U.S. patent application number 16/316914 was filed with the patent office on 2019-09-26 for natural fiber coated artificial turf infill.
This patent application is currently assigned to Melos GmbH. The applicant listed for this patent is Melos GmbH. Invention is credited to Stephan SICK, Jorg SIEKMANN.
Application Number | 20190292731 16/316914 |
Document ID | / |
Family ID | 57609806 |
Filed Date | 2019-09-26 |
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United States Patent
Application |
20190292731 |
Kind Code |
A1 |
SIEKMANN; Jorg ; et
al. |
September 26, 2019 |
NATURAL FIBER COATED ARTIFICIAL TURF INFILL
Abstract
The method includes providing a base composition including a
natural fiber, at least one first type of pigment, and a fluid
binding agent. The fluid binding agent includes at least one type
of polymer component. The natural fiber includes any one of hemp
fiber, burlap fiber, sisal fiber, elephant grass, cotton, coconut
fiber, and combinations thereof. The method further includes mixing
the base composition. The method further includes adding water and
a catalyst to the base composition during the mixing of the base
composition to cure the fluid binding agent and the at least one
first type of pigment into a base coating of the natural fiber.
Inventors: |
SIEKMANN; Jorg; (Guetersloh,
DE) ; SICK; Stephan; (Willich-Neersen, DE) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Melos GmbH |
Melle |
|
DE |
|
|
Assignee: |
Melos GmbH
Melle
DE
|
Family ID: |
57609806 |
Appl. No.: |
16/316914 |
Filed: |
July 21, 2017 |
PCT Filed: |
July 21, 2017 |
PCT NO: |
PCT/EP2017/068546 |
371 Date: |
January 10, 2019 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
D06M 15/564 20130101;
E01C 13/08 20130101; D06M 2101/06 20130101; D06N 7/0063
20130101 |
International
Class: |
E01C 13/08 20060101
E01C013/08; D06N 7/00 20060101 D06N007/00 |
Foreign Application Data
Date |
Code |
Application Number |
Jul 27, 2016 |
EP |
16181508.9 |
Dec 15, 2016 |
EP |
16204500.9 |
Dec 15, 2016 |
EP |
16204504.1 |
Dec 28, 2016 |
EP |
16207159.1 |
Claims
1. A method of manufacturing artificial turf infill (202, 202',
202''), wherein the method comprises: providing (800) a base
composition comprising a natural fiber (500), at least one first
type of of pigment, and a fluid binding agent, wherein the fluid
binding agent comprises at least one type of polymer component,
wherein the natural fiber comprises any one of the following: hemp
fiber, burlap fiber, sisal fiber, elephant grass, cotton, coconut
fiber, and combinations thereof; mixing (802) the base composition;
adding (804) water and a catalyst to the base composition during
the mixing of the base composition to cure the fluid binding agent
and the at least one first type of of pigment into a base coating
(502) of the natural fiber.
2. The method of manufacturing artificial turf infill of claim 1,
wherein the natural fiber consists of any one of the following:
hemp fiber, burlap fiber, sisal fiber, elephant grass, cotton,
coconut fiber, and combinations thereof.
3. The method of manufacturing artificial turf infill of claim 1,
wherein the method further comprises: providing (900) a subsequent
composition comprising the natural fiber with the base coating, a
at least one second type of of pigment, and the fluid binding
agent; mixing (902) the subsequent composition; adding (904) water
and the catalyst to the subsequent composition during the mixing of
the subsequent composition to cure the fluid binding agent and the
at least one second type of of pigment into a subsequent coating of
the natural fiber; an providing (906) the natural fiber with the
subsequent coating as artificial turf infill (202').
4. The method of manufacturing artificial turf infill of claim 3,
wherein any one of the following: the at least one first type of of
pigment is identical with the at least one second type of of
pigment, and the at least one first type of of pigment is a
different color from the at least one second type of of
pigment.
5. The method of manufacturing artificial turf infill of claim 3 or
4, wherein the natural fiber with the base coating and the
subsequent coating is re-coated at least one time by performing the
following sequence: providing (1000) a subsequent composition
(1222) by adding at least one additive and the fluid binding agent
to the natural fiber; mixing (1002) the subsequent composition; and
adding (1004) water and the catalyst to the subsequent composition
during the mixing of the subsequent composition to cure the fluid
binding agent and the at least one additive into a further coating,
wherein the natural fiber with the further coating is provided as
the artificial turf infill (202'').
6. The method of manufacturing artificial turf infill of claim 5,
wherein the at least one additive further comprises any one of the
following: the at least one first type of pigment, the at least one
second type of pigment, a flame retardant, aluminum trihydrate,
magnesium hydroxide, an intumescent component, ammonium
polyphosphate, exfoliated graphite, methylcellulose, zeolite, an
antibacterial agent, silver, chitosan, an IR reflective pigment, a
hindered amine light stabilizer, an anti-freeze additive, a
de-icing additive, sodium chloride, potassium chloride, sodium
formate, potassium formate, and combinations thereof.
7. The method of manufacturing artificial turf infill of any one of
the preceding claims, wherein the natural fiber comprises fibers
less than 5 mm long, more preferably less than 1.5 mm long.
8. The method of manufacturing artificial turf infill of any one of
the preceding claims, wherein the at least one first type of
pigment and/or the at least one second type of pigment comprises
any one of the following: an inorganic pigment, an organic pigment,
iron oxide, copper phthalo green complex, Chromium(III) oxide, a
Copper Phthalocyanine pigment, a nickel azopigment, titanium oxide,
and combinations thereof.
9. The method of manufacturing artificial turf infill of any one of
the preceding claims, wherein the polymer component comprises any
one of the following: at least one type of monomer, at least one
type of partially polymerized polymer, and combinations
thereof.
10. The method of manufacturing artificial turf infill of any one
of the preceding claims, wherein the polymer component is cured
into at least one type of polyurethane by the water and
catalyst.
11. The method of manufacturing artificial turf infill of any one
of the preceding claims, wherein the fluid binding agent comprises
a liquid polyurethane component.
