U.S. patent application number 12/027506 was filed with the patent office on 2008-08-07 for artificial turf.
This patent application is currently assigned to Domo N.V.. Invention is credited to Philippe Dierkens, Arnoud Fiolet.
Application Number | 20080187689 12/027506 |
Document ID | / |
Family ID | 38616656 |
Filed Date | 2008-08-07 |
United States Patent
Application |
20080187689 |
Kind Code |
A1 |
Dierkens; Philippe ; et
al. |
August 7, 2008 |
ARTIFICIAL TURF
Abstract
A tufted artificial turf having a flexible, water-permeable
support fabric provided with tufts is disclosed. The tufts include
parts of straight monofilament yarn and parts of curly monofilament
yarn and are manufactured from a compound yarn formed by twining
together the straight monofilament yarn with the curly monofilament
yarn.
Inventors: |
Dierkens; Philippe;
(Lokeren, BE) ; Fiolet; Arnoud; (Valkenswaard,
NL) |
Correspondence
Address: |
KNOBBE MARTENS OLSON & BEAR LLP
2040 MAIN STREET, FOURTEENTH FLOOR
IRVINE
CA
92614
US
|
Assignee: |
Domo N.V.
Gent Zwijnaarde
BE
|
Family ID: |
38616656 |
Appl. No.: |
12/027506 |
Filed: |
February 7, 2008 |
Current U.S.
Class: |
428/17 |
Current CPC
Class: |
D10B 2505/202 20130101;
D06N 7/0065 20130101; E01C 13/08 20130101; D02G 3/445 20130101 |
Class at
Publication: |
428/17 |
International
Class: |
A41G 1/00 20060101
A41G001/00 |
Foreign Application Data
Date |
Code |
Application Number |
Feb 7, 2007 |
BE |
2007/0050 |
Claims
1. Tufted artificial turf comprising a flexible, water-permeable
support fabric provided with tufts, wherein the tufts comprise
parts of straight monofilament yarn and parts of curly monofilament
yarn, wherein said tufts are manufactured from a compound yarn
composed by twining together said straight monofilament yarn with
the curly monofilament yarn.
2. Artificial turf according to claim 1, wherein said straight
monofilament yarn and said curly monofilament yarn are manufactured
from polyamide 6, polyamide 6.6 or polyamide 6.12, and preferably
from polyamide 6.
3. Artificial turf according to claim 1, wherein a resting height
of the curly yarn is between 1/5 to 3/5, preferably 1/3 to 2/3 of
the length of the straight monofilament yarn in the tufts and still
more preferably amounts to approximately 1/2 thereof.
4. Artificial turf according to claim 1, wherein said straight and
curly monofilament yarn each comprises 4 to 12 individual
filaments, preferably 6 to 10 individual filaments, and more
preferably 8 individual filaments.
5. Artificial turf according to claim 1, wherein said individual
filaments of the straight monofilament yarn each have a yarn number
of between 500 and 2000 dtex, preferably of between 750 and 1500
dtex, and most preferably of 1000 dtex.
6. Artificial turf according to claim 1, wherein said individual
filaments of the curly monofilament yarn each have a yarn number of
between 300 and 1500 dtex, preferably of between 500 and 1000 dtex,
and most preferably of 750 dtex.
7. Artificial turf according to claim 1, wherein said individual
filaments have a width of between 0.5 and 2 millimetre, preferably
of between 0.75 and 1.5 millimetre, and most preferably of 0.9
millimetre.
8. Artificial turf according to claim 1, wherein said individual
filaments have a thickness of between 50 .mu.m and 200 .mu.m,
preferably of between 100 .mu.m and 150 .mu.m, and most preferably
of 140 .mu.m.
9. Artificial turf according to claim 1, wherein said composed yarn
has a yarn number of between 10,000 and 20,000 dtex, preferably of
between 12,000 and 16,000 dtex, more preferably of between 13,000
and 15,000 dtex, and most preferably of 14,000 dtex.
10. Artificial turf according to claim 1, wherein said tufts are
arranged in rows which are located on mutual distances of between
4/16'' and 6/16''.
11. Artificial turf according to claim 1, wherein said tufts have
an average height of between 30 to 50 mm, preferably of between 35
to 40 mm and most preferably of 38 mm.
12. Artificial turf according to claim 1, wherein said artificial
turf lacks an infill layer.
Description
RELATED APPLICATIONS
[0001] This application claims priority to BE 2007/0050 filed Feb.
7, 2007.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention pertains to an artificial turf and to
the yarns required therefore. The object of the present invention
is to provide a new type of artificial turf comprising a
combination of straight and curly monofilament yarns. The thus
obtained artificial turf provides, on the one hand, the look of
natural grass, and on the other hand, the known use of a well-known
infill layer by filling for example sand and/or rubber particles
for enhancing the elasticity of the surface of the artificial turf
becomes superfluous.
