U.S. patent application number 15/382033 was filed with the patent office on 2017-06-22 for method and system for rescuing playability of synthetic turf.
This patent application is currently assigned to DryJect, Inc.. The applicant listed for this patent is DryJect, Inc.. Invention is credited to Christopher des Garennes, Tony Leonard, John F. Paddock, William F. Reardon.
Application Number | 20170175343 15/382033 |
Document ID | / |
Family ID | 59057800 |
Filed Date | 2017-06-22 |
United States Patent
Application |
20170175343 |
Kind Code |
A1 |
des Garennes; Christopher ;
et al. |
June 22, 2017 |
METHOD AND SYSTEM FOR RESCUING PLAYABILITY OF SYNTHETIC TURF
Abstract
A system and method of rescuing playability of synthetic turf
are disclosed. The system and method include kicking out infield
material, mixing existing infield material with fresh infield
material, injecting the mixed infield material, and kicking the
bent and depressed turf fibers back to an upright position. The
system and method also include performing the injecting pivoting
the injectors in multiple directions. The system and method further
include mixing water absorbent polymer particles with the mixed
infield material and injecting into the turf. The system and method
further include applying liquid materials to the fibers and
material of the synthetic turf. The system and method further
include injecting disinfectants into the turf.
Inventors: |
des Garennes; Christopher;
(Elkton, MD) ; Paddock; John F.; (Hainesport,
NJ) ; Reardon; William F.; (Glenside, PA) ;
Leonard; Tony; (Mickleton, NJ) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
DryJect, Inc. |
Hatboro |
PA |
US |
|
|
Assignee: |
DryJect, Inc.
Hatboro
PA
|
Family ID: |
59057800 |
Appl. No.: |
15/382033 |
Filed: |
December 16, 2016 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62268252 |
Dec 16, 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. A method of rescuing playability of synthetic turf, the method
comprising: kicking out infield material via injection of high
pressure liquid; mixing existing infield material with fresh
infield material; and kicking the bent and depressed turf fibers
back to an upright position.
2. The method of claim 1 wherein the injecting is performed by
pivoting the injectors in multiple directions.
3. The method of claim 1 further comprising mixing water absorbent
polymer particles with the mixed infield material and injecting
into the turf.
4. The method of claim 1 further comprising applying liquid
materials to the fibers and material of the synthetic turf.
5. The method of claim 1 further comprising injecting disinfectants
into the turf.
6. The method of claim 1 wherein the liquid is injected at a
pressure from 2200 to 2500 psi.
7. The method of claim 1 wherein the liquid is injected at a
pressure from 2500 to 3250 psi.
8. The method of claim 1 wherein the injection occurs using
3.times.1 spacing.
9. The method of claim 1 wherein the injection occurs using
3.times.2 spacing.
10. The method of claim 1 wherein the injection occurs using
3.times.3 spacing.
11. The method of claim 1 wherein the injection occurs at an angle
of between 15 and 0 degrees.
12. The method of claim 1 wherein the injection occurs at an angle
of less than 25 degrees.
13. The method of claim 1 wherein the injection occurs at an angle
in the range of approximately 8 to 11 degrees.
14. The method of claim 1 wherein the injection is from an
injection manifold with 7 to 32 injectors.
15. The method of claim 1 wherein the mixing occurs within the
field profile.
16. The method of claim 1 wherein the mixing occurs prior to
injection.
17. The method of claim 1 wherein the injection causes the kicking
of bent and depressed fibers.
18. A system for rescuing the playability of synthetic turf, the
system comprising: a manifold including a plurality of nozzles
distributed along a length; a peristaltic pump assembly that
comprises a motor that rotates a carriage assembly, an encoder
disc, a sensor, an inlet line fluidly coupled to an additive
reservoir, and an outlet line coupled to the manifold; a
pressurized fluid source fluidly coupled to the manifold, wherein
when the pressurized fluid is injected into the manifold, the
pressure in the manifold increases and the pressurized fluid mixes
with an additive delivered from the additive reservoir; and a
ground speed sensor; and a computer control system in communication
with the peristaltic pump assembly and the ground speed indicator,
wherein the computer control system controls an output of the
peristaltic pump to be proportional to the ground speed sensed and
wherein the increased pressure in the manifold causes the
pressurized fluid within the manifold to exit through the plurality
of nozzles to inject the pressurized fluid and the additive to be
injected into the soil by creating fractures in the soil, and
wherein the additive includes new infield material.
19. The system of claim 18 wherein the additive includes
disinfectant.
20. The system of claim 18 wherein the water absorbent polymer
particles.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional
Patent Application No. 62/268,252 filed Dec. 16, 2015, which is
incorporated by reference as if fully set forth.
FIELD OF INVENTION
[0002] This application generally relates to the field of turf
maintenance, ornamental horticulture, nursery growers, agriculture
and more specifically, to the rescue of synthetic turf that is
highly trafficked.
BACKGROUND
[0003] Synthetic turf fields have become more common. Synthetic
turf fields, also known as artificial turf, provide a surface of
synthetic fibers made to look like natural grass. These fields may
be in arenas and neighborhoods for sports that were originally or
are normally played on grass. These fields are also now being used
on residential lawns and commercial applications as well. These
fields are beneficial because of maintenance-artificial turf stands
up to heavy use, such as in sports, and requires no irrigation or
trimming. Abundant sunlight is not needed to keep these fields
looking nice. Domed, covered, and partially covered stadiums,
arenas and other fields may require artificial turf because of the
difficulty of getting grass enough sunlight to stay healthy.
