Note: Descriptions are shown in the official language in which they were submitted.
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PROGRESSIVE STAGE LOAD DISTRIBUTION AND ABSORPTION UNDERLAYMENT
SYSTEM
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This patent application is a Continuation-In-Part of and
claims priority to U.S.
Application Serial No. 16/182,931 filed November 7, 2018 and is related to the
following cases, the
contents of which are also incorporated by reference herein: U.S. Patent No.
9,394,702 issued. July 19,
2016; U.S. Patent No. 9,528,280 issued December 27, 2016; U.S. Application
Serial No. 151388,304
filed December 22, 201.6; U.S. Application Serial No. 15/333,291 filed October
25, 2016; and U.S.
Patent Application. Serial No. 15/682,956 tiled August 22, 201.7.
BACKGROUND OF THE INVENTION
(I) Field of the Invention
10002) Several aspects of this disclosure relate to a progressive
stage load distribution and
absorption underlayment system, primarily for comfort underfoot and injury
mitigation in such
environments of use as an elder care or senior living facility.
BRIEF SUMMARY OF THE INVENTION
[0003] lt would be desirable to implement below a superstructure
that receives percussive
impacts an underlayment system that will reduce impact forces and therefore
mince the potential risk
of injury associated with fall-related impacts on the surface. Potential
benefits include reducing injury
Sic due to falls on the flooring surface, minimizing system cost, maintaining
system durability,
facilitating installation, abating noise while offering surface quality and
comfort for both. patients and
caregivers.
100041 While such. underlayment layers provide some added benefit,
they also increase system
cost, installation complexity, and often reduce the durability of the top
flooring material. To date, no
commercially cost effective and durable underlayntent system has been
developed that provides a
substantial injury risk reduction due to falls on the variety of flooring
products. Severn! attempts have
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been made, but such approaches often fail to meet certain performance and cost
effectiveness
objectives.
100051 One important aspect when considering deploying an
underlayment system for impact
protection is the consistency in performance over the entire surface. The
impact performance of
previous approaches varies substantially when comparing the center of the
energy absorbing material
and the seams or joints between adjacent energy absorbing materials._ The
seams between foams, rolls
or panels, for example, lack cross linking or bonds between adjacent energy
absorbers. These areas
are weaker than the center of the energy absorber and deform at a lower
applied load compared to the
areas away from the seam. This results in areas where not only is the impact
performance inconsistent
across the surface, but also promotes toss of balance since locations are not
visible. Finally, these areas
can also promote inconsistent wear patterns in the floor covering that may
result in visual and structural
defects over time due the stress induced on the floor covering by the seams in
the underlayment. While
some technologies, like foam, may be weaker at the seams one can appreciate
that other products like
injection molded tiles maybe stronger at the seams and weaker in the center,
again creating
inconsistencies in impact, instability, and wear patterns across a flooring
surface.
100061 Another important aspect when considering deploying an
underlayment system for
impact protection is comfort and vibration damping under -foot. The ideal
underlayment product would
provide both enhanced comfort under foot while providing enhanced impact
protection. Conventional
approaches historically accomplished this by adding layers to the construction
which adds both cost
and system complexity. For example, two layers of foam that differ in density
and or chemistry may
be layered beneath the flooring surface where a so der layer enhances comfort
under foot and a second
more limi layer enhances the impact absorbing properties. Injection molded
tiles will often be
assembled between a layer of compliant foam and the finished flooring product.
Adding layers to
flooring system result in added costs, complexity-, and failure modes that are
undesn _____________ able.
[0001 Against this background, it would be desirable to develop a
progressive stage load
distribution and absorption system that would underlay a superstructure
material such as flooring
system to mitigate injuries and soften footfalls, while reducing noise and
vibration where possible.
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100081 Ideally, such a system would be of relatively low cost and
present a low profile to
minimize tripping, yet be durable. In several embodiments, an underlayment
infrastructure would be
compatible with a superstructure material such as sheet vinyl and carpet.
