U.S. patent application number 15/709420 was filed with the patent office on 2018-03-22 for organic infill for artificial turf fields.
The applicant listed for this patent is Tarkett Inc.. Invention is credited to Nicolas AUMONIER, Darren GILL, Jason SMOLLETT.
Application Number | 20180080182 15/709420 |
Document ID | / |
Family ID | 61618081 |
Filed Date | 2018-03-22 |
United States Patent
Application |
20180080182 |
Kind Code |
A1 |
AUMONIER; Nicolas ; et
al. |
March 22, 2018 |
ORGANIC INFILL FOR ARTIFICIAL TURF FIELDS
Abstract
The present invention relates to organic infill for artificial
turf fields. The organic infill includes at least one layer of
particles having walnut shell particles. At least 1% of the walnut
shell particles are particles that have a sieve size of 50 or
smaller sized particles. The at least one layer can further include
walnut shell particles in other sieve ranges, sand, or both, and be
intermixed in the at least one layer. The organic infill can also
include a layer of sand overlaying a backing of an artificial turf
field. The at least one layer overlays on the sand layer. The
organic infill can further include a layer of walnut shell
particles or extruded composite. The layer includes walnut shell
particles having a sieve range different from the sieve range in
the at least one layer. The layer overlays on the at least one
layer.
Inventors: |
AUMONIER; Nicolas;
(Montreal, CA) ; GILL; Darren; (Pincourt, CA)
; SMOLLETT; Jason; (Kirkland, CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Tarkett Inc. |
Farnham |
|
CA |
|
|
Family ID: |
61618081 |
Appl. No.: |
15/709420 |
Filed: |
September 19, 2017 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
62397295 |
Sep 20, 2016 |
|
|
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
E01C 13/08 20130101 |
International
Class: |
E01C 13/08 20060101
E01C013/08 |
Claims
1. An infill composition for artificial turf fields comprising: at
least one layer of particles comprising walnut shell particles, the
walnut shell particles include walnut particles that have a sieve
size of 50 or smaller sized particles, and the walnut particles
that have a sieve size of 50 or smaller sized particles are between
about 1% and about 5% by weight of the walnut shell particles.
2. The infill composition of claim 1, wherein the at least one
layer is applied over a backing of an artificial turf field and is
interspersed between artificial fibers.
3. The infill composition of claim 1, wherein the infill is an
organic infill that is without or is almost entirely without
containing rubber or similar materials.
4. The infill composition of claim 1, wherein the remainder of the
walnut shell particles in the layer includes an amount of walnut
shell particles in the 10-40 sieve range, wherein the amount of
walnut shell particles in the 10-40 sieve range is 50% or higher by
weight of the walnut shell particles.
5. The infill composition of claim 1, wherein the at least one
layer is made entirely from walnut shell particles.
6. The infill composition of claim 1, wherein the walnut shell
particles are raw or untreated crushed walnut shells.
7. The infill composition of claim 1, wherein the walnut shell
particles further comprise walnut shell particles in a first sieve
range, wherein the walnut shell particles in the first sieve range
include walnut shell particles larger than the particles having a
sieve size of 50 or smaller.
8. The infill composition of claim 7, wherein the amount of the
walnut shell particles in the first sieve range is above 90% by
weight of the walnut shell particles.
9. The infill composition of claim 7, wherein the first sieve range
is from 14 to 40.
10. The infill composition of claim 7, wherein the walnut shell
particles in the first sieve range and the particles between about
1% and about 5% by weight of the walnut shell particles are
intermixed in the at least one layer.
11. The infill composition of claim 7, wherein the at least one
layer of particles further comprises sand.
12. The infill composition of claim 11, wherein the particles
between about 1% and about 5% by weight of the walnut shell
particles, the walnut shell particles in the first sieve range, and
the sand are intermixed in the at least one layer of particles.
13. The infill composition of claim 1, wherein the particles
between about 1% and about 5% by weight of the walnut shell
particles are particles that have a sieve size from 50 to 100.
14. The infill composition of claim 1, wherein the at least one
layer of particles further comprising sand in a sieve size range
from 20 to 50.