However, these fields do have drawbacks that need to be addressed
including limited life, compaction periodic cleaning requirements,
and heightened health and safety concerns including issues with
increased temperatures.
[0004] These fields have been used for approximately 50 years and
there are more than 11,000 of these fields in use in the United
States alone with hundreds more being installed and renovated each
year. Over this time the fields have developed from the first
generation turf systems that include short-pile fibers without
infill to second generation and third generation turf systems that
feature longer fibers and sand infills, and infills that are
mixtures of sand and granules of recycled rubber, respectively.
[0005] However, these fields do have drawbacks set forth above.
Proper treatment and maintenance of these fields creates a higher
quality product, improved lifetime and provides for a more
aesthetically appealing landscape, and safer field of play, all
which creates a highly attractive and desirable area for play.
Therefore, a need exists for minimizing the negative effects and
properly treating these fields.
SUMMARY
[0006] A system and method of rescuing playability of synthetic
turf are disclosed. The system and method include kicking out
infield material via injection of high pressure liquid, mixing
existing infield material with fresh infield material, and kicking
the bent and depressed turf fibers back to an upright position. The
system and method include injecting by pivoting the injectors in
multiple directions. The system and method include mixing water
absorbent polymer particles with the mixed infield material and
injecting into the turf. The system and method include applying
liquid materials to the fibers and material of the synthetic turf.
The system and method include injecting disinfectants into the
turf. The system and method may include injecting the liquid at a
pressure from 2200 to 2500 psi and/or 2500 to 3250 psi. The system
and method may be performed using 3.times.1, 3.times.2, and/or
3.times.3 spacing. The injecting may occurs at an angle of between
15 and 0 degrees, an angle of less than 25 degrees, and/or at an
angle in the range of approximately 8 to 11 degrees. The system and
method may include mixing that occurs within the field profile
and/or prior to injection. The injection may cause the kicking of
bent and depressed fibers.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] The foregoing summary, as well as the following detailed
description of the preferred embodiments, will be better understood
when read in conjunction with the appended drawings. For the
purpose of illustrating the invention, there is shown in the
drawings embodiments which are presently preferred. It should be
understood, however, that the invention is not limited to the
precise arrangements shown.
[0008] FIG. 1 depicts synthetic turf;
[0009] FIG. 2 illustrates a side exploded view of the synthetic
turf of FIG. 1;
[0010] FIG. 3 is a schematic view of a system for injecting an
additive in or on the field surface in accordance with a disclosed
embodiment;
[0011] FIG. 4 is a perspective view of a rotating carriage with an
encoder disc in accordance with a disclosed embodiment;
[0012] FIG. 5 is a schematic side view of the system of FIG. 3 on a
movable platform in accordance with a disclosed embodiment;
[0013] FIG. 6 is a flow diagram of a method in accordance with a
disclosed embodiment; and
[0014] FIG. 7 illustrates a method for de-compacting and
disinfecting the turf.
[0015] To facilitate understanding, identical reference numerals
have been used, where possible, to designate identical elements
that are common in the figures. The figures are not drawn to scale
and may be simplified for clarity. It is contemplated that elements
and features of one embodiment may be beneficially incorporated in
other embodiments without further recitation.
DETAILED DESCRIPTION
[0016] Certain terminology is used in the following description for
convenience only and is not limiting. The words "front," "back,"
"forward," "backwards," "inner," and "outer" designate directions
in the drawings to which reference is made. Additionally, the terms
"a" and "one" are defined as including one or more of the
referenced item unless specifically noted otherwise. A reference to
a list of items that are cited as "at least one of a, b, or c"
(where a, b, and c represent the items being listed) means any
single one of the items a, b, or c, or combinations thereof. A
recitation of "into the field" or the like means to the surface of
the field as well as within the field depth unless the context
clearly indicated otherwise. The terminology includes the words
specifically noted above, derivatives thereof, and words of similar
import.
[0017] A system and method of rescuing playability of synthetic
turf are disclosed. The system and method include kicking out
infield material, mixing existing infield material with fresh
infield material, injecting the mixed infield material, and kicking
the bent and depressed turf fibers back to an upright position. The
system and method also include performing the injecting pivoting
the injectors in multiple directions. The system and method further
include mixing water absorbent polymer particles with the mixed
infield material and injecting into the turf. The system and method
further include applying liquid materials to the fibers and
material of the synthetic turf. The system and method further
include injecting disinfectants into the turf.
[0018] FIG. 1 depicts synthetic turf 1 in use today. As is shown in
FIG. 1, there is a set of fibers 10 that resemble or operate like
grass and there are a layer of granules 20 also known as in-fill at
the base of the set of fibers.
[0019] A side view of the synthetic turf 1 is illustrated in FIG.
