US20150098757A1

US20150098757A1 - Playground mats

Info

Publication number: US20150098757A1
Application number: US14/500,830
Authority: US
Inventors: Mark Mitchell
Original assignee: LITE CRUISE PROPERTIES LLC
Current assignee: LITE CRUISE PROPERTIES LLC
Priority date: 2013-10-07
Filing date: 2014-09-29
Publication date: 2015-04-09

Abstract

Systems and methods are described for connecting a first mat tile to a second mat tile, including, but not limited to, a first bracket embedded in the first mat tile and a second bracket embedded in the second mat tile. In various embodiments, the first bracket includes a first pin hole while the second bracket comprising a second pin hole. Systems and methods further include a pin coupled to the first bracket through the first pin hole and to the second bracket through the second pin hole.

Description

CROSS-REFERENCE TO RELATED PATENT APPLICATIONS

This application claims priority from Provisional Application No. 61/887,886, filed Oct. 7, 2013, incorporated herein by reference in its entirety.

BACKGROUND

1. Field
Embodiments described herein generally relate to tile connecting mechanisms, and specifically, to tile connecting mechanisms for connecting two or more mat tiles for playground mats.
2. Background
Mats have been used pervasively to enable safe playing environment for children playing on the mats. Generally, mats are placed underneath the playground to serve as a cushion when a person (e.g., a child) falls down. The mats prevent or at least alleviate injuries due to falling. The mats are also configured to support various playground equipment such as, but not limited to, swings, slides, sandboxes, seesaw, rides, play systems, climbers, crawl tubes, movable equipment, play houses, a combination thereof, and the like.
Given that the playground is of a substantially large size, the mats are divided into a plurality of mat tiles for cost-effective manufacturing, transportation, and installation. In particular, each mat tile is joined with a neighboring mat tile through connecting mechanisms during installation of the mat. Particular types of connecting mechanisms are favored for possessing traits such as, but not limited to, sturdiness, flexibility, resistance to adverse environmental effects, ease of installation, and the like.

SUMMARY

Various embodiments described herein relate to connecting mechanisms for joining two or more neighboring mat tiles for form a mat (e.g., a playground mat) to provide cushioning for a playground. Particular embodiments of the connecting mechanisms include, but not limited to, mating connectors, U-shaped brackets, and strip brackets. The connecting mechanisms are provided at edge portions of the mat tiles and joined by pins, rivets, screws, bolts, and/or the like. In addition, bracers or locks are provided to hold the pins in place.
A system for connecting a first mat tile to a second mat tile is disclosed, the system including, but not limited to, a first fastener, the first fastener including a first aperture for receiving a first rod, the first rod being embedded in the first mat tile; a first surface having a first pin hole; and a second surface having a second pin hole. Further included is a second fastener, the second fastener including: a second aperture for receiving a second rod, the second rod being embedded in the second mat tile; a third surface having a third pin hole; and a fourth surface having a fourth pin hole. The system additionally include a pin inserted into the first pin hole of the first surface, the second pin hole of the second surface, the third pin hole of the third surface, and the fourth pin hole of the fourth surface when the third surface is between the first surface and the second surface and when the second surface is between the third surface and the fourth surface, to secure the first rod and the second rod together when embedded in the respective mats in order to secure the mats together.
A system for connecting a first mat tile to a second mat tile is disclosed, the system including, but not limited to, a first U-shaped bracket, the first U-shaped bracket including at least one first aperture for receiving a first rod embedded in the first mat tile; a first surface having a first pin hole; and a first pin lock. The system also includes a second U-shaped bracket, the second U-shaped bracket including at least one second aperture for receiving a second rod embedded in the second mat tile; a second surface having a second pin hole; and a second pin lock. The system additionally includes a pin inserted into the first pin hole and the second pin hole to secure the first rod and the second rod together when embedded in the respective mats in order to secure the mats together, the pin being inserted into the first pin hole in a first direction and into the second pin hole in a second direction opposite to the first direction, the first pin lock being secured to a first distal end of the pin protruding beyond the first pin hole, and the second pin lock being secured to a second distal end of the pin protruding beyond the second pin hole. The first pin lock prevents the pin from moving in the second direction once inserted, and the second pin lock prevents the pin from moving in the first direction once inserted.
A system for connecting a first mat tile to a second mat tile is disclosed, the system including, but not limited to, a first strip bracket embedded into the first mat tile, the first strip bracket including: a first surface; a first pin hole; and a first pin lock provided at the first pin hole opposite to the first surface. The system also includes a second strip bracket embedded into the second mat tile, the second strip bracket including a second surface; a second pin hole; and a second pin lock provided at the second pin hole opposite to the second surface. The system additional includes a pin inserted into the first pin hole and the second pin hole to secure the first strip bracket and the second strip bracket together when embedded in the respective mats to secure the mats together, the pin being inserted into the first pin hole in a first direction and into the second pin hole in a second direction opposite to the first direction, the first pin lock being secured to a first distal end of the pin protruding beyond the first pin hole, and the second pin lock being secured to a second distal end of the pin protruding beyond the second pin hole, the first and second surfaces facing each other. The first pin lock prevents the pin from moving in the second direction once inserted, and the second pin lock prevents the pin from moving in the first direction once inserted.

BRIEF DESCRIPTION OF THE DRAWINGS

The details of one or more implementations are set forth in the accompanying drawings and the description below. Other features, aspects, and advantages of the disclosure will become apparent from the description, the drawings, and the claims, in which:

FIG. 1 is a perspective view of a mat according to an illustrative embodiment;

FIGS. 2A-B are perspective views of two interconnected tiles according to an illustrative embodiment;

FIG. 3 is a schematic cross-sectional view of a rod passing through a fastener according to an illustrative embodiment;

FIG. 4 is a schematic cross-sectional side view of a rod passing through a fastener according to an illustrative embodiment;

FIG. 5 is a schematic cross-sectional top view of a rod passing through a fastener according to an illustrative embodiment;

FIG. 6 is a schematic cross-sectional front view of a tile edge according to an illustrative embodiment;

FIG. 7 is a perspective view of two rods connected by fasteners according to an illustrative embodiment;

FIG. 8 is a schematic cross-sectional view taken along the line X in FIG. 7 of two rods running through the edges of the tiles and connected by fasteners and a rivet according to an illustrative embodiment;

FIG. 9 is a schematic cross-sectional view of the mat 102 including a safety surface according to an illustrative embodiment;

FIG. 10 is a schematic cross-sectional side view of two tiles connected by a connecting mechanism according to an illustrative embodiment;

FIG. 11A is a schematic cross-sectional bottom view of bottom surfaces of a first tile and a second tile interconnected by one embodiment of the connecting mechanism;

FIG. 11B is a cross-sectional view taken along the line X in FIG. 11A of the U-shaped brackets and the securing rods embedded inside the tiles connected by connecting mechanisms including the U-shaped brackets as shown in FIG. 11A;

FIG. 12 is a perspective view of connecting mechanisms configured along edges of two neighboring tiles;

FIG. 13A is a top or bottom view of a U-shaped bracket according to various embodiments;

FIG. 13B is a perspective view of the U-shaped bracket according to various embodiments;

FIG. 13C is a front view of the U-shaped bracket according to various embodiments;

FIG. 13D is a side view of the U-shaped bracket according to various embodiments;

FIG. 14A is a front perspective view of a pin lock according to various embodiments;

FIG. 14B is a front view of the U-shaped bracket provided with the pin lock according to various embodiments.

FIG. 14C is a back view of the U-shaped bracket provided with the pin lock according to various embodiments;

FIG. 14D is a cross-sectional view of the U-shaped bracket provided with the pin lock according to various embodiments;

FIG. 15A is a schematic cross-sectional bottom view of bottom surfaces of a third tile and a fourth tile interconnected by some embodiments of the connecting mechanism;

FIG. 15B is a schematic cross-sectional view taken along the line X in FIG. 15A of the strip brackets embedded inside the tiles connected by connecting mechanisms including the strip brackets as shown in FIG. 15A;

FIG. 16 is a perspective view of connecting mechanisms configured along edges of two neighboring tiles according to some embodiments;

FIG. 17A is a front or back view of a strip bracket according to various embodiments;

FIG. 17B is a front view of the strip bracket using the pin lock according to various embodiments;

FIG. 17C is a back view of the strip bracket using the pin lock according to various embodiments; and

FIG. 17D is a schematic cross-sectional view of the strip bracket using the pin lock according to various embodiments.

