U.S. patent application number 10/359634 was filed with the patent office on 2003-09-18 for synthetic grass with resilient granular top surface layer.
This patent application is currently assigned to Fieldturf Holdings Inc.. Invention is credited to Prevost, Jean.
Application Number | 20030175448 10/359634 |
Document ID | / |
Family ID | 27758300 |
Filed Date | 2003-09-18 |
United States Patent
Application |
20030175448 |
Kind Code |
A1 |
Prevost, Jean |
September 18, 2003 |
Synthetic grass with resilient granular top surface layer
Abstract
A synthetic grass assembly for installation on a supporting soil
substrate includes a pile fabric with a flexible sheet backing and
rows of upstanding synthetic ribbons representing grass blades,
extending upwardly from an upper surface of the backing. An infill
layer of two distinct graded courses of particulate material is
disposed interstitially between the upstanding ribbons upon the
upper surface of the backing and of a depth less than the length of
the ribbons. A bottom course of intermixed hard sand and resilient
rubber granules with substantially identical particle size
distribution characteristics is installed upon the backing and a
top course exclusively of resilient rubber granules is placed upon
the bottom course.
Inventors: |
Prevost, Jean; (Cote St-Luc,
CA) |
Correspondence
Address: |
BIRCH STEWART KOLASCH & BIRCH
PO BOX 747
FALLS CHURCH
VA
22040-0747
US
|
Assignee: |
Fieldturf Holdings Inc.
|
Family ID: |
27758300 |
Appl. No.: |
10/359634 |
Filed: |
February 7, 2003 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10359634 |
Feb 7, 2003 |
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09598149 |
Jun 21, 2000 |
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6551689 |
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09598149 |
Jun 21, 2000 |
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PCT/CA99/00704 |
Aug 3, 1999 |
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Current U.S.
Class: |
428/15 ;
428/17 |
Current CPC
Class: |
B32B 5/30 20130101; B32B
2262/0261 20130101; E01C 13/08 20130101; Y10T 428/2982 20150115;
B32B 3/085 20130101; B32B 3/16 20130101; Y10T 428/24405 20150115;
B32B 5/24 20130101; B32B 3/18 20130101; B32B 2410/00 20130101; B32B
3/30 20130101; Y10T 428/25 20150115; B32B 5/16 20130101; B32B
2264/0207 20130101; Y10T 428/23979 20150401; Y10T 428/23957
20150401; B32B 2307/554 20130101; B32B 5/024 20130101; B32B
2264/102 20130101; Y10T 428/2443 20150115; B32B 2307/50 20130101;
B32B 2307/552 20130101; B32B 2262/0253 20130101; Y10T 428/26
20150115; B32B 2264/12 20130101; Y10T 428/24372 20150115; Y10T
428/23921 20150401; B32B 2471/04 20130101; Y10T 428/24421
20150115 |
Class at
Publication: |
428/15 ;
428/17 |
International
Class: |
A41G 003/00; A41G
005/00; A41G 001/00 |
Foreign Application Data
Date |
Code |
Application Number |
Sep 21, 1998 |
CA |
2,247,484 |
Claims
The embodiments of the invention in which an exclusive property or
privilege is claimed are defined as follows:
1. A synthetic grass assembly for installation on a supporting
substrate, the assembly comprising: a pile fabric with a flexible
sheet backing and a plurality of upstanding synthetic ribbons of a
selected length, the ribbons extending upwardly from an upper
surface of the backing; an infill layer of particulate material
disposed interstitially between the upstanding ribbons upon the
upper surface of the backing and of a depth less than the length of
the ribbons, the particulate material selected from the group
consisting of: hard; and resilient granules; wherein the synthetic
ribbons: are longitudinally intermittently slit in a predetermined
pattern of slits; an upper portion of the ribbons extending above
the infill layer and longitudinally split into individual
free-standing strands of a selected width to represent grass
blades; and a lower portion of the ribbons having said slits
extended open forming laterally linked strands disposed in a
lattice structure enmeshing the surrounding particulate infill
material.
2. A synthetic grass assembly according to claim 1 wherein the
infill layer comprises: a bottom course of intermixed hard and
resilient granules, disposed upon the top surface of the backing;
and a top course substantially exclusively of resilient granules
disposed upon the bottom course, an upper portion of the synthetic
ribbons extending upwardly from a top surface of the top
course.
3. A synthetic grass assembly according to claim 2 wherein the
resilient granules in the top course are larger than the resilient
granules in the bottom course.
4. A synthetic grass assembly according to claim 2 wherein the hard
granules and resilient granules in the bottom course are of shape
defined in the range of 0.5 to 0.99 on the Krumbein scale of
sphericity.
5. A synthetic grass assembly according to claim 4 wherein the hard
granules and resilient granules in the bottom course are in the
range of 0.6 to 0.9 Krumbein scale.
6. A synthetic grass assembly according to claim 2 wherein the
resilient granules are selected from the group consisting of:
cryogenically ground rubber; rubber; cork; polymer beads; synthetic
polymer foam; styrene; perlite, neoprene, and EPDM rubber.
7. A synthetic grass assembly according to claim 2 wherein the hard
granules are selected from the group consisting of: sand; hard
aggregate; silica sand; gravel; slag; granulated plastic; and
polymer beads.
