Resilient flooring

Abstract

A resilient flooring comprising a first layer and second layer on top of the first layer, wherein the first layer is stiffer than the second layer and is formed with voids into which the second layer resiliently deforms when subjected to a downward force, the deformation being reversed when the force is removed.

Description

RESILIENT FLOORING

[0001] This invention relates to resilient flooring, and is concerned particularly although not exclusively with resilient flooring for sports tracks for enhancing an athlete's performance through energy conservation.

[0002] Athletics and sports tracks are essential for enabling optimal athletic performance in a wide range of sports and activities. However, current track structures exhibit several limitations that hinder their ability to provide the most efficient and supportive environment for athletes. These limitations stem from factors such as energy conservation, durability, ease of installation, adaptability to environmental conditions, and directional performance.

[0003] One key issue with existing track structures lies in their inability to efficiently conserve and return energy to the athlete. When a runner applies force to a surface during strides, much of the energy dissipates rather than being returned to propel the athlete forward. This energy loss can result in reduced athletic efficiency, impacting performance and increasing fatigue over time.Many current track materials, including rubber-based surfaces, exhibit volumetric incompressibility, which restricts the elastic deformation necessary for effective energy storage and return.

[0004] Durability is another significant concern. Sports tracks are exposed to varying environmental conditions, including temperature extremes, UV exposure, and precipitation. These factors can degrade track materials over time, leading to a shorter operational lifespan, increased maintenance costs, and inconsistent surface performance. Additionally, tracks designed to withstand environmental stress often compromise on other attributes, such as energy efficiency or user comfort.

[0005] Portability and ease of installation are further areas where existing track structures fall short. Many current tracks require complex and timeconsuming installation processes, making them impractical for temporary or mobile applications. The lack of portability restricts their utility in scenarios such as temporary athletic events or modular training setups.

[0006] Hard-wearing properties are essential for maintaining performance consistency under heavy and frequent usage, such as in competitive settings or high-traffic training facilities. However, achieving high durability often results in surfaces that are either too rigid or lack elasticity, compromising comfort and performance.

[0007] The directional performance of tracks poses a unique challenge. While some tracks are designed to optimize performance in a specific direction (monodirectional), others attempt to provide uniform performance in all directions (omni-directional). Existing solutions often fail to balance these requirements effectively, leading to suboptimal experiences for athletes depending on their sport or event.

[0008] In addition to the technical and performance challenges faced by existing athletic track surfaces, there is a pressing need for solutions that address the economic and regulatory dimensions of track design. Current high-performance running surfaces often come with a prohibitive cost, limiting their accessibility to elite facilities or well-funded organisations. Conversely, lower-cost options frequently fail to meet the performance, durability, or compliance standards required for competitive athletics. The void in the market for a midpriced, high-performing track surface remains a significant obstacle to the broader adoption of advanced track technologies.

[0009] Mass manufacturability presents another critical challenge. Existing state-of-the-art surfaces often rely on complex or labour-intensive production processes, which drive up costs and create supply chain inefficiencies. These factors make it difficult to produce high-quality surfaces at scale, restricting the availability of advanced tracks to select markets and regions.

[0010] Finally, compatibility with international athletic standards, including those set by governing bodies such as World Athletics, remains a fundamental requirement. Many current surfaces struggle to balance innovative design features with the stringent criteria imposed by these organisations. The need for a track that not only delivers superior performance and durability but also aligns with regulatory requirements for competitive events is essential to ensure widespread acceptance and usability in the global sports industry.

[0011] Addressing these needs requires a solution that harmonises performance, cost-efficiency, scalability, and regulatory compliance, ensuring that advanced athletic track technologies become accessible to a broader audience while meeting the rigorous demands of competitive sports.

[0012] Addressing these challenges is critical for advancing the performance, sustainability, and versatility of athletic tracks. Enhanced energy conservation, improved durability, simplified installation, and tailored directional performance are key areas where innovation can significantly improve current standards. Preferred embodiments of the present invention seek to address these longstanding issues with a novel approach to track design, ensuring a superior athletic experience while meeting the demands of modern sports infrastructure.

[0013] There is a need to improve the performance, sustainability, and versatility of athletic tracks and other sports flooring. There is a need to enhanceenergy conservation, improve durability, simplify installation, and tailor directional performance.

[0014] The prior art shows a number of devices which attempt to address these needs in various ways.

[0015] EP 2055833 (Mondo SPA) discloses flooring, designed primarily for running tracks, consisting of a treading layer made of elastomer material and a supporting layer also made of elastomer. On the side opposite the treading layer, the supporting layer features a network of elongated cavities, aligned in the running direction, bordered by ribbings forming a uniform mesh. These cavities occupy at least 28% of the supporting layer's volume, with a preference for at least 30%.