[0004] 2. Description of the Related Art
[0005] Many patent applications describe yarns for the manufacture
of synthetic turfs made of a variety of materials and combinations
thereof. Often, combinations are presented of polyethylene,
polypropylene, or block copolymers thereof. Further to the use of
these materials, the use of polyamide 6 (nylon) is also known, for
instance from the Japanese patent application JP-A-3.279.419.
[0006] Apart from the choice of material, many structural shapes of
yarns are known, among others straight monofill, fibrillated or
monofill curled yarns.
SUMMARY OF THE INVENTION
[0007] The present invention provides a specific combination of
structural shape and material for the yarns as a result of which
tufts are formed which do not need infill material. Therefore,
especially the application and the maintenance of such synthetic
turfs is simplified. Also, recycling possibilities are strongly
increased as a result of which these synthetic turfs are more
environment-friendly.
[0008] The present invention is related to yarns, tufted on a
carrier material. It is generally known that several yarns twisted
or twined together are tufted in a carrier material. In this way
standing tufts are formed, wherein each individual tuft is composed
of a multiple of filaments.
[0009] The invention relates mainly to a tufted artificial turf
comprising a flexible, water-permeable support fabric, provided
with tufts, wherein each tuft comprises partly of straight
monofilament yarn and partly of curly monofilament yarn,
characterised in that said tufts are manufactured from a compound
yarn composed from said straight monofilament yarn twined together
with the curly monofilament yarn.
[0010] According to the invention the support fabric comprises a
flexible way water-permeable plastic material, preferably a
laminate of a UV-stabilised tuft fabric from polypropylene,
provided with a latex backing. The specific weight of this laminate
amounts preferably between 800 and 1500 g/m.sup.2, and more
preferably between 1100 and 1400 g/m.sup.2.
[0011] The artificial turf according to the invention comprises
tufts, manufactured from a compound yarn, i.e. from straight
monofilament yarn and curly monofilament yarn, wherein the straight
and curly monofilament yarns are twined together such that the
curly monofilament yarn is nested around the straight monofilament
yarn, wherein the curly monofilament yarn provides partly stability
and partly elasticity to the straight monofilament yarn. Because of
this, an infill with for example sand or rubber particles is
superfluous.
[0012] In a preferred embodiment of the artificial turf according
to the invention, the curly and straight monofilament yarns of said
composed yarn are extruded from polyamide, for example polyamide 6,
polyamide 6.6 and polyamide 6.12, and more preferably polyamide
6.
[0013] In a further preferred embodiment, both the straight
monofilament yarn and the curly monofilament yarn of said composed
yarn each comprise preferably of 4 to 12 individual filaments, more
preferably of 6 to 10 individual filaments, and most preferably of
8 individual filaments.
[0014] The thickness and width of the filaments are such that they
resemble individual blades of grass; the width of the individual
filaments preferably ranges between 0.5 and 2 millimetre, more
preferably between 0.75 and 1.5 millimetre, and is most preferably
equal to approximately 0.9 millimetre.
[0015] The thickness of the individual filaments is not only
important to achieve the look of natural grass, but also to achieve
the desired properties of elasticity. The individual filaments
usually have a thickness between 50 .mu.m and 200 .mu.m, more
preferably between 100 .mu.m and 150 .mu.m and most preferably, it
amount to approximately 140 .mu.m.
[0016] The yarn number of the individual filaments of the straight
monofilament yarn usually ranges between 500 and 2000 dtex, more
preferably between 750 and 1500 dtex, and is most preferably equal
to approximately 1000 dtex. Whereas the yarn number of the
individual filaments of the curly monofilament yarn usually ranges
between 300 and 1500 dtex, more preferably between 500 and 1000
dtex, and most preferably is equal to approximately 750 dtex. The
total dtex value per tuft preferably ranges between 12,000 and
16,000, and more preferably between approximately 13,000 and
15,000, and is most preferably equal to approximately 14,000
dtex.
[0017] In a further preferred embodiment of the invention, the
individual filaments are manufactured in several shades, wherein
the straight monofilament yarn preferably comprises 2 to 6 dark
green and 2 to 6 olive green filaments, more preferably 3 to 5 dark
green and 3 to 5 olive green, and most preferably 4 dark green and
4 olive green filaments. The curly monofilament yarn preferably
comprises 1 to 3 beige and 3 to 9 light green filaments, more
preferably 1.5 to 4.5 beige and 2.5 to 7.5 light green, and most
preferably 2 beige and 6 light green filaments.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0018] The curly monofilament yarn is generally manufactured from a
straight monofilament yarn that is subjected to one or more heat
treatments. This treatment may take place as from the extrusion of
the yarn and/or during the processing step and/or on the finished
carpet. Preferably, the final curling and crimping is obtained
after a heat treatment during the coating of the tuft fabric with a
stabilizing agent, such as for example latex, as a result of which
also the tufts become firmly attached in the tuft fabric. In its
finished form the support fabric comprises a laminate of a tuft
fabric with an additional layer of a stabilizing agent, preferably
a latex, applied onto it.