100091 This disclosure includes a progressive or multi-stage load
distributing and absorbing
system that lies below a superstructure material which is exposed to
percussive forces. The progressive
stage load distributing and absorbing system is interposed between the
superstructure material and a
foundation below. In several embodiments, such progressive systems offer a
first and one or more
subsequent levels of reaction, to an impacting load, the reaction varying from
a initially relatively
compliant stage and then transforming to a gradually stiffer response to
further load absorption. This
behavior tends to offer a padded response to for example a heavy footfall or a
tumbling patient. As a
result, serious injury may be lessened or avoided.
100101 Several embodiments contemplate one or more progressive
stage load distributing and
absorbing tiles that are positioned side-by side. At least some of the tiles
have a barrier layer that lies
below the superstructure material - primarily to distribute, rather than
absorb an impacting force, such
as a heavy footfall. To cushion the blow, a load absorbing underlayment
infrastructure is positioned
below the barrier layer.
100111 The underlay.ment infrastructure in a typical tile has one
or more progressive stage "hat-
shaped" (defined below) absorbing members. In a preferred embodiment, each of
those members has
a relatively stiff initial load transmission subsystem that preferably lies
below and next to the barrier
layer. This subsystem at first transmits forces from the hit to a relatively
compliant stage absorbing
subsystem. In this disclosure "relatively" broadly refers to the relative
stiffness of the stiff and
compliant absorbing subsystems in response to a hit. The compliant subsystem
may be lowermost
(preferably), or in some embodiments be uppermost. After the compliant
subsystem. deflects and
perhaps bottoms out, the primary role of the stiff stage absorbing subsystem
reverts to load absorption,
rather than load transmission.
100121 Consider one relatively stiff force transmission subsystem
that primarily transmits,
rather than absorbs energy. As noted earlier, it lies below the barrier layer.
In that subsystem is a. basal
portion that. preferably is positioned adjacent to the barrier layer. The
basal portion originates as a
sheet material that is preferably thermoformed to produce the stiff and
compliant progressive stage
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absorbing members that constitute the disclosed infrastructure. Alternative
methods include
compression molding, casting, vacuum forming and injection molding.
100131 In at least some of the stiff stage progressive absorbing
members, a curvilinear waft
extends from the basal portion toward the foundation. Preferably, such a wall
has a draft angle (0,
Figure I) that lies between about 4 and 40 degrees. This wall has a top region
extending from the
basal portion and a bottom region at the opposite end portion of the wall. In
several embodiments, a
shoulder portion extends inwardly from the bottom region. In other
embodiments, the shoulder portion
may not exist. In those cases, there is a somewhat continuous transition.
between, the stiff and compliant
stage subsystems.
100141 Following impact upon the superstructure, ignoring optional
adhesives, a load is
transmitted across the barrier layer initially to the stiff stage subsystem of
the progressive stage
absorbing members of the underlayment infrastructure. Such load travels
through the wall of the stiff
stage absorbin.g subsystem, it reaches across a shoulder (if a shoulder
exists) and then to the compliant
stage absorbing subsystem before impinging on the foundation. If there is a
rebound or recoil, such
loads are delivered back to the stiff stage, which then assumes a more
compliant role rather than its
fo.tmer load-transmission role. In such walls, load absorption is achieved by
the wall bending inwardly
or outwardly to or toward an un-deflected position.
100151 One result of these subsystems cooperating in the described
manner is that the
compliant stage absorbing subsystem deflects before one or more of the stiffer
transmission stage
absorbing subsystems in response to the load. The relatively stiff subsystem.
is available to absorb what
remains of the impacting load after the compliant stage has deflected or
bottomed out. Consequently,
footfalls are softened, vibration is lessened, noise is reduced and injury
after a fall is mitigated.
