Fall protection tile system

Abstract

The invention pertains to a fall protection tile system consisting of at least one cover tile and one cushion base. The cover tile, fabricated from a flexible material, outlines a plane with a minimum of three sides, each side presenting a skirt portion 5 and a receiving portion. Notably, the skirt portion extends from the plane with a specific profile aimed at interlocking with a receiving portion of another cover tile. The cushion base, constructed of shock-absorbing material, is configured to snugly fit beneath the cover tile. The design ensures the skirt portion's extension retains the cushion base in its intended position beneath the cover tile. A feature of 10 the system is that both the cover tile and the cushion base are independent components within this fall protection system.

Description

[0001] Fall Protection Tile System

[0002] Technical Field

[0003] The present invention relates to a fall protection tile system that is easy to manufacture, easy to install and durable. In addition, the fall protection tile system is designed to be easily recyclable and in particular also reusable.

[0004] Background of the invention

[0005] Fall protections on playgrounds are commonly known in the art. There are solutions that require a molding on site or tile laying solutions and combinations thereof. Many shock-absorbing materials frequently employed today involve hazardous materials such as SBR (styrene butadiene), Isocyanates, Zinc, Hydrocarbons, Pll based binders comprising Isocyanates or other hazardous materials. Old or recycled tires that are widely used as base material for shockabsorbing flooring comprise a cocktail of the mentioned hazardous materials, for example Zink, polycyclic aromatic hydrocarbons and many unidentified cancerogenic and hormone-disturbing substances. The environment gets exposed to these hazardous materials in several ways. For example, when the shock absorbing material is molded on site by workers then these workers are typically directly exposed to hazardous materials due to fumes and chemical reaction products originating from the molded material during hardening. The molded material typically comprises a granulate, for example recycled tires, and a PU- based binder that is supposed to harden under atmospheric (outdoor) conditions. Leaving the molded material to harden under outdoor conditions can lead to further problems such as microplastic migration due to uncomplete hardening and the risk of certain chemical compounds still being open and not completely closed. Such open or partially open chemical compounds continue to release fumes and therewith potentially hazardous chemicals into the environment. This process can go on for a comparably long time, thus several months in the worst case.

[0006] Another problem that is often arising is that microplastic from such flooring systems or tiles, especially if they are made or installed on site, ends up in nature and / or water system even though microplastic filters and floor drains designed for filtering microplastic are used, as there is a risk that the curing or hardening is not complete when it happens outdoors and on site. A certain microplastic migration is however unavoidable due to the use of the fall protection flooring in, for example playgrounds, where shearing-forces occur that will lead to microplastic particles being ripped out from the fall protection flooring. Such expected microplastic migration may also end up in bodies of children, as they tend to orally take in and taste various objects with their mouths, especially when they are at a comparably young age. Pre-fabrication of flooring tiles is therewith desirable in order to reduce microplastic migration, since the hardening process takes place under controlled circumstances.

[0007] A fall protection flooring tile designed to be used on playgrounds is shown and illustrated in GB 2000726. The tiles are formed so that they can be interlocked with neighboring tiles, a tile comprising a water permeable wear layer made of granules and a base layer laminated to it. The base layer is made of resilient closed cell foam. The foam may be made of polyethylene and glued to the wear layer using a polyurethane binder. The base layer and the wear layer are specially designed; - the base layer comprising perforations in the shape of elongated slits. The wear layer comprises jags or prongs that are designed to engage jags or prongs of a neighboring tile. The tile of GB2000726 has some disadvantages in that it is made of a layered material and in that it is laminated, which makes it difficult to recycle the tile as the two different materials cannot be easily separate, it comprises sharp edges on the surface due to the jags or prongs, which are exposed to wear and use damages. In addition, due to the perforations, the lamination and the rather special design of the wear layer with the jags, it is rather expensive to produce the tile according to GB2000726. Finally, in the GB2000726 the base or foam layer below the wear layer has a thickness of 3 to 10 mm, which is not sufficient for shock absorption.

[0008] Summary of the Invention

[0009] In view of the above it would therefore be desirable to replace hazardous materials with non-hazardous more environmentally accepted alternatives, which provide sufficient fall protection as well as other advantageous properties such as abrasion and wear resistance. In addition, it would be desirable to provide a fall protection tile system, that is easy to recycle, easy to install and efficient to manufacture.