12. The method of manufacturing artificial turf infill of claim 11,
wherein the liquid polyurethane component comprises an NCO terminal
polymer, which may comprise a pre-polymer, a polymeric isocyanate,
an oligomeric isocyanate, a monomer, and a mixture thereof.
13. The method of manufacturing artificial turf infill of claim 11
or 12, wherein the liquid polyurethane component comprises an
aromatic diisocyanate of the group of toluene diisocyanate and/or
2,2'-Methylene diphenyl diisocyanate and/or 2,4'-Methylene diphenyl
diisocyanate and/or 4,4'-Methylene diphenyl diisocyanate.
14. The method of manufacturing artificial turf infill of claim 11,
12, or 13, wherein the liquid polyurethane component comprises an
aliphatic diisocyanate of the group hexamethylene diisocyanate,
isophorone diisocyanate, and/or 1,4-cyclohexyldiisocyanate.
15. The method of manufacturing artificial turf infill of any one
of claims 11 through 14, wherein the liquid polyurethane component
comprises an methylene diphenyldiisocyanate isomer mixture.
16. The method of manufacturing artificial turf infill of any one
of claims 11 through 15, wherein the liquid polyurethane component
comprises a hydroxyl component, wherein the hydroxyl component is
selected from the group of polyether polyol or polyester
polyol.
17. The method of manufacturing artificial turf infill of claim 16,
wherein the hydroxyl component is based on a polyetherpolyol with a
molecular weight between 500 and 10000, preferably the molecular
weight is between 1500 and 6000, and more preferably the molecular
weight is between 2000 and 4000.
18. The method of manufacturing artificial turf infill of any one
of the preceding claims, wherein the catalyst belongs to any one of
the following groups: a secondary amine catalyst, a tertiary amine
catalyst, and a metal organic catalyst.
19. The method of manufacturing artificial turf infill of any claim
3 through 18 with reference to claim 3, wherein the method further
comprises drying the subsequent composition before providing the
natural fiber as the artificial turf infill.
20. The method of manufacturing artificial turf infill of any one
of the preceding claims, wherein the method is at least partially
performed in a flow reactor.
21. The method of manufacturing artificial turf infill of any one
of claims 1 through 19, wherein the method is at least partially
performed as a batch process.
22. A method of manufacturing artificial turf (200), wherein the
method further comprises: installing (300) an artificial turf
carpet (100), wherein the artificial turf carpet comprises multiple
artificial turf fiber tufts (104); and providing (302) the
artificial turf by spreading a layer of artificial turf infill
(202, 202', 202'') between the multiple artificial turf fiber
tufts, wherein the artificial turf infill comprises natural fiber
(500), wherein the natural fiber comprises any one of the
following: hemp fiber, burlap fiber, sisal fiber, elephant grass,
cotton, coconut fiber, and combinations thereof, wherein the
natural fiber comprises at least one outer coating (502, 600, 700),
wherein the at least one outer coatings comprise at least one first
type of pigment and a binding agent, wherein the binding agent
comprises at least one type of polyurethane polymer.
23. Artificial turf infill (202, 202', 202''), wherein the
artificial turf infill comprises natural fiber (500), wherein the
natural fiber comprises any one of the following: hemp fiber,
burlap fiber, sisal fiber, elephant grass, cotton, coconut fiber,
and combinations thereof, wherein the natural fiber comprises at
least one outer coating (502, 600, 700), wherein the at least one
outer coating comprises at least one first type of pigment and a
binding agent, wherein the binding agent comprises at least one
type of polyurethane polymer.
24. The artificial turf infill of claim 23, wherein the at least
one outer coating comprises openings (504) that expose the natural
fiber.
25. An artificial turf, wherein the artificial turf comprises: an
artificial turf carpet (100), wherein the artificial turf carpet
comprises multiple artificial turf fiber tufts (104); and the
artificial turf infill (202, 202', 202'') according to claim 23 or
24.
26. The artificial turf of claim 25, wherein the artificial turf
further comprises a sprinkler system (400).
27. The method of manufacturing artificial turf infill of any one
of claims 1 through 21, wherein the base coating comprises first
openings (504) that expose the natural fiber.
28. The method of manufacturing artificial turf infill of any one
of claims 27 and 3 through 21 with reference to claim 3, wherein
the subsequent coating comprises second openings (504) that expose
the natural fiber.
29. The method of manufacturing artificial turf infill of claims 28
and 27, wherein a number of the first openings is bigger than a
number of the second openings.
30. The method of manufacturing artificial turf infill of any of
claims 27 through 29, wherein a portion of the first openings is
covered by the subsequent coating.
31. The method of manufacturing artificial turf infill of any one
of claims 5 through 21 and 27 through 30 with reference to claim 5,
wherein the further coating comprises third openings (504) that
expose the natural fiber.
32. The method of manufacturing artificial turf infill of claims 31
and 29, wherein the number of the second openings is bigger than a
number of the third openings.
33. The method of manufacturing artificial turf infill of claims
any one of claims 1 through 21 and 27 through 32 with reference to
claims 27 and 3, wherein a portion of the first openings is covered
by the subsequent coating.
34. The method of manufacturing artificial turf infill of claims
any one of claims 1 through 21 and 27 through 33 with reference to
claims 28 and 5, wherein a portion of the second openings is
covered by the further coating.
35. The method of manufacturing artificial turf infill of claims 28
and 31, wherein a number of the second openings is bigger than a
number of the third openings.
36. The artificial turf infill of claim 23 or 24, wherein the at
least one outer coating comprises openings (504) that expose the
natural fiber.
Description
FIELD OF THE INVENTION
[0001] The invention relates to artificial turf and methods for the
manufacture of artificial turf infill.
BACKGROUND AND RELATED ART
[0002] Artificial turf or artificial grass is surface that is made
up of fibers which is used to replace grass. The structure of the
artificial turf is designed such that the artificial turf has an
appearance which resembles grass. Typically artificial turf is used
as a surface for sports such as soccer, American football, rugby,
tennis, golf, for playing fields, or exercise fields. Furthermore
artificial turf is frequently used for landscaping
applications.
