Polymorphic Interlocking and Interchangeable Base System for Architectural, Landscape, and Recreational Feature Installations

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the priority benefit of U.S. Provisional Patent Application Ser. No. 63/682,473 filed on Aug. 13, 2024 and titled “POLYMORPHIC INTERLOCKING AND INTERCHANGEABLE BASE SYSTEM FOR INTERIOR/EXTERIOR ARCHITECTURAL AND/OR LANDSCAPE AND/OR SPORT AND RECREATION FEATURE INSTALLATION SYSTEM.” The aforementioned disclosure is hereby incorporated by reference herein in its entirety including all references cited therein.

FIELD OF THE INVENTION

The present disclosure relates generally to base and support systems for architectural, landscape, and recreational feature installations, and more specifically to polymorphic interlocking and interchangeable systems for creating versatile and durable structural foundations.

SUMMARY

Some embodiments include a system for forming a base for architectural, landscape, or recreational feature installations, including: a plurality of expanded polymer units, each expanded polymer unit including: a polymer base body having a planar top surface; a plurality of lateral edges; and a stepped transition surface adjacent each lateral edge, the stepped transition surface including a series of horizontal load-supporting steps perpendicular to a gravity vector; lateral interlocking features disposed on the plurality of lateral edges, the lateral interlocking features including complementary male and female profiles configured to engage corresponding male and female profiles of another expanded polymer unit to align adjacent planar top surfaces seamlessly; vertical interlocking profiles configured to engage corresponding vertical interlocking profiles of another expanded polymer unit to support stacking of expanded polymer units in a vertical interlocked assembly; a protective polymer coating applied to the planar top surface and to the stepped transition surface, the protective polymer coating including an elastomeric material configured to bond to the stepped transition surface; and wherein the lateral interlocking features enable rotational orientation of each expanded polymer unit in 90-degree increments relative to adjacent units to form horizontal interlocked assemblies without redesign of polymer base bodies; wherein the engaged lateral interlocking features maintain alignment in both horizontal and vertical planes to form a congruent, continuous structural foundation; and wherein each expanded polymer unit is field-modifiable by cutting or machining to accommodate insertion of at least one of plumbing, electrical components, structural elements, or decorative elements without altering the lateral interlocking features.

Some embodiments include a system, wherein the polymer base body of each expanded polymer unit includes expanded polymer foam.

Some embodiments include a system, wherein the stepped transition surface of each expanded polymer unit includes a series of stair-stepping transitions perpendicular to a gravity vector.

Some embodiments include a system, wherein the protective polymer coating has a thickness in a range of 0.1 inch to 1.0 inch.

Some embodiments include a system, wherein each expanded polymer unit further includes corner alignment features at each vertex of the polymer base body.

Some embodiments include a system, wherein the lateral interlocking features include complementary dovetail-shaped male and female profiles.

Some embodiments include a system, wherein the vertical interlocking profiles include complementary pin and socket features configured to align and support stacking of the expanded polymer units.

Some embodiments include a system, wherein each expanded polymer unit has a thickness of between 1 inch to 144 inches.

Some embodiments include a system, wherein the protective polymer coating includes a self-leveling elastomeric polymer curing within two hours, the curing being cross-linking of the protective polymer coating after application, resulting in a solid, durable finish.

Some embodiments include a system, further including a finishing overlay templated to an arrangement of the expanded polymer units, wherein the finishing overlay is one or more of artificial turf, stone veneer, and synthetic rubber.

Some embodiments include a system, wherein the protective polymer coating is applied to all sides of each expanded polymer unit.

Some embodiments include a system, wherein an adhesive used to join adjacent expanded polymer units includes an acrylic polymer adhesive.

Some embodiments include a system, wherein each expanded polymer unit is configured to be joined to another unit at any rotational orientation selected from 0 degrees, 90 degrees, 180 degrees, or 270 degrees.

Some embodiments include a system, wherein the lateral interlocking features are configured to maintain alignment of adjacent planar top surfaces in both horizontal and vertical planes.

Some embodiments include a system, wherein each expanded polymer unit is configured to accommodate the insertion of a drainage system.

Some embodiments include a system, wherein the protective polymer coating undergoes a chemical reaction and includes an elastomeric material having a hardness in of range of Shore D hardness of between 50 to 70.

Some embodiments include a system, wherein each expanded polymer unit further includes a gap in the protective polymer coating adjacent each lateral edge to facilitate seamless joining of adjacent units.

Some embodiments include a system, wherein the system further includes a kit including pre-cut overlays templated to an arrangement of the expanded polymer units.

Some embodiments include a process for forming a base for architectural, landscape, or recreational feature installations, the process including: manufacturing a stepped transition surface on a plurality of expanded polymer units using a single high-speed pass of a computer numerical control (CNC) machine; providing the plurality of expanded polymer units, each expanded polymer unit including: a polymer base body having a planar top surface; a plurality of lateral edges; wherein the stepped transition surface is adjacent each lateral edge, the stepped transition surface including a series of horizontal load-supporting steps perpendicular to a gravity vector; lateral interlocking features disposed on the plurality of lateral edges, the lateral interlocking features including complementary male and female profiles configured to engage corresponding male and female profiles of another expanded polymer unit; vertical interlocking profiles configured to engage corresponding vertical interlocking profiles of another expanded polymer unit; and a protective polymer coating applied to the planar top surface and to the stepped transition surface, the protective polymer coating including an elastomeric material configured to bond to the stepped transition surface; arranging the plurality of expanded polymer units such that the lateral interlocking features of adjacent units engage to align adjacent planar top surfaces seamlessly; rotating at least one of the plurality of expanded polymer units in 90-degree increments relative to adjacent units to achieve a desired configuration; stacking at least one expanded polymer unit on another expanded polymer unit by engaging the vertical interlocking profiles to form a vertical interlocked assembly; applying an adhesive to the lateral edges of adjacent expanded polymer units to bond the adjacent expanded polymer together, thereby forming a continuous structural foundation; filling any gaps in the protective polymer coating at the lateral edges with additional protective polymer coating to create a seamless surface transition; and modifying at least one expanded polymer unit by cutting or machining to accommodate insertion of at least one of plumbing, electrical components, structural elements, or decorative elements without altering the lateral interlocking features.

Some embodiments include an expanded polymer unit for forming a base for architectural, landscape, or recreational feature installations, the expanded polymer unit including: a polymer base body having a planar top surface; a plurality of lateral edges; a stepped transition surface adjacent each lateral edge, the stepped transition surface including a series of horizontal load-supporting steps perpendicular to a gravity vector; lateral interlocking features disposed on the plurality of lateral edges, the lateral interlocking features including complementary male and female profiles configured to engage corresponding male and female profiles of another expanded polymer unit to align adjacent planar top surfaces seamlessly; vertical interlocking profiles configured to engage corresponding vertical interlocking profiles of another expanded polymer unit to support stacking of expanded polymer units in a vertical interlocked assembly; a protective polymer coating applied to the planar top surface and to the stepped transition surface, the protective polymer coating including an elastomeric material configured to bond to the stepped transition surface; wherein the lateral interlocking features enable rotational orientation of the expanded polymer unit in 90-degree increments relative to adjacent units to form horizontal interlocked assemblies without redesign of polymer base bodies; wherein the engaged lateral interlocking features maintain alignment in both horizontal and vertical planes to form a congruent, continuous structural foundation; and wherein the expanded polymer unit is field-modifiable by cutting or machining to accommodate insertion of at least one of plumbing, electrical components, structural elements, or decorative elements without altering the lateral interlocking features.

BACKGROUND OF THE INVENTION

The approaches described in this section could be pursued, but are not necessarily approaches that have previously been conceived or pursued. Therefore, unless otherwise indicated, it should not be assumed that any of the approaches described in this section qualify as prior art merely by virtue of their inclusion in this section.

The installation of architectural, landscape, and recreational features, whether indoors or outdoors, relies significantly on the availability of robust base and support systems. These systems are designed to accommodate a wide range of applications, including playground structures, synthetic turf areas, sculptural elements, water features, golf greens, sports practice facilities, and landscape mounds. Each application imposes distinct requirements for shape, load-bearing capacity, and environmental compatibility. Despite advances in construction techniques, there continues to be a pronounced need for a foundation solution that can seamlessly adapt to both interior spaces and exterior environments without requiring extensive redesign or specialized tools for each new project.

Existing approaches attempt to address these demands through naturally derived materials such as soils, sands, and aggregates, or through manufactured components including interlocking panel systems, premanufactured units, and framed assemblies of metal or wood. While these methods can, in isolation, deliver functional outcomes, they generally require project-specific engineering and design efforts that scale non-linearly with the size and complexity of the installation. The repeated need to customize, cut, or supplement each base unit places a considerable burden on design teams, increases material waste, and drives up overall project costs, particularly as installations grow in scale or complexity.