[0010] Moreover, preparation of fall protection structures have hitherto, at least to a large extent, been made in-situ or on site as previously indicated. Needless to say, varying weather conditions, i.e. changes in temperature and rain may render such preparation slow and the produced protection structure may suffer from irregular properties, such as varying adhesiveness between layers making up the structure, impaired shock absorbance, as well as impaired abrasion and wear resistance and exposure of the workers to chemical vapors and fumes. Manually prepared playground layers may also result in thickness variation of layers, which also contribute to non-uniform shock absorbance properties.

[0011] In view of the above it is thus an object of the present invention to provide a fall protection tile system that is durable, non-hazardous, easy to handle and efficient to install.

[0012] In view of the above-mentioned problems the inventor of the present invention has discovered that is possible to provide a fall protection tile system that comprise two components that are not connected or laminated to one another, namely a wear layer or cover tile and a cushion base or shock absorbing element. The wear layer or cover tile being designed to keep the cushion base in position via skirt elements that protrude or extend from a surface of the wear layer.

[0013] Disclosed herein is a fall protection tile system comprising a cover tile and a cushion base, the cover tile being made of a flexible material, the cover tile comprising a plane and at least three sides, each side having at least one skirt portion and at least one receiving portion. The skirt portion being designed to extend away from the plane and comprises a profile that is designed to engage a receiving portion of another cover tile. The cushion base is made of a shock absorbing material and being designed to fit under the cover tile, whereby a part of the skirt portion extends or projects away from the plane so that the cushion base is kept in place under the cover tile by the skirt portions of each side. The cover tile and the cushion base are designed to be separate components of the fall protection tile system.

[0014] In one proposed embodiment the skirt portion that extends away from the plane is corresponding to the thickness of the cushion base so that the skirt portions extend onto a ground below the cushion base when the fall protection tile system is installed.

[0015] In another embodiment of the present invention the part of the skirt portion that extends away from the plane is smaller than the thickness of the cushion base so that the skirt portions does not extend onto a ground below the cushion base when the fall protection tile system is installed. The skirt portion may thus be freely suspended above a ground below the cushion base.

[0016] The above-described embodiment has certain advantages such as good shock absorbing properties, high flexibility due to the modular system as the cushion base and the cover tile are separate elements or components and easy recyclability as the two components are not glued or connected to one another, which means that even if they are made of a different material, they can be easily separated and recycled.

[0017] The cushion base may further comprise holes or other perforations that allow for water, in particular rainwater, drainage. The cover tiles may be designed to be porous so that they also let water and rainwater pass through.

[0018] In addition to the above the described fall protection tile system also allows for an easy manufacturing in particular of the cushion base in a factory; basically a foam plastic mat or material can be cut in the factory accordingly so that the cut pieces fit under the cover tile. Also, the manufacturing of the cover tile is simplified as it can be casted or injection moulded or the like and most of all easily pre-fabricated.

[0019] The cushion base may have a thickness of 2cm to 10cm, preferably 3cm to 7cm. This may lead to a good fall protection according to the EN 1177:2018 HIC standard.

[0020] In another embodiment the cushion base defines a plate-shape with a horizontal surface and wherein the size of the horizontal surface is designed to fit into a surface defined by the plane of the cover tile.

[0021] The above-mentioned feature may help for an easy assembly on site. The cushion bases can be laid out and positioned and then each cushion base may be covered by a cover tile and held in place via the skirt portions and the weight of the cover tile. It is however herewith noted that the cushion base should fit snuggly under the cover tile for optimal shock absorbing properties.

[0022] In another embodiment the cushion base and the cover tile are not connected or glued to one another.

[0023] In a further embodiment the profile of the skirt portion(s) is shorter than a total height of the skirt portion(s) and wherein the profile extends all the way to a free end of the skirt portion(s) and wherein the receiving portion of a neighbouring tile is arranged on an opposite side of an upper surface of the plane of the cover tile.

