U.S. patent application number 15/065138 was filed with the patent office on 2016-09-15 for artificial turf system.
This patent application is currently assigned to Nexxfield Inc. (4427017 Canada Inc.). The applicant listed for this patent is Nexxfield Inc. (4427017 Canada Inc.). Invention is credited to Seymour TOMARIN, Frederic VACHON.
Application Number | 20160265170 15/065138 |
Document ID | / |
Family ID | 56855869 |
Filed Date | 2016-09-15 |
United States Patent
Application |
20160265170 |
Kind Code |
A1 |
VACHON; Frederic ; et
al. |
September 15, 2016 |
ARTIFICIAL TURF SYSTEM
Abstract
An artificial turf system for installation over a receiving
surface that comprises a sheet member made of a flexible material,
with the sheet member defining a first surface for interfacing with
the receiving surface and a turf simulating surface. The artificial
turf system further comprises a plurality of primary yarns made of
straight fibers upwardly extending from the second surface of the
sheet member, and a plurality of secondary yarns made of textured
fibers upwardly extending from the second surface of the sheet
material and interspersed within the plurality of primary yarns,
wherein the plurality of secondary yarns representing more than 50%
in weight of the plurality of primary and secondary yarns together.
The primary and secondary yarns therefore simulate together the
look and feel of the different blades of grass of natural grass
cover.
Inventors: |
VACHON; Frederic; (Laval,
CA) ; TOMARIN; Seymour; (Dalton, GA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Nexxfield Inc. (4427017 Canada Inc.) |
Laval |
|
CA |
|
|
Assignee: |
Nexxfield Inc. (4427017 Canada
Inc.)
Laval
CA
|
Family ID: |
56855869 |
Appl. No.: |
15/065138 |
Filed: |
March 9, 2016 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62130113 |
Mar 9, 2015 |
|
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|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
E01C 13/08 20130101 |
International
Class: |
E01C 13/08 20060101
E01C013/08 |
Claims
1. An artificial turf system for installation over a receiving
surface, the artificial turf system comprising: a sheet member made
of a flexible material, the sheet member defining a first surface
for interfacing with the receiving surface and a second surface; a
plurality of primary yarns made of straight fibers upwardly
extending from the second surface of the sheet member; and a
plurality of secondary yarns made of textured fibers upwardly
extending from the second surface of the sheet material and
interspersed within the plurality of primary yarns; the plurality
of secondary yarns representing more than 50% in weight of the
plurality of primary and secondary yarns together.
2. The artificial turf system of claim 1, wherein the plurality of
secondary yarns are made of textured, thatched or crimped
fibers.
3. The artificial turf system of claim 1, wherein the primary and
secondary yarns are backstitched in parallel equally spaced apart
rows on the sheet material.
4. The artificial turf system of claim 1, wherein combined yarns
composed of the primary and secondary yarns are backstitched in
parallel equally spaced apart rows on the sheet material.
5. The artificial turf system of claim 3, wherein the rows form a
straight, S or Z pattern.
6. The artificial turf system of claim 3, wherein a distance
between two rows is ranged between 1/16'' and 1/2''.
7. The artificial turf system of claim 1, wherein the sheet
material is manufactured as one of a closed-weave woven, an
opened-weave woven, leno weave cross weave or non-woven
material.
8. The artificial turf system of claim 1, wherein the thickness of
the sheet member is substantially uniform and ranges between 0.20
mm to 2 mm.
9. The artificial turf system of claim 1, wherein the mass of each
of the plurality of primary yarns is ranged between 2,000 and
20,000 deniers.
11. The artificial turf system of claim 2, wherein the mass of each
of the plurality of secondary yarns is ranged between 2,000 and
20,000 deniers.
12. The artificial turf system of claim 1, wherein the plurality of
primary and secondary yarns are bound to the sheet member by heat,
pressure or with Polyurethane.
13. The artificial turf of claim 1, wherein the primary yarns have
a first length, the secondary yarns have a second length, and the
second length is at least equal to the first length.
14. The artificial turf of claim 1, wherein the plurality of
secondary yarns made of textured or thatch fibers represents one
of: more than about 51%, more than about 55%, more than about 60%,
more than about 65%, more than about 70%, more than about 75%, more
than about 80%, more than about 85%, more than about 90% and more
than about 95% in weight of the plurality of primary and secondary
yarns together.