[0003] Artificial turf may be manufactured using techniques for
manufacturing carpets. For example artificial turf fibers which
have the appearance of grass blades may be tufted or attached to a
backing. Often times artificial turf infill is placed between the
artificial turf fibers. Artificial turf infill is a granular
material that covers the bottom portion of the artificial turf
fibers. The use of artificial turf infill may have a number of
advantages. For example, artificial turf infill may help the
artificial turf fibers stand up straight. Artificial turf infill
may also absorb impact from walking or running and provide an
experience similar to being on real turf. The artificial turf
infill may also help to keep the artificial turf carpet flat and in
place by weighting it down.
[0004] European Patent EP 2 206 833 A1 discloses a method for
producing a particulate infill material for synthetic-grass
structures envisages providing a mass of thermoplastic material
with a filler consisting of coconut-based material and subjecting
said mass of thermoplastic material with the filler consisting of
coconut-based material to granulation so as to obtain the aforesaid
particulate infill material. Preferentially, the thermoplastic
material is in particulate form, and the coconut-based material is
in particulate form (fibrous, ground and/or shredded). The mixture
obtained by mixing the thermoplastic material and the coconut-based
material is preferentially heated in order to bring about softening
of the thermoplastic material with the corresponding formation of a
matrix of thermoplastic material that incorporates the
coconut-based material as filler.
SUMMARY
[0005] The invention provides for a method of manufacturing
artificial turf infill, a method of manufacturing artificial turf,
and artificial turf in the independent claims. Embodiments are
given in the dependent claims.
[0006] In one aspect the invention provides for a method of
manufacturing artificial turf infill. The method comprises first
providing a base composition comprising a natural fiber, a at least
one first type of of pigment, and a fluid binding agent. The fluid
binding agent comprises at least one type of polymer component. The
natural fiber comprises any one of the following: hemp fiber,
burlap fiber, sisal fiber, elephant grass, cotton, coconut fiber,
and combinations thereof.
[0007] The at least one first type of of pigment may be an
individual pigment or it may also be a combination or mixture of
different pigments. For example, the at least one first type of
pigment may be a green pigmentation used for coloring artificial
turf infill that is a mixture of green, white, yellow, and black
pigments.
[0008] In the next step the method further comprises mixing the
base composition. The method further comprises adding water and a
catalyst to the base composition during the mixing of the base
composition to cure the fluid binding agent and the at least one
first type of of pigment into a base coating of the natural fiber.
The term "base" in base coating is intended as a label to identify
the coating of the natural fiber. The term "base" as used herein is
therefore not intended to have a specific meaning outside of its
use as a label in the context of the coating of the natural fiber.
Hence, a "base coating" as understood herein is a coating that may
or may not form a base for one or more additional coatings.
[0009] This embodiment may be beneficial for a variety of reasons.
In one aspect the method may be beneficial because it may provide
for a means of partially coating the natural fiber. The natural
fibers are able to absorb and desorb water. It may be beneficial
before a sporting event or game to spray water onto the artificial
turf infill for it to absorb water. As the sunlight or hot air
heats the artificial turf infill it may then desorb or evaporate
water keeping the surface of an artificial turf cool. The amount of
time that the artificial turf infill is able to retain water may be
controlled by only partially covering the artificial turf
infill.
[0010] A further advantage may be that the base coating provides
protection for the natural fiber and helps it hold together. This
may provide for an artificial turf infill which lasts for a longer
period. Another advantage may be that the pigment provides a more
natural color for the artificial turf infill. For example a brown
or a green color may be used. If the natural fibers are brown
colored the inclusion of a green pigment may be beneficial in that
the artificial turf infill has both brown and green color and
therefore makes the resulting artificial turf look more realistic
or lifelike.
[0011] Another advantage may be that the fluid binding agent may
partially absorb into the natural fiber and provide for a very
strong bond between the natural fiber and the base coating. The use
of a fluid binding agent comprising at least one polymer component
may be beneficial because it may provide for a flexible artificial
turf infill which has lifelike and/or also shock absorbing
properties which help to protect people or players using an
artificial turf manufactured with an artificial turf infill.
[0012] The use of natural fibers, and hemp in particular, may
additionally be advantageous over coconut fibers as hemp and other
natural fibers may be less flammable. In some cases the hamp and
other natural fiber may also absorb water better than coconut
fibers do. The absorption of water by the natural fiber may be
advantageous because the artificial turf can be sprayed with water
before a game. The evaporation of water from the natural fibers may
have a natural cooling effect and may help reduce the temperature
of the artificial turf during a game which is played in
sunlight.
[0013] The use of hemp may also be beneficial because hemp is
naturally resistant to fungi in comparison with coconut fibers.
Hemp also has the benefit of being very skin friendly. Hemp is less
abrasive and/or prickly than many other natural fibers such as wood
chips or coconut fibers.
[0014] The use of natural fibers, and hemp in particular, as an
infill material may also be beneficial because it has superior
damping and shock absorption properties. A player who falls on an
artificial turf with an infill according to an embodiment may in
some cases be less likely to be hurt than if the player fell on an
artificial turf that had a predominantly coconut fiber based
infill.
[0015] The use of natural fibers may also be beneficial because
they have low thermal conductivities in comparison to, for example,
rubber granulate. This may help to reduce how hot an artificial
turf surface is when exposed to sunlight.
[0016] The method of manufacturing artificial turf infill may be
part of a method for manufacturing artificial turf.
[0017] In another embodiment the natural fiber consists of any one
of the following: hemp fiber, burlap fiber, sisal fiber, elephant
grass, cotton, coconut fiber, and combinations thereof.
[0018] In another embodiment the natural fiber consists of any one
of the following: hemp fiber, burlap fiber, and sisal fiber, and
combinations thereof. The use of the hemp fiber, burlap fiber, and
sisal fiber over other types of natural fibers may be beneficial
because these fibers provide superior water absorption properties
as well as an increased resistance to decay due to funguses.
