Note: Descriptions are shown in the official language in which they were submitted.
CA 02928211 2016-04-26
Modular Rollup Artificial Turf System
Cross-Reference to Related Patent Application
[0001] This application claims priority to, and the benefit of the filing
date, of
U.S. Provisional Patent Application No. 62/153,225, filed April 27, 2015,
which is
incorporated herein by reference in its entirety.
Field
[0002] This invention relates to artificial turf used for athletic fields.
More
specifically, this invention relates to a filled artificial turf with enhanced
versatility,
due to its roll up, unroll capability.
Background
[0003] Synthetic grass sports surfaces are well known. These surfaces are
becoming increasingly popular as replacements for natural grass surfaces in
stadiums, playgrounds, golf driving ranges, and other facilities. The
synthetic
grass surfaces stand up to wear much better than natural grass surfaces, do
not
require as much maintenance, and can be used in partially or fully enclosed
stadiums where natural grass cannot typically be grown.
[0004] Most synthetic grass surfaces comprise rows of strips or ribbons of
synthetic grass-like material, extending vertically from a backing mat with
particulate material infill in between the ribbons on the mat. One or more
layers
of aggregate material are introduced between the backing mat and on top of a
smoothed and compacted subgrade. The surfaces are preferably crowned to
promote water drainage. The ribbons of synthetic grass-like material usually
extend a short distance above the layer of particulate material and represent
blades of grass. The length of these fibers is dictated by the end use of the
playing surface. For example, football fields utilize fibers that are longer
than golf
driving range surfaces. The particulate material usually comprises sand. The
particulate matter can also comprise a mixture of sand and other materials,
including rubber infill. In these systems, the rubber infill and sand together
provide resiliency to the synthetic grass surfaces. In addition, the sand
particles
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add weight to hold down the backing material, thus helping to ensure that the
strips of synthetic grass do not move or shift during play. In more recent
systems, fields have been produced that utilize 100 percent resilient material
as
infill. The conventional use of infill in synthetic grass surfaces increases
the
difficulty of removal and storage of such systems.
[0005] For certain sporting facilities or venues, particularly indoor
arenas or
stadia, the facility can be used for a wide variety of events, including non-
sporting
events. Some of these events could have adverse effects on a typical
artificial
turf, due to excessive wear. These adverse effects tend to reduce the
playability
of, and shorten the effective life of, the artificial turf. Thus, there is a
need to
accommodate the multi-purpose needs of such facilities, while at the same time
minimizing or eliminating any adverse effects on the artificial turf used for
sporting events.
[0006] It is thus highly desirable to produce a non-filled transition (i.e.
non-
permanent) synthetic grass surface that is easily installed and removed in the
same facility for sporting events that has performance and durability
characteristics similar to natural surfaces. .
SUMMARY
[0007] Disclosed herein is a non-filled artificial turf field which can be
removed by disconnecting and rolling up a plurality of non-filled artificial
turf
mats, and reinstalled by unrolling and reconnecting the non-filled artificial
turf
mats. In a further aspect, disclosed herein is a method for installing and
subsequently removing the non-filled transition artificial turf field in a
quick and
efficient manner.
[0008] Because it is contemplated that the non-filled artificial turf mats
can
be arranged on a floor for a specific activity and then removed and stored
when a
different activity is to take place on the same floor, it is desirable to
provide a
system that allows the non-filled artificial turf mats to be easily attached
and
separated. In some aspects, the system is reusable in that it can permit the
non-
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filled artificial turf mats to be connected and then separated multiple times.
In
some embodiments in accordance with the invention, the system can allow the
non-filled artificial turf mats to be attached to each other and form a
substantially
contiguous top surface. In other embodiments, the non-filled artificial turf
mats
can be secured by a connecting system to reduce the likelihood of the mats
moving with respect to each other to provide gaps between the non-filled
artificial
turf mats.
[0009] In one aspect, a non-filled artificial turf field can be formed by
interconnecting a plurality of non-filled artificial turf mats, wherein each
of the
non-filled artificial turf mats comprises a turf layer and a foam substrate.
