U.S. patent application number 16/695806 was filed with the patent office on 2020-05-28 for artificial turf with opaque face yarn and translucent thatch yarn fibers.
This patent application is currently assigned to APT Advanced Polymer Technology Corp.. The applicant listed for this patent is APT Advanced Polymer Technology Corp. Polytex Sportbelage Produktions-GmbH. Invention is credited to Kris BROWN, Stefan HALLY, Ivo LOHR, Stephan SICK.
Application Number | 20200165785 16/695806 |
Document ID | / |
Family ID | 65243338 |
Filed Date | 2020-05-28 |
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United States Patent
Application |
20200165785 |
Kind Code |
A1 |
SICK; Stephan ; et
al. |
May 28, 2020 |
ARTIFICIAL TURF WITH OPAQUE FACE YARN AND TRANSLUCENT THATCH YARN
FIBERS
Abstract
An artificial turf includes translucent thatch yarn fibers and
opaque face yarn fibers that are integrated in a carrier.
Inventors: |
SICK; Stephan;
(Willich-Neersen, DE) ; BROWN; Kris; (Dalton,
GA) ; LOHR; Ivo; (Kempen, DE) ; HALLY;
Stefan; (Nettetal, DE) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
APT Advanced Polymer Technology Corp.
Polytex Sportbelage Produktions-GmbH |
Harmony
Grefrath |
PA |
US
DE |
|
|
Assignee: |
APT Advanced Polymer Technology
Corp.
Harmony
PA
Polytex Sportbelage Produktions-GmbH
Grefrath
|
Family ID: |
65243338 |
Appl. No.: |
16/695806 |
Filed: |
November 26, 2019 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62772108 |
Nov 28, 2018 |
|
|
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
D01F 6/60 20130101; D01F
1/04 20130101; F21S 8/022 20130101; G09F 19/228 20130101; D10B
2505/202 20130101; G09F 9/30 20130101; D06N 7/0071 20130101; E01C
13/08 20130101; D01F 1/10 20130101; D02G 3/445 20130101; D06N
2213/06 20130101; D06N 2209/0861 20130101; D01F 6/04 20130101; D01F
6/06 20130101; D06N 2209/0869 20130101; F21V 33/006 20130101; D06N
7/0065 20130101; D06N 3/0015 20130101 |
International
Class: |
E01C 13/08 20060101
E01C013/08; D02G 3/44 20060101 D02G003/44 |
Foreign Application Data
Date |
Code |
Application Number |
Jan 29, 2019 |
EP |
19154074.9 |
Claims
1. An artificial turf comprising: a carrier; translucent thatch
yarn fibers integrated in the carrier; and opaque face yarn fibers
integrated in the carrier.
2. The artificial turf of claim 1, wherein the length of the thatch
yarn fibers is smaller than the length of the face yarn fibers.
3. The artificial turf of claim 1, wherein the translucent thatch
yarn fibers are transparent.
4. The artificial turf of claim 1, wherein the artificial turf
comprises two or more subregions, wherein all face yarn fibers
contained in a subregion have the same color, which is different
from the color of the face yarn fibers contained in all subregions
adjacent to that subregion.
5. The artificial turf of claim 1, wherein the two or more
subregions form a color pattern being selected from a group
including: a logo of an organization; field markings and regions
defined by the field markings; symbols of a game; and a pattern
representing a text or an image.
6. The artificial turf of claim 1, wherein the face yarn fibers
includes one or more pigments.
7. The artificial turf of claim 1, wherein the thatch yarn fibers
are free of pigments.
8. The artificial turf of claim 1, wherein the thatch yarn fibers
and/or the face yarn fibers are selected from a group comprising
including polyethylene fibers, polyamide fibers, and polypropylene
fibers.
9. The artificial turf of claim 1, wherein the thatch yarn fibers
and/or the face yarn fibers are texturized.
10. The artificial turf of claim 1, wherein the thatch yarn fibers
include a nucleating agent and the face yarn fibers are free of the
nucleating agent or include a smaller amount of the nucleating
agent than the thatch yarn fibers.
