Back to results
US 11,980,805 B2Granted
Overlay systems and methods of installing overlay systems
AssigneeRS Sports Surfaces, LLC
InventorsTimothy Sadick, David Rich
Life of this patent
Estimating the term…
Abstract
A method of installing a binder-based overlay system may include contacting a layer of geotextile fabric to a surface of a substrate and applying a primer layer to a surface of the geotextile fabric. Two or more binder layers including infill particles may be applied over the primer layer. A resurfacer layer followed by one or more color layers may be applied over the two or more binder layers. The primer layer, one or more binder layers, resurfacer layer, and two or more color layers may cure upon application to form a monolithic layer upon the substrate.
Claims15
A method of installing a binder-based overlay system, comprising:
- contacting a layer of geotextile fabric to a surface of a substrate;
- applying a primer layer to a surface of the geotextile fabric, wherein the primer layer adheres to the geotextile fabric;
- applying two or more binder layers over the primer layer, Wherein the two or more binder layers adhere to the primer layer, and wherein at least one of the one or more binder layers comprise sand, rubber, rubber alternative, or a combination thereof within one or more of styrene acrylic or styrene butadiene;
- applying a resurfacer layer over the one or more binder layers and primer layer;
- applying two or more color layers over the resurfacer layer, wherein the primer layer, one or more binder layers, resurfacer layer, and two or more color layers are arranged together within a monolithic solid layer;
- seaming two adjacent pieces of the geotextile fabric comprising partially adhering or adhering a seaming material across a gap between two adjacent pieces of the geotextile fabric along an underside of the geotextile fabric pieces to seam the two adjacent piece of geotextile, fabric, wherein the seaming material overlaps each of the two adjacent geotextile fabric pieces by at least 3 inches from respective interfacing edges, and wherein the gap between two adjacent pieces of the geotextile fabric is seamed along an underside between the geotextile fabric pieces and the substrate but is not seamed along an upper side between the geotextile fabric and the primer layer;
- applying fiberglass mesh over the gap between two adjacent pieces of the geotextile fabric, wherein the fiberglass mesh extends over interfacing edges of the pieces of the geotextile fabric defining the gap and is applied prior to or during application of the primer layer;
- and
- wherein the geotextile fabric comprises a polyester, fiberglass yarns, or glass filaments.
6 more elements
A method of installing a binder-based overlay system, comprising:
- contacting a layer of geotextile fabric to a surface of a substrate;
- applying a primer layer to a surface of the geotextile fabric, wherein the primer layer adheres to the geotextile fabric;
- applying two or more binder layers over the primer layer, wherein the two or more binder layers adhere to the primer layer, and wherein at least one of the one or more binder layers comprise sand, rubber, rubber alternative, or a combination thereof within one or more of styrene acrylic or styrene butadiene;
- applying a resurfacer layer over the one or more binder layers and primer layer;
- applying two or more color layers over the resurfacer layer, wherein the primer layer, one or more binder layers, resurfaces layer, and two or more color layers are arranged together within a monolithic solid layer;
- and
- seaming two adjacent pieces of the geotextile fabric comprising partially adhering or adhering a seaming material across a gap between two adjacent pieces of the geotextile fabric along an underside of the geotextile fabric pieces to seam the two adjacent piece of geotextile fabric, wherein the seaming material overlaps each of the two adjacent geotextile fabric pieces by at least 3 inches from respective interfacing edges, and wherein the gap between two adjacent pieces of the geotextile fabric is seamed along an underside between the geotextile fabric pieces and the substrate but is not seamed along an upper side between the geotextile fabric and the primer layer.
4 more elements
A method of installing a binder-based overlay system, comprising:
- contacting a layer of geotextile fabric to a surface of a substrate;
- applying a primer layer to a surface of the geotextile fabric, wherein the primer layer adheres to the geotextile fabric;
- applying two or more binder layers over the primer layer, Wherein the two or more binder layers adhere to the primer layer, and wherein at least one of the one or more binder layers comprise sand, rubber, rubber alternative, or a combination thereof within one or more of styrene acrylic or styrene butadiene;
- applying a resurfacer layer over the one or more binder layers and primer layer;
- applying two or more color layers over the resurfacer layer, wherein the primer layer, one or more binder layers, resurfaces layer, and two or more color layers are arranged together within a monolithic solid layer;
- and
- seaming two adjacent pieces of the geotextile fabric comprising partially adhering or adhering a seaming material across a gap between two adjacent pieces of the geotextile fabric along an underside of the geotextile fabric pieces to seam the two adjacent piece of geotextile fabric.
4 more elements
A method of installing a binder-based overlay system, comprising:
- contacting a layer of geotextile fabric to a surface of a substrate;
- applying a primer layer to a surface of the geotextile fabric, wherein the primer layer adheres to the geotextile fabric;
- applying two or more binder layers over the primer layer, wherein the two or more binder layers adhere to the primer layer, and wherein at least one of the one or more binder layers comprise sand, rubber, rubber alternative, or a combination thereof within one or more of styrene acrylic or styrene butadiene;
- applying a resurfacer layer over the one or more binder layers and primer layer;
- and
- applying two or more color layers over the resurfacer layer, wherein the primer layer, one or more binder layers, resurfacer layer, and two or more color layers are arranged together within a monolithic solid layer;
- wherein a gap between two adjacent pieces of the geotextile fabric is seamed along an underside between the geotextile fabric pieces and the substrate but is not seamed along an upper side between the geotextile fabric and the primer layer.
4 more elements
A method of installing a binder-based overlay system, comprising:
- contacting a layer of geotextile fabric to a surface of a substrate;
- applying a primer layer to a surface of the geotextile fabric, wherein the primer layer adheres to the geotextile fabric;
- applying two or more binder layers over the primer layer, wherein the two or more binder layers adhere to the primer layer, and wherein at least one of the one or more binder layers comprise sand, rubber, rubber alternative, or a combination thereof within one or more of styrene acrylic or styrene butadiene;
- applying a resurfacer layer over the one or more binder layers and primer layer;
- and
- applying two or more color layers over the resurfacer layer, wherein the primer layer, one or more binder layers, resurfacer layer, and two or more color layers are arranged together within a monolithic solid layer;
- wherein the geotextile fabric comprises a polyester, fiberglass yarns, or glass filaments, and wherein the polyester, fiberglass yarn, or glass filaments are sewn to an upper surface of the geotextile fabric.
4 more elements
A method of installing a binder-based overlay system, comprising:
- contacting a layer of geotextile fabric to a surface of a substrate;
- applying a primer layer to a surface of the geotextile fabric, wherein the primer layer adheres to the geotextile fabric;
- applying two or more binder layers over the primer layer, Wherein the two or more binder layers adhere to the primer layer, and wherein at least one of the one or more binder layers comprise sand, rubber, rubber alternative, or a combination thereof within one or more of styrene acrylic or styrene butadiene;
- applying a resurfacer layer over the one or more binder layers and primer layer;
- applying two or more color layers over the resurfacer layer, wherein the primer layer, one or more binder layers, resurfacer layer, and two or more color layers are arranged together within a monolithic solid layer;
- and
- applying fiberglass mesh over a gap between two adjacent pieces of the geotextile fabric, Wherein the fiberglass mesh extends over interfacing edges of the pieces of the geotextile fabric defining the gap.
4 more elements
Dependencies are inferred from the claim text.