U.S. patent application number 11/473521 was filed with the patent office on 2007-02-22 for modular surfacing system.
Invention is credited to Neil E. JR. Krushke, Thomas Siebert.
Application Number | 20070042828 11/473521 |
Document ID | / |
Family ID | 37307407 |
Filed Date | 2007-02-22 |
United States Patent
Application |
20070042828 |
Kind Code |
A1 |
Krushke; Neil E. JR. ; et
al. |
February 22, 2007 |
Modular surfacing system
Abstract
A modular surfacing mat that includes a base mat, a top mat
secured to the base mat with an adhesive, and a top coat applied to
the top of the top mat to form a protective finish. The top coat
may be any coating that provides a protective top finish on the
mat, and is preferably a polyurea or polyurethane. The top coat may
include a colorant. The top mat is preferably at least partially
made from rubber. For example, recycled rubber may be used. The
adhesive that bonds the top mat to the base mat is preferably a
polyurethane or a polyurea. The base mat is preferably made from a
cellular foam structure. For example, cellular foam strucutre may
be closed cell polyethylene foam nuggets fused together in a
crosslinked matrix.
Inventors: |
Krushke; Neil E. JR.;
(Chagrin Falls, OH) ; Siebert; Thomas; (Shaker
Heights, OH) |
Correspondence
Address: |
SQUIRE SANDERS & DEMPSEY LLP
TWO RENAISSANCE SQUARE, 40 NORTH CENTRAL AVENUE
SUITE 2700
PHOENIX
AZ
85004-4498
US
|
Family ID: |
37307407 |
Appl. No.: |
11/473521 |
Filed: |
June 22, 2006 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60693240 |
Jun 22, 2005 |
|
|
|
60724555 |
Oct 6, 2005 |
|
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Current U.S.
Class: |
472/92 |
Current CPC
Class: |
E01C 2201/14 20130101;
B32B 25/00 20130101; B32B 2272/00 20130101; B32B 27/06 20130101;
E04F 15/105 20130101; E04F 15/02194 20130101; E04F 2201/095
20130101; E01C 13/08 20130101; B32B 5/18 20130101; B32B 27/32
20130101; E04F 2201/091 20130101; E01C 5/22 20130101; B32B 25/08
20130101; E04F 2201/096 20130101; E04F 15/107 20130101; B32B 27/40
20130101; E04F 2201/098 20130101 |
Class at
Publication: |
472/092 |
International
Class: |
A63J 3/00 20060101
A63J003/00 |
Claims
1. A modular surfacing mat comprising: a base mat; a top mat
secured to the base mat with an adhesive; and a top coat applied to
the top of the top mat to form a protective finish.
2. The modular surfacing mat of claim 1 wherein the top coat
includes a colorant.
3. The modular surfacing mat of claim 1 wherein the top coat is a
polyurethane.
4. The modular surfacing mat of claim 1 wherein the top coat is a
polyurea.
5. The modular surfacing mat of claim 1 wherein the top mat is at
least partially made of rubber.
6. The modular surfacing mat of claim 5 wherein the rubber is
recycled rubber.
7. The modular surfacing mat of claim 1 wherein the adhesive is a
polyurethane.
8. The modular surfacing mat of claim 1 wherein the adhesive is a
polyurea.
9. The modular surfacing mat of claim 1 wherein the base mat is a
closed cell foam mat.
10. The modular surfacing mat of claim 9 wherein the closed cell
foam mat is formed from closed cell polyethylene foam nuggets fused
together in a crosslinked matrix.
11. The modular surfacing mat of claim 1 wherein the base mat and
top mat have substantially symmetric horizontal cross sections.
12. The modular surfacing mat of claim 1 wherein the base mat and
top mat have three or more sides.
13. The modular surfacing mat of 12 wherein the three or more sides
of the base mat and top mat include tab and slot features of
interlocking two or more mats together.
14. A modular surfacing system comprising: two or more modular
surfacing mats comprising: a base mat; a top mat secured to the
base mat with an adhesive; and a top coat applied to the top of the
top mat to form a protective finish, wherein each base mat and top
mat has three or more sides.
15. The modular surfacing system of claim 14 wherein the three or
more sides of each base mat and top mat include tab and slot
features of interlocking two or more mats together.
16. The modular surfacing system of claim 14 wherein each base mat
and top mat has substantially symmetric horizontal cross
sections.
17. The modular surfacing system of claim 14 wherein the top coat
includes a colorant.
18. The modular surfacing system of claim 14 wherein the top coat
is a polyurethane.
19. The modular surfacing system of claim 14 wherein the top coat
is a polyurea.
20. The modular surfacing system of claim 14 wherein the top mat is
at least partially made of rubber.