Naturally derived base materials, though moldable into a variety of forms, suffer from drawbacks related to durability, consistency, and cleanliness. Their mass and variability pose notable challenges for interior installations and elevated surfaces, often necessitating strict structural requirements to manage load and settlement. Conversely, manufactured panel systems tend to exhibit uniform shapes and have limited capacity to conform to non-planar geometries. On-site cutting of these panels not only reduces structural integrity but also introduces alignment and sealing difficulties. High tooling and production costs for mold-based components further limit design flexibility and make diverse shape options financially restrictive.

The reliance on multiple disparate materials and complex assembly processes exacerbates these shortcomings by introducing differential thermal expansion, uneven weight distribution, and mismatched performance characteristics. Such inconsistencies undermine long-term durability, inflate maintenance budgets, and complicate repair efforts when wear or damage occurs. Moreover, the intricate nature of current installation methods demands highly skilled laborers and extended work hours, particularly in scenarios such as rooftop installations or elevated decks where weight constraints and safety margins are of significant importance. These factors collectively highlight the pressing need for a foundational system that streamlines design, reduces labor intensity, and delivers reliable performance across a broad spectrum of feature installations.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, where like reference numerals refer to identical or functionally similar elements throughout the separate views, together with the detailed description below, are incorporated in and form part of the specification, and serve to further illustrate embodiments of concepts that include the claimed disclosure, and explain various principles and advantages of those embodiments.

FIG. 1 is a system diagram illustrating a system of expanded polymer units forming a golf green system with integrated artificial turf, fringe turf, and additional structural elements, according to various embodiments of the present technology.

FIG. 2 is a system diagram illustrating a playground system with interlocking expanded polymer units and integrated features, according to various embodiments of the present technology.

FIG. 3 is a schematic illustrating various structural and functional elements integrated into an expanded polymer unit, according to various embodiments of the present technology.

FIG. 4 is a mechanical drawing illustrating a playground base system with integrated features, including a slide and a tunnel, according to various embodiments of the present technology.

FIG. 5 is a schematic illustrating lateral interlocking features disposed on the plurality of lateral edges of expanded polymer units including rotational and alignment features, according to various embodiments of the present technology.

FIG. 6 illustrates a mechanical drawing of the vertical interlocking modular system showcasing horizontal and vertical units joined by using vertical interlocking profiles, according to various embodiments of the present technology.

FIG. 7 illustrates a projection view of stacked system units demonstrating the vertical integration of base, intermediate, and top units including vertical interlocking profiles configured to engage corresponding vertical interlocking profiles of another expanded polymer unit to support stacking of expanded polymer units in a vertical interlocked assembly, according to various embodiments of the present technology.

FIG. 8 is an exploded view illustrating the interlocking components of the system, including alignment features for seamless integration, including vertical interlocking profiles configured to engage corresponding vertical interlocking profiles of another expanded polymer unit to support stacking of expanded polymer units in a vertical interlocked assembly, according to various embodiments of the present technology.

FIG. 9 illustrates a projection view of interlocking units demonstrating edge interfaces and alignment across horizontal and vertical planes, according to various embodiments of the present technology.

FIG. 10 is an illustration showing modular expanded polymer units showcasing their polymorphic interlocking design and versatility for creating diverse structural configurations, according to various embodiments of the present technology.

FIG. 11 illustrates a projection view of the modular system showcasing the resulting shape 1100 formed by interlocking of a plurality of expanded polymer units, according to various embodiments of the present technology.

FIG. 12 illustrates a system diagram showcasing the seamless integration of a plurality of expanded polymer units using interlocking features to form resulting shape, according to various embodiments of the present technology.

FIG. 13 illustrates a schematic of the polymer unit assembly, showcasing the integration of protective coatings, adhesive joints, and seamless surface transitions between two expanded polymer units, according to various embodiments of the present technology.

FIG. 14 illustrates the stepped surface design and the structural advantages associated with the stepped surface design compared to a non-stepped surface, according to various embodiments of the present technology.

FIG. 15 illustrates a mechanical drawing of an expanded polymer unit showcasing the field modification of the expanded polymer unit through cutting, according to various embodiments of the present technology.

DETAILED DESCRIPTION OF EMBODIMENTS

While the disclosed technology may have embodiment in many different forms, there is shown in the drawings and will herein be described in detail several specific embodiments with the understanding that the present disclosure is to be considered as an exemplification of the principles of the technology and is not intended to limit the technology to the embodiments illustrated. The terminology used herein is for the purpose of describing particular embodiments and is not intended to limit the technology.

The following detailed description is provided to illustrate various embodiments and implementations of the disclosed technology. The description is intended to enable those skilled in the art to make and use the disclosed technology, but it is not intended to limit the scope of the disclosed technology to the specific embodiments described herein. The disclosed technology generally relates to modular base systems for architectural, landscape, and recreational feature installations, with particular emphasis on polymorphic, interlocking, and interchangeable designs that provide versatility, durability, and ease of installation. The disclosed system addresses challenges in creating adaptable and scalable foundations for diverse applications, including but not limited to golf greens, playgrounds, and other structural or aesthetic installations.

The examples and embodiments described herein are provided for illustrative purposes and are not intended to cover all possible variations. Certain details, familiar to those skilled in the art, may be omitted for clarity and conciseness. The described technology is not restricted to the specific configurations, materials, or methods outlined, as various modifications, substitutions, and rearrangements can be made without deviating from the principles and scope of the disclosed subject matter. The disclosed technology is intended to include all such variations and equivalents as would be recognized by those skilled in the art.

The installation of architectural, landscape, and recreational features, whether indoors or outdoors, has long been hindered by the limitations of existing base systems. Conventional approaches rely on either naturally derived materials, such as soils, sands, and aggregates, or manufactured components, such as interlocking panels, premanufactured units, and framed assemblies of metal or wood. While these methods can provide functional outcomes, they are fraught with challenges. Naturally derived materials, though moldable, lack durability, cleanliness, and consistency, making them unsuitable for precise or long-term applications. Manufactured systems, on the other hand, are often constrained by uniform shapes, limited adaptability to non-planar geometries, and the need for on-site modifications that compromise structural integrity. Both approaches require significant labor, specialized tools, and project-specific engineering, leading to increased costs, material waste, and inefficiencies, particularly for large-scale or complex installations.

The disclosed system addresses these shortcomings by introducing a polymorphic interlocking and interchangeable base system that is modular and versatile. The system employs expanded polymer units with lateral and vertical interlocking features, enabling seamless assembly across horizontal and vertical planes. Unlike traditional systems, this approach allows for extensive scalability and adaptability without the need for redesign or additional engineering. The expanded polymer units are designed with stepped transition surfaces, which enhance load distribution and bonding strength while minimizing lateral shear forces. A protective polymer coating further ensures durability and resistance to environmental factors, such as moisture and UV exposure. The modular design supports rotational orientation in 90-degree increments, enabling precise alignment and seamless integration of units, even in complex or non-linear configurations.

This innovative system significantly reduces installation time, labor intensity, and material waste. The design removes the need for disparate materials and complex assembly processes, offering a unified solution that is lightweight, durable, and field-modifiable. The system's capacity to accommodate a wide range of finishing elements, such as artificial turf, stone veneers, and fall attenuation materials, further enhances its versatility. Additionally, the modular units can be pre-cut and templated for specific applications, streamlining installation and enabling rapid replacement of worn or damaged components. By addressing the limitations of prior approaches, this system provides a transformative solution for creating adaptable, scalable, and durable foundations for architectural, landscape, and recreational installations.

FIG. 1 is a system diagram illustrating a system of expanded polymer units forming a golf green system 100 with integrated artificial turf, fringe turf, and additional structural elements, according to various embodiments of the present technology. FIG. 1 shows a plurality of expanded polymer units forming the golf green system 100. The golf green system 100 demonstrates the integration of structural and functional elements to create a durable and versatile foundation for recreational installations. The golf green system is formed by a first expanded polymer unit 101, a second expanded polymer unit 102, a third expanded polymer unit 103, and a fourth expanded polymer unit 104, which are interconnected to provide a seamless and stable base. An artificial turf putting surface 105 overlays the expanded polymer units, serving as the primary functional surface for the golf green system 100. Adjacent to the putting surface 105 is fringe turf 106, which provides a transitional area that mimics the aesthetic and functional characteristics of a real golf green. Both the artificial turf putting surface 105 and fringe turf 106 are templated to match the underlying expanded polymer units, ensuring precise alignment and ease of installation. A golf cup 107 is integrated into the system, showcasing the capability of the expanded polymer units to accommodate embedded components. This integration can occur during the manufacturing process or through on-site modification, highlighting the adaptability of the system to specific design requirements. Furthermore, the second expanded polymer unit 102 features a stone veneer 109 applied to its surface, demonstrating the system's capacity to support architectural finishes. This functionality enables aesthetic customization while preserving structural integrity. Additionally, a planter with soil 108 is positioned atop the second expanded polymer unit 102, showcasing the system's ability to accommodate landscaping elements and other load-bearing features. The modular design of the expanded polymer units enables the golf green system 100 to be installed over various surfaces, including compacted soil, concrete, or other foundational materials. The interlocking features of the expanded polymer units ensure alignment and stability across both horizontal and vertical planes, creating a cohesive and durable installation.

