WO2006007862A1

WO2006007862A1 - Sports floor and method for producing an elastic cushioning layer

Info

Publication number: WO2006007862A1
Application number: PCT/EP2004/007944
Authority: WO
Inventors: Peter MÜHLBERGER; Hugo De Vries
Original assignee: Gebr. Wunderlich Gmbh & Co. Kg; Airlastic Bv
Priority date: 2004-07-16
Filing date: 2004-07-16
Publication date: 2006-01-26

Abstract

The invention relates to a sports floor (19) comprising a playable upper layer (21), an elastic cushioning layer (1) and an intermediate layer (20) that is located between the playable upper layer (21) and the cushioning layer (1). Said sports floor is characterised in that the elastic cushioning layer (1) has a cup structure (5) in the form of uniformly spaced recesses (2) with a depth t, which extend over the cushioning layer (1) and are produced by the deformation of a web (3) with a thickness d. Preferably the ratio t/d is greater than or equal to 1.2. The invention also relates to a method for producing an elastic cushioning layer (1) that comprises recesses (2) and consists of a plastic that is deformed during said method. The method is characterised in that the recesses (2) are uniformly spaced, have a cup structure (5) and are created by the deformation of the plastic. According to said method, a web (3) of plastic is softened by heating and then deformed and said deformation is obtained by the application of a vacuum or the action of a stamp to or on uniformly spaced points of the softened web (5).

Description

Sports floor and method for producing an elastic damping layer

The invention relates to a sports floor and a method for producing an elastic damping layer.

The PCT application PCT / NL03 / 00542 describes a method for producing a recordable surface, in particular a playing field, as well as the surface or playing field produced therewith.

The method comprises forming a relatively hard substrate on which at least one layer of elastic and / or damping material (hereinafter referred to as "damping layer") is applied, The method is characterized in that after arranging the relatively hard substrate and / or According to one embodiment, the air chambers are arranged in the upper region of the damping layer In this embodiment, their formation takes place by generating so-called "depressions" (recesses) in the damping layer from above. For this purpose, a device is proposed which has "protruding parts", which are moved over the uncured material, and the use of a profiled "pressure roller" is also contemplated the air- chambers forming depressions are formed directly upon depression of the Dämp¬ tion layer. This saves a work operation.

The aforementioned method has the disadvantage of poor material utilization. As far as "recesses" is concerned, it is clear that a one-sided sack opening is understood, which covers only a part of the material, the remainder remains unused.As far as a profile of a pressure roller is mentioned, it is not clear which structure will be preserved. The disadvantages of the method are also inherent in the product produced therewith.

The object of the invention is to provide a method with which, with good material utilization, an elastic damping layer suitable for a sports floor can be produced.

This object is achieved with the sports floor according to claim 1, the method according to claim 13 of the elastic damping layer according to claim 28, and the use according to claim 29 and 30, respectively. Further developments of the synthetic turf and the method are described in the subclaims.

The invention relates to a sports floor. The sports boot according to the invention comprises a playable upper layer, an elastic damping layer and an intermediate layer arranged between the recordable upper layer and the damping layer. According to the invention, the elastic damping layer (1) has a cup structure (5) produced by deformation of a web (3) of thickness d, which is formed by depressions (2) spaced apart from one another and extending over the damping layer (1). which have the depth t.

The ratio t / d is preferably 1, 2 or greater, but according to another embodiment of the invention may be in the range of 1.2 to 5, preferably in the range of 1.5 to 2. An example of this embodiment (in which t / d has the value 4) is described in more detail in connection with FIG. 4.

In another embodiment, the wells face down, i. in

Direction to a subsoil, which is located below the sports ground. This embodiment (also shown in FIG. is explained in conjunction with it) is particularly preferred. The cup structure according to the invention fundamentally leads to a stiffening effect. If the recesses are arranged downward, this stiffening effect can be used particularly advantageously.

The thickness d of the web may preferably be in the range of 2 to 10 mm, the depth t in the range of 3 to 40 mm.

In addition to their depth t, the depressions have a width b, which is preferably in the range from 10 to 40 mm, as a further geometry parameter.