8. A synthetic grass assembly according to claim 1 wherein the
particulate material of the infill comprises granules of size
ranging between 0.5 inches maximum nominal diameter and 50 screen
mesh standard.
9. A synthetic grass assembly according to claim 8 wherein the
particle sizes of 80% by weight of hard granules and resilient
granules in the bottom course are distributed in a range spanning a
numerical difference of 40 in screen mesh standard.
10. A synthetic grass assembly according to claim 9 wherein the
particle sizes of 80% by weight of hard granules and resilient
granules in the bottom course are distributed in a range spanning a
numerical difference of 20 in screen mesh standard.
11. A synthetic grass assembly according to claim 1 wherein the
synthetic ribbons are disposed in rows spaced apart a selected
minimum distance.
12. A synthetic grass assembly according to claim 11 wherein the
maximum distance between rows of synthetic ribbons tufted in the
fabric backing is 2.25 inches.
13. A synthetic grass assembly according to claim 12 wherein the
maximum distance between rows of synthetic ribbons tufted in the
fabric backing is 1.0 inch.
14. A synthetic grass assembly according to claim 13 wherein the
maximum distance between rows of synthetic ribbons tufted in the
fabric backing is 0.625 inches.
15. A synthetic grass assembly according to claim I wherein depth
of the infill layer is in the range between 90% to 40% of the
length of synthetic ribbons.
16. A synthetic grass assembly according to claim 15 wherein depth
of the infill layer is in the range between 85% to 55% of the
length of synthetic ribbons.
17. A synthetic grass assembly according to claim 16 wherein depth
of the infill layer is in the range between 80% to 70% of the
length of synthetic ribbons.
18. A synthetic grass assembly according to claim 1 wherein the
synthetic ribbons are fibers selected from the group consisting of:
polypropylene; polyethylene; nylon; and plastic.
19. A synthetic grass assembly according to claim 1 wherein the
upper portion of the synthetic ribbons are fibrillated into
individual strands of a width in the range between 1.0 to 15.0
mm.
20. A synthetic grass assembly according to claim 1 wherein the
synthetic ribbons are of a thickness in the range between 45 to 200
microns.
Description
TECHNICAL FIELD
[0001] The invention is directed to a synthetic grass with
grass-like ribbons forming a lattice enmeshing a particulate infill
having a bottom layer of equally sized sand and rubber granules,
and a top layer of rubber granules only.
BACKGROUND OF THE ART
[0002] Maintenance of natural grass turf on athletic playing or
landscaped areas is. expensive, natural grass does not grow well
within shaded enclosed stadiums and continuous heavy traffic wears
out areas in the natural turf surface. Natural turf surfaces
deteriorate under heavy use and exposed soil creates an undesirable
accumulation of water and mud. Synthetic grasses therefore have
been developed in order to reduce the expenses of maintaining
heavily used athletic playing areas, to render playing surfaces
more uniform, and increase the durability of the grass surface,
especially where professional sports are involved.
[0003] Synthetic grass is installed with a carpet-like pile fabric
having a flexible backing laid on a well drained compacted
substrate, such as crushed stone or other stabilized base material.
The pile fabric has rows of upstanding synthetic ribbons
representing grass blades extending upwardly from the top surface
of the backing.
[0004] Of particular interest to the present invention are the
various formulations for granular resilient fill that are placed
between the upstanding ribbons on the upper surface of the backing
to simulate the presence of soil. Most prior art systems involve
some use of hard particles such as sand or crushed slag particles,
together with resilient particles such as crumb rubber particles or
foam backing to provide resilience. The optimal choice of particle
sizes, particle shape, particle composition and installation in
multiple layers or courses is a feature of the present
invention.
[0005] U.S. Pat. No. 4,337,283 to Haas, Jr. discloses a homogeneous
infill mixture to imitate soil that is made of fine hard sand
particles mixed with 25% to 95% by volume resilient particles to
provide an improved resilient and less abrasive infill. Such
resilient granular material may include mixtures of granulated
rubber particles, cork polymer beads, foam rubber particles,
vermiculite, and the like.
[0006] U.S. Pat. No. 4,396,653 to Tomarin discloses a
non-homogeneous infill with rubber particles forming a base layer
and sand particles forming a top layer. The rubber particles
provide inner resiliency to the surface. The sand layer is exposed
and forms a stabilizing cover layer for the underlying rubber
particle layer.
[0007] A number of disadvantages result from the use of a uniformly
mixed granular infill as in the Haas system where hard sand
particles and resilient rubber particles are mixed and blended in a
uniform proportion throughout the depth of the infill. Synthetic
grass infill, for example, may comprise a mixture of 60% by weight
of sand and 40% granulated rubber particles uniformly mixed and
deposited between the upstanding synthetic grass ribbons to a depth
of 1 to 3 inches.
[0008] A high percentage of sand is preferred to minimize the cost
of such systems, since rubber particles are relatively expensive
compared to sand. The sand particles also provide an improved
degree of drainage that is needed where the synthetic grass surface
is not in an enclosed stadium for example. Rubber particles tend to
impede the free flow of water, whereas the capillary action of the
sand particles draws surface moisture downwardly due to the
differences in surface tension characteristics between rubber and
silica sand.
