Note: Descriptions are shown in the official language in which they were submitted.
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ARTIFICIAL TURF WITH COMPOSITE INFILL
Description
Field of the invention
The invention relates to artificial turf, in particular to artificial turfs
with infill and also
infill for artificial turf.
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Background and related art
Artificial turf or artificial grass is surface that is made up of fibers which
is used to
replace grass. The structure of the artificial turf is designed such that the
artificial
turf has an appearance which resembles grass. Typically artificial turf is
used as a
surface for sports such as soccer, American football, rugby, tennis, golf, for
playing
fields, or exercise fields. Furthermore artificial turf is frequently used for
landscaping
applications.
Artificial turf may be manufactured using techniques for manufacturing
carpets. For
example artificial turf fibers which have the appearance of grass blades may
be
tufted or attached to a backing. Often times artificial turf infill is placed
between the
artificial turf fibers. Artificial turf infill is a granular material that
covers the bottom
portion of the artificial turf fibers. The use of artificial turf infill may
have a number of
advantages. For example, artificial turf infill may help the artificial turf
fibers stand up
straight. Artificial turf infill may also absorb impact from walking or
running and
provide an experience similar to being on real turf. The artificial turf
infill may also
help to keep the artificial turf carpet flat and in place by weighting it
down.
European Patent EP 2 206 833 Al discloses a method for producing a particulate
infill material for synthetic-grass structures envisages providing a mass of
thermoplastic material with a filler consisting of coconut-based material and
subjecting said mass of thermoplastic material with the filler consisting of
coconut-
based material to granulation so as to obtain the aforesaid particulate infill
material.
Preferentially, the thermoplastic material is in particulate form, and the
coconut-
based material is in particulate form (fibrous, ground and/or shredded). The
mixture
obtained by mixing the thermoplastic material and the coconut-based material
is
preferentially heated in order to bring about softening of the thermoplastic
material
with the corresponding formation of a matrix of thermoplastic material that
incorporates the coconut-based material as filler.
Summary
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The invention provides for an artificial turf and the use of composite
components as
artificial turf infill in the independent claims. Embodiments are given in the
dependent claims.
The properties of the infill used in artificial turf may have a large impact
on how
realistically the artificial turf performs. Embodiments may use an a
artificial turf infill
that incorporates composite infill components. The composite infill components
comprise a water absorbent yarn that is covered with a jacket formed from an
elastomeric compound. The elastomeric compound provides protection for the
water
absorbent yarn and may also be used to color or control the appearance of the
artificial turf infill.
The water absorbent yarn may provide a means of efficiently storing water in
the
artificial turf infill. As the water evaporates it may serve to cool the
artificial turf.
Additionally, in football (soccer) players often slide in a controlled manner
as part of
the game. Having water in the artificial turf infill may aid players in
sliding.
In one aspect, the invention provides for an artificial turf comprising an
artificial turf
infill. The artificial turf infill comprises composite infill components. The
infill
components comprise a water absorbent yarn. A yarn as used herein encompasses
a continuous length of material that comprises a number or a large number of
interlocked fibers. The water absorbent yarn is covered with a jacket. The
jacket is
formed from an elastomeric compound. An elastomeric compound as used herein
encompasses a material that is formed with a polymer that has viscoelasticity.
The
jacket may be flexible and may return to its original position when deformed.
The
jacket comprises at least one opening. The at least one opening exposes the
water
absorbent yarn.
This embodiment may be beneficial because the water absorbent yarn may absorb
and retain water. The retention of water by an artificial turf infill may be
beneficial in
that it may help to limit the temperature of an artificial turf surface during
a game or
sporting event. The evaporation of water from the water absorbent yarn may
help to
cool the surface. Additionally, having water available in the artificial turf
infill may
also give superior properties to the artificial turf surface for playing
various games.
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For example in soccer or football it is common that players may make sliding
motions. Having water within the artificial turf infill may help to impart a
realistic slide
or sliding ability in the artificial turf that compares to real or organic
turf from grass.
In another embodiment, the elastomeric compound is elastic between between 5 C
and 50 C. The elastomeric compound may be elastic at temperatures greater or
lower than this range also. Being elastic at a minimum between 5 C and 50 C
may
have the advantage of making the artificial turf softer and more realistic.
In another embodiment, the water absorbent yarn has a circular cross section.