In one
aspect, the turf layer comprises a plurality of fibrillated yarns tufted
within the
multilayer backing material. The yarns can be tufted in a wide variety of pile
heights, patterns, gauges, and stitch patterns depending upon a desired end
use.
[0010] The bottommost layer of the multilayer backing material can be
coated
with an adhesive coating layer that is configured to bind to, and optionally
integrate with, at least a portion of the plurality of yarns that is exposed
on the
bottommost surface of the multilayer backing material. The foam substrate
comprising a shock resistant material can be adhered to the bottom of the
adhesive layer.
[0011] In operation, the bottom surface of the mats can be laid on a
substrate
such as a flooring material, concrete slab, or a leveled aggregate and dirt
subgrade. Selected non-filled artificial turf mats can be coupled together
utilizing
hook and loop fastening systems. To remove the assembled artificial turf
field,
each non-filled artificial turf mat is simply unhooked from the next adjacent
non-
filled artificial turf mat and rolled onto a roller
[0012] There has thus been outlined, rather broadly, certain embodiments of
the invention in order that the detailed description thereof herein may be
better
understood, and in order that the present contribution to the art may be
better
appreciated. There are, of course, additional embodiments of the invention
that
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will be described below and which will form the subject matter of the claims
appended hereto.
DESCRIPTION OF THE FIGURES
[0013] These and other features of the preferred embodiments of the
invention will become more apparent in the detailed description in which
reference is made to the appended drawings wherein:
[0014] Figure 1 is a perspective view of two adjoining non-filled
artificial turf
mats showing one mat being separated from the adjoining mat and being rolled
up for storage.
[0015] Figure 2 is a photograph of a cross-sectional view of a portion of a
non-filled artificial turf mat.
[0016] Figure 3 is a side view of two non-filled artificial turf mats
having a
connecting means for reducing movement between selectively adjoined artificial
turf mats and preventing gaps from occurring between the selectively adjoined
artificial turf mats.
[0017] Figure 4 is a side view of two non-filled artificial turf mats
connected to
each other using a connecting means in accordance with the embodiment shown
in Figure 3.
[0018] Figure 5 is a perspective view of an artificial turf mat having a
connecting means in accordance with the embodiment shown in Figure 3.
DETAILED DESCRIPTION
[0019] The present invention can be understood more readily by reference to
the following detailed description, examples, drawing, and claims, and their
previous and following description. However, before the present devices,
systems, and/or methods are disclosed and described, it is to be understood
that
this invention is not limited to the specific devices, systems, and/or methods
disclosed unless otherwise specified, as such can, of course, vary. It is also
to
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be understood that the terminology used herein is for the purpose of
describing
particular aspects only and is not intended to be limiting.
[0020] The following description of the invention is provided as an
enabling
teaching of the invention in its best, currently known embodiment. To this
end,
those skilled in the relevant art will recognize and appreciate that many
changes
can be made to the various aspects of the invention described herein, while
still
obtaining the beneficial results of the present invention. It will also be
apparent
that some of the desired benefits of the present invention can be obtained by
selecting some of the features of the present invention without utilizing
other
features. Accordingly, those who work in the art will recognize that many
modifications and adaptations to the present invention are possible and can
even
be desirable in certain circumstances and are a part of the present invention.
Thus, the following description is provided as illustrative of the principles
of the
present invention and not in limitation thereof.
[0021] As used throughout, the singular forms "a," "an" and "the" include
plural referents unless the context clearly dictates otherwise. Thus, for
example,
reference to "a connecting surface" can include two or more such connecting
surfaces unless the context indicates otherwise.
[0022] Ranges can be expressed herein as from "about" one particular value,
and/or to "about" another particular value. When such a range is expressed,
another aspect includes from the one particular value and/or to the other
particular value. Similarly, when values are expressed as approximations, by
use of the antecedent "about," it will be understood that the particular value
forms
another aspect. It will be further understood that the endpoints of each of
the
ranges are significant both in relation to the other endpoint, and
independently of
the other endpoint.
