Padding layer with drainage for sports playing field

There is described a panel assembly to be laid over a base surface and under a carpet-like top layer to install a multi-layered sports-playing field. The padding assembly comprises a panel comprising a top face and a bottom face, with the top face of the panel facing the carpet-like top layer and the panel further comprising drainage holes fluidly connecting the top face to the bottom face. The padding assembly also comprises a drain mat affixed to the bottom face of the panel with the drain mat operating as a fluid-permeable layer distancing the bottom face from the base surface. A method of installing a multi-layered sports-playing field is also described.

BACKGROUND

The subject matter disclosed generally relates to playing fields and more particularly to artificial sports playing fields. More particularly, the subject matter disclosed relates to panel assemblies for laying thereon artificial turfs of sports playing fields.

(b) Related Prior Art

Present day sports playing fields are often made of a mix of natural and synthetic/artificial material. A base layer of dirt, gravel, sand or other suitable material is sometimes provided. An artificial padding layer may then be installed on top of which a layer of artificial grass is laid. The artificial grass construction is very similar to most types of industrially-made carpets and can be filled or not with material like SBR, EPDM, TPE, coated sand, sand or other infill material.

The design consideration for sports playing fields include: athlete's safety, surface hardness, water drainage, heat management, ease of assembly/installation, durability/longevity, uniformity, resistance to change in weather according to seasons, stability, etc.

The playing field described herein was developed keeping all such factors in mind.

One particular challenge of such artificial playing fields relates to water drainage. Over the last decades, numerous patent applications have been filed that provide options to handle the water drainage challenge. For example, U.S. Pat. No. 9,771,692 B2 issued to Brock USA teaches to use an underlayment layer with a variety of projections for handling the flow of water for drainage. Another example is PCT Patent Application WO 2004/109017 A2 from Prevost that teaches a unit for a modular synthetic grass turf assembly.

SUMMARY

According to an embodiment, there is provided a panel assembly to be laid over a base surface and under a carpet-like top layer, the panel assembly comprising: a panel comprising a top face and a bottom face, the top face of the panel facing the carpet-like top layer, the panel further comprising drainage holes fluidly connecting the top face to the bottom face; and a drain mat affixed to the bottom face of the panel, the drain mat operating as a fluid-permeable layer distancing the bottom face from the base surface.

According to an aspect, the drain mat comprises one or more fibers defining an interminglement of fibers.

According to an aspect, the interminglement of fibers comprises, for any reference plane passing through the drain mat, a plurality of randomly oriented discrete fibers defining a plurality of non-hollow projections extending from the any reference plane.

According to an aspect, the intermingled fibers are made of one of Polyamide, Nylon, Polypropylene, polyethylene, Polyestere, or PVC.

According to an aspect, the top face of the panel comprises a top surface and a crown located above the top surface.

According to an aspect, the panel comprises top channels connected to the drainage holes.

According to an aspect, the panel has a thickness of between 0.25 and 6 inches.

According to an aspect, the panel is exclusively or partially made of one of Expanded Polypropylene (EPP) and of a Hybrid EPP (HEPP), wherein the HEPP comprises a mix of an EPP with at least one of an expanded Polyethylene (EPE), a Polyethylene (PE), a rubber material, a recyclable material in order to maximize hardness-flexibility ratio of the panel.

According to an aspect, the panel consists of a closed-cell structure made with closed-cell beads.

According to an aspect, the closed-cell beads are expanded closed-cell beads.

According to an aspect, the drain mat is affixed to the bottom face of the panel using one of a mechanical method, a chemical method and a thermal method.

According to an aspect, the drain mat has a thickness that distances the bottom face from the base surface when installed thereon, and wherein the thickness of the drain mat decreases to a minimum thickness when undergoing pressure, with the drain mat remaining water-permeable at the minimum thickness.