FIG. 2 is a system diagram illustrating a playground system 200 with interlocking expanded polymer units and integrated features, according to various embodiments of the present technology. FIG. 2 shows a plurality of expanded polymer units forming the playground system 200. For example, a first expanded polymer unit 201, a second expanded polymer unit 202, a third expanded polymer unit 203, and a fourth expanded polymer unit 204. The playground system 200 demonstrates the versatility and adaptability of the interlocking features for recreational installations. FIG. 2 shows a plurality of expanded polymer units interconnected to create a seamless and stable base for the playground installation. The interlocking features of the expanded polymer units ensure precise alignment and structural integrity across both horizontal and vertical planes, enabling the system to accommodate various design configurations. The playground system 200 is installed atop a concrete slab 205, showcasing the system's compatibility with a variety of foundational surfaces. While FIG. 2 illustrates installation on a level concrete slab 205, the system is capable of accommodating elevation changes, such as stair-stepping, slopes, or multi-level configurations, without requiring extensive redesign or additional engineering. For example, a fall attenuation system 206 is applied around a playground toy 208, providing enhanced safety for users (e.g., children) by reducing impact forces during falls. This feature highlights the system's ability to integrate functional elements tailored to specific applications. Adjacent to the fall attenuation system 206, a painted finish coat 207 is applied to the surface of the second expanded polymer unit 202, demonstrating the system's capacity for aesthetic customization. The painted finish coat 207 not only enhances the visual appeal of the playground system 200 but also provides additional protection to the underlying polymer units. Furthermore, the playground toy 208 is securely mounted onto the playground system 200, illustrating the system's capability to accommodate structural and functional components. The modular design of the expanded polymer units allows for the integration of various playground features, such as slides, tunnels, or climbing structures, either during the manufacturing process or through on-site modification. This adaptability ensures that the system can meet diverse design requirements while maintaining ease of installation and repairability. The playground system 200 demonstrates the ability of the interlocking expanded polymer units to support a wide range of finishing elements, structural components, and safety features, making the system suitable for both interior and exterior applications.

According to various embodiments, FIG. 1 and FIG. 2 each illustrate an exemplary example of the system being employed as the golf green system 100 system and as the playground system 200 where a plurality of expanded polymer units including the first expanded polymer unit 101, the second expanded polymer unit 102, the third expanded polymer unit 103, and the fourth expanded polymer unit 104 form the golf green system 100 of FIG. 1. Additionally, the first expanded polymer unit 201, the second expanded polymer unit 202, the third expanded polymer unit 203, and the fourth expanded polymer unit 204 form the playground system 200 of FIG. 2. The plurality of expanded polymer units provide unique lateral interlocking features to create the base and shape of each overall feature and/or architectural and/or structural element. Both the golf green system 100 of FIG. 1 and the playground system 200 of FIG. 2 may be installed in either an interior or exterior application. Systems of the present technology are designed to be installed over a level surface of the following, but not limited to: compacted soil, aggregates, concrete, wood, plastics, metal, masonry, and the like. For example, FIG. 2 shows the playground system 200 installed atop a level concrete slab 205. A level surface is not required as the system can be made to accommodate elevation changes such as stair stepping, different levels, slopes, and the like.

According to various embodiments, the base system allows for the overlayment, attachment, and the like, of various finishing elements to include, but not limited to: concrete, flooring materials, carpet, textiles, Ethylene Propylene Diene Monomer (EPDM), fall attenuation materials, veneers, water features, stone, and masonry, etc. Both exemplary examples the golf green system 100 and the playground system 200 provide examples of these applications. Overlaid onto the golf green system 100 is the artificial turf putting surface 105 and the fringe turf 106. In addition to the plurality of expanded polymer units being repeatable, where surface applications such as the turf putting surface 105 and fringe turf 106 are used, these overlayments are templated from the base system and are thereby readily duplicated/replicated, cut and joined together and provided with the base system as a kit for ease of installation thereby dramatically reducing installation time and man-hour requirements. This also allows for rapid and precise replacement of damaged or worn out overlayments.

According to various embodiments, the ability to attach, apply, veneer, paint, etc. various architectural and/or engineering elements is demonstrated in the exemplary examples of both the golf green system 100 and the playground system 200 where the stone veneer 109 is shown applied to the second expanded polymer unit 102. For example, a painted finish coat 207 is applied to the first expanded polymer unit 201 and the second expanded polymer unit 202. The fall attenuation system 206 is applied around the playground toy 208. For instance, the planter with soil 108 is placed atop second expanded polymer unit 102. These exemplary examples are only a few of the features, architectural, engineering, and structural elements that may be added or applied directly to the base system and are in no way meant to limit what can be added or applied to the system.

According to some embodiments, the present technology is capable of accommodating a wide range of inserted components and structural elements to include but not limited to: electrical, plumbing, beams, fasteners, tubing, anchors, playground features, landscape elements, structural features, architectural elements, decorations, sanitary systems, pet play area systems, and the like. FIG. 1 includes an example of an integrated component, the golf cup 107 which may be accommodated at the time of manufacture or may be added on site.

FIG. 3 is a schematic 300 illustrating various structural and functional elements integrated into an expanded polymer unit, according to various embodiments of the present technology. The schematic 300 of FIG. 3 includes multiple exemplary examples of elements that the system is capable of accommodating either at the time of manufacture or through on-site modification. Edge 301 edge is an exemplary example of an edge element which could be of any material and any size. Tubing 302 is an exemplary example of a tubing element which could be of any material and any size. Steel beam 303 is an exemplary example of a steel beam that may be accommodated at the time of manufacture or on-site during system installation. Structural concrete post 304 is an exemplary example of a structural concrete post with inserted threaded rods for mounting of items such as the playground toy 208 depicted in FIG. 2. The pipe 305 (e.g., conduit or plumbing) is an exemplary example of a curved pipe/conduit. Junction box 306 is an exemplary example of a junction box which can be of any size and/or application (not just electrical). Embedded drainage system 307 is an exemplary example of an embedded drainage system that may be used with the golf green system 100.

According to various embodiments, FIG. 4 is a mechanical drawing illustrating a playground base system 400 with integrated features, including a slide 403 and a tunnel 404, according to various embodiments of the present technology. The playground base system 400 is constructed using a plurality of expanded polymer units, such as a first expanded polymer unit 401 and a second expanded polymer unit 402, which are interconnected to form a seamless and stable foundation for recreational installations.

According to some embodiments, FIG. 4 provides an exemplary example of playground equipment installed into the playground base system 400 including the slide 403 and the tunnel 404. These exemplary examples are provided to showcase the limitless ability of the playground base system 400 to accommodate a wide range of components and structural elements, just to show a few examples.

In some embodiments, a first expanded polymer unit 401 and a second expanded polymer unit 402 demonstrate the modular and interlocking design of the system, which ensures precise alignment and structural integrity across both horizontal and vertical planes. This interlocking capability allows the playground base system 400 to accommodate various design configurations without requiring extensive redesign or additional engineering. The modularity of the system also enables the integration of diverse playground features, such as the slide 403 and the tunnel 404, either during the manufacturing process or through on-site modification.

According to some embodiments, the slide 403 is securely integrated into the playground base system 400, displaying the system's ability to support functional components that enhance the recreational experience. The integration of the slide 403 highlights the adaptability of the first expanded polymer unit 401 and the second expanded polymer unit 402 to accommodate structural elements with varying shapes and dimensions. Similarly, the tunnel 404 is embedded within the playground base system 400, further demonstrating the versatility of the system to incorporate features that promote interactive play. The tunnel 404 exemplifies the system's capacity to support curved and enclosed structures while maintaining overall stability and durability.

In some embodiments, the first expanded polymer unit 401 and the second expanded polymer unit 402 are designed to provide a durable and lightweight foundation that can be installed over various surfaces, including compacted soil, concrete, or other foundational materials. The protective polymer coating applied to the expanded polymer units enhances their resistance to environmental factors, such as moisture and UV exposure, ensuring long-term performance in both interior and exterior applications.

According to various embodiments, the playground base system 400 also benefits from the system's ability to accommodate elevation changes, such as slopes and mounds, as demonstrated by the integration of the slide 403 and the tunnel 404. This capability eliminates the need for additional materials or complex engineering to achieve multi-level configurations, making the system highly efficient and cost-effective for diverse playground designs.