Preferably, the elastic damping layer consists of a deformed plastic, which is preferably a thermoplastic foam. Foams of polyethylene (PE), polypropylene (PP) or polyvinyl chloride (PVC) are suitable.

In one embodiment, the recordable topsheet is constructed of a geotextile material laminated to the intermediate layer. Geotextiles are knitted, woven, knitted or stitched textile fabrics. In addition to geotextiles, it is possible to use all textile nonwovens, in particular knitted, woven, knitted or rusted nonwovens and spun nonwovens or needled nonwovens having a weight of between about 10 and 200 g / m ² and a thickness of 2/100 and 2 mm.

The intermediate layer itself may consist of rubber granulate, optionally with added minerals (sand, gravel, stones).

The invention further relates to a method for producing a Ver¬ recesses having elastic damping layer. The damping layer consists of a plastic that is deformed during the process. The depressions have the shape of a cup structure and are produced by softening and deforming a web of the plastic by heating, the deformation being achieved by applying a vacuum or by acting on a stamper at locations of the softened web that are evenly spaced apart from each other.

According to a first embodiment of the first variant of the method according to the invention, the application of vacuum by means of a suction device which has cups on one side, the inner shape of which corresponds to the shape of the recesses to be produced. On the other side, the suction device carries lines for applying the vacuum.

According to a further embodiment, the action of the stamp is effected by a stamping device which has a carrier and elevations projecting from this carrier in the direction of the web, the outer shape of which corresponds to the shape of the depressions to be produced. It is preferred that the carrier is a plate and the elevations are substantially perpendicular from the plate ab¬.

Alternatively, the carrier can also be a roller, the elevations projecting substantially perpendicular to the tangential direction from the roller. Suitable elevations have a lower part with the shape of a cylinder, on which a spherical cap is placed.

The other parameters or features of the method according to the invention (i.e., the depth t and width b of the recesses and the ratio t / d) are described as in the sports floor according to the invention.

For the purposes of this description, the term "cup structure" means the presence of wells which extend in a regularly repeating arrangement over the entire area of the elastic damping layer and have the depth t. The wells represent the outer end points of the wells, ie the point The depth t is defined as the inner end point of the depression, up to which the material of the web is deformed on the outer side of the cups during the execution of the method , ie as the point up to which the material of the web is deformed on the inside of the recesses during the passage ¹ 'of the method (see also FIG. 4).

The ratio between the depth t of the depression and the thickness d of the web is preferably t / d> 1.2. This means that the depression is at least 20% larger than the thickness d of the web, which inevitably results in a damping layer with a correspondingly greater total thickness D. Assuming that the thickness d of the web is not substantially changed during deformation, the following applies: D = 2 d + t In addition, in this embodiment, t / d ≥ 1.2, and therefore also D ≥ 3.2 d.

The thickness D of the damping layer and the thickness d of the web used are thus in the ratio of at least 3.2.

The method according to the invention inevitably leads to such a thinner cup structure. According to the method, the material to be deformed of the web is continuously bent from a first plane (the plane of the original web) almost rectangular and leads in a parallel second plane über¬ leads, then again bent at right angles and zu¬ to be fed back to the first level. The total thickness D of the resulting damping layer therefore results as indicated as a sum (2 d + t). Thus, the method is characterized by a very good material utilization and makes it possible to produce a damping layer with a substantially higher total thickness D with a (low-cost) material of small thickness d.

In general, the depth t and the thickness d represent control parameters for the properties of the damping layer according to the invention. If they are to be used exclusively for damping and stabilization purposes (as in an artificial turf), t is chosen to be rather small, ie in the range of approximately 5 to 8 mm. With larger values of t of about 6 to 12 mm, material with excellent acoustic properties is obtained which can be used (for example in a sound studio) for sound absorption). Wells of such great depth t are more likely to be referred to as "honeycombs" (and the resulting structure rather than "honeycomb"). In wells of suitable size, the sound is reflected so often until the energy of the sound wave is exhausted (it is said that the sound "runs dead.") A honeycomb structure suitable for sound absorption has, for example, the value d = 1 mm, t = 12 mm, t / d = 12 and D = 14. The subject matter of the invention therefore continues to be the use of the damping layer according to the invention for sound absorption. Because the recesses are spaced apart, there exists between each two recesses, an area in which the material is undeformed. As already mentioned, this material region lies in the first plane. The wall material of the recesses lying between the two planes has a stiffening effect, because it is loaded only in its longitudinal direction when loaded from above (for example, tread loading in an artificial turf). This results in a stabilizing effect in the sense of stiffening and allows the use of the damping layer according to the invention in an artificial turf. This use is also the subject of the invention.

