Recycled Plastic Granule Sports Pitch Substrate
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Solution Overview
Problem
Traditional artificial turf pitch construction methods are environmentally impactful and costly due to extensive excavation and use of materials like graded rock, and 'end of life' plastics are difficult to recycle and often end up in landfills due to their mixed and low-grade nature.
Innovation Solution
A substrate system using densified plastic granules as aggregate material, bound with Polyurethane, Bitumen, or Polyolefin, which provides base point loading, compression strength, in-built porosity, and controlled drainage, reducing the need for excavation and incorporating 'end of life' plastics to minimize environmental impact and costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional excavation and graded rock methods are used, then structural stability is achieved, but environmental impact and cost increase
Solution Approach 1:
The patent changes the material parameters from traditional graded rock to densified plastic granules with specific density ranges (0.8-1.8 g/cm³). This parameter change maintains structural stability while reducing environmental impact by recycling waste plastics instead of extracting and transporting natural stone materials.
Solution Approach 2:
The patent creates a composite substrate by combining densified plastic granules with binding agents (bitumen, polyurethane, or polyolefin). This composite material achieves the required mechanical strength and stability previously obtained from graded rock, while providing environmental benefits through plastic recycling.
2Object-affected harmful factors
If densified plastic granules are used, then environmental impact is reduced and cost decreases, but material strength must be maintained
Solution Approach 1:
The patent specifies critical density parameters for the plastic granules (0.8-1.8 g/cm³) and controls the binder content (5-20% by weight) to ensure the composite substrate achieves sufficient strength. These parameter controls allow weak plastic materials to gain the necessary mechanical properties for sports pitch substrates.
Solution Approach 2:
By creating a composite of plastic granules and binding agents, the patent transforms weak individual plastic particles into a strong unified substrate. The binder material holds the granules together, distributing loads and providing the structural strength needed to support sports surfaces.
3Reliability
If plastic granules are used as aggregate, then drainage efficiency is maintained through porosity, but material selection becomes more complex
Solution Approach 1:
The patent specifies that plastic granules with certain properties (density 0.8-1.8 g/cm³, specific size ranges) should be used in the substrate layer to naturally create appropriate porosity for drainage. This local quality requirement ensures drainage efficiency without adding complex drainage systems.
Solution Approach 2:
The densified plastic granules serve multiple functions simultaneously: they provide structural fill, create drainage porosity through their particle arrangement, and can be selected from recycled materials. This multi-functionality simplifies the overall system by eliminating the need for separate drainage components.
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 the environmental footprint and financial costs by reusing 'end of life' plastics, minimizing excavation, and maintaining structural integrity and drainage efficiency, while allowing for adaptable properties to suit various sports and geological conditions.
Implementation Method 1
A substrate system using densified plastic granules as aggregate material, bound with Polyurethane, Bitumen, or Polyolefin, which provides base point loading, compression strength
Implementation Method 2
in-built porosity, and controlled drainage
Data Source
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AI summary
The invention relates to a method of forming a substrate for a sports surface of a sports pitch. The invention also relates to a substrate obtained with the method according to the invention. Furthermore the invention also relates to a sports pitch provided with such substrate. According to the invention the method comprise the steps of: a) Agglomerating plastics materials; b) Granulating the agglomerated plastics materials to form granules having a predetermined range of sizes; c) In situ coating the granules with a binding material so that they form a fluent material; d) Forming a layer of the fluent material on the site of the sports pitch; and e) Setting the laid material such that the granules adhere where they contact each other to form a voided water permeable structure.