of the improved sports arena wall pad  300  and 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 pad  300  when installed. APA grade B-C exterior plywood with a coating of paint on the rear (arena wall-engaging side) surface  332  that matches the color of the vinyl wrapping  306  is preferred for use as plywood backing panel  302 . In particular embodiments, backing panels made of other materials and having equivalent functionality may be substituted for plywood backing panel  302 . 
         [0028]    First foam panel  304  is adhesively attached to plywood backing panel  302 , as shown, using a high-adhesive glue that remains stable in hot or cold weather. First foam pad  304  is 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 panel  304 . The thickness of first foam panel  304  may vary with the particular application for which the improved sports arena wall pad  300  will be used. First foam pad  304  has oppositely beveled opposing first and second sides  324  and  326  with first and second bevel angles α and β, respectively, as previously described. Preferably, first foam panel  304  covers a front surface of backing panel  302 , as shown. 
         [0029]    Second foam panel  305  is a high-density foam that is adhered to first foam panel  304  using 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 panel  305 . The high density of second foam panel  305  reduces rounding at the corners  314  and  318  from wrapping and provides additional protection for the athlete. Second foam panel  305  is preferably at least two inches thick to provide a total thickness  110  for the combined first and second foam panels  304  and  305  of at least five inches. Thicker combined first and second foam panels  304  and  305  are within the scope of the invention. Second foam panel  305  has oppositely beveled opposing first and second sides  328  and  330  with complimentary bevel angles α and β, respectively, as previously described. Preferably, second foam panel  305  covers the front surface of first foam panel  304 , as shown. 
         [0030]    Vinyl wrapping  306  covers first and second foam pads  304  and  305  and at least a portion of the rear surface  332  of the plywood backing panel  302 . Vinyl wrapping  306  is shown in exaggerated scale in  FIG. 3  for clarity of illustration. For non-limiting example, vinyl wrapping  306  is 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 wrapping  306  that at least partially covers the rear surface  332  of plywood backing  302  is stapled near the edge to the plywood backing  302 . In a particular embodiment, the vinyl wrapping  306  is 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 wrapping  306  to the plywood backing  302  involves some folding of the vinyl wrapping  306  on the rear surface  332  of the plywood backing  302 . Such folding is preferably done in a manner to avoid creating rain catchments in the folds. 
         [0031]    Z-clips  308  are a first part of a two-part wall-hanging system and are designed to be fastened to the plywood backing  302 , as shown, and to engage a second part  206  (see  FIG. 4 ) of the two-part wall hanging system that is fastened to the arena wall  204  (See  FIG. 4 ). For non-limiting example, Z-clips  308  are extruded aluminum, one-eighth of an inch thick and two and one-half inches wide, and are fastened to the plywood backing  302  with ¼″×1″ galvanized steel screws  320 . In various particular embodiments, various types of wall-hanging hardware may be used. 
         [0032]    Manufacturing of the improved sports arena wall pads  300  is similar to manufacturing of prior art sports arena wall pads  100 , except that the first and second foam pads  304  and  305  must be beveled on the sides, and the size of the improved sports arena wall pads  300  should be economically selected to adapt to commercially available widths of vinyl wrapping  306 , as the perimeter of the improved sports arena wall pads  300  is slightly greater than the perimeter of the prior art sports arena wall pads  100 . 
         [0033]    In addition to the improved sports arena wall pad  300  illustrated, an improved sports arena wall pad may be fashioned with one beveled side  316  and one non-beveled side  112  for use in corners of arena walls  204 . 
         [0034]      FIG. 4  is a diagrammatic top view illustrating a plurality  400  of the exemplary embodiments of the improved sports arena wall pads  300  of  FIG. 3 , according to a preferred embodiment of the present invention. When installed in linear sequence, as shown, the oppositely beveled sides  312  and  316  of improved sports arena wall pads  300  form a beveled seam  402  that does not create an area of reduced thickness  208  and does not open like seams  202  in response to impact. Improved sports arena wall pads  300  install in the same manner and, optionally, with the same hardware  308  and  320  as prior art sports arena wall pads  100 . As a result, improved sports arena wall pads  300  are easy to manufacture and install. The number of improved sports arena wall pads  300  illustrated is exemplary, and does not limit the number of improved sports arena wall pads  300  that can be arranged in linear fashion. Installation along gradually curved walls is also possible. 
         [0035]      FIG. 5  is a diagrammatic bottom view illustrating the plurality  400  of the exemplary embodiments of the improved sports arena wall pads  300  of  FIG. 3 , according to a preferred embodiment of the present invention. Bottom surfaces  502  of improved sports arena wall pads  300  have weep holes  504  (one of nine labeled) for venting water that may work its way into the improved sports arena wall pads  300 . The positioning of weep holes  504  is exemplary, and not intended to be limiting. Weep holes  504  may also vent air during impact, and may be sized to provide the best air cushioning affect for the athlete. 
