On-Site Elastic Layer Manufacturing from Recycled Turf Infill
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Solution Overview
Problem
Artificial turf systems face wear and tear due to intensive usage, UV exposure, thermal cycling, and environmental interactions, leading to the need for frequent replacement, which is economically and environmentally challenging.
Innovation Solution
A method for manufacturing an elastic layer on site by collecting and recycling infill from aged artificial turf, mixing it with a binding agent and fragments of aged elastic layers, and applying the fluid composite to a substrate to form a new elastic layer, which can be used to support a new artificial turf system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If artificial turf systems are replaced frequently due to wear, then the appearance and performance are maintained, but waste increases and installation costs increase
Solution Approach 1:
The patent recovers and reuses aged infill material from removed artificial turf systems by mixing it with binding agents to create elastic layer composites. This recovery process reduces waste by utilizing materials that would otherwise be discarded after 5-15 years of service.
Solution Approach 2:
The patent changes the physical state of infill material from solid particles to a fluid composite mixture by combining it with binding agents, enabling on-site application and forming a new elastic layer. This parameter change allows the same material to serve a new function in a different form.
2Ease of manufacture
If pre-mixed elastic composite is prepared off-site, then manufacturing is simplified, but transportation costs and logistics increase
Solution Approach 1:
The patent segments the elastic composite into two components: infill material that can be collected from existing turf and a binding agent that is applied on-site. This segmentation eliminates the need to transport pre-mixed composite while maintaining manufacturing simplicity.
Solution Approach 2:
The patent performs preliminary collection and mixing of infill material at the installation site before final composite formation, eliminating transportation of pre-mixed material and reducing logistics complexity while maintaining ease of manufacture.
3Ease of manufacture
If pre-mixed elastic composite is stored off-site, then manufacturing is simplified, but the mixture may solidify before application
Solution Approach 1:
The patent separates the elastic composite into infill material and binding agent components, allowing indefinite storage of each component without solidification issues. The binding agent is applied on-site in its liquid state, eliminating time-related solidification problems.
Solution Approach 2:
The binding agent is applied directly at the installation site in its liquid state, allowing the mixture to remain workable throughout the application process without requiring storage. The system serves itself by eliminating the need for off-site mixing and storage.
4Ease of manufacture
If aged artificial turf is removed completely, then replacement is simplified, but waste increases and costs increase
Solution Approach 1:
The patent recovers aged infill material and elastic layer fragments from removed artificial turf systems, mixing them with binding agents to create new elastic layers. This recovery process reduces waste and costs while maintaining replacement simplicity.
Solution Approach 2:
The patent creates new elastic layer composites by combining aged infill material, elastic layer fragments, and binding agents. This composite approach allows reuse of aged materials in a new functional form, reducing waste while maintaining system performance.
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
This approach reduces waste, lowers installation costs, and extends the lifespan of artificial turf systems by creating a durable, elastic layer that can be reused, thereby minimizing the environmental impact of frequent replacements.
Implementation Method 1
mixing the artificial turf infill, a binding agent, and fragments of an aged elastic layer for forming a fluid elastic composite
Implementation Method 2
applying the fluid elastic composite on a substrate at the site for forming the elastic layer
Data Source
AI summary
A method for manufacturing an elastic layer on site provides for collecting artificial turf infill from an aged artificial turf, mixing the artificial turf infill, a binding agent, and fragments of an aged elastic layer for forming a fluid elastic composite, and applying the fluid elastic composite on a substrate at the site for forming the elastic layer.