[0024] This may help to provide a smooth, and in some embodiments straight, line of the joint between two adjacent or neighbouring cover tiles and therewith increases durability. Any sharp edges or sharp corners along the joint line between two adjacent cover tiles reduces durability as such sharp corners will wear and tear quickly.

[0025] The fall protection tile system according to any of the preceding claims, wherein the cover tile further comprises a lip arranged adjacent the at least three sides of the cover tile and extending away from the plane in the same direction as the skirt portions and wherein said lip at least partially surrounds the cover tile so that the lip at least partially hugs the cushion base when it is placed under the cover tile. The lip may further help to keep the cushion base in a snug and correct position under the cover tile. In an embodiment the lip may be designed to surround or extend along all sides of the cover tile, without any interruption. Alternatively, the lip may be interrupted at regular intervals.

[0026] In another embodiment the cover tile may be made of one piece of a homogenous or uniform material for example granule material using a polyurethan based binder. Such a homogenous material may be water-permeable.

[0027] This reduces complexity and therewith cost and also allows for a rather straightforward production in a factory and therewith a controlled hardening and quality control of the cover tile.

[0028] In still another embodiment the cushion base is made of one piece of a homogenous material, for example foamed plastic.

[0029] Also, this may reduce complexity and may ease production and instalment of the fall protection tile system.

[0030] In an embodiment at least one side of the cover tile forms a straight line.

[0031] This may ease instalment and improve durability of the fall protection tile system. The straight line my be harmonic and smooth with no sharp edges or the like. The edge of the straight line may be rounded.

[0032] In another embodiment the skirt portion does not extend over more than half of a length of a corresponding side of the cover tile.

[0033] The skirt portion may extend over less than half of a length of the corresponding side, but it may also by much less such as a third or a quarter of the length of the corresponding side.

[0034] The cover tile may comprise four or more sides. In an embodiment the cushion base and the cover tile do not comprise any hazardous material or at least not above a certain concentration level. Hazardous material may be Isocyanates, Zink or Hydrocarbons. The concentration levels that are accepted are typically provided by a governing body.

[0035] This may improve or sustain the health of the workers installing the fall protection tile system and the people using the fall protection tile system, in particular the children.

[0036] In another embodiment the length of the part of the skirt portion(s) that projects from the plane is at least more or less the same as a thickness of the cushion base.

[0037] This may lead to an optimal shock absorbing behaviour as the cover tile and the cushion base can optimally work together for absorbing shocks or impacts originating from the cover tile.

[0038] A skirt portion herein should be understood as an element or part that is configured or designed to at least partially cover another element similar to a skirt. In this case the cover tile together with its skirt portions is designed to partially cover and keep the cushion base in position.

[0039] The cover tile may be made of a more robust material than the cushion base.

[0040] The cushion base may be made of a softer material than the cover tile.

[0041] The profile of the skirt portion is designed to fit, for example form- or clamp fit into the receiving portion of an adjacent cover tile.

[0042] Other modifications and designs within the scope of the invention may herewith be included in this patent application. In particular modifications of the skirt portions that are within the reach of the skilled person, fall under the scope of the present disclosure. Brief Description of the Drawings

[0043] The present invention will now be described, for exemplary purposes, in more detail by way of an embodiment(s) and with reference to the enclosed drawings, in which:

[0044] Fig. 1 schematically illustrates a perspective view of a fall protection tile system prior to installation according to an embodiment of the invention;

[0045] Fig. 2 schematically illustrates a perspective view of the fall protection tile system after installation;

[0046] Fig. 3 schematically illustrates a top-down view onto the fall protection tile system;

[0047] Fig. 4 schematically illustrates a cross sectional view onto the fall protection tile system according to the cut indicated in figure 3; and

[0048] Fig. 5 schematically illustrates a perspective view of the fall protection tile system with two adjacent cover tiles being installed.

[0049] Fig. 6a schematically illustrates a perspective view of a fall protection tile system prior to installation according to an embodiment of the invention wherein the skirt portion is configured to not extend onto the ground after installation;

[0050] Fig. 6b schematically illustrates a perspective view of the fall protection tile system after installation wherein the skirt portion is configured to not extend onto the ground after installation, and;

[0051] Fig. 6c schematically illustrates a cross sectional view of the fall protection tile system.