2. FIG. 2 depicts the fibers 10 that are abundantly shown in FIG.
1. Fibers 10 may consist of a yarn or fiber (most commonly
polyethylene, polypropylene or a blend of the two) of varying
thickness, which may be straight 10.1, twisted, curly 10.2 or
textured or a combination 10.3 of these types. Most commonly, the
yarn is produced in sheets, which are split into thin strips or
ribbons and then slit with razors to create multiple strands. The
ribbons are then twisted together and tufted through a backing
cloth to form the carpet. This type of carpet helps to stabilize
and prevent excess movement of the in-fill. Alternatively, some
carpets are manufactured from single strands of yarn, known as
monofilament. The quantity of yarn used and the distance between
the tufts (or stitch gauge) may vary from system to system. Some
systems use more yarn or closer tufts; others use more infill. Yarn
quantity is expressed in units of tex, a ratio of mass to length,
or in weight (ounces per square foot).
[0020] A backing cloth 30 or base layer is also illustrated in FIG.
2. A good backing cloth 30 is easily tufted, resists fraying,
absorbs coatings, is UV and rot-resistant, and has high dimensional
stability. This means that the finished product will not creep or
stretch, minimizing line movement.
[0021] Once the yarn has been tufted into the backing cloth 30,
coatings, including polyurethane and latex coatings, may be applied
to the backing to help to hold the tufts in place (called
increasing the "tuft bind") and to increase the dimensional
stability of the finished carpet. In some brands, the coatings are
applied only to the individual tufts, leaving the areas between the
tufts uncoated for drainage. In others, the entire backing is
coated and the carpet then is perforated for drainage if designed
for outdoor use. If perforated, the size, number and placement of
perforations may vary from brand to brand. If carpet is to be used
indoors and drainage is unnecessary, it may be ordered without
perforations to increase its strength. Once the carpet has been
installed, the fibers 10 may be further fibrillated to give them
the look and feel of natural grass.
[0022] Generally, at the base of the fibers is a layer of granules
20 (in-fill) that is also abundantly evident in FIG. 1. These
granules 20 may take many forms including sand and/or rubber, for
example. The granules 20 may also be of a myriad of different
shapes, such as circular, egg-like, oval, rods, cones, or the like.
The type and depth of the granule layer may vary from system to
system. This so called "in-fill" holds up the long fibers 10 in the
carpet and contributes significantly to the performance
characteristics of the turf. Granules 20 material most often are
granulated rubber or rubber and sand, either layered or mixed. The
rubber may be styrene-butadiene rubber (SBR) granules, black in
color and produced from recycled tires, or ethylene propylene
terpolymer (EPDM) granules, specifically produced to be granulated
and available in black or in colors. Clearly, the components and
the construction of synthetic turf systems vary. Depending upon the
system, different components may play more or less of a role in the
ultimate performance of the system. Some of the components
described are incompatible with others.
[0023] Over time, because of use and/or environmental reasons, the
granules 20 become displaced, compacted, and missing from the
synthetic field. Displaced granules 20 may occur from use, weather
or the like and may include one area of the field having more
granules that another, for example, and may include granule 20
clumping in regions of the field. For example, the center portion
of fields tends to receive more traffic during games and as a
result the granules 20 originally in this area tend to migrate away
from this portion of the field. Displacement of the granules 20 may
also occur from rain drainage, or snow removal, for example.
[0024] Missing granules 20 constantly occur with use. Every player
that plays on the field leaves with granules 20 attached to them.
This may include granules 20 in the shoes, socks, shorts, and hair,
for example. Use of the field generally causes some portion of the
granules 20 to "walk" away.
[0025] Compacted granules 20 are caused by environmental forces and
play, and are defined as granules 20 that a have begun to break
down as a result of the environment, compaction and play. These
compacted granules 20 may occur as a result of dust and dirt
build-up (fines) between or amongst the granules 20. The dirt and
dust may be carried onto the field, or blown by nature, for
example. This build-up may fill in voids between the granules 20
causing the field to become compacted and tight. This then may
escalate the degradation because the filled in voids provide less
space for water to move through the field so water may pool or
temporarily pool by draining slower, thereby exaggerating the
compaction.
[0026] As synthetic turf playing surfaces age they lose granules 20
due to a variety of factors some of which are described above. The
granules 20 loss increases the surface hardness and decreases the
safety of the field. The ability to add granules 20 once a field
has become worn and lost is critical. Normally at the end of a
synthetic field's life the field is removed and a new synthetic
turf is installed. Being able to add granules 20 back into these
fields may add a few years of life to a field. These additional
years may save athletic facilities money while also creating a
safer playing surface. Therefore having a machine that can add
granules 20 at variable rates to synthetic fields and
simultaneously reduce compaction, and provide cooling, and
disinfecting is essential.
[0027] In order to minimize the present shortfalls in artificial
fields, practices to care for the turf have developed including
dragging or brushing to redistribute infill, brushing to lift pile,
brushing and/or vacuuming to remove debris, localized topdressing
at heavy wear areas, grooming to relieve compaction of the
granules, and removal of moss, algae and/or weeds. Maintenance of
synthetic turf today generally consists of topdressing or grooming
that is primarily brushing the fibers to aid in their appearance
and knap. This may also aid in the displacement of granules 20 by
redistributing the granules 20 more evenly. This grooming does very
little in improving the compaction of the granules 20 or the
missing granules 20.
[0028] Other types of maintenance includes vacuuming or otherwise
removing the granules 20 and reintroducing new granules 20 or
material back into the turf. Grooming may be used after the
reintroduction of granules 20 to aid in the placement and levelness
of the granules 20.