This
embodiment may be advantageous because the artificial turf infill may have a
regular form that has predictable mechanical properties.
In another embodiment the water absorbent fiber comprises fibers that extend
in a
length direction that is perpendicular or mostly perpendicular to the circular
cross
section.
In another embodiment, the water absorbent yarn has a diameter. The diameter
may for example be circularly shaped. This embodiment may be advantageous
because the artificial turf infill may have a regular form that has
predictable
mechanical properties. In some examples, the yarn may comprise fibers that
have
an individual diameter smaller than the diameter of the yarn. For example the
individual diameter of the fibers may be a factor of at least 5, 10, or 50
times smaller
than the diameter of the yarn.
In another embodiment, the water absorbent yarn comprises interlocking fibers.
The
interlocking of fibers may be beneficial because the fibers may be less likely
to fall
apart during use.
In another embodiment, the water absorbent yarn comprises any one of the
following: hygroscopic fibers, burlap fibers, jute fibers, cotton fibers, wool
fibers,
hemp fibers, polyester fibers, natural fibers, kenaf synthetic fibers, fibers
with a
hydrophilic surface, and combinations thereof. The use of any of these fibers
or
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mixtures thereof may provide for an artificial turf infill that is able to
retain water in an
efficient means.
The use of burlap (jute) fibers may be beneficial because burlap has a high
5 resistance to molding and bacterial decay. Additionally, burlap is able
to store for its
weight a large amount of water. For example, infill material made with burlap
as the
water absorbent yarn may be able to store approximately 450 g of water per 1
kg of
dry artificial turf infill. The use of burlap may therefore provide for an
artificial turf
infill with superior water retention properties.
Burlap or jute fibers may also be easily recycled. Burlap is typically used
for the
storage of food such as in potato sacks. Old burlap materials or bags may be
re-
beaten to break up the fibers and then re-spun easily into a new yarn which
may be
used for manufacturing the artificial turf infill.
In another embodiment the jacket comprises any one of the following:
polyurethane,
rubber, a polyolefin elastomer, a dye, a UV protective additive, polyurethane
and
polyole, polyurethane and a temperature sensitive catalyst, a one-component
polyurethane, a two-component polyurethane, polyethylene, TPE, extruded PE,
extruded TPE, and combinations thereof.
In another embodiment, the jacket is formed from a cured liquid. The yarn
comprises a peripheral portion and a central region. The peripheral portion
surrounds the central region. The peripheral portion is partially saturated
with an
elastomeric compound. The central region is free of the elastomeric compound.
This
embodiment may be beneficial because the jacket may have superior adhesion to
the water absorbent yarn while at the same time leaving the central region
free to
absorb water.
In another embodiment, the jacket comprises between 6% and 10% of the
composite infill components by weight. That is to say that 90% to 94% of the
composite infill by weight is the water absorbent yarn.
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The use of a composite infill that has a jacket formed from the elastomeric
compound that covers the water absorbent yarn may further be beneficial
because
the jacket can impart qualities that the water absorbent yarn may not have by
itself.
For example the jacket may be dyed or colored so that the artificial turf
retains a
particular appearance. The use of a jacket may also protect the water
absorbent
yarn and extend its useful period.
In another embodiment, the jacket has a thickness between 4 p and 8 p.
In another embodiment, the jacket has a length between 0.4 mm and any one of
the
following: 0.5 mm, 1.0 mm, 1.5 mm, 2.0 mm, 2.5 mm, 3.0 mm, 3.5 mm, 4.0 mm, 4.5
mm, 5.0 mm, and 5.5 mm. The different length of the artificial turf infill may
have
different properties.
The artificial turf infill can be cut so that it is relatively symmetric with
regards to the
diameter and the length. This may provide an infill that is more granular and
packs
more tightly.
The use of artificial turf infill where the length is much longer than the
diameter may
be beneficial in some instances in that the artificial turf may intertwine
with itself and
also with fibers that are used to form the pile of the artificial turf. This
may help to
keep the composite infill components in place with respect to each other and
also
reduce the effect of splash. The splash effect is when a ball or other object
ballistically hits an artificial turf surface and amounts of the artificial
turf infill are
knocked away from the artificial turf surface. This results in artificial turf
infill being
knocked away from the artificial turf surface. This effect resembles a ball or
other
object splashing or hitting a puddle where water is knocked up. In this case
the
artificial turf infill is knocked up temporarily.
