FALL PROTECTION

Abstract

A fall protection tile for playgrounds includes an upper layer of granulated rubber selected from non-aromatic thermoset elastomers, non-aromatic thermoplastic elastomers, cork, or combinations thereof, the upper layer having a thickness ranging from 5 to 75 mm, and a lower layer of a crosslinked foamed polyolefin layer, the lower layer having a thickness ranging from 10 to 150 mm, wherein the upper and lower layers being joined, and wherein the thickness ratio of i) to ii) ranges from 0.03 to 2.5. A structure and an arrangement including such a fall protection tile as well as a method of manufacturing such a tile are also provided.

Claims

1. A fall protection tile for playground, comprising i.) an upper layer of granulated rubber selected from non-aromatic thermoset elastomers, non-aromatic thermoplastic elastomers, cork, or combinations thereof, the upper layer having a thickness ranging from 5 to 75 mm; and ii.) a lower layer of a crosslinked foamed polyolefin layer, the lower layer having a thickness ranging from 30 to 150 mm the upper and lower layers being joined, and wherein the thickness ratio of i) to ii) ranges from 0.03 to 2.5.

2. The fall protection tile according to claim 1, wherein a joint between the upper and the lower layers resists a shear force of at least 10 N during 60 seconds without deformation.

3. The fall protection tile according to claim 1, wherein the granulated rubber in the upper layer is ethylene propylene diene monomer (EPDM).

4. The fall protection tile according to claim 1, wherein the polyolefin layer is a polyethylene layer.

5. The fall protection tile according to claim 1, wherein the upper layer is prepared by moulding the granulated rubber admixed with an adhesive.

6. The fall protection tile according to claim 1, wherein the tile has a substantially rectangular or square shape having sides ranging from 200 to 1500 mm.

7. The fall protection tile according to claim 1, wherein the lower layer has a density ranging from 20 to 220 kg/m3.

8. The fall protection tile according to claim 1, wherein the lower layer ii) is provided with parallel and perpendicular slits at least about 20 mm from any edges thereof.

9. The fall protection tile according to claim 7, wherein the slits have a length ranging from 40 to 200 mm and a width ranging from 2 to 6 mm.

10. A method of manufacturing a fall protection tile according to claim 1, comprising joining the upper layer i) and the lower layer ii) are joined by applying an adhesive to at least one contact surface of i) or ii), wherein the adhesive is applied to at least peripheral portions of the at least one contact surface; and pressing the layers together for a time ranging from 1 to 240 seconds at a pressure ranging from 20 to 1000 kPa at a temperature ranging from 10 to 35° C.

11. The fall protection structure comprising a plurality of tiles according to claim 1.

12. The fall protection structure according to claim 11, wherein the lower layer of the tiles i.) is shaped to mechanically lock adjacent tiles thereby preventing adjacent tiles to move independently; or ii.) mechanically fixated to adjacent tiles by fixing elements.

13. The fall protection arrangement comprising a frame surrounding the peripheral tiles of the fall protection structure according to claim 11.

14. The fall protection arrangement according to claim 11, wherein a layer iii) for draining water is adhered to the lower layer ii) of claim 1.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0062] FIG. 1 shows an XLPE pad.

DETAILED DESCRIPTION

[0063] FIG. 1 shows a XLPE pad provided with slits (1) and recesses (2) for locking adjacent XLPE pads with corresponding locking elements in the form of extrusions (not shown) fitting the recesses.

EXAMPLE

[0064] The lower layer, a foamed XLPE (cross-linked polyethylene) pad having a density of 70 kg/m3 and a tensile strength of about 400 kPa in its lengthwise/crosswise directions, was prepared with dimensions of 10 mm (thickness)×498 mm (width)×498 mm (length). Four 10 mm layers of XLPE were then heat welded to one another to provide a 40 mm thick XLPE pad. Slits and portions of hourglass-shaped structures were subsequently punched out as shown in FIG. 1. The hourglasses may be equipped with a drainage channel of 2-4 mm.

[0065] As the XLPE pads with dimensions according to the above are prepared, the punched pads will have recesses 2 (cf. FIG. 1) or protrusions along their sides enabling mechanical locking with adjacent pads. The exterior portion of the XLPE pads need, however, not be punched. The pads may for example be mechanically attached to adjacent pads as the fall protection structure is mounted. In case a frame surrounds a plurality of pads, means for mechanically fixing adjacent pads may also be omitted.

[0066] The upper layer was prepared from granules of EPDM having a diameter ranging from 1 to 3 mm which were mixed with a commercially available polyurethane binder such as Stobielast® S 133.00 in a weight ratio of EPDM to binder ranging from 10 to 20% by weight to provide an EPDM pad layer with a thickness of 10 mm. Pads with dimensions 10 mm×500 mm (length)×500 mm (width) were eventually obtained following a moulding stage. A silicone-based release agent was used to avoid sticking of rubber to the mould while providing lubrication. The silicone was removed by means of sandpaper or emery cloth prior to applying an adhesive on the EPDM layer from the edges of the pad and up to 5 cm from the sides. A pressure sensitive hot melt adhesive such as GluFlex D 2670 was applied on the EPDM layer and allowed to penetrate into the EPDM granules, preferably under heating to a temperature of about 150 to 200° C. depending on the type of adhesive. The adhesive may also be applied on either layer or both on the lower and upper layers of the forming fall protection tiles.

[0067] The XLPE and EPDM layers were subsequently contacted to each other by centering the EPDM pad on the XLPE pad. The layered product is subsequently placed in a press for a time in the range of 1 to 240 seconds, typically 240 seconds, and at a pressure ranging from 20 to 1000 kPa. The temperature during the pressing stage was 20° C.

[0068] The joint between the upper and the lower layers, e.g. between EPDM and the XLPE pads of the tall protection tile, which was planar and 50 mm thick, was shown to resist a shear force of at least 10 N during 60 seconds without any occurring deformation.

[0069] EN 1177:2018 HIC tests were performed to show the performance of the layered protection tiles. The test was carried out on site. The drop height of 12 separate tests varied from 1.93 to 2.16 m. It turned out the HIC measurements ranged from 574 to 1002. All HIC values obtained were <1000 except for one test in which the drop height was 2.16 m. All drop heights around 2 meters showed to correspond to a HIC value well below 1000 which proved the layered tile according to the invention protected falls from 2 meters.