15. The artificial turf of claim 1, wherein at least one of a
material in which is made the secondary yarns and a process
performed on the secondary yarns render the secondary yarns more
rigid than the primary yarns.
16. The artificial turf of claim 1, wherein the primary yarns are
made of one of polyethylene, polypropylene, Polyamide, polyester
(PET), and a combination of polyethylene and polypropylene.
17. The artificial turf of claim 1, wherein the secondary yarns are
made of one of Polyamide, Polyester (PET), polyethylene,
polypropylene, and a combination of polyethylene and
polypropylene.
18. The artificial turf of claim 1, wherein the elevation of the
secondary yarns with respect to the second surface is less than the
elevation of the primary yarns with respect to the second surface.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority from U.S. patent
application 62/130,113 filed Mar. 9, 2015, the specification of
which is hereby incorporated herein by reference in its
entirety.
BACKGROUND
[0002] (a) Field
[0003] The subject matter disclosed generally relates to playing
fields and more particularly to artificial sports and amusement
playing fields. The subject matter disclosed may also relate to
artificial turf surface of all kinds (i.e., artificial sports
playing fields, artificial amusement playing fields, gymnasium
surfaces, backyard surfaces and the like).
[0004] (b) Related Prior Art
[0005] The use of artificial or synthetic turf has been growing
steadily in recent years. Artificial turf is a surface of synthetic
fibers made to look like natural grass. It is most often used in
arenas and fields for sports that were originally or are normally
played on grass.
[0006] However, it is now being used in other applications such as,
for residential lawns or landscapes, for pet areas, for child
playgrounds, for golf courses and putting greens, on roofs, decks
and patios as well.
[0007] The advantages of synthetic turf are numerous. For example,
synthetic turf does not need to be cared as much as real grass.
Moreover, synthetic turf is more durable.
[0008] There exist on the market numerous artificial or synthetic
turf systems aiming to provide improved comfort, sufficient
traction, and shock absorbent characteristics. For example and now
referring to PRIOR ART FIGS. 1A and 1B, there is shown a regular
artificial turf system 10 which includes a sheet member 12 made of
a flexible material and a plurality (substantially straight) fibers
14 upwardly extending from the sheet member 12. The plurality of
fibers 14, which creates a carpet-like top layer, therefore
includes a series of regularly spaced apart (or equally spaced)
parallel rows of backstitches 16. For providing the shock absorbent
characteristic, straight fiber support and sufficient traction for
the desired sport to the artificial turf system 10, a plurality of
rubber granules and/or sand (not shown, such as from recycled
tires) are often disposed on the artificial turf system 10.
[0009] Even though the rubber granules and/or sand used in modern
artificial synthetic turf tend to contain lower quantities of
harmful substances, such as metal (e.g., lead and zinc), inorganic
and organic compounds, it may significantly increase health
problems for those playing/walking on it, it may significantly
increase the surface temperature above the surface covering panel
and it may lead to some other environmental problems. The infill
also becomes compacted with time affecting directly shock
absorption and traction of the artificial synthetic turf to the
detriment of the players.
[0010] As for another example and referring now to PRIOR ART FIGS.
2A and 2B, there is shown an artificial turf system without infill
100 for installation over a receiving surface (not shown). The
artificial turf system 100 includes a sheet member 102 made of a
flexible material. The sheet member 102 defines a first surface or
primary backing 104 for interfacing with the receiving surface and
a second surface 106. The artificial turf system 100 further
includes a plurality of primary yarns 108 made of straight fibers
(monofilament, parallel fibrillated or fibrillated fibers) which
are upwardly extending from the second surface 106 of the sheet
member 102 and a plurality of secondary yarns 110 made of textured
fibers or thatch fibers which are upwardly extending from the
second surface 106 of the sheet member 102. The plurality of
secondary yarns 110 are positioned on the sheet member 102 such as
to intersperse with the plurality of primary yarns 108.
[0011] The plurality of secondary yarns 110 made of textured or
thatch fibers represent less than 50% in weight (aka face weight)
of the plurality of primary and secondary yarns 108, 110 taken
together. Therefore, the straight fiber support, traction and shock
absorbent characteristics are not optimized.