100161 Accordingly, several embodiments of this disclosure include
a progressive stage load
distributing and progressive stage energy absorbing system that lies below a
superstructure material
which is exposed to continual or intermittent percussive loads. Often, such
forces may cause a high
localized pressure, such as when forces from a wheelchair are exerted through
narrow Wheels.
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100171 In the underlayment infrastructure, load absorption is
mainly provided by groups of
progressive stage absorbing members that are provided in tiles thereof
(described below). Tiles are
united by inter-engagement of overlapping barrier layers that overhang the
ceilings of adjacent tiles_
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
100181 Figure 1 is a vertical section of one embodiment of a
progressive stage load distributing
and absorbing underlayment system.
/00191 Figure 2 is a top view of an embodiment of a progressive
stage load distributing and
absorbing underlayment system that has four quadrilateral, preferably
rectangular tiles_
100201 Figure 3 is a top view of an embodiment of a progressive
stage ioad distributing and
absorbing underlayment system that has four quadrilateral tiles with various
edge seams.
(00211 Figure 4 shows a hexagonal array of load absorbing members
in an underlayment
infrastructure.
100221 Figure 5 is an isometric view of these members, with a lobe
forming part of a compliant
stage.
100231 Figure 6 is an isometric view of an alternate embodiment of
such load absorbing
member, with a star-shaped compliant stage.
100241 Figure 7 illustrates progressive collapse of lobe-topped
members of varying height.
10025) Figure 8 illustrates progressive collapse of star-topped
load absorbing members
apertures of varying height.
100.261 Figure 9 illustrates progressive collapse of fiat roofed
members of varying height.
{00.271 Figure 10 is a cross sectional view of the progressive stage
load distributing and
absorbing system including an underlayment infrastructure with a progressive
load absorbing member,
including a stiff stage and one embodiment of a compliant stage.
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100281 Figure 11 illustrates a barrier layer of a tile that
overlaps a load absorbing infrastructure
below.
100291 Figure 12 shows an alternative (inverted) embodiment of a
load absorbing member.
DETAILED DESCRIPTION OF THE INVENTION
j00301 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.
j00311 This disclosure includes a progressive stage load
distributing and absorbing system 10
(Figure 1) that lies below a superstructure material 12 which is exposed to
steady or intermittent
percussive forces. The progressive stage load distributing and absorbing
system 10 is interposed
between a superstructure material (such as tile or carpeting, for example) 12
and a foundation 16
below.
1.00321 Several embodiments have one or more progressive stage load
distributing and
absorbing tiles 17 (Figures 2 - 3). At least some of the tiles 17 have a
barrier layer 18 that lies below
the superstructure material 12 primarily to distribute, rather than absorb an
impacting load, such as a
heavy footfall or a rolling wheelchair. To cushion the blow, mute noise and
deaden vibration, an
underlaytnent infrastructure (described tater) 20 is positioned below the
bather layer 18.
(00331 The tiles 17 that house the underlayment infrastructure 20
have one or more progressive
stage hat-shaped (defined below) absorbing members 21 (Figure 1). One or more
of those members
21 have a relatively stiff load transmission subsystem 23 that delivers force
to a compliant stage
absorbing subsystem 22 that is the first subsystem to deflect. Preferably, the
compliant stage 22
absorbing subsystem lies adjacent to the foundation I.
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100341 Included in the stiff force transmission (and later,
residual force-absorbing) subsystem
23 is a basal portion 24 that in several embodiments is positioned adjacent to
the barrier layer 18
(Figure I), The basal portion 24 originates as a sheet material that is
preferably thermoformed to
produce the progressive stage absorbing members 21 that constitute the
disclosed infrastructure 20.
100351 A curvilinear wall 26 extends from the basal portion 24
toward the foundation 16. In
this context, "curvilinear" means curved when viewed from above or below and
substantially linear
before impact when viewed from the side. This wall 26 has a top region 30
extending from the basal
portion 24 and a bottom. region 28 at the opposite end portion of the wall 26.