11. The artificial turf of claim 10, wherein the nucleating agent
is an organic acid, an organic acid ester or organic acid salt.
12. The artificial turf of claim 10, wherein the nucleating agent
is a salt of hexahydrophthalic acid, sorbic acid or salicylic acid,
in particular a calcium salt of hexahydrophthalic acid.
13. A layered surface structure comprising: a display layer; and an
artificial turf including translucent fibers, the artificial turf
being placed on top of the display layer; wherein the display layer
includes one or more display elements adapted to emit light signals
toward the artificial turf.
14. The layered surface structure of claim 13, the artificial turf
being an artificial turf including: a carrier; translucent thatch
yarn fibers integrated in the carrier; and opaque face yarn fibers
integrated in the carrier.
15. A method of manufacturing an artificial turf comprising:
providing a carrier; integrating translucent thatch yarn fibers in
the carrier; and integrating opaque face yarn fibers in the
carrier.
16. A method of manufacturing a layered surface structure
comprising: providing a display layer including one or more display
elements; placing an artificial turf including translucent fibers
on top of the display layer; wherein the display elements are
adapted to emit light signals toward the artificial turf.
Description
FIELD OF THE INVENTION
[0001] The invention relates to the field of synthetic surfaces and
the production thereof, and more particularly to artificial
turf.
BACKGROUND AND RELATED ART
[0002] Artificial turf or artificial grass is surface that is made
up of fibers that are used to replace grass. The structure of the
artificial turf is designed such that the artificial turf has an
appearance that resembles grass. Typically, artificial turf is used
as a surface for sports such as soccer, American football, rugby,
tennis, golf, or for other playing fields or exercise fields.
Furthermore, artificial turf is frequently used for landscaping
applications. An advantage of using artificial turf is that it
eliminates the need to care for a grass playing or landscaping
surface, such as regular mowing, scarifying, fertilizing, and
watering.
[0003] Some artificial turf types are known that comprise a
combination of different types of fibers, e.g., fibers of two
different lengths. For example, US patent application U.S. Pat. No.
6,299,959 B1 describes synthetic grass having both surface forming
nontextured fibers and textured thatch zone forming fibers to add
resilience and to lock in rubber granules that are distributed more
densely near the base of the fibers. In one embodiment of this
arrangement, the covering rubberlike particles are used to
stabilize the synthetic surface fibers in their upright
position.
[0004] However, applicant has observed that the process of
producing artificial turf containing two or more fibers of
different types is very complex, expensive, and error-prone. In
particular, if the artificial turf is to contain a pattern of two
or more colors (for example, if field markings, a club logo, or
similar are to be integrated into the artificial turf during the
manufacturing process), the manufacturing process becomes difficult
and expensive: in this case it is necessary to replace the fiber
currently being mechanically integrated with another fiber of the
desired color at the edges where a color transition takes place.
This fiber substitution must be carried out for all fiber types
used and must be coordinated with great precision. Otherwise, the
color transitions appear frayed and blurred. If coordination is not
successful, rejects or a product with blurred color transitions
will result. But even if the coordination of the color-related
change of all fiber types is successful and a sharp color
transition is achieved, the material consumption is still higher
for multicolor artificial turf and the rejects produced are higher
than for monochrome artificial turf. This is because the machines
that integrate the fibers into the fabric usually "consume" a
certain part of fiber for the purpose of clamping a fiber into the
machine. This fiber part will not be integrated into the artificial
turf. Hence, the production of artificial turf comprising a
multicolor pattern and two or more different fiber types is
technically difficult and leads to increased production costs even
in the case of a correct and precisely orchestrated change of all
fiber types.
SUMMARY
[0005] It is an object of the invention to provide for an improved
artificial turf and methods for producing the same. The problem is
solved by the features as specified in the independent claims.
Embodiments of the invention are given in the dependent claims. The
embodiments and examples described herein can freely be combined
with each other unless they are mutually exclusive.
[0006] In one aspect, the invention relates to an artificial turf
comprising a carrier, translucent thatch yarn fibers integrated in
the carrier, and opaque face yarn fibers integrated in the
carrier.