[0009] However, in both the Haas and Tomarin systems, abrasive hard
sand particles present in the top surface layer of infill causes
problems where such as games of football, rugby, soccer, field
hockey, baseball are played since players repeatedly fall down or
are knocked down on the playing surface. In such applications,
there is a need to protect players from skin abrasion caused by the
hard sand in the granular infill and from sand spraying into the
players eyes, ears and mouth.
[0010] The conventional infill is a mixture of sand and rubber
particles. The rubber particles are compressed and released when a
ball hits the surface or an athlete steps on the surface. In the
case of conventional soil, the soil and humus particles provide
some natural resilience but the rebound is more gradual due to
moisture, small particle size and relatively low natural
resilience. In the case of synthetic infills, the particles are
relatively dry and do not bond together. The rubber particles have
a spring-like rapid resilient rebound that tends to hurl adjacent
sand particles and rubber upwardly under force.
[0011] The synthetic infill is continuously subjected to water flow
and impact forces that tend to dislodge or segregate the particles,
such as from rainfall, flooding, the impact of bouncing balls,
vibration and impact from the feet and bodies of players in contact
with the top surface of the infill. A top layer with a high
proportion of sand will result in spraying of sand particles when a
ball or player impacts with the top surface of the infill. When
soccer balls roll on the infill surface, if any sand particles are
present at the top surface, sand particles are lifted by the
rolling ball by the suction force of air flowing around the
spinning ball and by static electric attraction. As a result the
smaller sand particles on the top surface of the infill are lifted
and sprayed in a "rooster tail" pattern behind the rolling ball.
Over time, areas of continuous sand spray or ball impact will
result in visible sand on the playing surface. It is considered
undesirable to have light colored sand visible in the synthetic
grass surface and, especially when clouds of sand are visible on
such impacts. In addition, exposed sand granules are highly
abrasive to the skin when players fall or slide on the top surface,
and could irritate eyes, ears, nose and mouth when sprayed, inhaled
or ingested.
[0012] A further disadvantage of conventional infills is that
abrasive sand particles remain on the top surface of the synthetic
grass and players on the surface who come in contact with the sand
particles experience skin abrasion. Over time, due to the dynamics
of water, vibration and impact, the smaller sand particles will
tend to settle toward the bottom of the infill layer and larger
more abrasive sand particles will rise to the top surface. The
small sand particles tumble downward in the voids between larger
particles under the influence of vibration, water and gravity.
Smaller particles accumulate at the lower portion of a granular
infill layer and tend to compact together. The larger sand
particles remain at the top of the granular layer and large
particles are highly abrasive to human skin relative to the smaller
particles.
[0013] As a result, over time the abrasive nature of the synthetic
system is increased and may result in particular areas of the
playing surface which experience heavy traffic being more abrasive
than other areas. Conventionally used hard particles and resilient
particles have angular surfaces. It has been found however that
angular particles tend to compact together more than spherical or
rounded particles since the friction between sharp angular surfaces
is greater. In addition, where a wide range of particle sizes is
used, the smaller particles fill in the interstices between the
larger particles and increase the degree of compaction.
[0014] When shredded rubber, or conventional ground rubber are used
the rubber particles have irregular surfaces often with fibrous
protrusions that trap air and hold water with surface tension. When
the infill is rained on or flooded, the air trapped by the
lightweight rubber particles causes the rubber particles to float.
This is undesirable since the rubber may wash down a drain with the
surface water flow, and the floating rubber separates from the
heavier sand in the infill mixture thereby leading to particle
segregation, sand compaction and loss of the resilience of the
infill.
[0015] Where sand is used for construction purposes such as road
building or in concrete mixes, it is highly desirable to have a
wide range of particle sizes specifically because a mix of small
and large particles will result in small particles filling of the
interstices between large particles, increased inter-particle
contact, superior compaction and therefore a higher load bearing
capacity. Where sand or granular aggregates are used in
construction applications, vibratory compactors are employed and
moisture content is controlled to produce maximum soil compaction
and density.
[0016] However, where sand is used as a component of a resilient
infill between the interstices of synthetic grass, excessive
compaction is highly undesirable. A high degree of compaction of
sand and contamination of the infill by airborne dirt and dust lead
to unwanted changes in the resiliency of the infill over time as a
result of use which may vary considerably over the synthetic grass
surface from areas of high use to areas of low use. Uniform
consistent resilience, elimination of maintenance and predictable
performance of the infill are the goals rather than high load
bearing strength.
[0017] The conventional solution to the compaction and separation
of infill particles is to periodically brush the synthetic grass.
Brushing serves to break up compacted material and remix the top
surface restoring the original composition of the infill mixture as
much as possible. Brushing increases the cost of maintenance,
exposes synthetic ribbons to significant wear, and is at best a
temporary solution since eventually the conventional infill
compacts again and must be brushed regularly.
[0018] The proper choice of spacing between rows of grass ribbons
has also proven to be problematic. Quite often the major complaint
of professional athletes is that cleats on shoes do not release
consistently from densely packed, matted, tightly woven or knitted
synthetic sport grass surfaces, causing knee and ankle injuries.
Older artificial grass surfaces were built much like indoor carpet
surfaces with very closely spaced upstanding fibers extending from
a woven base with resilient underlay. These fiber surfaces were
designed to remain upstanding and avoid matting when stepped upon.