DETAILED DESCRIPTION

Numerous specific details are set forth below to provide a thorough understanding of concepts underlying the described embodiments. It will be apparent, however, to one skilled in the art that the described embodiments are practiced without some or all of these specific details. In other instances, some process steps have not been described in detail in order to avoid unnecessarily obscuring the underlying concept.
Various embodiments described herein relate to connecting mechanisms for joining two or more neighboring mat tiles for form a mat (e.g., a playground mat) to provide cushioning for a playground. Particular embodiments of the connecting mechanisms include, but not limited to, mating connectors, U-shaped brackets, and strip brackets. The connecting mechanisms are provided at edge portions of the mat tiles and joined by pins, rivets, and/or the like. In addition, bracers or locks are provided to hold the pins and rivers in place.
FIG. 1 illustrates an exemplary mat 102 placed on a playground 100 underneath playground equipment according to some embodiments. The playground 100 is shown to include a playground equipment (e.g., a swing structure 114) positioned on top of the mat 102. Although only the swing structure 114 is shown on top of the mat 102, any other playground equipment is placed on of the mat 102 including, but not limited to, swings, slides, sandboxes, seesaw, rides, play systems, climbers, crawl tubes, movable equipment, play houses, fitness equipment (e.g., balance beams, pull-up bar, etc.), a combination thereof, and the like.
A person (e.g., a child 199) is shown standing on the mat 102. If the child 199 happens to fall from the swing structure 114 (for from any other equipment on the mat 102, or for any reason), the layers of the mat 102 reduce or prevent serious bodily injury to the child 199. In particular, a top layer 106 and a safety layer 104 of the mat 102 together provide impact absorbing functions.
The top layer 106 includes a plurality of tiles (e.g., tile 108, tile 110, tile 112, and the like) interconnected to each other by connecting mechanisms found along the edges of each tile. A tile in the mat 102 have all the edges interconnected to other tiles in the mat 102. For example, a tile 110 is interconnected to the four tiles surrounding the tile 110 by connecting mechanisms. The connecting mechanisms are installed along the edges of the tile 110, as well as along some or all the edges of the neighboring tiles (e.g., the tile 112).
A tile has one or more terminating (or perimeter) edges that are not connected to other tiles. For example, the tile 108 includes four edges 116, 118, 120, and 122, with the edges 120 and 122 having the connecting mechanisms which are used to connect the tile 102 to the two neighboring tiles 124 and 126. The terminating edges 116 and 118 of the tile 108 run along the perimeter of the mat 102, and, thus, do not have the connecting mechanisms embedded in them. In other embodiments, the terminating edges 116 and 118 have an embedded connecting mechanism, which terminates onto sub-surface.
As shown, the mat 102 includes the top layer 106 resting on top of the safety layer 104. The top layer 106 is loosely laid on top of the safety layer 104. The top layer 106 and the safety layer 104, being two separate products, allow for saving costs on the materials used in the safety layer 104 as disclosed herein. The safety layer 104 include one or more layers having ribbed structures as shown in FIG. 9. In other embodiments, the safety layer 104 is of other types of materials. For example, materials that are already installed on the playground 100 is used. In this example, the top layer 106 go on top of the playground materials already installed at the playground 100, and the attenuating qualities of the existing playground materials is used. During installation, the perimeter of the mat 102 is secured so that the edges of the mat 102 cannot be lifted up.
Although the illustrated tiles (e.g., the tile 108, the tile 110, the tile 112, and the like) in the mat 102 have a square shape, the tiles are of any shape, size, and color. For example, each tile is rectangular and have dimensions of 30 inches by 75 inches. The tiles are manufactured from rubber (e.g., recycled rubber) or another material suitable material. In some embodiments, each tile is of one solid color (e.g., all tiles are of color red). In other embodiments, the tiles are of different colors. As referred to herein (e.g., at least with respect to FIGS. 2A-17D), the tile 110 and the tile 112 are used to refer generally to generic tiles making up the mat 102.
Referring generally to FIGS. 2A-10, embodiments of a first type of connecting mechanisms (e.g., mating connectors) are illustrated for connecting the tiles. For example, the mating connectors include two fasteners, each of which includes a top surface and a bottom surface. The fasteners are mated such that the top surface from a first fastener is between the top and bottom surfaces of a second fastener. A hole is located in the top and bottom surfaces of each fastener, such that when mated, the holes from the surfaces of both fasteners align. A rivet engages the aligned holes of the surfaces of the fasteners to secure the fasteners together, thus securing the tiles.
FIGS. 2A-B are perspective views of 200 a, 200 b the bottom surface of the tile 110 and the tile 112 interconnected by mating connectors as connecting mechanisms according to various embodiments. Each side of each of the two tiles 110 and 112 is shown to include two notched spaces formed to fit a portion of a fastener (e.g., the mating connector). For example, as shown in FIG. 2A, the tile 112 includes four edges 202, 204, 206, and 208. Each of the four edges of the tile 110 include two (or more) notched space. In particular, the edge 202 of the tile 112 include notched spaces 210 and 212, while the edge 204 of the tile 112 includes notched spaces 214 and 216. The edge 206 of the tile 112 include notched spaces 218 and 220, while the edge 208 of the tile 112 include notched spaces 222 and 224.
As further shown in FIG. 2A, the tile 110 includes four edges 226, 228, 230, and 232. Each of the four edges 226, 228, 230, and 232 of the tile 110 include two notched space. In particular, the edge 226 of the tile 110 include notched spaces 234 and 236, while the edge 228 of the tile 110 include notched spaces 238 and 240. The edge 230 of the tile 110 include notched spaces 242 and 244, while the edge 232 of the tile 110 include notched spaces 246 and 248.
Each of the notched spaces in the tiles 110 and 112 are formed to fit at least a portion of a fastener. As illustrated in FIG. 2A, a portion of a fastener 250 protrudes from the notched space 210. As further shown in FIG. 3, a rod 304 embedded along the edge 314 of a tile 318 passes through a looped opening portion 310 of the fastener 302. The looped opening portion 310 of the fastener 302 is embedded inside the edge 314 of the tile 318. The remaining portion of the fastener 302 protrudes through the notched space 210.
The notched space 222 of the tile 112 align with the notched space 246 of the neighboring tile 110, while the notched space 224 of the tile 112 align with the notched space 248 of the tile 110, where each notched space contains a fastener. The portions of the fasteners protruding from the notched spaces 222 and 246 overlap such that the circular openings (e.g., circular opening 310 shown in FIG. 3) in each of the fasteners align allowing for a rivet 252 to pass through. Similarly, the portions of the fasteners protruding from the notched spaces 224 and 248 overlap such that the circular openings in each of the fasteners align allowing for a rivet 254 to pass through and secure the two tiles 110 and 112 together. The rivets 252 and 254 passing through the fasteners are fixed in place (e.g., by deforming the tail of the rivet after it is placed into the circular opening of the fastener) securing the two tiles 110 and 112 together. Each notched space include a flap portion formed with material from the top surface of the tile 110 or 112 so that the fasteners connecting the tiles are protected and are not visible. The flap portion is approximately 0.1 inch thick, 0.25 inch wide, and 0.2 inch deep. In other embodiments, the flap portions of the tile 110 or 112 are of the same or different dimensions.
Although the tiles 110 and 112 are shown to have four edges each, the tiles include any number of edges (e.g., 3, 5, 6, etc.). Although each tile edge is shown to have two notched spaces, each tile edge has any suitable number of notched spaces. For example, each tile edge has 6 notched spaces with fasteners protruding from each of these notched spaces. In this example, the notched spaces are evenly spaced from one another. The number of notched spaces is the same across all tile edges that are connected to another tile. In other embodiments, the number of notched spaces vary between the tile edges. For example, two edges of the tile have three notched spaces, while two other edges of the tile has 6 notched spaces.
In another example, a tile that is 75 inches long and 30 inches wide, has 5 fasteners along each of the edges that are 75 inches, and 2 fasteners along each of the edges that are 30 inches. In this example, from the corner of the tile in each direction, the first fastener is approximately 7.5 inches away, and the remaining fasteners are on 15 inch centers. As a result, when the tiles are aligned and connected, all the fasteners are 15 inches apart.
The notched spaces are located any distance from each other and/or the closest edge end. In some embodiments, the two notched spaces along the edge of a tile that are closest to the two ends of the tile edge are located the same distances from the closest edge end. For example, the notched space 214 is one inch from the left end of the edge 204, while the notched space 216 is located one inch from the right of the edge 204. In other embodiments, when more than two notched spaces are located on the tile edge, the notched spaces are equal distances from one another (e.g., one inch). In other embodiments, the tile has notched spaces across the perimeter of the tile at equal distances.
A first notched space in a first edge of the tile is located a first predetermined distance from a first end of the first tile edge, while a second notched space in the first edge of the tile is located a second predetermined distance from a second end of the first tile edge. The first predetermined distance and the second predetermined distance are different or the same. For example, the first notched space is two inches from the first tile edge, while the second notched space on the tile edge is also two inches away from the second tile edge. The notched spaces along the edges of the tiles have the same dimensions. For example, the width and length of each notched space are the same along the edges of the tile.
As shown in FIGS. 2A and 2B, the bottom surface of the tiles 110 and 112 have a plurality of recessed portions. The recessed portions (e.g., a recessed portion 256) in the two tiles are shown to have square shape. In other embodiments, the recessed portions are of any shape, including but not limited to, square, circle, rectangle, star-shape, etc. In other embodiments, one or more of the recessed portions have different shapes. For example, some of the recessed shapes have square shape, while remaining recessed portions have circle shape. In other embodiments, the shapes of the recessed portions of the tiles located along the perimeter of the mat 102 are different from the shapes of the recessed portions of the remaining tiles.
All the tiles forming the mat 102 include recessed portions as shown in FIGS. 2A-2B with respect to tiles 110, 112. In particular, each of the tiles 110, 112 in the mat 102 are 11 by 11 inches (or any other size, e.g., 30 inches by 75 five inches) and include any number of recessed portions (e.g., 36 recessed portions in each tile are shown in FIG. 2A). The shown square recessed portions are of the same size. For example, each recessed portion is 2 inches wide and 2 inches long. In this example, the ribs are on 2 inch centers. The depth of each recessed portion equal a ¼ of an inch or another dimension. In one example, the recessed portions are 15 inches apart. The distance from the edge of the tile to the fastener can vary. In this example, this distance is approximately 7½ inches. The first fastener is 7½ inches from the corner or edge of the tile. The recessed portions in the tiles 110, 112 advantageously reduce the costs of manufacturing the tiles 110, 112 because less material is needed.
The recessed portions are separated by rectangular elevated segments. Each recessed portion is surrounded by ribs (i.e., four rectangular elevated segments). In one example, the ribs are on 2 inch centers. In this example, each rib is approximately 0.3 inch wide and 0.35 inch tall. The outside edges are 0.6 inch wide. The recessed area is approximately 0.25 inch thick. Any other dimensions of the ribs and the recessed portions are used. The recessed portions are formed during molding process of the tiles 110, 112. In other embodiments, the recessed portions are formed by cutting out portions of predetermined dimensions from the bottom surface of the tiles 110, 112. The depth of the recessed portions is less than then depth of the tiles 110, 112 such that there is tile material left after the recessed portions are cut out.
The distance between the recessed portions along the edge of the tile are wider than the distances between any two recessed portions. For example, the distance from the left edge of the first tile to the recessed portions closest to the edge is 1 inch, while the distance between any two recessed portions is ½ an inch. The distance from the edge of the tile to the recessed portions located along the perimeter of the tile needs to be wide enough to allow for a rod to pass through. The ribs are on two inch centers. In this example, the approximate distance between the edge of the tile and the first recessed portion is the width of the rib (e.g., 0.3 inch) added to 0.075 inch. As a result, the perimeter width is approximately 0.6 inch.
