LOAD DISTRIBUTION AND ABSORPTION UNDERLAYMENT SYSTEM
20200141131 ยท 2020-05-07
Inventors
- Joel Matthew CORMIER (Lathrup Village, MI, US)
- Jackson Alexander Elliott (Plymouth, MI, US)
- Richard Francois Audi (Dearborn, MI)
- Donald Scott SMITH (Commerce, MI, US)
Cpc classification
E04H5/00
FIXED CONSTRUCTIONS
E04F15/02038
FIXED CONSTRUCTIONS
E04F2201/0107
FIXED CONSTRUCTIONS
E04F15/187
FIXED CONSTRUCTIONS
E04F2203/065
FIXED CONSTRUCTIONS
E04F15/02183
FIXED CONSTRUCTIONS
E01C13/02
FIXED CONSTRUCTIONS
E04F13/07
FIXED CONSTRUCTIONS
E04H9/06
FIXED CONSTRUCTIONS
E04F15/182
FIXED CONSTRUCTIONS
E04H1/02
FIXED CONSTRUCTIONS
E04H3/08
FIXED CONSTRUCTIONS
International classification
E04F15/22
FIXED CONSTRUCTIONS
E04F13/07
FIXED CONSTRUCTIONS
E01C13/02
FIXED CONSTRUCTIONS
E04H9/06
FIXED CONSTRUCTIONS
E04H1/02
FIXED CONSTRUCTIONS
E04F15/02
FIXED CONSTRUCTIONS
E02B3/06
FIXED CONSTRUCTIONS
E04H5/00
FIXED CONSTRUCTIONS
Abstract
A load distributing and absorbing system that lies below a superstructure material which is exposed to percussive forces. The load distributing and absorbing system is interposed between the superstructure material and a foundation. The system has a barrier layer that lies below the superstructure material and an underlayment infrastructure positioned below the barrier layer. Included in the underlayment infrastructure are hat-shaped absorbing members.
Claims
1. A load distributing and absorbing system that lies below a superstructure material which is exposed to percussive forces, the load distributing and absorbing system being interposed between an underside of the superstructure material and a foundation below, the load distributing and absorbing system comprising: one or more load distributing and absorbing tiles, at least some of the tiles having a barrier layer that lies below the superstructure material; an underlayment infrastructure positioned below the barrier layer, the underlayment infrastructure including one or more hat-shaped absorbing members, at least some of the hat-shaped absorbing members having a ceiling, the ceiling being positioned below the barrier layer; a curvilinear wall extending from the ceiling, the curvilinear wall having a lower portion; a floor that connects lower portions of the curvilinear wall, the floor lying above the foundation; and a number (A) of apertures defined in the floor, where 0<=A<100.
2. The load distributing and absorbing system of claim 1, wherein the superstructure material is selected from the group consisting of a ceramic tile, solid wood, a wood composite, a carpet, a carpet tile, sheet vinyl, a vinyl tile, a rigid vinyl tile, a rubber sheet, and a rubber tile, a grating, and an anti-slip metallic surface.
3. The load distributing and absorbing system of claim 1, wherein the foundation includes concrete, a gravel, a metal and a hardwood.
4. The load distributing and absorbing system of claim 3, wherein the barrier layer includes a rigid thermoplastic.
5. The load distributing and absorbing system of claim 1, further including a means for securing positioned between the superstructure material and the barrier layer, or between the barrier layer and a ceiling, or in both positions.
6. The load distributing and absorbing system of claim 1, wherein at least some of the absorbing members have a configuration defined at least in part by an upper portion of a wall of an absorbing member that extends from a ceiling, a shape of the upper portion being selected from the group consisting of a circle, an oval, an ellipse, a clover leaf, a race-track, and other curved perimeters.
7. The load distributing and absorbing system of claim 1, wherein at least some of the absorbing members have a configuration defined at least in part by an imaginary footprint defined by a lower portion of a wall adjacent to the floor, the footprint being selected from the group consisting of a circle, an oval, an ellipse, a clover leaf, a race-track, and other curved perimeters.