[0007] Said features may be advantageous because the production
process may be simplified enormously, rejects can be avoided, and
production costs can be reduced. Because the thatch yarn fibers are
translucent, they allow the light reflected by the face yarn fibers
to pass through. The color impression of the thatch yarn fibers
thus corresponds at least largely to the color impression of the
face yarn fibers. The face yarn fibers s are opaque, i.e., they
essentially do not allow ambient light to pass through but reflect
it, whereby the reflection typically takes place in such a way
that, depending on the wavelength, part of the incident light is
absorbed, while another part is reflected. The wavelength of the
part of the light reflected by the opaque face yarn fibers
determines the color impression of the face yarn fibers. The color
impression of the thatch yarn fibers is also determined by the
wavelength of the part of the light reflected by the face yarn
fibers, since the thatch yarn fibers are translucent, i.e., they
allow the incident light to pass through completely or to a large
extent. Embodiments of the invention may be advantageous because it
is no longer necessary to change the yarn spools when manufacturing
artificial turf areas where a color transition occurs. The same
single thatch yarn fiber bobbin can be used for the entire surface
of the artificial turf. A color change therefore only requires a
change of yarn during the integration of the face yarn fibers.
Since the thatch yarn fibers are translucent, they have no
influence on the color impression of the artificial turf, so the
same translucent yarn can be used over the entire surface of the
artificial turf to integrate the thatch yarn fibers into the
carrier. The coordination effort during the production of the
artificial turf may thus be considerably lower. The production of
rejects can be avoided or at least reduced, and yarn consumption
may also be reduced, as the same yarn spool can be used to
integrate all thatch yarn fibers across all color transitions.
[0008] In another advantageous aspect, the manufacturing process
may be accelerated, because in some manufacturing processes or
plants the yarn change still requires human interaction, which not
only increases the susceptibility to errors, but also slows down
the production process. By avoiding yarn change actions during the
integration of the thatch yarn fibers, the manufacturing process
may be accelerated.
[0009] According to embodiments, the length of the thatch yarn
fibers is smaller than the length of the face yarn fibers.
[0010] This can be advantageous because the greater length of the
face yarn fibers additionally enhances their optical dominance over
the shorter thatch yarn fibers. For example, the face yarn fibers
can be several millimeters or even several centimeters longer than
the thatch yarn fibers. In some embodiments, the thatch yarn fibers
can also be partially or completely covered by filler material. All
this can contribute to the beneficial effect that the color
impression of artificial turf is essentially based exclusively on
the face yarn fibers, not on the thatch yarn fibers. The thatch
yarn fibers may fulfill a mechanical function, e.g., make the turf
more elastic and retain filler material but do not make their own
contribution to the color or color-based design of artificial
turf.
[0011] According to embodiments, the translucent thatch yarn fibers
are transparent.
[0012] This may be advantageous, because in contrast to translucent
fibers that scatter incident light (essentially without changing
the wavelength), transparent fibers may transmit incident light
essentially without changing the wavelength and without changing
direction. This means that not only the approximate color
impression, but also the contours and other optical features of the
face yarn fibers, may be more strongly accentuated. The
contribution of the thatch yarn fibers to the color impression or
overall optical impression of the artificial turf may additionally
be reduced. As a result, the color transitions in the manufactured
artificial turf may appear even clearer and sharper.
[0013] According to embodiments, the artificial turf comprises two
or more subregions. All face yarn fibers contained in a subregion
have the same color that is different from the color of the face
yarn fibers contained in all subregions adjacent to that
subregion.
[0014] According to embodiments, the two or more subregions form a
color pattern. The color pattern can be selected, for example, from
a group comprising a logo of an organization, field markings and
regions defined by the field markings, symbols of a game, a pattern
representing a text or an image, or combinations thereof.
[0015] According to embodiments, the face yarn fibers comprise one
or more pigments.