FIG. 3 is a cross-sectional view 300 of a rod 304 running in the perimeter of a mat tile edge 314 and passing through a fastener 302. The fastener 302 is manufactured from a flattened rectangular metal piece by folding it to form two parallel surfaces 306 and 308 and a cylindrical opening 312. The cylindrical opening 312 of the fastener 302 allows the rod 304 to pass through it.
The rod 304 is of any length that is less than the length of the tile edge 314 into which the rod 304 is molded. For example, if the tile edge length is 30 inches, the rod is 28 inches long. The diameter of the rod is 0.12 of an inch. In other embodiments, the length of the rod 304 is proportionate to the length of the corresponding tile edge 314. For example, the length of the rod 304 is ⅔ of the length of the corresponding tile edge 314. The rod 304 is approximately ½ inch (or any other distance) shorter than the tile edge on each end. For example, if the tile edge 314 is 75 inches long, then the rod 304 is ½ inch short on each end. In this example, the rod 304 molded inside a 75 inches long tile edge 314 is 74 inches long.
Although not shown, the secondary tile edge 316 has a neighboring tile to which the secondary tile edge 316 needs to connect. A rod (not shown) is molded into the secondary tile edge 316, and pass through one or more fasteners. The number of fasteners on the rod 304 and the rod passing through the secondary tile edge 316 are the same or different. The two rods have the same dimensions (i.e., the same length and diameter). In other embodiments, the two rods have different dimensions.
As shown, the fastener 302 includes a top surface 306 and a bottom surface 308. A circular hole or opening 310 is located in the top surface 306 and also in the bottom surface 308. The flattened rectangular piece is folded such that the top surface 306 is located directly above the bottom surface 308 creating a gap between the two surfaces. As a result, the circular openings 310 in the top surface 306 and the bottom surface 308 are aligned to allow for a rivet (not shown) to pass through and hold the tiles (including the tile 318) in place. As shown, a portion of the flattened rectangular piece protrudes out of the side of the tile 318.
The dimensions of the circular openings 310 in the surfaces 306 and 308 match. For example, the diameter of the circular openings 310 are 0.1 of an inch. In another example, the circular openings 310 are 0.2 inch. Although the openings 310 are shown as circular openings, they can be of any other shape that matches the shape of the rivet that will pass through the openings to fixate the two neighboring tiles in place.
In other embodiments, the fastener 302 is a flattened rectangular piece that could be folded to form a triangular opening, a semi-circular opening, a square opening, a star-shaped opening, or any other appropriately shaped opening. The rod 304 would be shaped accordingly to the shape of the opening created by the rectangular piece. In other embodiments, the shapes of the opening of the rectangular piece and the rod 304 could be determined based on the frictional force required to keep two neighboring tiles together. In other embodiments, the shape of the opening could be configured to maximize the grip between the tiles.
One or more fasteners (e.g., the fastener 302) are placed on the rod 304 before the rod 304 is molded inside the edge 314 of the tile 318. The edge 314 of the tile 318 includes cut out sections (called “notched spaces” throughout) for the fasteners (e.g., fastener 302) to fit into. A portion of the fastener 302 protrudes from the tile 318 inside the notched space and the flap portion of the notched space protects the protruding portion of the fastener 302.
A rod 304 is molded into each side of each tile that needs to be attached to a neighboring tile. In some embodiments, the edges of the tiles that are at the outer perimeter of the mat 102 does not have rods molded inside. In other embodiments, more than one rods are molded into each tile edge. In these embodiments, multiple rods pass through one or more fasteners. For example, a fastener includes two or more cylindrical openings through which rods pass through.
FIG. 4 is a schematic cross-sectional side view 400 of the tile edge 314 having the rod 304 pass through the fastener 302. The fastener 302 includes the top surface 306 and the bottom surface 308 and a rounded portion 312 that loops around the rod 304. As shown, a portion of the fastener 302 protrudes from the side of the tile 318. The protruding portion of the fastener 302 fits into the notched space of the neighboring tile. As shown, the thickness of the tile 318 is 0.6 inch, and the distance between the top surface 305 of the flattened rectangular piece and the end bottom edge of the tile 318 is 0.3 inch. The rod 304 runs through approximately the middle of the tile edge 316.
A notched space 402 in the tile edge 316 is shown by a dashed line 406. A portion of the fastener 302 shown between the dashed line 406 and a dashed line 408 (along with the rod 304 passing through the cylindrical opening of the fastener 302) is molded inside a portion 402 of the tile edge. A second portion of the fastener 302 is located in the notched space 402 as outlined by the dashed lines 406. A third portion of the fastener 302, including a portion of the top surface 306 and a portion of the bottom surface 308 protrudes from the tile edge. The portion of the fastener 302 outside the edge of the tile 318 is approximately 0.18 inch. The portion of the fastener 302 to the dashed line 406 is approximately 0.3 inch. The portion of the fastener 302 that is molded inside the edge 316 of the tile 318 (i.e., the fastener portion between dashed lines 406 and 408) is approximately 0.44 of an inch.
FIG. 5 is a schematic cross-sectional top view 500 of the rod 304 passing through the fastener 302. As shown, approximately half of the circular openings 310 (i.e., a circular opening in the top surface 306 and a circular opening in the bottom surface 308) of the fastener 302 protrudes from the notched space of the tile edge 316, while the second half of the circular openings 310 is located inside the notched space. As a result, when a rivet goes through the openings 310 of the fastener 302 and through circular openings of a second fastener of a neighboring tile edge of another tile and is fixed in place, the two neighboring tiles are tightly connected to one another. As shown in FIG. 5, the distance between approximately the middle of the rod 304 to the edge 316 of the tile 318 is 0.33 inch. The rod is located from the edge 316 of the tile 318 any other distance that would allow for a rivet to pass through two aligned fasteners.
FIG. 6 is a schematic cross-sectional front view 600 of the edge 314 of the tile 318. The front view of the fastener 302 is shown. In particular, the fastener 302 is shown in include the top surface 306 and the bottom surface 308, with the top surface having an opening 310 and the bottom surface having an opening 312 through which a rivet passes to connect the tile 318 to a neighboring tile. The rod 304 passes through the edge 314 of the tile 318.
FIG. 7 is a perspective view 700 of two rods 702, 704 connected by fasteners 706, 708, 710, 712 according to some embodiments. Bottom surfaces of two neighboring tiles 110, 112 are shown. A rod is molded in each of the two abutting edges of the two tiles 110 and 112. As shown, the rod 702 is molded into the bottom edge of the tile 112, while the rod 704 is embedded in the top edge of the tile 110. The rod 702 passes through fasteners 710 and 712, while the rod 704 passes through fasteners 706 and 708.
The fasteners 710 and 706 are aligned such that the rivet 252 or another type of fastener can be passed through circular openings in the two flat surfaces of the fasteners 710 and 706. Similarly, the fasteners 712 and 708 are aligned such that the rivet 254 or another type of fastener can be passed through circular openings in the two flat surfaces of the fasteners 712 and 708. The rivets 252 and 254 are fastened to hold the tiles 110, 112 in place and eliminate any gap between the edges of the neighboring tiles 110, 112.
As shown in FIG. 3, each of the fasteners 707, 708, 710, 712 has two parallel surfaces (e.g., surfaces 306 and 308). To align the circular openings (310) in the fasteners 710, 706, the bottom surface of the fastener 706 is placed between the two parallel surfaces of the fastener 710. In another embodiment, to align the circular openings in the fasteners 710, 706, the bottom surface of the fastener 710 is placed between the two parallel surfaces of the fastener 706. In another embodiment, to align the circular openings in the fasteners 710, 706, the parallel surfaces of the fastener 710 is placed on top of the parallel surfaces of the fastener 706, vice versa.
To align the circular openings in the fasteners 712, 708, the bottom surface of the fastener 712 is placed between the two parallel surfaces of the fastener 708. In another embodiment, to align the circular openings in the fasteners 712, 708, the bottom surface of the fastener 712 is placed between the two parallel surfaces of the fastener 708. In another embodiment, to align the circular openings in the fasteners 712, 708, the parallel surfaces of the fastener 712 is placed on top of the parallel surfaces of the fastener 708, vice versa.
The positioning of the parallel surfaces of the fasteners 710, 706 are the same as the positioning of the parallel surfaces of the fasteners 712, 708. For example, the bottom surface of the fastener 706 is placed between the two parallel surfaces of the fastener 710; the bottom surface of the fastener 706 is placed between the two parallel surfaces of the fastener 710, while the bottom surface of the fastener 708 is placed between the two parallel surfaces of the fastener 712. In this configuration, the distance between the rod 704 and the bottom surface of the edge of the tile 112 is different than the distance between the rod 706 and the bottom surface of the edge of the tile 110 so that when the two tiles are connected by the fasteners 706, 708, 710, 712, the two tiles 110, 112 create an even top surface.
In other embodiments, the rods 702, 704 are in the same positions in their respective tile edges. In these embodiments, the fasteners 710, 706 are in different positions such that when the tiles are connected an even top surface is created. For example, the fastener 710 is placed higher than the fastener 706. In this example, the fastener can be flipped over to provide the clearance such that one fastener has an under grip and the other fastener has an over grip.
FIG. 8 is a cross-sectional view 800 of the two rods 702 and 704 embedded inside the mat tiles 110 and 112 and connected by connecting mechanisms including fasteners as shown in FIG. 7. The two rods 702, 704 are of equal length. The length of the rod is slightly less than the length of the tile edge into which the rod is embedded. For example, if the tile edge length is 30 inches, the rod is 28 inches long. The diameter of each of the rods 702, 704 is 0.12 inch. The diameter of the rod (e.g., the rods 702, 704) vary depending on the thickness of the tile into which the rod is embedded. The dimensions of the rods are provided here for exemplary purposes only. The length and diameter of a rod depend on the thickness of the tile.
The rod 702 is shown to run through a cylindrical opening of the fastener 710. The rod 704 is shown to run through a cylindrical opening of the fastener 706. In some embodiments, the two fasteners 706, 710 are aligned such that the upper surface of the fastener 706 fits between the top surface and the bottom surface of the fastener 710. In other embodiments, the two fasteners 706, 710 are aligned such that the bottom surface of the fastener 706 fits between the top surface and the bottom surface of the fastener 710. Upon alignment of the two fasteners 706, 710, the protruding portions of the fasteners 706, 710 are covered by the flap portion of the two corresponding notched spaces located on the edges of the tiles so that the fasteners are not visible from the top surface of the tiles 110, 112.
The rivet 252 or a screw is run through the openings of the two overlapping fasteners 706 and 710. The rivet 252 is fastened in place. Each edge of the tile that neighbors another tile has two or more fasteners that overlap with fasteners from neighboring tiles and have rivets pass through the overlapping openings. All the rivets are fastened tightly, and, as a result, seams along the edges of the neighboring tiles do not have any gaps.
When the tiles expand or contract due to hot or cold weather, the edges of the tiles do not move because they are tightly secured with the connecting mechanisms described herein. At the same time, the tiles have the opportunity to flex and attenuate impact. The seam between the interconnected tiles is almost invisible and is long term stable in all weather conditions. The top layer can be used on top of any surfaces. For example, some rubber tiles are manufactured out of shredded/recycled tires.
FIG. 9 is a schematic cross-sectional view 900 of the mat 102 including the top layer 106 and the bottom safety layer 104. The top layer 106 includes of a plurality of tiles interconnected as described above. The top layer 106 rests on top of the bottom safety layer 104. The top layer 106 and the bottom layer 104 are two separate products. The bottom layer 104 includes layering membranes, which reduce the structure in any one area. Although the safety layer 104 is shown to include two layers 902, 904, any other number of safety layers can be used. For example, three layers can be used for the bottom safety layer 704.