15. The infill composition of claim 14, wherein the walnut shell
particles and the sand are intermixed in the at least one
layer.
16. The infill composition of claim 1, further comprising a second
layer of particles comprising sand overlaying a backing of an
artificial turf field.
17. The infill composition of claim 16, wherein the least one layer
overlays the second layer.
18. The infill composition of claim 17, further comprising a third
layer of walnut shell particles or extrude composite, wherein the
third layer overlays the least one layer.
19. The infill composition of claim 18, wherein the walnut shell
particles further comprise walnut shell particles in a first sieve
range, and the walnut shell particles in the first sieve range
include walnut shell particles larger than the particles having a
sieve size of 50 or smaller.
20. The infill composition of claim 19, wherein the walnut shell
particles in the third layer are in a second sieve range that is
different from the first sieve range.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional
Application 62/397,295, filed on Sep. 20, 2016, the entirety of
which is herein incorporated by reference.
FIELD OF THE INVENTION
[0002] Embodiments of the present invention relate to organic
infill for artificial turf fields. More particularly, the
embodiments relate to organic infill comprising walnut shell
particles.
BACKGROUND OF INVENTION
[0003] There is currently a potential trend and related search with
respect to new infill materials and compositions for artificial
turf fields. A particular focus has been towards developing an
infill that uses organic materials. For example, some customers of
infill materials have sought to reduce or eliminate the use of
certain compounds such as recycled rubber for the infill of their
artificial turf fields.
[0004] As a matter of background, a significant amount of
engineering and development is devoted to developing artificial
turf field systems. With respect to the infill, each kind of
material often times has its own performance and structural
characteristics. Obtaining the right composition and arrangement of
materials can be challenging.
SUMMARY OF THE INVENTION
[0005] In accordance with principles of the present invention, an
infill composition for artificial turf fields is contemplated. In
one embodiment, the infill composition comprises at least one layer
of particles comprising walnut shell particles. The walnut shell
particles include walnut particles that have a sieve size of 50 or
smaller sized particles. The walnut particles that have a sieve
size of 50 or smaller sized particles are between about 1% and
about 5% by weight of the walnut shell particles.
[0006] In one embodiment, the at least one layer is applied over a
backing of an artificial turf field and is interspersed between
artificial fibers.
[0007] In one embodiment, the infill is an organic infill that is
without or is almost entirely without containing rubber or similar
materials.
[0008] In one embodiment, the remainder of the walnut shell
particles in the layer includes an amount of walnut shell particles
in the 10-40 sieve range. The amount of walnut shell particles in
the 10-40 sieve range is 50% or higher by weight of the walnut
shell particles.
[0009] In one embodiment, the at least one layer is made entirely
from walnut shell particles.
[0010] In one embodiment, the walnut shell particles are raw or
untreated crushed walnut shells.
[0011] In one embodiment, the walnut shell particles further
comprise walnut shell particles in a first sieve range. The walnut
shell particles in the first sieve range include walnut shell
particles larger than the particles having a sieve size of 50 or
smaller.
[0012] In one embodiment, the amount of the walnut shell particles
in the first sieve range is above 90% by weight of the walnut shell
particles. The first sieve range may be from 14 to 40. The walnut
shell particles in the first sieve range and the particles between
about 1% and about 5% by weight of the walnut shell particles may
be intermixed in the at least one layer. The at least one layer of
particles may further comprise sand. The particles between about 1%
and about 5% by weight of the walnut shell particles, the walnut
shell particles in the first sieve range, and the sand may be
intermixed in the at least one layer of particles.
[0013] In one embodiment, the particles between about 1% and about
5% by weight of the walnut shell particles are particles that have
a sieve size from 50 to 100.
[0014] In one embodiment, the at least one layer of particles
further comprises sand in a sieve size range from 20 to 50. The
walnut shell particles and the sand may be intermixed in the at
least one layer.