[0052] Detailed Description

[0053] Figure 1 illustrates a perspective view of the fall protection tile system 1 comprising a cover tile 2 and a cushion base 4. The cushion base 4 and the cover tile 2 are delivered as separate elements or components of the fall protection tile system 1 and then installed on site according to the further description herein. It is to be noted that the cover tile 2 and the cushion base 4 form a unit or pair and the fall protection tile system 1 may comprise several pairs of cover tiles 2 and cushion bases 4 in order to cover a larger area or surface such as a playground.

[0054] The cushion base 4 is designed to fit under the cover tile 2. This means that the surface area defined by the plane 6 of the cover tile 2 is greater than the surface area defined by the plane 8 of the cushion base 4. The cover tile 2 and the cushion base 4, respectively, are in the illustrated example rectangular or square having four sides, they may however be of triangular, hexagonal, octagonal or any other shape. The shape of the cushion base 4 may further not always correspond to the shape of the cover tile 2. In some embodiments, in particular with hexagonal or octagonal shape of the cover tile 2, the cushion base 4 may be of circular shape.

[0055] The cushion base 4 may further comprise a plurality of small holes or other perforations 9 (illustrated in figure 6a) for drainage purposes, while the cover tile 2 may be made of slightly porous or water-permeable material so that water can pass through it.

[0056] The cushion base 4 may be made of a polymeric foam made of polymers, such as preferably polyolefins. The cushion base 4 can be cut into the correct size and shape from polyolefin mats or the like. Other materials that can be used are styrene butadiene rubber (SBR), Expanded thermoplastic polyurethane (E-TPU) or Ethylene propylene diene monomer rubber (EPDM).

[0057] The cover tile 2 is designed to cover the cushion base 4 when it is installed, which is indicated by the arrows in figure 1.

[0058] Turning now to figure 2, which illustrates the fall protection tile system 1 in the installed configuration where the cushion base 4 is snug fitted under the cover tile 2 held in place by skirt portions 10 that extend from the plane 6 of the cover tile 2 along sides of the cushion base 4 onto a ground (not illustrated) below the cushion base 4. Each side of the cover tile 2 comprises a skirt portion 10, which extends from the plane 6 of the cover tile 2. All skirt portions 10 of one cover tile 2 thereby extend into the same direction, so that the cushion base 4 is held in place by these skirt portions 10 when the fall protection tile system 1 is installed. The cover tile 2 further comprises a lip 12 that extends in the same direction from the plane 6 of the cover tile 2 as the skirt portion 10. The lip 12 may be circumferential and continuous along the sides of the cover tile 2 or it might be interrupted at regular intervals. The lip 12 additionally keeps the cushion base 4 in a snug position under the cover tile 2 and is further illustrated in figure 4.

[0059] Each skirt portion 10 further comprises at least one profile 14, in the illustrated example three profiles 14, which extend in a direction perpendicular to the plane 6 of the cover tile 2. The profiles 14 do not extend all the way up to an upper end of the cover tile 2, whereby said upper end is defined by an upper surface of the plane 6. This improves durability as the actual joint between adjacent cover tiles 2 (c.f. figure 5) is straight and not interrupted with sharp edges or any other shapes that reduce durability. The profiles 14 are configured to engage receiving portions 16 of a neighboring cover tile 2. In figure 2 the receiving portions 14 are however visible on the same cover tile 2. The profiles 14 engage the receiving portions 16 via their conical shape so that they get clamped or form-fitted of some sort in the receiving portions 16. The connection between profiles 14 and receiving portions 16 is however releasable.

[0060] Turning now to figure 3, which shows a top-down view onto the cover tile 2 with the profiles 14 well visible. The double conical cross section or trapezoidal shape of the profiles 14 is well visible. In the shown example the cover tile 2 is a squareshaped tile but it can also be a rectangular, hexagonal, octagonal or any other shape.

