Classifications

• • E—FIXED CONSTRUCTIONS
  • E01—CONSTRUCTION OF ROADS, RAILWAYS, OR BRIDGES
  • E01C—CONSTRUCTION OF, OR SURFACES FOR, ROADS, SPORTS GROUNDS, OR THE LIKE; MACHINES OR AUXILIARY TOOLS FOR CONSTRUCTION OR REPAIR
  • E01C13/00—Pavings or foundations specially adapted for playgrounds or sports grounds; Drainage, irrigation or heating of sports grounds
  • E01C13/08—Surfaces simulating grass ; Grass-grown sports grounds
  • E01C13/083—Construction of grass-grown sports grounds; Drainage, irrigation or heating arrangements therefor
• • E—FIXED CONSTRUCTIONS
  • E01—CONSTRUCTION OF ROADS, RAILWAYS, OR BRIDGES
  • E01C—CONSTRUCTION OF, OR SURFACES FOR, ROADS, SPORTS GROUNDS, OR THE LIKE; MACHINES OR AUXILIARY TOOLS FOR CONSTRUCTION OR REPAIR
  • E01C13/00—Pavings or foundations specially adapted for playgrounds or sports grounds; Drainage, irrigation or heating of sports grounds
  • E01C13/02—Foundations, e.g. with drainage or heating arrangements
• • E—FIXED CONSTRUCTIONS
  • E01—CONSTRUCTION OF ROADS, RAILWAYS, OR BRIDGES
  • E01C—CONSTRUCTION OF, OR SURFACES FOR, ROADS, SPORTS GROUNDS, OR THE LIKE; MACHINES OR AUXILIARY TOOLS FOR CONSTRUCTION OR REPAIR
  • E01C13/00—Pavings or foundations specially adapted for playgrounds or sports grounds; Drainage, irrigation or heating of sports grounds
  • E01C13/04—Pavings made of prefabricated single units
  • E01C13/045—Pavings made of prefabricated single units the prefabricated single units consisting of or including bitumen, rubber or plastics

