U.S. patent application number 16/306701 was filed with the patent office on 2019-05-16 for artificial turf.
The applicant listed for this patent is Beaulieu International Group NV. Invention is credited to Mathijs (Marc) BEAUPREZ, Didier DEJAEGHERE, Marc VERLEYEN.
Application Number | 20190145057 16/306701 |
Document ID | / |
Family ID | 56119381 |
Filed Date | 2019-05-16 |
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United States Patent
Application |
20190145057 |
Kind Code |
A1 |
BEAUPREZ; Mathijs (Marc) ;
et al. |
May 16, 2019 |
ARTIFICIAL TURF
Abstract
Artificial turf (100) comprising a. a backing (200) having an
upper and a lower surface; and b. a plurality of first synthetic
grass fibers (300) attached to and extending upward from the upper
surface of said backing; and c. a plurality of second synthetic
grass fibers (400) attached to and extending upward from the upper
surface of said backing; wherein the height of the first synthetic
grass fibers is higher than the height of the second synthetic
grass fibers.
Inventors: |
BEAUPREZ; Mathijs (Marc);
(Sint-Amandsberg, BE) ; DEJAEGHERE; Didier;
(Deinze, BE) ; VERLEYEN; Marc; (Hulste,
BE) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Beaulieu International Group NV |
Waregem |
|
BE |
|
|
Family ID: |
56119381 |
Appl. No.: |
16/306701 |
Filed: |
June 8, 2017 |
PCT Filed: |
June 8, 2017 |
PCT NO: |
PCT/EP2017/064013 |
371 Date: |
December 3, 2018 |
Current U.S.
Class: |
428/17 |
Current CPC
Class: |
D05C 15/22 20130101;
D05C 15/12 20130101; E01C 13/08 20130101; D10B 2505/202
20130101 |
International
Class: |
E01C 13/08 20060101
E01C013/08; D05C 15/12 20060101 D05C015/12; D05C 15/22 20060101
D05C015/22 |
Foreign Application Data
Date |
Code |
Application Number |
Jun 10, 2016 |
EP |
16174026.1 |
Claims
1. Artificial turf comprising a. a backing having an upper and a
lower surface; b. a plurality of first synthetic grass fibers
attached to and extending upward from the upper surface of said
backing; and c. a plurality of second synthetic grass fibers
attached to and extending upward from the upper surface of said
backing; wherein the height of the first synthetic grass fibers is
higher than the height of the second synthetic grass fibers.
2. Artificial turf according to claim 1, wherein the first
synthetic grass fibers have a height from 20 mm to 80 mm.
3. Artificial turf according to claim 1, wherein the second
synthetic grass fibers have a height from 10 mm to 70 mm.
4. Artificial turf according to claim 1, wherein the average height
difference between the first and second synthetic fibers is at
least 6 mm.
5. Artificial turf according to claim 1, wherein said artificial
turf comprises said first synthetic grass fibers having a height
from 35 mm to 80 mm and said second synthetic grass fibers having a
height from 25 mm to 65 mm, wherein the average height difference
between the first and second synthetic grass fibers is at least 6
mm.
6. Artificial turf according to claim 1, wherein said artificial
turf comprises said first synthetic grass fibers having a height
from 20 mm to 40 mm and said second synthetic grass fibers having a
height from 10 mm to 34 mm, wherein the average height difference
between the first and second synthetic grass fibers is at least 6
mm.
7. Artificial turf according to claim 1, wherein said synthetic
grass fibers are upright oriented cut-pile fibers.
8. Artificial turf according to claim 1, wherein the respective
synthetic grass fibers are arranged in bundles of synthetic grass
fibers.
9. Artificial turf according to claim 1, wherein the first and
second synthetic grass fibers are arranged in different rows.
10. Artificial turf according to claim 9, wherein rows of said
first and second synthetic grass fibers are arranged in a random
pattern, with the provision that a row of said first synthetic
fibers is present after not more than 3 rows of said second
synthetic grass fibers.