8. The load distributing and absorbing system of claim 1, further including one or more tiles of underlayment infrastructures, wherein the barrier layer of a first tile extends from an edge thereof and overhangs at least some of the ceilings of an adjacent tile.
9. The load distributing and absorbing system of claim 8, wherein a group of tiles are conjoined, at least some of the absorbing members having a force-attenuation characteristic such that within the group, there is a user-determinable force attenuation property that may be uniform or varied within the group.
10. The load distributing and absorbing system of claim 9, wherein some tiles are joined together by mating registration features defined at edges of the barrier layers to form sub-assemblies of tiles.
11. The load distributing and absorbing system of claim 10, wherein the registration features are defined by a male feature in an edge of a barrier layer that engages a female feature in an edge of a barrier layer associated with an adjacent tile, the registration features being selected from the group consisting of male and female trapezoidal features, male and female keyholes, sawtooth arrangements, semicircles and jigsaw-like pieces.
12. The load distributing and absorbing system of claim 10, wherein the foundation is separated from the superstructure material by subassemblies of tiles.
13. A load distributing and absorbing infrastructure tile in a load distributing and absorbing system that lies below a superstructure material which is exposed to percussive forces, the load distributing and absorbing infrastructure tile being interposed between the superstructure material and a foundation below, the load distributing and absorbing infrastructure having a barrier layer for distributing at least some of the percussive forces that lies below the superstructure material and is quadrilateral with edges B1, B2, B3 and B4; an absorbing member for absorbing at least some of the percussive forces that is positioned below the barrier layer, the absorbing member being quadrilateral and having edges A1, A2, A3 and A4, the absorbing member including a ceiling, the ceiling being positioned below the barrier layer; a curvilinear wall extending from the ceiling, the continuous curvilinear wall having a lower portion; and a floor that connects facing sections of the curvilinear wall, the floor lying above the foundation, wherein the barrier layer is secured to the absorbing members so that edge B1 of the barrier layer overhangs edge A1 of the absorbing member and edge B2 overhangs edge A2, and edges A4 and A3 of the absorbing member extend beyond overlying edges B4 and B3 of the barrier layer, hereby creating an L-shaped platform and an L-shaped roof that engage corresponding features of adjacent infrastructure tiles.
14. A load distributing and absorbing system comprising an assembly of inter-engaging load distributing and absorbing infrastructure tiles of claim 13.
15. The load distributing and absorbing system of claim 1, wherein: a. the ceiling is thermoformed and has an average thickness (t), b. the wall is thermoformed and has an average thickness (T); and c. (T)>(t).
16. The load distributing and absorbing system of claim 1, further comprising: lower means for securing the ceiling of at least one absorbing member to the barrier layer.
17. The load distributing and absorbing system of claim 1, wherein the floor has an aperture that allows moisture to drain from the absorbing member.
18. The load distributing and absorbing system of claim 1, wherein the ceiling between adjacent absorbing members in a tile has a length that is less than a length of the floor of an adjacent absorbing member.
19. An underlayment infrastructure that is interposed between a superstructure material and a foundation, the underlayment infrastructure comprising: a barrier layer that lies below the superstructure material; a ceiling that is positioned proximate the barrier layer on a face thereof which lies opposite to the superstructure material; one or more absorbing members that have walls which extend convergingly away from the ceiling towards the floor that lies above the foundation, at least some of the one or more absorbing members having: a number (A) of apertures defined in the floor, where 0<=A<100; and lower means for securing at least one ceiling to the barrier layer.
20. The load distributing and absorbing system of claim 17, further comprising: upper means for securing the barrier layer to the superstructure material.
21. The force-attenuation system of claim 17, wherein some absorbing members are joined together to form sub-assemblies of tiles.
22. The force-attenuation system of claim 19, wherein some tiled sub-assemblies and associated barrier layers are quadrilateral and are united with neighboring sub-assemblies.
23. The load distributing and absorbing system of claim 1 further comprising one or more ribs extending at least partially between adjacent absorbing members.
