Mineral Wool Shock Pad for Flood-Resistant Sports Fields
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Solution Overview
Problem
Existing shock pads for sports fields are not environmentally friendly, sensitive to temperature, require plastic infill layers, and suffer from issues like flooding, high surface temperatures, and leaching of wetting agents, while failing to meet international sports governing body standards.
Innovation Solution
A shock pad using man-made vitreous fibers bonded with a cured aqueous binder composition free of phenol and formaldehyde, incorporating lignosulfonate lignins and cross-linkers, which absorbs water to prevent flooding, reduce surface temperature, and enhance durability and water retention without plastic infill.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional foam, rubber, plastic or polymeric shock pads are used, then shock absorption and energy restitution requirements are met, but environmental sustainability deteriorates
Solution Approach 1:
The patent uses man-made vitreous fibres (mineral wool) as a composite material alternative to traditional foam, rubber, plastic or polymeric shock pads. This composite material maintains the required shock absorption and energy restitution performance while being environmentally sustainable and free from harmful chemicals like phenol and formaldehyde.
Solution Approach 2:
The patent changes the material composition parameters by using mineral wool with specific density ranges (70 to 300 kg/m3) and thickness (30 to 300 mm) to achieve the required mechanical performance without relying on synthetic polymers, thereby improving environmental sustainability while maintaining reliability.
2Strength
If traditional polymeric shock pads are used, then structural integrity is maintained, but temperature sensitivity increases
Solution Approach 1:
The patent replaces temperature-sensitive polymeric materials with man-made vitreous fibres (mineral wool), which are inorganic and inherently less sensitive to temperature variations. This maintains structural integrity while reducing temperature sensitivity, allowing the shock pad to perform consistently across a wider temperature range.
3Reliability
If shock pads with poor drainage characteristics are used, then shock absorption is improved, but flooding risk increases
Solution Approach 1:
The patent specifies that the mineral wool shock pad should have porous characteristics that allow water to drain through into draining systems. This porosity enables the material to maintain shock absorption properties while simultaneously facilitating water drainage, thereby preventing flooding without compromising shock absorption performance.
4Reliability
If plastic infill layers are used to meet sports performance requirements, then play performance is improved, but microplastic pollution increases
Solution Approach 1:
The patent replaces plastic infill layers with man-made vitreous fibres, creating a composite material solution that maintains the required play performance characteristics (ball rebound, ball roll, shock absorption) while eliminating the source of microplastic pollution. The mineral wool provides the necessary mechanical properties without degrading into microplastics.
5Strength
If phenol-formaldehyde binders are used for man-made vitreous fibres, then mechanical handling properties are improved, but environmental safety deteriorates
Solution Approach 1:
The patent changes the binder composition parameters by using alternative binders that are free from phenol and formaldehyde, thereby maintaining adequate mechanical handling properties while improving environmental safety and eliminating harmful chemical emissions during production and use.
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 shock pad meets international sports standards, is durable and resilient, prevents flooding, reduces surface temperature, and is environmentally friendly, with improved water absorption and no need for plastic infill, while being cost-effective and safe to produce.
Implementation Method 1
the shock pad comprises at least one shock pad comprising a coherent plate having upper and lower major surfaces, wherein the coherent plate comprises at least one coherent layer comprising man-made vitreous fibres (MMVF) bonded with a cured aqueous binder composition
Implementation Method 2
man-made vitreous fibres (MMVF) bonded with a cured aqueous binder composition
Implementation Method 3
the aqueous binder composition prior to curing comprises: a component (i) in form of one or more lignosulfonate lignins having a carboxylic acid group content of 0.03 to 1.4 mmol/g, based on the dry weight of the lignosulfonate lignins, a component (ii) in form of one or more cross-linkers
Data Source
AI summary
The present invention relates to a sports field comprising:(i) a lower base layer;(ii) an upper grass and/or artificial grass layer;(iii) a shock pad layer, positioned between the base layer and the grass or artificial grass layer;wherein the shock pad layer comprises at least one shock pad comprising a coherent plate having upper and lower major surfaces, wherein the coherent plate comprises at least one coherent layer comprising man-made vitreous fibres (MMVF) bonded with a cured aqueous binder composition free of phenol and formaldehyde; wherein the aqueous binder composition prior to curing comprises:a component (i) in form of one or more lignosulfonate lignins having a carboxylic acid group content of 0.03 to 1.4 mmol/g, based on the dry weight of the lignosulfonate lignins,a component (ii) in form of one or more cross-linkers.