[0019] According to present the invention, the manufacturing of
curly monofilament yarn by means of a heat treatment can be
performed in 3 different ways, i.e. by means of a heat treatment of
the monofilament yarn directly after extrusion and before the
tufting process, by means of a heat treatment during the
application of the adhesion material (latex) on the tuft fabric, or
by means of a combination of both aforementioned heat treatments.
In a preferred embodiment the straight monofilament yarn is
subjected to a first heat treatment which takes place before the
tufting process such that an initial curling arises. Subsequently,
the straight and partly curly monofilament yarn is tufted in line
on a tuft fabric, after which a latex backing is applied to the
back of aforementioned tuft fabric by means of a second heat
treatment. The application of the latex backing and the associated
heat treatment completes on the one hand the curling and ensures on
the other hand an optimum fixing of the tufts in the tuft fabric.
After aforementioned heat treatment(s), the curly monofilament has
a shrinkage of at least 60% and more preferably of at least 50%.
Therefore, the rest height of the curly yarn ranges between 1/5 to
3/5, preferably 1/3 to 3/5 and most preferably approximately 1/2 of
the length of the straight monofilament yarn in the tuft. This
height ratio on the support fabric ensures that a good elasticity
and bonding strength to the artificial turf are obtained such that
an infill becomes superfluous.
[0020] Both aforementioned monofilament yarns are subsequently
twined together to form one yarn and this with a speed of
approximately 30 turns per running meter wherein the curly
monofilament yarn is nested around the straight monofilament yarn.
The finally obtained composed yarn has a yarn number which usually
ranges between 10,000 dtex and 20,000 dtex, preferably between
12,000 and 16,000, more preferably between 13,000 and 15,000 and is
most preferably approximately 14,000 dtex.
[0021] Preferably, the filaments in a tuft all have the same length
between 3 and 5 cm, more preferably between 3.5 cm and 4.5 cm and
most preferably approximately between 3.7 and 3.9 cm. The curly
filaments in their curly state have a length ranging between 40 and
60% with respect to the initial length. In general, the shrinkage
is obtained by a heat treatment.
[0022] The invention is further illustrated by means of the
examples below which illustrate some preferred embodiments of the
invention.
Example 1
[0023] The compound yarn comprises 8 filaments curly monofilament
yarn of polyamide 6 (nylon) with a compound dtex value of 6000 (8
filaments of each 750 dtex per filament) with a width of 0.9 mm, a
thickness of 140 .mu.m and a height of 38 mm in elongated form and
a height of approximately 24 mm in curly form with 8 filaments
straight monofilament (diamond structure) with a dtex value of
8000, a width of 0.9 mm and also a thickness of 140 .mu.m. These
yarns are twined together and subsequently this composed yarn is
linearly tufted with approximately 140 stitches per running meter
with a needle distance of 5/16'', and a pile height of 38 mm such
that a pile weight was obtained of approximately 2200 g/m.sup.2.
The support material comprises a polypropylene tuft fabric which is
UV-stabilised with a specific weight of approximately 164 g/m.sup.2
provided with a latex backing with 1000 g/m.sup.2.
[0024] The obtained artificial turf have the following
properties:
TABLE-US-00001 Colour stability Scale 7 (DIN 54004) UV-Stability
>6,000 u (DIN 53387) Water permeability 6.10.sup.-4 m/sec Flame
retardancy Class 1 (DIN 51960) Pile anchoring >30 N Chlorine
resistance 4-5 (DIN 54019) Resistance to seawater 4-5 (DIN
54007)
Example 2
[0025] In a similar manner a number of other artificial turfs were
tufted. Table I below gives the individual data for each type of
filament.
TABLE-US-00002 Ex 2 Ex 3 Ex 4 Ex 5 Ex 6 Ex 7 Ex 8 Ex 9 Curly PA
monofilament number 8 10 6 6 6 4 8 8 dtex (per fil) 740 600 1300
1100 1200 1500 800 750 length straight (mm) 40 42 38 39 45 40 38 46
length (curly) 25 20 18 17 21 16 15 19 width (mm) 0.6 0.8 1.4 0.9 1
0.95 0.85 0.6 thickness (.mu.m) 150 85 100 140 130 175 100 140
Straight PA monofilament number 8 6 10 8 12 12 10 8 dtex (by fil)
1000 1200 600 1500 1100 1000 1300 1200 length 40 42 38 42 48 38 38
46 width (mm) 0.8 0.9 0.5 1 0.9 0.8 1 0.7 thickness (.mu.m) 140 140
150 170 130 135 140 180
[0026] The thus obtained composed yarns are tufted on a tuft fabric
and provided with a water permeable backing, for example made of
latex.
[0027] It will be understood by those of skill in the art that
numerous and various modifications can be made without departing
from the spirit of the present invention. Therefore, it should be
clearly understood that the forms of the present invention are
illustrative only and are not intended to limit the scope of the
present invention.
* * * * *