U.S. patent application number 13/690751 was filed with the patent office on 2013-12-19 for synthetic flooring with area elastic properties.
This patent application is currently assigned to Connor Sports Flooring, LLC. The applicant listed for this patent is Connor Sports Flooring, LLC. Invention is credited to Jerome D. Covington.
Application Number | 20130333311 13/690751 |
Document ID | / |
Family ID | 48536119 |
Filed Date | 2013-12-19 |
United States Patent
Application |
20130333311 |
Kind Code |
A1 |
Covington; Jerome D. |
December 19, 2013 |
SYNTHETIC FLOORING WITH AREA ELASTIC PROPERTIES
Abstract
In accordance with a representative embodiment broadly described
herein, the present invention provides for a resilient athletic
surface. The surface includes a resilient base layer, an
intermediate layer, and a clear polymer wear layer. The athletic
surface is configured such that it is area elastic. In one
embodiment, the athletic surface can have a visual appearance of
being a wood surface or varnished wood surface.
Inventors: |
Covington; Jerome D.;
(Helena, AL) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Connor Sports Flooring, LLC |
Salt Lake City |
UT |
US |
|
|
Assignee: |
Connor Sports Flooring, LLC
Salt Lake City
UT
|
Family ID: |
48536119 |
Appl. No.: |
13/690751 |
Filed: |
November 30, 2012 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61565378 |
Nov 30, 2011 |
|
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|
Current U.S.
Class: |
52/177 |
Current CPC
Class: |
E04F 15/22 20130101;
E04F 15/166 20130101; E04F 15/12 20130101; E04F 15/225 20130101;
A63C 19/00 20130101 |
Class at
Publication: |
52/177 |
International
Class: |
E04F 15/22 20060101
E04F015/22; A63C 19/00 20060101 A63C019/00 |
Claims
1. A resilient athletic surface, comprising: a resilient base
layer; an intermediate layer; and a clear polymer wear layer;
wherein the athletic surface has area elastic properties.
2. The athletic surface of claim 1, wherein the resilient base
layer comprises recycled rubber particles.
3. The athletic surface of claim 1, wherein the resilient base
layer comprises foam particles.
4. The athletic surface of claim 1, wherein the resilient base
layer has a thickness of about 3 mm to about 15 mm.
5. The athletic surface of claim 1, wherein the clear polymer wear
layer comprises a polyuria polymer.
6. The athletic surface of claim 5, wherein the polyuria polymer
achieves a hardness of at least about 90 Shore A within about 12 to
about 18 hours of application to the intermediate layer.
7. The athletic surface of claim 5, wherein the polyuria polymer
has a tensile strength of at least about 1900 psi.
8. The athletic surface of claim 5, wherein the polyuria polymer
has a tensile strength of at least about 1950 psi.
9. The athletic surface of claim 5, wherein the polyuria polymer
has a tensile strength of at least about 2000 psi.
10. The athletic surface of claim 1, wherein the clear polymer wear
layer has a thickness of about 1 mm to about 3 mm.
11. The athletic surface of claim 1, wherein the clear polymer wear
layer has a thickness of about 1.3 mm to about 2.5 mm.
12. The athletic surface of claim 1, wherein the clear polymer wear
layer has a hardness of at least 94 Shore A.
13. The athletic surface of claim 1, wherein the clear polymer wear
layer has a hardness of at least about 95 Shore A.
14. The athletic surface of claim 1, wherein the clear polymer wear
layer has a elongation value of at least about 250%.
15. The athletic surface of claim 1, wherein the clear polymer wear
layer has an elongation value of at least about 300%.
16. The athletic surface of claim 1, wherein the clear polymer wear
layer has an elongation value of at least about 350%.
17. The athletic surface of claim 1, wherein the clear polymer wear
layer has an elongation value of at least about 400%.
18. The athletic surface of claim 1, wherein the clear polymer wear
layer has a tear strength of at least about 250 pli.
19. The athletic surface of claim 1, wherein the clear polymer wear
layer has a tear strength of at least about 300 pli.
20. The athletic surface of claim 1, wherein the intermediate layer
is a vinyl layer.