[0023] As used herein, the terms "optional" or "optionally" mean that the
subsequently described event or circumstance may or may not occur, and that
the description includes instances where said event or circumstance occurs and
instances where it does not.
CA 02928211 2016-04-26
[0024] In one embodiment and as shown in Figures 1 and 2, disclosed herein
is a non-filled artificial turf field 10 which can be removed by disconnecting
and
rolling up a plurality of non-filled artificial turf mats 20, and reinstalled
by unrolling
and reconnecting the filled artificial turf mats. In one aspect, a non-filled
artificial
turf field can be formed by interconnecting the plurality of non-filled
artificial turf
mats. In one aspect, each of the non-filled artificial turf mats 20 comprises
a turf
layer 40 and an underlying foam substrate 60. As used herein, the term "non-
filled" refers to an artificial turf mat having a turf layer that does not
comprise
particulate infill, such as sand and rubber infills as are conventionally
found in
artificial turf products.
[0025] In one aspect, the turf layer 40 comprises a plurality of
fibrillated yarns
42 tufted within a backing material 50. In one aspect, the plurality of
fibrillated
yarns 42 can comprise at least two different types of yarn (e.g., at least a
first
type of yarn 42' and a second type of yarn 42". In one example and not meant
to
be limiting, a first type of yarn can comprise a 8000 denier, high
performance,
outdoor, polyethylene, fibrillated tape yarn and a second type of yarn can
comprise a 4500 denier, 8-ply, texturized polyethylene yarn. In this aspect,
and
referencing Figure 2, the first yarn is a tape yarn that is configured to
provide the
look of "blades" of natural grass and to enhance the durability of the formed
mat
for sports use. In this aspect, the second yarn can be a texturized yarn that
is
configured to provide desired softness and "densifies" the resultant turf
layer of
the mat without the need for infill. Nylon, polyester, polypropylene and other
yarn
types can be used as well. It is also contemplated that the different types of
yarns forming the plurality of fibrillated yarns can be tufted in a wide
variety of
pile heights, patterns, gauges, and stitch patterns depending upon a desired
end
use.
[0026] The backing material 50 preferably is a multi-layer backing
comprising
of at least two backing layers. In one aspect, the backing material 50 can
optionally comprise at least two nonwoven backing layers, at least one
nonwoven
backing layer needled to at least one woven backing layer, at least two
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. .
nonwoven backing layers, at least one woven layer needled to another woven
layer, and the like. When the backing material 50 comprises at leats two
backing
layers, it is contemplated that each of the respective at least two backing
layers
can have the same or different pics counts. One skilled in the art will
appreciate
that the machine gauge, yarn size, stitch rate and needle size are all factors
when considering an appropriate backing material.
[0027] In one example and not meant to be limiting, the backing
material 50
can comprise two 15 pic, woven, polypropylene primary backings. In operation,
the respective polypropylene primary backings are fed individually from two
backing stands and into a tufting machine with one on top of the other. The
needles conventionally penetrate the backing material 50 with the plurality of
fibrillated yarns 42 to create a desired "pile" on the face of the artificial
turf mat.
In one aspect, it is contemplated that at least two fibrillated yarns of the
plurality
of fibrillated yarns can be fed to each needle. Due to the large needle size
and
the large filament size, it is desired that the backing material comprises at
least
two backing layers.
[0028] In a further aspect, the turf layer 40 can comprise an
adhesive coating
layer 44. In this aspect, the bottommost layer of the backing material 50 can
be
coated with the adhesive coating layer, which is configured to bind to, and
optionally integrate with, at least a portion of the plurality of fibrillated
yarns that is
exposed on the bottommost surface of the backing material (i.e., the
backstitch).