FIG. 5 is a schematic 500 illustrating lateral interlocking features disposed on the plurality of lateral edges of expanded polymer units including rotational and alignment features, according to various embodiments of the present technology. FIG. 5 demonstrates how lateral interlocking features disposed on the plurality of lateral edges, the lateral interlocking features including complementary male and female profiles configured to engage corresponding male and female profiles of another expanded polymer unit to align adjacent planar top surfaces seamlessly. Individual expanded polymer units of the plurality of expanded polymer units interact with one another. For example, a first expanded polymer unit 501, second expanded polymer unit 502, third expanded polymer unit 503, fourth expanded polymer unit 504, and fifth expanded polymer unit 505 can be rotated 0 degrees, 90 degrees, 180 degrees, or 270 degrees to interlock with the adjacent expanded polymer units. In addition to the complementary male and female profiles 506 of the plurality of expanded polymer units, all the alignment corners 507 feature an exemplary alignment system which provides a pseudo grid feature to ensure perfect alignment with adjacent expanded polymer units and the location of installation. This exemplary example purposely does not depict the polymorphic shape capability of the system as it is intended to describe the exemplary lateral interlocking features disposed on the plurality of lateral edges, the lateral interlocking features including complementary male and female profiles configured to engage corresponding male and female profiles of another expanded polymer unit to align adjacent planar top surfaces seamlessly.

According to some embodiments, FIG. 5 shows a how individual expanded polymer units interact to form a seamless and stable assembly. The first expanded polymer unit 501 is centrally positioned and surrounded by the second expanded polymer unit 502, the third expanded polymer unit 503, the fourth expanded polymer unit 504, and the fifth expanded polymer unit 505. Each expanded polymer unit is equipped with complementary male and female profiles 506 along its lateral edges. These profiles are configured to engage corresponding profiles on adjacent units, ensuring precise alignment and a secure interlock. The interlocking mechanism allows the expanded polymer units to be rotated in 90-degree increments (0 degrees, 90 degrees, 180 degrees, or 270 degrees) while maintaining compatibility and alignment with neighboring expanded polymer units.

According to some embodiments, the alignment corners 507 are located at each vertex of the expanded polymer units. These alignment corners 507 provide an additional alignment system that ensures proper positioning of the units relative to one another. This pseudo-grid feature facilitates accurate installation and prevents misalignment during assembly. The alignment corners 507 also enhance the structural integrity of the overall system by maintaining consistent spacing and orientation between adjacent units.

According to various embodiments, the complementary male and female profiles 506 and the alignment corners 507 collectively enable the expanded polymer units to form a cohesive and continuous planar surface. This design eliminates gaps or uneven transitions between units, making the system suitable for a wide range of applications, including architectural, landscape, and recreational installations. Furthermore, the modularity of the system, as illustrated in FIG. 5, highlights the adaptability of the system to various configurations and shapes. The ability to rotate and interlock the units in multiple orientations provides significant flexibility in design, enabling the creation of complex and customized layouts without requiring additional engineering or specialized tools.

An additional fundamental feature of the system is its ability to be stacked vertically with the same unlimited options in shape. The following exemplary examples are meant to depict this ability but in no way limit the system to just these examples. The first example is where units can be stacked atop one another resulting in either solid or open cavities.

FIG. 6 illustrates a mechanical drawing 600 of the vertical interlocking modular system displaying horizontal and vertical units joined by using vertical interlocking profiles, according to various embodiments of the present technology. FIG. 6 depicts the system as an open cavity where horizontal expanded polymer unit 602 provides the horizontal unit and a first vertical expanded polymer unit 601 and a second vertical expanded polymer unit 603 provide the vertical units of the system. For example, the lateral interlocking feature 604 of the system enables the joining of the horizontal expanded polymer unit 602, the first vertical expanded polymer unit 601, and the second vertical expanded polymer unit 603.

According to some embodiments, the vertical interlocking modular system, illustrating the integration of horizontal expanded polymer unit 602 and first vertical expanded polymer unit 601 and the second vertical expanded polymer unit 603 using lateral interlocking features 604. This configuration demonstrates the system's ability to form a stable and cohesive structure by combining horizontal and vertical components.

According to some embodiments, the horizontal expanded polymer unit 602 serves as the foundational horizontal element of the system. The horizontal expanded polymer unit 602 provides a planar surface that supports the vertical components and ensures structural stability. The horizontal expanded polymer unit 602 is equipped with lateral interlocking features 604 along its edges, which facilitate seamless integration with adjacent units. These interlocking features 604 ensure precise alignment and prevent displacement during assembly or use. The system further includes the first vertical expanded polymer unit 601 and the second vertical expanded polymer unit 603, which are positioned perpendicularly to the horizontal expanded polymer unit 602. The first vertical expanded polymer unit 601 and the second vertical expanded polymer unit 603 are designed to interlock with the horizontal expanded polymer unit 602 via the lateral interlocking features 604, creating a robust vertical connection. The first vertical expanded polymer unit 601 and the second vertical expanded polymer unit 603 form open cavities, displaying the system's ability to accommodate various configurations, such as hollow or solid structures, depending on the application requirements.

According to some embodiments, the lateral interlocking features 604 play a significant role in the system, allowing the horizontal expanded polymer unit 602 to securely join with the first vertical expanded polymer unit 601 and the second vertical expanded polymer unit 603. The lateral interlocking features 604 maintain the alignment of the units in both horizontal and vertical planes, contributing to structural integrity and load distribution across the assembly. This modular design enables the development of intricate and tailored configurations without requiring extra engineering or specialized tools. The open cavity created by the first vertical expanded polymer unit 601, the second vertical expanded polymer unit 603, and the horizontal expanded polymer unit 602 demonstrates the system's versatility, making the design applicable to various uses, such as architectural, landscape, and recreational installations. The capability to stack and interlock units vertically further improves the system's flexibility, allowing for multi-level or elevated arrangements.

FIG. 7 illustrates a projection view 700 of stacked system units demonstrating the vertical integration of base, intermediate, and top units including vertical interlocking profiles configured to engage corresponding vertical interlocking profiles of another expanded polymer unit to support stacking of expanded polymer units in a vertical interlocked assembly, according to various embodiments of the present technology. FIG. 7 shows a projection view 700 of stacked system units demonstrating the vertical integration of a polymer base body 701, an intermediate expanded polymer unit 702, and a top expanded polymer unit 703. This configuration highlights the modularity and vertical interlocking capabilities of the system, which enable the creation of multi-level assemblies with structural stability and design flexibility. The polymer base body 701 serves as the foundational unit in the assembly. The polymer base body 701 features a planar top surface designed to provide a stable and uniform base for the stacking of additional units. The polymer base body 701 is equipped with vertical interlocking profiles along the surface, which are configured to engage corresponding profiles on the intermediate expanded polymer unit 702. These interlocking profiles ensure precise alignment and secure attachment between the stacked units, maintaining structural integrity across the assembly.

According to some embodiments, the intermediate expanded polymer unit 702 is positioned above the polymer base body 701 and serves as a transitional layer in the vertical stack. The intermediate expanded polymer unit 702 is designed to integrate seamlessly with both the polymer base body 701 and the top expanded polymer unit 703. The intermediate expanded polymer unit 702 includes complementary vertical interlocking profiles on both its top and bottom surfaces, enabling secure connections with adjacent units in the stack. This dual-sided interlocking capability facilitates the creation of multi-tiered configurations, making the system adaptable to a wide range of architectural, landscape, and recreational applications.

According to various embodiments, the top expanded polymer unit 703 is placed above the intermediate expanded polymer unit 702 and represents the uppermost layer in the vertical assembly. Like the intermediate expanded polymer unit 702, the top expanded polymer unit 703 is equipped with vertical interlocking profiles that engage with the corresponding profiles on the intermediate expanded polymer unit 702. The design of the top expanded polymer unit 703 allows for the integration of additional components or finishing elements, such as architectural features, landscaping elements, or recreational structures, depending on the specific application requirements.

In some embodiments, the vertical interlocking profiles utilized in this assembly are configured to ensure both lateral and rotational alignment of the stacked units. This alignment capability eliminates gaps or misalignments between the units, resulting in a cohesive and stable structure. The modular design of the system allows for the stacking of units with varying shapes and dimensions, providing significant flexibility in design and application. The configuration illustrated in FIG. 7 demonstrates the system's ability to support complex, multi-level installations without the need for extensive redesign or additional engineering. This capability makes the system highly versatile and suitable for a wide range of uses, including elevated platforms, multi-tiered landscaping features, and structural foundations for architectural elements.

FIG. 8 is an exploded view 800 illustrating the interlocking components of the system, including alignment features for seamless integration, including vertical interlocking profiles configured to engage corresponding vertical interlocking profiles of another expanded polymer unit to support stacking of expanded polymer units in a vertical interlocked assembly, according to various embodiments of the present technology. FIG. 8 shows an exploded view 800 illustrating the interlocking components of the system, which include a polymer base body 801, an intermediate expanded polymer unit 802, and a top expanded polymer unit 803. The figure highlights the complimentary vertical interlocking profiles 804 and 805 that enable seamless integration and stacking of the expanded polymer units in a vertical interlocked assembly.

According to some embodiments, the polymer base body 801 serves as the foundational unit in the assembly. The polymer base body 801 features a planar top surface designed to provide a stable and uniform base for stacking additional units. The polymer base body 801 is equipped with vertical interlocking profiles, which are configured to engage corresponding profiles such as vertical interlocking profiles 804 on the intermediate expanded polymer unit 802. These interlocking profiles ensure precise alignment and secure attachment between the stacked units, maintaining structural integrity across the assembly.