Therefore to achieve this result, the fibers were spaced extremely
close together. However, the cleats on athletic shoes often did not
release properly especially when the foot was spun on the surface,
thereby resulting in knee and ankle injuries.
[0019] On the other hand, where pure sand is used as a surface, in
equestrian surfaces for example, the surface is relatively unstable
and sand particles displace easily. To stabilize such surfaces,
U.S. Pat. No. 4,819,933 to Armond (Fibresand Limited) provides a
mixture of sand with a relatively small percentage by weight of
straight synthetic fibers randomly distributed and cross-linking in
a loose displaceable network. The fibers serve to distribute
concentrated loads, hold the sand together under the weight of
horses hooves, athletic players' feet, wheeled vehicles or
implements. U.S. Pat. No. 5,326,192 to Freed (Synthetic Industries,
Inc.) also provides a method of improving the appearance and
performance characteristics of a turf surface by working discreet
bunches of synthetic fibers into the soil surface.
[0020] Granular infill combined with upstanding grass-like
synthetic ribbons address the disadvantages of the above systems to
a degree by providing a granular synthetic surface intermingled
with the upstanding fibers extending from a fabric backing to
better imitate a natural soil, embedded roots and grass. When the
cleats on an athlete's shoe embed in the granular infill, the loose
particles shift and displace somewhat like natural soil. At the
same time the upstanding synthetic grass ribbons enmesh with the
loose particles and the cleats to reduce or prevent slipping.
Without the synthetic ribbons, the loose particles would be very
difficult to run on much like a dry sand natural beach surface
whereas a dense mat of fibers would ensnare the cleats preventing
release and possibly causing personal injury.
[0021] Therefore the combined structure of upstanding ribbons and
loose particulate infill must be balanced or optimized to provide a
desirable playing surface. When the ribbons are densely packed
together, the cleats cannot release properly, but when the ribbons
are spaced too far apart, adequate traction and stability is not
available. Due to the high cost of artificial grass installations,
and risk of injury to highly skilled and highly paid athletes, a
predictable and reproducible artificial grass performance is
required.
[0022] Synthetic grass surfaces have also been constructed with
infill substantially of rubber only. Rubber particles are
relatively light, and shredded particles have fibrous surfaces that
trap air bubbles. As a result when flooded, the rubber particles of
some conventional installations have floated on the surface of
water draining off the synthetic grass surface. Rubber particles
drain away or are displaced resulting in areas of the synthetic
grass which have depleted infill thickness. A lack of uniform
infill thickness and resilience across the surface can result in
injuries and liability for the owner of the athletic field.
[0023] Despite several different rubber and sand infill
compositions and fiber structures in the prior art, several
significant disadvantages remain as noted above.
[0024] It is an object of the present invention to provide an
infill that will retain its properties throughout use without
substantial segregation or compaction of the infill and with a
reduced requirement for periodic brushing of the surface.
[0025] It is a further object of the invention to enhance the
resilience and reduce the abrasive nature of conventional granular
infills filling the interstices of the synthetic grass ribbons
while enabling the cleats of athletic shoes to properly release
without serious risk of injury.
[0026] It is a further object of the invention to eliminate the
spraying of sand particles and undesirable visible sand on the
infill surface.
DISCLOSURE OF THE INVENTION
[0027] The invention provides a novel synthetic grass assembly for
installation on a supporting soil substrate to provide a surface
that combines the look and feel of natural turf with the wear
resistance of synthetic grass. Although the description uses an
athletic playing field as an example, the invention is equally
applicable to any area suitable for grass cover such as high
traffic landscaped areas, road and highway medians, indoor gardens
or golf greens, and equestrian surfaces.
[0028] The grass assembly includes a pile fabric with a flexible
sheet backing and rows of upstanding synthetic ribbons representing
grass blades, extending upwardly from an upper surface of the
backing. A unique infill layer of two graded courses of particulate
material is disposed interstitially between the upstanding ribbons
upon the upper surface of the backing and at a depth less than the
length of the ribbons.
[0029] The ribbons are tufted through the water permeable fabric
backing and have intermittent longitudinal slits in a predetermined
pattern. During installation of the infill, the ribbons are brushed
lightly to return the ribbons to an upstanding position, from an
initially matted position that results from the compression of
ribbons due to rolling of the tufted fabric for shipping and
storage after manufacture. The ribbons may be about one inch wide
with several rows of slits across their width. The light brushing
tends to open a lower portion of the ribbons and extend the slits
open forming laterally linked strands disposed in a lattice
structure enmeshing the surrounding particulate infill. Once all
the infill is installed, the upper portion of the ribbons extending
above the infill layer are brushed aggressively. The ribbons are
longitudinally split by the brushing action along the slits into
several individual free-standing strands of a thinner width
resembling grass blades
[0030] The invention recognises that the granular infill is a
dynamic system of continuously moving hard and resilient particles
of different sizes and with different physical properties under the
influence of impact and vibration from play activity, surface
maintenance and weather precipitation. The invention accommodates
such dynamic activity in a number of ways.
