U.S. patent application number 12/520353 was filed with the patent office on 2010-04-15 for artificial turf.
Invention is credited to Johny Debaes.
Application Number | 20100092702 12/520353 |
Document ID | / |
Family ID | 38314175 |
Filed Date | 2010-04-15 |
United States Patent
Application |
20100092702 |
Kind Code |
A1 |
Debaes; Johny |
April 15, 2010 |
Artificial turf
Abstract
The object of the invention is to provide an artificial turf
which no longer requires the application of a coating on the back
of the ground fabric in order to secure the plastic blades of
grass. The object of the invention is achieved by providing an
artificial turf comprising a ground fabric and a number of plastic
blades of grass protruding from the ground fabric in which said
turf, as a result of the weave structure, has a pile fixation of at
least 15 N.
Inventors: |
Debaes; Johny; (Moorslede,
BE) |
Correspondence
Address: |
HYRA IP, PLC
12120 Sunset Hills Road, Suite 600
Reston
VA
20190
US
|
Family ID: |
38314175 |
Appl. No.: |
12/520353 |
Filed: |
December 19, 2007 |
PCT Filed: |
December 19, 2007 |
PCT NO: |
PCT/EP2007/011179 |
371 Date: |
June 19, 2009 |
Current U.S.
Class: |
428/17 |
Current CPC
Class: |
D10B 2505/202 20130101;
E01C 13/08 20130101; D03D 27/10 20130101; D06N 7/0068 20130101;
D06N 7/0065 20130101 |
Class at
Publication: |
428/17 |
International
Class: |
A41G 1/00 20060101
A41G001/00 |
Foreign Application Data
Date |
Code |
Application Number |
Dec 22, 2006 |
BE |
2006/0645 |
Claims
1. An artificial turf comprising a ground fabric made from
synthetic ground warp yarns and synthetic weft yarns and a number
of plastic blades of grass protruding from the ground fabric,
wherein said turf, as a result of the weave structure, has a pile
fixation of at least 15 N.
2. The artificial turf as claimed in claim 1, characterized in that
said turf, as a result of the weave structure, has a pile fixation
of at least 30 N.
3. The artificial turf as claimed in claim 1, characterized in that
the plastic blades of grass protruding from the ground fabric are
tied up in the ground fabric by a W weave in which the plastic
blade of grass is tied up at least twice over an intermediate weft
yarn between two upright legs of a pile burl.
4. The artificial turf as claimed in claim 1, characterized in that
the plastic blades of grass protruding from the ground fabric have
a density of at least 1000 tex.
5. The artificial turf as claimed in claim 1, characterized in that
the plastic blades of grass protruding from the ground fabric are
monofilament yarns which comprise at least six filaments.
6. The artificial turf as claimed in claim 1, characterized in that
the plastic blades of grass protruding from the ground fabric
protrude at least 20 mm above the ground fabric.
7. The artificial turf as claimed in claim 1, characterized in that
said ground fabric comprises binding and tension warp yarns and in
that the protruding plastic blades of grass are pile warp
yarns.
8. The artificial turf as claimed in claim 1, characterized in that
said turf has a fabric density of at least 120 warp yarn portees
per meter in the weft yarn direction.
9. The artificial turf as claimed in claim 8, characterized in that
each warp yarn portee comprises two tension warp yarns per ground
fabric.
10. The artificial turf as claimed in claim 9, characterized in
that said two tension warp yarns are situated on either side of at
least one pile warp yarn for each warp yarn portee.
11. The artificial turf as claimed in claim 9, characterized in
that pile warp yarns are situated between said two tension warp
yarns for each warp yarn portee.
12. The artificial turf as claimed in claim 9, characterized in
that only pile warp yarns are situated between said two tension
warp yarns for each warp yarn portee.
13. The artificial turf as claimed in claim 1, characterized in
that said turf has a weft yarn density of at least 3 weft yarns per
cm.
14. The artificial turf as claimed in claim 7, characterized in
that said turf, in addition to the grass blade-forming pile warp
yarns, also comprises supporting pile warp yarns.
15. The artificial turf as claimed in claim 7, characterized in
that said turf, in addition to the grass blade-forming pile warp
yarns, also comprises filler yarns.
16. The artificial turf as claimed in claim 15, characterized in
that the filler yarns extend mainly in the ground fabric.
17. The artificial turf as claimed in claim 1, characterized in
that said turf is woven according to a face-to-face weaving method.
Description
[0001] The present invention relates to an artificial turf
comprising a ground fabric made from synthetic ground warp yarns
and synthetic weft yarns and a number of plastic blades of grass
protruding from the ground fabric.