[0015] In one embodiment, the infill composition further comprises
a second layer of particles including sand overlaying a backing of
an artificial turf field. The least one layer overlays the second
layer. The infill composition may further comprises a third layer
of walnut shell particles or extrude composite, and the third layer
overlays the least one layer. The walnut shell particles further
comprise walnut shell particles in a first sieve range. The walnut
shell particles in the first sieve range may include walnut shell
particles larger than the particles having a sieve size of 50 or
smaller The walnut shell particles in the third layer may be in a
second sieve range that is different from the first sieve
range.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] FIG. 1 depicts illustrative infill having a layer of crushed
shells that includes a combination of large and fine walnut shell
particles in accordance with some embodiments of the present
invention;
[0017] FIG. 2 depicts illustrative infill comprising fine walnut
shell particles and sand in separate layers in accordance with some
embodiments of the present invention;
[0018] FIG. 3 depicts illustrative infill comprising a layer of
fine walnut shell particles and sand intermixed in accordance with
sonic embodiments of the present invention;
[0019] FIG. 4 depicts illustrative infill comprising a layer of
sand and a layer of walnut shell particles of two different
particle size ranges in accordance with some embodiments of the
present invention;
[0020] FIG. 5 depicts illustrative infill comprising a first layer
of sand and a second layer of walnut shell particles and sand in
accordance with some embodiments of the present invention;
[0021] FIG. 6 depicts the infill in FIG. 5 further comprising a
third layer of walnut shell particles or extruded composite in
accordance with some embodiments of the present invention;
[0022] FIG. 7 depicts illustrative infill comprising a first layer
of sand, a second layer of walnut shell particles and sand, and a
third layer of extruded composite in accordance with some
embodiments of the present invention; and
[0023] FIG. 8 provides an illustrative particle size distribution
for crushed walnut shell particles for use in a layer above the
sand layer in accordance with some embodiments of the present
invention.
[0024] The components in the figures are not necessarily to scale,
emphasis instead being placed upon illustrating the principles of
the invention. Moreover, all illustrations are intended to convey
concepts, where relative sizes, shapes and other detailed
attributes may be illustrated. schematically rather than literally
or precisely.
DETAILED DESCRIPTION OF THE INVENTION
[0025] In accordance with principles of the present invention,
embodiments of the present invention are directed to using crushed
walnut shells as a primary portion of the infill for an artificial
turf field. Infill, as shown in FIG. 1, refers to material that is
deposited over the turf backing 120 and forms a layer 105 around
the turf fibers 125. Infill is interspersed between the turf fibers
125 rising out of the turf backing 120. Infill generally has a
depth that covers a portion of the turf fiber (unexposed portion of
the turf fiber) leaving part of the turf fiber extending above the
infill (exposed portion of the turf fiber). Infill helps support
the turf fibers 125 in an upright position and is used to provide
traction and shock absorption. In some embodiments, the infill 105
comprises a layer of crushed shells that include a combination of
large 110 and fine 115 walnut shell particles and in particular,
the walnut shell particles (in the infill) include fine walnut
shell particles 115 that have particle sizes that are 0.595 mm and
lower, preferably 0.420 mm and lower, more preferably lower than
0.297, and even more preferably lower than 0.297 and higher than or
equal to 0.149 mm. Preferably, these fine walnut shell particles
115 are at least 1.0% (and no more than 10% or preferably no more
than 5%) by weight of the crushed shells in that layer and the
large walnut shell particles 110 are also contained in that layer
such as by containing about 50% by weight of the crushed shells or
preferably above 90% by weight of the crushed shells. In some
embodiments, the infill 105 when installed comprises a layer of
crushed shells that consists essentially of large 100 and fine 115
walnut shell particles, wherein at least 1% (and no more than 10%
or preferably no more than 5%) by weight of the crushed shells in
that layer are particles that have a seize size of 50 or smaller
size particles. From initial testing, it has been found that
including the fine walnut shell particles in combination with the
larger walnut shell particles provides improved performance
athletic fields, namely a more stable surface, providing better
foot stability and playability. In application, a composition of
crushed walnut shells is prepared and delivered to a field for
installation. The composition of the walnut shells is provided to
have the illustrative particle size and percentage weight
characteristics that are described in or understood from the
disclosure herein. Thus, it would for example provide one of the
source materials that are used in installing the infill on the
field.