[0061] Figure 4 illustrates a cross sectional view of the fall protection tile system 1 cut along line IV-IV of figure 3. The cushion base 4 and the cover tile 2 is illustrated and it can be seen how the lip 12 of the cover tile 2 and the skirt portion 10 of the cover tile 2 to hug the cushion base at least partially 4. This way the cushion base 4 stays securely in place under the cover tile 2 even though the cushion base 4 and the cover tile 2 are not connected, laminated or glued to one another. Figure 5 illustrates a fall protection tile system T showing how two neighboring cover tiles 2, 2’ interlock with one another via their skirt portions 10, 10’ and the corresponding receiving portions 16, 16’. The conical profiles of the skirt portions 10, 10’ engage cutouts of the receiving portions 16, 16’ for a form fit interlocking. The profiles 14, 14’ of the skirt portions 10, 10’ are designed conical with a longer base away from the skirt portions 10, 10’ so that the base of the profiles 14, 14’ lock and engage the cutouts of the receiving portions 16, 16’ in a releasable manner. The connection between the receiving portions 16, 16’ and the skirt portions 10, 10’ provides a certain clamping effect so that the two neighboring cover tiles 2, 2’ are drawn to one another during the connecting operation and when they are in the installed configuration. From the enlargement of figure 5 it is well visible that the cushion bases 4, 4’ are snug held in position via the lip 12 under the cover tile 2.

[0062] Figure 6a, 6b and 6c illustrates an embodiment of the present invention wherein a fall protection tile system T comprises skirt portions 10” which do not extend onto the ground below the cushioned base 4” when installed. This configuration may be preferred for several reasons, such as: providing an alternative load distribution; reducing wear and tear on the underlying floor; and, allowing the fall protection tile system 1” to better accommodate minor unevenness in the floor surface.

[0063] As can be seen in figure 6a to 6c the fall protection tile system 1” with shortened skirts is otherwise similar to the aforementioned embodiment with longer skirt. The illustrated embodiment comprises at least one cover tile 2” and at least one cushion base 4”. The cover tile 2” is preferably made of a flexible material. The cover tile 2” defines a plane 6” and has at least three sides, each side having at least one skirt portion 10” and at least one receiving portion 16”. The skirt portion 10” extends away from the plane 8” and comprising a profile 14” that is designed to engage a receiving portion 16” of another cover tile 2”. The cushion base 4” is preferably made of a shock absorbing material and is designed to fit under the cover tile 2”. In the illustrated embodiment, a part of the skirt portion 10” length that extends away from the plane 6” is smaller or shorter than the thickness of the cushion base 4” as measured in a vertical direction so that the cushion base 4” is kept in place under the cover tile 2” by the skirt portions 10” of each side and so that the skirt portions 10” does not extend onto a ground below the cushion base 4” when the fall protection tile system 1” is installed. The cover tile 2” and the cushion base 4” are separate components of the fall protection tile system 1”.

[0064] The embodiment illustrated in figure 6a further comprises cross-shaped perforations 9 distributed evenly over the plane 8” of the cushion base 4”. In other embodiments the perforations 9 may be another shape, such as lines, hexagons, or circles. They may also be distributed unevenly and further adapted as to distribute load in a specific manner, or further adapted as to allow for efficient drainage. In relation to embodiments allowing for drainage the cover tiles are preferably designed to be porous so that they also let water and rainwater pass through.

[0065] Figure 6c illustrates a cross sectional view of the fall protection tile system 1”. The cushion base 4” and the cover tile 2” are illustrated and it can be seen how the lip 12” of the cover tile 2” and the skirt portion 10” of the cover tile 2” hug the cushion base at least partially 4”. This way the cushion base 4” stays securely in place under the cover tile 2” even though the cushion base 4” and the cover tile 2” are not connected, laminated or glued to one another. As can be seen in figure 6c the skirt portion 10” and lip 12” do not extend onto the ground below the cushion base as they are designed shorter than the thickness of the cushion base 4” at least when measured on an inner side versus the plane of the cover tile 2”.

[0066] The invention has now been described referring to the figures and the corresponding embodiments. The embodiments may be varied within the scope of the invention and the person skilled in the art. For example, the percentage of the length of the sides of the cover tile that comprises the skirt portion and the receiving portion, respectively, may be 50 / 50, 30 / 30 or 20 / 20. In case of 50 / 50 0 percent of the length being free, in case of 30 / 30, 30% of the length being free or in case of 20 / 20 60% of the length being free whereby the free parts of the sides in the 30 / 30 and 20 / 20 cases only comprise the described lip 12 (c.f. figure 3). In addition, the lip 12 may be longer as illustrated in the figures, for example figure 3, and extend over about 50% of the thickness of the cushion base 4, 4’.