According to an aspect, the drain mat comprises a combination of a top layer and a bottom layer attached to each other and providing a spacing between the bottom face and the base surface, wherein the top layer has a substantially rippled shape while the bottom layer has a substantially flat shape and both the top layer and bottom layer are water-permeable.

According to an aspect, the panel and the drain mat are made of different materials in that the different materials have at least different mechanical characteristics.

According to an aspect, the panel and the drain mat form a single unit for installation over the base surface.

According to an aspect, the top face of the panel receives the carpet-like top layer directly without any other intermediary layer.

According to an aspect, the panel is made of a water-impervious material.

According to an embodiment, there is provided an underlayment to be laid over a base surface and under a carpet-like top layer, the underlayment comprising: a panel assembly comprising panels comprising edges and assembled together through their edges, wherein each one of the panels further comprises a top face and a bottom face with the top face of the panel facing the carpet-like top layer; a drain mat to be installed over the base surface and on which are laid the bottom faces of the panels, with the drain mat operating as a fluid-permeable layer distancing the bottom face of the panels from the base surface, wherein the panel assembly comprises drainage holes fluidly connecting the top face of the panel assembly to the bottom face of the panel assembly.

According to an aspect, the edges of the panels comprise an interlocking component interfacing with the interlocking component of another one of the panels for assembly.

According to an aspect, the underlayment further comprises draining spaces located where panels interface with each other, with the drain mat allowing fluid to flow under the panel assembly from the draining spaces.

According to an embodiment, there is provided a method of installing a multi-layered sports-playing field over a base surface comprising: laying down an underlayment over the base surface, comprising a drain mat operating as a fluid-permeable layer; and a panel assembly comprising panels comprising a top face, a bottom face, and drainage holes connecting the top face to the bottom face and allowing fluid to flow from the top face to the bottom face of the panel assembly, wherein the drain mat distances the bottom face from the base surface; and laying down a carpet-like top layer over the underlayment.

According to an aspect, the drain mat is affixed to the panels prior to the step of laying down the underlayment, and wherein the step of laying down the underlayment comprises assembling the panels into the panel assembly.

According to an aspect, the step of laying down the underlayment comprises: laying down the drain mat over a first portion of the base surface, and laying down and assembling two of the panels over the drain mat.

According to an embodiment, there is provided a panel assembly to be laid over a base surface and under a carpet-like top layer, the panel assembly comprising: a panel comprising a top face and a bottom face, the top face of the panel facing the carpet-like top layer, wherein the panel consists of a closed-cell structure made with closed-cell beads; and a drain mat affixed to the bottom face of the panel, wherein the drain mat operates as a fluid-permeable layer and maintains a distance adapted for fluid circulation between the bottom face and the base surface.

DETAILED DESCRIPTION

The realizations will now be described more fully hereinafter with reference to the accompanying figures, in which realizations are illustrated. The foregoing may, however, be embodied in many different forms and should not be construed as limited to the illustrated realizations set forth herein.

With respect to the present description, references to items in the singular should be understood to include items in the plural, and vice versa, unless explicitly stated otherwise or clear from the text. Grammatical conjunctions are intended to express any and all disjunctive and conjunctive combinations of conjoined clauses, sentences, words, and the like, unless otherwise stated or clear from the context. Thus, the term “or” should generally be understood to mean “and/or” and so forth.

In the following description, it is understood that terms such as “first”, “second”, “top”, “bottom”, “above”, “below”, and the like, are words of convenience and are not to be construed as limiting terms. The terms “top”, “bottom”, “vertical”, “horizontal” and the like are intended to be construed in their normal meaning in relation with an assembly comprising the present product, thus in relation with normal installation of the product in an artificial sports-playing field.

Referring now to the drawings, and more particularly toFIGS. 1 to 3, 13 and 14, a realization of a panel assembly100is shown. The panel assembly100is adapted for a multi-layered sports-playing field30(FIG. 14). The panel assembly100is for installation under a carpet-like top layer22(FIG. 13) and over a base surface40(FIG. 13). Such a base surface40may be anyone a natural ground, a base layer of dirt, of gravel, of sand or other suitable material. Other base surfaces may also comprise manufactured base surfaces such as concrete surfaces and flooring surfaces.