A headform 906 is shown to fall on top of the mat 102. For example, the headform 906 fall from an eight foot drop, or from any other distance, on to the mat. The headform 906 is six inches in diameter, and the mat 102 is approximately two to three inches thick. Upon impact, the headform 906 of this size affects an area that is approximately three inches in diameter. The impact is effectively attenuated by bridging the attenuating material of the bottom safety layer 104. The membranes of the bottom layer 104 are pulled tightly, so that the structure right underneath the impact is not necessary. By putting the tension in the surface, the impact is absorbed laterally, and the affected area is at least doubled. This in turn creates a lateral dissipation of energy, and creates a trampoline type of effect, which minimizes the risk of head injury to a child falling on the mat 102. In addition, the rods (e.g., the rods 702, 704) running through the edges of the tiles in the top layer 106 absorb the impact laterally. The rods in the top layer create the deflection of force, and lateral dissipation of energy. The trampoline effect is achieved by the mid-layer membranes (in the middle of the safety layers). When this membrane has tension on it, this tension in the membrane within the layer is what creates a trampoline effect.
The bottom safety layer 104 is shown to include two safety layers 902 and 904. Each of these two safety layers 902, 904 includes a plurality of angled ribs (e.g., rib 908). The ribs are protrusions of materials going toward the ground, at an angle to the bottom surface of the layer. In some implementations, the ribs can extend at an angle of 30 degrees, 60 degrees, or any other angle. The protrusions have a width that is widest near the top surface of the layer, while having the narrowest width closest to the bottom surface of the layer (e.g., layer 902). Accordingly, the width of the ribs narrows downwards.
The angle ribs are two inches tall, which would absorb an impact of approximately 8 feet. The two safety layers of the bottom safety layer are identical. In some implementations, the bottom layer of the two safety layers have different widths. For example, the second safety layer 904 has taller ribs than the first safety layer 902.
As shown, the ribs between the two layers do not need to line up. As shown, the ribs of the top safety layer are located in between the ribs of the bottom safety layer. However, the ribs of the top safety layer can be located anywhere with respect to the ribs of the bottom safety layer. Thus, the ribs of the two safety layer do not need to line up in any manner. The width of bottom safety layers are approximately 0.3 inch, while the depth is approximately 0.4 inch. Upon impact of the headform 906, the bottom surface of the tiles drives into the surface of the top safety layer 902. The membrane in the top safety layer 902 creates an air pocket 910 or chamber that further decelerates the force of the impact. The two ribs on each side of the created air pocket in the first safety layer 902 drive into the surface of the second safety layer 904, which in turn creates two air pockets 912, 914 in the second safety layer 904. The created air chambers 910, 912, 914 in the two safety layers 902, 904 decelerate the headform 906 and decrease the risk of head injury.
Furthermore, upon impact, the air underneath and/or in between the top layer 106 and the two safety layers 902, 904 compresses during the force of the impact and the compression of that air decelerate the headform 906. The air compression is then incorporated into the lateral attenuation of the impact. In other words, a vertical force received by the headform 906 may be converted into horizontal forces (substantially perpendicular to the vertical force) by the two safety layers 902, 904. As a result, less material is necessary to manufacture the two safety layers 902, 904 because the air pockets created upon impact decelerate the headform 906.
FIG. 10 is a schematic cross-sectional side view 1000 of a tile 1006 connected to a neighboring tile 1008 using a connecting mechanism, which includes rods 1010 and 1012, fasteners 1002 and 1004, and a rivet 1014. As shown, the rod 1010 passes through the fastener 1002. The fastener 1002 includes the top surface 1026 and the bottom surface 1024 and a rounded portion that loops around the rod 1010. The rod 1012 passes through the fastener 1004. The fastener 1004 includes the top surface 1022 and the bottom surface 1020 and a rounded portion that loops around the rod 1004.
As shown, a portion of the fastener 1002 protrudes from the side of the tile 1006 and a portion of the fastener 1004 protrudes from the side of the tile 1008. The protruding portion of the fastener 1004 fits into the notched space 1016 of the neighboring tile 1006, while the protruding portion of the fastener 1002 fits into the notched space 1018 of the neighboring tile 1008.
The notched space 1016 in the tile edge 1006 is shown by a dashed line 1030, while the notched space 1018 in the tile edge 1008 is shown by a dashed line 1032. As shown, the top surface 1022 of the fastener 1004 is positioned between surfaces 1024, 1026 of the fastener 1002, and the bottom surface 1024 of the fastener 1002 is positioned between surfaces 1022, 1020 of the fastener 1004. The rivet 1014 includes a rivet shaft and a head on one end. The rivet 1014 passes through the aligned circular openings in each of the surfaces 1020, 1022, 1024, 1026. The rivet 1014 is fixated in place when the tail of the rivet 1014 is bucked. Any other type of fastener is used to hold the fasteners 1002, 1004 in place.
Referring generally to FIGS. 11A-14D, embodiments of a second type of connecting mechanisms (e.g., U-shaped bracket connectors) are presented for connecting the tiles. At least one U-shaped bracket is provided on an edge of each tile to be connected. Each of the U-shaped brackets has a plate surface facing the plate surface of the other U-shaped bracket. Each plate surface includes a hole for receiving a pin. A first end of the pin may be inserted into a first plate surface of a first U-shaped bracket and a second end of the pin may then be inserted into a second plate surface of a second U-shaped bracket, thus securing the tiles associated with each U-shaped bracket.
FIG. 11A is a schematic cross-sectional bottom view 1100 a of bottom surfaces of a first tile 1190 a and a second tile 1190 b. Referring to FIGS. 1-2B and 11A, each of the first tile 1190 a and the second tile 1190 b may be the same as the tiles 110, 112. In particular, FIG. 11A shows a pair of U-shaped bracket (e.g., a first U-shaped bracket 1110 a and a second U-shaped bracket 1110 b) secured by a pin 1120 to connect the second tile 1190 b to the neighboring first tile 1190 a.
The first U-shaped bracket 1110 a is located on or at a first edge 1108 of the first tile 1190 a. Similarly, the second U-shaped bracket 1110 b is located on or at a second edge 1132 of the second tile 1190 b. Each of the first edge 1108 and second edge 1132 include a notched space for receiving the U-shaped brackets 1110 a, 1110 b. In other embodiments, the U-shaped brackets 1110 a, 1110 b are molded in as an integral part of the first edge 1108 or the second edge 1132. A first interior space 1123 a is provided (e.g., the first interior space 1123 a is not filled with material making up the first tile 1190 a) for allowing the pin 1120 to be received in the first interior space 1123 a without meeting the resistance of the tile material. Similarly, a second interior space 1123 b is provided (e.g., the second interior space 1123 b is not filled with material making up the second tile 1190 b) for allowing the pin to be received in the second interior space 1123 b without being obstructed by the resistance of the tile material. The first interior space 1123 a and/or the second interior space 1123 b have volumes equal to the volume of the pin 1120 when the pin is fully inserted (e.g., reaching securing rods 1150 a, 1150 b). The first interior space 1123 a and the second interior space 1123 b are defined by the walls of the U-shaped brackets 1110 a, 1110 b.
A surface space 1122 a is provided between a first plate surface 1140 a of the first U-shaped bracket 1110 a and a second plate surface 1140 b of the second U-shaped bracket 1110 b. The surface space 1122 a is provided when the first tile 1190 a and the second tile 1190 b are placed to abut each other. In other words, the surface space 1122 a is provided or otherwise formed when the first edge 1108 of the first tile 1190 a and the second edge 1132 of the second tile 1190 b are placed in contact with one another. The surface space 1122 a is occupied by at least a portion of the pin 1120. Alternatively, surface space 1122 a is nonexistent—that is, the first plate surface 1140 a and the second plate surface 1140 b are in contact with one another when the pin 1120 is received by both the first U-shaped bracket 1110 a the second U-shaped bracket 1110 b.
U-shaped brackets 1110 a, 1110 b is secured to the respective edges 1108, 1132 by a securing rod (e.g., a first securing rod 1150 a for the first U-shaped bracket 1110 a and a second securing rod 1150 b for the second U-shaped bracket 1110 b). The first securing rod 1150 a is embedded in the first edge 1108 of the first tile 1190 a and extends along (a longitudinal dimension of) the first edge 1108. The first securing rod 1150 a passes through the first U-shaped bracket 1110 a (e.g., through at least one securing holes as described herein). Similarly, the second securing rod 1150 b is embedded in the second edge 1132 of the second tile 1190 b and extends along (a longitudinal dimension of) the second edge 1132. The second securing rod 1150 b passes through the second U-shaped bracket 1110 b (e.g., through at least one securing holes as described herein). The first securing rod 1150 a and the second securing rod 1150 b are parallel to one another when the edges 1108, 1132 are in contact with one another. The securing rods 1150 a, 1150 b are a securing rod such as, but not limited to, the rod 304 of FIG. 3.
At least one blind hole (e.g., first blind holes 1160 a, 1160 b and second blind holes 1160 c, 1160 d) is formed on the respective edges 1108, 1132. Each of the blind holes 1160 a, 1160 b, 1160 c, 1160 d is concave with respect to the first edge 1108 or the second edge 1132. In particular, the blind holes 1160 a, 1160 b, 1160 c, 1160 d are cylindrical (or other suitable shapes such as, but not limited to, spherical, rectangular, and the like) concave volumes (i.e., blind holes) formed on the edges 1108, 1132. For example, each of the two first blind holes 1160 a, 1160 b is located proximal to (e.g., on either side of) the first U-shaped bracket 1110 a when viewed from the bottom of the tiles 1190 a, 1190 b. Similarly, each of the two second blind holes 1160 c, 1160 d is located proximal to (e.g., on either side of) the second U-shaped bracket 1110 b when viewed from the bottom of the tiles 1190 a, 1190 b. The securing rods 1150 a, 1150 b are visible in the first blind holes 1160 a, 1160 b and second blind holes 1160 c, 1160 d, respectively. The blind holes 1160 a, 1160 b, 1160 c, 1160 d are used to couple the securing rods 1150 a, 1150 b to the first U-shaped bracket 1110 a and/or the second U-shaped bracket 1110 b. For example, an operator installing the mat 102 by putting together the tiles 1190 a, 1190 b adjusts the positions of the securing rods 1150 a, 1150 b with respect to the first U-shaped bracket 1110 a or the second U-shaped bracket 1110 b. For example, the operator engages (e.g., with fingers or tools) the portion of the securing rods 1150 a, 1150 b exposed by the blind holes 1160 a, 1160 b, 1160 c, 1160 d and shifts the securing rods 1150 a, 1150 b along the longitudinal dimension of the respective edges 1108, 1132 (also the longitudinal dimension of the securing rods 1150 a, 1150 b).
In some embodiments, the securing rods 1150 a, 1150 b are moved relative to both the tiles 1190 a, 1190 b and the U-shaped brackets 1110 a, 1110 b. In other embodiments, the U-shaped brackets 1110 a, 1110 b are shifted with the securing rods 1150 a, 1150 b. In embodiments in which each of the tiles 1190 a, 1190 b includes a plurality of the U-shaped brackets, at least one of the U-shaped brackets 1110 a, 1110 b is associated with at least one blind hole (e.g., the blind holes 1160 a, 1160 b, 1160 c, 1160 d). That is, the securing rods 1150 a, 1150 b may be seen and adjusted through at least one blind hole provided at either side of at least one of the U-shaped brackets 1110 a, 1110 b. At least another of the U-shaped bracket 1110 a, 1110 b is not associated with any blind holes at all.
In some embodiments, the blind holes 1160 a, 1160 b, 1160 c, 1160 d are filled (e.g., with the mat material) after the positions of the securing rods 1150 a, 1150 b (and or the U-shaped brackets 1110 a, 1110 b) are adjusted. In other embodiments, the blind holes 1160 a, 1160 b, 1160 c, 1160 d remain unfilled post-installation.
The securing rods 1150 a, 1150 b serve as stoppers for the pin 1120. For example, as the pin 1120 enters from the surface space 1122 a to the first interior space 1123 a (or the second interior space 1123 b), the pin 1120 extends as far into the first interior space 1123 a (or the second interior space 1123 b) as a force inserting the pin 1120 permits. The securing rods 1150 a, 1150 b are provided to be positioned with respect to the U-shaped brackets 1110 a, 1110 b such that the pin 1120 comes in contact with the securing rods 1150 a, 1150 b. After such contact, the pin 1120 would not be able to be pushed further in the inserting direction due to the securing rods 1150 a, 1150 b.
