Turf Underlayment Panel Edges That Keep Drainage Paths Open
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Solution Overview
Problem
Existing artificial turf systems face issues with infill material migration, leading to reduced stability and impact absorption due to depletion of infill constituents, and the potential formation of a hard layer that compromises the turf's performance.
Innovation Solution
A turf underlayment layer comprising panels with top projections forming drainage channels and vertical support extensions that prevent sagging of the turf assembly, while allowing for water drainage and accommodating panel movement, is used to support the artificial turf system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If panels are assembled together to form drainage paths, then water drainage is enabled, but panel edges may move toward each other closing drainage paths
Solution Approach 1:
The panel edges are designed with a non-linear shape that allows dynamic adjustment. The drainage projections can move relative to each other to maintain spacing and drainage path openness while accommodating panel movement, transforming a static structure into a dynamic one that adapts to changing conditions.
Solution Approach 2:
The edge structure is segmented into multiple drainage projections spaced apart from each other. This segmentation allows individual projections to move independently while maintaining overall drainage functionality, preventing complete closure of drainage paths even when panels move toward each other.
2Strength
If vertical support extensions are added to panel edges, then turf assembly support is improved, but device complexity increases
Solution Approach 1:
The vertical support extensions are merged with the non-linear edge shape and drainage projections into a single integrated edge structure. This combination allows multiple functions (support, drainage, movement accommodation) to be achieved without adding separate components, thereby reducing overall device complexity while maintaining strength.
Solution Approach 2:
The non-linear edge shape serves multiple functions simultaneously: it provides structural support for the turf assembly, creates drainage paths when panels are assembled, and accommodates panel movement. This multi-functionality eliminates the need for separate components, reducing complexity while enhancing support capabilities.
3Reliability
If panel edges are made non-linear, then drainage paths remain open during panel movement, but manufacturing precision requirements increase
Solution Approach 1:
The non-linear shape is applied locally to specific portions of the panel edges rather than the entire edge. The drainage projections are positioned at specific locations along the non-linear edge, allowing precise control of drainage path openness only where needed while simplifying manufacturing requirements for the rest of the edge structure.
Data Source
AI summary
An underlayment layer is configured to support an artificial turf assembly. The underlayment layer comprises plurality of panels, each panel comprising a core with a top side and a bottom side. The top side has a plurality of top projections. The top projections form top side water drainage channels. The panels have edges, with the edges of one panel abutting the edges of adjacent panels, thereby forming a drainage path between adjacent panels. The panel edges have vertical support extensions that extend into the drainage paths between adjacent panels. The vertical support extensions have an upper surface for supporting an artificial turf assembly overlying the turf underlayment layer, and the panel edges having one or more complementary indentations corresponding to vertical support extensions of adjacent panels. When the panels move toward each other, thereby closing drainage paths between adjacent panels, the vertical support extensions are received in the corresponding indentations.