[0016] GB 2000726 (Freudenberg) discloses a flat outdoor floor tile or slab that comprises a bottom layer made of closed-cell soft foam with geometrically distributed openings across its surface. Bonded to this layer is a water-permeable covering made of resiliently cemented granules. The tile features projections and corresponding recesses along its edges, allowing it to interlock with adjacent tiles.

[0017] EP 0913424 (Mondo SPA) discloses a flooring arrangement, primarily designed for use in athletics tracks, comprising a tread layer extending in a defined plane, along with support formations extending from the tread layer in specific directions. Some of these support formations are inclined in relation to the plane of the tread layer. Additionally, the flooring exhibits differential resilience, depending on how stress is applied.

[0018] Whilst the prior art appears to address the issue of providing flooring systems, particularly for sports applications, that balance elastic compliance,support, and stability, they are not optimised for high performance. Whilst the prior art incorporates ribbing structures arranged in specific patterns to achieve differentiated resilience and enhance performance based on movement direction, they are not designed for mass market applications. Some solutions focus on anchoring mechanisms for stability, though their contribution to overall support and compliance is limited. Whilst the prior art aims to go some way towards enhancing energy conservation and therefore performance, it does not maximise energy conservation, improve durability, simplify installation, and tailor directional performance to track use.

[0019] Preferred embodiments of the present invention aim to provide a sports track that provides directional energy conversion and propulsion in the direction of travel of an athlete engaging with the track. Preferred embodiments of the present invention also aim to provide a mass market, modular arrangement of sports track that can be moved and installed in different configurations, at various locations, and on various surfaces with relative ease.

[0020] According to a first aspect of the present invention there is provided a resilient flooring comprising a first layer and second layer on top of the first layer, wherein the first layer is stiffer than the second layer and is formed with voids into which the second layer resiliently deforms when subjected to a downward force, the deformation being reversed when the force is removed.

[0021] Preferably, the first layer comprises plastics.

[0022] Preferably, the second layer comprises natural rubber.

[0023] A third, flexible surface layer may be provided above the second layer.

[0024] Said first layer may comprise a plurality of projections surrounded by said voids.

[0025] Said voids may extend continuously around said projections.

[0026] Said projections may have the shape of a frustum of a cone or pyramid.

[0027] The cone or pyramid may be asymmetrical, such that the upper layer deforms preferentially in one direction when subjected to a downward force.

[0028] Said projections may have a mutual spacing in the range 5 to 20mm, preferably 8 to 16mm.

[0029] Said projections may have an upper surface with a mean diameter in the range 2.5 to 5mm, preferably 3 to 4.8mm.

[0030] Said projections may be arranged in a hexagonal pattern.

[0031] Said voids may be arranged as an array with walls that define the voids.

[0032] Said voids may be hexagonal in plan view.

[0033] Said voids may be rectangular in plan view.

[0034] Said voids may have a maximum dimension in plan view in the range 10 to 30mm, preferably 15 to 25mm.

[0035] Said walls may have a thickness in the range 1 to 5mm, preferably 1.5 to 3mm.

[0036] A resilient flooring according to any of the preceding aspects of the invention may comprise a plurality of tiles arranged next to one another, each tile comprising said layers.

[0037] The resilient flooring may further comprise connectors that join adjacent ones of the tiles.

[0038] Said connectors may be elongate, extending along the sides of the tiles.

[0039] Said connectors may be selectively illuminable.

[0040] Said tiles may be polygonal in plan view.

[0041] The polygon may be a square, an oblong or an octagon.

[0042] The tiles may have a maximum dimension in the range 0.5 to 5 metres, preferably 1.0 to 2.0 meters.

[0043] The second or third layer may have a top surface that is formed with a pattern to enhance grip.

[0044] The resilient flooring may be formed with a camber to shed water.

[0045] The resilient flooring may be provided with gutters to receive water shed by the flooring.

[0046] A resilient flooring according to any of the preceding aspects of the invention may be configured as a sports track or arena.