The pin 1120 may be a nail, screw, rivet, bolt and the like. In some embodiments, the pin 1120 is a rivet such as, but not limited to, the rivets 252, 254. In particular, the rivet (e.g., in embodiments where the rivet is the pin 1120) is deformable when in contact with the securing rods 1150 a, 1150 b so as to prevent the rivet from exiting or otherwise disengaged from the first U-shaped bracket 1110 a and/or the second U-shaped bracket 1110 b. In other embodiments, the pin 1120 is a threaded pin (e.g., similar to a threaded screw without a head). Both ends of the pin 1120 include a flat end. The threads on the pin 1120 are used for engaging the pin holes (which are also threaded) in the manner described. In addition, the threads of the pin 1120 are used for engaging any support structures (e.g., securing structures, locks, bracers, and the like) as described. The pin 1120 is a number 8 pin, having a diameter of approximately 0.115-0.165 inch. The length of the pin 1120 is one of 0.25 inch, 0.5 of an inch, 0.75 of an inch, 1 inch, or the like.
FIG. 11B is a schematic cross-sectional view 1100 b of the U-shaped brackets 1110 a, 1110 b and the securing rods 1150 a, 1150 b embedded inside the tiles 1190 a, 1190 b connected by connecting mechanisms including the U-shaped brackets 1110 a, 1110 b as shown in FIG. 11A. The securing rods 1150 a, 1150 b are of equal or unequal length. The length of the securing rods 1150 a, 1150 b is slightly less than the length of the respective one of the first edge 1108 or the second edge 1132. In one particular example, if the tile edge length of the first edge 1108 and/or the second edge 1132 is 30 inches, the securing rods 1150 a, 1150 b is 28 inches long. In other embodiments, a plurality of securing rods (such as the securing rods 1150 a, 1150 b) is provided in a same tile edge. The diameter of each of the securing rods 1150 a, 1150 b is 0.12 inch. In other embodiments, the diameter of each of the securing rods 1150 a, 1150 b is one of 0.06 inch, 0.18 inch, 0.24 inch, and/or the like. The diameter of the securing rods 1150 a, 1150 b varies depending on the thickness of the tiles 1190 a, 1190 b in which the securing rods 1150 a, 1150 b are embedded. The dimensions of the securing rods 1150 a, 1150 b are provided here for exemplary purposes only. The length and diameter of the securing rods 1150 a, 1150 b are directly proportional to the thickness of the tiles 1190 a, 1190 b.
The first securing rod 1150 a is shown to run through a first cylindrical opening (e.g. a securing hole) of the first U-shaped brackets 1110 a. The second securing rod 1150 b is shown to run through a second cylindrical opening (e.g., a securing hole) of the second U-shaped brackets 1110 b. The U-shaped brackets 1110 a, 1110 b are aligned such that a pin hole of the first U-shaped bracket 1110 a and a pin hole of the second U-shaped bracket 1110 b align. The pin 1120 is inserted into the respective pin holes of the first U-shaped bracket 1110 a and the second U-shaped bracket 1110 b. In particular, a first end the pin 1120 is inserted or otherwise coupled to the pin hole of first U-shaped bracket 1110 a. A first distal end of the pin 1120 protrudes from the first U-shaped bracket 1110 a. When the pin 1120 is blocked by the first securing rod 1150 a and could not be inserted more, a portion including a second end of the pin 1120 is protruding from the first tile 1190 a. Then, the second end of the pin 1120 is inserted into the pin hole of the second U-shaped bracket 1110 b. The pin 1120 is pushed through the pin hole of the second U-shaped bracket 1110 b toward the second securing rod 1150 b until the securing rod 1150 b prevents the pin 1120 from being inserted further. A second distal end of the pin 1120 protrudes from the second U-shaped bracket 1110 b. This usually occurs when the operator pushes the two tiles (e.g., the first tile 1190 a and the second tile 1190 b) closely together when one tile (e.g., the first tile 1190 a) already has the second end of the pin 1120 protruding from the first tile 1190 a. Such processes are executed for each U-shaped bracket residing on a given edge of a tile. When the pin 1120 insertion is completed, seams along the edges (e.g., the first edge 1108 and the second edge 1132) of the neighboring tiles (e.g., the first tile 1190 a and the second tile 1190 b) do not have any gaps.
When the first tile 1190 a and the second tile 1190 b expand or contract due to hot or cold environmental temperature, the first edge 1108 and the second edge 1132 of the tiles 1190 a, 1190 b do not move because they are tightly secured with the U-shaped brackets 1110 a, 1110 b described herein. At the same time, the first tile 1190 a and the second tile 1190 b are capable of flexing and attenuating impact. The seam between the interconnected tiles 1190 a, 1190 b is almost invisible and is long term stable in all weather conditions.
FIG. 12 is a perspective view 1200 of connecting mechanisms configured along edges of two neighboring tiles. Bottom surfaces of two neighboring tiles (e.g., the first tile 1190 a and the second tile 1190 b) are shown. Referring to FIGS. 1-2B and 11A-12, various connection groups (e.g., a first connection group 1220 a and a second connection group 1220 b) are provided along the first edge 1108 of the first tile 1190 a and the second edge 1132 of the second tile 1190 b. Each of the connection groups 1220 a, 1220 b includes the connection mechanisms features in FIGS. 11A-11B. For example, first connection group 1220 a includes the first U-shaped bracket 1110 a, the second U-shaped bracket 1110 b, the pin 1120, and other associated components/features shown in FIGS. 11A-11B. The second connection group 1220 b mirrors the components described with respect to the first connection group 1220 a.
The first securing rod 1150 a and the second securing rod 1150 b are molded in the two abutting edges (the first edge 1108 and the second edge 1132) of the tiles 1190 a, 1190 b. As shown, the first securing rod 1150 a is embedded (molded) into the first edge 1108, while the second securing rod 1150 b is embedded (molded) in the second edge 1132. The first securing rod 1150 a passes through the first U-shaped bracket 1110 a and a corresponding first U-shaped bracket 1110 a′ for the second connection group 1220 b. The second securing rod 1150 b passes through the second U-shaped bracket 1110 b and a corresponding second U-shaped bracket 1110 b′ for the second connection group 1220 b.
With respect to the first connection group 1220 a, the first U-shaped bracket 1110 a is positioned at a mirrored position on the first edge 1108 corresponding to the position of the second U-shaped bracket 1110 b on the second edge 1132. Similarly, with respect to the second connection group 1220 b, the first U-shaped bracket 1110 a is positioned at a mirrored position on the first edge 1108 corresponding to the position of the second U-shaped bracket 1110 b′ on the second edge 1132. The operator connecting the tiles 1190 a, 1190 b first aligns one connection group when the tiles 1190 a, 1190 b are placed one next to the other based on the positions of the U-shaped brackets. The rest of the connection groups is aligned (incidentally) in the process given the mirrored positions of the corresponding U-shaped brackets.
The connection groups 1120 a, 1120 b are provided for other edges on the tiles 1190 a, 1190 b when those edges require connecting mechanisms for connecting to a neighboring tile. While two connection groups 1220 a, 1220 b are shown in FIG. 12, it should be appreciated that one, three, or more connection groups are provided along each edge of a tile. The connection groups are spaced evenly or unevenly.
FIG. 13A is a top or bottom view 1300 a of a U-shaped bracket 1395 according to various embodiments. FIG. 13B is a perspective view 1300 b of the U-shaped bracket 1395 according to various embodiments. FIG. 13C is a front view 1300 c of the U-shaped bracket 1395 according to various embodiments. FIG. 13D is a side view 1300 d of the U-shaped bracket 1395 according to various embodiments. Now referring to FIGS. 1 and 11A-13D, the U-shaped bracket 1395 is the first U-shaped bracket 1110 a or the second U-shaped brackets 1110 b. The U-shaped bracket 1395 includes at least a front portion 1340 and two side portions (e.g., a first side portion 1320 a and a second side portion 1320 b).
The front portion 1340 is a thin rectangular plate (e.g., cube, cuboid, and the like) in some embodiments. In other embodiments, the front portion 1340 is any type of plates having suitable shapes (e.g., circular, rectangular, or the like). The front portion 1340 includes a pin hole 1310 a for receiving the pin 1120. As better shown in FIGS. 13A-13C, the pin hole 1310 a is located in the center of the front portion 1340 according to some embodiments. In other embodiments, the pin hole 1310 a is provided at suitable positions on the front portion 1340 other than the center. An inner surface area 1312 of the pin hole 1310 a is smooth. In other embodiments, the inner surface area 1312 of the pin hole 1310 a is threaded for receiving the pin 1120 having a threaded surface. The diameter of the pin hole 1310 a is the same or slightly larger than the diameter of a cross section of the pin 1120. The diameter of the pin hole 13010 a is 0.17-0.195 inch (e.g., 0.173 inch, 0.19 inch, or the like).
The front portion 1340 includes a front surface such as, but not limited to, the first plate surface 1140 a and the second plate surface 1140 b. The front surface faces outward away from an interior space 1323 (e.g., the first interior space 1123 a or the second interior space 1123 b). The interior space 1323 is defined by the front portion 1340, the first side portion 1320 a, and the second side portion 1320 b. The front surfaces of two of the U-shaped brackets (e.g., the U-shaped brackets 1395) face each other when the pin 1120 is received by both the U-shaped brackets.
In various embodiments, the first side portion 1320 a and the second side portion 1320 b are joined with the front portion 1340. Each of the first side portion 1320 a and the second side portion 1320 b is substantially perpendicular to the front portion 1340. In other embodiments, the angles between the front portion 1340 and each of the first side portion 1320 a and the second side portion 1320 b is acute and/or obtuse.
The first side portion 1320 a includes a first securing hole 1310 b, and the second side portion 1320 b includes a second securing hole 1310 c. Each of the first securing hole 1310 b and the second securing hole 1310 c is configured to receive a securing rod (e.g., the first securing rod 1150 a, the second securing rod 1150 b, and the like). The first securing hole 1310 b and the second securing hole 1310 c are positioned such that when the securing rod is received by both the first securing hole 1310 b and the second securing hole 1310 c, the securing rod is parallel to the front portion 1340. As best shown in FIGS. 13A, 13B, and 13D, the first securing hole 1310 b is positioned on the first side portion 1320 a away from the front portion 1340 (e.g., toward the securing rod). Similarly, the second securing hole 1310 c is positioned on the second side portion 1320 b away from the front portion 1340 (e.g., toward the securing rod).
FIG. 14A is a front perspective view of a pin lock 1400 according to various embodiments. FIG. 14B is a front view of the U-shaped bracket 1495 provided with the pin lock 1400 according to various embodiments. FIG. 14C is a back view of the U-shaped bracket 1495 provided with the pin lock 1400 according to various embodiments. FIG. 14D is a cross-sectional view of the U-shaped bracket 1495 provided with the pin lock 1400 according to various embodiments. Now referring to FIGS. 1 and 11A-14D, the U-shaped bracket 1495 is the first U-shaped bracket 1110 a, the second U-shaped brackets 1110 b, or the U-shaped bracket 1395. The U-shaped bracket 1495 includes at least a front portion 1490 (e.g., the front portion 1340) and two side portions 1485 a, 1485 b (e.g., the first side portion 1320 a and the second side portion 1320 b, respectively).
The pin lock 1400 is a flat strip composed of flexible material such as, but not limited to, metal. The pin lock 1400 includes a lock body 1420. The lock body 1420 is connected to a first securing tab 1410 a and a second securing tab 1410 b for securing the lock body 1420. The lock body 1420 includes at least one holding tabs (e.g., a first holding tab 1430 a and a second holding tab 1430 b) for receiving a pin 1499 (e.g., the pin 1120). For example, when the pin 1499 is in contact with (tips of) the holding tabs 1430 a, 1430 b, the pin 1499 pushes the holding tabs 1430 a, 1430 b in the direction of insertion of the pin 1499 along a longitudinal dimension of the pin 1499. The direction of insertion with respect to a tile is characterized as away from a neighboring tile and toward a majority portion of the tile in which the neighboring tile is to be connected. The direction of insertion with respect to the tile is a direction from an exterior space outside of the tile toward a securing rod provided on an edge of that tile.
An engaging space 1440 is defined by the holding tabs 1430 a, 1430 b (more specifically, the ends of the holding tabs 1430 a, 1430 b). The engaging space 1440 is a carved-out space provided substantially in the center of the lock body 1420. The engaging space 1440 is of a substantially rhombus shape. The engaging space 1440 is configured to allow the insertion of the pin 1499.
When pushed by the pin 1499, each of the holding tabs 1430 a, 1430 b is bent with respect to the lock body 1420 at the bending edge (e.g., a first bending edge 1435 a and a second bending edge 1435 b) by virtual of the flexible material from which the pin lock 1400 is composed of. A slit on either side of the holding tabs 1430 a, 1430 b is provided to allow such movement of the holding tabs 1430 a, 1430 b. As best shown in FIG. 14D, the holding tabs 1430 a, 1430 b are bent at the respecting bending edges 1435 a, 1435 b away from the lock body 1420 in the direction of insertion (e.g., toward the securing rod 1475). The securing rod 1475 is the first securing rod 1150 a and/or the second securing rod 1150 b.