21. The athletic surface of claim 1, wherein the intermediate layer
has a wood grain print on a surface thereof.
22. The athletic surface of claim 1, further comprising painted
images disposed between the intermediate layer and the polymer wear
coat.
23. The athletic surface of claim 1, wherein the intermediate layer
has a thickness of about 1.8 mm to about 2.4 mm.
24. The athletic surface of claim 1, wherein the intermediate layer
has a thickness of about 1.9 mm to about 2.3 mm.
25. The athletic surface of claim 1, wherein the intermediate layer
has a wood-like appearance.
Description
[0001] This application claims the benefit of U.S. Provisional
Patent Application No. 61/565,378, filed Nov. 30, 2011, and which
is incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to synthetic flooring, and
more specifically to area elastic synthetic flooring for use in
athletic and related activities.
BACKGROUND OF THE INVENTION AND RELATED ART
[0003] Many types of athletic and sports flooring products have
been designed and produced in order to satisfy the requirements of
not only professional and collegiate sports competition, but also
for the practice of physical and sporting activities of lower
levels such as primary and secondary schools, community centers, or
private gyms. The technical criteria of sports floors vary
depending on the intended use, but that brings with it financial
and economic constraints. The wide range of use for athletic
flooring surfaces demands floor areas ranging from about 100 square
feet to about 100,000 square feet and thus the choice and design of
sports floors in relation to their criteria and conditions of use
have considerable financial consequences. With this in mind, there
are several different types of flooring that are currently
available including both point elastic floors and area elastic
floors.
[0004] Point elastic floors are made of synthetic materials
produced in one or more layers and typically come in the form of
strips rolled out to the desired length that are placed directly
onto the receiving concrete base. In point elastic flooring the
weight of the user is spread over an area only slightly greater
than the surface area of the user's foot. Thus, the impact zone has
a size that is only a few centimeters (3 to 5 cm) larger than the
area contacted by the foot. This type of covering is satisfactory
in relation to its low cost and its high of durability (wear,
maintenance, resistance to impacts); however, the sporting
properties are limited due to the thickness-flexibility compromise
of the floor which prevents the cushioning layer from being
increased without experiencing problems of stability of support.
Additionally, the synthetic nature and look of most point elastic
floors typically does not provide the aesthetically pleasing look
of traditional wood floors.
[0005] Area elastic floors are typically made of wood-based
materials and provide desirable performance characteristics and
aesthetically pleasing looks. In area elastic floors the load of
the user (e.g. athlete) is spread over an area much greater than
the contact area of the user's foot (approximately 50 cm around the
foot). One common example of an area elastic floor is a wood.
Traditionally, wood flooring starts from the concrete base followed
by a first covering made of polyurethane foam of a certain
thickness onto which are placed two superposed tiers of wood panels
arranged in staggered pattern, with a finish covering. This type of
floor is often used in facilities where basketball is played,
particularly competitive basketball, due to the sporting properties
provided by these floors. Unfortunately, the investment cost for
most area elastic sports floors of this type is extremely high. The
fitment and installation time is long due to the disposition of the
two tiers of wood panels and the difficulties of correctly filling
the whole surface area of the facility in question. In addition,
and from the technical point of view, traditional area elastic wood
floors can suffer from certain drawbacks or disadvantages including
sensitivity and damage due to humidity and/or temperature
fluctuations, high costs of maintenance, and the requirement for
regular revarnishing. Due to the high costs of installation and
maintenance, area elastic floors, such as described above, are
typically used only in high level sports facilities and gymnasia
for particular sporting activities such as basketball, handball and
volleyball.
[0006] With all of this in mind, research continues into flooring
compositions and systems than can provide the durability and costs
associated with typical synthetic flooring while providing the
aesthetics and area-elastic performance of traditional wood
flooring systems.