[0012] The plurality of primary and secondary yarns 108, 110 which
creates together a carpet-like top layer 112 includes a series of
regularly spaced apart (or equally spaced) parallel rows of
backstitches 114, 116 tufted or knitted in straight line, in
"zigzag" or in a S pattern. The series of regularly spaced apart
parallel rows of backstitches 114, 116 include a series of
regularly spaced apart parallel rows of backstitches 114 made of
the plurality of primary yarns 108 and a series of regularly spaced
apart parallel rows of backstitches 116 made of the plurality of
secondary yarns 110, which are interspersed within the series of
regularly spaced apart parallel rows of backstitches 114 made of
the plurality of primary yarns 108.
[0013] The fact that the artificial turf system 100 combines both
the plurality of primary yarns 108 made of straight fibers and the
plurality of secondary yarns 110 made of textured or thatch fibers
provides straight fiber support and player traction to the
artificial turf system 100. However, according to this
configuration, the straight fiber support, players traction and
shock absorbent characteristic are not optimized.
[0014] There is therefore a need for improved non infilled
artificial turf system that optimizes straight fiber support,
player traction and shock absorbent characteristics and that would
overcome the above-noted drawbacks.
SUMMARY
[0015] According to an embodiment, there is provided an artificial
turf system for installation over a receiving surface. The
artificial turf system comprises a sheet member made of a flexible
material, the sheet member defining a first surface for interfacing
with the receiving surface and a second surface. The artificial
turf system further comprises a plurality of primary yarns made of
straight fibers upwardly extending from the second surface of the
sheet member and a plurality of secondary yarns made of textured
fibers upwardly extending from the second surface of the sheet
material and interspersed within the plurality of primary yarns.
The plurality of secondary yarns represent more than 50% in weight
of the plurality of primary and secondary yarns together.
[0016] According to an aspect, the plurality of secondary yarns are
made of textured, thatched or crimped fibers.
[0017] According to another aspect, the the primary and secondary
yarns are backstitched in parallel equally spaced apart rows on the
sheet material.
[0018] According to another aspect, combined yarns composed of the
primary and secondary yarns are backstitched in parallel equally
spaced apart rows on the sheet material.
[0019] According to another aspect, the artificial turf system with
combined yarns composed of the primary and secondary yarns are
backstitched in parallel equally spaced apart rows on the sheet
material, with the rows forming a straight, S, or Z pattern.
[0020] According to another aspect, the artificial turf system with
combined yarns composed of the primary and secondary yarns are
backstitched in parallel equally spaced apart rows on the sheet
material, with a distance separating two rows being ranged between
1/16'' and 1/2''.
[0021] According to another aspect, the sheet material is
manufactured as one of a closed-weave woven, an opened-weave woven,
leno weave cross weave or non-woven material.
[0022] According to another aspect, the thickness of the sheet
member is substantially uniform and ranges between 0.20 mm to 2
mm.
[0023] According to another aspect, the mass of each of the
plurality of primary yarns is ranged between 2,000 and 20,000
deniers.
[0024] According to another aspect, the plurality of secondary
yarns are made of textured, thatched or crimped fibers and the mass
of each of the plurality of secondary yarns is ranged between 2,000
and 20,000 deniers.
[0025] According to another aspect, the plurality of primary and
secondary yarns are bound to the sheet member by heat, pressure or
with Polyurethane.
[0026] According to another aspect, the primary yarns have a first
length, the secondary yarns have a second length, and the second
length is at least equal to the first length.
[0027] According to another aspect, the plurality of secondary
yarns made of textured or thatch fibers represents one of: more
than about 51%, more than about 55%, more than about 60%, more than
about 65%, more than about 70%, more than about 75%, more than
about 80%, more than about 85%, more than about 90% and more than
about 95% in weight of the plurality of primary and secondary yarns
together.
[0028] According to another aspect, at least one of a material in
which is made the secondary yarns and a process performed on the
secondary yarns render the secondary yarns more rigid than the
primary yarns.
[0029] According to another aspect, the primary yarns are made of
one of polyethylene, polypropylene, Polyamide, polyester (PET), and
a combination of polyethylene and polypropylene.
