Load distribution and absorption underpayment system

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 offers protection from injury following a fall, the system being located in a senior living environment or elder care facility, a hospital or an out-patient facility, a daycare facility, or a residential home, the load distributing and absorbing system lying below a barrier layer which is exposed to percussive or heavy point-applied forces exerted by the fall, a wheelchair, or a bed, the load distributing and absorbing system being interposed between the barrier layer and a foundation below, the load distributing and absorbing system comprising: a plurality of load distributing and absorbing tiles, at least some of the tiles having 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 primarily for load distribution, the ceiling being positioned below the barrier layer; a curvilinear wall primarily for load absorption extending from the ceiling, the curvilinear wall having a lower portion; and a floor that connects lower portions of the curvilinear walls of adjacent hat-shaped absorbing members within a tile, the floor lying above the foundation; means for securing positioned between the barrier layer and a ceiling, wherein the means for securing includes a pressure-sensitive adhesive that provides securement by a pre-applied adhesive which requires pressure to activate and remains pliable after application, wherein the barrier layer of a first tile extends from two edges thereof and overhangs ceiling portions of two adjacent tiles to create an L-shaped platform that distributes a load between tiles that is applied to a central region of a tie or to a seam between adjacent tiles and promote inter-engagement of adjacent tiles without slippage, wherein at least some tiles are joined together by mating registration features proximate the edges of the barrier layers, the mating registration features being defined by a male feature extending from an edge of a barrier layer that engages a female feature defined within an edge of a barrier layer in an adjacent tile, thereby inhibiting relative lateral movement between adjacent tiles, so that the overhang of the barrier layers and proximity of the absorbing members on adjacent tiles distribute a load applied to the barrier layer over a broad area, thereby distributing the load when applied either on a seam between adjacent tiles or within a tile, so that an effect of applying a given point load to a central portion of a tile is substantially equivalent to applying the given point load to a seam between adjacent tiles, at least some of the absorbing members having a force-attenuation characteristic such that within a group of tiles, there is a user-determinable force attenuation property that may be uniform or varied within a tile or within a group of tiles or within both an individual tile and a group of tiles.

2. The load distributing and absorbing system of claim 1, wherein the barrier layer is selected from the group consisting of a ceramic tile, wood, a wood composite, a carpet, a carpet tile, sheet vinyl, a vinyl tile, a rigid vinyl tile, a rubber sheet, 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 2, wherein the barrier layer includes a rigid thermoplastic.

5. The load distributing and absorbing system of claim 1, wherein at least some of the hat-shaped 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.

6. The load distributing and absorbing system of claim 1, wherein at least some of the hat-shaped absorbing members have a configuration defined at least in part by an imaginary footprint defined by the 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.

7. A load distributing and absorbing infrastructure tile in a load distributing and absorbing system that lies below a barrier layer which is exposed to percussive or point-applied forces, the load distributing and absorbing infrastructure tile being interposed between the barrier layer and a foundation below, wherein the barrier layer distributes at least some of the percussive or point-applied forces and is quadrilateral with edges B1, B2, B3 and B4, the edges B1 and B2 including female registration features defined therewithin, the edges B3 and B4 including male registration features extending therefrom; an absorbing member for absorbing at least some of the percussive or point-applied 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 hat-shaped energy absorbing units, at least some of the hat-shaped energy absorbing units having a ceiling primarily for load distribution, the ceiling being positioned below the barrier layer; a curvilinear wall primarily for load absorption, the curvilinear wall extending from the ceiling, the curvilinear wall having a lower portion; and a floor that connects the lower portions of the curvilinear wall of adjacent hat-shaped energy absorbing units, the floor lying above the foundation, wherein the barrier layer is positioned in relation to an absorbing member so that edge B1 of the barrier layer overhangs edge A1 of the absorbing member and edge B2 overlies edge A2, and edges A4 and A3 of the absorbing member extend beyond edges B4 and B3 of the barrier layer, thereby creating an L-shaped platform and an L-shaped roof that engage corresponding features of adjacent infrastructure tiles.