21. The modular surfacing system of claim 20 wherein the rubber is
recycled rubber.
22. The modular surfacing system of claim 14 wherein the adhesive
is a polyurethane.
23. The modular surfacing system of claim 14 wherein the adhesive
is a polyurea.
24. The modular surfacing system of claim 14 wherein the base mat
is a closed cell foam mat.
25. The modular surfacing system of claim 24 wherein the closed
cell foam mat is formed from closed cell polyethylene foam nuggets
fused together in a crosslinked matrix.
26. The modular surfacing system of claim 24 wherein the two or
more modular surfacing mats include a first group of modular
surfacing mats and a second groups of modular surfacing mats,
wherein the first group of modular surfacing mats have a base mat
with a first density of closed cell foam and the second group of
modular surfacing mats have a base mat with a second density of
closed cell foam.
27. The modular surfacing system of claim 26 wherein the first
density is greater than the second density, whereby the first group
of modular surfacing mats meet a higher fall height safety standard
than the second group of modular surfacing mats.
28. The modular surfacing system of claim 22 wherein the first and
second group of modular surfacing mats have substantially the same
thickness.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional
Application No. 60/693,240, filed Jun. 22, 2005, and U.S.
Provisional Application No. 60/724,555, filed Oct. 6, 2005, the
contents of both of which are incorporated herein by reference.
DESCRIPTION OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates generally to surfacing
systems, and more particularly to a modular surfacing system for
use in recreational, institutional and other applications.
[0004] 2. Background of the Invention
[0005] Many factors are taken into consideration when selecting
flooring and surfacing products for use in recreational and
institutional settings. Such factors may include cost, ease of
installation, durability, and aesthetics. In addition, safety and
handicap accessibility are also often considered. Conventional
flooring and surfacing systems are often exhibit poor
characteristics with regard to at least one of these factors.
[0006] In playground and recreational settings, most injuries occur
when people fall from playground equipment from a height of 3 to 10
feet onto the ground. To reduce the severity of these injuries, the
U.S. Consumer Products Safety Commission (CPSC) has issued
guidelines that playground safety surfacing must meet in order to
be designated as an approved safety surface. The American Society
for Testing and Materials (ASTM) has interpreted guidelines issued
by the CPSC into standardized testing procedures in order to
determine if a safety surface meets the CPSC requirements. One such
standard is ASTM F1292-04--Standard Specification for Impact
Attenuation of Surface Systems Under and Around Playground
Equipment. Critical Fall Height or Head Impact Criteria (HIC) is
the ability of a surface to absorb and dissipate the force created
when falling from a specified height in order to protect from life
threatening head injuries. The areas in and around playground
equipment must be able to provide adequate impact attenuation from
the highest point of the playground equipment. Currently, in the
U.S., that is measured from the highest platform. In Canada, falls
are measured from a specified measurement over the guard
railing.
[0007] Conventional surfacing systems often vary the thickness of
the surfacing to meet different ASTM safety standards, specifically
standards for safe fall height like ASTM F1292. However, fall
height requirements for some areas such as playgrounds vary across
the area. For example, fall height requirements for an area around
a swing may be greater than fall height requirements around
playground equipment that is lower to the ground. As such, when
choosing a playground surface, it is often necessary to select a
surfacing that will meet the highest fall height requirement for
the entire playground because surfaces that meet different
requirements have different thicknesses. This increases the cost of
installing such a surface because thicker surfaces are generally
more costly than thinner surfaces.
[0008] One of the least expensive methods for surfacing ground
under playground equipment is known as "engineered wood fiber," or
"EWF." An engineered wood fiber surface traditionally is comprised
of specialty shredded virgin wood or recycled pallets, wood chips
or other cushioning materials scattered like mulch on the ground
under the playground equipment. Unfortunately, engineered wood
fiber can shift and become uneven due to weather and or kick-out by
children, providing less protection in one spot than in another
spot. If a person was to fall onto a less-protected spot, they
could suffer injuries that would have been avoided had the
engineered wood fiber been more evenly distributed.
[0009] Another problem with some engineered wood fiber is that
areas protected by engineered wood fiber are rarely wheelchair
accessible. The ASTM has promulgated a wheelchair accessibility
standard known as F1951, and entitled "Standard Specification for
Determination of Accessibility of Surface Systems Under and Around
Playground Equipment Document Number," that playgrounds that are
protected only by engineered wood fiber are not likely to meet. In
1990, Congress passed the Americans with Disabilities Act commonly
referred to as the ADA. The US Access Board has worked with outside
agencies to determine guidelines for surface accessibilities. As
the government becomes more aggressive in enforcing standards for
handicap accessibility, the likelihood increases that engineered
wood fiber will be targeted as failing to meet minimal
standards.