[0002] Artificial turf is being used increasingly often as a
replacement for natural turf because: [0003] the climatic
conditions are not always suitable for natural turf; [0004] the
load to which the natural turf is subjected (during sports events)
damages the playing field, which makes it necessary to leave
considerable intervals before using the playing field again; [0005]
natural turf requires a lot of care and attention.
[0006] It is well known to produce artificial turf in which plastic
fibers (grass blades) are connected to a carrier material in which
the plastic grass blades preferably protrude from the carrier
material at right angles. The plastic grass blades are generally
hard and smooth plastic fibers, such as polyolefins (polyethylene,
polypropylene and mixtures) or polyamides.
[0007] Usually, the carrier material is a textile cloth through
which the plastic grass blades are tufted. This means that a
plastic grass blade is pushed through the cloth by means of a
needle to form a loop. On the other side of the textile cloth, a
hook takes over the loop which has been produced and takes this
loop to the desired level. The loop is then usually cut through,
resulting in the formation of two upright grass blades.
[0008] With the known manufacturing techniques for producing
artificial turf, the plastic blades of grass have to be secured in
the carrier material subsequently by applying a coating in order to
achieve a satisfactory pile fixation. If the plastic blades of
grass consist of a bundle of individual monofilaments, the coating
also has to secure the various filaments with respect to one
another in order to achieve a satisfactory pile fixation due to the
smoothness of the individual filaments.
[0009] However, applying such coatings has various drawbacks:
[0010] high cost price; [0011] additional operation required on an
additional and rather large device; [0012] expensive
after-treatment of the resulting artificial turf at a temperature
which is generally 80.degree. C. or higher in order to dry the
coating. Such an after-treatment will adversely affect the
properties of the plastic blades of grass and result in a
significant shrinking of this material (shrinkage of up to 10%);
[0013] impact on the environment, in particular as a result of the
applied coating (e.g. bitumen, latex) leaching out during use, and
at the end of service life of the turf.
[0014] It is an object of the invention to provide an artificial
turf in which the plastic blades of grass are secured sufficiently
without requiring the application of a coating on the back of the
ground fabric.
[0015] The object of the invention is achieved by providing an
artificial turf comprising a ground fabric made from synthetic
ground warp yarns and synthetic weft yarns and a number of plastic
blades of grass protruding from the ground fabric in which said
turf, as a result of the weave structure, has a pile fixation of at
least 15 N. More particularly, the turf has a pile fixation of at
least 20 N, preferably 25 N, as a result of the weave
structure.
[0016] According to a preferred embodiment of the artificial turf,
said turf, as a result of the weave structure, has a pile fixation
of at least 30 N, more particularly of at least 40 N. The pile
fixation values are measured according to the standardized method
according to ISO 4919 (1978).
[0017] With a more preferred artificial turf according to the
present invention, the plastic blades of grass protruding from the
ground fabric are tied up in the ground fabric by a W weave in
which the plastic blade of grass is tied up at least twice over an
intermediate weft yarn between two upright legs of a pile burl.
Tying up the plastic blades of grass several times between the
upright pile legs of a pile burl has a very positive effect on the
securing of this plastic blade of grass. Some preferred weaves are:
5/12 W, 7/16 W, 9/20 W as well as 3/6 W, 5/10 W and 7/12 W.
For example with a 5/12 W weave structure, one pile burl with two
pile legs is formed every 12 weft yarns and wound around 5 weft
yarns: the first pile leg passes underneath a weft yarn, then over
a subsequent weft yarn, underneath a subsequent weft yarn, again
over the next weft yarn and then again underneath the next weft
yarn, ultimately protruding from the fabric and forming the second
pile leg of the pile tuft. The expression "tying up the plastic
blades of grass over a weft yarn between the pile legs" is
understood to mean that the plastic blade of grass winds itself
around a weft yarn which is situated on the side of the artificial
turf from which the plastic blades of grass protrude. In said 5/12
W weave, each pile burl does this twice.
[0018] In the case of a particular artificial turf according to the
present invention, the plastic blades of grass protruding from the
ground fabric have a density of at least 1000 tex. Preferably, said
plastic blades of grass have a density of at least 1200 tex, more
preferably at least 1400 tex. In particular, the plastic blades of
grass protruding from the ground fabric have a density of at least
1600 tex, more preferably of at least 1800 tex and most preferably
2000 tex. High-density pile warp yarns are held more firmly in the
ground fabric, which improves the securing and fixation of the
pile.