[0031] The top surface is kept substantially sand free using a pure
rubber particle top course of relatively large particles,
preferably substantially larger than those particles in the bottom
layer. Any smaller sand particles that migrate up to the top
surface from the displacement action of cleats will then be able to
percolate, through the voids between the larger top surface
particles, downward back to the bottom course under the influence
of water, vibration and gravity. A bottom course of sand and rubber
mixed together is provided beneath the pure rubber top course for
additional resilience, moisture drainage and as a ballast for
stabilisation of the fabric backing.
[0032] The particle shapes are substantially spherical to reduce
inter-particle contact friction, improve drainage and prevent
compaction. The spherical shape reduces resistance to particle
displacement and therefore reduces the degree of compaction
compared to conventional angular particles. In terms of the
Krumbein sphericity standard, known to those skilled in the art,
the particle shapes are broadly in the range of 0.5 to 0.99 but
preferably in the range between 0.6 and 0.9 being well rounded or
substantially spherical.
[0033] The particle size distribution for hard sand and resilient
rubber particles in the bottom course are chosen to be
substantially identical to each other and preferably particle sizes
are limited for sports or athletic playing surfaces to the range of
14-30 screen mesh standard. To accommodate other uses of the
synthetic grass surfaces, the size of particles may range from 0.5
inches to 50 screen mesh standard. Larger particles may be used for
equestrian applications up to about 0.25 inches but these large
granules are too abrasive for contact with human skin. Particles
smaller than 50 screen mesh standard tend to create dust and may
lead to undesirable compaction, reduced rate of water percolation
and particle segregation. Naturally occurring soil particles of
this size range are classified as medium sand, coarse sand and fine
gravel sized particles.
[0034] By "substantially identical" size distribution it is meant
that when the bottom infill layer is analysed through conventional
soil laboratory sieve analysis, and graphically presented on a
standard sieve analysis semi-logarithmic graph (y-axis showing
0-100 percent passing the sieve size or smaller by weight and
x-axis showing sieve/particle size logarithmically) the line for
hard particles and the line for resilient particles are ideally
superimposed on each other to a substantial extent. Therefore the
hard and resilient particles have substantially equal particle
sizes and the distribution of sizes is substantially the same.
[0035] The standard sieve analysis graphs are by nature an
imprecise "rough and ready" measure, since natural soils vary
considerably over the surface of a building site for example. The
sieve analysis graphs generally do not show the largest 10% and the
smallest 10% of particle sizes since these extremes are considered
statistically insignificant due to the natural variation in soil
particle sizes. Therefore conventionally, only the middle 80% of
particles are considered when examining soil particle sizes in a
sieve analysis.
[0036] Applying this practice to the invention, numerically or
scientifically defined, where the particle sizes of 80% by weight
of hard and resilient granules in the bottom course are distributed
in a range spanning a numerical difference of 40 screen mesh
standard, the particle size distribution is considered
substantially identical or very well sorted. Since the sand and
rubber may be graded to any specification desired, it is preferred
that the numerical difference be even less such as 20 screen mesh
standard to produce a more uniform infill. For example, completely
spherical manufactured glass beads would have a numerical
difference approaching zero. However since sand is a naturally
occurring substance created from the erosion of rock, the particle
size distribution and sphericity vary considerably. A numerical
difference of 20 screen mesh standard may result in a particle size
distribution between 10 to 30 for equestrian surfaces or between 20
to 40 for athletic playing surfaces, for example.
[0037] In practice, the most inexpensive hard particulate material
is usually sand that is found in a naturally segregated deposit
and/or has been mechanically graded to suit various common
construction uses, such as for use in concrete mixes and roadbed
construction. The demand for sand to be used for artificial grass
installation is relatively low and therefore if a design calls for
a specially segregated or graded sand particle size distribution,
the cost of such material would be increased somewhat.
[0038] When deciding on the specific materials to be used in any
location, it is preferable to use whatever acceptable sand is
readily available near to the installation site. It is a relatively
simple matter when purchasing resilient particles to specify the
resilient particle size 20 distribution such that it is within the
ranges discussed above and superimposed on the measured sand
particle size distribution. Resilient particles must be processed,
ground and shipped from a manufacturing facility no matter where
the installation site is located. The marginal cost of
manufacturing resilient particles with a particle size distribution
matching the particle size distribution of the sand particles is
relatively low compared to the alternative of grading the size
distribution of the sand particles to match the resilient
particles.
[0039] By manufacturing the resilient particles to match the size
distribution of the readily available sand at the installation
site, the bottom layer of infill with mixed sand and rubber
particles of equally distributed sizes will result in the benefit
of significantly reduced settling and separation of the particle
mixture in service.
[0040] In contrast, conventional mixes of resilient particles
generally have significantly larger particles than the available
graded sand. As a result the lighter larger resilient particles
migrate upwardly and the heavier smaller hard sand particles
migrate downwardly under the combined influence of gravity,
vibration, rainfall and downwardly percolating water. Segregation
of differently sized particles leads to loss of optimum compaction
and uneven traction in conventional mixed infill layers.
[0041] It has been found by the inventor that the separation of
hard and resilient particles in the mixed bottom layer can be
prevented or substantially reduced by (1) selecting hard and
resilient particles of equal or substantially identical size
distribution (2) selecting a relatively narrow range of particle
sizes and (3) choosing generally spherical particle shapes for both
hard and resilient particles. The minimal variation in particle
size discourages compaction since there are no relatively smaller
particles to fill the interstices between larger particles when all
particles are of substantially equal size. The spherical shapes
reduce resistance to inter-particle displacement and reduce the
tendency of adjacent particles to lock together.
