Recycled Rubber Shock Pad for Sports Surfaces
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Solution Overview
Problem
Hard surface sports courts, such as those for tennis and pickleball, can cause injuries due to lack of cushioning and have suboptimal ball responsiveness, while existing cushioned solutions are expensive, time-consuming to install, and cannot be applied over damaged substrates.
Innovation Solution
A sports surfacing system using a rubber shock pad made of 70-90% post-consumer recycled crumb rubber bound with polyurethane adhesive, which can be adhered seamlessly to substrates, including cracked surfaces, and a sports surface layer with abrasive particles bonded to a plastic film with a pressure-sensitive adhesive, allowing for easy installation and cushioned performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of stationary object
If hard surface materials are used for sports courts, then durability and low maintenance are improved, but injury risk increases and ball responsiveness deteriorates
Solution Approach 1:
The patent uses a composite material system consisting of resilient particles (70-90% post-consumer recycled crumb rubber) bound with polyurethane adhesive to create a cushioned surface layer. This composite structure combines the durability of cured polyurethane with the shock-absorbing properties of rubber particles, achieving both longevity and injury reduction.
Solution Approach 2:
The invention applies cushioning properties locally at the surface level where players make contact, while the substrate beneath maintains its structural durability. The resilient particle layer provides localized shock absorption exactly where needed (at the playing surface) without compromising the overall court structure.
2Adaptability or versatility
If cushioned surface layers are applied over damaged substrates, then adaptability is improved, but installation complexity increases
Solution Approach 1:
The patent incorporates crack isolation and surface leveling properties directly into the adhesive formulation before application. The polyurethane adhesive is pre-engineered to bridge cracks and create a uniform bonding surface, eliminating the need for separate crack repair or surface preparation steps.
Solution Approach 2:
The adhesive's chemical and physical parameters are optimized to provide both crack isolation and leveling functionality. The adhesive's viscosity, curing characteristics, and bonding strength are specifically tuned to flow into and bond across cracked surfaces while simultaneously creating a smooth, level installation surface.
3Object-affected harmful factors
If traditional cushioning materials are used, then injury protection is improved, but installation time and cost increase
Solution Approach 1:
The patent merges multiple functions into a single integrated layer: the resilient particle cushioning layer simultaneously provides shock absorption, surface uniformity, and crack coverage. This consolidation eliminates the need for separate cushioning layers, leveling compounds, and crack repair materials that would otherwise require sequential installation.
Solution Approach 2:
The resilient particle mixture is self-leveling and self-bonding. When applied, the material naturally distributes itself to create a uniform surface and bonds to the substrate through the polyurethane adhesive's inherent tack and curing properties, eliminating the need for additional leveling operations or separate bonding steps.
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 provides a cushioned, durable, and low-maintenance sports surface that reduces injury risk and enhances ball responsiveness, with improved installation efficiency and adaptability to various substrate conditions.
Implementation Method 1
a rubber shock pad comprising about 70% to 90% post-consumer recycled crumb rubber bound with a polyurethane adhesive
Implementation Method 2
a sports surface layer formed from abrasive particles bonded by a polymer to a dimensionally stable plastic film. The bottom surface of the layer can be coated with a pressure-sensitive adhesive covered by a removable protective liner
Data Source
AI summary
Described are sports surface layers, systems for surfacing sports surfaces, and methods of surfacing sports surfaces. The system for surfacing a sports surface includes a rubber shock pad comprising about 70% to 90% post-consumer recycled crumb rubber bound with a polyurethane adhesive. A sports surface layer can be formed from abrasive particles bonded by a polymer to a dimensionally stable plastic film. The bottom surface of the layer can be coated with a pressure-sensitive adhesive covered by a removable protective liner. Methods for surfacing a sports surface are also provided.