8. A load distributing and absorbing system comprising an assembly of inter-engaging load distributing and absorbing infrastructure tiles of claim 7.

9. The load distributing and absorbing system of claim 1, wherein the ceiling between the walls of an absorbing member in a tile has a length that is less than a length of the floor between adjacent absorbing members.

10. The load distributing and absorbing system of claim 1, further comprising one or more ribs extending at least partially between adjacent absorbing members.

11. The load distributing and absorbing system of claim 1, wherein the barrier layer includes: a material selected from the group consisting of a floor located in a senior living or elder care facility; a hospital or out-patient facility; a wall protection material; a day care floor; and a flooring material in homes and residences.

12. A load distributing and absorbing system that lies below a barrier layer that is exposed to percussive or point-applied forces, the load distributing and absorbing system being interposed between the barrier layer and a foundation below, the load distributing and absorbing system comprising: a plurality of load distributing and absorbing tiles, at least some of such tiles having 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 primarily for load distribution, the floor being positioned below the barrier layer that connects facing sections of the curvilinear walls of adjacent hat-shaped absorbing members; wherein the barrier layer of a first tile includes male and female registration features, extends from two edges of the first tile and overhangs at least some of the floors of hat-shaped absorbing members in an adjacent tile, so that overhang of the barrier layers and proximity of the absorbing members associated with adjacent tiles distribute a load applied to the barrier layer over a broad area, thereby distributing a load when applied either on a seam between adjacent tiles or within a tile.

13. The load distributing and absorbing system of claim 1, wherein the registration features are selected from a group consisting of trapezoids, keyholes, saw-teeth, semicircles, and shapes configured as mating pieces of a jigsaw puzzle, the registration features serving to avoid soft spots or read-through defects in form or appearance of the barrier layer.

14. The load distributing and absorbing system of claim 1, wherein the hat-shaped absorbing members have a shape selected from a group consisting of 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 pit helmet, a porkpie hat, a top hat, a steampunk hat, a safari hat and a trilby hat.

15. The load distributing and absorbing system of claim 14, wherein the hat-shaped absorbing members lack a ridgeline or crease in the continuous curvilinear wall associated with an absorbing member, a presence of such features tending to promote stress concentration and leading to probable failure over time when exposed to percussive blows, the presence of such features tending to concentrate, rather than distribute or absorb incident forces.

16. The load distributing and absorbing system of claim 1, wherein the barrier layer is made from a strong, thin layer of a polycarbonate (PC) and the absorbing member is made from a resilient thermoplastic polyurethane (TPU).

Description

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

(1) FIG. 1 is a top view of one embodiment of a load distributing and absorbing underlayment system that has four quadrilateral, preferably rectangular tiles.

(2) FIG. 2 is a sectional view through two illustrative adjacent abutted tiles.

(3) FIGS. 3-5 depict representative assembled flooring systems which include an underlayment infrastructure and a superstructure, such as three flooring products.

(4) FIG. 6 shows a four-tile arrangement where adjacent tiles lie in the same orientation.

(5) FIG. 7 suggests a three-seam intersection or staggered configuration of adjacent tiles.

(6) FIG. 8 depicts an illustrative height transition member that transitions from a higher safety flooring system to another flooring product that is lower in height.

(7) FIG. 9 is a cross sectional view of one transition feature overlapping an adjacent tile.

(8) FIG. 10 represents an alternative design of barrier layer mating registration features.

(9) FIG. 11 illustrates a load distributing and absorbing system with a barrier layer where no adjacent tile exists and a pressure-sensitive adhesive is exposed on a tile edge.

(10) FIG. 12 shows an alternative (inverted) embodiment.

DETAILED DESCRIPTION OF THE INVENTION

(11) 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.