[0010] Another method for surfacing ground under playground
equipment is known as "loose fill." Loose fill is similar to
engineered wood fiber in that it is scattered on the ground under
the playground equipment, but loose fill is traditionally made of
rubber chips or other cushioning material. Some loose fill is made
of shredded tires or other recycled materials. Like engineered wood
fiber, loose fill can shift and become uneven, providing less
protection in one spot than in another spot. Loose fill is also
unlikely to meet the ASTM standard F1951. Consequently, playgrounds
covered with loose fill are unlikely to be certified as wheelchair
accessible.
[0011] A third prevalent method for surfacing ground under
playground equipment is called unitary surfacing, such as a rubber
mat or a "pour-in-place" surface (described below). Many
commercially-available rubber mats are adequate to protect children
from falls of 3 to 6 feet. Rubber mats may be purchased as separate
interlocking pieces of rubber mat. For example, rubber mats are
available in 2-ft by 2 ft, 3-ft by 3-ft, or 3-ft by 4-ft, sections
that can be locked together.
[0012] Rubber mats, however, can be very heavy to ship. To cover an
entire playground, a very large number of separate interlocking
pieces may be needed, and each piece may be required have a
thickness adequate to protect children from at least a moderate
fall. Also, rubber mats can be very expensive and can be easily
vandalized. Due to the cost and the weight, rubber mats are not
appropriate for all playgrounds.
[0013] "Pour-in-place," surfaces are more common than rubber mats.
A pour-in-place surface is a unitary surface that is manufactured
on the playground itself. First, a shock-absorbing material such as
fine rubber crumbs, small rubber chunks, and/or rubber slivers are
dumped into a mixer that is similar to a portable cement mixer.
This mixture may be, for example, shredded recycled tires. A
suitable liquid that subsequently can form a polymer upon exposure
to moisture in the air, such as a polyurethane, is then poured into
the mixer and mixed with the shock absorbing material to create a
slurry. The slurry subsequently is transported, generally in a
wheelbarrow or in several buckets, to a site that is to be
protected. Laborers then trowel the slurry over the site and allow
the slurry to set for at least a day. A guard might be posted to
prevent children from playing on the surface during the day that is
necessary for the slurry to set. Later, a second slurry composed of
colored rubber particles in the same polymeric liquid precursor is
poured and troweled over the previously prepared site to form a
finished consolidated colored rubber surface.
[0014] The pour-in-place method is very labor intensive. Covering a
typical 2000 square-foot playground may require three laborers two
full work days to install. If the liquid precursor polyurethane is
not mixed thoroughly enough with the fine rubber crumbs, the entire
surface might have to be torn up and the site resurfaced so that
the fine rubber crumbs can be distributed or mixed more evenly. Up
to thirty percent of all pour-in-place surfaces fail during the
first year, primarily due to improper temperature and humidity
conditions. Pour-in-place surfaces are typically porous, allowing
water and environmental wastes to seep into cracks and pores,
possibly lowering the Head Impact Criteria within a short time.
These porous surfaces can act like a giant filter, trapping dirt,
pollen and waste.
SUMMARY OF THE INVENTION
[0015] In view of the foregoing, the present invention provides
modular surfacing mats and a modular surfacing system that is
applicable for use useable outdoors (e.g., on playgrounds) as well
as indoors (e.g., for institutional settings such as nursing
homes).
[0016] According to one embodiment, the invention provides a
modular surfacing mat that includes a base mat or shock absorbing
mat, a top mat secured to the base mat with an adhesive, and a top
coat applied to the top of the top mat to form a protective finish.
The top coat may be any coating that provides a protective top
finish on the mat, and is preferably a polyurea or polyurethane.
The top coat may include a colorant. The top mat is preferably at
least partially made from rubber. For example, recycled rubber may
be used. The adhesive that bonds the top mat to the base mat is
preferably a polyurethane or a polyurea, but any adhesive may be
used. The base mat is preferably made from a closed cell foam. For
example, the closed cell foam may be closed cell polyethylene foam
nuggets fused together in a crosslinked matrix. The closed cell
foam may also be made of expanded polypropylene, expanded
polyethylene, or expanded polystyrene.
[0017] According to another embodiment of the invention, one or
more modular surfacing mats may be combined to form a modular
surfacing system. Preferably, the base mat and top mat of each
modular mat have substantially symmetric horizontal cross sections
and three or more sides. Each of these may be straight or have tab
and slot features of interlocking two or more mats together.
Straight side mats allow for easier customization by the end user,
while mats with slot and tab features allow for improved locking of
a plurality of mats together. The slot and tab features may be of
any shape that allows for mats to interlock, such as mortise and
tenon, dovetail, or generally shaped like a puzzle piece.