11. Artificial turf according to claim 9, wherein the first
synthetic grass fibers are randomly tufted across the artificial
turf.
12. Artificial turf according to claim 1, wherein the first and
second synthetic fibers have a different cross-section, colour,
colour hue, dtex, resiliency or any combination thereof.
13. Artificial turf according to claim 8, wherein the synthetic
fibers within a given bundle of fibers, have a different
cross-section, colour, colour hue, dtex, resiliency or any
combination thereof.
14. Artificial turf according to claim 1, further comprising thatch
yarns, said thatch yarns.
15. Artificial turf according to claim 1, in the form of tiles.
16. Artificial turf according to claim 2, wherein the second
synthetic grass fibers have a height from 10 mm to 70 mm.
17. Artificial turf according to claim 1 6, wherein the average
height difference between the first and second synthetic fibers is
at least 6 mm.
18. Artificial turf according to claim 14 wherein said thatch yarns
are present in the bundles of said second synthetic grass
fibers.
19. Artificial turf according to claim 1 5 wherein s aid tiles
comprise interlocking means.
20. Artifical turf according to claim 1, wherein the average height
difference between the first and second synthetic fibers is at
least 10 mm.
Description
TECHNICAL FIELD
[0001] The present invention relates to artificial turf, in
particular for landscaping.
BACKGROUND OF THE INVENTION
[0002] Artificial turf is a surface of synthetic fibers made to
look like natural grass. It is often used as a sportsfield, a
playground, a residential lawn or for landscaping purposes.
[0003] Artificial turf comes in various qualities, from low-end
mats with limited quality to high-end mats with a more natural look
or improved comfort and quality for sports.
[0004] The cheapest qualities typically are low-pile mats wherein
the synthetic fibers are flat-shaped tapes. These mats have a
reduced lifetime and beyond the fact that they are green, do not
resemble real grass.
[0005] The high-end qualities come in different forms, depending on
the use of the mats. For sports, the mats are configured to provide
sufficient comfort (shock-absorption), resiliency and elasticity
(e.g. for good ball bouncing effect), and may comprise infills.
Professional sports-turf is moreover bound to specific
requirements, set by sports federations such as FIFA. For
residential lawns and landscape, the requirements are somewhat
different, with the biggest requirement that they look like natural
grass.
[0006] Despite the many efforts to make artificial turf look more
natural, there is still a need for further improvement.
[0007] It is therefore an object of the present invention to
provide artificial turf that looks more natural than artificial
turf available today.
[0008] It is a further object of the present invention to provide
high-pile natural-looking grass that can be made in an economical
way.
SUMMARY OF THE INVENTION
[0009] The present invention relates to artificial turf comprising
[0010] a. a backing having an upper and a lower surface; and [0011]
b. a plurality of first synthetic grass fibers attached to and
extending upward from the upper surface of said backing; and [0012]
c. a plurality of second synthetic grass fibers attached to and
extending upward from the upper surface of said backing;
[0013] characterised in that the height of the first synthetic
grass fibers is higher than the height of the second synthetic
grass fibers.
DRAWINGS
[0014] FIG. 1 shows an artificial turf (100) according to an
embodiment of the present invention, comprising a backing (200), a
plurality of first synthetic grass fibers (300), and a plurality of
second synthetic grass fibers (400). The first synthetic grass
fibers (300) are longer than the second synthetic grass fibers
(400).
[0015] FIG. 2 shows an another embodiment of an artificial turf
(100) of the present invention, comprising thatch yarns (500).
DETAILED DESCRIPTION OF THE INVENTION
[0016] Artificial turf according to the present invention comprises
a backing. The term "backing" as used herein refers to a substrate,
preferably a thermoplastic substrate, which can be woven or
nonwoven. The backing has an upper and a lower surface, and the
backing is configured for supporting synthetic grass fibers.
[0017] The term "synthetic grass fibers" as used herein, refers to
elongated objects which are attached to the backing. When attached
to the backing, the synthetic grass fibers protrude from the upper
surface of the backing, and form the grass surface. Synthetic grass
fibers include synthetic extruded fibers (monofilaments) and
(slit-film) tapes.
