Modular surfacing system

Abstract

A modular surfacing mat that includes a base mat, a top mat secured to the base mat with an adhesive, and a top coat applied to the top of the top mat to form a protective finish. The top coat may be any coating that provides a protective top finish on the mat, and is preferably a polyurea or polyurethane. The top coat may include a colorant. The top mat is preferably at least partially made from rubber. For example, recycled rubber may be used. The adhesive that bonds the top mat to the base mat is preferably a polyurethane or a polyurea. The base mat is preferably made from a cellular foam structure. For example, cellular foam strucutre may be closed cell polyethylene foam nuggets fused together in a crosslinked matrix.

1 . A modular surfacing mat comprising: 
 a base mat;    a top mat secured to the base mat with an adhesive; and    a top coat applied to the top of the top mat to form a protective finish.    
   
   
       2 . The modular surfacing mat of  claim 1  wherein the top coat includes a colorant.  
   
   
       3 . The modular surfacing mat of  claim 1  wherein the top coat is a polyurethane.  
   
   
       4 . The modular surfacing mat of  claim 1  wherein the top coat is a polyurea.  
   
   
       5 . The modular surfacing mat of  claim 1  wherein the top mat is at least partially made of rubber.  
   
   
       6 . The modular surfacing mat of  claim 5  wherein the rubber is recycled rubber.  
   
   
       7 . The modular surfacing mat of  claim 1  wherein the adhesive is a polyurethane.  
   
   
       8 . The modular surfacing mat of  claim 1  wherein the adhesive is a polyurea.  
   
   
       9 . The modular surfacing mat of  claim 1  wherein the base mat is a closed cell foam mat.  
   
   
       10 . The modular surfacing mat of  claim 9  wherein the closed cell foam mat is formed from closed cell polyethylene foam nuggets fused together in a crosslinked matrix.  
   
   
       11 . The modular surfacing mat of  claim 1  wherein the base mat and top mat have substantially symmetric horizontal cross sections.  
   
   
       12 . The modular surfacing mat of  claim 1  wherein the base mat and top mat have three or more sides.  
   
   
       13 . The modular surfacing mat of  12  wherein the three or more sides of the base mat and top mat include tab and slot features of interlocking two or more mats together.  
   
   
       14 . A modular surfacing system comprising: 
 two or more modular surfacing mats comprising: 
 a base mat;  
 a top mat secured to the base mat with an adhesive; and  
 a top coat applied to the top of the top mat to form a protective finish,  
 wherein each base mat and top mat has three or more sides.  
   
   
   
       15 . The modular surfacing system of  claim 14  wherein the three or more sides of each base mat and top mat include tab and slot features of interlocking two or more mats together.  
   
   
       16 . The modular surfacing system of  claim 14  wherein each base mat and top mat has substantially symmetric horizontal cross sections.  
   
   
       17 . The modular surfacing system of  claim 14  wherein the top coat includes a colorant.  
   
   
       18 . The modular surfacing system of  claim 14  wherein the top coat is a polyurethane.  
   
   
       19 . The modular surfacing system of  claim 14  wherein the top coat is a polyurea.  
   
   
       20 . The modular surfacing system of  claim 14  wherein the top mat is at least partially made of rubber.  
   
   
       21 . The modular surfacing system of  claim 20  wherein the rubber is recycled rubber.  
   
   
       22 . The modular surfacing system of  claim 14  wherein the adhesive is a polyurethane.  
   
   
       23 . The modular surfacing system of  claim 14  wherein the adhesive is a polyurea.  
   
   
       24 . The modular surfacing system of  claim 14  wherein the base mat is a closed cell foam mat.  
   
   
       25 . The modular surfacing system of  claim 24  wherein the closed cell foam mat is formed from closed cell polyethylene foam nuggets fused together in a crosslinked matrix.  
   
   
       26 . The modular surfacing system of  claim 24  wherein the two or more modular surfacing mats include a first group of modular surfacing mats and a second groups of modular surfacing mats, wherein the first group of modular surfacing mats have a base mat with a first density of closed cell foam and the second group of modular surfacing mats have a base mat with a second density of closed cell foam.  
   
   
       27 . The modular surfacing system of  claim 26  wherein the first density is greater than the second density, whereby the first group of modular surfacing mats meet a higher fall height safety standard than the second group of modular surfacing mats.  
   
   
       28 . The modular surfacing system of  claim 22  wherein the first and second group of modular surfacing mats have substantially the same thickness.