Cushioned surface structure and methods for making the same
OwnerDaniel B. Hanksinventor
Life of this patent
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Abstract
A cushion surface structure, such as for a tennis court, is disclosed. In an exemplary embodiment, the surface structure includes one or more elastomeric layers comprising elastomeric particles, such as ground tire rubber, applied to a base surface. The elastomeric layers may comprise either loose elastomeric particles, or a matrix of elastomeric particles and an adhesive binder. To fill the voids of the elastomeric layers and provide a smooth, flat playing surface, one or more fill layers of dry fill material, such as silica sand, may be formed over the elastomeric layers. A color-fill system may be applied over the top fill layer, and one or more layers of a color mix may be applied over the color-fill system.
Claims50
A cushioned surface structure comprising:
- at least one elastomeric layer comprising at least 5% by weight of elastomeric particles;
- at least one fill layer consisting of dry fill material applied over the elastomeric layer to fill voids between the elastomeric particles;
- and
- a coating-compound applied over the fill layer.
A cushioned surface structure comprising:
- at least one elastomeric layer comprising elastomeric particles;
- a first fill layer overlaying the elastomeric layer, the first fill layer consisting of dry fill material;
- a second fill layer overlaying the first fill layer, the second fill layer consisting of dry fill material, wherein the fill material of the first fill layer has a particle size that is generally larger than the particle size of the fill material of the second fill layer;
- and
- a coating-compound layer applied over the second fill layer.
A cushioned surface structure comprising:
- at least one elastomeric layer comprising elastomeric particles;
- a first fill layer overlaying the elastomeric layer, the first fill layer consisting of dry fill material;
- a second fill layer overlaying the first fill layer, the second fill layer consisting of dry fill material, wherein the fill material of the first fill layer has a particle size that is generally larger than the particle size of the fill material of the second fill layer;
- and
- wherein a color-fill layer overlays the second fill layer.
A cushioned, surface structure comprising:
- a first elastomeric layer comprising elastomeric particles;
- a second elastomeric layer overlaying the first elastomeric layer, the second elastomeric layer comprising elastomeric particles that are generally smaller in size than the elastomeric particles of the first elastomeric layer;
- at least one fill layer overlaying the second elastomeric layer for filling voids in the elastomeric layers;
- and
- a coating-compound layer overlaying the at least one fill layer.
A method of forming a cushioned surface structure, the method comprising:
- forming at least one elastomeric layer comprising at least 5% by weight of elastomeric particles;
- applying at least one fill layer over the at least one elastomeric layer, the fill layer consisting of dry fill material having a particle size that is smaller than the elastomeric particles such that the fill material fills voids between the elastomeric particles;
- and
- applying a coating-compound over the at least one fill layer.
A method of forming a cushioned surface structure on an existing sub-surface, the method comprising:
- applying at least a lower elastomeric layer lover the sub-surface, the lower elastomeric layer comprising elastomeric particles;
- applying at least an upper elastomeric layer over the lower elastomeric layer, the upper elastomeric layer comprising elastomeric particles that are generally smaller in size than the particles of the lower elastomeric layer;
- applying at least one fill layer over the upper elastomeric layer for filling the voids in the elastomeric layers
- applying a coating-compound over the at least one fill layer.
A cushioned surface structure for covering an underlying sub-surface, comprising:
- an elastomeric layer comprising elastomeric particles overlying the sub-surface;
- a composite layer overlying the elastomeric layer, the composite layer comprising a matrix of elastomeric particles and a binder;
- an adhesive layer covering the composite layer;
- a fill layer overlying the composite layer and adhering to the adhesive layer;
- a color-fill layer overlying the fill layer;
- and
- a color-coating layer overlying and adhering to the color-fill layer.
A method of forming a cushioned surface structure on an underlying sub-surface, the method comprising:
- applying an elastomeric layer of elastomeric particles over the sub-surface;
- applying a composite layer over the elastomeric layer, the composite layer comprising a matrix of elastomeric and a binder;
- applying an adhesive layer over the composite layer;
- applying a fill layer over the adhesive layer while the adhesive layer is still wet;
- applying a color-fill layer over the fill layer;
- and
- applying a color-coating layer over the color-fill layer.
Dependencies are inferred from the claim text.