[0019] In another embodiment, the method further comprises
providing a subsequent composition comprising the natural fiber
with the base coating, the at least one second type of pigment and
the fluid binding agent. The method further comprises mixing the
subsequent composition. The method further comprises adding water
and the catalyst to the subsequent composition during the mixing of
the subsequent composition to cure the fluid binding agent and the
at least one second type of pigment into a subsequent coating of
the natural fiber.
[0020] The at least one second type of pigment and the at least one
first type of pigment may be identical or they may be different. If
they are the same then the coating of the natural fiber will be of
a uniform color. If the at least one second type of pigment and the
at least one first type of pigments are different colors then the
two colors can be chosen so that the resulting artificial turf
infill has a more natural and earth like appearance.
[0021] The method further comprises providing the natural fiber
with the subsequent coating as artificial turf infill.
[0022] The coating of the natural fiber in at least two steps as
described above, may be beneficial because it may provide for
better coating of the natural fiber For example, during the mixing
of the base composition individual fibers of the natural fiber will
touch and interact with each other as the base coating on each of
the fibers forms. The physical contact between different natural
fibers will however cause defects. By coating the natural fiber
particles a second time with the subsequent coating, much higher
coverage of the natural fiber can be achieved.
[0023] As an example, during the formation of the base coating or
the subsequent coating the coverage is each only 90% of the surface
of the natural fiber. After the base coating has been deposited,
roughly 10% of each granule of the natural fiber would be uncoated.
There would be small surface defects. Deposition of the subsequent
coating would then also cover 90% of the surface. As the
interaction between the fibers or particles of the natural fiber is
essentially a random process, one can expect that 90% of the
defects that were exposed after the deposition of the base coating
are coated in this case. The result of doing two coatings is then
an artificial turf infill that is 99% coated with only minor
amounts of defects, where the natural fiber is not coated with
either the base coating or the subsequent coating. This effect may
be used to control how quickly water can evaporate from the natural
fiber, and thus control how long the cooling effect of this
evaporation will be active.
[0024] Improving the coverage of the natural fiber may be
beneficial in several different situations. For example, it may be
desirable to color the artificial turf infill the same or a similar
color as fibers or tufts, which are used to manufacture an
artificial turf carpet. This may provide a more realistic-looking
play surface or playfield. Another advantage is that the
elastomeric natural fiber may be better coated and may therefore
have superior wear qualities or may even be better isolated from
the environment.
[0025] In another embodiment the natural fiber comprises fibers
with a length less than 5 mm long.
[0026] In another embodiment the natural fiber comprises fibers
with a length less than 1.5 mm long.
[0027] In another embodiment the natural fiber comprises fibers
with a length less than 2.5 mm long.
[0028] In another embodiment the curing of the base coating and the
curing of the subsequent coating is a polymerization process.
Within the claims, the term `cure` or `curing` may be replaced with
polymerization.
[0029] In another embodiment the subsequent coating at least
partially covers the base coating.
[0030] In another embodiment the base coating only partially covers
the natural fiber.
[0031] In another embodiment the subsequent coating only partially
covers the base coating.
[0032] In another embodiment the natural fiber with the base
coating and the subsequent coating is re-coated at least one time
by performing the following sequence. The first step in the
sequence is provide a subsequent composition by adding at least one
additive and the fluid binding agent to the natural fiber that has
already been coated with the base coating and the subsequent
coating. The next step in the sequence is to mix the subsequent
composition. The next step in the sequence is to add water and the
catalyst to the subsequent composition during the mixing of the
subsequent composition to cure the fluid binding agent and the at
least one additive into a further coating. The natural fiber with
the further coating is provided then as the artificial turf infill.
This embodiment may be beneficial because an additional functional
coating or layer may be put on the natural fiber. If the at least
one first and/or second type of pigment is used again then the
natural fiber may be coated a third or more times to improve the
coverage and the coating of the natural fiber. Again, this effect
may be used to control how quickly water can evaporate from the
natural fiber, and thus control how long the cooling effect of this
evaporation will be active.
[0033] This embodiment may also be beneficial because it may enable
the deposition of so-called functional layers or additives, which
may add to the utility or wear or usefulness of the artificial turf
infill.
[0034] In another embodiment the PU catalyst is partially or
completely water soluble and is one of the group: secondary amine,
tertiary amine, a metal organic catalyst.
[0035] Utilization of these catalysts can facilitate production of
coatings having openings that expose the natural fiber. In
addition, coatings made using these catalysts can have structural
integrity and/or durability, and/or mechanical properties which are
compatible with the requirements for artificial turf infill.
[0036] Moreover control of a quantity of these catalysts can
provide for a control of a number and/or size of the openings. As
it is mentioned above and further in the text the openings in their
own turn can provide for proper absorption and desorption of water
from the surface of the fiber opened to air in the openings. At it
is mentioned above the processes of water absorption and desorption
of water can facilitate keeping the artificial turf infill and as a
consequence the artificial turf cool.
[0037] In another embodiment the liquid PU component is based on an
NCO terminal polymer which might be a pre-polymer, a polymeric
isocyanate, an oligomeric isocyanate, a monomer and a mixture
hereof.
[0038] In another embodiment the liquid PU component is based on an
aromatic diisocyanate of the group toluene diisocyanate and/or
2,2'-Methylene diphenyl diisocyanate and/or 2,4'-Methylene diphenyl
diisocyanate and/or 4,4'-Methylene diphenyl diisocyanate.
[0039] In another embodiment the liquid PU component is based on an
aliphatic diisocyanate of the group hexamethylene diisocyanate,
isophorone diisocyanate and 1,4-cyclohexyldiisocyanate.
[0040] In preferred embodiment the liquid PU component is based on
methylene diphenyl diisocyanate (MDI) isomer mixture.
[0041] In another embodiment the hydroxyl component for the
production of the PU is out of the group polyether polyol or
polyester polyol.
[0042] In another embodiment the hydroxyl component is based on a
polyetherpolyol of the molecular weight 500 to 10000. In a
preferred embodiment the polyetherpolyol has a molecular weight of
1500-6000. In a very preferred embodiment the molecular weight is
in the range of 2000-4000.