SUMMARY OF THE INVENTION
[0007] In accordance with a representative embodiment broadly
described herein, the present invention provides for a resilient
athletic surface. The surface includes a resilient base layer, an
intermediate vinyl layer, and a clear polymer wear layer. The
athletic surface is configured such that it is area elastic. In one
embodiment, the athletic surface has a visual appearance of being a
wooden surface.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] Features and advantages of the present invention will be
apparent from the detailed description that follows, and when taken
in conjunction with the accompanying drawing together illustrate,
by way of example, features of the invention. It will be readily
appreciated that these drawings merely depict representative
embodiments of the present invention and are not to be considered
limiting of its scope, and that the components of the invention, as
generally described and illustrated in the figures herein, could be
arranged and designed in a variety of different configurations.
Nonetheless, the present invention will be described and explained
with additional specificity and detail through the use of the
accompanying drawings, in which:
[0009] FIG. 1 is a side cross-sectional view of one embodiment of
the athletic surface of the present invention.
[0010] Reference will now be made to additional embodiments and
specific language will be used herein to describe the same. It will
nevertheless be understood that no limitation of the scope of the
invention is thereby intended. Furthermore, the following detailed
description and representative embodiments of the invention will be
best understood with reference to the accompanying drawing, wherein
the elements and features of the embodiments are designated by
numerals throughout.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
[0011] While these exemplary embodiments are described in
sufficient detail to enable those skilled in the art to practice
the invention, it should be understood that other embodiments may
be realized and that various changes to the invention may be made
without departing from the spirit and scope of the present
invention. Thus, the following more detailed description of the
embodiments of the present invention is not intended to limit the
scope of the invention, as claimed, but is presented for purposes
of illustration only and not limitation to describe the features
and characteristics of the present invention, to set forth the best
mode of operation of the invention, and to sufficiently enable one
skilled in the art to practice the invention. Accordingly, the
scope of the present invention is to be defined solely by the
appended claims.
[0012] Definitions
[0013] It should be noted that, the singular forms "a," "an," and,
"the" include plural referents unless the context clearly dictates
otherwise. Thus, for example, reference to "a substrate" includes
reference to one or more of such substrates, and reference to "the
substrate" includes reference to one or more of such
substrates.
[0014] As used herein, the term "substantially" refers to the
complete or nearly complete extent or degree of an action,
characteristic, property, state, structure, item, or result. For
example, an object that is "substantially" enclosed would mean that
the object is either completely enclosed or nearly completely
enclosed. The exact allowable degree of deviation from absolute
completeness may in some cases depend on the specific context.
However, generally speaking the nearness of completion will be so
as to have the same overall result as if absolute and total
completion were obtained. The use of "substantially" is equally
applicable when used in a negative connotation to refer to the
complete or near complete lack of an action, characteristic,
property, state, structure, item, or result.
[0015] As used herein, "tensile strength" refers to the standard
definition of the term and is determined using the testing
methodology prescribed in ASTM D412.
[0016] As used herein, "hardness" when used in connection with the
polymer wear coat of the athletic surface of the present invention
refers to the polymer wear coat's ability to resist to permanent
indentation. Unless otherwise stated, the hardness of the wear coat
is determined using the testing methodology prescribed in ASTM
D2240.
[0017] As used herein, "elongation" refers to the standard
definition of the term when used to describe properties of a
polymeric material such as the polymer used in the polymer wear
layer of the athletic surfaces of the present invention. The
elongation value is determined using the testing methodology
prescribed in ASTM D412.
[0018] As used herein, the term "tear strength" when used in
connection with polymer wear layer of the athletic surface of the
present invention refers to the ability of the wear layer to resist
tearing. The tear strength value is determined used the testing
methodology prescribed in ASTM D624.
[0019] As used herein, "area elastic" as used to describe athletic
surfaces disclosed herein refers to athletic surfaces in which a
point force causes deflection over a relatively large area around
the point of application of force. Area elastic floors can have
shock absorption of at least about 40% to about 75% (using standard
shock absorption testing methodology) and vertical deformation of
at least about 2.3 mm to about 5.0 mm (based on standard vertical
deformation testing methodology).
[0020] As used herein, the term "about" is used to provide
flexibility to a numerical range endpoint by providing that a given
value may be "a little above" or "a little below" the endpoint.
