Unitary Roll-Form Shock Pad for Outdoor Field Installations
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Solution Overview
Problem
Existing outdoor field installations require complex and costly sequential installation of separate drainage and shock-absorbing components, which are not economically viable for large areas and do not provide uniform shock absorption and drainage.
Innovation Solution
A unitary roll-form shock and drainage pad made of integrally formed flexible polymer foam with uniformly spaced grooves and macroscopic holes for efficient drainage, and slots for temperature stability, allowing for continuous length and reduced basis weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate drainage and shock-absorbing components are installed sequentially, then drainage function is achieved, but installation complexity and time increase substantially
Solution Approach 1:
The patent combines separate drainage and shock-absorbing components into a single integrated pad structure. The pad includes a shock-absorbing layer with embedded drainage channels and void spaces, eliminating the need for sequential installation of multiple layers and reducing installation complexity while maintaining reliable drainage function.
Solution Approach 2:
The integrated pad performs multiple functions simultaneously: it provides shock absorption through the foam layer, drainage through embedded channels and void spaces, and filtration through geotextile layers. This multi-functional design replaces multiple separate components with a single universal element.
2Strength
If molded impervious plastic core is used for drainage blanket, then structural strength is improved, but shock absorption capability deteriorates
Solution Approach 1:
The patent changes the material parameter from rigid molded plastic to flexible closed-cell foam, fundamentally altering the mechanical properties. This allows the core structure to provide both structural integrity and shock absorption capability through the foam's compressible yet resilient nature.
Solution Approach 2:
The patent creates a composite structure combining closed-cell foam material with embedded drainage channels and geotextile layers. This composite approach integrates the structural strength needed for installation with the shock absorption properties of foam and the drainage functionality of the channel system.
3Reliability
If recycled closed-cell polyethylene foam sheet is used, then shock absorption is provided, but drainage performance becomes difficult to control precisely
Solution Approach 1:
The patent segments the drainage function into distinct, intentionally formed channels and void spaces within the foam structure. This segmentation allows precise control over water flow paths and drainage rates, overcoming the uncontrolled drainage of recycled foam while maintaining shock absorption properties.
Solution Approach 2:
The patent changes the drainage mechanism from relying on random interstitial spaces in recycled foam to using intentionally formed channels with controlled dimensions, spacing, and connectivity. This parameter control enables precise tailoring of drainage performance while preserving shock absorption.
4Area of stationary object
If multiple pieces are required to span field width, then coverage area is achieved, but number of seams increases
Solution Approach 1:
The patent produces drainage pads in long continuous lengths (e.g., 15-25 meters or more) that can span the entire width of a sports field in a single piece. This preliminary sizing action eliminates the need for on-site seam joining, reducing installation complexity and potential failure points while achieving full field coverage.
5Strength
If high basis weight foam sheet is used, then durability is improved, but handling and maneuvering difficulty increases
Solution Approach 1:
The patent optimizes the foam basis weight to achieve a balance between durability and handleability. By controlling foam density and thickness parameters, the pad maintains sufficient strength for installation and long-term use while remaining flexible and manageable during handling and installation operations.
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 unitary pad provides excellent drainage and uniform shock absorption across large areas with reduced seams and lower installation costs, facilitating efficient and uniform performance.
Implementation Method 1
a shock-absorbing layer made of a closed-cell foam material
Implementation Method 2
drainage channels in its lower surface... vertical drainage through such a sheet depends entirely on the interstitial spaces between the foam particles
Data Source
AI summary
A unitary roll-form shock and drainage pad for an outdoor field installation is formed by a continuous length of shock-absorbing polymer foam sheet. The sheet has a plurality of grooves in its lower surface, the grooves extending continuously along the length of the foam sheet and being spaced apart across the width of the foam sheet, each groove having a crest defining a maximum penetration of the groove through the thickness of the foam sheet. The foam sheet further defines a plurality of rows of vertically extending holes extending from the upper surface of the sheet toward the lower surface, the holes in each row being spaced apart along the length of the foam sheet and being aligned with a respective one of the grooves such that the holes extend into the crest of the groove. A plurality of elongate through-going slots radiate out from each of at least some of the holes.