[0047] For a better understanding of the invention and to show how embodiments of the same may be carried into effect, reference will now bemade, by way of example, to the accompanying diagrammatic drawings, in which:

[0048] Figure 1 shows one possible embodiment of resilient flooring in side view, showing a triple layer arrangement, with first layer, second layer and surface layer;

[0049] Figure 2 shows an isometric view of one possible embodiment of first layer showing a grid of frustoconical projections with voids therebetween;

[0050] Figure 3 shows one embodiment of monodirectional resilient flooring, showing a first layer comprising a grid of directional projections and voids therebetween;

[0051] Figure 4 shows the resilient flooring of Figure 3 in partial exploded view, showing a surface layer and a second layer removed from the first layer;

[0052] Figure 5 is a perspective view of the first layer of Figures 3 and 4;

[0053] Figure 6 shows the first layer of Figure 5 in plan view and sectional view on A-A, showing one possible arrangement of inclined projections and voids therebetween;

[0054] Figure 7 shows a further embodiment of monodirectional resilient flooring showing a first layer comprising an alternative array of directional projections and voids therebetween;

[0055] Figure 8 shows the resilient flooring of Figure 7 in partial exploded view, showing a surface layer and second layer removed from the first layer;

[0056] Figure 9 shows the first layer of Figures 7 and 8 in perspective;

[0057] Figure 10 shows the first layer of Figure 9 in plan view and sectional view on A-A, showing inclined projections and voids therebetween;

[0058] Figure 11 shows one embodiment of omnidirectional resilient flooring;

[0059] Figure 12 shows the resilient flooring of Figure 11 in partial exploded view, showing a first layer comprising a hexagonal grid of walls creating hexagonal voids therebetween;

[0060] Figure 13 shows the first layer of Figures 11 and 12 in perspective;

[0061] Figure 14 shows the first layer of Figure 13 in plan view and sectional view on A-A;

[0062] Figure 15 shows a further embodiment of omnidirectional resilient flooring;

[0063] Figure 16 shows the resilient flooring of Figure 15 in partial exploded view, showing a first layer comprising a square grid of walls with square voids therebetween;

[0064] Figure 17 shows the first layer of Figures 15 and 16 in perspective;

[0065] Figure 18 shows the first layer of Figure 17 in plan view and sectional view on A-A;

[0066] Figure 19 shows yet another embodiment of omnidirectional resilient flooring;

[0067] Figure 20 shows the resilient flooring of Figure 19 in partial exploded view, showing a first layer comprising an array of tapered projections secured to a compliant membrane;

[0068] Figure 21 shows the first layer of Figures 19 and 20 in perspective;

[0069] Figure 22 shows the first layer of Figure 21 in plan view and sectional view on A-A;

[0070] Figure 23 shows a further embodiment of omnidirectional resilient flooring;

[0071] Figure 24 shows the resilient flooring of Figure 23 in partial exploded view, showing a first layer comprising a grid of tapered, round projections and voids therebetween;

[0072] Figure 25 shows the first layer of Figures 23 and 24 in perspective;

[0073] Figure 26 shows the first layer of Figure 25 in plan view and sectional view on A-A,;

[0074] Figure 27 shows one embodiment of connector alongside a surface layer of resilient flooring;

[0075] Figure 28 shows a partial exploded view of resilient flooring showing a surface layer and a tiled arrangement of first layer with a plurality of tiles connected together to form a grid, shown with one embodiment of connector comprising a line marker light;

[0076] Figure 29 shows one embodiment of connector configured to releasably secure to at least one first layer tile, to releasably secure tiles together, with enlarged detail B;

[0077] Figure 30 shows one possible arrangement of modular resilient flooring comprising an array of tiles covered by a single surface layer;

[0078] Figure 31 shows a typical resilient flooring structure;

[0079] Figure 32 shows a resilient flooring when not subjected to a load;

[0080] Figure 33 shows the resilient flooring of Figure 32 when subjected to a load, showing a second layer sinking into voids between projections in a first layer;

[0081] Figure 34 shows a layered arrangement of first layers with second layer sandwiched therebetween, when not subjected to a load;

[0082] Figure 35 shows the resilient flooring of Figure 34 when subjected to a load;

[0083] Figure 36 shows an array of resilient flooring modules covered with a single surface layer, and provided with tape strips for securing to ground;

[0084] Figure 37 shows the resilient flooring of Figure 36 when subjected to surface water;

[0085] Figure 38 shows one embodiment of layering tape strips to alter the height of resilient flooring modules from the ground;

[0086] Figure 39 shows a cambered surface that is realised when the resilient flooring of Figure 38 is placed on the ground;

[0087] Figure 40 shows one embodiment of connectors between cambered groups of resilient flooring modules, the connectors incorporating a gutter;

[0088] Figure 41 shows a plan view of a first layer provided with conical projections;

[0089] Figure 42 is a plan view similar to Figure 41, showing the first layer provided with a plurality of drainage holes; and

[0090] Figure 43 shows an alternative arrangement of drainage slits within the first layer.

[0091] In the figures like references denote like or corresponding parts.

[0092] It is to be understood that the various features that are described in the following and / or illustrated in the drawings are preferred but not essential. Combinations of features described and / or illustrated are not considered to be the only possible combinations. Unless stated to the contrary, individual features may be omitted, varied or combined in different combinations, where practical.