[0018] Preferably, the artificial fibers are arranged in bundles,
preferably in bundles of monofilaments. The synthetic grass fibers
preferably have a dtex from 250-2500, and one bundle may contain 4
to 20 fibers.
[0019] The synthetic grass fibers are manufactured from materials
chosen from the list comprising polypropylene (PP); any variant of
polyethylene (PE) including low density polyethylene (LDPE), linear
low density polyethylene (LLDPE), and high density polyethylene
(HDPE)); polyester (PET); and polyamide (PA). Preferably, the
synthetic grass fibers are manufactured from LLDPE to provide more
softness and improved resiliency.
[0020] The synthetic grass fibers used in the artificial turf of
the present invention may further comprise additives selected from,
but not limited to, the group of infrared reflectants, UV
stabilisers, fire-retardants, matting agents, luminescent compounds
(phosphorescent or fluorescent compounds), fillers (e.g. chalk,
talk).
[0021] The synthetic grass fibers may have a cross-section selected
from, but not limited to, a rectangular, a diamond-shape, a round,
an elliptical, a multilobal (Y, X), a C-shaped, a V-shaped, a
W-shaped, a S-shaped or a .OMEGA.-shaped cross-section, and have
dimensions of e.g. 50-500 .mu.m thickness and 0.5-5.0 mm width. The
synthetic grass fibers may further comprise a backbone nerve,
and/or a micro-textured surface to resemble grass blade nerves to
further improve the resemblance to natural grass blades. The
synthetic grass fibers are typically in a green colour e.g. a
uni-colour or a mixed shade of green and other colours.
[0022] The synthetic grass fibers may be tufted or woven through
the backing. Preferably, the fibers are tufted through the backing.
In some embodiments, the synthetic grass fibers may be formed in
loop piles or cut piles. The synthetic grass fibers are preferably
arranged in bundles of fibers. Typically, 6-10 and preferably 8
monofilaments are present per bundle.
[0023] The artificial turf of the present invention comprises first
and second synthetic grass fibers which are attached to, and extend
upward from the upper surface of the backing.
[0024] The height of the plurality of first synthetic grass fibers
is higher than the height of the plurality of second synthetic
grass fibers. Preferably, the average difference between the height
of the plurality of first and second synthetic grass fibers is at
least 6 mm, in some embodiments at least 10 mm, but typically less
than 20 mm (but greater height differences are not excluded). The
first synthetic grass fibers preferably have a height from 20 mm to
80 mm. The height of the second synthetic grass fibers is
preferably from 10 mm to 70 mm. The height is determined from the
upper surface of the backing to the top of the extended fibers, in
a normal state of the turf. As there may be some variation in
height between individual fibers, the height of the first and
second synthetic io grass fibers can be determined by taking the
average height of 10 of each of the first and second fibers of the
turf.
[0025] Various height combinations for first and second artificial
fibers are possible, some of which are described hereinafter.
[0026] In one embodiment, the artificial turf is a high-pile turf
and comprises first artificial fibers having a height from 35 mm to
80 mm, and second artificial fibers having a height from 25 mm to
65 mm. The difference in height between first and second synthetic
grass fibers is at least 6 mm, but is preferably at least 10 mm.
This embodiment is a very economical way of creating a high-pile
carpet, yet using a lot less material.
[0027] In another embodiment, the artificial turf is a low-to-mid
pile turf and comprises first artificial fibers having a height
from 20 mm to 40 mm, and wherein the second artificial fibers have
a height from 10 mm to 34 mm. The difference in height between
first and second synthetic grass fibers is at least 6 mm, and for a
low-to-mid pile turf the difference in height is preferably not
more than 10 mm.
[0028] In yet another embodiment, the artificial turf has first
artificial fibers and second artificial fibers having a more
extreme height difference. For example the first artificial fibers
may have a height from 50-80 mm or even 60-80 mm, while the second
artificial fibers have a height from 10-30 mm, or even 10-20
mm.