[0026] As a general matter, various types of infill arrangements
are contemplated. For example, two layer, three layers, or other
arrangements are contemplated. For convenience, the present
description primarily discusses two and three layer embodiments.
Embodiments of the present invention are directed to providing
organic infill solutions. The materials that are discussed are
primarily sand and crushed walnut shells but it should be
understood that other materials can be included or substituted. In
some embodiments, the infill material is directed to having the
crushed walnut shells, in effect, replace crumb rubber infill
materials. As such, the infill is devoid or substantially devoid of
crumb rubber or similar materials. For example, in such
embodiments, one layer of the infill (e.g., one of the multiple
layers in the infill) can be made entirely (100% by weight),
substantially (e.g., 65% or higher or 75% or higher by weight),
primarily (e.g., 50% or higher by weight), or predominantly (e.g.,
45% or higher by weight, or a percentage by weight that is higher
than the percentage by weight of any other particle or sand in the
same layer) of the crushed walnut particles. In sonic embodiments,
that layer when installed can consist essentially of the crushed
walnut particles, wherein at least 1% (and no more than 10% or
preferably no more than 5%) by weight of the crushed walnut
particles in that layer are particles that have a seize size of 50
or smaller size particles. In some embodiments, the infill can be
only one layer, and the only layer can be made entirely (100% by
weight), substantially (e.g., 65% or higher or 75% or higher by
weight), primarily (e.g., 50% or higher by weight), or
predominantly (e.g., 45% or higher by weight, or a percentage by
weight that is higher than the percentage by weight of any other
particle or sand in the layer) of the crushed walnut particles. In
some embodiments, the only one layer when installed can consist
essentially of the crushed walnut particles, wherein at least 1%
(and no more than 10% or preferably no more than 5%) by weight of
the crushed walnut particles in that layer are particles that have
a seize size of 50 or smaller size particles. The walnut shells can
provide shock absorbency and traction. It is possible for the
infill layer to include other organic materials or other
materials.
[0027] The following description provides a number of examples of
embodiments of the present invention.
[0028] The infill may include or comprise fine walnut shell
particles in a particular size range (e.g., as specified by a range
of sieve-sizes). The range of sieve-sizes may be from 30 to 200
(i.e., 0.595 mm-0.074 mm), and preferably 50 to 100 (i.e., 0.297
mm-0.149 mm). In some embodiments, the infill may comprise sand
(e.g., in a layer) that is in a particular size range. The range of
sieve-sizes for sand may be from 20 to 50 (i.e., 0.841 mm-0.297
mm). The infill may comprise the aforementioned fine walnut shell
particles and sand in separate layers (one overlaying the other) or
they are preferably intermixed as shown in FIGS. 2-3. FIG. 2
depicts illustrative infill 205 comprising fine walnut shell
particles and sand in separate layers. The first layer 210
(sequentially in the order of layers from bottom to top, where
bottom is closest to the ground) is preferably a sand layer. In a
second layer 215, the infill may comprise fine particles. The
second layer 215 may comprise the aforementioned fine walnut shell
particles, the aforementioned fine sand, or a combination thereof.
When the second layer 215 includes both the fine walnut shell
particles and the sand, the fine walnut shell particles and the
sand are preferably intermixed. FIG. 3 depicts illustrative infill
305 comprising a layer 310 of fine walnut shell particles and sand
intermixed. In some embodiments, the layer 310 when installed
consists essentially of fine walnut shell particles and sand,
wherein at least 1% (and no more than 10% or preferably no more
than 5%) by weight of the fine walnut particles in that layer 310
are walnut particles that have a seize size of 50 or smaller size
particles.
[0029] As a precaution, the present description uses the word "may"
in order to avoid an understanding that only the specific
embodiments that are described are contemplated by the scope of the
invention.
