Base for turf system

• US 8,603,601 B2
• Filed: 12/12/2012
• Issued: 12/10/2013
• Est. Priority Date: 01/19/2007
• Status: Active Grant

• Current Assignee: Brock USA LLC
• Original Assignee: Brock USA LLC
• Inventors: Sawyer, Steven Lee, Sawyer, Daniel C., Runkles, Richard R.
• Primary Examiner(s): JUSKA, CHERYL ANN
• Application Number:
  US13/711,688
• Publication Number:
  US 20130101351A1
• Time in Patent Office: 363 Days
• Field of Search: 428/17, 428/44, 428/87, 428/95, 428/131, 428/156, 428/157, 428/172, 428/53, 428/81, 428/304.4, 525/81, 525/78
• US Class Current: 428/53
• CPC Class Codes: D10B 2505/202 Artificial grass
• CPC Class Codes: E01C 13/02 Foundations, e.g. with drainage or heating arrangements E01C13/003, E01C13/083, E01C13/10 take precedence; drainage of soil E02B11/00
• CPC Class Codes: E01C 13/08 Surfaces simulating grass ; Grass-grown sports grounds grass-like surfaces for skiing E01C13/12
• CPC Class Codes: E01C 13/083 Construction of grass-grown sports grounds; Drainage, irrigation or heating arrangements therefor
• CPC Class Codes: E01C 3/003 characterised by material or composition used, e.g. waste or recycled material E01C3/006, E01C3/04 and E01C3/06 take precedence
• CPC Class Codes: E01C 3/006 made of prefabricated single units E01C3/06 takes precedence
• CPC Class Codes: E01C 5/003 characterised by material or composition used for beds or joints; characterised by the way of laying
• CPC Class Codes: Y10T 428/16 Two dimensionally sectional layer
• CPC Class Codes: Y10T 428/169 Sections connected flexibly with external fastener
• CPC Class Codes: Y10T 428/17 Three or more coplanar interfitted sections with securing means
• CPC Class Codes: Y10T 428/192 Sheets or webs coplanar
• CPC Class Codes: Y10T 428/23979 Particular backing structure or composition
• CPC Class Codes: Y10T 428/24273 including aperture
• CPC Class Codes: Y10T 428/24355 Continuous and nonuniform or irregular surface on layer or component [e.g., roofing, etc.]
• CPC Class Codes: Y10T 428/24479 including variation in thickness
• CPC Class Codes: Y10T 428/249953 Composite having voids in a component [e.g., porous, cellular, etc.]

Abstract

A turf underlayment layer for supporting an artificial turf assembly includes a plurality of panels assembled together, each panel being made from a plurality of polyolefin beads bonded together, each panel further including a core, a top side having a plurality of projections, and a bottom side having a plurality of projections, the top projections forming top side water drainage channels and the bottom projections forming bottom side water drainage channels, the panels having edges, at least one of the panel edges having at least one drainage projection, the drainage projection spacing the abutting panel edges apart, with the resultant spacing of the edges of abutting panels forming a drainage path at the intersection of the abutting panels.

Claims

1. A turf underlayment layer for supporting an artificial turf assembly, the turf underlayment layer comprising a plurality of panels assembled together, each panel including a core, a top side having a plurality of projections, and a bottom side, the top projections forming top side water drainage channels, the panels having edges, with the edges of one panel abutting the edges of adjacent panels, at least one of the panel edges having at least one drainage projection, the drainage projection spacing the abutting panel edges apart, with the resultant spacing of the edges of abutting panels forming a drainage path at the intersection of the abutting panels, wherein the panels are made from a plurality of polyolefin beads, the plurality of polyolefin beads bonded together by at least one of pressure and heat to produce a substantially water-impervious surface.

2. The underlayment layer of claim 1 in which the abutting panel edges have a corresponding recess that accepts a portion of the projection to interlock the abutting panels.

3. The underlayment layer of claim 1 in which the projection of the panels is a positioning datum to facilitate installation.