Given the dimensions (e.g., the cross-section diameter) of the pin 1499, the pin 1499 may not be able to clear the engaging space 1440 defined by the holding tabs 1430 a, 1430 b without contacting and pushing the tips of the holding tabs 1430 a, 1430 b in the inserting direction. The cross-section diameter of the pin 1499 allows the pin 1499 to clear a vertical dimension (e.g., a dimension perpendicular to a longitudinal dimension) of the engaging space 1440. The cross-sectional diameter of the pin 1499 is larger than the horizontal dimension (e.g., the longitudinal dimension) of the engaging space 1440. Given that a pin hole 1493 (e.g., the pin hole 1310 a) is approximately of the same circumference as the pin 1499, at least a portion (e.g., the tips) of the holding tabs 1430 a, 1430 b is seen through the pin hole 1493 when the pin 1499 is not inserted.
The lock body 1420 is provided in an interior space (e.g., first interior space 1123 a and the second interior space 1123 b) as defined by the front portion 1490 and the side portions 1485 a, 1485 b. In particular, the lock body 1420 is placed in contact with (or proximal to) an inner surface of the front portion 1490. The inner surface being a surface of the front portion 1490 facing away from the other U-shaped bracket that is connecting with the U-shaped bracket 1495 and toward the securing rod associated with the U-shaped bracket 1495.
Each of end portions of the holding tabs 1430 a, 1430 b includes triangle tips or otherwise serrated tips to engage the threaded pin 1499 when the pin 1499 is inserted. In particular embodiments, each of the end portions of the holding tab 1430 a, 1430 b is of a rectangular with a triangular space cut out from the end portions, the apex of the triangular space pointing at one of the securing tabs 1410 a, 1410 b. The end portions of the holding tabs 1430 a, 1430 b are configured to engage the threads on the pin 1499 (e.g., at first and/or second distal ends of the pin 1499) when and after the securing tabs 1410 a, 1410 b are bent due to the insertion of the pin 1499. In particular, the end portions prevent the pin 1499 from being drawn by forces in the opposite direction of the direction of insertion. Accordingly, the securing tabs 1410 a, 1410 b prevent tiles from disconnected to one another after the tiles have been connected.
Securing apertures 1450 a, 1450 b are located at either side of the pin hole 1493 for receiving the securing tabs 1410 a, 1410 b. The securing tabs 1410 a, 1410 b are configured to be bendable at or around the respective bending locations 1415 a, 1415 b away from the lock body 1420. In particular, the securing tabs 1410 a, 1410 b are received at the securing apertures 1450 a, 1450 b. At least a portion (e.g., an end portion) of the securing tabs 1410 a, 1410 b are in contact with an exterior surface (e.g., the first plate surface 1140 a and the second plate surface 1140 b) of the front portion 1490. The end portion of the securing tabs 1410 a, 1410 b are bent toward the pin 1499 or away from the pin 1499 to be secured on the exterior surface of the front portion 1490.
Now referring generally to FIGS. 14A and 15A-17D, embodiments of a third type of connecting mechanisms (e.g., strip brackets) are illustrated for connecting the tiles. At least one strip bracket is provided along an edge of each tile to be connected. Each strip bracket includes a plurality of holes for engaging pins. The flat surfaces of the strip brackets from two neighboring tiles face each other. A first (distal) end of a pin is inserted into one of the plurality of holes for a first strip bracket of a first tile. Then, a second (distal) end of the pin is inserted into one of the plurality of holes for a second strip bracket of second tile. Thus, the first tile and the second tile are secured together.
FIG. 15A is a schematic cross-sectional bottom view 1500 a of bottom surfaces of a third tile 1590 a and a fourth tile 1590 b interconnected by some embodiments of the connecting mechanism. Referring to FIGS. 1-2B and 15A, each of the third tile 1590 a and the fourth tile 1590 b is the tile 110 and 112. In particular, FIG. 15A shows a pair of strip brackets (e.g., a first strip bracket 1510 a and a second strip bracket 1510 b) secured by a plurality of pins (e.g., a first pin 1520 a, second pin 1520 b, third pin 1520 c, and the like) to connect the fourth tile 1590 b to a neighboring tile, the third tile 1590 a.
The first strip bracket 1510 a is located on or at a third edge 1508 (e.g., the edge 208) of the third tile 1590 a. Similarly, the second strip bracket 1510 b is located on or at a fourth edge 1532 (e.g., the edge 232) of the fourth tile 1590 b. In some embodiments, each of the third edge 1508 and fourth edge 1532 receives the strip brackets 1510 a, 1510 b. In other words, the strip brackets 1510 a, 1510 b are built in (e.g., molded in as an integral part of) the third edge 1508 or the fourth edge 1532. In other embodiments, the strip brackets 1510 a, 1510 b are provided on a surfaces of the edges 1508, 1532 facing each other. Interior spaces within the edges 1508, 1532 are provided for each of the pins 1520 a, 1520 b, 1520 c to be provided in the edges 1508, 1532 (e.g., through the strip brackets 1510 a, 1510 b) without meeting the resistance of the tile material.
In various embodiments, each of the interior spaces has a volume equal to or slightly larger than the volume that one of the pins 1520 a, 1520 b, 1520 c occupies when the pin is inserted fully. A pin (e.g., the pins 1520 a, 1520 b, 1520 c) has been inserted fully when it is inserted into the edges 1508, 1532 to contact the first stopper portion 1509 or the second stopper portion 1533. Each of the stopper portions 1509, 1533 is a part of edges 1508, 1532. The stopper portions 1509, 1533 are composed of the same material (e.g., various types of rubber) as the edges 1508, 1532. At least a portion of the stopper portions 1509, 1533 is composed of a material that is more rigid than the material making up the edges 1508, 1532. For example, some parts of the stopper portions 1509, 1533 are composed of rubber of a higher rigidity than the rubber of the edges 1508, 1532. The first stopper portion 1509 is positioned past the first strip bracket 1510 a in an direction of insertion of the pins 1520 a, 1520 b, 1520 c to prevent the pins 1520 a, 1520 b, 1520 c from being inserted pass an appropriate boundary, beyond which the connection is deemed to be unstable. This is because insufficient lengths of the pins 1520 a, 1520 b, 1520 c (e.g., at the opposite ends of the pins 1520 a, 1520 b, 1520 c) protruding from the first strip bracket 1510 a may cause unstable engagement with a corresponding bracket (e.g., the second strip bracket 1510 b.)
In various embodiments, each of the pins 1520 a, 1520 b, 1520 c is a nail, screw, rivet, bolt, and the like. In some embodiments, each of the pins 1520 a, 1520 b, 1520 c is a rivet such as, but not limited to, the rivets 252, 254. In particular, the rivet is deformable when in contact with the stopper portions 1509, 1533 so as to prevent the rivet from exiting or otherwise disengaged from the first strip bracket 1510 a and/or the second strip bracket 1510 b. In other embodiments, each of the pins 1520 a, 1520 b, 1520 c is a threaded pin (e.g., a headless threaded screw, a socket head screw, a double-head screw, and/or the like). Both ends of each of the pins 1520 a, 1520 b, 1520 c include a substantially flat end. The threads on each of the pins 1520 a, 1520 b, 1520 c are used for engaging the pin holes (which are also threaded) in the manner described. In addition, the threads of each of the pins 1520 a, 1520 b, 1520 c is used for engaging any support structures (e.g., securing structures, locks, and the like) as described. Each of the pins 1520 a, 1520 b, 1520 c is a number 8 pin, having a diameter of approximately 0.155-0.165 inch. The length of each of the pins 1520 a, 1520 b, 1520 c is one of 0.25 inch, 0.5 inch, 75 inch, 1 inch, or the like. The first strip bracket 1510 a and the second strip bracket 1510 b include pin holes for receiving the pins 1520 a, 1520 b, 1520 c.
Given that the first strip bracket 1510 a and the second strip bracket 1510 b are molded into the edges 1508, 1532, the interior spaces within the edges 1508, 1532 for receiving the pins 1520 a, 1520 b, 1520 c are generated by inserting a placeholder during the manufacturing process. For example, the placeholder is a nail, screw, rivet, or bolt of substantially similar size as the pin. The placeholder is inserted into the first strip bracket 1510 a and the second strip bracket 1510 b (e.g., through any pin holes therein). Then, the first strip bracket 1510 a and its associated placeholders is positioned into the mold as a unit for molding the rubber around the first strip bracket 1510 a and its associated placeholders. Similarly, the second strip bracket 1510 b and its associated placeholders is positioned into the mold as a unit for molding the rubber around the second strip bracket 1510 b and its associated placeholders. Upon the completion of the molding process, the placeholders is released from the corresponding strip brackets 1510 a, 1510 b. Each placeholder is a number 10 screw. Diameter associated with each placeholder is 0.170-0.195 inch (e.g., 0.173 inch, 0.19 inch, or the like)
FIG. 15B is a schematic cross-sectional view 1500 b of the strip brackets 1510 a, 1510 b embedded inside the tiles 1590 a, 1590 b connected by connecting mechanisms including the strip brackets 1510 a, 1510 b as shown in FIG. 15A. Referring to FIGS. 1-2B and 15A-15B, the third tile 1590 a and the fourth tile 1590 b are neighboring tiles. The third pin 1520 c is shown to be engaged by both the first strip bracket 1510 a and the first strip bracket 1510 b. Given the cross-sectional view, the first pin 1520 a and the second pin 1520 b are hidden behind the third pin 1520 c.
The strip brackets 1510 a, 1510 b are aligned such that a pin hole of the first strip bracket 1510 a and a pin hole of the second strip bracket 1510 b align. The third pin 1520 c (as well as the first pin 1520 a and the second pin 1520 b) is inserted into the respective pin holes of the first strip bracket 1510 a and the second strip bracket 1510 b. In particular, a first distal end the third pin 1520 c (as well as the first pin 1520 a and the second pin 1520 b) is inserted or otherwise couple to the pin hole of the first strip bracket 1510 a first. The first distal end of the pin third pin 1520 c protrudes from the first strip bracket 1510 a. When the third pin 1520 c (as well as the first pin 1520 a and the second pin 1520 b) is blocked by the stopper portions 1509, 1533 and could not be inserted more, a portion including a second distal end of the third pin 1520 c (as well as the first pin 1520 a and the second pin 1520 b) is protruding from the third tile 1590 a. Then, the second distal end of the third pin 1520 c (as well as the first pin 1520 a and the second pin 1520 b) is inserted into the pin hole of the second strip bracket 1510 b. The pin 1120 is pushed through the pin hole of the second strip bracket 1510 b toward the second stopper portion 1533 until the second stopper portion 1533 prevents the third pin 1520 c (as well as the first pin 1520 a and the second pin 1520 b) from being inserted further. The second distal end of the pin third pin 1520 c protrudes from the second strip bracket 1510 b. This usually occurs when the operator pushes the two tiles (e.g., the third tile 1590 a and the fourth tile 1590 b) closely together when one tile (e.g., the third tile 1590 a) already has the second end of the third pin 1520 c (as well as the first pin 1520 a and the second pin 1520 b) protruding from the third tile 1590 a. Such processes are executed for each strip bracket residing on a given edge of a tile. When the pin insertion is completed, seams along the edges (e.g., the third edge 1508 and the fourth edge 1532) of the neighboring tiles (e.g., the third tile 1590 a and the fourth tile 1590 b) do not have any gaps.
When the third tile 1590 a and the fourth tile 1590 b expand or contract due to hot or cold environmental temperature, the third edge 1508 and the fourth edge 1532 of the tiles 1590 a, 1590 b do not move because they are tightly secured with the strip brackets 1510 a, 1510 b described herein. At the same time, the third tile 1590 a and the fourth tile 1590 b are capable of flexing and attenuating impact (e.g., at the space between two strip brackets). The seam between the interconnected tiles 1590 a, 1590 b is almost invisible and is long term stable in all weather conditions.
Each the strip brackets 1510 a, 1510 b is include a ridged portion. For the first strip bracket 1510 a, a first ridged portion 1550 a is provided. For the second strip bracket 1510 b, a second ridged portion 1550 b is provided. The ridged portions 1550 a, 1550 b extend along the longitudinal axis of the corresponding strip brackets 1510 a, 1510 b at a top portion of the strip brackets 1510 a, 1510 b and/or at a bottom portion of the strip brackets 1510 a, 1510 b. For illustrative purposes, ridges portions 1550 a, 1550 b are shown to be on a top portion of the strip brackets 1510 a, 1510 b. The ridged portions 1550 a, 1550 b are connected to the rest of the strip brackets 1510 a, 1510 b and are bent in any suitable an angle (e.g., 30 degrees, 60 degrees, 90 degrees, 120 degrees, and/or the like). The longitudinal dimensions of the ridged portions 1550 a, 1550 b extend along the longitudinal dimension of the strip brackets 1510 a, 1510 b. The lengths of the ridged portions 1550 a, 1550 b equal to the lengths of the strip brackets 1510 a, 1510 b. The ridged portions 1550 a, 1550 b are configured to extend only a portion (e.g., a middle portion) of the strip brackets 1510 a, 1510 b. The length of the ridged portions 1550 a, 1550 b is approximately 50%, 75%, 85%, or 90% of the length of the strip brackets 1510 a, 1510 b. The width of the strip brackets 1510 a, 1510 b (the dimension shown in FIG. 15B) is approximately 5%, 10%, 12% or 15% the width of the associated strip brackets 1510 a, 1510 b.
The ridged portions 1550 a, 1550 b reinforce the associated strip brackets 1510 a, 1510 b. The strip brackets 1510 a, 1510 b are made from flexible material. While some flexibility is favored given the shrinking/expansion characteristics and the material compositions of the tiles 1590 a, 1590 b, an appropriate amount of sturdiness as provided by the ridged portions 1550 a, 1550 b) is beneficial given that the strip brackets 1510 a, 1510 b are to hold the tiles 1590 a, 1590 b in place.
