Field

This invention relates to a vibration resistant construction component, such as a floor or wall panel, floor tile, floor board, support strut or partition member that when combined form a slab.

Background

It is widely understood that the transmission of high frequency vibrating forces, through the human body, can causes irreversible damage. It is also understood that repeated, relatively low level impact forces on the human body, can also cause harm and irreversible injury over time.

In many jurisdictions maximum daily vibration exposure levels are prescribed by legislation, for example in the workplace to help keep employees safe. In the UK, these maximum daily vibration exposure levels are typically set by the ‘Health & Safety Executive’ or HSE.

However, in some circumstances, for example because of the nature of work or due to the limited space available, it has not always been possible to provide an optimal solution to reducing shock and vibration to an acceptable safe level.

Examples of such situations are where vehicles (or marine craft) have to travel across undulating terrain (or rough seas) quickly, which often results in exposure of occupants to high levels of vibration and sometimes exposure to unpredictable and intense shock forces.

Specific examples of where such high levels of vibration and unpredictable and intense shock forces are experienced occur in a footwell of certain categories of fast heavy off-road vehicles and when standing on a deck of small fast boats vehicles or craft. The invention arose in order to mitigate the aforementioned problems by providing a vibration resistant construction component which may be formed into a floor panel, wall panel, floor tile, floor board, support strut or partition or another rigid item.

Prior Art

UK patent application GB 2 589 839A (Sea Sure ltd) discloses a seat with shock absorbers that may be formed of a resilient material such as a thermoplastic polyurethane polymer, that contact each other when they are resiliently deformed by an applied force.

International patent application WO 0231377A2 (SKYDEX TECHNOLOGIES INC) discloses a flexible, shock absorbing component providing cushioning for surfaces, especially wall and floor surfaces. The shock absorbing component includes two sheets of thermoplastic, each sheet with inwardly facing, opposing, resiliently compressible indentations extending into a cavity between the two sheets.

Korean patent application KR 2015/0089634 (KIM KYOUNG JOONG) discloses a cushion moulding panel made by injection moulding a soft synthetic plastics material.

There is a need for a vibration resistant construction component which is lightweight and is capable of absorbing a wide variety of impact forces including high frequency repetitive forces of relatively modest magnitudes, as well as lower frequency more intense forces or shocks.

Summary of the Invention

According to a first aspect of the present invention there is provided a vibration resistant construction component comprises: a first platform connected to a second platform by a plurality of pairs of adjacent curved ribs, the curved ribs deform elastically upon application of a compressive force which squeezes the first and second platforms together until pairs of adjacent curved ribs contact one another, the curved ribs have a profile that is dimensioned to increase an area of contact between pairs of adjacent curved ribs, in dependence of the magnitude of the compressive force, and thereby increase the stiffness of the construction component.

By virtue of the increase in the contact area between adjacent curved ribs, the invention therefore effectively increases the stiffness of the construction component, to the compressive force in dependence on the magnitude of the compressive force and in a passive manner, that is without the need for any external control or stiffness varying means.

In some embodiments of the vibration resistant construction component the pairs of adjacent curved ribs curve towards one another at their centres and apart at their longitudinal edges, along which they are connected to the first and second platforms.

In some embodiments the curved ribs have a profile that is substantially constant.

Optionally pairs of adjacent curved ribs have a profile that is tapered. An advantage with this configuration is that the component is tuneable to specific frequencies or types or magnitudes of forces.

In another embodiment the vibration resistant construction component has pairs of adjacent curved ribs whose profile varies along their lengths. The ribs with these varying profiles may be used in some regions of the construction component in order to impart a specific impacts resistance capability or to dampen a specific force which occurs, or is likely to occur, in its vicinity. It is appreciated therefore that the construction component may have varying regions of impact resistance according to a specific user requirement.

Preferably a slab is formed from a construction component, in which its, that is the pairs of adjacent curved ribs, are parallel one to another across an entire length of the construction component, and the construction component is sandwiched between sheets of material. The material may be wood, such as plywood, or a synthetic plastics material, such as polyethylene, or metal, such as aluminium. Adjacent construction components may be bonded together over their entire contacting surfaces or they may be connected one to another at a plurality of separate locations. In the latter arrangement it will be appreciated that a greater degree of flexure is achieved, whereas in the former arrangement the slab tends to be stiffer.

Alternatively, a slab may be formed from a construction components in which its elements are arranged in an offset manner, so that pairs of adjacent curved ribs are staggered to form an array. An advantage of this arrangement is that the construction component has a consistent bending coefficient in both lengthwise (y- axis) and across (x-axis) because pairs of adjacent curved ribs along one axis of the array are offset from pairs of adjacent curved ribs along an adjacent axis of the array.

In another embodiment a slab is formed from multiple layers of the construction component. Optionally these multiple layers may be the same or of different thicknesses and/or the elements (pairs of adjacent curved ribs) which are contained in each layer may be the same or of different thickness, or formed from materials with different stiffnesses and/or adjacent layers are oriented so the axes of different layers of elements are in different directions.