[0021] As used herein, a plurality of items, structural elements,
compositional elements, and/or materials may be presented in a
common list for convenience. However, these lists should be
construed as though each member of the list is individually
identified as a separate and unique member. Thus, no individual
member of such list should be construed as a de facto equivalent of
any other member of the same list solely based on their
presentation in a common group without indications to the contrary.
In addition, various embodiments and example of the present
invention are referred to herein along with alternatives for the
various components thereof. It is understood that such embodiments,
examples, and alternatives are not to be construed as de facto
equivalents of one another, but are to be considered as separate
and autonomous representations of the present invention.
[0022] Concentrations, amounts, levels and other numerical data may
be expressed or presented herein in a range format. It is to be
understood that such a range format is used merely for convenience
and brevity and thus should be interpreted flexibly to include not
only the numerical values explicitly recited as the limits of the
range, but also to include all the individual numerical values or
sub-ranges encompassed within that range as if each numerical value
and sub-range is explicitly recited. As an illustration, a
numerical range of "about 1 to about 5" should be interpreted to
include not only the explicitly recited values of about 1 to about
5, but also include individual values and sub-ranges within the
indicated range. Thus, included in this numerical range are
individual values such as 2, 3, and 4 and sub-ranges such as from
1-3, from 2-4, and from 3-5, etc., as well as 1, 2, 3, 4, and 5,
individually. This same principle applies to ranges reciting only
one numerical value as a minimum or a maximum. Furthermore, such an
interpretation should apply regardless of the breadth of the range
or the characteristics being described.
[0023] Invention
[0024] With the above definitions in mind, the present invention is
drawn to a resilient athletic surface. The surface includes a
resilient base layer, an intermediate vinyl layer, and a clear
polymer wear layer. The athletic surface is configured such that it
is area elastic. In one embodiment, the athletic surface has a
visual appearance of being a wood surface or varnished wood
surface. In contrast to most synthetic flooring surfaces that are
typically heat sealed rows, tiles or pieces, the athletic flooring
surfaces of the present invention are monolithic area elastic
surfaces that can be manufactured on site minimizing or eliminating
the need for extensive seeming of jointing.
[0025] FIG. 1 shows an exemplary embodiment of an athletic surface
of the present invention. Moving from the bottom of the figure, the
athletic surface includes a resilient base layer 8 configured to be
disposed on a solid substrate material (not shown). The substrate
material could be a concrete, asphalt, packed earth, or other
generally hard and substantially flat substrate onto which an
athletic surface might be applied. The resilient base layer of the
embodiment has an intermediate vinyl layer 4 adhered on its upper
surface utilizing an adhesive layer 6. The clear polymer wear layer
2 is disposed on the upper surface of the intermediate vinyl layer
opposite the resilient base layer.
[0026] The resilient base layer of the athletic surface disclosed
herein can be made of a variety of manmade and or natural materials
so long as they have the requisite resiliency and durability. For
example, in one embodiment, the resilient base layer can include
rubber and recycled rubber materials, ground foam particles,
combinations thereof, and the like. The thickness of the resilient
base layer can vary depending on a number of factors including, but
not limited to, the type and properties of substrate onto which the
athletic surface is intended to be used and the nature of the
materials which make up the resilient base layer. In one
embodiment, the resilient base layer can have a thickness of about
3 mm to about 15 mm. In another embodiment, the resilient base
layer can have a thickness of about 4 mm to about 14 mm. The
resilient base layer can also include an anti-microbial compound to
inhibit growth of microbial organisms in the athletic surface.
[0027] The intermediate layer is disposed on the upper surface of
the resilient base layer and can be adhered to the base layer using
an adhesive compound. In one embodiment, the adhesive compound can
be formulated to have minimal penetration into the resilient base
layer while still providing adequate adhesiveness to maintain the
intermediate layer in contact with the resilient base layer. It is
important that the adhesive compound provide adequate adhesion in
order for the flooring to have desirable structural stability.
However, excess penetration of the adhesive compound into the
resilient pad can diminish the resilient properties of the
resilient pad thereby resulting in a less suitable and functional
floor. Accordingly, providing an adhesive compound formulated for
minimal penetration into the resilient base layer while still
providing sufficient adhesion can be important. Non-limiting
examples of an adhesive that can be used include water based
urethane adhesives such as o-VOC 100% solids urethane adhesives
that can be either rolled or spray applied. The intermediate layer
can be made of vinyl or other similar materials.