According to some embodiments, the intermediate expanded polymer unit 802 is positioned above the polymer base body 801 and serves as a transitional layer in the vertical stack. The intermediate expanded polymer unit 802 is designed to integrate seamlessly with both the polymer base body 801 and the top expanded polymer unit 803. The intermediate expanded polymer unit 802 includes complementary vertical interlocking profiles 804 and vertical interlocking profiles 805 on both its top and bottom surfaces, respectively, enabling secure connections with adjacent units in the stack. The dual-sided interlocking capability facilitates the creation of multi-tiered configurations, making the system adaptable to a wide range of architectural, landscape, and recreational applications.

According to various embodiments, the top expanded polymer unit 803, which is cylindrical in shape, is positioned above the intermediate expanded polymer unit 802 and serves as the uppermost layer in the vertical assembly. Similar to the intermediate expanded polymer unit 802, the top expanded polymer unit 803 includes vertical interlocking profiles that engage with the corresponding profiles on the intermediate expanded polymer unit 802. The cylindrical design of the top expanded polymer unit 803 highlights the system's capacity to accommodate diverse shapes and configurations, further broadening its adaptability. This component can facilitate the integration of additional elements or finishing features, such as architectural details, landscaping components, or recreational structures, depending on the specific application requirements. For example, the vertical interlocking profiles 804 and the vertical interlocking profiles 805 are configured to ensure both lateral and rotational alignment of the stacked units. This alignment capability eliminates gaps or misalignments between the units, resulting in a cohesive and stable structure. The modular design of the system allows for the stacking of units with varying shapes and dimensions, providing significant flexibility in design and application. The exploded view in FIG. 8 illustrates how the vertical interlocking profiles 804 and the interlocking profiles 805 facilitate the assembly process, ensuring that the units remain securely connected while maintaining structural integrity. This configuration demonstrates the system's capacity to support complex, multi-level installations without requiring extensive redesign or additional engineering. The modularity and interlocking capabilities of the system provide significant versatility and adaptability for a broad range of applications, including elevated platforms, multi-tiered landscaping features, and structural foundations for architectural elements. These example shapes are not intended to limit what vertical unit shapes can be created for the system as the options are limitless.

FIG. 9 illustrates a projection view 900 of interlocking units demonstrating edge interfaces and alignment across horizontal and vertical planes, according to various embodiments of the present technology. For example, because each expanded polymer unit is unique in shape unto itself, each adjoining expanded polymer unit must match the adjoining edge profile in the same vertical plane but also must match the surface plane in angle, slope, and curvature. The interlocking edge profile surfaces must also adhere to these same parameters. FIG. 9 shows an example of how these individual expanded polymer units must integrate within the system to provide a seamless and congruent base surface. For example, a first expanded polymer unit 901, a second expanded polymer unit 902, a third expanded polymer unit 903, and a fourth expanded polymer unit 904 must all join at their respective edge interfaces with the exact same vertical edge profile as shown at edge interface 905. For instance, transitioning from the second expanded polymer unit 902 to third expanded polymer unit 903, the units must remain aligned in both the horizontal plane (X, Y plane) 906 as well as the two vertical planes both vertical plane (X, Z) 908 and vertical plane (Y, Z) 907. Additionally, units must remain parallel/tangent to each other at the point of intersection to prevent misaligned/sharp edge transitions between units.

According to some embodiments, another feature of this system is the ability of the system to join with other previously created units and either expand into a much larger system and/or change shape to produce a completely different and unique installation while employing previously designed/created units alone or with the addition of newly designed/created units. Units within the system are designated by alpha/numeric organizational symbology for horizontal plane (X, Y) 906 with edges identified by letters for vertical plane (Y, Z) 907. Edges are further identified by which edge of another unit they will adjoin by the corresponding unit symbology and edge letter for vertical plane (X, Z) 908. In some instances, when more than one unit will adjoin another, the symbology is preceded by that group identifier.

According to some embodiments, FIG. 9 shows a projection view 900 of interlocking expanded polymer units, illustrating the edge interfaces 905 and alignment across horizontal and vertical planes. FIG. 9 demonstrates the seamless integration of multiple expanded polymer units, specifically the first expanded polymer unit 901, the second expanded polymer unit 902, the third expanded polymer unit 903, and the fourth expanded polymer unit 904. These units are interconnected at their respective edge interfaces 905, ensuring precise alignment and structural continuity.

According to some embodiments, the edge interface 905 is a feature of the system, designed to maintain congruence between adjoining units. Each expanded polymer unit is shaped in a specific manner to ensure that the edge profile of one unit aligns with the edge profile of the adjoining unit in the same vertical plane. This alignment plays a key role in achieving a seamless and congruent base surface. The interlocking edge profiles are engineered to adhere to strict parameters, including angle, slope, and curvature, to prevent misalignment or sharp transitions between units.

In various embodiments, the alignment of the expanded polymer units is maintained across multiple planes. In the horizontal plane (X, Y plane) 906, the units are aligned to ensure a continuous and level surface. Additionally, the alignment extends to the vertical planes, including the vertical plane (Y, Z) 907 and the vertical plane (X, Z) 908. This multi-plane alignment ensures that the units remain parallel or tangent to each other at their points of intersection, eliminating any potential for uneven or sharp edge transitions.

According to various embodiments, the modular design of the expanded polymer units allows for their integration into a cohesive system. Each unit is designed to match the adjoining units not only in edge profile but also in surface plane characteristics. This design approach ensures that the system can accommodate complex geometries and configurations without requiring additional engineering or customization. The capability to maintain alignment across all planes enhances the structural integrity and aesthetic appeal of the overall assembly, making the system suitable for a wide range of architectural, landscape, and recreational applications.

According to some embodiments, another notable feature of the system, as illustrated in FIG. 9, is the capacity for scalability and adaptability. The interlocking design enables the system to be expanded or reconfigured by adding or rearranging units. This flexibility allows for the creation of larger or custom-shaped installations while utilizing previously designed units. The alpha-numeric organizational symbology depicted in the FIG. 9 further facilitates the identification and alignment of units during assembly, ensuring precision and efficiency in installation.

FIG. 10 is an illustration showing modular expanded polymer units displaying their polymorphic interlocking design and versatility for creating diverse structural configurations, according to various embodiments of the present technology. FIG. 10 includes six distinct expanded polymer units: the first expanded polymer unit 1001, the second expanded polymer unit 1002, the third expanded polymer unit 1003, the fourth expanded polymer unit 1004, the fifth expanded polymer unit 1005, and the sixth expanded polymer unit 1006. Each unit demonstrates specific geometric features and interlocking capabilities, enabling seamless integration into a wide range of architectural, landscape, and recreational applications.

According to some embodiments, the first expanded polymer unit 1001 features a curved surface that transitions smoothly from one edge to another, displaying the system's ability to accommodate non-linear geometries. This design is particularly suited for applications requiring aesthetic or functional curvature, such as water features or sculptural elements. Each expanded polymer unit in FIG. 10 is equipped with lateral interlocking features along the edges, enabling seamless alignment and secure connections with adjacent units. These interlocking features ensure structural integrity and allow for rotational orientation in 90-degree increments, providing significant design flexibility. The polymorphic nature of the units allows for combination in various configurations, supporting the creation of complex and customized layouts without requiring additional engineering or specialized tools. The modularity and diversity of the expanded polymer units illustrated in FIG. 10 highlight the system's capacity to accommodate a virtually limitless range of shapes and configurations. This adaptability makes the system suitable for a broad spectrum of applications, from recreational installations to architectural and landscape projects.

FIG. 11 illustrates a projection view of the modular system displaying the resulting shape 1100 formed by interlocking of a plurality of expanded polymer units, according to various embodiments of the present technology. FIG. 11 demonstrates the versatility and adaptability of the system in creating complex and cohesive structural configurations. The resulting shape 1100 is constructed using multiple expanded polymer units (as shown in FIG. 10, including the second expanded polymer unit 1002, the third expanded polymer unit 1003, the fifth expanded polymer unit 1005, and the sixth expanded polymer unit 1006. Each of these units is shaped in a specific manner and equipped with lateral interlocking features that enable seamless integration with adjacent units. The interlocking features ensure precise alignment and structural stability across both horizontal and vertical planes, allowing the system to form a continuous and congruent surface.

According to some embodiments, the second expanded polymer unit 1002 serves as a foundational component within the assembly, providing a stable base for adjoining units. The third expanded polymer unit 1003 introduces a contoured surface, displaying the system's ability to accommodate non-linear geometries and create functional or aesthetic features, such as depressions or mounds. The fifth expanded polymer unit 1005 and the sixth expanded polymer unit 1006 further contribute to the overall shape by adding additional contours and structural elements, demonstrating the polymorphic nature of the system.