[0029] In some embodiments, the artificial turf may further
comprise a plurality of third, or even fourth, synthetic grass
fibers, wherein the height of the plurality of third and/or fourth
synthetic grass fibers lies in-between the heights of the first and
second synthetic grass fibers. The use of third and/or fourth
synthetic grass fibers would further improve the natural look of
the artificial grass. The third and fourth synthetic grass fibers
may have an average height difference versus the first and second
synthetic grass fibers, respectively, of 3-10 mm.
[0030] The higher, first (and optional third) synthetic grass
fibers are preferably monofilaments as these are most prominently
visible and more resemble real grass blades. This may be less of
importance for the lower, second (and optional fourth) synthetic
grass fibers as these are less visible to the human eye. The
selection of the lower synthetic grass io fibers may further depend
on other aspects, such as providing support to the higher
artificial grass fibers. However, in a highly preferred embodiment,
all synthetic grass fibers of the artificial turf of the present
invention are monofilaments.
[0031] In a preferred embodiment, at least the first (and optional
third) synthetic grass fibers, and more preferably all synthetic
grass fibers of the artificial turf of the present invention, are
upright-oriented cut-pile fibers, and even more preferably, the
synthetic grass fibers are arranged in bundles of synthetic grass
fibers.
[0032] The first, second and optional third or fourth, synthetic
grass fibers may be the same in composition, shape, cross-section,
resiliency, colour, and/or colour hue. However, to improve the
natural look and feel of the artificial turf, the various first,
second, and optional third and fourth synthetic grass fibers may be
different in composition, shape, cross-section, resiliency, colour,
and/or colour hue. Even more preferably, within one bundle of
artificial grass fibers, fibers with different properties may be
combined. For example, synthetic grass fibers with a different
composition, cross-section, colour and/or colour hue are present in
a given bundle of fibers. In one embodiment, the synthetic grass
fibers may be totally randomized within a given bundle of fibers.
For example, synthetic grass fibers may be used which have an
irregularly-shaped cross-section along their length, as described
in co-pending European patent application n.degree. 15202837.9,
entitled "Artificial Turf Monofilaments".
[0033] In preferred embodiments of the artificial grass of the
present invention, variations between the high (first and
optionally third) and the low (second and optionally fourth)
artificial grass fibers may be present: [0034] resiliency: low
fibers are preferably more resilient than high fibers. The low
fibers will better support the high fibers. [0035] shape: high
fibers preferably have a cross-section which resembles more the
natural grass fibers, for example diamond-, S- or V-shape. [0036]
dtex: low fibers preferably have a lower dtex than high fibers.
[0037] colour: through colour variations, the age of artificial
turf can be created. For example, low fibers may be lighter,
resembling young growing grass leaves. In another example, the low
fibers may be darker resembling older cut grass leaves. Preferably,
high fibers are lime green and low fibers are olive green.
[0038] The synthetic grass fibers are preferably arranged as
bundles of fibers. The first, second, and optional third or fourth,
synthetic grass fibers are preferably arranged in separate rows.
For each type of fibers (first, second, optional third and fourth),
a separate bar is used with x number of positions along the width
of the turf, to insert the fibers through the backing. During
production, the respective bars and thus the resulting rows of
fibers are perpendicular to the machine direction.
[0039] In one embodiment, rows of first (high "H") artificial
fibers are alternated with rows of second (low "L") synthetic grass
fibers. This leads to a LHLHLHLH . . . arrangement.
[0040] However, in a more preferred embodiment, the rows of first
and second synthetic grass fibers are arranged in a more random
pattern, to further improve the natural look of the artificial
turf. This leads to arrangements such as e.g. LLLHHLHHHLLLHLLHHL .
. . In this more random arrangement, it is however highly preferred
that there is at least one row of first synthetic grass fibers
after not more than 3, and preferably not more than 2, rows of
second synthetic grass fibers, to prevent unwanted stripes to be
visually present. Overall, it is preferred that there are more rows
of lower height fibers. This has the additional advantage that an
artificial turf can be created with good natural look while using
less material.