(12) FIG. 1 is a top view of one embodiment of a load distributing and absorbing underlayment system 10 that has four quadrilateral, preferably rectangular, tiles 17, 19, 21, 23. These tiles are positioned relative to one another by inter-engaging mating registration features 50, 52, including male 50 and female 52 features provided along the edges of a barrier layer 18. Each tile 17, 19, 21, 23 has an infrastructure 20 with a plurality of absorbing members 22 for load absorption and a barrier layer 18 for load distribution.

(13) Consider FIG. 10. The barrier layer 18 (in this case) is quadrilateral with edges B1, B2, B3 and B4. A sub-assembly of underlying absorbing members 22 includes individual members 22 that are conjoined by their ceilings 24 which, before for example thermoforming take the form of a planar basal sheet. The absorbing members 22 join together and coordinate to form a periphery of the sub-assembly that is quadrilateral and has edges A1, A2, A3 and A4. Each barrier layer 18 is securely affixed to one or more of the ceilings 24 in a tile. In some cases, the barrier layer 18 is affixed to one or more of the ceilings 24 by means for securing 55 such as an adhesive or by mechanical means including screws, rivets, pins and the like.

(14) 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 (FIGS. 1, 11) of the barrier layer 18 and an open L-shaped roof formed by the ceilings 24 of the absorbing members 22 in the sub-assembly. In adjacent tiles, the L-shaped roof 27 associated with a given tile 19 supports the L-shaped platform of the barrier layer 18 of an adjacent tile.

(15) One consequence of this arrangement is that adjacent tiles engage each other in such a way as to inhibit relative lateral movement therebetween.

(16) Interlocking engagement of adjacent tiles in a group is provided by mating registration features 50, 52 (FIGS. 1, 6, 7). In a preferred embodiment, these mating registration features 50, 52 are trapezoidal in shape. For example, a male trapezoid 50 abuts a female trapezoid 52 along the edges of adjacent tiles 17, 19, 21, 23. It will be appreciated that there are alternative shapes of mating registration features, such as keyholes, sawtooth, semicircles, jigsaw-like pieces, etc.

(17) FIG. 2 is a vertical sectional view through two illustrative adjacent abutted tiles, such as 17/19, 21/23, 17/21, 19/23 in FIG. 1. One version of an underlayment system 10 according to the present disclosure includes a barrier layer 18 which in some embodiments is in contact with the ceilings 24 of hat-shaped absorbing members 22.

(18) 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.

(19) 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.

(20) 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.

(21) The floor 30 or ceiling 24 of an absorbing member 22 may be flat or crenelated.

(22) 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.

(23) 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.

(24) Thus, an underlayment infrastructure 20 is created by the juxtaposition of a barrier layer 18 and a sub-assembly of absorbing members 22.

(25) An assembly of absorbing members 22 and overlying barrier layer 18 forms a tile 17, 19, 21, 23 (FIG. 1). Adjacent tiles are inter-engaged by overlapping and underlapping edges of the barrier layer 18 in the manner described above. Preferably, a small, but acceptable, gap exists between barrier layers 18 associated with adjacent tiles. The barrier layer 18 of one tile overlaps at least some of the exposed absorbing members 22 of an adjacent tile.

(26) If desired, an adhesive 55 (FIG. 2) can be applied to one or both surfaces prior to the application of pressure which then adhesively attaches a barrier layer 18 to a tile 17, 19, 21, 23. adjacent tiles. An underlayment infrastructure 20 is thus assembled when the edges of adjacent tiles are brought into registration through the inter-engagement of mating registration features 50, 52 of adjacent edges of associated barrier layers 18.

(27) 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.

(28) 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.

(29) FIGS. 3, 4 and 5 depict a representative assembled flooring system which includes the underlayment infrastructure 20 and three superstructure materials 12, such as flooring products. Those figures depict a section through a typical carpet system (FIG. 3), a sheet vinyl or rubber system (FIG. 4), and rigid wood or composite tiles (FIG. 5). Commercial carpet systems are most often bonded directly to a foundation 16 or subfloor or to an underlayment material using an adhesive. Sheet vinyl or rubber are typically adhesively bonded to the underlayment material. The rigid wood or composite tiles may or may not be adhesively bonded to the underlayment material, depending on the product recommendations.