[0029] In an embodiment, an injection system, such as those
detailed in U.S. Pat. No. 5,605,105 and U.S. Pat. No. 7,581,684,
both of which are incorporated herein by reference as if fully set
forth, are used to inject materials including granules 20 and/or
polymer into or onto the synthetic field. This technique
de-compacts the old and unsafe/unplayable field to de-compact,
provide cooling products, and disinfect using high pressure fluid,
such as water or air, the high pressure injection with simultaneous
injection of dry material granules 20. This method of injecting
granules 20 and/or polymer into the field results in thorough and
precise distribution with the added benefit of little surface
disruption. The high pressure fluid from the injection system may
begin or even complete the process of de-compacting the granules 20
remaining in the field. One method and device for inserting
granules 20 and/or polymer into the field is described in detail
below.
[0030] A blend of agents may be applied to retard the expansion of
a water absorbent polymer until after the polymer has been
delivered to the target area in the field. For example, a
cross-linked potassium polyacrylate polymer is blended with the
desired additives, such as food grade emulsifiers, stabilizers,
preservatives and growth enhancers. The polymer is then coated,
such as with vegetable oil and proprietary formula which forms a
protective coating that retards the ability of the polymer to
absorb water, thus delaying expansion of the polymer into a
gel-like substance. The coated polymer may then be formulated into
a liquid for injection into the field as set forth herein. Once the
polymer has been injected into the field, the protective coating
may be washed off either by the process of placing the polymer into
the field after some precipitation or irrigation or both, enabling
the polymer to absorb water and swell to full capacity.
[0031] In an embodiment, the dry polymer particles are 200-800
microns in size to reduce degradation rates. A larger particle size
is also desirable because larger particles may absorb more water,
resulting in greater and longer lasting benefit to the field.
Microbes present in the field consume the particles and do so more
quickly with the smaller particles reducing the benefit to the
field. Accordingly, the larger particle size may provide a benefit
to compensate for microbial activity and extend particle presence
in field.
[0032] Synthetic turf surface temperature can become elevated
during the hottest times of the day. Different cooling techniques
have attempted to reduce surface temperatures. Irrigation has been
found to reduce surface temperature for a period of 15 to 30
minutes; however, the effect was short lived and surface
temperature returned to the previous temperature. Due to durations
of athletic events rewetting is not an option to keep surface
temperatures reduced. This creates the need for an option to reduce
the surface temperature that can keep temperatures reduced for
extended periods of time. Polymers that could release moisture over
time and keep surface temperatures lower are a possible solution
for reducing surface temperatures on synthetic turf. The polymer
disclosed herein may include cross-linked polymers and food grade
emulsifiers, stabilizers, preservatives, and growth enhancers. The
polymer may be formulated into a liquid flowable form with a blend
of agents to short-term retard the expansion of the polymer. Once
in or on the field, the expansion of the polymer may be retarded
until the coating is completely washed off as a result of
precipitation or irrigation. The expanded polymer increases the
capacity of the field to remain cool and resist temperature
changes. This in turn decreases water runoff due to the hydrophilic
nature of the polymer. The presence of the water absorbent polymer
helps to moderate field temperature and makes aeration more
effective. This increases the playability and lifetime of the
field.
[0033] In an embodiment, larger particle sizes may be used to
decrease the rate of degradation of the particles and prevent
consumption by microbes, which consume or otherwise breakdown
smaller polymer particles more quickly.
[0034] In order to provide at least one context within which the
present granules 20 and/or polymer may be inserted or applied, the
following description is provided. FIG. 3 schematically shows an
embodiment of a system 100 for placing material including the
granules and/or polymer or other additives on or in the field. FIG.
5 is a schematic side view of the system of FIG. 3 on a movable
platform in accordance with a disclosed embodiment. The system 100
includes a peristaltic pump assembly 102. The peristaltic pump
assembly 102 is configured for placing material on or in the field
S. The device delivers material, including granules, polymer and
disinfectant, at least to the surface S of the field and into the
subsurface to a desired depth D (field depth). This depth D may be
the distance from the top of surface S to the backing (not shown in
FIG. 3 although shown relative to backing 30 in FIG. 2). The
peristaltic pump assembly 102 is generally known to include a
plurality of rollers 103 supported rotation on a rotating carriage
assembly 104. As the carriage 104 rotates as indicated by arrow 105
under the influence of a variable voltage motor 208 (FIGS. 3 and
4), rollers 103 successively compress a resilient tube 106 to urge
a material within the tube 106 in the direction of rotation (i.e.,
corresponding with arrow 105). An axial face of the rotating
carriage assembly 104 may include an encoder disc 202. The encoder
disc 202 has features 204, for example holes 204, formed around a
perimeter of the disc 202 as illustrated in FIG. 4. A sensor 206
(FIG. 3) is positioned to read, or sense, data from the encoder
disc 202, for example the number of features 204 passing in a given
period of time, and provide that data to a computer control system
or controller 108.
[0035] A first end 106a of the resilient tube 106 is fluidly
coupled to an additive reservoir 110 containing an additive 111.