A connection space 1570 is provided between the first strip bracket 1510 a and the second strip bracket 1510 b. For example, an exterior surface of the first strip bracket 1510 a and an exterior surface of the second strip bracket 1510 b define the connection space. At least a portion (e.g., a middle portion) of the third pin 1520 c (as well as the first pin 1520 a and the second pin 1520 b) is provided within the connection space 1570 when the tiles 1590 a, 1590 b are connected. The connection space 1570 is not filled with any tile material. In other embodiments, the connection space 1570 is filled with tile material.
FIG. 16 is a perspective view 1600 of connecting mechanisms configured along edges of two neighboring tiles according to some embodiments. Bottom surfaces of two neighboring tiles (e.g., the third tile 1590 a and the fourth tile 1590 b) are shown. Referring to FIGS. 1-2B and 15A-16, various bracket groups (e.g., a first bracket group 1620 a, a second bracket group 1620 b, a third bracket group 1620 c, a fourth bracket group 1620 d, and a fifth bracket group 1620 e) are provided along the third edge 1508 of the third tile 1590 a and the fourth edge 1532 of the fourth tile 1590 b. Each of the bracket groups 1620 a-1620 e includes the connection mechanisms shown in FIGS. 15A-15B. For example, each of the bracket groups 1620 a-1620 e includes the first strip bracket 1510 a, the second strip bracket 1510 b, the first pin 1520 a, the second pin 1520 b, the third pin 1520 c, and other associated components/features shown in FIGS. 15A-15B.
The strip brackets associated with each of the bracket groups 1620 a-1620 e are molded in the two abutting edges (the third edge 1508 and the fourth edge 1532) of the tiles 1590 a, 1590 b. Each strip bracket associated with each of the bracket groups 1620 a-1620 e is configured to support (e.g., with a corresponding number of pin holes) one or more pins, although three pins are shown in FIGS. 15A-16. In exemplary embodiments, each strip bracket supports 10 pins (e.g., having 10 pin holes). Though five bracket groups are shown, it should be appreciate that each of edges 1508, 1532 supports one or more bracket groups. The number of bracket groups may be 1, 3, 5, 6, 10, and the like. The longitudinal dimension (e.g., the dimension extending along the longitudinal dimension of the edges 1508, 1532) of the strip brackets may be 5 inches, 10 inches, 20 inches, 35 inches, 70 inches, 75 inches, or the like.
In particular embodiments, the edges 1508, 1532 may each be 75 inches long. Five bracket groups 1620 a-1620 e are provided alone each of the edges 1508, 1532. Each of the bracket groups 1620 a-1620 e includes strip brackets having a longitudinal dimension of 10 inches. Each of the spaces between two of the bracket groups 1620 a-1620 e is 5 inches. 2½ inches are provided between the ends of the edges 1508, 1532 and a nearest bracket group (e.g., the first bracket group 1620 a and the fifth bracket group 1620 e). The arrangement (e.g., spacing) of the brackets (e.g., the bracket groups 1620 a-1620 e) can effectively curb undesired curvature or serpentining of the edges 1508, 1532. That is, sufficient numbers of the brackets having appropriate longitudinal dimensions may be provided along the edges 1508, 1532 by providing increased points/surfaces of engagement to connecting the edges 1508, 1532. The appropriate spacing may be set (e.g., in the manner described above) such that materials may be saved and installation may be simplified, all without substantially affecting the curbing features of the strip brackets.
FIG. 17A is a front or back view of a strip bracket 1700 according to various embodiments. Referring to FIGS. 1-2B, 15A-17A, the strip bracket 1700 is the first strip bracket 1510 a or the second strip bracket 1510 b. The strip bracket 1700 includes a bracket body 1720 and a ridge 1730. The ridge 1730 is the first ridged portion 1550 a or the second ridged portion 1550 b.
The bracket body 1720 is of a substantially rectangular shape, with its longitudinal dimension extending in the longitudinal dimension of the associated edges 1508, 1532. The thickness of the bracket body 1720 may be 0.05 inch, 0.1 inch, 0.2 inch, or the like. A plurality of pin holes (e.g., a first pin hole 1710 a, a second pin hole 1710 b, . . . , and a tenth pin hole 1710 j) are arranged along the longitudinal dimension of the bracket body 1720. In some embodiments, each of the pin holes 1710 a-1710 j is configured to receive a pin (e.g., the pins 1520 a-1520 c). In other embodiments, one or more of the pin holes 1710 a-1710 j may not receive a pin. In the embodiments in which the diameter of each of the pins 1520 a-1520 c is 0.155-0.165 inch, each of the pin holes 1710 a-1710 j has a diameter of 0.17-0.195 inch (e.g., 0.173 inch, 0.19 inch, or the like). In particular embodiments, the distance between a center of one pin hole and a center of another pin hole is approximately 1 inch.
At least one securing aperture is provided for at least one pin hole. The securing aperture is used for receiving a pin lock (e.g., the pin lock 1400 of FIG. 14A). For example, a first securing aperture 1740 a and a second securing aperture 1740 b are associated with the second pin hole 1710 b. In some embodiments, the first securing aperture 1740 a and the second securing aperture 1740 b are positioned at either side of the second pin hole 1710 b. In another example, a third securing aperture 1750 a and a fourth securing aperture 1750 b are associated with the ninth pin hole 1710 i. The third securing aperture 1750 a and the fourth securing aperture 1750 b are positioned at either side of the ninth pin hole 1710 i.
The ridge 1730 is manufactured as a part of the plane defined by the bracket body 1720. The ridge 1730 is bent or folded along the folding mark 1735 to provide sturdiness and rigidity to the bracket body 1720.
Referring generally to FIGS. 17B-17D, the strip bracket 1700 is shown with a pin lock 1400 of FIG. 14A. In other words, the pin lock 1400 shown in FIG. 14A can be implemented with the strip bracket 1700 as described herein. FIG. 17B is a front view of the strip bracket 1700 using the pin lock 1400 according to various embodiments. FIG. 17C is a back view of the strip bracket 1700 using the pin lock 1400 according to various embodiments. FIG. 17D is a schematic cross-sectional view of the strip bracket 1700 using the pin lock 1400 according to various embodiments. Now referring to FIGS. 1-2B, 14A, 15A-17D, a portion of the strip bracket 1700 (e.g., a portion including the second pin hole 1710 b and the associated first securing aperture 1740 a and the second securing aperture 1740 b) is illustrated in FIGS. 17B-17D. For clarity, the ridge 1730 is not shown.
The lock body 1420 includes at least one holding tabs (e.g., a first holding tab 1430 a and a second holding tab 1430 b) for receiving a pin 1799 (e.g., the pins 1520 a-1520 c). For example, when the pin 1799 is in contact with (tips of) the holding tabs 1430 a, 1430 b, the pin 1799 pushes the holding tabs 1430 a, 1430 b in the direction of insertion of the pin 1799. The direction of insertion with respect to a tile is characterized as away from a corresponding tile to be connected to the tile. The direction of insertion with respect to the tile is a direction from an exterior space outside of the tile toward a stopper portion 1775 (e.g., the first stopper portions 1509) provided on an edge (the first edge 1508) of that tile (e.g., the third tile 1590 a).
An engaging space 1440 is defined by the holding tabs 1430 a, 1430 b (more specifically, the ends of the holding tabs 1430 a, 1430 b). The engaging space 1440 is a carved-out space provided substantially in the center of the lock body 1420. The engaging space 1440 is of a substantially rhombus shape. The engaging space 1440 is configured to allow the insertion of the pin 1799.
When pushed by the pin 1799, each of the holding tabs 1430 a, 1430 b is bent with respect to the lock body 1420 at the bending edge (e.g., a first bending edge 1435 a and a second bending edge 1435 b) by virtual of the flexible material from which the pin lock 1400 is made of. A slit on either side of the holding tabs 1430 a, 1430 b is provided to allow such movement of the holding tabs 1430 a, 1430 b. As best shown in FIG. 17D, the holding tabs 1430 a, 1430 b are bent at the respecting bending edges 1435 a, 1435 b away from the lock body 1420 in the direction of insertion (e.g., toward the stopper portion 1775).
Given the dimensions (e.g., the cross-section diameter) of the pin 1799, the pin 1799 may not be able to clear the engaging space 1440 defined by the holding tabs 1430 a, 1430 b without contacting and pushing the tips of the holding tabs 1430 a, 1430 b in the inserting direction. The cross-section diameter of the pin 1799 allows the pin 1799 to clear a vertical dimension (e.g., a dimension perpendicular to a longitudinal dimension) of the engaging space 1440. The cross section diameter of the pin 1799 is larger than the engaging space 1440 in a horizontal dimension (e.g., the longitudinal dimension) of the lock body 1420. Given that the second pin hole 1710 b is approximately be of the same circumference as the pin 1799, at least a portion (e.g., the tips) of the holding tabs 1430 a, 1430 b is seen through the second pin hole 1710 b when the pin 1799 is not inserted.
The lock body 1420 is received in an interior surface of the strip bracket 1700. The interior surface is facing the stopper portion 1775 (or the center of the tile). In particular, the lock body 1420 is placed in contact with (or proximal) to the interior surface of the strip bracket 1700. In other words, the interior surface being a surface of the strip bracket 1700 facing away from the other strip bracket that is mating with the strip bracket 1700.
Each of end portions of the holding tabs 1430 a, 1430 b includes triangle tips or otherwise serrated tips to engage the threads on the pin 1799 when the pin 1799 is inserted. In particular embodiments, each of the end portions of the holding tab 1430 a, 1430 b is of a rectangular base shape with a triangular space cut out from the end portions, the apex of the triangular space pointing toward the closes one of the securing tabs 1410 a, 1410 b. The end portions of the holding tabs 1430 a, 1430 b are configured to engage the threads on the pin 1799 (e.g., at the protruding first and/or second distal end) when and after the securing tabs 1410 a, 1410 b are bent due to the insertion of the pin 1799. In particular, the end portions prevent the pin 1799 from being drawn by forces in the opposite direction of the direction of insertion. Accordingly, the securing tabs 1410 a, 1410 b prevent tiles from disconnected to one another after the tiles have been connected.
Securing apertures 1740 a, 1740 b are located at either side of the second pin hole 1710 b for receiving the securing tabs 1410 a, 1410 b. The securing tabs 1410 a, 1410 b are configured to be bendable at or around the respecting bending locations 1415 a, 1415 b away from the lock body 1420. In particular, the securing tabs 1410 a, 1410 b are bent to be received at the securing apertures 1740 a, 1740 b. At least a portion (e.g., an end portion) of the securing tabs 1410 a, 1410 b is in contact with an exterior surface (e.g., the surface opposite to the interior surface of the strip bracket 1700 and facing the neighboring tile) of the strip bracket 1700. The end portion of the securing tabs 1410 a, 1410 b is bent toward the pin 1799 (also the second pin hole 1710 b) or away from the pin 1799 (and the second pin hole 1710 b) to be secured on the exterior surface of the strip bracket 1700.
While this specification contains many specific implementation details, these should not be construed as limitations on the scope of any inventions or of what may be claimed, but rather as descriptions of features specific to particular implementations of particular inventions. Certain features that are described in this specification in the context of separate implementations can also be implemented in combination in a single implementation. Conversely, various features that are described in the context of a single implementation can also be implemented in multiple implementations separately or in any suitable subcombination. Moreover, although features may be described above as acting in certain combinations and even initially claimed as such, one or more features from a claimed combination can in some cases be excised from the combination, and the claimed combination may be directed to a subcombination or variation of a subcombination.
Similarly, while operations are depicted in the drawings in a particular order, this should not be understood as requiring that such operations be performed in the particular order shown, in sequential order or that all illustrated operations be performed to achieve desirable results. In certain circumstances, multitasking and parallel processing may be advantageous. Moreover, the separation of various system components in the implementations described above should not be understood as requiring such separation in all implementations and it should be understood that the described program components and systems can generally be integrated together in a single software product or packaged into multiple software products.
Thus, particular implementations of the subject matter have been described. Other implementations are within the scope of the following claims. In some cases, the actions recited in the claims can be performed in a different order and still achieve desirable results. In addition, the processes depicted in the accompanying figures do not necessarily require the particular order shown, or sequential order, to achieve desirable results. In certain implementations, multitasking or parallel processing may be utilized.