According to various embodiments, the modular design of the system allows for the rotational orientation of each unit in 90-degree increments, enabling the creation of diverse configurations without the need for additional engineering or customization. This flexibility is evident in the arrangement of the units within the resulting shape 1100, where the units are rotated and interlocked to form a cohesive structure. The interlocking mechanism ensures that the units remain securely connected, even under load or environmental stress. The resulting shape 1100 demonstrates the system's capacity to support a wide range of applications, including architectural, landscape, and recreational installations. The modularity and adaptability of the expanded polymer units enable the creation of complex and customized layouts, making the system suitable for both interior and exterior environments. Additionally, the system allows for the integration of various surface finishes, such as artificial turf putting surface 105, which further enhances the versatility and aesthetic appeal of the system.

FIG. 12 illustrates a system diagram displaying the seamless integration of a plurality of expanded polymer units using interlocking features to form resulting shape 1200, according to various embodiments of the present technology. FIG. 12 demonstrates the versatility and adaptability of the polymorphic interlocking system in creating complex and cohesive structural configurations. The resulting shape 1200 is constructed using multiple expanded polymer units (shown in FIG. 10), including a first expanded polymer unit 1001, a second expanded polymer unit 1002, a third expanded polymer unit 1003, and a fourth expanded polymer unit 1004. Each expanded polymer unit is distinct in shape and equipped with lateral interlocking features that enable seamless integration with adjacent units. These interlocking features ensure precise alignment and structural stability across both horizontal and vertical planes, allowing the system to form a continuous and congruent surface.

According to some embodiments, the first expanded polymer unit 1001 serves as a stable base for adjoining units. The second expanded polymer unit 1002 introduces a contoured surface, displaying the system's ability to accommodate non-linear geometries and create functional or aesthetic features, such as slopes or mounds. The third expanded polymer unit 1003 further contributes to the overall shape by adding additional contours, demonstrating the polymorphic nature of the system. The fourth expanded polymer unit 1004 acts as a transition unit, seamlessly connecting angular and rounded shapes within the assembly.

According to various embodiments, the modular design of the system allows for the rotational orientation of each unit in 90-degree increments, enabling the creation of diverse configurations without the need for additional engineering or customization. This flexibility is evident in the arrangement of the units within the resulting shape 1200, where the units are rotated and interlocked to form a cohesive structure. The interlocking mechanism ensures that the units remain securely connected, even under load or environmental stress. The resulting shape 1200 exemplifies the system's capacity to support a wide range of applications, including architectural, landscape, and recreational installations. The modularity and adaptability of the expanded polymer units enable the creation of complex and customized layouts, making the system suitable for both interior and exterior environments. Additionally, the system allows for the integration of various surface finishes, such as the artificial turf putting surface 105, which further enhances the versatility and aesthetic appeal of the system.

FIG. 13 illustrates a schematic 1300 of the polymer unit assembly, displaying the integration of protective coatings, adhesive joints, and seamless surface transitions between two expanded polymer units, according to various embodiments of the present technology. FIG. 13 shows a schematic 1300 of the polymer unit assembly, illustrating the integration of protective polymer coatings 1302, adhesive joints 1303, and smoothly transitioning unit surfaces 1306 between two expanded polymer units 1301. FIG. 13 highlights the process and components involved in achieving a cohesive and durable assembly of the expanded polymer units 1301.

According to various embodiments, the expanded polymer units 1301 are coated with a protective polymer coating 1302, which serves as a durable outer layer to enhance the resistance of the units to environmental factors such as moisture, UV exposure, and mechanical wear. The protective polymer coating 1302 is applied to the top surface of each unit and may also extend to other sides depending on the specific requirements of the installation. A gap 1307 is intentionally left in the protective polymer coating 1302 near the edges of the units to facilitate the application of additional protective coating 1304 during the joining process. The joining process begins with the dry setting of the expanded polymer units 1301, followed by the application of an adhesive acrylic polymer at the joint 1303 where the units adjoin. The adhesive acrylic polymer is preferred due to its capacity to create a homogeneous bond between the units, thereby transforming the individual units into a unified expanded polymer unit. This adhesive maintains structural integrity and prevents separation under load or environmental stress.

According to various embodiments, once the adhesive has been applied and the units are securely bonded, the gap 1307 in the protective polymer coating 1302 is filled with additional protective coating 1304. This step may be performed using a trowel 1305, which allows for precise application and ensures that the surfaces of the adjoining units transition smoothly and seamlessly into one another. The smoothly transitioning unit surfaces 1306 is uniform and free of gaps or irregularities, maintaining both the aesthetic appeal and functional performance of the assembly. The additional protective coating 1304 not only bridges the gap 1307 between the units but also reinforces the bond created by the adhesive, further enhancing the durability and longevity of the assembly. This method of joining and coating is also applicable for repairing damaged units, allowing for the restoration of the assembly to a like-new condition. The repair process involves cutting, removing, and replacing damaged sections, followed by the reapplication of adhesive and protective coating as described. The integration of protective polymer coatings 1302, adhesive joints 1303, and smoothly transitioning unit surfaces 1306 in FIG. 13 demonstrates the modularity and adaptability of the expanded polymer unit system, making the system suitable for a wide range of architectural, landscape, and recreational applications.

According to various embodiments, the expanded polymer units 1301, once shaped is coated with a thin protective polymer coating followed by an additional protective polymer top coating 1302 that has an elastomeric quality up to a hardness like concrete. This additional layer may be only applied to the top surface or all sides depending on the protective requirements of the installation. For example, the protective polymer coating may have a thickness in a range of 0.1 inch to 1.0 inch. For instance, this protective polymer coating 1302 may have a thickness from a range 0.1 inches to an upper limit defined by the needs of the installation. A gap 1307 in this protective coating 1302 is provided between the edges of the unit and the initial protective coating application to provide for an additional protective coating 1304 resulting in a uniform finish across units. This represents a manufacture completed unit ready to ship to the end-user. These units are purposely shaped flat for the purpose of clearly illustrating the system unit construction. This method applies to all units regardless of shape.

According to some embodiments, once on site and the units have been dry set together, units are permanently joined through the application of an adhesive acrylic polymer that is applied to the sides of each unit at joint 1303 where each unit adjoins the next. This acrylic polymer is the preferred method as it results in all bonded units becoming one homogenous expanded polymer unit; however, it does not mean that other adhesives cannot be used in various embodiments. Once all joints are set with the adhesive, the protective coating gap is then filled with additional protective coating 1304 using a trowel 1305 to ensure both unit surfaces smoothly, accurately and seamlessly transition to the other smoothly transitioning unit surfaces 1306. This is also the same method that would be used to repair a damaged unit in order to bring it back into a like-new condition as these units are readily repairable by simply adding new protective coating or cutting, removing and replacing and/or expanding all or part of the expanded polymer unit(s).

FIG. 14 illustrates the stepped transition surface 1401 design and the structural advantages associated with the stepped transition surface 1401 design compared to a non-stepped surface, according to various embodiments of the present technology. According to some embodiments, the manufacture of the system units 1400 (e.g., the expanded polymer units) surface shape results in stepped transition surface 1401 that are level (perpendicular to the vector of gravity) to provide additional lateral load strength to the surface coating 1402 by maintaining the load transferred to the expanded polymer unit in a vertical direction rather than a lateral, sloped shearing direction of a non-stepped surface 1403 (e.g., a smooth curved surface). For illustration purposes, the stepped transition surface 1401 shows the implications of a downward sloped, lateral shear load of the non-stepped surface 1403. FIG. 14 illustrates the specific surface geometry of the expanded polymer units, which incorporates a series of horizontal load-supporting steps (e.g., stepped transition surface 1401) to improve structural integrity and load distribution.

According to some embodiments, the stepped transition surface 1401 is designed to be perpendicular to the vector of gravity, ensuring that any load applied to the surface coating 1402 is transferred vertically into the expanded polymer unit. This design minimizes lateral shear forces, which are common in non-stepped surfaces 1403. By directing the load vertically, the stepped transition surface 1401 reduces the risk of surface coating 1402 delamination or structural failure, thereby improving the durability and longevity of the system.

According to various embodiments, for example, the surface coating 1402, which is applied over the stepped transition surface 1401, benefits from the increased surface area provided by the steps. This additional surface area enhances the bonding strength between the surface coating 1402 and the underlying expanded polymer unit. The surface coating 1402 is typically composed of a polymer-based elastomeric material that provides resistance to environmental factors such as moisture, UV exposure, and mechanical wear. The stepped transition surface 1401 ensures that the surface coating 1402 remains securely adhered, even under significant load or environmental stress.

According to various embodiments, the non-stepped surface 1403, also depicted in FIG. 14, demonstrates the limitations of traditional sloped designs. The non-stepped surface 1403 is more susceptible to lateral shear forces, which can compromise the adhesion of the surface coating and lead to premature failure. The evaluation of the stepped transition surface 1401 alongside the non-stepped surface 1403 highlights the technical advantages of the stepped design in maintaining structural integrity and load distribution.