24. The load distributing and absorbing system of claim 1, wherein the superstructure material includes: a material selected from the group consisting of a surface such as a floor located in a senior living or elder care facility; a hospital or out-patient facility; a marine environment, including boating decks and docks; a sports-playing surface; a walking/running track; a golf playing surface; a soccer, rugby, lacrosse, or football field; a stairway; a work mat; a work platform; an anti-fatigue mat; an enhanced comfort mat; a wall protection material; a playground; a day care floor; a flooring material in homes and residences; a military blast mat; and a seat in a military vehicle that may detonate a land mine.
25. The load distributing and absorbing system of claim 1, further including one or more transition features to smoothly graduate from one height and type of superstructure material to another superstructure material of another type and height.
26. A load distributing and absorbing system that lies below a superstructure material that is exposed to percussive forces, the load distributing and absorbing system being interposed between the superstructure material and a foundation below, the load distributing and absorbing system comprising: one or more load distributing and absorbing tiles, at least some of such tiles having a barrier layer that lies below the superstructure material; an underlayment infrastructure positioned below the barrier layer, the underlayment infrastructure including one or more hat-shaped absorbing members, at least some of the hat-shaped absorbing members having an inverted ceiling, the inverted ceiling being positioned proximate the foundation; a curvilinear wall extending above the ceiling; an overlying floor positioned below the barrier layer that connects facing sections of the curvilinear wall.
27. A method for making the load distributing and absorbing system of claim 1, comprising the steps of: a. providing a semi-molten sheet from which the ceiling, the wall and the floor of the absorbing members are to be prepared; b. forming and cooling the sheet to prepare sub-assemblies of absorbing members; e. adhering a barrier layer across the absorbing members to form an underlayment infrastructure tile; j. adjoining tiles of underlayment infrastructures to form assemblies of tiles for installation in an environment of use.
28. The method of claim 27, the method of step (b) is selected from the group consisting of thermoforming, compression molding, vacuum forming and injection molding.
Description
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
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DETAILED DESCRIPTION OF THE INVENTION
[0033] As required, detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention that may be embodied in various and alternative forms. The figures are not necessarily to scale; some features may be exaggerated or minimized to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ alternative embodiments of this disclosure.
[0034]
[0035] Consider
[0036] Edge B1 of the barrier layer 18 overhangs edge A1 of the sub-assembly of absorbing members 22 and edge B2 overhangs edge A2. Thus, edges A3 and A4 of the sub-assembly of absorbing members 22 extend beyond overlying edges B3 and B4 of the barrier layer 18. This arrangement creates an overhanging L-shaped platform 25 (
[0037] One consequence of this arrangement is that adjacent tiles engage each other in such a way as to inhibit relative lateral movement therebetween.
[0038] Interlocking engagement of adjacent tiles in a group is provided by mating registration features 50, 52 (
[0039]
[0040] As used herein the term hat-shaped includes frusto-conical. Such hat-shaped members 22 may have a lower portion 28 that has a footprint which is circular, oval, elliptical, a cloverleaf, a race track, or some other rounded shape with a curved perimeter. Similarly, for an upper portion 36 of an absorbing member 22. As used herein the term hat-shaped includes shapes that resemble those embodied in at least these hat styles: a boater/skimmer hat, a bowler/Derby hat, a bucket hat, a cloche hat, a fedora, a fez, a gambler hat, a homburg hat, a kettle brim or up-brim hat, an outback or Aussie hat, a panama hat, a pith helmet, a porkpie hat, a top hat, a steam punk hat, a safari hat or a trilby hat. See, e.g., https://www.hatsunlimited.com/hat-styles-guide, which is incorporated by reference.
[0041] As used herein the terms hat-shaped and frusto-conical exclude structures that include a ridge line or crease in a continuous curvilinear wall 26 associated with an absorbing member 22, because such features tend to promote stress concentration and lead to probable failure over time when exposed to percussive blows. They tend to concentrate, rather than distribute or absorb incident forces.
[0042] Connecting the ceiling 24 and the floor 30 of an absorbing member 22 is a curvilinear wall 26. When viewed laterally, a curvilinear wall 26 appears substantially linear or straight before being subjected to an impact force that may reign on a barrier layer 18. When viewed from above or below, the footprint of the lower portion 28 or upper portion 36 may appear circular, elliptical, oval, a clover leaf, a race-track or some other rounded shape with a curved perimeter.