In several embodiments,
a shoulder portion 25 extends inwardly from the bottom region_
10036] After impact; loads are transmitted across the bather layer
18 to the stiff force
transmission subsystem. 23, and then to the compliant stage absorbing
subsystem 22 that extends from
the stiff stage subsystem 23, in many embodiments towards the foundation 16.
/9037] To set the stage (returning to Figures 2 - 3), in exemplary
embodiments of a progressive
stage energy absorbing underlayment system 10, there are four tiles 17 secured
to one another. This
arrangement of adjacent tiles produces four-tile seams and two-tile scams.
Four areas are magnified
in Figure 2 to show three unique seam conditions compared to the tile central
area. The tile central
area (far left) has no seams and constitutes above 85% of the system surface
area. The other 15%
includes seams of various configurations that need to perform in a similar
manner to the tile central
area. This is in contrast with the four-tile seam (lower left) where four
bather layers intersect. The
straight two-panel seam (lower right) and straight two-panel male/female
registration seam. (upper
right) are also depicted in Figure 2,
100381 In Figure 2, there is a staggered configuration that forms a
progressive stage load
distribution and energy absorbing system. This arrangement of adjacent tiles
produces three-panel
(Figure 3) and two-panel seams. Three areas have been magnified in Figure 3 to
show the remaining
three unique seam conditions that contrast with the four shown in Figure 2.
The two-tile sinusoidal
edge seam (lower left) is where the trim edge of the adjacent underlayment
infrastructure is sinusoidal.
The three-tile seam (bottom middle) is where three barrier layers intersect.
Finally, we see one example
of the two-tile male/female registration sinusoidal edge seam (lower right).
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100391 Figure 4 is a bottom view of one embodiment of a
thermoformed underlayrnent
infrastructure 20 showing an array of energy absorbing members 21 in a
hexagonal configuration. The
basal portion 24 between adjacent members 21 may be planar or ribbed,
depending on the desired
layout_ Generally, the hexagonal array is preferred due the dense arrangement
of adjacent structures.
100401 As described herein, there are three alternative embodiments
of a representative
compliant stage subsystem ¨ a lobe feature, a star-shaped feature, and a
configuration in which
adjacent groups of members have different heights.
190411 Figure 5 is an isometric bottom view of a lobe embodiment 38
of a compliant stage 22
in typical load absorbing members 21. Here, there is an array of hat-shaped
progressive stage
absorbing members 21 that possess a male lobe 38 whose base 40 is recessed
within the shoulder 25
of the member 21. The lobe 38 is surrounded by a moat-like depression which is
recessed into the
shoulder. The top of the lobe extends beyond the plane of the shoulder, much
like a tower that lies
inside and above the moat. This moat draws material, into itself during the
thermoforming process and
preferentially lobe walls.
100421 Figure 6 is an isometric view of a star-shaped feature 42
that crowns the compliant
stage 22. The star may have 3-10 arms 44. A nucleus portion 46 of a star-
shaped feature 42 has a
geometry that may be selected from any number of polygonal shapes to create a
feature that is both
recessed within and protrudes from the shoulder portion 25 of the member 21.
This depth-up draw
occurs largely because a small footprint creates a weakening and a lower
resistance to an applied load
for the "drawn feature" (e.g., compliant stage 22) compared to a "host
feature" (e.g., stiff stage 23).
Portions of the star may be relatively flat or be recessed.
j00431 Figure 9 is sectional view through a third alternate ("sky
scraper") embodiment 48 of
a progressive stage u.nderlayment infrastructure 10 in which adjacent load
absorbing members 21 or
groups of load absorbing members are of different heights. Separating each of
such members is a basal
portion 24, i.e., the substantially unchanged portion of the sheet that enters
the thermoforming process.