In one aspect, it is contemplated that this adhesive coating layer 44 can seal
the
portion of the plurality of fibrillated yarns that is exposed on the
bottommost
surface of the backing material to the bottommost layer of the backing
material
and can add a layer of dimensional stability to the backing. In one aspect,
the
adhesive layer is applied at about 15 to 30 ounces per square foot, and more
preferably about 20 ounces per square foot, onto the bottommost layer of the
backing material.
[0029] In one aspect, it is contemplated that the adhesive layer 44
can
comprise ECOWORX Broadloom (EBL) extruded coating (SHAW INDUSTRIES
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GROUP, INC., Dalton, Georgia, United States of America), which is configured
to
lock the backstitch by encapsulation and provides a surface for the underlying
foam substrate to adhere. Since the EBL coating is a thermoplastic, as opposed
to a standard latex or polyurethane coating, it has good adhesion
characteristics.
The use of EBL allows for acceptable tuft-binds without a latex pre-coat. In
one
exemplary aspect, a conventional hot melt methodology can be utilized to apply
the adhesive layer thereon the bottommost surface of the backing material.
Guidance to EBL can be found in U.S. Patent Application Nos. 11/915,553,
12/952,709, 13/036,457, 13/887,866, and 13/953,156, and in U.S. Patent Nos.
7,338,698, 7,357,971, 7,910,194, 8,283,017, and 8,496,869, each of which is
incorporated by reference herein in its entirety.
[0030] It is contemplated that latex formulations with very low filler
content
can also be used as the adhesive layer. Optionally, it is also contemplated
that a
secondary backing can be adhered to the adhesive layer to facilitate adhesion
to
the underlying foam substrate by providing more surface area or to create a
different surface texture.
[0031] In one aspect, the underlying foam substrate 60 can comprise a shock
resistant material that can be adhered to the bottom surface of the turf
layer. In
one exemplary aspect, the underlying foam substrate can comprise a cross-
linked, polyethylene foam pad. To meet desired athletic performance and safety
requirements, the underlying foam substrate can be between about 0.375 inches
to about 0.625 inches in cross-sectional height. Exemplary, non-limiting
properties of a suitable cross-linked, polyethylene foam pad can include: a
density of about 6 lb/ft3; a tensile strength of about 136 psi; elongation
percentage of about 160%; tear resistance of about 39; compressive strength of
about: 14 psi (at 10% deflection), about 20 psi (at 25% deflection), about 29
psi
(at 40% deflection), and about 37 psi (at 50% deflection); a compression set
of
about 13%; thermal stability of less than about 0.5% change (24 hours at 158
F);
water absorption of less than 0.07 lb/ft2 (skived); and a working temperature
of
between about -56 F to about +210 F.
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[0032] In various non-limiting examples, versions of the exemplary suitable
cross-linked, polyethylene foam substrate 60 were tested and had the
properties
shown in Table 1.
Table 1: Exemplary Properties of Foam Substrate
Version Density Weight Height Gmax Force Vertical
(lb) (Oz) (inches) Reduction Deflection
(%) (mm)
1 6 48 0.375 78.1 71 10.4
2 6 48 0.25 98.1 68.1 9.8
3 6 48 0.625 96.6 68.6 10.3
[0033] In exemplary aspects, the desired range for Gmax (surface hardness)
can be less than or equal to 100. In further exemplary aspects, the desired
range for Force Reduction can be between 55-75 %. In still further exemplary
aspects, the desired range for vertical deflection can be between about 8 and
about 11 mm. As one will appreciate, the characteristics of the disclosed foam
substrate 60 can permit compliance with FIFA 1 STAR standards.
[0034] In one aspect, the upper surface 62 of the underlying foam substrate
60 can be adhered to the lower surface 45 of the adhesive layer 44. In one
exemplary methodology, it is contemplated that the foam substrate can be flame
laminated to the turf layer. In this aspect, the upper surface 62 of the foam
substrate can be heated by being exposed to a flame to partially melt the top
surface of the foam substrate to a desired depth. Subsequently, the bottom
surface of the turf layer can be attached to the heated top surface of the
foam
substrate and the joined turf layer and the foam substrate can then be run
between two rollers to compress and bind the respective turf layer and the
foam
substrate together.