Referring particularly toFIG. 13, the carpet-like top layer22typically consists of an artificial turf carpet as described, for example, in Patent Application US 2016/02655170 A1 from the Applicant and herein integrated by reference. The top layer22may be installed directly over the panel assembly100as will be discussed below or with one or more intermediary layers in-between.

According to a realization, the top layer22comprises a series of regularly spaced apart (or equally spaced) parallel rows of backstitches23separated by a backstitch distance, with the panel assembly100adapted for the installation of the top layer22thereover.

Referring particularly toFIGS. 1 to 3, the panel assembly100comprises a panel110comprising a top face112and a bottom face114. The top face112of the panel110is adapted to receive the carpet-like top layer22once installed as an artificial-sports playing field30. The panel110comprises drainage holes116connecting the top face112to the bottom face114. The drainage holes116provides paths for fluid, typically water, to travel from the top face112of the panel110to its bottom face114and thus preventing undesired accumulation of liquid about the top layer22. In other embodiments, the panel110does not comprise drainage holes.

According to a realization, the top face112comprises top channels122separated by a channel distance. The channel distance is the distance between centers of two adjacent top channels122. According to a realization, the channel width and distance separating adjacent top channels122are selected based on the backstitch distance separating adjacent rows of backstitches23for the same number of rows of backstitches23falling in each of the top channels122.

Referring additionally toFIGS. 9 to 11, the top channels122further define a top crown125and a top surface127, with the drainage holes116being connected to the top surface127. The distance between the top surface127and the top crown125(i.e., a top-face irregularity129) and the width of the top channels122are selected fora maximum flow of fluid to be drained. These dimensions being related to the size(s) and number of drainage holes116per surface unit.

Typically, the panel110has a thickness (measured from the top crown125) that is normally uniform and may range between one fourth (0.25) of an inch and six (6) inches. The panel110is typically made of material that may comprise exclusively or a mix of Expanded Polypropylene (EPP). According to a realization, the panel110is made of Hybrid EPP (HEPP), which is a mix of an EPP with an expanded Polyethylene (EPE), a Polyethylene (PE), a rubber material, a recyclable material or another suitable material to maximize the hardness-flexibility ratio. According to a realization, the panel110consists of a closed-cell structure made with closed-cell beads. According to a realization, the closed-cell beads and expanded closed-cell beads. According to a realization, the material of the panel110defines a water-impervious surface preventing fluid to flow from the top face112to the bottom face114through the material.

According to a realization (not shown), the bottom face114may comprise bottom channels (similar to top channels122) extending over the bottom face114. Accordingly, the bottom face114of the panel110comprises, as looked at top side down, bottom-face irregularity comparable in nature to top-face irregularity129.

According to realizations, the bottom-face irregularity may vary from null to equal to the top-face irregularity129. According to a typical realization, the bottom-face irregularity is smaller than the top-face irregularity129.

According to a realization, the bottom-face irregularity results from the presence of bottom channels. According to another realization, the bottom-face irregularity results from an uneven bottom face114, the bottom face114comprising bumps (not shown) or other sources of unevenness randomly spread over the bottom face114.

According to a realization, the drainage holes116comprise a top opening area131about the top face112and a bottom opening area133about the bottom face114, wherein the bottom opening area133is greater in size than an opening area measured at another elevation according to the thickness orientation of the panel110. The variation in size of the opening are increases the surface of the drain mat140receiving fluid flowing though the drainage holes116per unit of fluid drained and thus the surface of exchange of fluid between the bottom face114and the base surface40. According to a realization, the smallest opening area of a drainage hole116is located in-between the top face112and the bottom face114. Thus, the drainage holes116take the shape of two funnels connected by their smallest openings located somewhere between the top face112and the bottom face114. According to an embodiment, the panel110and the drain mat140are made of different materials in that the different materials have at least different mechanical characteristics.