A curvilinear wall 26 extends there from and a floor 27 lies across the lower
portion 28 of the
curvilinear wall. Such a structure could be installed so that the basal
portion 24 is positioned adjacent
to the bather layer 18. In an inverted configuration (see, e.g., Figure 12),
the basal portion 24 is
positioned adjacent to the foundation 16. Note that the plane (or ceiling or
floor portion) of each
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member 21 is flat (i.e., it lacks a drawn feature) and lies parallel to the
foundation 16. The first section
(I) shows that the system, at a minimum, bears the weight of the
superstructure 12 itself. Under an
applied load in excess of the taller member yield force, the taller weaker
members begin compressing
and absorbing a portion of the total load exerted (see, (If)). This continues
until the floor of the shorter
members contacts the foundation (see, (111)). At that stage, the force
required to compress the system
further is greater than that required to compress the taller members.
100441 The compression characteristics of the taller and shorter
members 21 can be tuned by
selecting material type, material thickness, draw depth and the like to
develop characteristics that
enhance comfort under foot, dampen vibrations, or absorb sound. The third
section (111) in Figure 9
shows the response of the system to an even higher applied load. Under this
load level, which is likely
at a level tuned to reduce the risk of fall injury, both the taller and
shorter members collapse in a
controlled manner to absorb the impact load.
100451 In each embodiment of the compliant stage (see, e.g. Figures
7-8), there is a progressive
collapse of members from the weakest to the strongest. However, there is an
additional level of crush
resistance. The first section (1) shows the compression of the drawn feature
(e.g., a lobe) that extends
from the member's floor in. a direction opposite to that in which the still
stage compliant subsystem
lies. Once the drawn feature collapses (11), the load is transferred to the
taller member (relatively stiff
subsystem) which begins bearing its share of the load. Once the applied force
exceeds the yield force
of the taller members, they begin to collapse until they compress to the point
where the smaller
members contact the foundation (111). Finally, once an applied load exceeds
the force required to yield
the entire load distributing and absorbing system, the taller and shorter
apertures collapse
simultaneously IV).
100461 Figure 8 shows that the star-shaped embodiment of the
compliant stage collapses in. a
somewhat different manner from the lobes in Figure 7.
100471 Alternative embodiments include absorbing member shapes
beyond those depicted
(e.g., those having a wall that is not curvilinear, but having a drawn feature
in the associated member
floor). Such a wall may be curved for instance, when viewed from the side in
an undeflected condition.
if desired, ribs may be provided for added stiffness between load absorbing
members. Further, arrays
of members may be arranged in a configuration (in contrast to Figure 4) that
is other than hexagonal.
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in some applications and environments, materials may be selected that are
other than thermoplastic
polyurethane and polyearbonate.
{0048j
In one embodiment of a progressive
stage load distributing and absorbing underlayment
system 10 (e.g., Figure 2), there are has four quadrilateral, preferably
rectangular, tiles 17. A
representative tile appears in Figure 11. Such 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..
{0049]
In Figure 11, the barrier layer 18
(in this case) is quadrilateral with edges Bl. B2, 83
and 134. A sub-assembly of underlying absorbing members 22 includes individual
members 22 that
are conjoined by basal portions 24 which, before for example thermoforming
take the form of a planar
basal sheet. The absorbing members 22 coordinate to form a periphery of the
sub-assembly that in
many cases is quadrilateral and has edges Al, AZ A3 and A4. Each barrier layer
18 preferably is
securely affixed to one or more of the ceilings 24 in a tile. In some eases,
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.
100501
To promote inter engagement between
tiles in an assembly, edge B1 of the barrier layer
18 overhangs edge Al of the sub-assembly of absorbing members 22 and edge 132
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 of the bather layer 18 and an open L-shaped overhanging portion formed by
the ceilings 24 of the
absorbing members 22 in the sub-assembly. In adjacent tiles, the L-shaped
overhanging portion 27
associated with. a given tile 19 supports the L-shaped platform of the bather
layer 1.8 of an adjacent
tile. One consequence of this arrangement is that adjacent tiles engage each
other in such a way as to
inhibit relative lateral movement therebetween.