[0030] In some embodiments, as shown in FIG. 4, the infill 405 may
comprise a layer 410 of sand and a layer 415 of walnut shell
particles of two different particle size ranges. The layer 415 of
walnut shell particles may comprise walnut shell particles A in a
first particle size range and walnut shell particles B in a second
particle size range that is different from or includes at least
some smaller particles than the first particle size range. The
second layer 415 can include walnut shell particles that are in
both ranges and are preferably intermixed. The walnut shell
particles A in the first range may be considered as large particles
whereas walnut shell particles B in the second range may be
considered as fine particles. The two ranges can overlap, but the
fine particles are preferably at least 2% by weight of the layer of
walnut shell particles. In some embodiments, the layer 415 when
installed consists essentially of the different size range walnut
shell particles, wherein at least 1% (and no more than 10% or
preferably no more than 5%) by weight of the different size range
walnut shell particles in that layer 415 are walnut particles that
have a seize size of 50 or smaller size particles.
[0031] In one illustration of embodiments, the infill may comprise
a first layer of sand and a second layer of walnut shell particles
(refers to crushed walnut shell particles). The second layer may
include walnut shell particles in a first range of sieve-sizes from
8 to 50 (i.e., 2.38 mm-0.297 mm), preferably from 14 to 40 (i.e.,
1.41 mm-0.420 mm), and more preferably from 14 to 30 (i.e., 1.41
mm-0.595 mm) The second layer may also include walnut shell
particles in a second range of sieve-sizes from 30 to 200 (i.e.,
0.595 mm-0.074 mm) and preferably from 50 to 100 (i.e., 0.297
mm-0.149 mm). In some embodiments, the second layer when installed
consists essentially of walnut shell particles in the first range
and walnut shell particles in the second range, wherein at least 1%
(and no more than 10% or preferably no more than 5%) by weight of
the walnut shell particles in the first and second range in the
second layer are walnut particles that have a seize size of 50 or
smaller size particles.
[0032] In another illustration, as shown in FIG. 5, the infill 505
may comprise a first layer 510 of sand and a second layer 515 of
walnut shell particles and sand. The second layer 515 may include
walnut shell particles C in a first range of sieve-sizes from 8 to
50, preferably from 14 to 40, and more preferably from 14 to 30.
The second layer 515 may also include walnut shell particles D in a
second range of sieve-sizes from 50 to 100, and preferably from 30
to 200. The amount of walnut shell particles C in the first range
is preferably 70% or higher (e.g., 90%) by weight (e.g., of that
layer) and the amount of walnut shell particles D in the second
range is preferably 20% or lower (e.g., 2%) by weight (e.g., of
that layer). The second layer 515 may further include sand E. The
sand E may have a sieve-size in the range of 20 to 50 (i.e., 0.841
mm-0.297 mm). Thus, the second layer 515 may include walnut shell
particles C, Din both ranges and sand E and are preferably
intermixed. In some embodiments, the layer 515 when installed
consists essentially of walnut shell particles in the first,
second, and third range of sieve-sizes and sand, wherein at least
1% (and no more than 10% or preferably no more than 5%) by weight
of the walnut shell particles in the first, second, and third range
of sieve-sizes in that layer 415 are walnut particles that have a
seize size of 50 or smaller size particles.
[0033] In the above embodiments, the infill 605, as shown in FIG.
6, may further comprise a third layer 520 of walnut shell particles
or extruded composite. The third layer 520 may include walnut shell
particles F in a third range of sieve-sizes that is different from
or larger than the first range of sieve-sizes. Preferably, the
third range is from 10 to 14 (i.e., 2.00 mm-1.41 mm). As noted, it
possible that the range can overlap with the other ranges. The
third layer 520 can provide a function such as to assist in cooling
or temperature control.
[0034] In any of the embodiments described in this application, the
walnut shell particles are preferably raw or untreated crushed
walnut shells. For example, the preferred walnut shell particles
are shells that have not been treated with anti-microbial
additives. The walnut shells are preferably English walnut shells.