The first end 106a resilient tube 106 may be directly coupled to
the reservoir 110 or may have one or more intermediate fluid
conduits forming inlet line 124. The additive reservoir 110
contains an additive 111 that may comprise one or more miscible or
immiscible liquids or one or more solids suspended in one or more
liquids, as in a slurry, or other compositions, such as a gel,
suitable for pumping via a peristaltic pump.
[0036] A second end 106b of the resilient tube 106 is fluidly
coupled to the manifold 112 either directly or through one or more
intermediate fluid conduits forming outlet line 126. A check valve
120 is placed in the outlet line 126 between the peristaltic pump
102 and the manifold 112. The check valve 120 is configured to
allow flow from the peristaltic pump 102 to the manifold 112 but to
prevent or block flow from the manifold to the peristaltic pump
102. The peristaltic pump is controlled to constantly provide an
amount of additive to the manifold 112, except for during an
injection, discussed below. As the additive 111 flows into the
manifold 112, the pressure within the manifold is at or near
atmospheric pressure (i.e., 0 pounds per square inch gage) allowing
a free flow of the additive. In an embodiment as illustrated, the
second end 106b of the resilient tube 106 is coupled with the
manifold at a midpoint L/2 of the length L of the manifold via
outlet line 126.
[0037] The manifold 112 includes a plurality of nozzles 114. In the
non-limiting embodiment illustrated schematically in FIG. 3, eight
nozzles 114 are shown evenly spaced along the length L, although
spacing need not be even. In other embodiments, a greater or lesser
number of nozzles 114 may be used with even or uneven spacing. The
nozzles 114 are in direct fluid communication with the interior of
the manifold 112 as illustrated. In an embodiment, one or more
nozzles 114 may have a valved connection with the manifold 112.
[0038] A source of pressurized fluid 116 is in fluid communication
with the manifold 112 via pressure line 128. In an embodiment, the
point of attachment between the manifold 112 and the source of
pressurized fluid 116 is at a midpoint L/2 of the length L of the
manifold 112 via pressure line 128. In an embodiment, the source of
pressurized fluid 116 is attached to the manifold 112 adjacent to
the second end of the resilient tube 106.
[0039] The source of pressurized fluid 116 may be an accumulator or
other device or structure configured to supply a fluid 117 at a
substantially constant pressure. This fluid 117 may include or be
disinfectant or other material discussed herein. As used herein, a
fluid 117 is a fluid at a pressure greater than the surrounding
atmospheric pressure. This pressure is sometimes referred to a gage
pressure to distinguish it from the total, or absolute, pressure
which includes atmospheric pressure. In some embodiments, the fluid
117 may be at a pressure of up to 4,000 pounds per square inch, for
example the pressure of the fluid 117 may range from about 2,000
pounds per square inch to about 4,000 pounds per square inch.
[0040] A valve, for example a poppet valve 118, is placed in the
pressure line 128 between the source of pressurized fluid 116 and
the manifold 112, such as adjacent to the manifold 112. The poppet
valve 118 is configured to provide a blast or a jet of fluid 117 to
the manifold. Advantageously, the blast or jet of fluid 117
interacts with the additive 111 delivered to the manifold by the
second end of the resilient tube 106b. The interaction of the fluid
117 and the additive 111 in the manifold evenly, or substantially
evenly disperses the additive 111 in the fluid 117.
[0041] The (gage) pressure within the manifold 112 varies from
atmospheric pressure to approximately the pressure of the
pressurized fluid source 116. Accordingly, a check valve is not
included, as the contents of the manifold will not flow in the
direction of the pressurized fluid source 116. However, a check
valve may be placed in the pressure line to insure the contents of
the manifold do not enter the high pressure source 116.
[0042] In an embodiment, a hopper 132 containing a dry filler
material 134 may be coupled via line 136 to the nozzles 114 (only
shown connected to one nozzle 114 in FIG. 3 for clarity). Dry
filler material 134 may include the polymer, rubber, sand or other
material discussed herein. As the injected material travels through
the nozzles 114, the velocity of flow causes a vacuum in the
nozzles 114 behind the flow. This vacuum can be used to draw the
dry material 134 into the nozzle 114 and flow in or on the field
surface S or ground G by the injection. The flow of the dry
material 134 into the nozzles 114 can be controlled by a valve at
the hopper 132 or individually by valves at the nozzles 114.
[0043] The system 100 may be used to rescue unplayable fields and
add additional usage by de-compacting, cooling, and/or disinfecting
the field. Specifically, a 3.times.1 to 3.times.3 spacing may be
used with a 2500-3250 psi water injection, for example. An angle
between 15-0 degrees may be used for injections to provide a clean
level surface after injection. Use of angles outside of this range
may still provide de-compaction and other benefits, but with
lessening efficiency. For example, other angles up to 25 degree may
be used with less effective results. Approximately 10 degrees
including a range of 8-11 degrees provides measured benefits in
de-compaction. Swivel injectors may be used opposite the direction
of travel of the device described below. The device may be equipped
with 3/4 inch suctions lines and a modified hopper for the 3/4 inch
lines.
[0044] The system 100 can be supported on a platform 302 movable
with respect to the surface S of the field or field depth as
illustrated in FIG. 3. The platform 302 can be designed to be
pulled or towed and may be attached to, at a hitch 304, a tractor
or other vehicle suitable for towing (not shown). The system 100
has wheels 306 that operate as a free-wheel as the system 100 is
towed along the surface S. The platform 304 could also be
self-propelled with at least one wheel 306 as a drive wheel.