[0028] The intermediate layer can be a solid color or can have a
print or pattern on its upper surface. In one embodiment, the
intermediate layer can have a wood grain print on its upper
surface. In another embodiment, the vinyl layer can have one or
more painted image or line disposed on its upper surface such that
it can be seen through the clear polymer wear coat. The images or
game lines are permanent and will not chip, peal, or wear due to
their location under the clear polymer wear layer. In one
embodiment, the intermediate layer can have a thickness of about
1.8 mm to about 2.4 mm. In another embodiment, the intermediate
layer has a thickness of about 1.9 mm to about 2.3 mm.
[0029] The clear polymer wear layer of the disclosed athletic
surface is generally transparent and can be formed of a single
polymer, a copolymer, or combination of polymers. The clarity of
the upper wear surface is useful because it allows for the viewing
of the print on the intermediate layer thereby allowing the
athletic surface to have aesthetically pleasing properties. When
the print on the intermediate layer is a wood grain print, the
athletic surface can have the appearance of a traditional natural
wood athletic floor. The polymer wear layer of the athletic
surfaces of the present invention has excellent properties that
minimize splitting, tearing, and damage. In fact, the polymer wear
layer has sufficient wear and strength properties that it not only
functions well as a traditional athletic floor but it can also be
used for skating and/or wheel chair use without causing damage to
the floor.
[0030] Although other clear polymer materials may be used so long
as they provide the desired area elastic effect, in one embodiment,
the clear polymer wear layer can include a polyuria polymer. In
another embodiment, the polymer utilized in the polymer wear layer
can have the property that it achieves a hardness of at least about
90 Shore A within about 12 to about 18 hours of application to the
intermediate layer. In still another embodiment, the clear polymer
wear layer of the athletic surface can have a hardness of at least
about 94 Shore A after curing. In yet a further embodiment, the
clear polymer wear layer of the athletic surface can have a
hardness of at least about 95 Shore A after curing.
[0031] In one aspect of the present invention, the clear polymer
wear layer of the athletic surface can have an elongation value of
at least about 250%. In another embodiment, the clear polymer wear
layer can have an elongation value of at least about 300%. In
another embodiment, the clear polymer wear layer can have an
elongation value of at least about 350%. In still a further
embodiment, the clear polymer wear layer can have an elongation
value of at least about 400%. In a further aspect of the invention
the clear polymer wear layer can have a tear strength of at least
about 250 pli. In another embodiment, the clear polymer wear layer
can have a tear strength of at least about 300 pli.
[0032] In one embodiment, the polymer utilized in the clear polymer
wear layer be formulated to cure and achieve the requisite hardness
without the need apply thermal heat or UV light. The ability of the
polymer used in the polymer wear layer to cure without the need to
thermal heat or UV light is particularly beneficial because it
allows the athletic surface to be manufactured in the on-site and
over large areas.
[0033] The polymer used in the polymer wear layer can be formulated
to have a cured tensile strength of at least about 1900 psi. In
another embodiment, the polymer used in the polymer wear layer can
have a tensile strength of at least about 1950 psi. In yet a
further embodiment, the polymer used in the polymer wear layer can
have a tensile strength of at least about 2000 psi.
[0034] The clear polymer wear layer of the athletic surface can
have a thickness that is sufficient provide adequate stiffness and
rigidity to achieve the desired area elastic effect. In one
embodiment, the clear polymer wear layer of the athletic surface
can have a thickness of about 1 mm to about 3 mm. In yet another
embodiment, the clear polymer wear layer can have a thickness of
about 1.3 mm to about 2.5 mm.
[0035] While the forgoing examples are illustrative of the
principles of the present invention in one or more particular
applications, it will be apparent to those of ordinary skill in the
art that numerous modifications in form, usage and details of
implementation can be made without the exercise of inventive
faculty, and without departing from the principles and concepts of
the invention. Accordingly, it is not intended that the invention
be limited, except as by the claims set forth below.
* * * * *