[0016] According to embodiments, the thatch yarn fibers are free of
pigments. This may be advantageous, because pigments may directly
as well as indirectly cause a scattering of light (turning a
transparent fiber into a merely translucent fiber). Applicant has
observed that some of the pigments, e.g., phthalocyanine green, act
as nucleating agents, which boost the formation of microcrystals in
the polymer material of the fiber. The pigments may induce
heterogeneous nucleation in the fiber. Hence, the pigments as well
as the microcrystals induced by the pigments may result in a
scattering of light. However, in general a transparent fiber is
considered more desirable than a merely translucent fiber because
the "optical contribution" of a transparent fiber to the look of
artificial turf is smaller, and color borders of complex color
patterns may be sharper and clearer if the thatch yarn fibers are
transparent and not just translucent.
[0017] According to embodiments, the thatch yarn fibers and/or the
face yarn fibers are selected from a group comprising polyethylene
(PE) fibers, polyamide (PA) fibers, and polypropylene (PP) fibers.
In particular, the fibers can be PE fibers or fibers comprising a
mixture of PE and PA, e.g., a blend of PE and PA. For example, the
fibers can be PE fibers comprising threadlike regions of PA that
increase the rigidity of the fibers.
[0018] According to embodiments, the thatch yarn fibers and/or the
face yarn fibers are texturized. Texturization of fibers may
increase the elasticity of the artificial turf, because the
texturized fibers may have a damping and cushioning effect. In an
additional beneficial aspect, the texturization may result in a
random orientation of the fibers, thereby improving the
ball-rolling properties and ensuring that the trajectory of a
rolling or bumping ball is a straight line.
[0019] According to preferred embodiments, the face yarn fibers are
non-texturized and the thatch yarn fibers are texturized.
[0020] According to embodiments, the thatch yarn fibers comprise a
nucleating agent. The face yarn fibers are free of the nucleating
agent or comprise a smaller amount of the nucleating agent than the
thatch yarn fibers.
[0021] Applicant has observed that some pigments, e.g.,
phthalocyanine green and phthalocyanine blue, act as a nucleating
agent. Hence, these pigments act as seeds for microcrystals that
may form when the fiber is manufactured or further processed. For
example, when a polymer mass is extruded to form a polymer film or
monofilament used for manufacturing a fiber, or when a fiber is
stretched, the nucleating agent will boost the creation of polymer
microcrystals. Such crystals may scatter light that passes through
the fiber. If a fiber comprises a large quantity of a nucleating
agent, the microcrystals formed in their vicinity will scatter the
light and make a fiber nontransparent. The fiber may still be
translucent if the majority of light beams entering the fiber with
the nucleating agent can leave the fiber without a significant
change of the wavelength composition, but the fiber may not be
transparent anymore because the light entering the fibers is
scattered and leaves the fiber in many different, random
directions.
[0022] According to embodiments, the nucleating agent is a salt of
hexahydrophthalic acid, in particular a calcium salt of
hexahydrophthalic acid.
[0023] According to embodiments, the nucleating agent is an organic
acid, an organic acid ester or organic acid salt. For example, the
nucleating agent can be a sorbic acid ester or a sorbic acid salt
such as sodium sorbate, potassium sorbate, and calcium sorbate, or
a salicylic acid salt such as sodium salicylate. According to a
further embodiment, the nucleating agent is a mixture of
zinc-stearate and a calcium salt of 1,2-cyclohexane-dicarboxylic
acid. For example, the mixture can comprise about 30-40%, e.g.
about 34% by weight the zinc-stearate, the rest of the mixture
consisting of the 1,2-cyclohexane-dicarboxylic acid.
[0024] Said features may be advantageous because organic acid salts
have been observed to be easily distributable homogeneously within
the polymer mass used for manufacturing the fibers. Providing a
polymer fibers with a homogeneous dispersion of nucleating agent
molecules may be advantageous, because the microcrystals forming at
the nucleating agent molecules are dispersed homogeneously also. In
effect, the homogeneous dispersion of crystals will reduce light
scattering and may provide for fibers that are not only
translucent, but also transparent.
[0025] According to embodiments, the nucleating agent is a
colorless substance.
[0026] According to embodiments, the thatch yarn fibers comprise
the nucleating agent in an amount of 0.01% to 2.0% by weight of the
fibers. Preferably, the thatch yarn fibers comprise the nucleating
agent in an amount of 0.1% to 1.0% by weight of the fiber. In
particular, the thatch yarn fibers comprise the nucleating agent in
an amount of about 0.2% by weight of the fiber.