[0093] Figure 1 illustrates one embodiment of a resilient flooring system 1, comprising a multi-layered structure with a first layer 4, a second layer 3, and a third surface layer 2. The first layer 4 is constructed from a relatively rigid material, such as plastics, and features an array of upward projections 5. These projections 5 are strategically spaced to create multiple voids 6 between them. This structural design provides a foundation with localised voids or cavities that interact with the layers above.

[0094] In this example, the voids 6 extend continuously around the projections 5 to connect with one another but, as will become apparent from the following description, the voids 6 exhibit localised behaviour in regions bounded by the projections 5 so that, in effect, multiple voids 6 are created.

[0095] The second layer 3 is composed of a resilient, elastomeric material, such as rubber, selected for its capacity to undergo elastic deformation under mechanical stress, the deformation being reversed when the stress is removed. This layer 3 is adhered to the first layer 4 specifically at the apexes of the projections 5, leaving the voids 6 beneath it unobstructed. This configuration allows the second layer 3 to flex and deform into the voids 6 when subjected to compressive forces.

[0096] The third, surface layer 2 is designed to interact directly with external forces, such as the impact from an athlete's foot, and transfers an applied load to the underlying second layer 3. Upon application of a downward force, the surface layer 2 compresses, causing localised deformation of the second layer 3. Due to its elastic nature, the second layer 3 compresses into the voids 6 between the projections 5 of the first layer 4. This deformation stores mechanical energy in the form of elastic potential energy within the second layer 3.

[0097] As the applied load begins to diminish— for instance, when the athlete's foot transitions from vertical loading to forward propulsion— the second layer 3 begins to recover its original form due to its elastic properties. The portions of the second layer 3 that had compressed into the voids 6 rebound, releasing the stored elastic potential energy. This rebound action generates an upward and forward-directed reactive force that acts against the athlete's foot, effectively aiding propulsion and conserving some of the energy that would otherwise dissipate. This mechanism not only enhances energy return but alsocontributes to improved athletic performance by providing subtle, yet effective, assistance in forward movement.

[0098] The surface layer 2 may consist of conventional track surface materials designed to provide optimal performance and safety, and ensuring grip. These materials can include synthetic compounds such as polyurethane, rubber granules, or latex-bound surfaces, all engineered to offer durability, shock absorption, and enhanced grip for athletes. Additionally, the surface layer 2 may incorporate specialised flooring solutions tailored for various sports venues, including indoor courts, multi-purpose arenas, and outdoor athletic tracks. These alternative flooring options might feature modular tiles, cushioned vinyl, or engineered wood surfaces to accommodate specific sports requirements, improve performance, and ensure safety across diverse sporting activities.