100511
As shown in Figures 2 ¨ 3,
interlocking engagement of adjacent tiles in a group is
provided by mating registration features 50, 52. In a preferred embodiment,
these mating registration
features 50, 52 are trapezoidal in shape. For example, a male trapezoid 50
abuts a female trapezoid
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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.
{00521 As used herein the term "hat-Shaped" includes fru.sto-
conical, which may or may not
be inverted, as described later. Such hat-shaped members 22 may have a top
wall 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 a bottom wall portion 30 of an
absorbing member 21. 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 clothe 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:fiwww.hatsunlimitedecomihat-styles-guide, which is incorporated by
reference.
100531 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
21, 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.
/00541 Connecting the basal portion 24 between absorbing members and
the floor 27 of an
absorbing member 22 in most embodiments is a curvilinear wall 26. When viewed
laterally, a
curvilinear wall 26 appears substantially linear or straight before being
subjected to an impact that
may reign through the superstructure 12 on a barrier layer 18. When viewed
from above or below, the
footprint of the bottom portion 30 or top portion 28 may appear circular,
elliptical, oval, a clover leaf,
a race-track or some other rounded shape with a curved perimeter.
100551 The floor 27 of an absorbing member 21 may be flat or
crenelated. As noted earlier,
the floor 27 or in some cases the basal portion 24 may have a drawn lobe
feature 38 or a star-Shaped
feature 42 extending therefrom.
[00561 The absorbing members 21 may be manufactured from a resilient
thermoplastic and be
formed into fmsto-conical or hat-shaped members that protrude from a basal
sheet 24 which before
exposure to a forming process is substantially flat.
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100571 In one preferred embodiment, the barrier layer 18 is made
from a strong thin layer of a
polycarbonate (PC), a composite or a metal or other suitable rigid mated al,
the absorbing member 21
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
TN/.
100581 Thus, an underlayment infrastructure 20 is created by the
juxtaposition of a bather layer
18 and an underlying infrastructure of progressive stage absorbing members 21.
10059.1 An assembly of absorbing members 21 and overlying barrier
layer 18 forms a tile 17.
Adjacent tiles are inter-engaged by overlapping and underlapping edges of the
barrier layer /8 in the
manner described above. Preferably, a small, but acceptable, gap exists
between bather layers 18
associated with adjacent tiles.
100601 If desired, a means for securing, such as an adhesive 55 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. An underlayment infrastructure 20 is thus assembled when the edges of
adjacent tiles are brought
So registration through the inter.-engagement of mating registration features
50, 52 of adjacent edges
of associated barrier layers 18.
100611 While a pressure sensitive adhesive is a preferred
embodiment of means for securing
55 a barrier layer 18 to the basal portion or ceiling 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, etct
100621 The overlap of the bather 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 compliant and stiff
stages in the absorbing
members.
100631 In more detail, selected features of the disclosed
progressive load distributing and
absorbing system include:
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100641 A: Engineered Performance Consistency
100651 Traditional flooring systems, which are installed over rigid
surfaces such as concrete,
tend to have little energy absorbing capabilities, thereby posing a risk for
fall related injuries. Due the
rigid nature of their construction!, they do however provide a consistent
surface in terms of 'firmness
and stability under foot. A rigid surface such as a foundation supports the
flooring product over its
entire area. This is essential for products like ceramic tile, glass tile,
wood flooring, and the like.
100661 One challenge in developing, installing, and maintaining an
attractive, yet compliant
flooring system that reduces the risk of injury lies in engineering the system
to maintain a consistent
firmness and stability over the entire flooring surface throughout its normal
life cycle, while being
compliant. The system must balance compliance needs, yet accommodate other
activities like walking,
naming, rolling in a wheelchair, and supporting other items such. as
furniture, equipment, and other
objects. An ideal load distributing and absorbing system needs to be firrn and
stable under foot under
such normal activities and at the same time be engineered to deflect or stroke
to the greatest degree
possible during a potentially injurious fall or impact event.
