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.

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 fa...

AI Technical Summary

Benefits of technology

[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.

Problems solved by technology

Such factors may include cost, ease of installation, durability, and aesthetics.

Conventional flooring and surfacing systems are often exhibit poor characteristics with regard to at least one of these factors.

This increases the cost of installing such a surface because thicker surfaces are generally more costly than thinner surfaces.

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.

Another problem with some engineered wood fiber is that areas protected by engineered wood fiber are rarely wheelchair accessible.

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.

Like engineered wood fiber, loose fill can shift and become uneven, providing less protection in one spot than in another spot.

Consequently, playgrounds covered with loose fill are unlikely to be certified as wheelchair accessible.

Rubber mats, however, can be very heavy to ship.

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.

The pour-in-place method is very labor intensive.

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.

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