Optionally an anti-slip coating or mat is provided on at least one of the upper or lower surfaces of the construction component.

In another embodiment a metal plate or composite material or polymer may be overlaid or bonded to a slab or a single construction component in order to form a blast panel or shock absorbing sheet.

In some embodiments a polymer, a para-aramid synthetic fibre material, such as Kevlar (RTM), may be used to provide strength and impact resistance.

In some embodiments a heat resistant material, such as cold-formed polyurethane polymer matting, may be placed over or bonded to the vibration resistant construction component. Ideally interspacing of the pairs of adjacent curved ribs is selected according to a range of magnitudes of shock forces and vibration forces. Therefore, when a relatively flexible construction component is required the distance between pairs of adjacent curved ribs are selected such that they tuned to absorb certain frequency ranges of vibrating impact forces.

Alternatively, when a stiffer construction component is required the distance between elements (pairs of adjacent curved ribs) may be less so that they are spaced more closely together.

Typically pairs of curved ribs are spaced around 10.00 mm apart at their closest, unrelaxed centres, more preferably pairs of curved ribs are spaced around 5.00 mm apart at their closest, unrelaxed centres, and most preferably pairs of ribs are spaced around 2.00 mm apart at their closest, unrelaxed centres.

In addition to varying the interspacing of the pairs of adjacent curved ribs, arranged in pairs as elements, or as an alternative thereto, the thickness of each curved rib in the vibration resistant construction component, is selected according to a range of magnitudes of shock forces and vibration forces. For example, alternating elements in an array forming the construction component have different thicknesses and/or ribs have varying tapering in order to be adapted to absorb specific vibrations or shock loads.

In some embodiments ends or edge portions of the construction component are open. This reduces the need for any complex control or excess maintenance and ensures that the vibration absorbing properties are substantially homogeneous across the entire surface of the construction component. However, end or edge caps or covers may be deployed to prevent ingress of debris or any solid materials into an interior of the construction component, which could impair the efficiency of the construction component, as such debris might bridge the gaps and so transmit forces which may lead to damage to the construction component or to the item it is protecting. The elastic material used is ideally a thermoplastic vulcanised polymer (TPV), such as a Santoprene (RTM) which is an elastic material which flexes and compresses in order to absorb impact forces. Preferably pairs of adjacent curved ribs are formed from an elastic material, such as a cured ethylene propylene diene monomer (EPDM) rubber with particles encapsulated in a polypropylene matrix.

Ideally the Shore A hardness of the elastic material is in the range from 60 to 80. However, it is appreciated that the particular stiffness properties of the material are selected as required by the application and nature of the type of shocks that the construction component will experience.

In some embodiments the vibration resistant construction component reduces high frequency vibrations (for example in excess of 10Hz) without accelerations typically, for example below 2g. Therefore, for example, the vibration resistant construction component reduces transmission from a vehicle chassis (or deck of a boat) to a person standing, sitting or kneeling on it.

In one embodiment the thickness of the upper and lower surface of the construction component can be varied. Likewise the thickness of the upper and lower surface of the construction component can be variable throughout its length and/or width.

In one embodiment a vibration and shock mitigation mat, decking or slab includes a plurality of individual vibration resistant construction that are resilient to compression from vibration and shock impact.

Preferred embodiments of the invention will now be described, by way of example only, and with reference to the following Figures in which:

Brief Description of Figures

Figure 1 shows an overall view of a construction component and with two pairs of adjacent curved ribs; Figured 2 shows an alternative embodiment of the construction component with webbing, defined by interconnected ribs, of a greater thickness (t) than the embodiment shown in Figure 1 ;

Figure 3 shows an above plan views of offset construction components elements;

Figure 4 shows how adjacent elements are interconnected by way of holes formed in curved edges 40;

Figure 5 shows how adjacent elements, formed from at least a pair of adjacent curved ribs, are connected one to another using a nylon line;

Figure 6 shows an overall view of an array of offset elements interconnected to form a mat or slab;

Figure 8 is an overall view of the mat with an overlying anti-slip surface;

Figure 9 is a diagrammatic view showing how force (F) urges pairs of ribs to increase the contact area (A) thereby increasing the stiffness to an incident shock;

Figure 10 is an overall diagrammatic view of an example of a composite slab comprising two construction components overlaid one on another, with an adhesive bonding layer therebetween; and

Figure 11 is an overall diagrammatic view of another example of a composite slab comprising two construction components overlaid one on another and sandwiched between upper and lower sheets of material which are bonded to the construction components with an adhesive bonding layer.

Detailed Description of Preferred Embodiments of the Invention

Referring to the Figures a vibration resistant construction component 10 comprises: a first platform 12 connected to a second platform 14 by a plurality of pairs of adjacent curved ribs 16a and 16b. Referring to Figures 1 and 2, the pairs of curved ribs 16a and 16b deform elastically upon application of a compressive force F which squeezes the first platform 12 and second platform 14 together, in the direction of arrow F, until pairs of adjacent curved ribs 16a, 16b and 16c, 16d contact one another at area A shown diagrammatically in Figure 9.