[0018] According to still another embodiment of the invention, a
modular surfacing system may include two or more modular surfacing
mats that include a first group of modular surfacing mats and a
second group of modular surfacing mats. The first group of modular
surfacing mats has a base mat with a first density of closed cell
foam and the second group of modular surfacing mats has a base mat
with a second density of closed cell foam. The first and second
groups of modular surfacing mats have the substantially the same
thicknesses. In this way, mats of differing densities, and as such
different fall height characteristics, may be used on the same
playground as they have the same thickness.
[0019] According to other aspects of the invention, an adhesive
sealant may also be used to bond one or more base mats to a
substrate that underlies the modular surfacing mats. Examples of
substrates include concrete, cement, asphalt, crushed limestone,
tile, linoleum, wood, and existing pour-in-place surfaces.
[0020] According to another aspect of the invention, the modular
surfacing mats may configured as a multi-layer arrangement having a
plurality of layers, each of the plurality of layers being at least
one of a base mat and a top mat with an adhesive as both the
topcoat and adhesive between the layers.
[0021] According to another aspect of the invention, the modular
surfacing mats may be configured with a plurality of layers that
include a first seam having a first direction and a second seam
having a second direction, the first seam having a relationship to
the second seam, the relationship being one of substantially
parallel, substantially perpendicular, and substantially diagonal.
In addition, the first layer may overlap the second layer.
[0022] It is to be understood that the descriptions of this
invention herein are exemplary and explanatory only and are not
restrictive of the invention as claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] FIG. 1 is a vertical cross-sectional view of a modular
surfacing mat in accordance with one embodiment of the
invention.
[0024] FIG. 2 is a vertical cross-sectional view of a modular
surfacing mat with a carpeted top mat in accordance with one
embodiment of the invention.
[0025] FIG. 3 is a vertical cross-sectional view of a modular
surfacing mat with an artificial turf top mat in accordance with
one embodiment of the invention
[0026] FIG. 4 shows examples of shapes of modular surfacing mats
according to various aspects of the invention.
[0027] FIG. 5 shows vertical cross-sectional views of modular
surfacing mats with differing base mat densities in accordance with
one embodiment of the invention.
[0028] FIG. 6 shows the arrangement of modular surfacing mats in a
modular surfacing system according to one embodiment of the
invention.
[0029] FIG. 7 shows a vertical cross-section of a multiple layer
mat according to one embodiment of the invention.
DESCRIPTION OF THE EMBODIMENTS
[0030] Reference will now be made in detail to the present
exemplary embodiments of the invention, examples of which are
illustrated in the accompanying drawings.
[0031] In accordance with various embodiments of the present
invention, a surfacing systems, and more particularly, a modular
surfacing system for use in recreational, institutional and other
applications is described.
[0032] FIG. 1 is a vertical cross-sectional view of a modular
surfacing mat in accordance with one embodiment of the invention.
Modular surfacing mat 100 includes a base mat 101, an adhesive 102,
a top mat 103, and a top coat 104. The top mat is bonded to the
base mat with adhesive 102. Top coat 104 provides a protective
finish to top mat 103.
[0033] Base mat 101 is preferably made from a cellular foam
structure. Cellular foam structures may be formed from various
densities of expanded polymers including polyethylene,
polypropylene, poly(ethylene-co-propylene), and other expanded
polymers such as polystyrene. crosslinked polyurethanes,
thermoplastic elastomers, etc. Preferably, the base mat is formed
from a closed cell foam structure. Closed cell foam is a cellular
foam structure material that includes millions of tiny, air-filled
bubbles or closed cells, which contribute to its cushioning
characteristics. For example, the closed cell foam utilized may be
formed from closed cell polyethylene foam nuggets fused together in
a crosslinked matrix. In addition, the base mat may be formed from
a plurality of recycled closed cell polyethylene foam nuggets. The
mat also may contain other recycled materials comprised of
polyurethanes, linear rubbers, vulcanized rubbers, EPDM rubbers
(both linear and crosslinked), polymers used in the automotive
industry or other deformable materials or combinations thereof
permanently fused together in a crosslinked matrix. Depending on
their original source, these recycled materials may or may not
exist in a foamed state. The base mat is therefore shock and impact
absorbent, capable of helping prevent injury by absorbing shock and
dissipating the G-forces associated with a fall and impact.