[0099] Figure 2 shows one possible embodiment of first layer 4 in three dimensional view, showing one possible shape of projections 5. In this embodiment the projections 5 comprise frustoconical projections 7. This shape of projection 5 provides a flat surface onto which the second layer 3 can be secured, by adhesives or otherwise, and creates a suitable shape of void 6 between projections 5 that make up the array.[000100] Figure 3 shows a module or tile of resilient flooring 1, showing multiple layers 2, 3, 4 joined together. Figure 4 shows the resilient flooring of Figure 1 with the surface layer 2 and second layer 3 removed from the first layer 4. The first layer 4 comprises a uniform array of projections 5 and corresponding voids 6 therebetween.[000101] Figure 5 shows the first layer 4 on its own, showing the arrangement of projections 5. The projections 5 are also shown in more detail in Figure 6 withplan view and cross-section A-A. The projections 5 in this embodiment comprise irregular pyramidal shapes.[000102] The projections 5 of the first layer 4 may comprise various geometric configurations to achieve specific performance characteristics. These shapes can include regular pyramidal forms with symmetrical sloping sides, providing uniform support and consistent energy return. Alternatively, irregular or oblique pyramidal projections may feature asymmetrical slopes, resulting in varied force distribution and directional energy return upon compression. Flat-topped pyramidal shapes or truncated cones (frustums) may also be utilised to modify surface response and enhance stability.[000103] When these projections 5 are arranged in a uniform array or grid, voids 6 are naturally formed between adjacent projections. These voids 6 may exhibit different cross-sectional profiles, with some being symmetrical and others having steeper or uneven sides. The geometry of these voids 6 directly influences the behaviour of the resilient second layer 3 when subjected to pressure, such as from a footstep. Symmetrical voids 6 provide balanced compression and rebound, while asymmetrical or steeper voids generate directional return forces due to uneven displacement. This directional force can enhance propulsion or stability, depending on the intended application, by guiding the return motion of the resilient second layer 3, and therefore in some circumstances the surface layer 2, into specific vectors.[000104] Symmetrical voids 6 allow for uniform deformation of the second layer 3, resulting in balanced compression and even energy distribution. This uniform rebound supports consistent force return, aiding in overall stability and reducing the risk of injury by distributing impact forces evenly across the foot.[000105] In contrast, asymmetrical or steeper voids 6 introduce directional variability in the deformation of the resilient second layer 3. When an athlete's foot applies pressure, the second layer 3 compresses unevenly into these voids 6, causing the material to rebound more forcefully along the path of least resistance. This directional return force can be harnessed to enhance forward propulsion during running by aligning steeper void slopes in the direction of travel. Additionally, such design can provide targeted energy return, assisting athletes in accelerating or decelerating more efficiently. The asymmetrical voids 6 may also contribute to lateral stability by controlling the rebound vector, reducing the likelihood of ankle rolls or missteps during rapid directional changes common in sprinting and agility drills.[000106] Figure 7 shows an alternative embodiment of resilient flooring 1 showing multilayers sandwiched together. Figure 8 shows first layer 4 exploded from the second layer 3 and surface layer 2. In this embodiment the first layer 4 comprises a grid of oblique, flat-topped pyramids for projections 5. Again, the oblique arrangement creates a directional return force when a force is applied through the second layer 3. Figures 9 and 10 show this first layer 4 in more detail with the projections 5 comprising a square-based pyramidal shape featuring a steeper slope on one side compared to the others, combined with a flattened or truncated top surface. This design introduces intentional asymmetry, resulting in directional compression and rebound behaviour.[000107] When pressure is applied, such as from a runner's foot, the steeper side of the projection allows for quicker deformation and a stronger directional return force opposite to the slope. The flattened top surface enhances stability and surface contact, reducing abrupt transitions and offering consistent energy return. The flattened top also provides greater surface area for bonding the first layer 4 to the second layer 3, so that the second layer 3 elastically deforms intothe voids 6, rather than sliding. This configuration can be strategically positioned to influence movement dynamics, providing both propulsion and lateral support tailored to athletic performance requirements.[000108] Figures 11, 12, 13 and 14 show a further embodiment of resilient flooring 1 where first layer 4 comprises an array or grid of interconnected walls 8, creating a continuous framework of enclosed voids 6. Specifically, the walls 8 define hexagonal cells arranged in a honeycomb-like structure. This configuration allows for uniform distribution of pressure and efficient load transfer across the surface. The hexagonal voids 6 provide a balanced and multidirectional deformation response when resilient second layer 3 is compressed, promoting consistent energy return and stability. The honeycomb design also enhances material efficiency by minimizing weight whilst maintaining structural integrity.[000109] The geometry of the hexagonal voids 6 influences the deformation behaviour of the resilient second layer 3. Under foot impact, the second layer 3 compresses into these voids 6, distributing force evenly due to the symmetrical cell structure. This even compression results in predictable and stable rebound forces, reducing localised stress and enhancing comfort. In certain configurations, varying the wall thickness or introducing slight asymmetries in the hexagonal cells can direct the rebound force to assist in propulsion or lateral support, similar to the function of asymmetrical voids.[000110] Figures 15, 16, 17 and 18 show yet a further embodiment where the first layer 4 consists of an array of square-shaped walls 8 forming square voids 6 between adjacent walls. This arrangement creates a uniform and orthogonal structure that offers predictable and evenly distributed deformation when subjected to pressure. The square voids 6 facilitate a balanced compression andrebound response, ensuring consistent force distribution across the surface. This configuration can be optimised by varying wall thickness or height to adjust the stiffness and energy return, providing tailored support for different athletic activities. The square grid design also simplifies manufacturing and allows for modular construction, offering flexibility in surface customisation.