[0045] A sensor 308 may be attached to a wheel 306, either
free-wheel or drive wheel, for selectively sensing data
corresponding to ground speed. In an embodiment, the data relates
to angular displacement corresponding to rotations of a wheel 306
of a known diameter. Between the sensor 308 and the controller 108
is a communication link 310 to facilitate communication of ground
speed data between the sensor 308 and the controller 108.
[0046] In the non-limiting embodiment illustrated in FIG. 3, the
entire system 100 is supported on the platform 302 for ease of
illustration only. Some components may be supported for movement
over the surface S in a separate vehicle. The communication link
310 may be a wired link, or may be a wireless link connection.
[0047] When the output motor 208 rotates the carriage assembly 104,
rollers 103 compress the resilient tube 106 within a cavity
peristaltic pump 102 to draw the additive 111 from the additive
reservoir 110 through the first end portion 106a and force the
additive 111 through the second end 106b of the resilient tube. In
an embodiment, the carriage assembly 104 can rotate in a clockwise
(as illustrated) or counter-clockwise direction and additives in
the resilient tube 106 can be urged within the flexible tube in the
direction of travel of the rollers 103 (i.e., corresponding with
arrow 105 in FIG. 3).
[0048] The additives 111 are provided or metered out by the
peristaltic pump 102 in precision amounts to the injection manifold
112. This is accomplished by mounting an encoder disc 202 on the
carriage assembly 104 (FIG. 4). The encoder disc 202 may be formed
from a metal, for example stainless steel, with features, such as
holes 204 that are sensed by a sensor 206, for example a Hall
Effect proximity sensor. As shown in FIG. 4, the sensor 206, for
example a proximity sensor, is mounted to the peristaltic pump
housing and detects the absence or presence of metal directly in
front of it. In an embodiment the proximity sensor 50 reads the
revolutions of the encoder disc 202 per a period of time and
reports the revolutions to a computer control system, controller
108 via communication link 130. The communication link 130 may be a
wired link or a wireless link to facilitate transmission of at
least a control signal from the controller 108 to the motor 208. As
illustrated in the non-limiting embodiment of FIG. 4, each through
hole 204 in the encoder disc 202 represents 1/40 of the peristaltic
pump's 102 volume per revolution. For example, if the peristaltic
pump's 102 volume per revolution is 0.16 ounces, each hole would be
equal to 0.0036 ounce. As illustrated in FIG. 3, the computer sends
a control signal, for example a variable output voltage, to the
motor 208 to pump the additive material 111 at a given revolution
per period of time. In other words, the controller 108 controls the
amount of material that is output from the peristaltic pump 102.
The desired amount of material output can be pre-set at the
controller 108 and may vary from approximately 3 oz. per 1,000 sq.
ft. to approximately 365 oz. per 1,000 sq. ft. The peristaltic pump
102 output is controlled by the controller 108 based on data
provided by the sensor 206 and the sensor 308. The sensor 308
provides ground speed data to central controller 108.
[0049] As shown in FIG. 3, the additives 111 of the peristaltic
pump 102 are provided to the injection manifold 112 through a
valve, check valve 120, and high pressure fluid, for example water,
is injected through a poppet valve assembly 118, adjacent to the
valve 120 where the additive materials 111 of the peristaltic pump
102 are provided. When high pressure fluid (e.g., water) is
injected into the injection manifold 112, the injection causes the
pressure in the manifold 112 to rise. The pressure in the manifold
112 can rise to the same, or substantially the same, pressure as
the pressurized fluid source 116. This increase in pressure closes
the check valve 120 that allows the additive 111 to flow into the
manifold. The pressure within the manifold 112 causes the fluid 117
and the additive 111, mixed under the influence of the fluid 117
jet in the manifold 112, to exit the manifold through the nozzles
114. The nozzles 114 may be in free and open fluid communication
with the atmosphere as illustrated, or may include one or more
valves to restrict the flow out of the manifold 112.
[0050] As the pressure drops in the manifold 112, the check valve
moves into an open position and the additives 111 again enter the
mixing chamber. Injection of the fluid 117 into the injection
manifold 112 stops the movement of the additive into the injection
manifold for duration of approximately 0.05 to 0.30 seconds. During
this time period, the pressure in the mixing chamber increases from
approximately 0 p.s.i. (gage, therefore corresponding to
atmospheric pressure) to approximately 4,000 p.s.i. (gage). After
each injection of fluid 117 into the manifold 112, the pressure in
the manifold 112 decreases to approximately 0 p.s.i.; during this
period, between high pressure injections, the additives move into
the injection manifold 112. The mixture of additives and high
pressure water is pumped into or onto the field as noted below.
[0051] During the period when the check valve 120 is closed and the
pressure in the manifold 112 is elevated, the carriage assembly 104
of peristaltic pump 102 continues to turn as controlled by the
variable voltage motor 208. The second end portion 106b of the
resilient tube 106 or the outlet line 126, or both the resilient
tube 106 and the outlet line 126, acts as an accumulator for the
additive materials 111 pumped during that time period.