(30) FIGS. 6 and 7 show two different tile orientations. FIG. 6 shows a four-tile arrangement 17, 19, 21, 23 where adjacent tiles lie in the same orientation. This orientation is preferred as it minimizes the number of edge cuts when the installation site is rectangular. FIG. 7 suggests a three-seam intersection or staggered configuration of adjacent tiles. The periodicity of the male 50 and female features 52 in the barrier layer 18 are engineered such that the tiles can be staggered relative to one another to create a “T” seam (FIG. 7) as opposed to a seam in the four-tile intersection (FIG. 6). Both configurations contemplate overlapping the barrier layer 18 of one tile with another (see also, e.g., FIG. 2).

(31) 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.

(32) A preferred embodiment of the finished tiles is a 5 ft×2.5 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.

(33) Flooring systems are rarely uniformly dimensioned or shaped throughout a facility. Flooring transitions from one product to another often require a transition feature 58 (FIGS. 8, 9) to smoothly graduate from one height and type of product to a product of another type and height. In some cases, sheet vinyl flooring is usually around 2 mm in thickness. But rigid products can be as high as 8 or 9 mm. Commercial carpet often lies somewhere in between sheet vinyl and rigid.

(34) FIG. 8 shows an illustrative engineered height transition 58 that transitions from an 11 mm safety flooring system to another flooring product that is lower in height. The transition from 11 mm to 1 mm over a length of approximately 150 mm meets the Americans with Disabilities Act (ADA) requirements for wheelchairs.

(35) FIG. 9 is a cross sectional view of one transition feature 58 overlapping an adjacent tile. In such cases, the transition has a barrier layer 18 extending across the tiles which overlaps adjacent sub-assemblies 54 of absorbing members 22 and provides a sloped section 60 (FIG. 9) to transition down to an alternative construction. While the transition feature 58 could be positioned almost anywhere within a flooring surface, these transitions would often occur near a doorway from one room to the next. For example, a facility may choose to deploy carpet and underlayment in a patient room for comfort and sheet vinyl with no underlayment in a hallway. The transition feature 58 can be cut where the height matches the height of the adjacent flooring system.

(36) 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. FIG. 10 represents one alternative interlock design.

(37) 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.

(38) 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.

(39) 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.

(40) 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.

(41) 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.

(42) 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.

(43) 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 FIG. 10. Adding these pieces would be most logical starting from a wall edge so that the first piece does not need to be trimmed back and a full tile can be installed without trimming.

(44) Advantages of the disclosed load distributing and absorbing system include:

(45) Military grade impact protection for seniors;

(46) Reduction in the risk of hip and other fractures due to falls;

(47) Reduction in the risk of traumatic brain injury due to falls;

(48) Reduction in fatigue with enhanced comfort under foot;

(49) Stability under foot when and where desired;

(50) Conformance of engineered transitions meet ADA accessibility requirements;

(51) Enhanced sound absorption;

(52) Enhanced vibration dampening;

(53) Low profile for renovation or new construction;

(54) Ease of installation;

(55) Compatibility with conventional flooring adhesives;

(56) Light weight;

(57) Affordable;

(58) Durable and capable of withstanding hundreds of impacts;

(59) Can be installed over green concrete;

(60) Provides additional thermal insulation;

(61) Incorporates post-industrial content;

(62) Acts as a vapor barrier.

(63) Testing has demonstrated that use of various embodiments of the disclosed system may lead to a:

(64) 20-fold reduction in risk of critical head injury

(65) 60% reduction in the probability of moderate head injury

(66) 3-fold reduction in GMAX

(67) 2.5-fold reduction femoral neck force during falls for average older females

(68) 3-fold increase in force reduction

(69) 2.5-fold reduction in energy restitution

(70) firm and stable and stable surface that supports mobility

(71) substantially more comfort under foot for caregivers and older adults.

(72) 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.

(73) 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

(74) 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.