Referring particularly toFIGS. 1 to 5 and 12, to the bottom face114of the panel110is affixed a drain mat140, with the bottom face148of the drain mat140being laid in contact with the base surface40for the installation of the artificial sports playing field30over the base surface40.

According to realizations, the drain mat140is affixed to the bottom face114of the panel110using one of mechanical methods, chemical methods and thermal methods, or a combination of methods thereof. Examples of mechanical methods comprise rivets (e.g., plastic rivets115), screws, clamps, staples, stitching, and pressure. Examples of chemical methods comprise bonding glue, adhesives overlaying a to-be-affixed portion of the drain mat140, etc. Examples of thermal methods comprise heat bonding accompanied or not with pressure in order to fuse a portion of the drain mat140with the bottom face114.

According to a realization, the drain mat140comprises intermingled fibers142forming a fluid permeable layer144. The intermingled fibers142of the drain mat140globally have a chaotic, chaotic-like of a regular path resulting in sections of fibers142having vertical paths, horizontal paths, and a mix thereof. The assembled intermingled fibers142define a permeable layer144covering the bottom face114and having a thickness145that distances the bottom face114from the base surface40when installed. According to a realization, the intermingled fibers142are made of one of Polyamide, Nylon, Polypropylene, polyethylene, Polyestere, PVC. According to a realization, the thickness145of the drain mat140when no pressure is applied over it is between about between 4 mm to 15 mm, and is about between 3 mm to 10 mm when a pressure of 7 to 10 pounds per square is applied thereon. Therefore, the drain mat has a thickness that distances the bottom face from the base surface when installed thereon, and wherein the thickness of the drain mat decreases to a minimum thickness when undergoing pressure, with the drain mat remaining water-permeable at the minimum thickness

The interminglement of fibers may be seen or conceptualized as comprising, for any reference plane passing through the drain mat, a plurality of randomly oriented discrete fibers defining a plurality of non-hollow projections extending from the reference plane. For example, a reference149may be a plane parallel to the bottom face114and at a random distance from the bottom face114. For another example, a reference may be a plane perpendicular to the bottom face114. For another example, a reference may be a plane crossing both the bottom face114and the fluid permeable layer144at a non-perpendicular angle, thus sloped relative to the general orientation of the panel assembly100.

Now referring toFIGS. 4 and 5, another realization of a panel assembly200comprises a drain mat240having a rigid core210, and comprising a combination of layers246and248having a thickness245that provides a spacing between the bottom face214and the base surface40(seeFIG. 13). In one realization, the top layer246and the bottom layer248are attached to each other and the top layer246has a substantially rippled shape while the bottom layer248has a substantially flat shape.

Now referring toFIGS. 6 to 8, another realization of a panel assembly300comprises a drain mat340made of unibody non-porous material, the drain mat340comprising open portions thereby defining a fluid-porous layer. The drain mat340further has a thickness345spacing the bottom face314from the base surface40.

Now referring toFIGS. 13 and 14, a plurality of panel assemblies100are assembled together to form an underlayment130for a multi-layered artificial sports-playing field30.

Referring additionally toFIGS. 15 to 17, according to a realization, the panel assemblies100comprise on their edges155interlocking components160for assembly with a substantially identical panel assembly100.

According to a realization, the interlocking components160comprise tab (male)162and blank (female)164portions. The tab portions162have a straight external edge166comprising a slit168to account for expansion of the at least one of the tab portions162occurring upon an increase in temperature of the panel assemblies100. According to a realization, the width of the slit168is between five (5) mm and twenty-five (25) mm.