The pairs of curved ribs 16a, 16b have a profile P? that is dimensioned to increase the area A of contact between the pairs of adjacent curved ribs 16a and 16b, in dependence of the magnitude of the compressive force F. This thereby increases the stiffness of the construction component.

Referring to Figure 9, which shows diagrammatically how the pairs of curved ribs 16a and 16b deform elastically upon application of the compressive force F shown as a series of incrementally increasing point loads L1 , L2, L3 and L4 which squeezes the first (upper) platform 12 and second (lower) platform 14 together. The first platform 12 and second platform 14 are imperative to the operational functionality.

The first platform 12 and second platform 14 ensure that pairs of curved ribs are open ended annuli held together in a parallel manner. They the first platform 12 and second platform 14 hold the pairs of curved ribs 16a, 16b firmly in place as they are forced horizontally together and progressively stiffen as the pairs of curved ribs 16a, 16b ribs meet and deform. This enables the device to resist and attenuate vertical shock and vibrational forces of differing frequencies and amplitudes.

Figure 9 shows:

1 . At L1 the ribs 16 of material support a static load.

2. At L2 the load increases, and the ribs 16 deform and touch, resisting further movement and so begin to stiffen the structure.

3. At L3 the intersection of the ribs 16 start to form a vertical member, which goes into compression and is therefore much “stiffer”, resisting the higher load. 4. At L4 the intersection continues to extend the vertical section and so increases still further.

5. The ribs 16 in effect define webs of material and have thickness which can vary according to the nature of vibration and shocks they are intended to absorb. The pairs of curved ribs 16a, 16b are sufficiently stiff to maintain their form when a static load is applied. This may be for example a person standing, kneeling or resting their feet on a floor or deck or whilst in a sitting position.

Figure 2 shows an alternative embodiment of the construction component with ribs that define a layer of a greater thickness than the embodiment in Figure 1 . Figure 4 shows how adjacent elements, consisting of pairs of adjacent curved ribs, are interconnected by way of hole 20a formed in the first platform 12 and hole 20b formed in the second platform 14. Holes 20d and 20c are formed on opposite sides of the first 12 and second 14 platforms respectively and on opposite sides of tabs (as shown in Figure 6. Figure 5 shows how adjacent pairs of elements 10A and 10B are connected one to another using a nylon line or wire 50 which passes through the aforementioned holes.

Figure 6 shows an overall view of an array of elements 25, 27 and 29 interconnected to form a mat or slab. Element 25 in one group (or row) is aligned with element 27 in an adjacent group (or row). End tabs 24, 26 are shaped and dimensioned to interengage one with another and to assist in retaining the elements in an array. In an alternative embodiment the elements in one group (or row) may be offset (not shown) from elements in an adjacent group (or row).

Figure 7 is an overall view of the mat or slab with an overlying anti-slip surface 77.

Figure 8 is a diagrammatic view showing how an increasing force (L1 , L2, L3 and L4) urges pairs of adjacent ribs to increase their contact area A, thereby increasing the stiffness.

1. The gap between the ribs can be varied. 2. In one embodiment the thickness of the ribs can be varied, it can be parallel or variable throughout its length.

3. The height between the lower platform and upper platform can vary. This version is 38mm.

4. An approved automotive grade of the material can also be used for inside the cabin of a vehicle or boat.

Figure 10 is an overall diagrammatic view of an example of a composite slab 100 comprising two construction components 42, 52 overlaid one on another. The construction components 42, 52 may be connected together by way of mechanical connectors (not shown) and are offset, ideally at right angles one to another. An adhesive bonding layer 60 is applied between construction components 40, 52.

Figure 11 is an overall diagrammatic view of another example of a composite slab 200 comprising two construction components 70, 80 which are offset at right angles one to another. The construction components 70, 80 placed one on another and are sandwiched between upper 90 and lower 92 sheets of material and may be connected to the upper 90 and lower 92 sheets of material by way of mechanical connectors (not shown) or an adhesive layer. The construction components 70, 80 may be connected together with an adhesive bonding layer 65 or with mechanical connectors (not shown).

A top hard-wearing surface 77, which may be painted or coated with a waterproof or anti-slip paint can be attached to the surface of the slab, as shown for example in Figure 10.

Optionally in an alternative, the slab formed from two or more construction components, may be coated with or have impregnated therein or be formed from an automotive flame and smoke resistant grade material.

It will be appreciated that three (or more) layers of construction components may be used, in which case, the three construction components may be offset at 60° one to another. The construction component 10 is made up from flexible elements comprising pairs of ribs 16 arranged in horizontal lengths or sections, as shown for example in Figures 1 and 2. The density of the material from which the ribs 16 are formed, the shape of the ribs and the thickness of the ribs can vary enabling the structure to be “tuned” to absorb a range of different types of shock and vibration frequencies.

Typical ratios of intersection (i) to rib thickness for a flooring material are:

The invention has been described by way of examples only and it will be appreciated that variation to the aforementioned embodiments may be without departing from the scope of protection as defined by the claims.