Synthetic Grass Mat with Bell Protrusions and Hexagonal Cells
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Solution Overview
Problem
Existing synthetic grass playing field mats face challenges in coupling synthetic grass of varying thickness, reducing rubber granules and sand usage while maintaining performance, and ensuring effective drainage and energy absorption.
Innovation Solution
A mat with a central membrane featuring bell-shaped protrusions and a lower cellular structure of adjacent hexagonal cells, made from a rubber compound derived from recycled tires and polyolefin resins, which absorbs and distributes impact energy uniformly across the surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional mat structures are used, then synthetic grass can be supported, but the mat cannot effectively drain rainwater leading to puddle formation
Solution Approach 1:
The mat structure is segmented into multiple functional layers: a upper layer with bell-shaped protrusions for impact absorption, a central membrane for structural support, and a lower cellular structure with polygonal cells for drainage. This segmentation allows each layer to perform its specific function optimally, with the lower cellular structure creating channels that efficiently drain rainwater through to the base layer, preventing puddle formation while maintaining reliability.
Solution Approach 2:
The drainage function is enhanced by transitioning from a flat two-dimensional surface to a three-dimensional cellular structure with vertical channels. The polygonal cells in the lower region create multiple drainage pathways that extend vertically through the mat thickness, enabling efficient rainwater drainage in the vertical dimension while maintaining surface integrity.
2Reliability
If traditional mat structures are used, then synthetic grass can be supported, but impact energy is not absorbed uniformly, affecting player safety
Solution Approach 1:
The mat employs local quality variations through its bell-shaped protrusions distributed across the upper surface. Each protrusion creates a localized impact absorption zone with optimized geometry, while the overall pattern distributes these localized zones uniformly across the entire mat surface. This ensures that impacts from any direction are absorbed consistently, maintaining player safety and compositional stability.
Solution Approach 2:
The mat uses composite material construction combining different rubber compounds with varying hardness and elasticity properties. The upper layer material is optimized for impact absorption, while the central membrane and lower cellular structure use materials optimized for structural support and energy distribution. This composite approach enables uniform energy absorption across the entire mat while maintaining structural integrity.
3Reliability
If traditional mat structures are used, then synthetic grass can be supported, but the mat lacks dimensional stability during installation and use
Solution Approach 1:
The central membrane serves multiple functions: it provides structural support, maintains dimensional stability, and acts as a barrier layer. This multi-functional design eliminates the need for separate stabilization layers, simplifying installation while ensuring the mat maintains its dimensions during both installation and use. The membrane's universal role in structural support and stability maintenance makes the mat easy to install yet dimensionally stable.
4Reliability
If traditional mat structures are used, then synthetic grass can be supported, but large quantities of rubber granules and sand are required, increasing cost
Solution Approach 1:
The invention extracts and integrates the drainage function directly into the mat structure through the lower cellular structure with polygonal cells. This eliminates the need for separate drainage layers and reduces the quantity of rubber granules and sand required, as the cellular structure itself provides the drainage pathways. The extraction of drainage functionality from separate components allows for reduced material usage while maintaining performance.
Solution Approach 2:
The lower cellular structure employs a porous material design with polygonal cells that create interconnected drainage channels. This porous structure provides efficient drainage and impact absorption with reduced material density, allowing the mat to maintain required performance while using smaller quantities of rubber granules and sand. The porous geometry optimizes the ratio of structural integrity to material consumption.
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 mat effectively absorbs and releases energy from impacts, maintains dimensional stability, and reduces the need for rubber granules and sand, while ensuring efficient drainage and compliance with international regulations, making it reliable, easy to install, and cost-effective.
Implementation Method 1
absorb and release energy at the upper protrusion of the bell 3; absorb and release energy at the lateral wall 3a of the bell 3; absorb and release energy at the central membrane 2 that supports the bell 3; absorb and release energy at the hexagonal cellular structure 5 at the pins 6
Implementation Method 2
a lower region with a cellular structure formed by mutually adjacent polygonal cells
Implementation Method 3
ensuring the draining of rainwater in order to avoid the creation of puddles
Data Source
AI summary
A mat for synthetic grass playing fields, includes a central membrane adapted to support in an upper region a number of substantially bell-shaped protrusions. The central membrane is provided in a lower region with a cellular structure formed by mutually adjacent polygonal cells. A high-performance high-drain mat for synthetic grass playing fields is provided to support synthetic grass.