Definitions

• the present invention relates to a drainage mat system with built-in damping and anti-fatigue properties and improved drainage behaviour, the process for preparation of such system and the use of such system.
• Drainage systems for mainly outdoor application in sports and leisure e.g. turf, artificial turf, sports tracks, athletic grounds, slopes, playgrounds etc.
• building and construction flat and green roofing, draining counterpart to irrigation, such as in greenhouses etc.
• thermoplastic resin based materials mainly PE, as in JP 8135157 , KR 102008019194 ; with drain holes in JP 5272110 , JP 59072302 , KR102005011423 ; with ripples in JP 59059120 ; from PVC with drain holes in JP 2195910 ).
• a major object of the present invention thus is to provide a system or material not showing the above mentioned deficiencies but exhibiting easy, i.e. economic and ecological, manufacturing and handling/mounting/application, showing excellent drainage effect and a high level of built-in damping ability leading to anti-stress and anti-fatigue properties.
• the claimed material comprises at least one layer (A), which is made from an expanded elastomer and/or thermoplastic elastomer and/or thermoplastic and/or thermoset based polymer mixture, or combinations thereof, which is preferably crosslinked to improve mechanical and wear properties.
• the polymer mixture is expanded by physical and/or chemical expansion agents to an open cell sponge or closed cell foam, depending on the required damping and drainage properties.
• the polymer mixture may contain fillers, such as oxides, carbonates, hydroxides, carbon blacks, recycled (ground) rubber, other recycled polymer based materials, fibers etc., and additives, such as flame retardants, biocides, plasticizers, stabilizers, colors etc., of any kind in any ratio.
• the polymer mixture may be crosslinked by any applicable mean of crosslinking, such as sulphur, peroxide, radiation, bisphenolics, metal oxides etc.
• A can show low densities if applied as underlay mat, but also can be compounded and expanded to densities higher than water to prevent floating if applied without covering, support or loading. It is found that (A) provides damping already if an elastic modulus (E-modulus) below 5 is achieved, allowing to use various combinations of polymer based compounds and various combinations of layers (A) made thereof.
• E-modulus elastic modulus
• the claimed material comprises a set of pin holes (B) in layer (A).
• the pin holes can be applied in a wide variety of size and pattern, however, it is found that the pin holes are preferably applied in a size not smaller than 0.1" (0.25 cm), especially preferred in a size bigger than 0.2" (0.5 cm); it is also found that the preferred distance of the pin holes is at least 1" (2.5 cm), especially preferred at least 2.5" (6.35 cm).
• the pin holes (B) can be brought into (A) directly when manufacturing in a molding process by fixing pins in the mold accordingly, or by perforating them into (A) e.g. after extrusion by pins or round knives or the like.
• the pin holes (B) not only do provide good drainage effect, but also will contribute to the damping properties by slightly "softening" the mat (see table 1).
• the claimed material furthermore comprises a surface structure (C) on either one or both sides of (A) which is characterized by ripples or ridges or grooves.
• the structure can be of round (sinus like) and/or triangular and/or trapezoidal and/or rectangular shape. It can be integrated into the material (A) by applying the structure (C) e.g. in a mold when manufactured by molding, or by using a respective die shape when manufacturing by extrusion, or by embossing the respective structure (C) into (A).
• the surface structure (C) will ensure that water will be rapidly transported to the pin holes (B) if the structure can be found on the top side of (A), or structure (C) will ensure that water will be drained away from the pin holes when being applied on the bottom side of (A), or both effects may be combined.
• Table 2 shows the significantly better drainage properties of pin hole/ridge systems in comparison to pin hole only systems.
• the surface structure will also slightly contribute to the damping properties.
• the claimed material furthermore may comprise additional layers (D) providing additional drainage and/or damping and/or other properties, such as reinforcement, impact resistance etc.
• the layers (D) can e.g. comprise fibres or nonwoven, wire mesh, resin sheet etc. of any kind. Layers (D) can be fixed to (A) by mechanical or chemical means or being in contact only. If (D) is applied as directly connected surface layer the composite may be used not only as underlay mat, but in direct exposure, means, as e.g. a playground or sports or roof mat without turf or soil covering.
• Another basic advantage of the claimed material is the fact that its drainage and damping properties are very constant over a wide temperature range leading to the fact that its playability and "feel" remain unchanged no matter if it is used in summer or winter.
• composition will allow to add any desired additives beneficial for the intended application, such as UV stabilizers, biocides (e.g. for preventing mold growth), absorbers (e.g. scavengers for odor, harmful substances etc. to protect the environment) etc.
• additives beneficial for the intended application such as UV stabilizers, biocides (e.g. for preventing mold growth), absorbers (e.g. scavengers for odor, harmful substances etc. to protect the environment) etc.
• a resulting advantage of the material is the fact that it can be blended or filled with or can contain scrapped or recycled material of the same kind to a very high extent not losing relevant properties significantly.
• a basic advantage of the claimed material is the fact that it is free of fibres and can be produced also free of PVC if required, both of them being under survey and being discussed for environmental and health issues.
• a further advantage of the claimed material is that phthalates are not needed as plasticizers, which are partially under discussion and partially prohibited already for the same reason.
• a further advantage of the claimed material is the possibility to adapt its properties to the desired property profile (concerning mechanics, damping, water intake, porosity etc.) by expanding it to an appropriate foam cell structure from totally open-cell to totally closed-cell.
• This can be achieved by modifying the crosslinking system(s), the expansion agent(s) and the base matrix, as well as the density.
• the material thus can be modified from water repellent to water absorbing; it can be altered to damp from high to low frequencies or frequency bands, and good playability is always ensured.
• a further advantage of the claimed material is the fact that it is easily colourable to match to the application, e.g. green for turf, brown for soil, etc.
• a mat of 5/8" (1.56 cm) thickness and 3 feet (91 cm) width had been produced by extruding, expanding and crosslinking a rubber compound (Armaprene® TU, Armacell GmbH, Weg/Armacell LLC., Conover NC). The mat then was cut into pieces of 3 feet (91 cm) length. One part of the pieces was furnished with pin holes of 0.25" (0.64 cm) diameter in an average distance of 3" (7.6 cm). A second part was embossed on one side by heated embossing rollers or structured hot plates, respectively, and then furnished with pin holes. A third part was used for comparative testing and left without embossing or applying pin holes.
• Example 1 Test of mats according to ASTM F355-01: Standard Test Methods for Shock-Adsorbing Properties of Playing Surface Systems and Materials.
• Data obtained from this test method are indicative of cushioning properties of the playing surface system and materials under the specific conditions selected.
• the playing system is impacted at a specified velocity with a missile of given mass and geometry to determine the maximum value of G encountered during impact.
• a turf system (the turf material used for all tests was a standard 42 Oz -2.25" PH-monofilament synthetic turf) was positioned over the sub base (crushed rock) with a clear view bumper (G max test equipment) placed over the entire playing surface system. The missile was released, so as to impact the center of the assembly at a velocity of 3.43 m/s at a drop height of 24" (61 cm).
• Example 2 Test according to British Standard 7044 Method 4: Determination of Infiltration Rate - Buffered Ponding-Type Infiltrometer
• the test conducted determines the rate at which water enters the turf surface under defined constant head conditions and reflects the permeability of the surface tested.
• the turf material used for all tests was a standard 42 Oz (2.25" PH) monofilament synthetic turf.
• Table 2 Drainage properties of elastomeric mats (all innovative examples) Infill Pad type Infiltration rate [inches/hour] Infiltration rate [centimeters/hour] 3.3 lbs/ft 2 Rubber mixed with 3.0 lbs/ft 2 Sand 5/8" Perforated Pad 25 45 3.3 lbs/ft 2 Rubber mixed with 3.0 lbs/ft 2 Sand 5/8" Perforated Pad with Ridges 31 79

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• Engineering & Computer Science (AREA)
• Architecture (AREA)
• Civil Engineering (AREA)
• Structural Engineering (AREA)
• Road Paving Structures (AREA)

Priority Applications (1)

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Publications (1)

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Family Applications (1)

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Cited By (3)

Citations (36)

• 2010
  • 2010-05-17 EP EP10162925A patent/EP2388375A1/fr not_active Withdrawn

Patent Citations (36)

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