[000111] In Figures 19, 20, 21 and 22 the first layer 4 comprises a grid of flattopped conical projections 5 interconnected by low-profile walls 8 arranged in a diamond-shaped grid pattern. This configuration enhances the structural cohesion of the projections 5 while maintaining flexibility in the surface response. The diamond arrangement of the low walls 8 creates elongated voids 6 between the conical projections 5, which allows for controlled deformation and directional energy return when the second layer 3 is compressed. The interconnected design provides improved lateral stability and distributes impact forces more evenly, reducing localised stress and enhancing overall comfort. This arrangement can also be engineered to guide rebound forces in specific directions, contributing to improved athletic performance by supporting forward propulsion and agility.[000112] In yet another arrangement of resilient flooring 1, Figures 23, 24, 25 and 26 show a first layer 4 comprising conical shapes 5 with flattened or truncated tops. This first layer 4 combines the benefits of a curved conical surface with a stable, flat contact area, enhancing both shock absorption and surface grip. The conical projections 5 allow for gradual and controlled compression under load, promoting smooth energy transfer and rebound.Additionally, the bases of the voids 6 between these projections 5 may be equipped with strategically placed holes. These holes serve dual purposes: facilitating efficient drainage to prevent water accumulation on the surface and reducing the overall material weight of the structure. This configurationimproves surface performance in wet conditions and contributes to lighter, more responsive flooring systems ideal for athletic applications.[000113] The first layer 4 may comprise a serrated edge along its perimeter designed to facilitate interlocking with adjacent flooring tiles. This serrated configuration enables seamless connection between neighbouring tiles, enhancing overall structural stability and preventing lateral movement during use. The interlocking mechanism also aids in distributing impact forces more uniformly across the surface, reducing the risk of tile separation under dynamic loads. This design ensures a secure, continuous surface ideal for modular sports flooring systems, simplifying installation and maintenance while improving durability and performance.[000114] Figure 27 shows one possible embodiment of connector 10 for connecting neighbouring tiles, neighbouring portions of surface layer 2, or adjacent layers of the resilient flooring 1. The connector 10 may comprise a line marker, that may also illuminate, particularly where the resilient flooring 1 is used for a multi lane athletics track. Figure 28 shows the resilient flooring 1 comprising the first layer 4 made up of multiple tiles 9 interconnected together, and provided with a single surface layer 2 covering multiple tiles 9.[000115] Figure 29 shows a further embodiment of resilient flooring 1 where the surface layer is the second layer 3 and therefore the surface layer is configured to deform into the voids 6 between the projections 5. An enlarged view B of this embodiment is also shown. In this embodiment the first layer 4 is made up of modular elements.[000116] Figure 30 illustrates a modular array of resilient flooring 1, composed of tiles 9 that are interconnected to cover a larger surface area. The surface layer2 may consist of a single piece that spans across multiple tiles 9. This surface layer 2 may be rolled out over the tiles 9. Such an arrangement minimises the number of joints in the surface, thereby reducing the risk of trip hazards.Additionally, the surface layer 2 provides protection for the resilient flooring 1 against environmental factors, such as rainwater, dirt, and debris.[000117] In this example, the large tiled array of resilient flooring 1 consists of 35 tiles 9, arranged in a 7-by-5 panel. This configuration allows a single mould tool to produce flooring for varying track widths. Furthermore, gaps between the tiles 9 may enable the resilient flooring 1 to adapt to uneven ground surfaces.[000118] Figure 31 illustrates an example of existing (known) sports flooring, where a rubber layer, referred to as second layer 3, is positioned directly on top of an additional rubber layer 11. In this configuration, the second layer 3 is unable to compress under load because it is fully constrained by the underlying rubber layer 11.[000119] This lack of compressibility leads to significant energy loss during use. When an athlete interacts with the surface, the energy from their movement cannot be absorbed effectively by the flooring. Instead, the energy is dissipated as heat or vibration within the rigid structure, reducing the efficiency of energy return to the athlete. This results in decreased performance as the surface does not provide the necessary compliance to cushion impacts or enhance propulsion. Furthermore, the absence of impact absorption increases the likelihood of discomfort or fatigue for athletes over prolonged periods of use.[000120] Figures 32 and 33 depict the stages of compression of the second layer 3. Under load, the elastomeric second layer 3 deforms and expands into the voids 6 located between the projections 5. This deformation continues until theload is removed. Upon release, the second layer 3 recovers its original shape, providing the athlete with a return of stored energy.[000121] This process minimises energy loss because the elastomeric properties of the second layer 3 enable it to store the energy generated during compression and release it effectively when the load is removed. This energy return helps to enhance the athlete's performance, as the surface not only cushions the impact but also aids in propulsion by channelling the stored energy back to the athlete.[000122] The compliance of the second layer 3 plays a critical role in absorbing the impact forces from the athlete's movements. When the athlete interacts with the surface, the compliance allows the second layer 3 to adapt and conform to the force applied, thereby reducing the stress on the athlete's joints and muscles. This impact absorption helps prevent fatigue and injury, while also contributing to a more comfortable and efficient athletic experience.[000123] Figure 34 shows a further embodiment where the second layer 3 is sandwiched between two first layers 4, showing one possible arrangement of resilient flooring 1 comprising additional layers. The resilient flooring 1 may comprise a first layer 4 and a second layer 3. There may also be one or more surface layers 2 over the surface of the second layer 3. Figures 34 and 35 show a further embodiment comprising a first layer 4 on the base, a second layer 3 configured to engage with the first layer, a further first layer 4 inverted and configured such that the projections 5 of this further first layer 4 are aligned with the voids 6 of the first layer 4 at the base. The second layer 3 is squeezed between the two first layers 4.[000124] Figure 36 shows a modular arrangement of resilient flooring, with a single surface layer 2, and provided with tape 12 to secure resilient flooringmodules 1 to ground. Figure 37 shows the same arrangement of resilient flooring when subjected to surface water 13, which pools on the surface layer 2.