Polymeric Foam Support Layer With Cross-Channel Drainage
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Solution Overview
Problem
Conventional support layers for artificial turf systems face challenges in balancing drainage properties with weight, thickness, and impact absorption, leading to complex designs that are difficult to manufacture and maintain.
Innovation Solution
A support layer formed from polymeric foam with alternating first and second channels on opposite sides, featuring through drainage holes that connect the channels for efficient water flow, and optionally including pillars for increased stiffness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional support layers use complex designs with multiple channels and drainage holes to improve drainage properties, then drainage efficiency is improved, but the support layer becomes thicker and heavier
Solution Approach 1:
The support layer is divided into multiple functional zones: first channels for water intake, second channels for water transport, and through drainage holes for vertical drainage. This segmentation allows efficient drainage distribution without requiring a single complex thick structure, reducing overall weight while maintaining drainage reliability.
Solution Approach 2:
The invention adds vertical dimension with through drainage holes that penetrate the support layer thickness, creating three-dimensional drainage pathways. This multi-directional approach (horizontal channels + vertical holes) achieves superior drainage without increasing planar dimensions or weight, as water can drain through multiple spatial paths simultaneously.
2Reliability
If conventional support layers increase the number and complexity of drainage channels to improve drainage, then drainage properties are improved, but manufacturing complexity increases
Solution Approach 1:
The invention extracts and separates drainage functions into distinct modular elements: first channels, second channels, and through drainage holes. Each element has a specific drainage function, allowing independent optimization and simplified manufacturing of each component while achieving comprehensive drainage coverage when assembled together.
Solution Approach 2:
Different regions of the support layer are assigned different functions: first channels are optimized for water intake from the turf, second channels for water transport, and through drainage holes for vertical drainage. This localized functional differentiation allows each region to be optimized for its specific purpose, simplifying the overall design while improving drainage efficiency.
3Strength
If conventional support layers reduce the amount of drainage holes and channels to improve support and impact properties, then support characteristics are improved, but drainage properties are strongly reduced
Solution Approach 1:
The invention merges multiple drainage functions (horizontal water collection, horizontal water transport, and vertical water discharge) into a single integrated support layer structure. The first channels, second channels, and through drainage holes work together as a unified drainage system, maintaining support characteristics while achieving comprehensive drainage without requiring separate components.
Solution Approach 2:
The support layer is designed with multi-functionality: it provides structural support for the artificial turf while simultaneously performing multiple drainage functions through its channel and hole system. The polymeric foam material and integrated channel design allow the same structure to fulfill both support and drainage requirements, eliminating the need to choose between the two functions.
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
The design provides improved flexibility, reduced weight, and enhanced shock absorption and drainage properties, while maintaining or exceeding the performance of conventional support layers.
Implementation Method 1
the support layer having excellent shock absorption and drainage properties
Implementation Method 2
said support layer...is formed of a polymeric foam
Implementation Method 3
the first side of the support layer is provided with a plurality of first channels, extending parallel in a first longitudinal direction for allowing liquid to flow through the plurality of first channels along the first side
Data Source
Figure 1
Figure 2
Figure 3A
AI summary
A support layer for supporting a playing field assembly, said support layer having a first side and a second side, and having a longitudinal direction, a width direction, and a height direction, said support layer having a layer thickness in the height direction, and is formed of a polymeric foam, wherein the first side of the support layer is provided with a plurality of first channels, extending parallel in a first longitudinal direction, and wherein the second side of the support layer is provided with a plurality of second channels, extending parallel in a second longitudinal direction, wherein each of said plurality of first channels has a first depth in the height direction and each of said plurality of second channels has a second depth in the height direction, wherein the first depth and the second depth are smaller than the layer thickness, wherein each of said plurality of first channels comprises a first base side extending parallel to the first side and first sidewalls extending from the first base side towards the first side, and wherein each of said plurality of second channels comprises a second base side extending parallel to the second side and second sidewalls extending from the second base side towards the second side, wherein the support layer comprises a plurality of through drainage holes, wherein each of said plurality of drainage holes is positioned at a cross section of a first channel of said plurality of first channels and a second channel of said plurality of second channels, wherein each of said plurality of drainage holes opens at a first end in a first channel of said plurality of first channels and at a second end in a second channel of said plurality of second channels . An artificial turf system, comprising a base layer, the support layer, and a playing field assembly.