[0043] The floor 30 or ceiling 24 of an absorbing member 22 may be flat or crenelated.
[0044] The absorbing members 22 may be manufactured from a resilient thermoplastic and be formed into frusto-conical or hat-shaped members 22 that protrude from a sheet which before exposure to a forming process is substantially flat.
[0045] In one preferred embodiment, the barrier layer 18 is made from a strong thin layer of a polycarbonate (PC), the absorbing member 22 is made from a resilient thermoplastic polyurethane (TPU), and the means for securing 55 is provided by a pressure sensitive adhesive (PSA) which bonds well to both the PC and TPU.
[0046] Thus, an underlayment infrastructure 20 is created by the juxtaposition of a barrier layer 18 and a sub-assembly of absorbing members 22.
[0047] An assembly of absorbing members 22 and overlying barrier layer 18 forms a tile 17, 19, 21, 23 (
[0048] If desired, an adhesive 55 (
[0049] While a pressure sensitive adhesive is a preferred embodiment of means for securing 55 a barrier layer 18 to the ceilings 24 of a tile, alternatives for attaching overlapped tiles together through their associated barrier layers 18 include mechanical means for attaching such as Velcro, tape, rivets, etc.
[0050] The overlap of the barrier layers 18 and proximity of the absorbing members 22 on adjacent tiles distributes a load applied to the barrier layer 18 over a broad area. Loads are evenly distributed when applied either on a seam between adjacent tiles or within a tile. Loads are at least partially absorbed by flexure and possible rebound of the walls in the absorbing members.
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[0053] It will be appreciated that in some applications, a given sub-assembly 54 absorbing members 22 may have more than one overlying barrier layer 18.
[0054] A preferred embodiment of the finished tiles is a 5 ft2.5 ft rectangular tile. Tiles of this size can be delivered to the job site on densely packed pallets. They fit through any doorway. Alternatively, any number of polygonal arrangements of tiles including hexagons and the like could form a load distribution and absorbing system 10. However, the four-sided structures are preferred to conform with rectangular rooms.
[0055] Flooring systems are rarely uniformly dimensioned or shaped throughout a facility. Flooring transitions from one product to another often require a transition feature 58 (
[0056]
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[0058] In alternative embodiments, mating registration features 50, 52 may resemble jigsaw puzzle pieces or rectangles. Overlap of a barrier layer over an adjacent tile of absorbing members is facilitated by a tight gap between adjacent tiles. This feature helps avoid soft spots or read through defects in form and appearance.
[0059] The absorbing members 22 may be made from various materials. In a preferred example, they may be thermoformed from a resilient thermoplastic polyurethane from a 0.5 mm to 2.0 mm base stock. Such units may have a curvilinear wall 26 with 5 to 45 degrees of draft and be 5-30 mm in height. Such constructions are primarily suitable for commercial applications.
[0060] Other environments of deployment, such as residential, may require less durability and resiliency since they experience relatively little wear. In such cases, the absorbing members 22 or the barrier layer 18 could be produced from other less resilient and less expensive thermoplastics such polyethylene, polypropylene, acrylonitrile butadiene styrene, polycarbonate and the like. Residential applications may require less durability and resiliency since they experience only a fraction of the force distribution. Additionally, a casting or injection molding process could also be deployed to produce a similar product or structure.
[0061] For commercial applications, barrier layer materials 18 are preferably made of polycarbonate between 0.5 mm and 2.0 mm in thickness with a surface texture.
[0062] Alternative approaches to affixing the superstructure material 12 to the barrier layer 18 or the barrier layer to the ceiling 24 of an absorbing member 22 through means for securing 34 will now be described. Styrene butadiene rubber and polypropylene-based pressure sensitive adhesive, like HB Fuller 2081, is preferred over other adhesive types based on its affinity for both PC and TPU layers. Pressure sensitive adhesive is preferred over other types of adhesive systems as it allows for adjacent tiles to be adhered to one another with a pre-applied adhesive that requires only pressure to activate. Unlike rigid thermosetting adhesive systems, the PSA remains pliable over the life of the system. However, other adhesives could be utilized to permanently or temporarily bond the layers together. The HB Fuller adhesive preferred is specific to the materials of construction and an alternative might be better suited to a different build of materials.