Further advantages, features and possible applications of the invention will become apparent from the following examples and the drawings; show it:

1 shows the schematic representation of an embodiment of the erfindungs¬ proper method using a suction device,

2 shows the schematic representation of an embodiment of the method according to the invention using a stamping device,

3 shows an embodiment of the method according to the invention using a stamping device in the form of a stamping roller,

4 shows a sectional drawing and a perspective view of the elastic damping layer according to the invention, and FIG. 5 shows the use of the damping layer according to the invention in a sports floor.

Fig. 1 shows a schematic representation of an embodiment of the inventive method using a suction device. The direction of manufacture takes place in accordance with the arrow 23, i. in the picture from left to right. The suction device 4 is fed to a web 3, which initially passes through a heating device 18. The heater 18 is used to heat and soften the web 3. The heating can be done with hot air or (preferably) by using IR radiation.

After heating, the web 2 enters the area of action of a suction device 4 which, in the embodiment shown, has six wells 6 arranged one behind the other. The inner shape of the wells 6 corresponds to the shape of wells to be created 2. To the wells can via lines 7 a Vacuum be created. By a double arrow 24 is indicated that the suction device 4 can be lowered or raised.

Specifically, the manufacturing process is such that after the insertion of a portion (ie, a certain length) of the heated web 2 in the area of effect of the suction device 4, the web 2 stopped and lowered the Saugeinrich¬ device 4 and via the lines 7, the vacuum is created. After the formation of the depressions 2, the vacuum is switched off and the wells 6 are ventilated. The suction device 4 can then be raised and another section of the heated strip 3 introduced and the process repeated. The exemplary mode of operation is intermittent, but it is also possible to work continuously.

As will be explained in detail in connection with FIG. 4, the cup structure 5 according to the invention has a characteristic structure. It consists of the depressions 2 (which extend upward in FIG. 1) and of counter-depressions 9 (which extend downwards in FIG. 1) arranged next to them. This results in an unchanged region 8. The overall ent¬ standing structure has a high rigidity and allows the use of the er¬ inventive damping layer in an artificial turf.

FIG. 2 is a schematic representation of an embodiment of the method according to the invention using a stamping device. FIG. It shows a plate-shaped stamping device 10 which is constructed from a plate 11 and elevations 12. The elevations 12 have a lower cylindrical portion 13, to which a spherical cap 14 connects. The elevations 11 are substantially perpendicular from the plate 10 from. For clarification, a survey 12 together with lower part 13 and attached ball callus is shown enlarged. The details of the production are as described in FIG. 1, ie it is in a corresponding manner, the punch device 10 is raised (arrow 24) to press the wells 2 in the heated sheet 3. However, there is the difference that the web 3 has to be guided thereby. This takes place with a perforated plate 15 arranged between the web 3 and stamping device 10, into which holes (holes) are machined into which the elevations 12 enter. fit (further explanations to the perforated plate 15, see Fig. 3). Again, you can work intermittently or continuously.

3 shows an embodiment of the method according to the invention with use of a stamping device 15 in the form of a stamping roller. The production direction is again indicated by the arrow 22. The web 3, after being heated by a heater (not shown), passes into the nip formed by a stamp roller 16 and a perforated roller 17. It can be seen that the elevations 12 correspond to those of the stamp plate 10 of FIG. 2 completely, but are here placed on a roller. The function of the perforated plate 15 of FIG. 2 (guiding the heated web during the depression of the depressions 2) is taken over here by the perforated roller 17.