[0034] Alternatively the base mat may be formed from crosslinked
rubber particles such as natural rubber, styrene butadiene rubber,
or EPDM (Ethylene Propylene Diene Rubber). This material is
manufactured to a crumb like consistency in a variety of colors. In
these cases, the rubber may be either linear or crosslinked. Closed
cell foams are made when poly resins are combined with other
ingredients and extruded pellets expand to become consistently
shaped beads of expanded foam. Closed cell structure foams provide
sufficient protection to prevent or minimize the effects of
physical abuse, corrosion, temperature extremes, chemical attack,
aging, and other adverse conditions. Its softness, resilience,
impact strength, anti-abrasion, and strain recovery characteristics
make it ideal for continued impact protection even after repeated
impacts.
[0035] Any thickness of base mat may be used, but preferably has a
thickness between substantially 50 mm (2'') and substantially 12 mm
(1/2''), depending on the required fall height of the project.
[0036] Top mat 103 is preferably made at least partially from
rubber, and most preferably from recycled rubber. For example, the
top mat may be manufactured from recycled rubber, primarily scrap
tires that are ground up to produce a crumb rubber material that is
consolidated into a solid surfacing. Other types of top mats such
as PVC, carpeting, and synthetic turf (e.g., Astro Turf) may also
be used. Any thickness of top mat may be used, but it is preferably
12 mm (1/2'') thick.
[0037] An adhesive 102 is used to secure top mat 103 to base mat
101. Preferably, adhesive 102 is a polyurethane or polyurea.
However, any adhesive capable of bonding top mat 103 to base mat
102 may be used.
[0038] Top coat 104 may be any material that provides a protective
and/or decorative finish to top mat 104. Preferably, top coat 104
is a polyurethane or polyurea. Polyurethane (which may be
water-based) or polyurea top coats form very wear-resistant
barriers and may be water-resistant such that water or
environmental wastes do not penetrate. Alternatively, the top-layer
coating may be applied in such as a manner that water and
environmental wastes are allowed to drain through the surface. The
polyurethane or polyurea coating can be cut, for example, with a
circular saw, so if there were somehow some damage to a portion of
the modular surfacing system, the damage could be cut out and
replaced with another section of like material. In accordance with
the first embodiment of the present invention, the topcoat sealant
(which may be an adhesive sealant) provides a colorful protective
barrier against at least one of: deterioration due to moisture,
weathering, UV degradation, and normal wear and tear. The topcoat
sealant also has pigments that produce a variety of colors in the
adhesive sealant. If desired, a logo or other design may be painted
onto the top mat before the topcoat sealant coating is applied, and
will be visible after the topcoat sealant coating cures.
[0039] The polyurea or polyurethane top coat can be applied at room
temperature, with a brush, roller, or sprayer, and cures in
approximately 45 minutes. If desired, the polyurea, polyurethane,
or other sealant can be applied at ambient or an elevated
temperature by either spraying, rolling (with a roller), brushing
or squeegeeing, and bonds the two surfaces together and produces a
durable top coat. The sealant adhesive used between the various
layers of the modular surfacing system may or may not be a polyurea
or polyurethane. The polyurea used as a topcoat may be an aromatic
polyurea, an aliphatic polyurea, an aromatic aliphatic polyurea, a
polyurea containing cycloaliphatic structures or combinations
thereof. When used as an adhesive between the various layers of the
modular surfacing system, the polyurea may or may not be the same
chemical composition as the polyurea used in the topcoat. The
compositions of polyurea may be varied widely from diverse groups
of monomeric reactants to produce topcoat surface property
characteristics tailored to particular end use requirements such as
hardness, stiffness, softness/resiliency/elasticity, anti-skid,
abrasion resistance, chemical resistance, and gloss/matte
appearance.
[0040] Top coat 104 may also contain one or more pigments or
colorants to add color to the modular surfacing mat. Top coat 104
may also be applied in different manners to provide for different
textures (e.g., smooth or rough texture). In some situations, top
mat 103 may already have a protective finish, and as such, an
additional top coat may not be needed. In addition, some top mats
may not be suited for application of an additional top coat. FIGS.
2 and 3 show examples of modular surfacing mats that do not need a
top coat.
[0041] FIG. 2 is a vertical cross-sectional view of a modular
surfacing mat with a carpeted top mat in accordance with one
embodiment of the invention. Modular surfacing mat 200 includes a
base mat 101 and an adhesive 102 as described above with reference
to FIG. 1. However, rather than the top mat shown in FIG. 1,
modular surfacing mat 200 includes a carpet layer 203. Carpet layer
203 may be any type of carpeting material. This embodiment is
preferably used in indoor settings, but may also be used in outdoor
settings.
[0042] FIG. 3 is a vertical cross-sectional view of a modular
surfacing mat with an artificial turf top mat in accordance with
one embodiment of the invention. Modular surfacing mat 300 includes
a base mat 101 and an adhesive 102 as described above with
reference to FIG. 1. However, rather than the top mat shown in FIG.