[0019] According to an advantageous embodiment of the artificial
turf according to the invention, the plastic blades of grass
protruding from the ground fabric are monofilament yarns which
comprise at least six filaments. Preferably, these monofilament
yarns comprise 8 filaments, more preferably 10 filaments and in a
most preferred embodiment, the monofilament yarns comprise 12
filaments. Thus, a 1600 tex monofilament yarn can comprise 8
filaments of 200 tex each.
[0020] In a preferred embodiment of the artificial turf, the
plastic blades of grass protruding from the ground fabric protrude
at least 20 mm above the ground fabric. Preferably, the plastic
blades of grass protrude 25 mm above the ground fabric, more
preferably 30 mm. In a particular embodiment of the turf, the
plastic blades of grass protrude 40 mm, more preferably 50 mm,
still more preferably 60 mm and most preferably 65 mm, above the
ground fabric.
[0021] In a more preferred artificial turf according to the present
invention, said ground fabric comprises binding and tension warp
yarns and the protruding plastic blades of grass are pile warp
yarns. The binding and tension warp yarns are preferably synthetic
yarns, such as for example polypropylene, polyethylene or
polyester. The pile warp yarns are in particular synthetic yarns
made from, for example, polypropylene, polyethylene or
polyamide.
[0022] According to a particularly preferred embodiment of the
artificial turf according to the invention, said turf has a fabric
density of at least 120 warp yarn portees per meter, more
particularly 166 warp yarn portees per meter, in the weft yarn
direction. Preferably, the turf has a fabric density of 200 warp
yarn portees per meter, in particular 240 warp yarn portees per
meter, in the weft yarn direction.
[0023] Warp yarn portee is understood to mean a combination of
binding, tension and pile warp yarns which are situated in the same
reed tooth, which combination repeats in the weft yarn
direction.
[0024] Preferably, each warp yarn portee comprises two tension warp
yarns per ground fabric. Furthermore, each warp yarn portee
preferably comprises two binding warp yarns per ground fabric and
at least one pile warp yarn.
[0025] According to a first, more particularly preferred embodiment
of the artificial turf according to the invention, said two tension
warp yarns are situated on either side of at least one pile warp
yarn for each warp yarn portee. Preferably, the binding warp yarns
are outside the latter, in other words between two tension warp
yarns which do not have any pile warp yarns between them. This has
the advantage that the tight tension warp yarns hold the pile warp
yarns firmly in position in the weft yarn direction which results
in a clamping effect on the pile warp yarns. This contributes to a
good pile fixation.
[0026] According to a second, more preferred embodiment of the
artificial turf according to the invention, the pile warp yarns are
situated between said two tension warp yarns for each warp yarn
portee.
[0027] According to a second, more preferred embodiment of the
artificial turf according to the invention, only pile warp yarns
are situated between said two tension warp yarns for each warp yarn
portee.
[0028] In a preferred embodiment of the artificial turf according
to the invention, said turf has a weft yarn density of at least 3
weft yarns per cm, more preferably of 4 weft yarns per cm. In a
particular embodiment, said turf has a weft yarn density of 4.6
weft yarns per cm, more preferably of 5.3 weft yarns per cm and
most preferably of 6 weft yarns per cm.
[0029] According to a particularly preferred embodiment of the
artificial turf according to the invention, said turf, in addition
to the grass blade-forming pile warp yarns, also comprises
supporting pile warp yarns. The supporting pile warp yarns are pile
warp yarns which shrink after having been cut through and form a
base layer on the ground fabric which: [0030] support grass
blade-forming pile warp yarns; [0031] form a shock-absorbing layer,
as a result of which they can completely or partially replace the
filling of the artificial turf; [0032] give stability to the ground
fabric.
[0033] According to yet another preferred embodiment of the
artificial turf according to the invention, said turf, in addition
to the grass blade-forming pile warp yarns and/or supporting pile
warp yarns, also comprises filler yarns. Filler yarns are
understood to be warp yarns which extend mainly in the ground
fabric and protrude from the fabric virtually without forming pile.
One of the characteristics of filler yarns is the fact that they
increase the stability of the artificial turf and, by their
presence in the ground fabric of the artificial turf, limit the
free space for the pile warp yarn, thus further improving the pile
fixation. The expression "the filler yarns extend mainly in the
ground fabric" is understood to mean that they extend mainly or
solely between the layers of weft yarns. In some cases, they may be
tied up from time to time over one of these weft yarns in order to
be attached to the fabric to a sufficient degree.
[0034] The artificial turf is preferably woven according to a
face-to-face weaving method. According to this face-to-face weaving
method, a top and a bottom fabric are woven on a face-to-face
weaving device.
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