Abstract: A multi-level unitary safety surface tile. The tile may be of monolithic construction. The tile may include rubber. The tile may include an upper level and a lower level. Hollow protrusions may extend between the levels. At least one protrusion may include resilient walls extending from the upper layer and converging to a protrusion bottom-cap in the lower level. Inter-protrusion ribs may span between and support adjacent protrusions. With the lower layer disposed upon an underlayer, the protrusions may support the upper level. The tile may attenuate impact forces incident upon the upper layer. The tile may constitute a unitary safety surface. The tile may include structures facilitating interlocking of adjoining tiles into a multi-tile unitary safety surface. Protrusion extensions and/or support ribs may support the structures. The tile may be manufactured in a one-piece molding process utilizing mold forms maintained parallel to opposable faces of a mold press.

Abstract: A safety surface with an engineered shock-absorbing base. The base may include one or more engineered resilient mats. The mats may be fabricated of repurposed tire rubber. The mats may be adjoined edgewise. Adjoined mats may be coupled together. The base may overlay a surface. The base may include upward-facing pockets. Interiors of the pockets may receive loose fill. An upper layer may cover the base. The upper layer may bond to the base. The upper layer may seal the loose fill within the safety surface. The upper layer may include poured-in-place surfacing. The upper layer may be textured. The upper layer may include synthetic turf. Impact upon the upper layer may be attenuated by flexion of the base. Mats may be coupled without hardware fasteners. Exterior surfaces of pockets of one mat may be nested into complementarily contoured features of an adjoining mat.

Abstract: A unitary safety surface tile. The tile may interlock with at least one other tile. Each tile may be configured for disposing on a base of loose fill. Each tile may be configured for receiving a covering of loose fill. Each tile may include a plurality of hollow pockets. Each of the pockets may connect to at least one other pocket along a top edge of each pocket. Each of the pockets may engage the base of loose fill and/or receive the covering of loose fill. Each of the pockets may include one or more apertures for allowing passage of fluid through each of the pockets. Each tile may further include a plurality of edges. The edges may border the plurality of pockets. Each of one or more of the edges may be adapted for engaging at least one edge of at least one other unitary safety surface tile.

Abstract: A unitary safety surface tile is provided. The tile may interlock with at least one other tile. The tiles may be configured for disposing on a base of loose fill and for receiving a covering of loose fill. The tiles may include a plurality of hollow inverted pyramidal shaped pockets. Each of the pockets may connect to at least two other pockets along a top edge of each pocket. Each of the pockets may engage the base of loose fill and/or receive the covering of loose fill. Each of the pockets may include one or more apertures for allowing passage of fluid through each of the pockets. Each tile may further include a plurality of edges. The edges may border the plurality of pockets. Each of at least two of said plurality of edges may be adapted for engaging at least one edge of at least one other tile.

Abstract: Method for manufacturing a unitary mat on site includes placing loose fill material into a defined area in which the mat is to be formed, mixing rubber particles with at least one binder to form a mixture, placing the mixture over the loose fill material, and allowing the mixture to dry whereby the dried mixture in combination with the loose fill material forms the unitary mat. In one embodiment, the loose fill material includes only rubber particles, without a binder. The mixture placed over these loose rubber particles seals and contains the loose rubber particles. The mixture may incorporate color, e.g., by adding a colorant to the mixture and/or using colored rubber particles. Alternatively or additionally, an additional, colored mixture may be prepared and placed over the dried mixture.

Abstract: Method for manufacturing a unitary mat on site includes placing loose fill material into a defined area in which the mat is to be formed, mixing rubber particles with at least one binder to form a mixture, placing the mixture over the loose fill material, and allowing the mixture to dry whereby the dried mixture in combination with the loose fill material forms the unitary mat. In one embodiment, the loose fill material includes only rubber particles, without a binder. The mixture placed over these loose rubber particles seals and contains the loose rubber particles. The mixture may incorporate color, e.g., by adding a colorant to the mixture and/or using colored rubber particles. Alternatively or additionally, an additional, colored mixture may be prepared and placed over the dried mixture.