100671 Additionally, the layers of the load distributing and
absorbing system need to work in
concert in order to maintain an attractive appearance after years of repeated
wear and abuse. Ideally,
the system needs to remain unblemished before, during, and after impact events
and everyday
activities.
100681 The disclosed system is engineered for performance
consistency at any and all points.
Seven unique conditions were identified to confirm performance consistency via
the scientific method
and statistical probability analysis. These conditions will be described
below. This will be followed
by a description of the test devices and their intended purpose. Finally, a
statistical analysis will be
reported below that analyzes the consistency in performance across the entire
surface.
(00691 131 Enhanced Load Distributing and Absorbing flooring System
100701 Themnafomting begins with a basal sheet of material of
constant thickness. The
thermoplastic raw material is heated to the softening point and then stretched
over a form tool via
vacuum, pressure, and mechanical means. The thickness of the therrnotbrated
part is a function of the
base raw material thickness, raw material type, form temperature, and tool
geometry which includes
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depth of draft, draft angle, and the upper assist design and clearance.
Generally, areas where the depth
of draw is greatest, the material is stretched in multiple directions. This
results in thinner wall profiles
than areas that experience less stretching.
100711 Load absorbing members typically have a thicker ceiling and
floor, while there is
substantial thinning in the curvilinear wall. These members produce a
generally "square wave" force
versus displacement response to an applied load. There is an initial ramp up
in. force until the wall
buckles and then maintains a relatively constant reaction force to the applied
load throughout the
available stroke. In members formed from the same base thickness, ceteris
paribus, taller structures
will yield at a lower load level than shorter structures.
10072] Representative applications and advantages include:
= Military grade impact protection for seniors;
= Reduces the risk of hip and other fractures due to falls;
= Reduces the risk of traumatic brain injury due to falls;
= Reduces fatigue with enhanced comfort under foot;
it Stable under foot and is there when needed;
= Engineered transitions between adjacent tiles meet ADA accessibility
requirements;
= Enhanced sound transmission loss performance;
= Enhanced system vibration dampening;
= Low profile for renovation or new construction;
= Easy to install;
= Compatible with conventional flooring adhesives;
= Lightweight;
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= .Affordable;
= Durable and capable of withstanding many impacts;
= Can be installed over green concrete;
= Provides additional thermal insulation;
= incorporates post-industrial content;
= Acts as a vapor barrier.
100731 Testing has demonstrated that use of various embodiments of
the disclosed system may
lean to a:
= 20-fold reduction in risk of critical head injury;
= 60% reduction in the probability of moderate head injury;
= 3-fold reduction in (WAX;
= 2.5-fold reduction femoral neek force during falls for average older
females;
= 3-fold increase in force reduction;
= 2.5-fold reduction in energy restitution;
= firm and stable and stable surface that supports mobility;
= substantially more comfort under foot for caregivers and older adults.
10074] Test data also indicate that the proposed progressive stage
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.
WO 2020/180931
PCT/US2020/020893
100751 TABLE OF REFERENCE -NUMBERS
Reference No. Component
Progressive stage load distributing and absorbing system
12 Superstructure material
14 Underside of 12
16 Foundation
[7
18 Barrier layer
19 Tile
thiderlayment inthistrue,tture
21. Absorbing member
22 Compliant stage absorbing subsystem
23 Stiff stage absorbing subsystem
24 Basal portion
Shoulder portion
26 Curvilinear wall
27 Floor
Top region of 26
Bottom region of 26
32 Apertures
34 Means for securing
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36 Upper portion of 26
1
38 Lobe
40 Base of lobe
Star-shaped feature
44 Ann of 42
46 Nucleus of42
48 Skyscraper embodiment
50 Male registration feature
52 Fetnale registration feature
54 Sub-assemblies of absorbing members
55 Lower means for securing
56 Intermediate means for securing
58 Upper means for securing
61
62
f00761 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.
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