US 11,980,805 B2
Overlay systems and methods of installing overlay systems
Timothy Sadick, Seymour, CT (US); and David Rich, Oxford, CT (US)
Assigned to RS Sports Surfaces, LLC, Seymour, CT (US)
Filed by RS Sports Surfaces, LLC, Seymour, CT (US)
Filed on Oct. 26, 2022, as Appl. No. 17/974,269.
Application 17/974,269 is a continuation of application No. 15/836,857, filed on Dec. 9, 2017, abandoned.
Claims priority of provisional application 62/431,955, filed on Dec. 9, 2016.
Prior Publication US 2023/0124212 A1, Apr. 20, 2023
Int. Cl. A63C 19/12 (2006.01); A63C 19/02 (2006.01); A63C 19/04 (2006.01); A63C 19/06 (2006.01); B32B 3/06 (2006.01); B32B 3/18 (2006.01); B32B 5/02 (2006.01); B32B 5/16 (2006.01); B32B 5/26 (2006.01); B32B 7/12 (2006.01); B32B 13/04 (2006.01); B32B 25/04 (2006.01); B32B 27/06 (2006.01); B32B 27/30 (2006.01); B32B 37/12 (2006.01); B32B 37/18 (2006.01); B32B 37/24 (2006.01); B32B 38/00 (2006.01); E01C 13/04 (2006.01)
CPC A63C 19/12 (2013.01) [A63C 19/02 (2013.01); A63C 19/04 (2013.01); A63C 19/065 (2013.01); B32B 3/06 (2013.01); B32B 3/18 (2013.01); B32B 5/022 (2013.01); B32B 5/024 (2013.01); B32B 5/028 (2013.01); B32B 5/16 (2013.01); B32B 5/26 (2013.01); B32B 7/12 (2013.01); B32B 13/04 (2013.01); B32B 25/04 (2013.01); B32B 27/06 (2013.01); B32B 27/302 (2013.01); B32B 27/308 (2013.01); B32B 37/12 (2013.01); B32B 37/18 (2013.01); E01C 13/045 (2013.01); B32B 37/24 (2013.01); B32B 2038/0064 (2013.01); B32B 2262/101 (2013.01); B32B 2264/102 (2013.01); B32B 2305/38 (2013.01); B32B 2315/06 (2013.01); B32B 2319/00 (2013.01); B32B 2333/00 (2013.01); B32B 2419/04 (2013.01); B32B 2471/00 (2013.01); B32B 2471/04 (2013.01)] 15 Claims
OG exemplary drawing
 
2. 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.