Modular Turf Foundation With Contoured Foam Impact Insulation
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Solution Overview
Problem
Existing artificial surfaces, such as turf fields and playgrounds, lack safer, simpler, and more cost-effective contoured and elevated features that are impact-resistant, insulative, stable, durable, and flexible, while addressing issues like heat management and impact absorption.
Innovation Solution
A modular foundation structure comprising a structural base layer of shaped rigid foam with contoured and elevated features, covered by an adhesive layer and an impact and thermal protective layer, which includes a combination of Expanded Polystyrene (EPS) and Expanded Polypropylene (EPP) foam, providing enhanced impact absorption and thermal insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional artificial turf systems are used, then the surface provides basic functionality, but it lacks adequate impact absorption and thermal insulation properties
Solution Approach 1:
The system is divided into distinct modular layers: a structural base layer providing contour support, an intermediate impact-absorbing layer, and a top artificial turf layer. This segmentation allows each layer to perform its specific function optimally while maintaining overall system simplicity through standardized assembly procedures.
Solution Approach 2:
The patent combines multiple materials with complementary properties: the structural base layer uses rigid foam for shape retention, the intermediate layer uses soft foam for impact absorption, and the top layer uses artificial turf for surface functionality. This composite structure achieves superior impact absorption and thermal insulation without excessive complexity.
2Adaptability or versatility
If contoured and elevated features are added to artificial surfaces, then functionality is enhanced, but heat management becomes more difficult
Solution Approach 1:
The structural base layer is formulated with specific thermal properties to provide insulation at the contoured regions where it is most needed. The varying thickness of the base layer in contoured areas creates localized thermal management, with thicker sections providing greater insulation where heat buildup would be most problematic.
Solution Approach 2:
The combination of rigid foam in the structural base layer and soft foam in the intermediate layer creates a composite structure with enhanced thermal insulation properties. This multi-material approach manages heat more effectively than single-material systems, particularly in contoured features where heat distribution is non-uniform.
3Ease of manufacture
If modular foundation sections are used, then assembly and customization are simplified, but the number of components and assembly steps increases
Solution Approach 1:
The foundation is divided into modular sections that can be manufactured separately and assembled on-site. Each module contains integrated layers (structural base, intermediate, and artificial turf), reducing the need for multiple separate assembly steps while maintaining customization flexibility through different module configurations.
Solution Approach 2:
Multiple functional layers are combined into integrated modular units during manufacturing. The structural base layer, intermediate impact-absorbing layer, and artificial turf layer are pre-assembled as single modules, reducing the total number of assembly operations required on-site while maintaining the benefits of modularity for transportation and installation.
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 solution offers modular, customizable, and impact-resistant features that absorb repeated impacts, provide fall safety, and maintain thermal stability, while being resistant to chemicals and oils, thus enhancing the safety and durability of artificial surfaces.
Implementation Method 1
The structural base layer may include a shaped rigid foam having contoured and elevated features
Implementation Method 2
provide thermal insulation
Implementation Method 3
The adhesive layer may cover the structural base layer, and the impact and thermal protective layer may be attached to the structural base layer via the adhesive layer
Data Source
AI summary
A modular foundation structure for artificial surface systems may include a plurality foundation sections. Each of the foundation section may comprise a structure base layer, an adhesive layer, and an impact and thermal protective layer. The adhesive layer may cover the structural base layer, and the impact and thermal protective layer may be attached to the structural base layer via the adhesive layer. The foundation sections may be provided as separate foundation sections that may be positionable to be attached to one another to form the modular foundation structure. The foundation sections may be attachable one another with a section adhesive. Embodiments may include a connection edge that may be positioned to surround and abut a perimeter of the modular foundation structure. Embodiments may also include an artificial surface layer that may be positioned to cover an upper surface area of the modular foundation structure.