[0043] In another embodiment the at least one additive comprises
the at least one first and/or second type of pigment.
[0044] In another embodiment the at least one additive further
comprises a flame retardant like aluminum trihydrate, magnesium
hydroxide turning a by itself burnable or flammable elastomeric
material into a flame retardant infill material.
[0045] In another embodiment this flame retardant additives creates
an intumescent coating and is based on intumescent component
comprising ammonium polyphosphate or exfoliated graphite or a
mixture hereof.
[0046] In another embodiment the at least one additive further
comprises zeolite. The addition of zeolite may be beneficial
because then the surface of the artificial turf infill may be able
to absorb or de-absorb water. For example before a football game,
which is scheduled to be held in the sun or in hot conditions,
water may be sprayed onto the artificial turf and the zeolite may
absorb an amount of water. As the sun or hot air heats the
artificial turf infill during the game, the evaporation of water
may cool the playing surface for the players and make the use of
the artificial turf more pleasant.
[0047] In another embodiment the at least one additive further
comprises methylcellulose, which may be beneficial in a similar way
like zeolite for absorbing and desorbing of water, rendering a
cooling effect at hot climatic conditions.
[0048] In another embodiment the at least one additive further
comprises an antibacterial agent.
[0049] In another embodiment the at least one additive further
comprises silver. Silver may be beneficial as an antibacterial
agent.
[0050] In another embodiment the at least one additive further
comprises chitosan, showing natural antibacterial properties.
[0051] In another embodiment the at least one additive further
comprises an IR reflective pigment. The use of the IR reflective
pigments as mixed metal oxides may be beneficial because it may
reflect infrared light. This may reduce the heating of the
artificial turf infill. A specific advantage may be that in this
case the comparably expensive and precious pigments are merely on
the surface of the infill natural fibers.
[0052] In another embodiment the at least one first and/or second
type of pigment comprises an inorganic pigment, an organic pigment
or mixtures thereof.
[0053] In another embodiment the at least one first and/or second
type of pigment comprises any one of the following: iron oxide,
iron oxide hydroxide, chromium(III) oxide, a copper Phthalocyanine
pigment, a nickel azopigment, titanium oxide and combinations
thereof.
[0054] In another embodiment the at least one type of additive is
hindered amine light stabilizer (HALS) which is able to protect the
PU coating as well as the elastic and/or compression resilient
natural fiber against UV degradation.
[0055] In another embodiment the at least one type of additive is a
thermostabilizing agent, protecting the elastic and/or compression
resilient natural fiber against thermal degradation.
[0056] In another embodiment the at least one type of additive is
an anti-freeze/deicing additive of the group: sodium chloride,
potassium chloride, calcium chloride, sodium formate, potassium
formate or a mixture hereof. The additive is migrating into the
neighborhood of the natural fiber and by this inhibits the
formation of ice by freezing humidity between the infill natural
fiber particles.
[0057] In another embodiment the fluid binding agent further
comprises any one of the following: a surfactant, a polyurethane
aliphatic isocyanate, a polyurethane aromatic isocyanate, zeolite,
an antibacterial agent, silver, IR reflective pigment, and
combinations thereof.
[0058] In another embodiment the polymer component comprises any
one of the following: at least one type of monomer, at least one
type of partially polymerized polymer, and combinations
thereof.
[0059] In another embodiment the polymer component is cured into at
least one type of polyurethane by the water and the catalyst.
[0060] For example the polymer component could be methylene
diphenyl diisocyanate. The polymer component could also comprise
polyols.
[0061] In another embodiment the catalyst comprises any one of the
following: an amine catalyst and a metal organic catalyst.
[0062] In another embodiment the method further comprises drying
the subsequent composition before providing the natural fiber as
the artificial turf infill.
[0063] It may also be possible to dry the base composition after
coating the natural fiber with the base coating; however, it is not
necessary. The water, which is leftover from the formation of the
base coating on the elastic and/or compression resilient natural
fiber may be used in the reaction of the subsequent
composition.
[0064] In another embodiment the method is at least partially
performed in a flow reactor. In the flow reactor the natural fiber
is slowly moved along a linear sequential path, where the natural
fibers are generally mixed and moved along. The benefit of using a
flow reactor is that the artificial turf infill may be produced on
a continuous basis.
[0065] In another embodiment the method is at least partially
performed as a batch process. The base coating is formed on the
natural fiber during an initial or base batch and the subsequent
coating is formed on the natural fiber during a subsequent batch.
Forming the base coating and the subsequent coating in separate
batches may be beneficial because it may enable precise control
over the formation of the base and subsequent coatings.
[0066] In another aspect the invention provides for a method of
manufacturing artificial turf. The method comprises installing an
artificial turf carpet. The artificial turf carpet comprises
multiple artificial turf fiber tufts. For example, the artificial
turf carpet may be a tufted artificial turf carpet. There may be a
backing which has tufts of artificial grass fibers tufted into it.
The method further comprises providing the artificial turf by
spreading a layer of artificial turf infill between the multiple
artificial turf fiber tufts. The artificial turf infill comprises a
natural fiber. The natural fiber comprises at least two outer
coatings. Each of the two outer coatings comprises at least one
first and/or second type of pigment and a binding agent. The
binding agent comprises at least one type of polyurethane polymer.
This method may be beneficial because the artificial turf infill
may be more completely covered with the two outer coatings. This
may for instance provide superior optical appearance of the
artificial turf infill. It may also provide better wear and
longevity of the artificial turf infill.
[0067] In another aspect the invention provides for artificial turf
infill. The artificial turf comprises natural fiber. The natural
fiber comprises any one of the following: hemp fiber, burlap fiber,
sisal fiber, and combinations thereof. The natural fiber comprises
at least one outer coating. The at least one outer coating
comprises at least one first type of pigment and a binding agent.
The binding agent comprises at least one type of polyurethane
polymer. The at least one outer coating comprises openings that
expose the natural fiber.
[0068] Utilization of the binging agent comprising at least one
type of the polyurethane polymer can be advantageous because it can
provide the coating with openings which has structural integrity
and/or durability, and/or mechanical properties which are
compatible with the requirements for artificial turf infill.