The term "pile" as used herein refers to the fibers collectively used to form
the
artificial turf surface. For example, an artificial turf carpet may comprise a
large
number of artificial turf fibers which are attached to a backing. The
artificial turf
fibers are collectively referred to as the pile, and the pile forms the
artificial turf
surface.
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Increasing the length of the artificial turf infill may also have the
advantage that the
artificial turf infill packs less tightly. This may reduce how securely the
cleats of an
athletic shoe grip the artificial turf. The length can be adjusted such that
cleats grip
the surface sufficiently to enable athletic performance to balanced by the
need of
the shoe to release the surface to reduce injury to the player.
In another embodiment, the composite infill components have a thickness
between
0.3 mm and 0.5 mm. The thickness of the composite infill components may also
be
considered to be the outside diameter or thickness of the jacket. The choice
of the
thickness between 0.3 mm and 0.5 mm may be beneficial because the composite
infill components do not pack too hard within the artificial turf surface but
are still
short enough that they are able to pack compactly to form a surface which
resembles real turf.
In another embodiment, the jacket is a cylindrical jacket. The jacket may for
instance
be due to an extrusion process or may be due to an effect where the yarn is
coated.
Either of these may result in a cylindrical jacket. In some instances the
jacket has an
oval-shaped profile or may be asymmetric.
In another embodiment, the at least one opening is a cylindric section. For
example
the composite infill components could be cylindrical-shaped and one or two
ends
may be cut such that they resemble cylindric sections.
In another embodiment, the at least one opening is two openings. For example
in
one embodiment the composite infill components may be cylindrical-shaped and
they may be cut on both sides of the cylinder thus exposing the water
absorbent
yarn.
In another embodiment, the artificial turf comprises an artificial turf carpet
with a pile.
The artificial turf carpet comprises a backing. The artificial turf carpet
further
comprises artificial grass fibers. The artificial grass fibers are tufted into
the backing.
The artificial grass fibers form the pile. The artificial grass fibers are
secured to the
backing. The artificial turf infill is distributed within the pile.
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In another embodiment, the artificial turf comprises a sand layer between the
backing and the artificial turf infill. The sand layer may help to hold the
artificial turf
carpet in place. Placing the artificial turf infill on the sand layer may help
to provide
for a superior artificial turf surface. For example the sand layer may provide
for
ready drainage of standing water on the artificial turf. However, having too
much
drainage may be a disadvantage because the artificial turf infill is
preferably damp or
has some moisture to maintain cooling of the artificial turf surface as well
as making
it easy to slide on the artificial turf. The use of the composite infill
components may
provide for an artificial turf infill that readily and quickly absorbs water.
When water
is sprayed on the surface or it rains the composite infill components will
quickly
absorb any water or large portions of the water which initially goes on the
surface.
Any extra water may then flow into the sand layer where it is drained away
from the
surface.
In another embodiment, the artificial turf comprises a drainage system for
draining
standing water from the artificial turf. The backing of the artificial turf or
an elastic
layer may be placed on the drainage system. As with the embodiment that
comprises the sand layer, this may provide for a way of regulating the amount
of
water that is on the artificial turf. The artificial turf infill will quickly
absorb water and
any excess will then be drained away by the drainage system.
In another embodiment, the composite infill components have a length. The
water
absorbent yarn is substantially aligned with the length. The yarn may be made
from
a collection of fibers which is twisted or formed into a thread or a strand-
like
structure. The yarn may have a length that represents the average orientation
of
fibers.
In another aspect, the invention provides for the use of composite components
as
artificial turf infill. The composite components comprise a water absorbent
yarn. The
water absorbent yarn is covered with a jacket. The jacket is formed from an
elastomeric compound. The jacket comprises at least one opening. The at least
one
opening exposes the water absorbent fibers. The advantages of the use of the
composite components in artificial turf infill have been previously discussed.
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It is understood that one or more of the aforementioned embodiments of the
invention may be combined as long as the combined embodiments are not mutually
exclusive.