[0030] According to another aspect, the secondary yarns are made of
one of Polyamide, Polyester (PET), polyethylene, polypropylene, and
a combination of polyethylene and polypropylene.
[0031] According to another aspect, the elevation of the secondary
yarns with respect to the second surface is less than the elevation
of the primary yarns with respect to the second surface.
[0032] According to another embodiment, there is provided an
artificial turf system for installation over a receiving surface.
The artificial turf system comprises a sheet member made of a
flexible material, the sheet member defining a first surface for
interfacing with the receiving surface and a second surface. The
artificial turf system further comprises a plurality of primary
yarns made of substantially straight fibers upwardly extending from
the second surface of the sheet member and having a first elevation
with respect to the second surface, and a plurality of secondary
yarns upwardly extending from the second surface of the sheet
material, the plurality of secondary yarns having a second
elevation, lesser than the first elevation, with respect to the
second surface. The artificial turf system has the plurality of
primary and secondary yarns backstitched to the sheet material such
as each backstitch is composed of a plurality of secondary yarns
surrounding at least one primary yarn.
[0033] According to a further embodiment, there is provided an
artificial turf system for installation over a receiving surface.
The artificial turf system comprises a sheet member made of a
flexible material, the sheet member defining a first surface for
interfacing with the receiving surface and a second surface. The
artificial turf system further comprises a plurality of primary
yarns made of substantially straight fibers upwardly extending from
the second surface of the sheet member and having a first elevation
with respect to the second surface, and a plurality of secondary
yarns upwardly extending from the second surface of the sheet
material and interspersed within the plurality of primary yarns,
the plurality of secondary yarns having a second elevation, lesser
than the first elevation, with respect to the second surface. The
plurality of secondary yarns are representing more than 50% in
weight of the plurality of primary and secondary yarns
together.
[0034] Features and advantages of the subject matter hereof will
become more apparent in light of the following detailed description
of selected embodiments, as illustrated in the accompanying
figures. As will be realized, the subject matter disclosed and
claimed is capable of modifications in various respects, all
without departing from the scope of the claims. Accordingly, the
drawings and the description are to be regarded as illustrative in
nature, and not as restrictive and the full scope of the subject
matter is set forth in the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0035] Further features and advantages of the present disclosure
will become apparent from the following detailed description, taken
in combination with the appended drawings, in which:
[0036] FIG. 1A is a picture showing the top surface of an infilled
artificial turf system in accordance with the PRIOR ART;
[0037] FIG. 1B is a picture showing the bottom surface of the
infilled artificial turf system in accordance with the PRIOR
ART;
[0038] FIG. 2A is a picture showing the top surface of a non
infilled artificial turf system in accordance with the PRIOR
ART;
[0039] FIG. 2B is a picture showing another side (perpendicular to
the side shown in FIG. 2A) of the non infilled artificial turf
system of FIG. 2A in accordance with the PRIOR ART;
[0040] FIG. 3 is a picture showing the top surface of an artificial
turf system in accordance with an embodiment;
[0041] FIG. 4 is a picture showing the side of the artificial turf
system of FIG. 3;
[0042] FIG. 5 is a picture showing a close-up view of the
artificial turf system of FIG. 3; and
[0043] FIG. 6 is a picture showing the bottom surface of the
artificial turf system of FIG. 3.
[0044] It will be noted that throughout the appended drawings, like
features are identified by like reference numerals.
DETAILED DESCRIPTION
[0045] In embodiments, there are disclosed artificial turf systems
for applying on receiving surfaces.
[0046] Referring now to the drawings, and more particularly to
FIGS. 3-6, there is shown a non infill artificial turf system 200
for installation over a receiving surface (not shown) in accordance
with an embodiment. The non infill artificial turf system 200
includes a sheet member 202 made of a flexible material. The sheet
member 202 defines a first surface, or primary backing 204 for
interfacing with the receiving surface, and a second surface 206.