Moreover the openings can provide for the cooling effect of the
artificial turf infill mentioned above and further in the text.
[0069] In another embodiment the natural fiber consists of any one
of the following: hemp fiber, burlap fiber, sisal fiber, and
combinations thereof.
[0070] In another aspect the invention provides for an artificial
turf. The artificial turf comprises an artificial turf carpet. The
artificial turf carpet comprises multiple artificial turf fiber
tufts. The artificial turf further comprises the artificial turf
infill according to an embodiment. The artificial turf infill is
distributed between the artificial turf fiber tufts.
[0071] In another embodiment the artificial turf further comprises
a sprinkler system. The use of a sprinkler system with the
artificial turf may be beneficial because it may be used to
automatically wet the artificial turf infill. For example this may
be a convenient means of watering the artificial turf during a half
time so that the artificial turf can be kept cooler during game
play.
[0072] It is understood that one or more of the aforementioned
embodiments of the invention may be combined as long as the
combined embodiments are not mutually exclusive.
BRIEF DESCRIPTION OF THE DRAWINGS
[0073] In the following embodiments of the invention are explained
in greater detail, by way of example only, making reference to the
drawings in which:
[0074] FIG. 1 illustrates an example of an artificial turf
carpet;
[0075] FIG. 2 illustrates an example of artificial turf;
[0076] FIG. 3 shows a flow chart which illustrates a method of
manufacturing artificial turf;
[0077] FIG. 4 illustrates an example of an artificial turf which
incorporates a sprinkler system;
[0078] FIG. 5 illustrates an example of an artificial turf
infill;
[0079] FIG. 6 illustrates a further example of an artificial turf
infill;
[0080] FIG. 7 illustrates a further example of an artificial turf
infill;
[0081] FIG. 8 shows a flow chart which illustrates a further method
of manufacturing artificial turf infill;
[0082] FIG. 9 shows a flow chart which illustrates a further method
of manufacturing artificial turf infill;
[0083] FIG. 10 shows a flow chart which illustrates a further
method of manufacturing artificial turf infill;
[0084] FIG. 11 illustrates an example of a batch reactor; and
[0085] FIG. 12 illustrates an example of a flow reactor.
DETAILED DESCRIPTION
[0086] Like numbered elements in these figures are either
equivalent elements or perform the same function. Elements which
have been discussed previously will not necessarily be discussed in
later figures if the function is equivalent.
[0087] FIGS. 1 and 2 illustrate the manufacture of an artificial
turf using an artificial turf carpet and artificial turf infill. In
FIG. 1 an artificial turf carpet 100 can be seen. The artificial
turf carpet 100 comprises a backing 102. The artificial turf carpet
100 shown in FIG. 1 is a tufted artificial turf carpet in this
example. The artificial turf carpet is formed by artificial turf
fiber tufts 104 that are tufted into the backing 102. The
artificial turf fiber tufts 104 are tufted in rows. There is row
spacing 106 between adjacent rows of tufts. The artificial turf
fiber tufts 104 also extent a distance above the backing 102. The
distance that the fibers 104 extend above the backing 102 is the
pile height 108. In FIG. 1 it can be seen that the artificial turf
carpet 100 has been installed by placing or attaching it to the
ground 110 or a floor.
[0088] FIG. 2 illustrates an artificial turf 200 manufactured from
the artificial turf carpet 100 of FIG. 1. To manufacture the
artificial turf 200 a infill 202 made up of natural fibers with at
least one outer coating is used. The at least one outer coating
comprises at least one type of pigment and a binding agent, wherein
the binding agent comprises at least one type of polyurethane
polymer. The natural fiber may for example be any one of the
following: hemp fiber, burlap fiber, sisal fiber, elephant grass,
cotton, coconut fiber, and combinations thereof. FIG. 2 shows the
artificial turf carpet 200 after artificial turf infill 202 has
been spread out and distributed between the artificial turf fiber
tufts 204.
[0089] FIG. 3 shows a flowchart which illustrates a method of
manufacturing the artificial turf 200 shown in FIG. 2. First in
step 300 the artificial turf carpet 100 is installed on a surface.
The artificial turf comprises multiple artificial turf fiber tufts.
Next in step 302 the artificial turf 200 is provided by spreading a
layer of the artificial turf infill 202 between the multiple
artificial turf fiber tufts 104. The artificial turf infill
comprises natural fiber. The natural fiber comprises any one of the
following: hemp fiber, burlap fiber, sisal fiber, elephant grass,
cotton, coconut fiber, and combinations thereof. The natural fiber
comprises at least one outer coating. The at least one outer
coating comprises at least one type of pigment and a binding agent.
The binding agent comprises at least one type of polyurethane
polymer.
[0090] FIG. 4 shows a further example of the artificial turf 200.
In this example an automatic sprinkler system 400 has been
integrated into the artificial turf 200. The sprinkler 400 is
depicted as spraying water 402 on an upper surface of the
artificial turf 200. The use of an artificial sprinkler may be
beneficial in combination with the infill component that comprises
both the rubber natural fiber and the natural fiber. The natural
fiber may absorb water which through evaporation can help to keep
the surface of the artificial turf 200 cool.
[0091] FIG. 5 shows an example of an artificial turf infill 202
manufactured from a natural fiber 500. The view in FIGS. 5, 6 and 7
are cross-sectional views. The natural fiber is shown as being
partially coated with an outer coating 502. The outer coating 502
is formed from at least one first type of pigment and a binding
agent. The binding agent comprises at least one type of
polyurethane polymer. The outer coating 502 may provide coloration
which may help the artificial turf infill appear more realistic.
The outer coating 502 may also help serve to protect and keep the
natural fiber 500 from breaking apart prematurely during use. The
openings 504 in the outer coating 502 provide access to the
atmosphere for the natural fiber 500. This enables the natural
fiber 500 to absorb and desorb water. For example when an
artificial turf is wetted with for example the sprinkler shown in
FIG. 4 the natural fiber can then absorb water. The amount of
openings 504 controls how quickly the artificial turf infill 202
will lose its water and its cooling effect.
