Binder-Based Overlay System for Athletic Surface Crack Repair
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Solution Overview
Problem
Athletic playing surfaces such as tennis courts and basketball courts deteriorate over time due to cracks and deformations, affecting performance and safety, and existing maintenance methods do not provide sufficient durability, planarity, and comfort.
Innovation Solution
A binder-based overlay system comprising a layer of seaming material, geotextile fabric, primer, binder layers of sand or rubber, resurfacer, and color layers, along with infill-based systems using geotextile fabric, adhesive, and infill layers of sand or rubber, to correct deformations and enhance surface quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional maintenance methods are used on athletic surfaces, then initial construction cost is reduced, but durability and resistance to cracks deteriorate over time
Solution Approach 1:
The overlay system is divided into multiple functional layers including geotextile fabric for crack prevention, binder layers for structural integrity, and color layers for surface quality. Each layer performs a specific function, allowing the system to achieve high durability without requiring a complete replacement of the entire surface.
Solution Approach 2:
The system combines different materials with complementary properties: geotextile fabric provides tensile strength and crack resistance, binder materials provide adhesion and structural support, and color layers provide surface quality. This composite approach achieves superior durability while maintaining manageable complexity through specialized functional division.
2Manufacturing precision
If existing surface correction methods are applied, then immediate cost is reduced, but planarity and surface quality deteriorate
Solution Approach 1:
The geotextile fabric layer is installed first to prevent crack propagation and provide a stable base. Primer is applied beforehand to ensure proper adhesion of subsequent layers. This preliminary preparation ensures high planarity and surface quality while simplifying the overall installation process by addressing potential problems before they occur.
Solution Approach 2:
The overlay system allows for localized application and correction. Different areas can be treated with specific layer configurations based on their condition, enabling precise control over planarity and surface quality without requiring complete system replacement or complex global adjustments.
3Ease of operation
If simple overlay systems are used, then installation complexity is reduced, but comfort and safety deteriorate
Solution Approach 1:
The system segments comfort-enhancing functions into specific layers: the geotextile fabric provides cushioning and impact absorption, while the binder and color layers provide surface quality and traction. This segmentation allows the system to deliver superior comfort and safety while maintaining a manageable installation process through clear functional division.
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 systems provide superior durability, improved planarity, and comfort, effectively preventing cracks and deformations, thus enhancing the quality and safety of athletic surfaces.
Implementation Method 1
a primer layer adhered to the layer of geotextile fabric
Implementation Method 2
one or more binder layers comprising sand, rubber, or a rubber alternative, or a combination thereof adhered to the primer layer
Data Source
AI summary
A method of installing a binder-based overlay system may include contacting a layer of geotextile fabric to a surface of a substrate and applying a primer layer to a surface of the geotextile fabric. Two or more binder layers including infill particles may be applied over the primer layer. A resurfacer layer followed by one or more color layers may be applied over the two or more binder layers. The primer layer, one or more binder layers, resurfacer layer, and two or more color layers may cure upon application to form a monolithic layer upon the substrate.