[0052] The mixture of additives 111 and fluid 117 is injected in or
on the surface S to the ground G under high pressure through
nozzles 114. The velocity of the fluid 117 moving through the
nozzles 114 allows the mixture to be forced into the field profile
from depths D of approximately 1 to 12 inches.
[0053] FIG. 6 is a flow diagram representing a method 400 for
placing an additive onto or into the field surface according to a
disclosed embodiment. At 402 data related to ground speed of the
system 100 is sensed by a sensor, for example sensor 308, which may
include an encoder disc mounted to a wheel 306 and a proximity
sensor fixed to the movable platform 302. The data is communicated
to the controller 108 where the data may be stored.
[0054] At 404, the ground speed of the system 100 including at
least the manifold 112 and nozzles 114 is calculated at the
controller 108 from the data received.
[0055] At 406, an area per unit time covered by the nozzle assembly
114 at the calculated ground speed is calculated at the controller
108.
[0056] The controller 108 determines at 408 the amount of additive
111 required at the nozzles 114 in order to apply a predetermined
amount of additive per unit area to the field.
[0057] At 410, the controller 108 provides a control signal, for
example a variable voltage, via the communications link 130 to the
peristaltic pump 102 to deliver the determined amount of an
additive 111 to the manifold 112. Under the pressure generated by
the peristaltic pump 102 in outlet line 106b, the check valve 120
is caused to open, allowing the determined amount of additive 111
to be delivered to the manifold 112.
[0058] At 412, poppet valve 118 opens and a fluid 117 is introduced
to the manifold 112. As the fluid 117 enters the manifold, the
check valve 120 is urged to close and the manifold become
pressurized to the same, or substantially the same, pressure as the
fluid 117. The fluid 117 enters the manifold 112 as a jet or a
blast and distributed the additive within the manifold 112.
[0059] At 414, the pressurized manifold forces the mixture of fluid
and additive through the nozzles 114 and injects the mixture of
fluid and additive onto or into the field surface. The sequence can
be repeated for a set number of cycles programmed into the
controller 108.
[0060] The method for rescuing poor quality synthetic fields is a
combination or any one or more of the three unique techniques that
have been introduced herein including de-compacting, cooling, and
disinfecting using new granules and/or polymer.
[0061] As discussed, the system and method may utilize existing
U.S. Pat. No. 5,605,105 and U.S. Pat. No. 7,581,684 using
modifications so that a new and different service is made available
to existing synthetic turf that extends the playability, safety,
etc. of the field for an extended period of time. This extended
period of time is much greater than any existing maintenance
service presently being offered in the industry.
[0062] The machine and service may use high pressure water, air or
combination or water and air, with a special swivel kit that
modifies the manifold, venture suction, to provide pulsing
injections at 3.times.1 to 3.times.3 spacing as described. The
result of this and other modifications is that a compacted failing
turf is de-compacted cabled, and disinfected for a long period of
time or use.
[0063] A method 500 for de-compacting and disinfecting the infield
is illustrated in FIG. 7. Method 500 includes the kicking out of
infield material at step 505. The kicking out of material may be by
the injection blast. The injection blast may be set at an angle and
pulse rate. An angle between 15-0 degrees may be used for
injections to provide a clean level surface after injection. Use of
angles outside of this range may still provide de-compaction and
other benefits, but with lessening efficiency. For example, other
angles up to 25 degree may be used with less effective results.
Approximately 10 degrees including a range of 8-11 degrees provides
measured benefits in de-compaction.
[0064] At step 510 the mixing of the existing de-compacted,
decomposed and deteriorated infield material with new fresh clean
infield material occurs. This mixing may occur in the hopper, for
example. New infield material is injected at step 515. This new
infield material may be completely new infield material that mixes
with the old infield material upon injection or application, or it
may be a mixture of new and old infield material for injection or
application. The use of water at 2200 to 2500 psi to carry the
infield material into the field profile may cause the mixing of the
new (and old) injected infield material with current used material.
This injection may occur at a rate up to 12 cubic feet per 1000
square feet of treated area. Kicking the bent and depressed turf
fibers back to an upright position at step 520. The kicking of the
turf fibers may occur simultaneously with the injection of step 515
allowing the back fill of the treated field with new material to
realign the fibers, as well. This creates a stabilized effect and
foundation to hold fibers in the upright position. The kicking of
step 520 may be performed by the injection manifold with 7-32
injectors set at a predetermined angle. Pivoting the injectors in
multiple directions at step 525 allows the machine to operate in
multiple directions. For example, the injectors may be pivoted in
two directions allowing the machine to operate in two directions.
Swivel injectors may be used opposite the direction of travel of
the device described below.
[0065] Method 500 may also include mixing water absorbent polymer
particles with additives for inclusion with the fibers and material
at step 530. This mixing may include blending a water absorbent
polymer with food grade emulsifier, stabilizers, preservatives and
growth enhancers to form a polymer blend, coating the polymer blend
with an agent to retard absorption of water, and formulating the
coated polymer blend into a liquid. This liquid may then be applied
at step 535 to the fibers and material before, during or after
injection at step 515. Step 535 of injecting a water absorbent
polymer blend into or onto the field may aid in lowering the
temperature of the playing surface. Injecting at step 535 may be
performed by mixing the liquid with water and injecting into the
field structure, for example.