The non infill artificial turf system 200 further includes a
plurality of primary yarns 208 made of straight fibers
(substantially straight fibers) which are upwardly extending from
the second surface 206 of the sheet member 202 and a plurality of
secondary yarns 210 made of textured fibers or thatch fibers which
are upwardly extending from the second surface 206 of the sheet
member 202. Because of their curly shape, the plurality of
secondary yarns 210 position themselves automatically on the sheet
member 202 in all direction and therefore result in surrounding the
plurality of primary yarns 208.
[0047] The plurality of secondary yarns 210 made of textured or
thatch fibers represents more than 50% in weight of the plurality
of primary and secondary yarns 208, 210 taken together. More
particularly, the plurality of secondary yarns 210 made of textured
or thatch fibers may represent one of: more than about 51%, more
than about 55%, more than about 60%, more than about 65%, more than
about 70%, more than about 75%, more than about 80%, more than
about 85%, more than about 90% and more than about 95% in weight of
the plurality of primary and secondary yarns 208, 210 taken
together.
[0048] The plurality of primary and secondary yarns 208, 210 which
creates together a carpet-like top layer 212 includes a series of
regularly spaced apart (or equally spaced) parallel rows of
backstitches 214. These rows can be straight, in S or Z patterns,
tufted or knitted. According to one embodiment, parallel rows of
backstitches 214 of primary yarns 208 are alternated with parallel
rows of backstitches of 214 secondary yarns 210. According to
another embodiment, the series of regularly spaced apart parallel
rows of backstitches 214 are made of a plurality of secondary yarns
210 surrounding or with at least one or a plurality of primary
yarns 208. The combined yarn is therefore composed of both primary
yarns 208 and secondary yarns 210. Regardless of the embodiment,
the plurality of primary yarns 208 are therefore interspersed
within the plurality of secondary yarns 210.
[0049] The fact that the non infill artificial turf system 200
combines both the plurality of primary yarns 208 made of straight
fibers and the plurality of secondary yarns 210 made of textured or
thatch fibers (more than 50% face weight of the plurality of
secondary yarns is greater than the face weight of the plurality of
primary yarns) provides improved straight fiber support, player
traction and shock absorbent characteristics to the shock absorbent
surface covering panel 200.
[0050] As shown in FIGS. 3-6, and as better shown in FIG. 6, the
non infill artificial turf system 200 includes a plurality of
backstitches 214a. Each backstitch 214a similarly includes a
plurality of primary yarns 208 made of straight fibers with a
plurality of secondary yarns 210 made of textured or thatch fibers,
such as to allow the plurality of secondary yarns 210 made of
textured or thatch fibers to represent more than 50% in weight of
the plurality of primary yarns 208 and secondary yarns 210 taken
together.
[0051] Each backstitch 214a may be separated by a backstitch
distance. The backstitch distance may range between 1/16'' and
1/2''.
[0052] The sheet member 202 or several sheet members used together
may include materials made of but not exclusively limited to Olefin
(Polypropylene), Polyamide (Nylon), Polyethylene Terephalate (PET)
virgin or a recyclable material, Polyestere Woven and non woven,
cordura material either 100% or combination of these materials,
manufactured in a closed-weave woven, an opened-weave woven, leno
weave cross weave or non-woven material suitable to maximize
ability to tuft, provide tuft bind of the primary and secondary
yarns, provide dimensional stability, the hardness-flexibility
ratio of the sheet member, provide penetration of the sheet by the
secondary coating which is applied to the bottom of the sheet
member and which can be made of polyurethane or latex or acrylic or
some other material suitable to ask as a binder to hold the fibers
in place to the sheet member or to allow the binding of the fibers
to the sheet member by heat, pressure or with Polyurethane.
[0053] The thickness of the sheet member 202 is normally
substantially uniform and may range between 0.20 mm to 2 mm.
[0054] The total mass (total of the mass of each filament) of each
primary yarn filament 208 may be in a range between 2,000 to 20,000
deniers. The total mass of each primary yarn 208 may be in a range
between 2,000 and 20,000 deniers depending on the denier per
filament (DPF) and number of filaments in the yarn. Preferably, the
total mass of each primary yarn filament 208 is ranged between
4,000 and 16,000 deniers.