         [0036]      FIG. 6  is a diagrammatic front view illustrating the plurality  400  of the exemplary embodiments of the improved sports arena wall pads  300  of  FIG. 3 , according to a preferred embodiment of the present invention. Beveled side  312  is shown. Any number of improved sports arena wall pads  300  may be arranged together. The particular rectangular proportions shown are merely exemplary, and are not intended to limit the invention. 
         [0037]      FIG. 7  is a diagrammatic rear view illustrating the plurality  400  of the exemplary embodiments of the improved sports arena wall pads  300  of  FIG. 3 , according to a preferred embodiment of the present invention. Placement of Z-clips  308  (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. 
         [0038]      FIG. 8  is a diagrammatic horizontal cross-sectional view illustrating another exemplary embodiment of an improved sports arena wall pad  800 , according to a preferred embodiment of the present invention. Improved sports arena wall pad  800  has a plywood backing  802  with oppositely beveled opposing first and second sides  820  and  822 . 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 sides  820  and  822  may be rounded to reduce wear on the vinyl wrapping  306 . 
         [0039]    Plywood backing  802  is preferably thick enough to support the improved sports arena wall pad  800  during storage, transport, installation, and in the particular use for the improved sports arena wall pad  800 . For non-limiting example, a plywood backing  802  for an improved sports arena wall pad  800  in a professional baseball arena is ¾ of an inch thick. For a smaller improved sports arena wall pad  800 , a plywood backing that is five-eighths of an inch thick may suffice. The thickness of the plywood backing  802  must be sufficient to engage screws  320  large enough to secure the Z-clips  308  that support the weight of the improved sports arena wall pad  800  and 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 pad  800  when installed. APA grade B-C exterior plywood with a coating of paint on the rear (arena wall-engaging side) surface  332  that matches the color of the vinyl wrapping  306  is preferred for use as plywood backing  802 . In particular embodiments, panels made of other materials and having equivalent functionality may be substituted for plywood backing  802 . 
         [0040]    First foam pad  304  is adhesively attached to plywood backing  802 , as shown, using a high-adhesive glue that remains stable in hot or cold weather. First foam pad  304  is 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 pad  304 . 
         [0041]    The thickness of first foam pad  304  may vary with the particular application for which the improved sports arena wall pad  300  will be used. First foam pad  304  has oppositely beveled opposing first and second sides  324  and  326  with first and second complimentary bevel angles α and β, respectively, as previously described. 
         [0042]    Second foam pad  305  is a high-density foam that is adhered to first foam pad  304  using 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 pad  305 . The high density of second foam pad  305  reduces rounding at the corners  314  and  318  and provides additional protection for the athlete. Second foam pad  305  is preferably at least two inches thick to provide a total thickness  110  for the combined first and second foam pads  304  and  305  of at least five inches. Thicker combined first and second foam pads  304  and  305  are within the scope of the invention. Second foam pad  305  has oppositely beveled opposing first and second sides  328  and  330  with complimentary bevel angles α and β, respectively, as previously described. 
         [0043]    Vinyl wrapping  306  covers first and second foam pads  304  and  305  and at least a portion of the rear surface  332  of the plywood backing panel  802 . Vinyl wrapping  306  is shown in exaggerated scale in  FIG. 3  for clarity of illustration. For non-limiting example, vinyl wrapping  306  is 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 wrapping  306  that at least partially covers the rear surface  332  of plywood backing  802  is stapled near the edge to the plywood backing  802 . In a particular embodiment, the vinyl wrapping  306  is 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 wrapping  306  to the plywood backing  802  involves some folding of the vinyl wrapping  306  on the rear surface  332  of the plywood backing  802 . Such folding is preferably done in a manner to avoid creating rain catchments in the folds. 
         [0044]    Z-clips  308  are 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 part  206  (see  FIG. 4 ) of the two-part wall hanging system that is fastened to the arena wall  204  (See  FIG. 4 ). For non-limiting example, Z-clips  308  are extruded aluminum one-eighth of an inch thick and two and one-half inches wide and are fastened to the plywood backing  802  with ¼″×1″ galvanized steel screws  320 . In various particular embodiments, various types of wall-hanging hardware may be used. 
         [0045]    Manufacturing of the improved sports arena wall pads  800  is similar to manufacturing of prior art sports arena wall pads  100 , except that the plywood backing panel  802  and the first and second foam pads  304  and  305  must be beveled on the sides, and the size of the improved sports arena wall pads  800  should be economically selected to adapt to commercially available widths of vinyl wrapping, as the perimeter of the improved sports arena wall pads  800  is slightly greater than the perimeter of the prior art sports arena wall pads  100 . 
         [0046]    Although applicant has described applicant&#39;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. 
         [0047]    Further, many other advantages of applicant&#39;s invention will be apparent to those skilled in the art from the above descriptions and the claims below.

Technology Category: 1