[0092] FIG. 6 shows a further example of an artificial turf infill
202'. The artificial turf infill 202' is again shown as a
cross-sectional view of the natural fiber 500. In this example an
additional subsequent coating 600 has been applied to the natural
turf fiber 500. The subsequent coating 600 is shown as covering
some of the openings 504 that were present in FIG. 5. As a result a
number of openings is reduced by applying the additional subsequent
coating. Thus the process of water absorption and desorption
through the openings can be tuned to a desired level by applying
the subsequent coating. The subsequent coating 600 also partially
covers some of the previously coated base coating 502. As a result
the structural integrity, and/or durability, and/or mechanical
properties of the coating comprising the outer coating 502 and the
subsequent coating 600 can be improved or tuned to a desired level.
The subsequent coating 600 may comprise a second type of pigment
and the binding agent. The binding agent comprises at least one
type of polyurethane polymer again. In some instances the first and
at least one second type of of pigments are identical. In other
cases they may be two different colors. Using two colors that are
the same may enable more uniform color coding of the natural fiber
500. Using two different colors may enable a more lifelike
appearance for the natural fiber 500. It can be seen that the
number of openings 504 has been greatly reduced. This may provide
for a means of controlling how exposed the natural fiber 500 is to
the atmosphere. This may enable control of how quickly the
artificial turf infill 202' loses water when it is exposed to heat
and sunlight. This may have the effect of prolonging the cooling
effect.
[0093] FIG. 7 shows a further example of an artificial turf infill
202'' as illustrated by showing a further cross-sectional view of
the natural fiber 500. The artificial turf fiber 500 displayed in
FIG. 7 is similar to that in FIG. 6 except an additional further
coating 700 has been coated over the subsequent coating 600 and the
base coating 502. It can be seen that the number of openings 504
has again been greatly reduced. If a sufficient number of coatings
are used then the artificial turf fiber 500 may be completely
encapsulated in coatings. The further coating 700 may comprise at
least one pigment and a binding agent where the binding agent
comprises at least one type of polyurethane polymer. The further
coating, the subsequent coating 600 and/or the base coating 502 in
all of the examples shown in 5, 6 and 7 may also comprise various
functional additives or components. For example there may be
components which are used to provide flame retardants, provide
infrared reflection or other properties.
[0094] Such an iterative processing of applying coatings can
provide for an effective control of a number of openings and/or
areas of the openings. In addition this iterative process can
provide for a production of an integral coating of the artificial
turf infill which has desired mechanical and/or structural
properties and/or required wear and longevity.
[0095] FIG. 8 shows a flowchart which illustrates a method for
manufacturing the artificial turf infill 202 illustrated in FIG. 5.
First in step 800 a base composition is provided which comprises
the natural fiber 500. The base composition further comprises a at
least one first type of of pigment which may be a collection of
multiple pigments and a fluid binding agent. The fluid binding
agent comprises at least one type of polymer component. The natural
fiber comprises any one of the following: hemp fiber, burlap fiber,
sisal fiber, elephant grass, cotton, coconut fiber, and
combinations thereof. Next in step 202 the method further comprises
mixing the base composition. Then finally in step 804 the method
further comprises adding water and a catalyst to the base
composition during the mixing of the base composition to cure the
fluid binding agent and the at least one first type of of pigment
into a base coating 502 of the natural fiber 500.
[0096] FIG. 9 shows a flowchart which illustrates a method of
manufacturing artificial turf infill 202' shown in FIG. 6. The
method of FIG. 9 includes the steps 800, 802, and 804 from FIG. 8.
The method after performing step 804 further comprises providing a
subsequent composition comprising the natural fiber 500 with the
base coating 502. The subsequent composition further comprises a at
least one second type of of pigment which may be the same or
different than the at least one first type of of pigment and the
fluid binding agent. The at least one second type of of pigment may
also be a single pigment or formed from a collection of different
pigments. Next in step 902 the method further comprises mixing the
subsequent composition. Next the method further comprises the step
904 of adding water and the catalyst to the subsequent composition
during the mixing of the subsequent composition to cure the fluid
binding agent and the at least one second type of of pigment into a
subsequent coating 600 of the natural fiber 500. The method then
further comprises 906 providing the natural fiber with the
subsequent coating as the artificial turf infill 202'.
[0097] FIG. 10 shows a flowchart which illustrates a method of
manufacturing an artificial turf infill 202'' such as illustrated
in FIG. 7. The method illustrated in FIG. 10 uses the artificial
turf infill 202' illustrated in FIG. 6. The method in FIG. 10 also
includes the method steps of FIG. 9. After step 906 is performed
the method further comprises providing 1000 a subsequent
composition by adding at least one additive and the fluid binding
agent to the natural fiber. The method then proceeds to step 1002
where the subsequent composition is mixed. Then finally in step
1004 water and catalyst are added to the subsequent composition
during the mixing of the subsequent composition to cure the fluid
binding agent and the at least one additive into a further coating
700 of the natural fiber. The method may end in step 1004 where the
resulting artificial turf 202'' infill is provided. However, the
addition of the subsequent coatings may be performed multiple
times. The arrow going from step 1004 to 1000 indicates that this
process may be repeated as many times as is desired. This step may
be performed multiple times to add additional properties to the
artificial turf infill such as greater coverage of openings 504 or
even adding additional colors or functional coatings which may for
instance be used to provide flame retardants, infrared reflective,
antibacterial properties or even antifungal properties.