[0055] The mass (total of the mass of each filament) of each
secondary yarn 210 may be in a range between 2,000 and 20,000
deniers. The mass of each secondary yarn 210 may be in a range
between 2,000 and 20,000 deniers depending on the denier per
filament (DPF) and number of filaments in the yarn. Preferably, the
total mass of each secondary yarn filament 210 is ranged between
4,000 and 16,000 deniers.
[0056] The material of the plurality of primary yarns 208 may
include polyethylene, polypropylene, Polyamide, polyester (PET), a
combination of polyethylene and polypropylene and the like.
[0057] The shape and construction of the plurality of primary yarns
208 may include flat face fibers, monofilament fibers, monotape
yarn and fibrillated yarn, polyfilament fibers, parallel
fibrillated or fibrillated fibers and split fibers. The primary
yarns 208 may be made from extrusion and take different shapes such
as a rectangular cross-section ribbon, diamond, horseshoe, U, V, S
shape or a flat rectangular general cross section with its shorter
sides rounded. Its cross-section may feature one or more
curved-convex projections for instance. When backstitched to the
sheet member 202, the straight (or substantially straight) primary
yarns 208 are set upwardly extending from the second surface to
simulate the blades of grass of natural grass cover.
[0058] The material of the plurality of secondary yarns 210 may
include Polyamide, Polyester (PET), polyethylene, polypropylene, a
combination of polyethylene and polypropylene and the like.
[0059] The shape and construction of secondary yarns 210 may
include texturized monofilament, monotape yarn and fibrillated
yarn.
[0060] According to an embodiment, the physical characteristics of
the secondary yarns 210 are selected to obtain secondary yarns 210
that are more rigid than the primary yarns 208, therefore having
the secondary yarns 210 providing the desired support while having
the primary yarn 208 providing the desired texture. These desired
physical characteristics may be commonly obtained through selection
of a more rigid material for the secondary yarns 210 than for the
primary yarns 208. Alternatively, a process (physical or chemical)
over the secondary yarns 210 modifying its physical characteristics
may be used to obtain the desired rigidity.
[0061] The plurality of secondary yarns 210, while described herein
as textured fibers or thatch fibers, may not require, according to
one embodiment, to be textured. However, it is referred to herein
as "textured" to distinguish itself in all embodiment from the
primary "straight" yarn 208. The secondary yarns 210 may be made of
a plurality of filiform formations arranged in turfs so as to
provide a better simulation of the blades of grass of natural grass
cover. The manufacturing of secondary yarns 210 to provide the
desired shape and structure may be performed, for instance, by
means of a heat, chemical or mechanical treatment before use
through which the secondary yarns 210 are crimped. Accordingly,
second yarns 210 may consist of yarns of at least the same length
of the first yarns 208 that, when processed, result in the desired
shorter looking secondary yarns 210.
[0062] Still referring to Figs. FIGS. 3-6, and more particularly to
FIG. 4, the elevation 218 of the primary yarns 208 from the second
surface is illustrated as greater than the elevation 220 of the
secondary yarns 220 from the second surface regardless the real
length of the primary and secondary yarns 208 and 210. Thereby the
secondary yarns 210 provide the desired fiber support of the
primary yarns 208, player traction and shock absorbing
characteristics.
[0063] The tufting process of both primary and secondary yarns 208
and 210 can be performed by stitching both the primary and
secondary yarns 208 and 210 concurrently, using the same needle.
Alternatively, the primary yarns 208 and secondary yarns 210 may be
stitched separately, using distinct needles. The latter result in
parallel backstitches of primary yarns 208 and secondary yarns
210.
[0064] Depending the tufting configuration selected, the tufting
gauge can vary from 3/16'' to 3/4''.
[0065] The non infill artificial turf system 200 as described above
may increase protection for child in playgrounds, may provide
improved players traction and shock absorbent characteristics for
sport fields of all kinds, and may reduce the surface temperature
above the panel. The plurality of secondary yarns 210 in sufficient
quantity (more than 50% in weight) render the presence of rubber
granules unnecessary to provide straight fiber support, while
provide adequate traction for players and shock absorbent
characteristics.
[0066] While preferred embodiments have been described above and
illustrated in the accompanying drawings, it will be evident to
those skilled/in the art that modifications may be made without
departing from this disclosure. Such modifications are considered
as possible variants comprised in the scope of the disclosure.
* * * * *