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[0035] When the joined turf layer and the foam substrate have cooled, the
joined materials can be scored, milled and fitted with connection means to
form
the respective individual non-filled artificial turf mats. In one aspect, the
individual non-filled artificial turf mats can have a width of between about 2
feet to
about 12 feet. The mats can have any shape, but it is preferred that the mats
have a generally rectangular shape with the elongate length exceeding the
width.
[0036] In another aspect, to aid in rolling up an individual turf mat, each
mat
20 can have a plurality of slits 22 defined into the bottom surface of the
underlying foam substrate that extend the entire width, or substantially the
entire
width, of the turf mat. Each slit extends upwardly toward the overlying turf
layer
to a desired depth in the foam substrate. In various aspects, the slits can
extend
about 10%, about 20%, about 30%, about 40%, about 50%, about 60%, about
70%, about 80%, about 90%, or about 95% of the cross-sectional height of the
foam substrate (moving upwardly from the bottom surface of the mat). In
exemplary aspects, it is contemplated that the slits can extend from about 50%
to
about 99% of the cross-sectional height of the foam substrate. In further
exemplary aspects, it is contemplated the slits can extend from about 75% to
about 95% of the cross-sectional height of the foam substrate.
[0037] In operation, the bottom surface of the mats can be laid on a
substrate
such as a flooring material, concrete slab, or a leveled aggregate and dirt
subgrade and married to adjoining mats to create a floating, portable athletic
field. The connection means is configured to be suitable for selective joining
and
separating the artificial turf mats. As one will appreciate, also disclosed
herein is
method for installing and subsequently removing the transition artificial turf
field
in a quick and efficient manner.
[0038] Because it is contemplated that the non-filled artificial turf mats
can be
arranged on a floor for a specific activity and then removed and stored when a
different activity is to take place on the same floor, it is desirable to
provide a
system that allows the non-filled artificial turf mats to be easily attached
and
separated. In some aspects, the system can be reusable in that it can permit
the
CA 02928211 2016-04-26
non-filled artificial turf mats to be connected and then separated multiple
times.
In some embodiments in accordance with the invention, the system can allow the
non-filled artificial turf mats to be attached to each other and form a
substantially
contiguous top surface. In other embodiments, the non-filled artificial turf
mats
can be secured by connection means for reducing movement between
selectively adjoined artificial turf mats and preventing gaps from occurring
between the selectively adjoined artificial turf mats. In one aspect, the
connection means can comprise the connecting system described in U.S. Patent
Nos. 8,307,600, 8,596,011, 8,733,056, 8,800,233, and 9,278,243, each of which
is incorporated herein by reference in its entirety.
[0039] Selected non-filled artificial turf mats can be coupled together
utilizing
hook and loop fastening systems. To remove the assembled artificial turf
field,
each non-filled artificial turf mat can be unhooked from the next adjacent non-
filled artificial turf mat and rolled onto a roller 90 as exemplarily shown in
Figure
1.
[0040] In another embodiment, as shown in Figures 3 -5, the system can
comprise a means for selectively connecting adjoining artificial turf mats 20.
As
shown in Figure 3, the foam substrate 60 of each artificial turf mat 20 can
define
a longitudinally extending shoulder member 64 defining a downwardly facing,
substantially horizontal, first connecting surface 65 on one longitudinal edge
and
a longitudinally extending shelf member 66 defining an upwardly facing,
substantially horizontal, second connecting surface 67 on the opposite
longitudinal edge. It is contemplated that the respective shoulder member and
shelf member can extend the entire longitudinal length of the artificial turf
mat
and be sized and shaped for a complementary fit with each other. In one
aspect,
it is contemplated that the formed complementary fit between the respective
shoulder member and shelf member can result in the turf layers of the adjoined
artificial turf mats being positioned substantially parallel to each other
(assuming
the underlying floor surface is level) to define a substantially flat top
surface or
working surface.