Still referring toFIG. 15. According to another realization, the panel assemblies100comprise interlocking tab (male)162and blank (female)164portions. The tab portions162has a straight external edge166and a protrusion170extending from the straight external edge166to ensure a minimal spacing between two adjacent panels assemblies100. The protrusion170may thereby absorb the expansion of the panel assemblies100. According to a realization, the protrusion170has a height and a width in a range of about one eighth (0.125) of an inch to one half (0.500) of an inch. According to another realization, the protrusion170has a height in a range of about one eighth (0.125) of an inch to one fourth (0.250) of an inch and a width in a range of about one fourth (0.250) of an inch to one half (0.500) of an inch.

Still referring toFIG. 15. According to another realization, the panel assemblies100comprise interlocking tab (male)162and blank (female)164portions. The tab portions162have a lateral edge169and a protrusion172extending from the lateral edge169to ensure a minimal spacing between two adjacent panel assemblies100. The protrusion172thereby absorbing the contraction of the panel assemblies100occurring upon a decrease in temperature (cold weather). According to a realization, the protrusion172has a height in a range of one eighth (0.125) of an inch to one fourth (0.250) of an inch and a width in a range of one fourth (0.250) of an inch to one half (0.500) of an inch.

Still referring toFIG. 15. According to another realization the panel assemblies100comprise interlocking tab (male)162and blank (female)164portions. The tab portions162having a straight external edge166and a lateral edge169. The straight external edge166comprises a slit174in an area near the lateral edge169to form a hinged portion capable of absorbing the contraction of the panel assemblies100. According to a realization, the width of the slit174is between five (5) mm and twenty-five (25) mm.

Referring particularly toFIG. 16, according to a realization, the panel assemblies100comprise interlocking components160comprising interlocking fingers182and184comprising a portion extending horizontally from the edges and a portion extending vertically from the horizontal portion distant from the edges. The fingers182and184hook together when panel assemblies100are assembled together. The fingers182extending upwardly comprises drainage holes186on its horizontal lowest portion. The drainage holes186of the fingers182allows fluid to flow from the top face112, following the outer surface of interlocking components160down to the bottom face114. Protrusions (not shown) over the outer vertical faces of the finger182or edge of the contacting panel assembly100provide contact and clearance to respond to thermal expansion and contraction as to guarantee clearance for fluid flow following the edge down to the drainage hole186. According to a realization, the protrusions set a clearance of about one eighth (0.125) of an inch between the vertical hooking faces of the finger182and their contacting edge for expansion and contraction that occur with temperature changes.

Referring particularly toFIG. 17, according to a realization the fingers282and284comprises a hooking surface at an acute angle, for instance forty-five (45) degrees from a plane perpendicular to the top face112or bottom face114and extending from about the edges268. The finger282extending upwardly comprises drainage holes286on its lowest portion close to the edge268. The drainage holes286of the fingers182allow fluid to flow from the top face112, following the surface of interlocking components160down to the bottom face114. Protrusions (not shown) over the outer vertical faces of the finger282or edge268of the contacting panel assembly100provide contact and clearance to respond to thermal expansion and contraction as to guarantee clearance for fluid flow down to the drainage hole286. According to a realization, the protrusions set a clearance of about one eighth (0.125) of an inch between the vertical hooking faces of a finger282and its contacting edge268for expansion and contraction that occur with temperature changes.

According to a realization, the panel110is rigid with some flexibility. The panel110cannot be rolled onto itself. When the panel110is held by one side, bending is minimal to null.

According to a realization, a method of installing a multi-layered sports playing field30over a base surface40comprises laying down an underlayment130over the base surface40, comprising (1) a drain mat140operating as a fluid-permeable layer and (2) a panel110comprising a top face112, a bottom face114, and drainage holes116fluidly connecting the top face112to the bottom face114and allowing fluid to flow from the top face112to the bottom face114of the panel110, wherein the drain mat140distances the bottom face114from the base surface40. The method further comprises laying down a carpet-like top layer22over the underlayment130.