[0041] Accordingly, in some preferred embodiments, rows of first
and second synthetic grass fibers are arranged in a random pattern,
with the provision that a row of first synthetic fibers is present
after not more than 3 rows of second synthetic grass fibers.
[0042] Preferably, the distance between fibers or between bundles
of fibers in a given row (stitches) is from 6-32, preferably from
10-18, per 10cm. The distance between consecutive rows of fibers
(gauge) is preferably 3/4, 3/8, 3/16 or 5/16 inch.
[0043] In other embodiments, it may be envisaged to omit (by not
tufting fibers) certain positions in a given row, especially for
the high artificial fibers. Alternatively, it may be envisaged to
tuft the high fibers only at selected positions by means of
computer io controlling (randomizer). This would lead to
differentiation/randomisation of the artificial turf also in the
cross-machine direction, thereby further improving the natural look
of the turf. Accordingly, in some embodiments, the first synthetic
grass fibers are randomly tufted across the artificial turf.
[0044] In another embodiment, an artificial turf is created with
alternating areas of dark and light green fibers, as is typically
present on sports fields. This can be effected by tufting rows of
dark green first grass synthetic fibers, alternated with rows of
lighter green synthetic grass fibers.
[0045] In a further embodiment, the artificial turf of the present
invention may comprise thatch yarns, which extend upward from the
upper surface of the backing. Thatch yarns are made of
monofilaments or slit film tapes which have been textured (curled),
and simulate grass roots or moss. Preferably, thatch yarns are
inserted together with other fibers in a given bundle of fibers. As
such, they are not present as separate rows between the rows of
synthetic grass fibers. Preferably, the thatch yarns are
incorporated in the bundles of the lowest synthetic grass fibers,
i.e. the bundles of second synthetic grass fibers. Preferably,
thatch yarns are inserted in random bundles of synthetic grass
fibers, or only in certain areas of the turf.
[0046] In some embodiments, the artificial turf of the present
invention is provided on a roll for installation. In some
embodiments, the width of the artificial turf is from at least 2 m
to at most 4 m and the length of the artificial turf is from at
least 10 m to at most 30 m.
[0047] Alternatively, the artificial turf may be provided in the
form of tiles for installation, which may comprise interlocking
pieces. The interlocking means may be part of a backing onto which
the artificial turf is attached.
[0048] In some embodiments, the artificial turf may further
comprise additional backing layers (attached to the lower surface
of the backing, to protect the synthetic grass fiber attachments)
and/or a cushioning layer for improved walking comfort. The backing
and additional backing layers may be translucent or transparent,
and may be combined with one or more light sources which may be
integrated in-between backing layers or positioned underneath the
backing layers. This would allow to create artificial turf which
during the day would resemble real grass, but also allow aesthetic
creations at night using light.
[0049] The artificial grass of the present invention is preferably
used for residential lawn or landscaping purposes. However, other
uses such as sportsfields and playgrounds may also be possible.
EXAMPLE
[0050] Artificial turfs according to the present invention are made
according to the following parameters:
[0051] Fibers are tufted through a polypropylene woven backing and
finished at the back side with a black latex to protect the
tufts.
TABLE-US-00001 Example 1 Example 2 Example 3 Height first
artificial 31 mm 35 mm 40 mm grass fiber Height second 18 mm 23 mm
28 mm artificial grass fibers Height thatch yarns 15 mm 18 mm 24
mm
[0052] Properties of the fibers:
TABLE-US-00002 First artificial grass Second artificial fibers
grass fibers Thatch yarns material LLDPE LLDPE LLDPE cross-section
diamond shape diamond shape rectangular shape colour Lime green
Olive green Beige/Brown dtex 875 1050 625
[0053] Rows of first artificial fibers are alternated with rows of
second artificial fibers with a gauge of 3/16''.
[0054] Within a given row, fibers are arranged in bundles of fibers
with 8 monofilaments per bundle and 120 stitches per 10 cm.
* * * * *