Athletic Play Surface with Moisture Barrier and Encapsulation
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Solution Overview
Problem
Existing athletic play surfaces, such as pickle ball courts, face high construction and maintenance costs due to site preparation and ongoing deterioration, with defects requiring costly resurfacing and moisture issues affecting gameplay safety.
Innovation Solution
A method involving a moisture-resistant substrate layer, a woven scrim layer with open cells, and a flowable curable material to form an encapsulation layer that can be applied directly over existing damaged surfaces, providing a durable and low-maintenance play surface with minimal downtime.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a new athletic play surface is constructed over existing damaged surfaces, then construction costs and site preparation requirements are reduced, but the underlying moisture and defects may still affect performance
Solution Approach 1:
The play surface is divided into multiple functional layers: a moisture barrier layer to block moisture from the substrate, a reinforcement layer with woven scrim for structural support, and a wear layer for gameplay. This segmentation allows each layer to address specific issues (moisture, structural integrity, surface performance) independently, enabling construction over existing damaged surfaces while maintaining reliability
Solution Approach 2:
The moisture barrier layer acts as an intermediary between the damaged existing surface and the new play surface layers. It prevents moisture transmission from the substrate while allowing the new layers to function properly, thus enabling cost-effective construction over problematic substrates without compromising surface performance
2Ease of manufacture
If traditional athletic play surfaces are used, then initial construction is possible, but ongoing maintenance costs are high due to deterioration and surface defects
Solution Approach 1:
The design allows the wear layer to be replaced independently when deteriorated, while retaining the moisture barrier and reinforcement layers. This selective replacement reduces maintenance costs by avoiding complete surface removal and reconstruction, addressing the high ongoing maintenance issue while keeping initial construction feasible
3Reliability
If site preparation is performed to clear and prepare large areas for court surface, then proper surface installation is ensured, but construction costs increase substantially
Solution Approach 1:
The multi-layer construction segments the installation process into manageable steps that can be performed over existing surfaces with minimal preparation. The moisture barrier layer adapts to the existing substrate condition, reducing the need for extensive site clearing and preparation while ensuring proper installation quality
Solution Approach 2:
The moisture barrier layer serves multiple functions: it blocks moisture, provides a stable base for subsequent layers, and adheres to various existing surface types (concrete, asphalt, wood) without requiring specific preparation. This universality reduces construction costs by eliminating the need for extensive site-specific preparation while maintaining installation quality
4Reliability
If extensive surface defects are present, then complete replacement or resurfacing is required, but this increases maintenance costs and downtime
Solution Approach 1:
The layered construction allows the wear layer to be separated and replaced independently of the structural layers. When surface defects occur, only the wear layer needs replacement rather than complete surface removal, reducing repair costs and downtime while maintaining play surface safety
Solution Approach 2:
The wear layer is designed as a replaceable component that can be discarded when deteriorated and replaced while retaining the moisture barrier and reinforcement layers. This reduces repair costs and minimizes downtime compared to traditional complete surface replacement, addressing both safety and maintenance cost concerns
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution reduces construction and maintenance costs by allowing the play surface to be retrofitted over existing surfaces, resisting moisture intrusion, and enabling quick repair of physical damage, ensuring a safe and durable athletic play area with minimal disruption.
Implementation Method 1
a flowable curable material that passes through open cells formed in the scrim layer and contacts the substrate layer, substantially filling the open cells of the scrim layer
Implementation Method 2
The athletic play surface promotes adhesion between layers
Implementation Method 3
a moisture-resistant substrate layer is provided on top of the base surface
Data Source
AI summary
An athletic play surface having a moisture-resistant substrate layer located on top of a base surface. A woven scrim layer is positioned on top of and adhered to the substrate layer. A plurality of open cells extend through the scrim layer. An encapsulation layer is formed using a flowable curable material that is poured over the scrim layer and that hardens. The curable material passes through the open cells of the scrim layer, contacts the base surface, and then substantially fills the plurality of open cells of the scrim layer. A portion of the encapsulation layer extends beyond a top of the scrim layer to a height H. A decorative layer, such as paint and court lines, may be applied on top of the encapsulation layer.