Multi-Level Safety Tiles with Integral Protrusions
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Solution Overview
Problem
Existing safety surfaces for playgrounds and recreational areas, such as poured-in-place rubber or edge-joined rubber tiles, are hard and lack durability, and the formation of unitary surfaces from interlockable tiles is complex, requiring assembly of multiple components and layers, which complicates manufacturing and maintenance.
Innovation Solution
Development of multi-level unitary safety surface tiles with integral sub-surface protrusions and interlocking features that allow for on-site assembly without extraneous hardware, providing a durable and accessible safety surface that attenuates impact forces without the need for multiple components or layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If unitary surfaces are formed from interlockable tiles, then durability is improved, but device complexity increases due to assembly of multiple components and layers
Solution Approach 1:
The patent combines multiple functional layers (upper surface layer, protrusion layer, and substrate underlayer) into a single integrated tile component. The protrusions are formed as integral features within the upper surface layer itself, eliminating the need for separate assembly steps while maintaining the durability benefits of multi-layer construction.
Solution Approach 2:
The tile is segmented into distinct functional zones within a single component: the upper surface layer provides the cushioning surface, the integrated protrusions provide impact attenuation, and the substrate underlayer provides structural support. This internal segmentation allows each function to be optimized while maintaining overall simplicity.
2Object-affected harmful factors
If sub-surface protrusions are added to tiles, then impact attenuation is improved, but ease of manufacture deteriorates due to difficulty of assembly
Solution Approach 1:
The protrusions are merged with the upper surface layer as an integral feature rather than a separate component. This is achieved through molding techniques where the protrusions are formed directly within the rubber or polymer material during the manufacturing process, eliminating assembly operations while maintaining effective impact attenuation.
Solution Approach 2:
The manufacturing approach changes from assembly-based to molding-based production. By adjusting the molding process parameters and using appropriate mold designs, the protrusions are formed as integral features of the upper surface layer, significantly simplifying manufacturing while maintaining the impact attenuation function.
3Ease of operation
If unitary surfaces are made from poured-in-place rubber, then accessibility is improved, but durability deteriorates
Solution Approach 1:
The safety surface is segmented into modular tiles that can be individually replaced when worn, rather than requiring replacement of the entire poured-in-place surface. This modular approach maintains the continuous, accessible surface quality while significantly improving durability through targeted replacement of only the worn portions.
Solution Approach 2:
The tile incorporates composite construction with multiple material layers: a cushioning upper surface layer, integrated protrusion structures, and a supportive substrate underlayer. This composite structure provides both the accessibility of a continuous surface and the durability of a multi-layer construction that can be selectively replaced.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution results in a high-quality, durable, and accessible safety surface that effectively attenuates impact forces, meeting ADA standards and facilitating easy maintenance, while simplifying the manufacturing process by eliminating the need for complex assembly of multiple components.
Implementation Method 1
Resilience and resistance to compression of the protrusions may attenuate impact of a fall upon the upper surface
Implementation Method 2
resistance to compression of the protrusions may attenuate impact of a fall upon the upper surface
Data Source
AI summary
A multi-level unitary safety surface tile. The tile may be of monolithic construction. The tile may include rubber. The tile may include an upper level and a lower level. Hollow protrusions may extend between the levels. At least one protrusion may include resilient walls extending from the upper layer and converging to a protrusion bottom-cap in the lower level. Inter-protrusion ribs may span between and support adjacent protrusions. With the lower layer disposed upon an underlayer, the protrusions may support the upper level. The tile may attenuate impact forces incident upon the upper layer. The tile may constitute a unitary safety surface. The tile may include structures facilitating interlocking of adjoining tiles into a multi-tile unitary safety surface. Protrusion extensions and/or support ribs may support the structures. The tile may be manufactured in a one-piece molding process utilizing mold forms maintained parallel to opposable faces of a mold press.