[0063] Other applications for the disclosed load distributing and absorbing system 10 exist. It will be appreciated that this disclosure is mainly focused on fall protection for older adults or infirm patients in areas where slips and falls are prone to occur. However, it is conceivable that the system could be used in other applications or environments of use beyond fall protection. As non-limiting examples, these include work mats, blast mats, boat matting, work platforms, anti-fatigue mats, enhanced comfort mats, wall protection, playgrounds, day care floors, residences, sports surfaces, and other surfaces where those in contact with the surface might benefit from the technology.
[0064] The system 10 can be enhanced by further layers that provide an added function. The barrier layer 18 may include an additional layer of PSA film for the attachment of a superstructure material 12 such as a flooring surface or an additional sound abatement layer such as rubber, cork, vinyl barrier, and insulators. The absorbing members 22 may also have additional layers for sound abatement or adhesive.
[0065] In some cases, the load distributing and absorbing system 10 may benefit from the addition of a barrier layer 18 where no adjacent tile exists, and the PSA is exposed on a tile edge as in
[0066] Advantages of the disclosed load distributing and absorbing system include:
[0067] Military grade impact protection for seniors;
[0068] Reduction in the risk of hip and other fractures due to falls;
[0069] Reduction in the risk of traumatic brain injury due to falls;
[0070] Reduction in fatigue with enhanced comfort under foot;
[0071] Stability under foot when and where desired;
[0072] Conformance of engineered transitions meet ADA accessibility requirements;
[0073] Enhanced sound absorption;
[0074] Enhanced vibration dampening;
[0075] Low profile for renovation or new construction;
[0076] Ease of installation;
[0077] Compatibility with conventional flooring adhesives;
[0078] Light weight;
[0079] Affordable;
[0080] Durable and capable of withstanding hundreds of impacts;
[0081] Can be installed over green concrete;
[0082] Provides additional thermal insulation;
[0083] Incorporates post-industrial content;
[0084] Acts as a vapor barrier.
[0085] Testing has demonstrated that use of various embodiments of the disclosed system may lead to a:
[0086] 20-fold reduction in risk of critical head injury
[0087] 60% reduction in the probability of moderate head injury
[0088] 3-fold reduction in GMAX
[0089] 2.5-fold reduction femoral neck force during falls for average older females
[0090] 3-fold increase in force reduction
[0091] 2.5-fold reduction in energy restitution
[0092] firm and stable and stable surface that supports mobility
[0093] substantially more comfort under foot for caregivers and older adults.
[0094] Test data indicate that the proposed load distributing and absorbing systems have the potential to substantially reduce the risk of injury and improve the quality of life for both older adults and caregivers.
TABLE-US-00001 TABLE OF REFERENCE NUMBERS Reference No. Component 10 Load distributing and absorbing system 12 Superstructure material 14 Underside 16 Foundation 17 Tile 18 Barrier layer 19 Tile 20 Underlayment infrastructure 21 Tile 22 Absorbing members 23 Tile 24 Ceiling 25 Platform 26 Curvilinear wall 27 Roof 28 Lower portion 30 Floor 32 Apertures 34 Means for securing 36 Upper portion 38 Ceiling 40 Lower portion 42 Tiles of underlayment infrastructures 44 First tile 46 Edge 48 Adjacent tile 50 Male registration feature 52 Female registration feature 54 Sub-assemblies of absorbing members 55 Lower means for securing 56 Upper means for securing 58 Transition feature 60 Sloped section 61 Optional lower layer (e.g. sound or vibration dampening) 62 Optional upper layer
[0095] While exemplary embodiments are described above, it is not intended that these embodiments describe all possible forms of the invention. Rather, the words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the invention. Additionally, the features of various implementing embodiments may be combined to form further embodiments of the invention.