4. The underlayment layer of claim 1 wherein the bottom side includes a plurality of bottom side drainage channels, the core having a plurality of drain holes connecting the top side water drainage channels to the bottom side water drainage channels for fluid communication between the panel top side and bottom side, the plurality of drain holes being dispersed over the panel and being spaced apart and sized such that the top side water drainage channels intersect with the bottom side water drainage channels at the drain holes.

5. The underlayment layer of claim 4 in which the top projections are generally square shaped projections having a friction enhancing surface configured as one of bumps, raised nibs, ribs, and dots.

6. A turf underlayment layer for supporting an artificial turf assembly, the turf underlayment layer comprising a plurality of panels assembled together, each panel including a core, a top side having a plurality of projections, and a bottom side having a plurality of projections, the top projections forming top side water drainage channels and the bottom projections forming bottom side water drainage channels, the panels having edges, with the edges of one panel abutting the edges of adjacent panels, at least one of the panel edges having at least one drainage projection to space the abutting panel edges apart, with the drainage projection being formed from a compressible material, thereby enabling one panel in the turf underlayment layer to move relative to an abutting panel by compression of the drainage projection wherein the compressible material is an expanded foam bead material, and the panel edges have at least two drainage projections.

7. The underlayment layer of claim 6 in which the drainage projection is a positioning datum to facilitate installation.

8. The underlayment layer of claim 6 in which the panels are made from a plurality of polyolefin beads, the plurality of polyolefin beads bonded together by at least one of pressure and heat to produce a substantially water-impervious surface.

9. The underlayment layer of claim 6 in which a plurality of drain holes connects the top side channels to the bottom side channels for fluid communication, the plurality of drain holes being dispersed over the panel top side and bottom side, the top projections and bottom projections terminating in generally flat support surfaces, and being spaced apart and sized such that the top side water drainage channels intersect with the bottom side water drainage channels at the drain holes, with the flat support surfaces of the top projections having smaller support surface areas than the flat support surfaces of the bottom projections.

10. A panel for supporting an artificial turf assembly, the panel including a core, a top side having a plurality of projections, and a bottom side having a plurality of projections, the top projections forming top side water drainage channels and the bottom projections forming bottom side water drainage channels, the panel having edges, with at least one of the panel edges having at least one drainage projection formed from a compressible material, wherein the panel is made from a plurality of polyolefin beads bonded together by at least one of pressure and heat to produce a substantially water-impervious surface, the top side water drainage channels being in fluid communication with the bottom side water drainage channels through a plurality of drainage holes extending through the core.

11. The panel of claim 10 wherein the top projections and bottom projections terminate in generally flat support surfaces, with the flat support surfaces of the top projections having smaller support surface areas than the flat support surfaces of the bottom projections.

12. The panel of claim 10 wherein a plurality of drain holes extend through the core, and the top and bottom flat support surfaces being spaced apart and sized such that the top side water drainage channels cross over the bottom side water drainage channels at the drain holes.

13. A turf underlayment panel for supporting an artificial turf assembly, the panel including a core, a top side, and a bottom side, the top side having a plurality of spaced apart projections that define top side water drainage channels that are in fluid communication with bottom side water drainage channels, the panel further having at least two interlocking edges to enable interlocking with other panels, wherein one of the at least two interlocking edges includes a dovetail recess defined by spaced apart dovetail projections, and wherein each dovetail projection defines a male pattern that is generally half of the size of the dovetail recess and half the shape of the dovetail recess, wherein one of the at least two interlocking edges includes drainage projections to facilitate movement in response to thermal expansion and contraction, and to define a water drainage opening at the edge of the panel, wherein the plurality of spaced-apart top side projections are generally square projections having a height of in a range of about 0.5 millimeters to about 6 millimeters defining flat support surfaces configured to support artificial turf, the flat support surfaces each having a friction enhancing structure in the form of one of raised dots, ribs, or bumps that minimize relative movement of an artificial turf carpet relative to the panel, the panel being formed from an expanded foam bead polyolefin material having a density range of from about 45 grams per liter to about 70 grams per liter.