[0042] The fibrillated grass-like synthetic ribbons at the top
surface tend to retain the relatively large top rubber particles in
a loose net-like flexible structure. The loose criss-crossed net of
fibrillated fibres also allows dislodged rubber particles to work
back into the underlying top rubber course when foot traffic passes
over the particles and synthetic ribbons. The combination of pure
top rubber course and network of fibrillated ribbons gives the look
and feel of a natural turf surface.
[0043] The synthetic ribbons between the fabric backing and the top
course provide a degree of resistance to particle displacement in
the mixed bottom course by forming an open net or lattice structure
of vertically oriented strands laterally cross-linked together. The
mixed sand and rubber bottom course provides firm resilient support
for the relatively thin rubber top course. The sand content of the
mixed course in particular provides the necessary weight for
ballast and better drainage due to the capillary action of the
sand.
[0044] The relatively thin top course that is in immediate contact
with the athlete's body, has a high resilience where physical
contact occurs and results in low skin abrasion due to the
exclusive use of rubber. The sand content in the mixed bottom
course provides ballast weight to hold the grass in place and to
quickly drain the surface. Drainage is especially necessary where
there is a risk of freezing and selection of a more coarse mixture
for improved drainage may be required in cold climates. The
resilient particles in the mixed course also provide subsurface
resiliency in addition to the top surface resiliency provided by
the top layer.
[0045] The choice of hard and resilient particles of substantially
equal size distribution substantially reduces compaction and
reduces the maintenance requirements. The top pure rubber top
course will always remain substantially free of sand due to the
choice of particle sizes. Sand may be displaced from the mixed
bottom layer to the surface of the top layer by agitation caused by
contact with the player's cleats during a game or practice session
much in the same manner as conventional soil is disturbed by this
action. However the size of sand particles is chosen to be smaller
than the size of resilient particles in the top course. The
downward washing of the displaced sand particles by rainwater
draining through the top resilient surface or from the vibration
and agitation of foot traffic returns the smaller sand particles to
the bottom course where they came from.
[0046] The two layer installation with rubber only in the top layer
and mixed sand and rubber in the lower layer produces a resilient
surface at lower cost and lower thickness than conventional methods
such as described in U.S. Pat. Nos. 4,337,283 to Haas and 4,396,653
to Tomarin. The prior art infill layers with large and small
particles tend to compact or consolidate into a more firm compacted
surface. The invention maintains its resilience even when used in
thin layers since the top layer is of pure rubber granules and the
mixed lower course does not tend to separate or compact. Thus a
more predictable long term resiliency is created.
[0047] The synthetic ribbons can be manufactured and tufted to the
fabric backing. It is preferred to slit the ribbons with relatively
short longitudinal slits spaced apart across the width of the
ribbons. Then after installation of the infill the upper portion of
the synthetic ribbons are fibrillated, split or frayed vertically
on site by passing over the installed surface with a brush. The
ribbons when manufactured have a longitudinally oriented structure
and therefore aggressive brushing action on the top surface tends
to tear or split the ribbons into thinner grass-like strands by
extending the slits longitudinally to form densely packed
individual grass-like strands.
[0048] Where ribbons are brushed and split on site by brushing, the
upper portions of the ribbons are frayed or split into thin
grass-like strands whereas the lower portions remain intact and are
merely stretched open into an expanded web, net or lattice
structure, to a greater extent than when the fibres were initially
tufted into the backing. A direct benefit of this lattice structure
is the stabilisation of the particulate infill by intermeshing the
particles between the fibrillated grass-like strands and within the
expanded web-like fibre structure. The lower web-like portion
stabilises the infill and the upper grass-like portion allows for
cleat penetration and release, rainfall penetration and drainage,
adds a slight surface resilience due to the curved grass-like
strands, and captures the large resilient particles of the top
course in a grass-like net structure.
[0049] On-site fibrillation of the fibres also permits a more dense
top surface coverage of grass-like strands. The relatively wide
ribbons with short slit perforations as initially installed can be
spaced apart a sufficient distance to permit granular infill to be
installed between the ribbons. When the infill has been fully
installed, the brushing of the widely spaced ribbons splits them
into thinner grass-like strands that fill in the gap between the
ribbons and better cover the top surface of the granular infill.
The dense net of criss-crossed fibrillated strands contain the
large top course rubber granules while allowing cleat penetration
and permitting water to drain through. The split ribbons add better
grass-like strand coverage of the visible surface at a lower cost.
In applications not oriented to sports uses, such as in landscaping
or decorative applications, less dense fibre distributions can be
used resulting in lower cost for the same visually apparent
coverage as conventional closely spaced synthetic grasses.
[0050] Further details of the invention and its advantages will be
apparent from the detailed description and drawings included
below.