Brief description of the drawings
In the following embodiments of the invention are explained in greater detail,
by way
of example only, making reference to the drawings in which:
Fig. 1 illustrates an example of an artificial turf;
Fig. 2 illustrates a further example of an artificial turf;
Fig. 3 illustrates a further example of an artificial turf;
Fig. 4 illustrates an example of a composite infill component;
Fig. 5 shows a side view of the composite infill component of Fig. 4;
Fig. 6 illustrates a machine for coating yarn;
Fig. 7 illustrates a two component coater for coating a yarn with a two
component jacket;
Fig. 8 illustrates a further example of a machine for coating yarn; and
Fig. 9 illustrates a further example of a machine for coating yarn.
Detailed Description
Like numbered elements in these figures are either equivalent elements or
perform
the same function. Elements which have been discussed previously will not
necessarily be discussed in later figures if the function is equivalent.
Fig. 1 shows an example of an artificial turf 100. The artificial turf 100
comprises an
artificial turf carpet 102. The artificial turf carpet comprises a backing 104
and also
artificial grass fibers 106. The artificial grass fibers 106 are tufted into
the backing
104 and are secured 108 to the backing 104. The artificial turf fibers 106
form a pile
103. The artificial turf carpet 102 is resting on a ground 110 or surface.
Between and
distributed between the artificial grass fibers 106 and within the pile 103 is
an
artificial turf infill 112. In this example the artificial turf infill 112 is
made from
individual composite infill components 114.
Fig. 2 shows a further example of an artificial turf 200. The artificial turf
200 is similar
to the artificial turf 100 shown in Fig. 1 except there is additionally a sand
layer 202
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between the artificial turf infill 112 and the backing 104. The use of the
sand layer
202 may be advantageous because it may help to hold the artificial turf carpet
102
in place. It may also have the technical benefit that the sand layer 202 works
in
conjunction with the artificial turf infill 112 to regulate the amount of
water on the
5 surface of the artificial turf 200. For example if it rains or if water
is sprayed onto the
surface of the artificial turf 200 the composite infill components 114 will
rapidly
absorb and saturate with water. The sand layer 202 may then aid in draining
away
excess water and preventing it from standing on the surface of the artificial
turf 200.
10 Fig. 3 shows a further example of an artificial turf 300. The artificial
turf 300 is similar
to the artificial turf 200 shown in Fig. 2 with the addition of several
additional layers.
Directly underneath the backing 104 is an elastic layer 302. The elastic layer
may
for example be a mat or other material such as sand and elastomeric granulate
or a
mixture thereof that readily absorbs shock. The elastic layer 302 is optional.
The
backing 104 and/or the elastic layer 302 may have holes or may be porous so
that
water that is standing on the artificial turf 300 can be drained away. The
elastic layer
302 is directly sitting on a drainage system 304. The drainage system 304 may
comprise granulate material, drainage tiles, drainage pipes or other system
for
rapidly draining water off the surface of the artificial turf 300. The
artificial turf
depicted in Fig. 300 may have superior qualities when water is used to cool or
improve sliding properties. Water that initially goes on the surface is
readily
absorbed by the composite infill components 114 that make up the artificial
turf infill
112. When they have filled with water excess water may then go into and
possibly
be stored in the sand layer 202. When the sand layer 202 is saturated it may
drain
through the backing 104 and/or the elastic layer 302 into the drainage system
304.
Fig. 4 shows an example of a composite infill component 114. In this example
the
composite infill component is cylindrical-shaped. However, it is not necessary
for the
composite infill component to have a cylindrical shape or be perfectly
cylindrical as
is depicted. The composite infill component 114 can be seen as having a length
400
and a diameter 402. In an inner core of the composite infill component 114 is
water
absorbent yarn 404. Surrounding the water absorbent yarn 404 is a jacket 406
which serves as a protector or a cladding for the water absorbent yarn 404.
The
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composite infill component 114 as depicted may be manufactured by coating a
yarn
404 with a jacket material 406.
It can be seen that in this example the composite infill component 114 has had
both
ends cut, there are therefore two exposed openings 408. The openings 408 form
cylindric sections in this example. Some of the properties of the artificial
turf infill can
be adjusted by changing the diameter 402 and the length 400. If the length 400
is
similar to the diameter 402 then the artificial turf infill will take on a
grain-like or a
granular form. As the length 400 is increased the properties of the artificial
turf infill
may change. For example the artificial turf infill may pack less densely. The
density
may therefore be adjusted by controlling the length 400 or controlling the
distribution
of lengths 400. Additionally, as the length 400 is increased the tendency of
the
artificial turf infill to splash may be reduced because the various composite
infill
components 114 may become entwined with themselves and/or artificial grass
fibers.
