Aspects of construction of safety mats

Abstract

An array of resilient floor tiles is assembled into a continuous sheet after being laid down. An array of included, sacrificial resistive wires is buried along the edges of the tiles and is controllably heated in order to cause welding of the edges of tiles across the paths of the wires to neighbouring tiles. Subsequently the wires may be used to give the array integral tensile strength. The welded array is provided with greater strength for resisting use, expansive and contractile forces caused by environmental heat and cold and also long-term tile contraction owing to loss of plasticiser as may be seen with PVC-based tiles.

1 . A method for joining together flexible, resilient tiles having complementary edge configurations, comprising the steps of:
 positioning a plurality of the tiles in an array with complementary edges aligned;   extending an elongate, electrically conductive, sacrificial member with tensile strength greater than the material of the tiles, along and between the complementary edges;   pressing the tiles together so that complementary pairs of edges are abutted together with the conductive member engaged between them;   and heating the conductive member to melt the material of the tiles along the abutted complementary edges and thereby weld the edges together.   
     
     
         2 . A method as claimed in  claim 1 , wherein the conductive member is heated to a temperature in the range from 140° C. to 180° C. 
     
     
         3 . A method as claimed in  claim 1 , further including the step of connecting the conductive member to an electricity supply and control means, whereby the conductive member is heated by resistance to an electric current passed through it. 
     
     
         4 . A method as claimed in  claim 3 , wherein the electric current produces a power input in the range from about 50 to 150 watts per metre length of the conductive member. 
     
     
         5 . A method as claimed in  claim 3 , wherein the conductive member is flexible, and is comprised of at least one wire. 
     
     
         6 . A method as claimed in  claim 5 , wherein the wire is formed from a stainless steel. 
     
     
         7 . A method as claimed in  claim 5 , wherein the wire is comprised of two or more entwined strands. 
     
     
         8 . A method as claimed in  claim 1 , wherein the conductive member is arranged with a section projecting beyond the edges of the tiles at both ends; further including the step of attaching the projecting sections to anchoring means; whereby the array of tiles can be anchored to a substrate by the anchoring means and the conductive member. 
     
     
         9 . A method as claimed in  claim 1 , wherein the step of pressing the tiles together is achieved by means including a clamp comprised of at least one pair of tile-engaging elements movably mounted with respect to each other on a support structure, and a drive mechanism by which the paired tile-engaging elements can be moved with respect to each other;
 further including the step of applying the clamp across adjoining tiles with the tile-engaging elements of at least one pair being each engaged with a different said tile;   and the step of operating the drive mechanism to move the tile-engaging elements closer together, to press the tiles together.   
     
     
         10 . A method as claimed in  claim 9 , wherein the tiles have apertures therein, and the tile-engaging elements comprise projections adapted to fit into the apertures;
 and the step of applying the clamp across adjoining tiles includes engaging the projections in the apertures.   
     
     
         11 . A method as claimed in  claim 1 , wherein supplementary heat for remedying local deficiencies is obtained by use of a heated metal block. 
     
     
         12 . Apparatus for performing the method of  claim 1 , including:
 a plurality of flexible and resilient tiles having upper and lower surfaces and a plurality of edges such that apposed edges of said tiles can be aligned in order to provide substantially continuous conjoined upper and lower surfaces;   an elongate, flexible electrically conductive member of a length greater than an edge of the tiles, with tensile strength greater than the material of the tiles;   and means to heat the conductive member.   
     
     
         13 . Apparatus as claimed in  claim 12 , wherein the plurality of flexible and resilient tiles have complementary, configurations such that edges of two said tiles can be aligned and adjoined to provide substantially continuous conjoined upper and lower surfaces 
     
     
         14 . Apparatus as claimed in  claim 12 , wherein the conductive member is comprised of stainless steel wire. 
     
     
         15 . Apparatus as claimed in  claim 12 , wherein the conductive member is a wire comprised of two or more entwined strands. 
     
     
         16 . Apparatus as claimed in  claim 12 , wherein the means to heat the conductive member comprises an electricity supply and control means, and connecting means adapted to connect to the conductive member so as to pass a voltage-controlled and time-controlled electric current through the member, and includes means for indicating the delivered voltage and current. 
     
     
         17 . Apparatus as claimed in  claim 16 , wherein the electricity supply includes means for controlling the time of delivery and displaying a recommended cooling time. 
     
     
         18 . Apparatus as claimed in  claim 12 , further including a clamp comprised of at least one pair of tile-engaging elements movably mounted with respect to each other on a support structure, and a drive mechanism by which the paired tile-engaging elements can be moved with respect to each other. 
     
     
         19 . Apparatus as claimed in  claim 18 , wherein the drive mechanism includes a lever adapted and arranged to move at least one said tile-engaging element. 
     
     
         20 . Apparatus as claimed in  claim 18 , wherein the tiles have apertures in at least one said surface, and the tile-engaging elements comprise projections shaped and arranged to fit into and engage with the apertures. 
     
     
         21 . Apparatus as claimed in  claim 18 , further including a plurality of anchors each adapted to be fixed into a substrate and to be attached to an adjacent end of the conductive member.