1, modular surfacing mat 300 includes an artificial turf layer 303.
Artificial turf layer 303 may be any type of artificial turf. This
embodiment is suitable for both indoor and outdoor use.
[0043] As shown in each of FIGS. 1 through 3 each base mat and top
mat have substantially symmetric horizontal cross sections. In this
way, multiple modular surfacing mats may be installed next to each
other to create a continuous surface. The modular surface mats of
FIG. 1 through may be constructed in any shape that allows for
multiple mats to be installed together to form a substantially
continuous surface.
[0044] FIG. 4 shows examples of shapes of modular surfacing mats
according to various aspects of the invention. Modular surface mats
400 are shown to be in a square shape, however any polygonal shape
may be used. By constructing the modular surface mats in a square
shape, the end user has the flexibility to install the mats in any
configuration by cutting the mats to shape. Modular surface mats
401, 408, and 409 are shown in shapes with interlocking tabs and
slots. Modular surfacing mat 401 has generally "puzzle-shaped"
slots 402 and tabs 403. Modular surfacing mat 408 has generally
square-shaped slots 404 and tabs 405. Modular surfacing mat 409 has
dovetail-shaped slots 406 and tabs 47. The shapes the surfacing
mats show in FIG. 4 are exemplary only. Any shape that allows for
the mats to be placed next to each other to form a substantially
continuous surface may be used.
[0045] FIG. 5 shows vertical cross-sectional views of modular
surfacing mats with differing base mat densities in accordance with
one embodiment of the invention. As shown in FIG. 5, modular
surfacing mats 100a and 100b have substantially the same thickness
of 1'' to 21/4'' However, as can be seen in the exaggerated view of
base mats 101a and 101b, the closed cell foam is formed with
different densities. By using different densities of foam in the
base mat while maintaining the same thickness, modular surfacing
mats the meet different fall height densities may be created. The
foam density is controlled by the amount of foam beads contained
within the tool or form when creating the foam. The more beads
forced into the tools, the harder or stiffer (and more dense) the
final product will be. By having modular surfacing mats with
different fall height ratings yet the same thickness, an end user
may efficiently install the higher fall-rated (and often more
expensive) high density foam mats (e.g., 101a) in places where
needed and/or required. For example, in playground settings, the
fall height rating of surfaces surrounding certain playground
equipment is mandated by state and/or local government. In general,
the taller the piece of playground equipment, the higher the fall
rating of surfaces that surround the equipment.
[0046] Multiple modular surfacing mats, with or without different
densities of base mats and different fall height ratings, may be
combined to form a modular surfacing system. FIG. 6 shows the
arrangement of modular surfacing mats in a modular surfacing system
according to one embodiment of the invention. In the embodiment
shown in FIG. 6, modular surfacing mats with different densities
are shown in a playground setting forming a modular surfacing
system 600. Crosshatched modular surfacing mats 101a are installed
within a predetermined circle around playground equipment 601.
Modular surfacing mats 101b are used outside this circle. Referring
back to FIG. 5, modular surfacing mats 101a have a higher density
base mat than modular surfacing mats 101b, and thus a higher fall
height rating. Additional levels of base mat density (and thus fall
height rating) could be used for installations where two or more
fall height ratings regions are needed.
[0047] FIG. 7 shows a vertical cross-section of a multiple layer
mat according to one embodiment of the invention. As shown in FIG.
7, modular surfacing mat 700 may include two base mats 101 and two
top mats 103. Each layer is secured to the next with adhesive 102,
and a top coat 104 is applied to the top. It should be noted that
each base mat and top mat may be comprised of different materials
to carry out different functions. For example, modular surfacing
mat 700 may utilize a base mat that is useful to prevent water
accumulation, a first top mat may that is useful to absorb shock
and impact, and an additional top mat that has thermally
dissipative properties that allow children to play barefoot
regardless of the heat or cold of the ground. As such, when using a
multiple layer modular surfacing mat, each layer may have desirable
properties and is also sufficiently light-weight to be carried
easily to the site.
[0048] Installation
[0049] When a modular surfacing mat or system is desired at a site,
such as a playground, modular surfacing mats (or their individual
components) are carried to the site. The modular surfacing mats may
be pre-constructed or may be assembled on site. The site may
already have a covering, such as concrete, cement, asphalt, crushed
limestone, tile, or linoleum. Such a covering may be regarded as a
substrate on which the modular surfacing system is constructed.
[0050] If desired, the base mat is adhered to the substrate. In
many situations, adhering the base mat to the substrate can be
effective to prevent the base mat from slipping out of position. If
desired, the base mat is secured to the substrate by either bonding
with an adhesive sealant or with anchors.