According to various embodiments, the stepped transition surface 1401 also facilitates rapid and precise manufacturing. The steps of the stepped transition surface 1401 can be created using a cutting process, such as hot wire CNC machining, which ensures uniformity and repeatability across all units. This manufacturing efficiency reduces production time and costs while maintaining high-quality standards. Overall, the stepped transition surface 1401, in combination with the surface coating 1402, provides a robust and adaptable foundation for a wide range of architectural, landscape, and recreational applications. The design not only enhances load-bearing capacity but also ensures seamless integration with other system components, representing a significant advancement in the modular base system.

According to various embodiments, a zoom detailed view 1404 shows a zoomed close up view of the stepped transition surface 1401 illustrating how the CNC machining process imparts a faceted pattern texture atop the horizontal steps of the stepped transition surface 1401, which creates added surface area for bonding compared to the non-stepped surface 1403 (e.g., a smooth surface). For example, the faceted pattern texture atop the horizontal steps of the stepped transition surface 1401 is calculated to add at least 50% more bonding surface and results in even more lateral sheer and tortional strength between the surface coating 1402 (e.g., the polymer topcoat) and the polymer panel. For instance, the 50% increase in surface area does not include the vertical step riser, which adds additional surface bonding area.

According to some embodiments, the stepped transition surface 1401 is made by a process in which a CNC machine moves in a horizontal plane that creates the level stair steps of the stepped transition surface 1401. The speed of CNC machine for making the stepped transition surface 1401 has at least two advantages including the speed at which the bit traverses the polymer material far exceeds normal CNC machining speeds for polymer shaping because a transition to transfer to a smaller bit is not necessary. This speed results in an approximately 100-fold decrease in machining time. This is coupled with the fact that the height/width of the bit makes it able to remove large vertical sections of material without having to perform multiple stepdown passes to remove excess material and go through bit changes.

A problem is the field of manufacturing the polymer units is that bit changes for the CNC machine are also required in typical polymer machining to achieve a smooth and shaped finish but these bit changes are time consuming for the manufacturing process. This manufacturing process requires bit changes for the CNC machine to progressively smaller and more rounded bits requiring slower and even more tightly spaced repeated passes by the CNC machine. By comparison, the manufacturing process of the present technology is designed to achieve the opposite unexpected effect, producing faceted horizontal step surfaces, which saves time. This is accomplished by balancing bit RPM and bit type with the rapid horizontal transit speed of the CNC machine. This approach results in a structurally sound outcome in a single high-speed pass, unlike traditional methods of polymer machining that require multiple successive passes, each becoming slower and narrower with every bit change.

According to some embodiments, the stepped transition surface 1401 also facilitates rapid and precise manufacturing. The steps can be created using a cutting process, such as hot wire CNC machining, which ensures uniformity and repeatability across all units. This manufacturing efficiency reduces production time and costs while maintaining high-quality standards.

According to various embodiments, overall, the stepped transition surface 1401, in combination with the surface coating 1402, provides a robust and adaptable foundation for a wide range of architectural, landscape, and recreational applications. The design not only enhances load-bearing capacity but also ensures seamless integration with other system components manufacturing efficiency, representing a significant advancement in the modular base system.

FIG. 15 illustrates a mechanical drawing 1500 of an expanded polymer unit displaying the field modification of the expanded polymer unit through cutting, according to various embodiments of the present technology. Due to the homogeneous design of the system units and the protective coatings applied 1503, these units can be field modified by using any of a number of hand or power cutting, routing and/or machining tools (this is in no way an exhaustive list of tools that may be used to modify the system units). In this example, expanded polymer unit has a cut 1501 created by a user with a handheld saber saw 1502. As shown in FIG. 3, other types of cuts, routing and machining can be made to the expanded polymer units to include routing a channel for pipe 305 (e.g., conduit or plumbing insertion). For example, a circular saw angle cut to provide a channel for the pipe 305 (e.g., a conduit or plumbing). Removal of material to accommodate on-site structural units such as the steel beam 303 and the structural concrete post 304. These exemplary examples represent only a few options for field modifying the system units and are in no way meant to indicate the limitations for the methods used to modify the system units.

Some embodiments include a system for forming a base for architectural, landscape, or recreational feature installations, comprising: a plurality of expanded polymer units, each expanded polymer unit comprising: a polymer base body having a planar top surface; a plurality of lateral edges; and a stepped transition surface adjacent each lateral edge, the stepped transition surface comprising a series of horizontal load-supporting steps perpendicular to a gravity vector; lateral interlocking features disposed on the plurality of lateral edges, the lateral interlocking features including complementary male and female profiles configured to engage corresponding male and female profiles of another expanded polymer unit to align adjacent planar top surfaces seamlessly; vertical interlocking profiles configured to engage corresponding vertical interlocking profiles of another expanded polymer unit to support stacking of expanded polymer units in a vertical interlocked assembly; a protective polymer coating applied to the planar top surface and to the stepped transition surface, the protective polymer coating comprising an elastomeric material configured to bond to the stepped transition surface; and wherein the lateral interlocking features enable rotational orientation of each expanded polymer unit in 90-degree increments relative to adjacent units to form horizontal interlocked assemblies without redesign of polymer base bodies; wherein the engaged lateral interlocking features maintain alignment in both horizontal and vertical planes to form a congruent, continuous structural foundation; and wherein each expanded polymer unit is field-modifiable by cutting or machining to accommodate insertion of at least one of plumbing, electrical components, structural elements, or decorative elements without altering the lateral interlocking features.

In some embodiments the polymer base body of each expanded polymer unit comprises expanded polymer foam.

In some embodiments the stepped transition surface of each expanded polymer unit comprises a series of miniature stair-stepping transitions perpendicular to a gravity vector.

In some embodiments the protective polymer coating has a thickness in a range of 0.1 inch to 1.0 inch. The specified thickness range of 0.1 inch to 1.0 inch for the protective polymer coating ensures an optimal balance between durability, flexibility, and ease of application. This range provides sufficient material to form a robust barrier against environmental factors such as moisture, UV radiation, and mechanical wear, while avoiding excessive material usage that could increase weight or cost. The thickness is sufficient to maintain the integrity of the coating under load and stress, ensuring long-term performance in both interior and exterior applications. For example, by maintaining this thickness range, the coating can effectively bond to the underlying expanded polymer unit, particularly on the stepped transition surface, enhancing adhesion and load distribution. The range also allows for uniform application using standard coating techniques, such as self-leveling or troweling, ensuring a smooth and seamless finish across the surface of the polymer units. This facilitates the creation of a continuous structural foundation without gaps or weak points, improving the overall durability and reliability of the system. Additionally, the specified thickness range supports the integration of various finishing overlays, such as artificial turf or stone veneer, by providing a stable and consistent base for these materials. This enhances the versatility of the system for diverse architectural, landscape, and recreational applications. The range also ensures that the coating remains lightweight enough for ease of handling and installation, particularly in scenarios where weight constraints are significant, such as rooftop installations or elevated decks.

In some embodiments each expanded polymer unit further comprises corner alignment features at each vertex of the polymer base body.

In some embodiments the lateral interlocking features comprise complementary dovetail-shaped male and female profiles.

In some embodiments the vertical interlocking profiles comprise complementary pin and socket features configured to align and support stacking of the expanded polymer units.

In some embodiments each expanded polymer unit has a thickness of between 1 inch to 144 inches. In some instances an edge of expanded polymer unit will slope to 0.5 inches in thickness where an edge profile/transition to a floor is required, though the expanded polymer unit itself will not be less than 1 inch of thickness overall. The specified range of thickness for the expanded polymer unit, between 1 inch and 144 inches, provides flexibility in accommodating a wide variety of applications, from lightweight installations to heavy-duty structural foundations. This range ensures that the system can be tailored to address particular load-bearing requirements, environmental conditions, and design constraints, making the system suitable for diverse architectural, landscape, and recreational installations. The ability to slope the edge of the expanded polymer unit to 0.5 inches in thickness facilitates seamless transitions between the base system and adjacent surfaces, such as floors or ground levels. This design minimizes tripping hazards, improves accessibility, and enhances the aesthetic integration of the base system into surrounding environments. For example, in playgrounds or sports facilities, the sloped edge can provide a smooth transition to surrounding flooring materials, ensuring safety and usability. Furthermore, maintaining a minimum overall thickness of 1 inch ensures the structural integrity of the expanded polymer unit, even in areas where the edge profile is reduced. This design prevents compromise in load distribution or durability, ensuring that the system remains robust and reliable under various operational conditions. Additionally, the consistent minimum thickness supports the application of protective coatings and interlocking features without affecting their performance or alignment.

In some embodiments the protective polymer coating comprises a self-leveling elastomeric polymer curing within two hours, the curing being cross-linking of the protective polymer coating after application, resulting in a solid, durable finish.

Some embodiments further include a finishing overlay templated to an arrangement of the expanded polymer units, wherein the finishing overlay is one or more of artificial turf, stone veneer, and synthetic rubber.

In some embodiments the protective polymer coating is applied to all sides of each expanded polymer unit.

In some embodiments an adhesive used to join adjacent expanded polymer units comprises an acrylic polymer adhesive.