[000125] Figures 38 and 39 show a further arrangement of resilient flooring where tape strips 12 are layered to achieve different heights for the resilient flooring modules 1. Figure 39 shows the same arrangement but with a cambered surface. The thickness of the tape strips 12 or number of tape strips 12 in a stack dictate the amount that the surface is cambered. A cambered surface helps to prevent water from pooling, and helps surface water to drain off to the sides.[000126] Figure 40 shows one possible embodiment of gutters 14 formed in elongate rubber strips 10. The rubber strips 10 may also incorporate lane marking and LED illumination. The rubber strips 10 may be configured to connect adjoining modular arrangements of resilient flooring 1, and where these comprise a cambered surface, any surface water 13 would drain into the gutter 14. The rubber strip connector 10 may be extruded. It may comprise a different colour to the surface layer 2 to provide a marker between lanes. It may be manufactured from a translucent material that allows light to diffuse through it, and provided with a plurality of LEDs.[000127] Figure 41 shows a first layer 4 comprising a solid plastic base, with an array of conical projections 5. This first layer 4 may have reduced compliance on uneven ground or a rough surface, and also may allow water to collect within the structure. Figure 42 shows a similar arrangement of first layer 4 but provided with an array of drainage holes 15. This helps to reduce material usage, thus decreasing the cost. Trapped water can drain into a permeable surface below. It also increases the flexibility of the first layer 4 allowing it to conform to uneven ground and improving panel compliance.[000128] Figure 42 shows two further arrangements of drainage holes 15, that comprise an array of slits within the first layer 4. These slits allow the first layer 4 to be bent to be able to create curved panels. The slits would also allow any trapped water to drain away.[000129] Resilient flooring 1 according to all of above described and illustrated embodiments is of particular use for an athletics track. These tracks typically comprise multiple lanes, and often form a loop. When these athletics tracks incorporate the resilient flooring 1 as herein described, they are designed to address the limitations of existing rubber-based athletic surfaces. Specifically, the first layer 4 compensates for the volumetric incompressibility of rubber, allowing for the recovery of energy from the elastic compression of the rubber track surface. The track structure is manufactured using a sandwich construction comprising flexible and rigid layers to achieve a balance of performance, durability, and cost-efficiency.[000130] The structure includes the rigid first layer 4 or base layer that minimises energy loss by enabling controlled deformation of the second layer 3, or softer rubber layer placed above it. This rigid first layer 4 also serves to create voids 6 and provides structural integrity, whilst maintaining minimal manufacturing costs. The modular nature of the track design, achieved through different tile shapes and sizes, facilitates easy installation and scalability for various applications. Additionally, the track features a gentle camber and integrated lane gutters eliminating the need for traditional through-track drainage systems.[000131] The first layer 4 utilises the high energy-return properties of natural rubber to create a surface capable of recovering and returning strain energy to the athlete during decompression. The first layer 4 is specifically designed tomitigate the effects of rubber's high Poisson's ratio, which approaches 0.5 due to the material's volumetric incompressibility. This property of rubber typically results in high stiffness and large energy losses as the material undergoes uncontrolled deformations during compression.[000132] To address these challenges, the first layer 4 introduces structured features that allow the rubber layer to flex and strain without requiring a volumetric change. The first layer 4 may be constructed from a stiff plastic material configured with projections 5 and voids 6. When a thin rubber sheet is placed over this structured base, the voids 6 between the projections 5 provide the necessary space for the rubber to deform during compression, thereby reducing energy losses and decreasing stiffness.[000133] In one embodiment, the second layer 3 comprises a high-resilience, 100% natural rubber with a Shore A hardness of approximately 38. This material selection enhances the energy return properties of the track. To further optimise performance, surface layer 2 may be placed above the rubber. This hard, high-stiffness layer effectively distributes applied loads, such as those from a runner's foot, ensuring consistent pressure transmission to the underlying rubber and maximising the energy recovery effect.[000134] The resilient flooring 1 should be designed with dimensions suitable for use on both standard outdoor and indoor tracks. Outdoor tracks typically have a standard width of 1.22 metres, while indoor tracks range from 0.9 to 1.22 metres in width. To ensure versatility and adaptability, the resilient flooring lshould be modular, portable, and lightweight enough to be positioned manually, facilitating ease of use across different environments and setups.[000135] The panel width for the force platform is determined by therequirements of governing bodies, such as World Athletics, and should fall within the range of 0.9 meters to 1.22 meters. The panel length is designed to strike a balance between modularity and minimizing the number of joints, with a recommended range of 1.0 meters to 5.0 meters. This length is also constrained by the panel's mass, which should be between 10 kilograms and 50 kilograms to ensure manageability. The panel thickness is specified to be between 10 millimetres and 25 millimetres. Long panels of Mass Market Track may be rolled to improve portability and assist transport.[000136] In this specification, the verb "comprise" has its normal dictionary meaning, to denote non-exclusive inclusion. That is, use of the word "comprise" (or any of its derivatives) to include one feature or more, does not exclude the possibility of also including further features. The word "preferable" (or any of its derivatives) indicates one feature or more that is preferred but not essential.[000137] All or any of the features disclosed in this specification (including any accompanying claims, abstract and drawings), and / or all or any of the steps of any method or process so disclosed, may be combined in any combination, except combinations where at least some of such features and / or steps are mutually exclusive.[000138] Each feature disclosed in this specification (including any accompanying claims, abstract and drawings), may be replaced by alternative features serving the same, equivalent, or similar purpose, unless expressly stated otherwise. Thus, unless expressly stated otherwise, each feature disclosed is one example only of a generic series of equivalent or similar features.[000139] The invention is not restricted to the details of the foregoing embodiment(s). The invention extends to any novel one, or any novelcombination, of the features disclosed in this specification (including any accompanying claims, abstract and drawings), or to any novel one, or any novel combination, of the steps of any method or process so disclosed.