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[0041] In one aspect, elongated stripes of attaching material 70 can be
adhered to the respective first and second connecting surfaces. The attaching
material can be attached to the respective first and second connecting
surfaces
65, 67 by any suitable method such as, but not limited to, flame lamination,
gluing, double sided tape, and sewing. In one aspect, attaching material 70
provided with an adhesive on the back can also be used. In one exemplary
aspect, the attaching material 70 can be, for example, a hook and loop
attaching
material or other conventional attaching material that is capable of being
attached and detached multiple times. In another embodiment, the loop portion
of the attaching material can be mounted to the horizontal first connecting
surface 65 of the longitudinally extending shoulder member, and the hook
portion
of the attaching material is mounted on the horizontal second connecting
surface
67 of the longitudinally extending shelf member. Alternatively, the hook
portion
of the attaching material can be mounted to the horizontal first connecting
surface 65 of the longitudinally extending shoulder member, and the loop
portion
of the attaching material is mounted on the horizontal second connecting
surface
67 of the longitudinally extending shelf member. One example, and not meant to
be limiting, of a hook and loop material is a series of products sold under
the
trade name VELCRO.
[0042] In further exemplary aspects, it is contemplated that the non-filled
artificial turf mats can be coupled together utilizing magnetic attraction
forces. In
these aspects, it is contemplated that the attaching material on the first
connecting surface can comprise at least one magnet having a first polarity,
while
the attaching material on the second connecting surface can comprise at least
one magnet having a second polarity that is opposite the first polarity to
thereby
generate a magnetic attraction between the first and second connecting
surfaces
when the magnets are sufficiently aligned (or proximate one another). It is
further contemplated that each of the first and second connecting surfaces can
define receptacles (holes, openings, and the like) for receiving and retaining
respective magnets.
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[0043] In still further exemplary aspects, it is contemplated that the non-
filled
artificial turf mats can be coupled together utilizing at least one projection
defined
by one of the first and second connecting surfaces and a corresponding trench
defined by the other of the first and second connecting surfaces. In these
aspects, the trench can be spaced from an edge of the mat and run
substantially
parallel to an edge of the mat, and each projection can be configured for
selective complementary insertion into the trench. In exemplary aspects, the
trench and the at least one projection can have a rectangular cross-sectional
shape; however, it is contemplated that any shape, including chamfered and
rounded shapes, can be used.
[0044] One skilled in the art will appreciate that when non-filled
artificial turf
mats of the present invention are selectively secured together via exemplary
connection means, the turf layers of both of the adjoining mats form the
substantially contiguous top or working surface.
[0045] As shown in Figure 4, when the attaching material 70 is attached to
the second connecting surface 67 of the longitudinally extending shelf member
66, the attaching material can extend over the end edges of the longitudinally
extending shelf member. Optionally, the attaching material can further extend
to
the bottom surface of the foam substrate that underlies the longitudinally
extending shelf member. In this aspect, the attaching material, when wrapped
around the end edges onto the bottom surface of the foam substrate can provide
endurance and support of the attaching and detaching of adjoining artificial
turf
mats from each other. When the artificial turf mats are selectively detached
from
each other, the attaching material receives forces that can eventually wear
down
the attaching material. By extending the attaching material over the end edges
of
the longitudinally extending shelf member and, optionally, to the bottom
surface
of the foam substrate that underlies the longitudinally extending shelf
member,
wearing of the attaching material can be greatly reduced.
[0046] Although several embodiments of the invention have been disclosed
in the foregoing specification, it is understood by those skilled in the art
that many
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modifications and other embodiments of the invention will come to mind to
which
the invention pertains, having the benefit of the teaching presented in the
foregoing description and associated drawings. It is thus understood that the
invention is not limited to the specific embodiments disclosed hereinabove,
and
that many modifications and other embodiments are intended to be included
within the scope of the appended claims. Moreover, although specific terms are
employed herein, as well as in the claims which follow, they are used only in
a
generic and descriptive sense, and not for the purposes of limiting the
described
invention, nor the claims which follow.
14