[0098] FIG. 11 illustrates some equipment which may be used for
manufacturing the artificial turf infill 202, 202', 202'' as
depicted in FIGS. 5 through 7. The mixing vat can be used to
perform any of the methods shown in FIGS. 8 through 10. FIG. 11
depicts a mixing vat 1100. The mixing vat has a rotatable shaft
1102 that is connected to a number of mixing paddles 1104. The
mixing vat 1100 is filled with natural fibers 500. The natural
fiber 500 can then be manufactured into artificial turf infill 202
by forming an base composition. The base composition comprises the
the natural fiber 500, optionally at least one first type of
pigment, and a fluid binding agent. The fluid binding agent, may
for example, comprises at least one type of polymer component. Next
in step the base composition is mixed. During this step, the mixing
water and catalyst are added to the base composition to cure the
fluid binding agent and the optional at least one type of pigment
into an outer coating 502 that bonds to the surface of the natural
fibers 500. Likewise, the artificial turf infills 202' and 202'' as
depicted in FIGS. 6 and 7 can be performed by using the methods
depicted in FIGS. 9 and 10.
[0099] The apparatus depicted in FIG. 11 may be used for
manufacturing the artificial turf infill as batches. It is also
possible to manufacture the artificial turf infill as a continuous
process using a flow reactor.
[0100] FIG. 12 illustrates an example of a flow reactor 1200. The
example shown in FIG. 12 is illustrative and is not drawn to scale.
The flow reactor 1200 comprises a rotatable shaft 1202 that is
connected to a screw conveyor 1204. The screw conveyor 1204 is
similar to an Archimedes screw, which is mounted horizontally. The
flow reactor 1200 is shown as being filled with natural fiber 500.
As the rotatable shaft 1202 is turned, it causes the natural fiber
500 to move through the flow reactor 1200. At an entrance there is
an inlet 1208 for the natural fiber 500. This may be done on a
continual basis as the shaft 1202 is rotated. This causes the
natural fiber 500 to go to a first inlet 1210 for fluid binding
agent and optionally at least one first type of pigment. At inlet
1210 the at least one at least one first type of of pigment and the
fluid binding agent are added to the natural fiber 504 and become
mixed with it as the shaft 1202 is rotated. When they are
thoroughly mixed, the natural fiber 1204 and the rubber natural
fiber 1206 and the at least one first type of pigment and the fluid
binding agent form an base composition 1220. This base composition
1220 is then transported beneath a first inlet for water and
catalyst 1212. The water and catalyst may be added on a continual
or intermittent basis at this inlet 1212.
[0101] As the base composition 1220 is transported further along
the flow reactor 1200 fluid binding agent and at least one pigment
cure into the outer coating 502 such as depicted in FIG. 5. At this
point, the artificial turf infill 202 has been formed.
[0102] In some examples the flow reactor may additional inlets so
that additional layers or coatings can be applied. FIG. 7 also
depicts optional inlets 1214 and 1216. After the outer coating 502
is formed, the base composition 1220 is transported underneath the
second inlet 1214 for at least one pigment and fluid binding agent.
At this point more of the pigment and fluid binding agent are added
and the base composition 1220 becomes the subsequent composition
1222. The pigments used for the base composition and the subsequent
composition may be identical or they may be different.
[0103] The subsequent composition 1222 is mixed and transported
underneath the second inlet for water and catalyst 1216. The water
and catalyst are then mixed with the subsequent composition 1222
and over time are further transported to the end of the flow
reactor 1220. By the time the subsequent composition 1222 has
reached the end of the flow reactor 1200 the subsequent coating 600
has formed on the natural fibers 500. At the very end, then the
artificial turf infill 202' exits the flow reactor 1200 at an
outlet 1217. The the natural fiber 500 is then artificial turf
infill 202'. The artificial turf infill 202' is then shown as
entering into an optional dryer 1218.
[0104] It is clear from FIG. 12 that the flow reactor may also be
extended. For example if it is desired to put a third or fourth or
even more coatings, the number of inlets in the flow reactor 1200
can simply be increased. This may involve moving the natural fiber
at a different rotational rate or possibly even making the flow
reactor 1200 longer.
LIST OF REFERENCE NUMERALS
[0105] 100 artificial turf carpet [0106] 102 backing [0107] 104
artificial turf fiber tufts [0108] 106 row spacing [0109] 108 pile
height [0110] 110 ground or floor [0111] 200 artificial turf [0112]
202 artificial turf infill [0113] 202' artificial turf infill
[0114] 202'' artificial turf infill [0115] 300 installing an
artificial turf carpet [0116] 302 providing the artificial turf by
spreading a layer of artificial turf infill between the multiple
artificial turf fiber tufts [0117] 400 sprinkler [0118] 402 water
[0119] 500 natural fiber [0120] 502 base coating [0121] 504 opening
[0122] 600 subsequent coating [0123] 700 further coating [0124] 800
providing a base composition comprising a natural fiber, a at least
one first type of of pigment, and a fluid binding agent [0125] 802
mixing the base composition [0126] 804 adding water and a catalyst
to the base composition during the mixing of the base composition
to cure the fluid binding agent and the at least one first type of
of pigment into a base coating of the natural fiber [0127] 900
providing a subsequent composition comprising the natural fiber
with the base coating, a at least one second type of of pigment,
and the fluid binding agent [0128] 902 mixing the subsequent
composition [0129] 904 adding water and the catalyst to the
subsequent composition during the mixing of the subsequent
composition to cure the fluid binding agent and the at least one
second type of of pigment into a subsequent coating of the natural
fiber [0130] 906 providing the natural fiber with the subsequent
coating as artificial turf infill [0131] 1000 providing a
subsequent composition by adding at least one additive and the
fluid binding agent to the natural fiber [0132] 1002 mixing the
subsequent composition [0133] 1004 adding water and the catalyst to
the subsequent composition during the mixing of the subsequent
composition to cure the fluid binding agent and the at least one
additive into a further coating [0134] 1100 mixing vat [0135] 1102
rotatable shaft [0136] 1104 mixing paddles [0137] 1200 flow reactor
[0138] 1202 rotatable shaft [0139] 1204 screw conveyor [0140] 1208
inlet for natural fiber [0141] 1210 first inlet for at least one
pigment and fluid binding agent [0142] 1212 first inlet for water
and catalyst [0143] 1214 second inlet for at least one pigment and
fluid binding agent [0144] 1216 first inlet for water and catalyst
[0145] 1217 outlet [0146] 1218 dryer [0147] 1220 base composition
[0148] 1222 subsequent composition
* * * * *