[0066] Method 500 may also include injecting disinfectants at step
540. The disinfectants may be applied at step 540 to the fibers and
material before, during or after injection at steps 515 and/or 535.
The disinfecting of step 540 simultaneously with injecting of step
515 of dry infield materials and kicking at step 505 out of old
worn deteriorated, infected infield material may result in much
better coverage and results in application of the disinfectant. The
combination may create a much greater zone of treatment, better
coverage (top to bottom) compared to existing topical and other
existing service options. The disinfecting results in much more
complete disinfecting of the total turf area. This new zone of
treatment is deep into the previously hard, compacted and
impenetrable areas of the infield material down to the turf
backing.
[0067] The kicking out of step 505 in conjunction with the
injection of step 515 with high volumes of new infield material may
dilute the broken down failing existing infield material as a
percentage of all the infield material. This will result in less
compaction, higher infiltration rates and safer turf. The injection
of new infield material at step 515 in combination with the
existing material as a routine maintenance program to synthetic
turf 1-5 times per year will result in significant turf life
extension. In 6-10 hours this injection service can accomplish turf
rescue that replenishes the turf to a safe level (G MAX numbers of
approximately 165) at substantially less labor, energy, and cost of
other field maintenance services. This extends the life of the turf
thus postponing the turf replacement investment for a period of
time.
[0068] The use of the present process and apparatus produced
improved playing surfaces. Testing has been performed using to
determine the influence of the system on the addition of crumb
rubber into a synthetic surface that is near end-of-life and to
determine if a polymer added by the process described herein may
lower synthetic turf surface temperatures.
[0069] The testing is performed using Astroturf GameDay 360 (a
blend of monofilament and slit film) synthetic turf installed over
a gravel base. Prior to treatment applications the test field
received 300 simulated traffic events using the Baldtree traffic
simulator (BTS). Surface hardness measurements for the test field
ranged between 200-206 GMAX with the F355 Apparatus A device, and
149-155 GMAX with the Clegg Impact Soil Tester. The test field was
not within compliance for the ASTM (200 GMAX with F355), Synthetic
Turf Council (165 GMAX with F355), and NFL (100 GMAX with Clegg)
surface hardness thresholds, respectively. All plots were groomed
using a brush to standup the turf fibers prior to rescue
treatments. The presently described recue treatment is performed
using the described apparatus using a 3''.times.2'' spacing to
incorporate either crumb rubber and/or sand infill.
[0070] Surface hardness was collected using the F355 Apparatus A
(F355) and Clegg Impact Surface Tester (CIST). The F355 is the
current ASTM and STC standard device for measuring surface hardness
on synthetic turf. The CIST was also used due to its common use on
natural turf athletic fields, and its current use for testing all
surfaces on National Football League Stadiums. Additionally, it has
been reported that infill depth is highly correlated to surface
hardness. Therefore, infill depth was collected every time surface
hardness data were taken. With increasing traffic, infill depths
decreased likely due to walk-off rubber and infill compaction
(settling) from simulated traffic events as described
hereinabove.
[0071] Results indicate that the treatment with two passes of crumb
rubber using the described process and apparatus provided a
decrease in surface hardness with new results of 151 GMAX. Two
passes of crumb rubber (177 GMAX) significantly (P<0.001)
reduced the surface hardness for 150 simulated traffic events.
[0072] One pass of crumb rubber injection only (174 GMAX)
significantly (P<0.001) reduced the surface hardness for 100
simulated traffic events compared to the brushing only (167 GMAX)
treatment.
[0073] Injection of sand (172 GMAX) did not reduce surface hardness
compared to the brushing alone (165 GMAX) treatment. The two passes
of crumb rubber treatment reduced surface hardness below the STC's
acceptable surface hardness threshold of 165 GMAX. The two passes
injecting crumb rubber significantly reduced surface hardness below
the acceptable STC 165 GMAX threshold of these acceptable values
were maintained over 100 simulated traffic events
[0074] Similar results were found to the F355 for surface hardness
data. Results indicated that with two passes of crumb rubber
treatment significantly (P<0.001) decreased the surface hardness
to 59 GMAX. The treatment with one crumb rubber injection (112
GMAX) pass was effective at significantly (P<0.001) decreasing
the surface hardness; however, it did not have as large of a
reduction as the treatment with two passes of crumb rubber
injection (96 GMAX). The two pass crumb rubber injection (96 GMAX)
treatment was the only treatment that went below the NFL's
acceptable surface hardness threshold of 100 GMAX.
[0075] The treatment with two passes of injecting crumb rubber
reduced surface hardness below the acceptable NFL 100 GMAX
threshold. Through 150 simulated events, the treatment with two
passes of crumb rubber significantly (P<0.001) reduced surface
hardness of a worn synthetic turf surface greater than all other
treatments.
[0076] Having thus described various methods, configurations, and
features of the present poppet valve in detail, it is to be
appreciated and will be apparent to those skilled in the art that
many physical changes, only a few of which are exemplified in the
detailed description above, could be made in the apparatus and
method without altering the inventive concepts and principles
embodied therein. The present embodiments are therefore to be
considered in all respects as illustrative and not restrictive, the
scope of the invention being indicated by the appended claims
rather than by the foregoing description, and all changes which
come within the meaning and range of equivalency of the claims are
therefore to be embraced therein.
* * * * *