Crushed walnut shells are shells produced by applying mechanical
force to raw or untreated walnut shells to break raw or untreated
walnut shells into smaller pieces of walnut shells. In some
embodiments, raw or untreated walnut shells (not crushed) may also
be used. Also in any of the embodiments described in this
application, the first layer of sand is disposed closer to the
backing of the artificial turf compared to the second layer of
walnut shell particles or the second layer of walnut shell
particles and sand. Also in any of the embodiments described in
this application, the third layer of walnut shell particles is
disposed further from the backing of the artificial turf compared
to the second layer of walnut shell particles or the second layer
of walnut shell particles and sand. Also in any of the embodiments
described in this application, the first layer of sand may comprise
sand having a sieve-size in the range of 20 to 50. The first layer
of sand may also be known as a ballast layer or a stabilizing
layer. Also in any of the embodiments described in this
application, the first layer may be a layer made of material(s)
that has characteristics or performance like sand or a layer made
of sand and other material(s) that has characteristics or
performance like sand. Also in any of the embodiments described in
this application, each layer in the infill may have the same or
different thicknesses, and the thickness may be modified to meet
specific performances. For example, the first layer (the sand
layer) may have a thickness between 1/8'' and 3/4'', the second
layer (the layer containing walnut shell particles only or both
walnut shell particles and sand) may have a thickness between 1/2''
and 11/2'', and the third layer (the layer containing walnut shell
particles or extruded composite) may have a thickness between 1/8''
and 1''.
[0035] For example, referring to FIG. 7, the infill 705 may
comprise a first layer 710 of sand F, a second layer 715 of walnut
shell particles G, H and sand I, and a third layer 720 of extruded
composite. In the first layer 710, the sand F may have a range of
sieve-sizes from 20-50. The sand F may be disposed on the backing
725 of an artificial turf 730. In the second layer 715, the sand I
may have a range of sieve-sizes from 20-50 and the walnut shell
particles may have a range of sieve-sizes from 14-30 (particles G).
The walnut shell particles includes shell particles that fall into
sieve 50-100 size at 2.5% by weight of the second layer 715
(particles H). Thus, the second layer 715 may include walnut shell
particles G, H and sand I and are preferably intermixed. The
intermixed walnut shell particles G, H and sand I may be disposed
on the first layer 710. In the third layer 720, the extruded
composite may be disposed on the second layer 715. In some
embodiments, the second layer 715 consists essentially of walnut
shell particles G, H and sand I, wherein at least 1% (and no more
than 10% or preferably no more than 5%) by weight of the walnut
shell particles G, in that layer 715 are walnut particles that have
a seize size of 50 or smaller size particles.
[0036] FIG. 8 provides an illustrative particle size distribution
for crushed walnut shell particles for use in a layer above the
sand layer. As shown, the significant portion of the particle size
distribution is constituted by sieve sizes 14-30. It can include
other sieve sizes. In particular it includes particles below 50
sieve at 2% by weight, which is described above. The inclusion
provides enhanced performance.
[0037] In implementation, the turf system may typically also
include the installation of pad that are position under the backing
to provide additional shock absorption.
[0038] In any of the above embodiments, the illustrative weight
percentages can mean approximate weight percentages, instead of
exact weight percentages. The term approximate or about means
.+-.0.5%, preferably .+-.0.2%, and more preferably .+-.0.1% of the
illustrative weight percentage. For example, approximate or about
5% by weight means between and including 4.9% and 5.1% by
weight.
[0039] Exemplary infills, artificial turfs, and turf systems are
described for illustrative purposes. Further, since numerous
modifications and changes will readily be apparent to those having
ordinary skill in the art, it is not desired to limit the invention
to the exact constructions as demonstrated in this disclosure.
Accordingly, all suitable modifications and equivalents may be
resorted to falling within the scope of the invention. Applications
of the technology to other fields are also contemplated.
[0040] It should be understood that combinations of described
features or steps are contemplated even if they are not described
directly together or not in the same context.
[0041] It is to be understood that additional embodiments of the
present invention described herein may be contemplated by one of
ordinary skill in the art and that the scope of the present
invention is not limited to the embodiments disclosed. While
specific embodiments of the present invention have been illustrated
and described, numerous modifications come to mind without
significantly departing from the spirit of the invention, and the
scope of protection is only limited by the scope of the
accompanying claims.
* * * * *