BRIEF DESCRIPTION OF THE DRAWINGS
[0051] In order that the invention may be readily understood, one
preferred embodiment of the invention will be described by way of
example, with reference to the accompanying drawings wherein:
[0052] FIG. 1 is a cross-section through a synthetic grass assembly
with infill installed showing the flexible sheet backing with
upstanding ribbons and the infill layer built up of a top course of
relatively large resilient rubber granules and a bottom course of
mixed hard sand and resilient rubber granules of identical smaller
particle size distribution;
[0053] FIG. 2 is a similar cross-section showing the final
configuration of the grass-like strands slightly curved as a result
of aggressive surface brushing to further fibrillate the ends of
the ribbons;
[0054] FIG. 3 is a side view of a synthetic ribbon as manufactured
with a series of short longitudinally slit perforations;
[0055] FIG. 4 is a side view of a synthetic ribbon at the lower end
twisted prior to tufting into the fabric backing and at the upper
end laterally stretched to reveal the web-like grass-blade
structure that resulting from the lateral stretching and
longitudinal extension of the slits;
[0056] FIG. 5 is a table showing the graphical depiction of
particle size distribution resulting from standard sieve analysis
of infill courses; and
[0057] FIG. 6 is a table showing a visual representation of
particles graded on the Krumbein sphericity scale.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0058] With reference to FIG. 1, the invention relates to a
synthetic grass assembly consisting of a pile fabric with an infill
layer of particulate matter which is installed on a supporting soil
substrate to provide a game playing surface.
[0059] The pile fabric includes a flexible sheet backing 1 that
could include two or more layers of open weave fabric, one of which
may be dimensionally stable netting to prevent stretching during
installation and use. Extending upwardly from an upper surface of
the backing 1 is a large number of upstanding synthetic ribbons 2.
As indicated in FIG. 1, the ribbons 2 are tufted through the
backing 1 spaced apart in rows by a distance W and of a length L.
The length `L` of fibres is selected depending upon the total depth
(5 plus 6) of infill and the desired resilience of the completed
synthetic grass assembly.
[0060] Disposed interstitially between the upstanding ribbons 2
upon the upper surface of the backing 1 is an infill layer 3 of
particulate matter. The particulate matter may be selected from any
number of commonly available hard granules such as: sand; hard
aggregate; silica sand; gravel; slag; granulated plastic; and
polymer beads. The resilient granules may be selected from:
cryogenically ground rubber; rubber; cork; polymer beads; synthetic
polymer foam; styrene; perlite, neoprene, ground tires, and EPDM
rubber.
[0061] The infill layer 3 is made up of a top course 6 and a bottom
mixed course 5. The mixed bottom course 5 is of intermixed hard
sand granules and resilient rubber granules. The mix is selected on
the basis distribution by volume of different sizes of hard
granules and resilient granules that are substantially identical
and range in size between 0.5 inches and 50 screen mesh standard.
Preferably the range of particle sizes is limited to avoid small or
fine particles that fill the interstices between larger particles
and encourage compacting. The preferred range is between 14 and 30
screen mesh standard. Depending on the application, the range of
particle sizes in the mixed course can be limited to between 10-30,
15-30 or 20-40 screen mesh standard as selected to suit design
parameters. The shape of hard and resilient granules is
substantially spherical and not angular as in the prior art to
further discourage compaction and settling.
[0062] As shown in the graph of FIG. 5, a standard screen sieve
analysis is depicted with a vertical axis linear scale of "percent
by weight passing the sieve size" or alternatively "percent
smaller" and the horizontal axis being a logarithmic scale showing
particle and/or sieve size. The example line shown in FIG. 5
indicate relatively uniform mixtures of particles with a narrow
range of particle sizes. Ideally the line on FIG. 5 for sand
particle size distribution and the line for rubber particle size
distribution are identical and would be shown superimposed on each
other. However, as an example, the 10-30 range mentioned above is
graphically illustrated as a shaded zone within which any line will
meet the requirements of this particle size restriction.
[0063] The top course 6 is substantially exclusively of resilient
rubber granules. An upper portion 7 of the synthetic ribbons 2
extends upwardly from a top surface 8 of the top course 6. The
resulting artificial grass surface can be adapted for several
indoor and outdoor uses, such as: athletic playing fields; horse
racing fields, playgrounds, landscaped areas, and recreational
areas.
[0064] In order to deposit dual layers, brushes pass over the
backing with a mixed sand and rubber material many times to ensure
that the ribbons are upstanding when embedded in the infill and not
submerged under the infill, and to further slightly expand the
ribbons to open the slits and produce a lattice structure that
stabilizes the infill preventing excessive displacement of the
infill particles after installation. After the mixed lower infill
layer is laid a substantially pure rubber particulate material is
placed as a resilient top layer.
[0065] To deposit the bottom layer a spreader may be used and
thereafter the surface is brushed to raise the nap of the pile
fabric and position the ribbons 2 in a generally upright position
prior to depositing the top course 6. After spreading each layer,
it is necessary to brush the surface and raise the ribbons to an
upstanding position as shown in the drawings.
[0066] It may be preferred that after installation of the top
course 6, the upper portion 7 of the synthetic ribbons 2 is further
fibrillated by aggressively passing over the surface with a brush.