In some embodiments each expanded polymer unit is configured to be joined to another unit at any rotational orientation selected from 0 degrees, 90 degrees, 180 degrees, or 270 degrees.

In some embodiments the lateral interlocking features are configured to maintain alignment of adjacent planar top surfaces in both horizontal and vertical planes.

In some embodiments each expanded polymer unit is configured to accommodate the insertion of a drainage system.

In some embodiments the protective polymer coating undergoes a chemical reaction and comprises an elastomeric material having a hardness in of range of Shore D hardness of between 50 to 70. This specified hardness range of Shore D 50 to 70 for the elastomeric material ensures that the protective polymer coating achieves an optimal balance between flexibility and rigidity and is similar to concrete. This hardness level provides sufficient structural integrity to resist mechanical wear, impact, and deformation under load, while maintaining enough elasticity to absorb stresses caused by environmental factors such as thermal expansion, contraction, or vibration. The chemical reaction during curing, which cross-links the elastomeric material, enhances the durability and adhesion of the coating to the underlying expanded polymer unit. This process creates a robust bond that prevents delamination or cracking, even under prolonged exposure to moisture, UV radiation, or temperature fluctuations. In practical applications, this hardness range allows the coating to withstand heavy loads and abrasive forces, making the coating appropriate for high-traffic areas such as playgrounds, sports facilities, or architectural installations. Additionally, the elastomeric properties ensure that the coating can accommodate minor surface irregularities or movements without compromising the seamless integration of adjacent units, thereby maintaining the structural and aesthetic continuity of the installation.

In some embodiments each expanded polymer unit further comprises a gap in the protective polymer coating adjacent each lateral edge to facilitate seamless joining of adjacent units.

In some embodiments the system further comprises a kit including pre-cut overlays templated to an arrangement of the expanded polymer units.

Some embodiments include a process for forming a base for architectural, landscape, or recreational feature installations, the process comprising: manufacturing a stepped transition surface on a plurality of expanded polymer units using a single high-speed pass of a computer numerical control (CNC) machine; providing the plurality of expanded polymer units, each expanded polymer unit comprising: a polymer base body having a planar top surface; a plurality of lateral edges; wherein the stepped transition surface is adjacent each lateral edge, the stepped transition surface comprising a series of horizontal load-supporting steps perpendicular to a gravity vector; lateral interlocking features disposed on the plurality of lateral edges, the lateral interlocking features including complementary male and female profiles configured to engage corresponding male and female profiles of another expanded polymer unit; vertical interlocking profiles configured to engage corresponding vertical interlocking profiles of another expanded polymer unit; and a protective polymer coating applied to the planar top surface and to the stepped transition surface, the protective polymer coating comprising an elastomeric material configured to bond to the stepped transition surface; arranging the plurality of expanded polymer units such that the lateral interlocking features of adjacent units engage to align adjacent planar top surfaces seamlessly; rotating at least one of the plurality of expanded polymer units in 90-degree increments relative to adjacent units to achieve a desired configuration; stacking at least one expanded polymer unit on another expanded polymer unit by engaging the vertical interlocking profiles to form a vertical interlocked assembly; applying an adhesive to the lateral edges of adjacent expanded polymer units to bond the adjacent expanded polymer together, thereby forming a continuous structural foundation; filling any gaps in the protective polymer coating at the lateral edges with additional protective polymer coating to create a seamless surface transition; and modifying at least one expanded polymer unit by cutting or machining to accommodate insertion of at least one of plumbing, electrical components, structural elements, or decorative elements without altering the lateral interlocking features.

Some embodiments include an expanded polymer unit for forming a base for architectural, landscape, or recreational feature installations, the expanded polymer unit comprising: a polymer base body having a planar top surface; a plurality of lateral edges; a stepped transition surface adjacent each lateral edge, the stepped transition surface comprising a series of horizontal load-supporting steps perpendicular to a gravity vector; lateral interlocking features disposed on the plurality of lateral edges, the lateral interlocking features including complementary male and female profiles configured to engage corresponding male and female profiles of another expanded polymer unit to align adjacent planar top surfaces seamlessly; vertical interlocking profiles configured to engage corresponding vertical interlocking profiles of another expanded polymer unit to support stacking of expanded polymer units in a vertical interlocked assembly; a protective polymer coating applied to the planar top surface and to the stepped transition surface, the protective polymer coating comprising an elastomeric material configured to bond to the stepped transition surface; wherein the lateral interlocking features enable rotational orientation of the expanded polymer unit in 90-degree increments relative to adjacent units to form horizontal interlocked assemblies without redesign of polymer base bodies; wherein the engaged lateral interlocking features maintain alignment in both horizontal and vertical planes to form a congruent, continuous structural foundation; and wherein the expanded polymer unit is field-modifiable by cutting or machining to accommodate insertion of at least one of plumbing, electrical components, structural elements, or decorative elements without altering the lateral interlocking features.

While this technology is susceptible of embodiments in many different forms, there is shown in the drawings and has been described in detail several specific embodiments with the understanding that the present disclosure is to be considered as an exemplification of the principles of the technology and is not intended to limit the technology to the embodiments illustrated.

Although the terms first, second, etc. may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not necessarily be limited by such terms. These terms are only used to distinguish one element, component, region, layer or section from another element, component, region, layer or section. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the present disclosure.

The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be necessarily limiting of the disclosure. As used herein, the singular forms “a,” “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms “comprises,” “includes” and/or “comprising,” “including” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.

Example embodiments of the present disclosure are described herein with reference to illustrations of idealized embodiments (and intermediate structures) of the present disclosure. As such, variations from the shapes of the illustrations as a result, for example, of manufacturing techniques and/or tolerances, are to be expected. Thus, the example embodiments of the present disclosure should not be construed as necessarily limited to the particular shapes of regions illustrated herein, but are to include deviations in shapes that result, for example, from manufacturing.

Any and/or all elements, as disclosed herein, can be formed from a same, structurally continuous piece, such as being unitary, and/or be separately manufactured and/or connected, such as being an assembly and/or modules. Any and/or all elements, as disclosed herein, can be manufactured via any manufacturing processes, whether additive manufacturing, subtractive manufacturing and/or other any other types of manufacturing. For example, some manufacturing processes include three dimensional (3D) printing, laser cutting, computer numerical control (CNC) routing, milling, pressing, stamping, vacuum forming, hydroforming, injection molding, lithography and/or others.

Any and/or all elements, as disclosed herein, can include, whether partially and/or fully, a solid, including a metal, a mineral, a ceramic, an amorphous solid, such as glass, a glass ceramic, an organic solid, such as wood and/or a polymer, such as rubber, a composite material, a semiconductor, a nano-material, a biomaterial and/or any combinations thereof. Any and/or all elements, as disclosed herein, can include, whether partially and/or fully, a coating, including an informational coating, such as ink, an adhesive coating, a melt-adhesive coating, such as vacuum seal and/or heat seal, a release coating, such as tape liner, a low surface energy coating, an optical coating, such as for tint, color, hue, saturation, tone, shade, transparency, translucency, non-transparency, luminescence, anti-reflection and/or holographic, a photo-sensitive coating, an electronic and/or thermal property coating, such as for passivity, insulation, resistance or conduction, a magnetic coating, a water-resistant and/or waterproof coating, a scent coating and/or any combinations thereof.

Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure belongs. The terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and should not be interpreted in an idealized and/or overly formal sense unless expressly so defined herein.

Furthermore, relative terms such as “below,” “lower,” “above,” and “upper” may be used herein to describe one element's relationship to another element as illustrated in the accompanying drawings. Such relative terms are intended to encompass different orientations of illustrated technologies in addition to the orientation depicted in the accompanying drawings. For example, if a device in the accompanying drawings is turned over, then the elements described as being on the “lower” side of other elements would then be oriented on “upper” sides of the other elements. Similarly, if the device in one of the figures is turned over, elements described as “below” or “beneath” other elements would then be oriented “above” the other elements. Therefore, the example terms “below” and “lower” can, therefore, encompass both an orientation of above and below.

The description of the present disclosure has been presented for purposes of illustration and description, but is not intended to be exhaustive or limited to the present disclosure in the form disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art without departing from the scope and spirit of the present disclosure. Exemplary embodiments were chosen and described in order to best explain the principles of the present disclosure and its practical application, and to enable others of ordinary skill in the art to understand the present disclosure for various embodiments with various modifications as are suited to the particular use contemplated.

While various embodiments have been described above, it should be understood that they have been presented by way of example only, and not limitation. The descriptions are not intended to limit the scope of the technology to the particular forms set forth herein. Thus, the breadth and scope of a preferred embodiment should not be limited by any of the above-described exemplary embodiments. It should be understood that the above description is illustrative and not restrictive. To the contrary, the present descriptions are intended to cover such alternatives, modifications, and equivalents as may be included within the spirit and scope of the technology as defined by the appended claims and otherwise appreciated by one of ordinary skill in the art. The scope of the technology should, therefore, be determined not with reference to the above description, but instead should be determined with reference to the appended claims along with their full scope of equivalent.