In addition, Fig. 3 shows the perforated plate 15 used in the method of Fig. 2. It can be seen that it has an incorporated hole pattern which is optically shaping the final product. When compared with the elastic damping layer 1 shown in Fig. 4 it is clear that the patterns are identical. Of course, stamping device 10 and perforated plate 15 form a mechanical functional unit, i. they must have the same pattern, the same. This also applies to stamping roller 16 and perforated roller 17.

4 shows a sectional drawing and a perspective view of the elastic damping layer 1 according to the invention. The sectional drawing serves to illustrate the dimensional relationships between the depressions 2 and the web 3. In the example shown, t (filled double arrow) is 10 mm and d (solid individual arrows) 2 , 5 mm. Thus, for the ratio t / d = 10 / 2.5 = 4. The total thickness D of the elastic damping layer 1 (open double arrow) is 12.5 mm, that is obtained starting from a 2.5 mm thick web 2 a Fivefold the material thickness. It is thus possible to produce a damping layer 1 which is considerably thicker in relation to this with relatively thin (that is to say inexpensive) web material. This leads to the already mentioned good material utilization of the method according to the invention. The strength (eg against tread) suffers therefrom only insignificantly, because one receives the - also already discussed - stabilizing stiffening effect. This is similar to an egg carton. Furthermore, in FIG. 4, the width b of a depression 2 is also drawn in at one point. It is also 8 mm.

Fig. 4 is illustrative and is therefore drawn only schematically with respect to t. As already mentioned, the value of t represents a control parameter for the properties of the damping layer. In a practical damping layer, typically d = 4 mm, and at most approximately t = 8 mm, where t / d = 8/4 = 2. The total thickness D is 16 mm in this case. The width b is typically 22 mm. When used for sound absorption, it is typical that d = 1 mm, and a maximum of about t = 12 mm, thus t / d = 12. The total thickness D in this case is 14 mm, a typical value for width b 18 mm.

The perspective view of the erfindungsge¬ dimensional elastic damping layer 1 also contained in Fig. 4 (with respect to the upper drawing) is a view from above, under conditions of use of FIG. 5 also from above. The uniform distribution of the recesses 2 over the total area of the damping layer 1 and the resulting cup structure can be seen.

Reference should be made to an important difference between the above-described damping layer according to the invention and that disclosed in PCT application PCT / NL03 / 00542. The cup structure according to the invention with uniformly spaced depressions inevitably comprises - as already mentioned - the existence of undeformed regions between adjacent depressions. Two of these undeformed regions are marked in FIG. 4 by reference numeral 8. Just as inevitably arises behind each undeformed area 8 a counter-recess 9, d. h a material-free room.

In contrast to ¹ is in the cushioning layer of the above PCT application to form a structure, are beitet in eingear¬ in a layer of air chambers which, however, in the rest of a solid material (rubber granules or the like.) Represents dar¬.

5 shows the use of the damping layer 1 according to the invention in a sports floor 19. Hissing a playable upper layer 21 and the damping layer 1 is an intermediate layer 20. The installation of the damping Layer 1 takes place - as shown in FIG. 5 - preferably in such a way that the depressions 2 face downwards, ie in the direction of the substrate 22. For clarity, in the figure, the substrate 22 has a low (usually not present in practical use). Distance shown.

LIST OF REFERENCE NUMBERS

1 elastic damping layer

2 deepening

3 train

4 suction device

5 bowl structure

6 bowls

7 line

8 undeformed area

9 counter-recessing

10 plate-shaped punch device

11 plate

12 survey

13 lower part

14 spherical cap

15 perforated plate

16 stamping roller

17 perforated roller

18 Heinze device

19 sports floor

20 intermediate layer

21 playable upper class

22 underground

23 Production direction

24 Direction of lowering / raising

Claims

claims

1. Sportbόden (19), comprising a playable upper layer (21), an Elas¬ tische damping layer (1) and between the recordable Ober¬ layer (21) and the damping layer (1) arranged intermediate layer (20), characterized geken characterized, in that the elastic damping layer (1) has a cup structure (5) produced by deformation of a web (3) of thickness d, which is formed by recesses (2) which are regularly spaced apart and extend over the damping layer (1) and which form the Have depth t.

2. sports floor according to claim 1, characterized in that the ratio nis t / d 1, 2 or greater.