[0051] On the other hand, if the modular surfacing system is to be
used in-doors, then adhering the base mat to a substrate may not be
necessary. For example, in a nursing home or daycare center,
adhering the base mat to the substrate may be unnecessary.
[0052] If it is desired that the base mat be adhered to the
substrate, then an adhesive sealant may be used. The adhesive
sealant is, for example, polyurethane. The adhesive sealant may
cover the entire surface between the substrate and the base mat, or
may be used in spots, or may be used only on the periphery. A
determination of how the adhesive sealant can best be used to
adhere the base mat to the substrate should consider environmental
conditions that the base mat may encounter. The adhesive sealant
also may be selected from the group consisting of pressure
sensitive adhesives, adhesives specially designed for the base mat
and particular substrate involved, or commercially available
adhesives.
[0053] Another reason for adhering the base mat to the substrate is
to help protect the substrate or the base mat from becoming
slippery and hard due to freezing water. The modular surfacing
system may be constructed to divert rainwater to a periphery of the
modular surfacing system, and adhering the base mat to the
substrate may be useful to prevent water from accumulating under
the base mat. The base mat can be easily trimmed and fitted using
either a knife, hand saw or reciprocating saw.
[0054] Once the base mat has been placed into position, regardless
of whether it has been adhered to the substrate, the top mat may be
placed on the base mat. The top mat is also easily transportable to
the site on which the modular surfacing system is desired to be
assembled. Because the modular surfacing system is comprised of
layers, each layer may be easily carried to the site by one or two
laborers, without the weight considerations that might be
prohibitive if a single rubber mat were to be used. Also, because
the top mat need not be composed of the same material as the base
mat, mats may be chosen from different suppliers.
[0055] The top mat typically is shipped in a roll (for situations
where modular surfacing mats are not preconstructed) and is secured
over the base mat using an adhesive (e.g., polyurea, polyurethane
coating other commercially available adhesives). The top mat, like
the base mat, can easily trimmed by using either a knife, hand or
reciprocating saw. Once the top mat is installed and secured to the
base mat, a top coat is applied to bond all materials together.
[0056] It will be recalled that an adhesive may be used to adhere
the base mat to the substrate. Additionally, an adhesive may be
placed, if at all, at the periphery of each modular surfacing mat.
Also, a top surface of a top mat is covered with a top coat (which
may be a sealant). Any of these adhesives and top coats may be
identical to any of the other adhesives and top coats, or a variety
of adhesive and top coats (some adhesive, some not) may be used.
The top coat that is used to cover the top surface of the top mat
need not be adhesive, since no further mats are to be placed on the
top surface of the top mat. Any or all of these adhesives and/or
top coats may be polyurea. If desired, polyurea need not be present
in the modular surfacing system. The top coat provides several
advantages including wheelchair accessibility.
[0057] Because the modular surfacing system is comprised of layers,
each layer being a mat, the modular surfacing system can be both
customized and transported easily. The modular surfacing system can
be customized easily, since additional mats can be added. For
example, under gymnastics equipment, where athletes may fall while
in awkward body positions or with additional velocity, additional
layers of mats can be added to exceed mandated and/or recommended
safety margins by any desired margin.
[0058] When multiple mats are used, the mats may be stacked and
overlapped. The mats may also be placed along side one another to
form a layer (i.e., a first layer), and then other mats are stacked
on top of the first layer to form an additional layer. When the
mats are placed along side one another, a first seam may exist
between adjacent mats within the first layer. The additional layer
may have a second seam that is parallel, perpendicular, or diagonal
with respect to the first seam (i.e., the seam of the first
layer).
[0059] Detailed Installation
[0060] Installing the Base Mat
[0061] In this installation description, the base mats are assumed
to be of an interlocking design, which does not need to be glued
together. Before installation of the base mat, the sub-base
(substrate) should be compacted and smooth. The sub-base should be
without ridges, rolls, or depressions, as the base mats are of
uniform thickness.
[0062] To start, snap a chalk line around the perimeter of the
installation area (e.g., a playground), making sure it is square.
Start installing the base mats from a square corner of the
playground, interlocking them together. Use a fine hand saw to cut
any straight lines, and a keyhole or drywall saw for fitting the
mat around the equipment. Use some of the waste material to
completely fill in any gaps.
[0063] Installing the Top Mat
[0064] The top mat is installed much like you would the base mat,
interlocking them together, cutting and fitting around the
equipment. If using a utility knife to cut the top mat, it is
recommended that you change blades often to ensure a clean cut.
