Base for turf system

• US 9,790,646 B2
• Filed: 12/07/2016
• Issued: 10/17/2017
• 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:
  US15/372,056
• Publication Number:
  US 20170089016A1
• Time in Patent Office: 314 Days
• 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

An underlayment layer is configured to support an artificial turf assembly. The underlayment layer comprises a core with a top side and a bottom side. The top side has a plurality of spaced apart, upwardly oriented projections that define channels suitable for fluid flow along the top side of the core when the underlayment layer is positioned beneath an overlying artificial turf assembly.

Claims

1. A turf underlayment layer comprised of an assembly of panels, the panels including a top side having a plurality of projections, a bottom side, and panel edges, the plurality of top side projections forming top side channels that extend across the top side of the panel to allow drainage of fluid across the top side of the panel, and the bottom side having bottom side channels that extend across the bottom side of the panel to allow drainage of fluid across the bottom side of the panel, the panels being shaped with a recess for interlocking with one or more adjacent panels in the assembly of panels, and 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 turf underlayment layer of claim 1 in which the recess is a dovetail recess for interlocking with one or more adjacent panels in the assembly of panels.

3. The turf underlayment layer of claim 2 in which the dovetail recess is formed by two spaced apart dovetail projections.

4. The turf underlayment layer of claim 2 in which the panels have dovetail projections for interlocking with adjacent panels in the assembly of panels.

5. The turf underlayment layer of claim 2 including dovetail projections, and in which the dovetail recesses and dovetail projections are sized to provide relative movement of abutting panels in response to thermal conditions or load-applied deflections.

6. The turf underlayment layer of claim 1 in which the top projections have a friction enhancing surface configured as one of bumps, raised nibs, ribs, and dots.

7. The turf underlayment layer of claim 1 including a plurality of drain holes positioned through the panel to allow fluid to flow from the top side of the panel to the bottom side of the panel.

8. The turf underlayment layer of claim 7 in which at least some of the drain holes intersect both a top side channel and a bottom side channel.

9. The turf underlayment layer of claim 1 in which the bottom drainage channels are defined by bottom projections protruding downwardly.

10. A turf underlayment layer comprised of an assembly of panels, the panels including a top side having a plurality of projections, a bottom side, and panel edges, the plurality of top side projections forming top side channels that extend across the top side of the panel to allow drainage of fluid across the top side of the panel, and the bottom side having bottom side channels that extend across the bottom side of the panel to allow drainage of fluid across the bottom side of the panel, the panels being 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.

11. The turf underlayment layer of claim 10 in which the top projections have a friction enhancing surface configured as one of bumps, raised nibs, ribs, and dots.

12. The turf underlayment layer of claim 10 in which the top projections have a friction enhancing surface configured as raised nibs.

13. The turf underlayment layer of claim 10 in which the top projections are square projections having rounded corners and substantially vertical straight side edges.

14. A turf underlayment layer comprised of an assembly of panels, the panels including a top side having a plurality of projections, a bottom side, and panel edges, the plurality of top side projections forming top side channels that extend across the top side of the panel to allow drainage of fluid across the top side of the panel, and the bottom side having bottom side channels that extend across the bottom side of the panel to allow drainage of fluid across the bottom side of the panel, the edges of the panels being shaped so that where the edges of a panel abut the edges of an adjacent panel in the assembly of panels the edges of the panels form a drainage slot capable of allowing water to flow from the top side of the panels to the bottom side of the panels.

15. The turf underlayment layer of claim 14 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.

16. The turf underlayment layer of claim 14 in which the edges of the panels have recesses and projections to enable interlocking of adjacent panels.

17. The turf underlayment layer of claim 16 in which the projections are smaller than the recesses so that the drainage slot formed by the edges of the abutting panels allows water to flow from the top side of the panels to the bottom side of the panels.

18. A turf underlayment layer comprised of an assembly of panels, the panels including a top side having a plurality of projections, a bottom side, and panel edges, the plurality of top side projections forming top side channels that extend across the top side of the panel to allow drainage of fluid across the top side of the panel, and the bottom side having a lower surface that extends across the bottom side of the panel to allow drainage of fluid across the bottom side of the panel, the edges of the panels being shaped with a recess to mate with the edges of similar panels to form a drainage slot capable of allowing water to flow from the top side of the panels to the bottom side of the panels, the panels being 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.