This operation splits the upper portions 7 and spreads the strands
uniformly over the top surface 8. The manufactured width of the
ribbons 2 is relatively wide such as one inch and the on-site
brushing operation further splits the ribbons opening the slits
longitudinally and forming thinner grass-like strands of a thinner
width as illustrated. The upper ends of the ribbons 2 are brushed
more vigorously to achieve the following advantages over prior art
methods. Laying over of the fibrillated upper portions 7,
interlocks the ribbon ends into a loose network which more
realistically simulates the appearance of natural grass. The
fibrillated ends impart a slight resilience since they are slightly
raised or fluffed and more accurately simulate the resilience of
natural grass when balls, during play, bounce on the completed
surface. The bent over ends as well hide the rubber crumbs of the
top course 6 from view, hold the crumb particles in place and allow
a movement of dislodged crumbs back and forth between the top
course 6 and upper side of the fibrillated ribbons 2. By splitting
or fibrillating the ends of the ribbons 2, less surface tension is
created and water more easily permeates through the top surface 8
and is drained away through the bottom course 5.
[0067] The ribbons 2 include a top structure of multiple grass-like
strands fibrillated on site and an expanded web-like lower
structure left substantially in their original state but
mechanically expanded into a web lattice due to interaction with
the infill as it is deposited. Ribbons may be chosen from fibers
such as polypropylene, polyethylene, nylon and plastic. A mix of
thick and thin width of fibrillated strands produces a more natural
appearance and causes a ball to roll in a more predictable manner
depending on the resistance of the fibers to the ball during play.
Modification of the ribbon width and density in the grass will also
modify the ball rolling characteristics.
[0068] The ribbons, when initially tufted to the fabric backing,
may be of a width in the range of 1-3 inches, and when fibrillated
the individual grass-like strands may be in the range of 1 mm to 15
mm (1/8 inch to 1/2 inch approx.) in width. Expressed in terms used
in the art, the strands range from 800 to 5000 Denier, and the
thickness of ribbons and strands range preferably from 45 to 200
microns (.mu.).
[0069] It has been found through experiment and experience that the
size and shape of hard granules and resilient granules
significantly affects the turf performance characteristics. It has
also been found that the spacing of ribbons and the variation in
depth of infill can have strong influence on the performance of the
synthetic grass assembly.
[0070] The hard and resilient particle sizes should range between
0.5 inches and 50 U.S. screen mesh standard, however preferably a
narrower range of 14-30 avoids the risk of compaction. Hard
granules larger than 14 screen mesh standard can be perceived as
somewhat abrasive by users of the athletic surface if direct
contact is made. However, since the fibres above the top surface
tend to arch over and shield the user from direct contact with an
arched resilient fibrous matting of synthetic fibres, somewhat
larger particles can be used without perceiving the particles as
abrasive. Particles smaller than 50 screen mesh standard will tend
to impede the percolation of water and detrimentally affect the
drainage characteristics of the infill layer 3 in relatively wet
climates. In dry climates, use of smaller particles may be
desirable to maintain an optimal moisture content for optimal level
of compaction and resilience. Larger resilient particles (such as
14 screen mesh standard) may be used where skin contact with the
surface and potential abrasion from the nature of the sport are
expected. Preferably the sand is washed and graded to remove
substantially all the fine particles below size 50 mesh.
[0071] The natural tendency of the large relatively light rubber
particles to migrate to the top and the complementary tendency of
smaller heavier sand particles to migrate to the bottom of the
infill layer 3 is reduced by use of equally sized particles.
Particle migration is also reduced by the interaction with the
synthetic web-like ribbon structure and by the use of spherical
particle shape. The bottom course of the infill retains its initial
mixture of equally sized sand and resilient particles due to the
selection of substantially identical particle sizes and the
interference to particle movement resulting from the web-like
structure of the ribbons in contact with the bottom infill layer.
These characteristics of the infill tend to discourage compaction
and maintain the uniform predictable resilience of the infill.
[0072] With a pure rubber resilient top course 6, resilience is
provided at the contact surface where the perception of resilience
actually needed. Preferably the particle size of rubber particles
in the top layer 6 of infill are larger than the sand and resilient
particles in the bottom layer 5. The larger particles of the top
layer permit smaller particles of the bottom layer to fall back
down through gaps between the large particles, and as a result, the
particle size compositions of the layers remain distinct. The
resilience of the final layer of infill can be fine tuned by
testing resilience at the surface and gradually spreading rubber
particles to marginally increase the thickness of the top course 6
and achieve the desired resilience of the final top course.
[0073] The synthetic ribbons are preferably disposed in rows spaced
apart a selected minimum distance "W". Depending on the firmness
desired and the degree of freedom required for cleats to rotate for
various sports, the spacing "W" can vary between 2.25 inches and
0.625 inches or less. A closer spacing provides firmer support for
the infill 3 whereas a wider spacing permits easier rotation of
embedded cleats.
[0074] The depth of the infill layer 3 relative to the length "L"
of synthetic ribbons can range from 90% to 40% however the
preferred range for most applications will be 85% to 55% or 80% to
70%. For example, where the length of ribbons L is 2 inches, a
depth of infill equal to 75% would be a depth of 1.5 inches
(2.0.times.0.75=1.5) with the remaining 0.5 inches of ribbon
extending above the top surface of the infill.
[0075] Although the above description and accompanying drawings
relate to a specific preferred embodiment as presently contemplated
by the inventor, it will be understood that the invention in its
broad aspect includes mechanical and functional equivalents of the
elements described and illustrated.
* * * * *