Modular Surface Underlayment with Interlocking Shock Tiles
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing shockpad systems for sports and flooring surfaces are costly, time-consuming to install, and fail to efficiently absorb energy like natural grass, with issues such as variation in installation thickness, expansion, and high maintenance requirements.
Innovation Solution
A modular surface underlayment system comprising interlocking quadrilateral energy-absorbing modules that accommodate thermal expansion and contraction, allowing for pre-assembled subassemblies to be shipped and easily installed, with optional granular materials for enhanced performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If modular shockpad systems are used to absorb energy like natural grass, then energy absorption performance is improved, but installation time and cost increase
Solution Approach 1:
The shockpad system is divided into modular panels that can be independently manufactured and assembled. Each panel contains integrated shock-absorbing elements, allowing the system to be installed in sections rather than as a single large unit, reducing overall installation time while maintaining energy absorption performance
Solution Approach 2:
The shock-absorbing elements are pre-installed within each panel during manufacturing before shipment to the installation site. This preliminary action eliminates the need to install these components on-site, reducing installation time and labor while ensuring consistent energy absorption characteristics
2Manufacturing precision
If modular shockpad systems are used to mimic natural grass response, then performance consistency is improved, but system complexity increases
Solution Approach 1:
The shock-absorbing elements are designed with specific geometric parameters (size, shape, material properties) that are optimized to mimic natural grass response characteristics. By controlling these parameters during manufacturing, consistent performance is achieved across all panels without requiring complex assembly procedures
Solution Approach 2:
Each modular panel is designed to perform multiple functions: providing shock absorption, supporting the playing surface, and accommodating thermal expansion. This multi-functionality is achieved through integrated design rather than separate components, maintaining performance consistency while limiting system complexity
3Reliability
If traditional shockpad systems are installed, then energy absorption is provided, but maintenance requirements increase
Solution Approach 1:
The modular panels are designed to be replaceable rather than repairable. When a panel becomes worn or damaged, it can be easily removed and replaced with a new panel, eliminating the need for complex repair procedures. The interlocking design allows for quick removal and replacement, minimizing facility downtime while maintaining energy absorption performance
4Ease of manufacture
If shockpad systems are used to reduce installation costs, then initial investment is reduced, but packaging and transportation efficiency decreases
Solution Approach 1:
The modular panels are designed to nest within each other during storage and transportation. This nesting configuration significantly reduces the volume required for shipping and storage, allowing more panels to be transported in each shipment, thereby reducing overall transportation costs while maintaining affordable installation pricing
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 system reduces installation time and costs, provides energy absorption similar to natural grass, and requires minimal maintenance, while being lightweight and cost-effective, with high packaging density for efficient transportation and storage.
Implementation Method 1
the interposed underlayment system absorbs and redistributes at least some of the energy applied by an impacting object such as a football helmet or a golf ball through flexure of the underlayment system
Implementation Method 2
A modular surface underlayment system comprising interlocking quadrilateral energy-absorbing modules that accommodate thermal expansion and contraction
Data Source
AI summary
A surface underlayment system and its method of manufacture that is sandwiched between an impact-receiving upper surface and a lower foundation. The energy absorbing system has subassemblies of interconnected modules that cooperate to absorb and distribute impact forces applied thereto. Each module has one or more frustoconical support structures. At least some of the frustoconical support structures have bases that underlie the upper impact-receiving surface such as a golf putting green, a football field, marine decking, and senior living flooring.