Claims

CLAIMS1. A resilient flooring comprising a first layer and second layer on top of the first layer, wherein the first layer is stiffer than the second layer and is formed with voids into which the second layer resiliently deforms when subjected to a downward force, the deformation being reversed when the force is removed.

2. A resilient flooring according to claim 1, wherein the first layer comprises plastics.

3. A resilient flooring according to claim 1 or 2, wherein the second layer comprises natural rubber.

4. A resilient flooring according to claim 1, 2 or 3, further comprising a third, flexible surface layer above the second layer.

5. A resilient flooring according to any of claims 1 to 4, wherein said first layer comprises a plurality of projections surrounded by said voids.

6. A resilient flooring according to claim 5, wherein said voids extend continuously around said projections.

7. A resilient flooring according to claim 6, wherein said projections have the shape of a frustum of a cone or pyramid.

8. A resilient flooring according to claim 7, wherein the cone or pyramid is asymmetrical, such that the upper layer deforms preferentially in one direction when subjected to a downward force.

9. A resilient flooring according to any of claims 5 to 8, wherein said projections have a mutual spacing in the range 5 to 20mm, preferably 8 to 16mm.

10. A resilient flooring according to any of claims 5 to 9, wherein said projections have an upper surface with a mean diameter in the range 2.5 to 5mm, preferably 3 to 4.8mm.

11. A resilient flooring according to any of claims 5 to 10, wherein said projections are arranged in a hexagonal pattern.

12. A resilient flooring according to any of claims 1 to 4, wherein said voids are arranged as an array with walls that define the voids.

13. A resilient flooring according to claim 12, wherein said voids are hexagonal in plan view.

14. A resilient flooring according to claim 12, wherein said voids are rectangular in plan view.

15. A resilient flooring according to claim 12, 13 or 14, wherein said voids have a maximum dimension in plan view in the range 10 to 30mm, preferably 15 to 25mm.

16. A resilient flooring according to any of claims 12 to 15, wherein said walls have a thickness in the range 1 to 5mm, preferably 1.5 to 3mm.

17. A resilient flooring according to any of the preceding claims, comprising a plurality of tiles arranged next to one another, each tile comprising said layers.

18. A resilient flooring according to claim 17, further comprising connectors that join adjacent ones of the tiles.

19. A resilient flooring according to claim 18, wherein said connectors are elongate, extending along the sides of the tiles.

20. A resilient flooring according to claim 17 or 18, wherein said connectors are selectively illuminable.

21. A resilient flooring according to claim 18, 19 or 20, wherein said tiles are polygonal in plan view.

22. A resilient flooring according to claim 21, wherein the polygon is a square, an oblong or an octagon.

23. A resilient flooring according to any of claims 17 to 22, wherein the tiles have a maximum dimension in the range 0.5 to 5 metres, preferably 1.0 to 2.0 meters.

24. A resilient flooring according to any of the preceding claims, wherein the second or third layer has a top surface that is formed with a pattern to enhance grip.

25. A resilient flooring according to any of the preceding claims, formed with a camber to shed water.

26. A resilient flooring according to any of the preceding claims, provided with gutters to receive water shed by the flooring.

27. A resilient flooring according to any of the preceding claims, configured as a sports track or arena.

28. A resilient flooring substantially as hereinbefore described with reference to the accompanying drawings.

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