[0065] To Begin:
[0066]
[0067] Measure in two feet from the edge of the playground and snap
a chalk line. This is your starting point for the top mat. Next
apply the adhesive directly to the base mat, coating the entire
surface for a first row of top mats. Use a squeegee or a trowel to
spread the adhesive to a consistency of approximately 1/32 of an
inch thick and about wide enough to cover the over the edge-line of
the first row of top mats. Install your first row of the top mats
making sure it is square along the chalk line. Next, apply adhesive
on the base mat for the next row. Avoid getting the adhesive on the
surface of the top mats.
[0068] Joining the Top Mat and Seams
[0069] A bad seam will not effect the impact attenuation or the
accessibility of the surface, but a bad seam can affect the
appearance of the final product. The Top Coat will assist in hiding
some bad seams, but attention to this step will produce an
"invisible" seam. Avoid getting the adhesive on the surface of the
top mats. Interlock and install the second mat so the seam is
flush. Do not apply adhesive to the edges of the top mat as this
will result in visible seams.
[0070] Continue this pattern, cutting and fitting the top mat
around the playground equipment. Try to avoid gaps, but they can be
filled with a mixture of fine loose top mat and adhesive. Smooth
out all patches with a putty knife or other trowel.
[0071] Cutting the Top Mat
[0072] The top mat can be cut with either a utility knife or 6''
Aviation snips.
[0073] It is recommended that the utility knife have a titanium
blade for easier cutting and longer blade life. For each cut, snap
a chalk line first to ensure a straight cut. Be sure to change
blades often to keep a neat and clean cut.
[0074] Install beveled edges as required. If needed only at the
approach, you may use a reciprocating saw with fine blade to cut
the top and base mats at the angle needed, then glue a top mat onto
the angle, overlapping the base mat, making sure enough adhesive is
used to adhere the angled top mat. If the playground has curbs, be
sure to glue the top mat to the curbs for a tight seal.
[0075] Applying the Top Coat
[0076] Next, the top coat is applied. For example, the top coat may
be a two-party polyurea such as TuffShell.TM. Topcoat sealant
available from SafeStructure LLC of Solon, Ohio. TuffShell.TM.
Topcoat sealant is a two-part, technically advanced polymer coating
designed to add color, UV resistance, and extra durability to your
playground surface. It is extremely durable, is applied at ambient
temperatures, and is resistant to most water- and petroleum-based
chemicals.
[0077] For best results, the surface temperatures of the playground
should be above 50.degree. F., and below 130.degree. F. Surfaces
must be completely dry, free of moisture, no bubbles, and clean of
any debris.
[0078] Using a 3/8'' hand drill with a large mixer head, mix the
color material with Part "B" for at least 3 minutes. Mix Part "B"
with Part "A" (four gallons). Use the larger mixer to blend
materials for at least 3-4 minutes, occasionally scraping sides and
bottom with the mixer to ensure complete blending of products.
Blending is complete when you do not see any streaks in the
material. The total of Part "A" and Part "B" produces the
five-gallons of the polymeric top coating, which is now ready to
use.
[0079] Work time of TuffShell Top Coat is about 40 minutes. You and
your equipment must be ready to apply this material quickly.
[0080] Using a disposable 3'' paintbrush cut-in the surface around
the edges and playground equipment. Beginning at the farthest from
your exit point, pour a workable amount of the Top Coat Sealant
into a tray, or dip roller into bucket. Using the 18'' roller with
at least a 1/2'' nap, outfitted with an extension handle, spread a
thin coat of the top coating evenly, working the coating into the
surface with a cross hatch pattern. For the first thin coat,
application rate should be approximately 800 sq. ft. per 5 gallons.
With the second heavier coat, application rate should be
approximately 400 sq. ft. per 5 gallons.
[0081] Apply a second heavier coat of the top coating evenly,
leaving the coating on the surface with a crosshatch pattern.
Protect the surface from intrusion during the drying time until
tack free. The TuffShell Top Coat Sealant is humidity sensitive and
therefore cure times vary with locale, time of day and time of
year. Although play could resume after two to four hours, we
recommend considering the weather conditions, and that heavier
applications could prolong the drying time 12- to 24-hours.
[0082] As will be appreciated, the modular surfacing system may
also be used in manufacturing facilities or other locations where
heavy fragile items or people are in danger of falling or
colliding, such as flooring under baggage handling areas, parcel
handling areas, movie theater aisles, and sidewalks. The modular
surfacing system may also be installed vertically, such as on a
baseball diamond outfield back wall.
[0083] Other embodiments of the invention will be apparent to those
skilled in the art from consideration of the specification and
embodiments disclosed herein. Thus, the specification and examples
are exemplary only, with the true scope and spirit of the invention
set forth in the following claims and legal equivalents
thereof.
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