3. Sports floor according to claim 2, characterized in that the ratio t / d of depth 5 to thickness in the range of 1, 2 to 10, preferably from 1, 5 to 5.

4. Sports floor according to one of the preceding claims, characterized gekenn¬ characterized in that the elastic damping layer (1) is arranged so that the recesses (2) point downwards.

5. Sports floor according to one of the preceding claims, characterized in that the thickness d is 2 to 10 mm.

6. Sports floor according to one of the preceding claims, characterized gekenn¬ characterized in that the depth t is 3 to 40 mm.

7. Sports floor according to one of the preceding claims, characterized gekenn¬ characterized in that the width b of the recesses (2) is 10 to 40 mm.

8. Sports floor according to one of the preceding claims, characterized gekenn¬ characterized in that the elastic damping layer (1) consists of a deformed plastic.

9. Sports floor according to claim 8, characterized in that the deformed plastic is a thermoplastic foam.

10. Sports floor according to claim 9, characterized in that the foam is a polyethylene, polypropylene or polyvinyl chloride foam.

11. Sports floor according to one of the preceding claims, characterized gekenn¬ characterized in that the recordable upper layer (21) of the intermediate layer (20) laminated material is constructed of geotextile.

12. Sports floor according to one of claims 1 to 11, characterized in that the intermediate layer (20) is expanded from rubber granules, optionally stones are added.

13. A method for producing an elastic damping layer (1), wherein the damping layer (1) recesses (2) and consists of a Kunst¬ material which is deformed during the process, characterized in that the recesses (2) are evenly spaced from each other and thus have a cup structure (5) and are produced by the deformation of the plastic, whereby a web (3) of the plastic softens and deforms by heating and wherein the deformation is effected by applying vacuum or action of a plastic Stamp takes place at mutually equally spaced locations of the softened web (5).

14. The method according to claim 13, characterized in that the application of vacuum by a suction device (4) takes place, which on one side Näp¬ Fe (6), the inner shape of the shape of the Vertie¬ to be generated cavities (2), and on the other side carries lines (7) for applying the vacuum.

15. The method according to claim 13, characterized in that the action of the punch by a stamping device (10, 15) takes place, the one

Carrier (11, 16) and from the carrier (11, 16) in the direction of the web (5) ab¬ standing elevations (11) whose outer shape corresponds to the shape of the recesses (3) to be generated.

16. The method according to claim 15, characterized in that the carrier is a plate (10) and the elevations (11) protrude substantially perpendicularly from the plate (10).

17. The method according to claim 15, characterized in that the carrier is a roller (16) and the elevations (11) substantially perpendicular to

Tangentialrichuntg from the roller (16) protrude.

18. The method according to claim 16 or 17, characterized in that the elevations (11) have a cylindrical lower part (13) mounted thereon with a spherical cap (14).

19. The method according to any one of claims 13 to 18, characterized in that the ratio t / d between the depth t of the recess (2) and the thickness of the track (3) is 1, 2 or greater.

20. The method according to any one of claim 19, characterized in that the ratio t / d from depth to thickness in the range of 1, 2 to 5, preferably from 1, 5 to 2.

21. The method according to any one of claims 13 to 20, characterized in that the thickness d is 2 to 5 m.

22. The method according to any one of claims 13 to 21, characterized in that the depth t is 5 to 40 mm.

23. The method according to any one of claims 13 to 22, characterized in that the width b of the recesses (2) is 10 to 40 mm.

24. The method according to any one of claims 13 to 23, characterized in that the plastic is a thermoplastic foam.

25. The method according to claim 24, characterized in that the foam is a polyethylene, polypropylene or polyvinyl chloride foam.

26. The method according to any one of claims 13 to 25, characterized in that the recordable upper layer (21) of the intermediate layer (20) an¬ laminated material is constructed of geotextile.

27. The method according to any one of claims 13 to 25, characterized in that the intermediate layer (20) is expanded from rubber granules, optionally stones are added.

28. Elastic damping layer, produced by a method according to one of claims 13 to 27.

29. Use of the elastic damping layer according to claim 28 as a damping layer in an artificial turf.

30. Use of the elastic damping layer according to claim 28 for sound absorption.