Claims

CLAIMS1. A fall protection tile system (1 , T) comprising at least one cover tile (2, 2’) and at least one cushion base (4, 4’), the cover tile (2, 2’) being made of a flexible material, the cover tile (2, 2’) defining a plane (6) and at least three sides, each side having at least one skirt portion (10, 10’) and at least one receiving portion (16, 16’), the skirt portion (10, 10’) extending away from the plane (6) and comprising a profile (14, 14’) that is designed to engage a receiving portion (16, 16’) of another cover tile (2, 2), the cushion base (4, 4’) being made of a shock absorbing material and being designed to fit under the cover tile (2, 2’), characterized in that a part of the skirt portion (10, 10’) that extends away from the plane (6) so that the cushion base (4, 4’) is kept in place under the cover tile (2, 2’) by the part of the skirt portions (10, 10’) that extends away from the plane (6) of each side, wherein the cover tile (2, 2’) and the cushion base (4, 4’) are separate components of the fall protection tile system (1 , T).

2. The fall protection tile system according to claim 1 , wherein the part of the skirt portion (10, 10’) that extends away from the plane (6) is corresponding to the thickness of the cushion base (4, 4’) so that the skirt portions (10, 10’) extend onto a ground below the cushion base (4, 4’) when the fall protection tile system (1 , T) is installed.

3. The fall protection tile system according to claim 1 , wherein the part of the skirt portion (10, 10’) that extends away from the plane (6) is smaller as measured in a vertical direction than the thickness of the cushion base (4, 4’) as measured in the vertical direction, so that the part of the skirt portions (10, 10’) that extend away from the plane (6) are freely suspended above a ground below the cushion base (4, 4’).

4. The fall protection tile system according to any of the previous claims, wherein the profile (14, 14’) of the skirt portion(s) (10, 10’) is shorter than a total height of the skirt portion(s) (10, 10’) and wherein the profile (14, 14’) extends all the way to a free end of the skirt portion(s) (10, 10’) and whereinthe receiving portion (16, 16’) is arranged on an opposite side of an upper surface of the plane (6) of the cover tile (2, 2’). The fall protection tile system according to any of the previous claims, wherein the cover tile (2, 2’) further comprises a lip (12) arranged adjacent the at least three sides of the cover tile (2, 2’) and extending away from the plane (6) in the same direction as the skirt portions (10, 10’) and wherein said lip (12) at least partially surrounds the cover tile (2, 2’) so that the lip (12) at least partially hugs the cushion base (4, 4’) when it is placed under the cover tile (2, 2’). The fall protection tile system according to any of the previous claims, wherein the cushion base (4, 4’) defines a plate-shape with a horizontal surface or plane (8) and wherein the size of the horizontal surface or plane (8) is designed to fit into a surface defined by the lip (12) of the cover tile (2, 2’). The fall protection tile system according to any of the previous claims, wherein the cover tile (2, 2’) is made of one piece of a homogenous material for example granule material using a polyurethan based binder. The fall protection tile system according to any of the previous claims, wherein the cushion base (4, 4’) has a thickness of 2cm to 10cm, preferably 3cm to 7cm. The fall protection tile system according to any of the previous claims, wherein the cushion base (4, 4’) is made of one piece of a homogenous material, for example foamed plastic. The fall protection tile system according to any of the preceding claims, wherein the skirt portion (10, 10’) does not extend over more than half of a length of a corresponding side of the cover tile (2, 2’). The fall protection tile system according to any of the preceding claims, wherein at least one of the sides of the cover tile (2, 2’) is formed as a straight line.

12. The fall protection tile system according to any of the preceding claims, wherein the cover tile (2, 2’) comprises four or more sides.

13. The fall protection tile system according to any of the preceding claims, wherein the cushion base (4, 4’) and the cover tile are free from any hazardous material such as Isocyanates, Zink or Hydrocarbons.

14. The fall protection tile system according to any of the preceding claims, wherein the cushion base (4, 4”) comprises perforations (9”).

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