Fig. 5 shows a side view of the composite infill component 114. The side view
shows the opening 408. The water absorbent yarn 404 has a central region 500
and
a peripheral region 502. The peripheral region of the water absorbent yarn 404
contacts the jacket 406. In some examples, the jacket 406 may be applied as a
liquid or fluid to the water absorbent yarn 404. Some of the fibers of the
yarn may
contact or intermingle with the material used to form the jacket 406. This may
result
in a region which is fully or partially saturated with the jacket material.
The region
which is fully or partially saturated is the peripheral region 502. The
central region
500 is not filled with any of the jacket material 406. The central region 500
is free to
absorb the full amount of water that it is capable of. In some examples the
peripheral region 502 may help the adhesion of the jacket 406 to the water
absorbent yarn 404.
Fig. 6 shows an example of a coating machine 600 which is used to coat yarn
404.
In this example there is a spool with uncoated yarn 602 which passes through
the
machine to a spool with coated yarn 604. The coated yarn 604 may be later cut
into
the composite infill components. In some examples the yarn 404 after it has
been
coated is immediately cut into the composite infill components. After leaving
the
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spool 602 the yarn 404 passes through a two-component coater 606. The two-
component coater 606 puts the jacket on the yarn 404 in liquid form. The
coated
yarn 404 then passes optionally through a heater or dryer 608. The heater or
dryer
608 may for instance be used to remove water from the jacket material and in
some
instances may also be used to activate a catalyst.
Fig. 7 illustrates the two-component coater 606 in greater detail. The two-
component coater 606 has an inlet for a first component 700 and an inlet for a
second component 702. The two components may for instance be components of a
two-component polyurethane coating. The first and second 700, 702 inlets then
join
into a mixing chamber 704 where the two components mix. The mixed components
then travel to an applicator ring 706. The ring has jets or sprays 708 that
are used to
spray the jacket material onto the water absorbent yarn 404 as it passes
through the
two-component coater 606. The mixture of the two components can be chosen such
that the coating on the water absorbent yarn 404 is uniform and cures without
dripping or dropping. Depending upon the particular mixture used the heater or
dryer 608 may or may not be used.
Fig. 8 shows an alternative coating machine 800. In the Fig. shown in Fig. 8
the two-
component coater 606 has been replaced with a shower head 802. The shower
head 802 sprays or drops the liquid jacket material onto the yarn 404 as it
passes
under the shower head 802. In some examples there may be an additional
component after the shower head 802 which removes excess liquid jacket
material.
For example the yarn 404 may pass through an orifice or on roller wheels which
helps to regulate the amount of fluid which is applied to the yarn 404.
Fig. 9 shows a further example of a coating machine 900. This machine 900 is
similar to the machines 800 and 600 shown in Figs. 8 and 6. However, in this
example a bath 902 is used. The yarn 404 enters the bath 902 and acquires some
jacket material in liquid or fluid form. It then optionally passes through a
heater 608
which may for instance be used to dry or activate a catalyst. In some examples
there is an additional component between the bath 902 and the heater 608 to
remove excess fluid. For instance the yarn 404 may pass through an orifice or
over
rollers which are used to remove excess jacket material. The example shown in
Fig.
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9 may for instance use a jacket material or coating which is a single
component. If a
catalyst is used the bath 902 can be left standing for a long time and may be
used
continuously without the worry that the coating material will prematurely set.
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List of reference numerals
100 artificial turf
102 artificial turf carpet
103 pile
104 backing
106 artificial grass fibers
108 secured to backing
110 ground
112 artificial turf infill
114 composite infill component
200 artificial turf
202 sand layer
300 artificial turf infill
302 elastic layer
304 drainage system
400 length
402 diameter
404 water absorbent yarn
406 jacket
408 opening
500 central region
502 peripheral region
600 coating machine
602 spool with yarn
604 spool with coated yarn
606 two component coater
608 heater or dryer
700 inlet first component
702 inlet second component
704 mixing chamber
706 applicator ring
708 jet or spray of liquid jacket material
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800 coating machine
802 showerhead
900 coating machine
902 bath
5