Claims

What is claimed is:

1. A system for connecting a first mat tile to a second mat tile, the system comprising:

a first fastener, the first fastener comprising:

a first aperture for receiving a first rod, the first rod being embedded in the first mat tile;

a first surface having a first pin hole; and

a second surface having a second pin hole;

a second fastener, the second fastener comprising:

a second aperture for receiving a second rod, the second rod being embedded in the second mat tile;

a third surface having a third pin hole; and

a fourth surface having a fourth pin hole;

a pin inserted into the first pin hole of the first surface, the second pin hole of the second surface, the third pin hole of the third surface, and the fourth pin hole of the fourth surface when the third surface is between the first surface and the second surface, and when the second surface is between the third surface and the fourth surface, to secure the first rod and the second rod together when embedded in the respective mats in order to secure the mats together.

2. A system for connecting a first mat tile to a second mat tile, the system comprising:

a first U-shaped bracket, the first U-shaped bracket comprising:

at least one first aperture for receiving a first rod embedded in the first mat tile;

a first surface having a first pin hole; and

a first pin lock;

a second U-shaped bracket, the second U-shaped bracket comprising:

at least one second aperture for receiving a second rod embedded in the second mat tile;

a second surface having a second pin hole; and

a second pin lock;

a pin inserted into the first pin hole and the second pin hole to secure the first rod and the second rod together when embedded in the respective mats in order to secure the mats together, the pin being inserted into the first pin hole in a first direction and into the second pin hole in a second direction opposite to the first direction, the first pin lock being secured to a first distal end of the pin protruding beyond the first pin hole, and the second pin lock being secured to a second distal end of the pin protruding beyond the second pin hole, whereby:

the first pin lock prevents the pin from moving in the second direction once inserted; and

the second pin lock prevents the pin from moving in the first direction once inserted.

3. A system for connecting a first mat tile to a second mat tile, the system comprising:

a first strip bracket embedded into the first mat tile, the first strip bracket comprising:

a first surface;

a first pin hole; and

a first pin lock provided at the first pin hole opposite to the first surface;

a second strip bracket embedded into the second mat tile, the second strip bracket comprising:

a second surface;

a second pin hole; and

a second pin lock provided at the second pin hole opposite to the second surface;

a pin inserted into the first pin hole and the second pin hole to secure the first strip bracket and the second strip bracket together when embedded in the respective mats to secure the mats together, the pin being inserted into the first pin hole in a first direction and into the second pin hole in a second direction opposite to the first direction, the first pin lock being secured to a first distal end of the pin protruding beyond the first pin hole, and the second pin lock being secured to a second distal end of the pin protruding beyond the second pin hole, the first and second surfaces facing each other, whereby the first pin lock prevents the pin from moving in the second direction once inserted, and the second pin lock prevents the pin from moving in the first direction once inserted.