[0027] This may be advantageous, because a polymer fiber that is
free of a pigment and that comprises the above mentioned substances
as the nucleating agent preferably within an amount range as
specified above will be transparent. In an additional beneficial
aspect, artificial turf fibers comprising a nucleating agent will
have an increased surface roughness thanks to the crystals formed
at the surface. Hence, when the fibers are incorporated in the
carrier and are optionally partially embedded in a liquid PU- or
latex-based backing that later solidifies, the fibers are fixed
more strongly in the carrier and the optional backing.
[0028] In an additional beneficial aspect, calcium salt of
hexahydrophthalic acid is colorless, i.e., it does not generate a
color impression that is recognizable by the human eye.
[0029] According to embodiments, the thatch yarn fibers are free of
a light absorbing substance (such as e.g. light absorbing pigments
or fillers) and are free of a nucleating agent. This may have the
advantage that the production costs are reduced and the resulting
thatch yarn fibers are still translucent (but typically not
transparent).
[0030] In a further aspect, the invention relates to a layered
surface structure comprising a display layer and an artificial turf
placed on top of the display layer. For example, the artificial
turf that is placed on top of the display layer can solely comprise
translucent, e.g., transparent, fibers and be free of any opaque
fibers. According to embodiments, the artificial turf that is
placed on top of the display layer is an artificial turf comprising
opaque and translucent fibers as described in accordance with
embodiments and examples of an artificial turf described herein and
as illustrated, for example, in FIGS. 1-6. The display layer
comprises one or more display elements adapted to emit light
signals toward the artificial turf.
[0031] For example, the display elements can be electronic display
elements. The display elements can be adapted and configured to
visually represent and display information, e.g., information
provided by one or more control units that are operatively coupled
to the display elements.
[0032] In a further aspect, the invention relates to a method of
manufacturing an artificial turf. The method comprises providing a
carrier, integrating translucent thatch yarn fibers in the carrier,
and integrating opaque face yarn fibers in the carrier.
[0033] In a further aspect, the invention relates to a method of
manufacturing a layered surface structure. The method comprises
providing a display layer comprising one or more display elements
and placing an artificial turf comprising translucent fibers on top
of the display layer. The electronic display elements are adapted
to emit light signals toward the artificial turf.
[0034] For example, the artificial turf that is placed on top of
the display layer can solely comprise translucent, e.g.,
transparent, fibers and be free of any opaque fibers.
[0035] According to embodiments, the artificial turf that is placed
on top of the display layer is an artificial turf comprising opaque
and translucent fibers according to any one of the embodiments and
examples described herein.
[0036] A "translucent fiber" (also called diaphanous fiber) as used
herein is a fiber made of material that has the physical property
of allowing light to pass through the material without being
scattered. On a macroscopic scale (one where the dimensions
investigated are much larger than the wavelength of the photons in
question), the photons can be said to follow Snell's Law.
[0037] A "transparent fiber" as used herein is a fiber made of
material that has the physical property of allowing light to pass
through, but does not necessarily (again, on the macroscopic scale)
follow Snell's law; the photons can be scattered at either of the
two interfaces, or internally, where there is a change in index of
refraction.
[0038] Translucency (also called translucence or translucidity) is
a superset of transparency. A translucent medium allows the
transport of light, while a transparent medium not only allows the
transport of light but also allows for image formation. Transparent
materials appear clear, with the overall appearance of one color,
or any combination leading up to a brilliant spectrum of every
color. The opposite property of translucency is opacity.
[0039] An "opaque fiber" as used herein is a fiber made of a
material that does not transmit light. Many such substances have a
chemical composition that includes what are referred to as
absorption centers. Many substances are selective in their
absorption of white light frequencies. They absorb certain portions
of the visible spectrum while reflecting others. The frequencies of
the spectrum that are not absorbed are either reflected or
transmitted for our physical observation. This is what gives rise
to color. The attenuation of light of all frequencies and
wavelengths is due to the combined mechanisms of absorption and
scattering.
[0040] A "subregion of an artificial turf" as used herein is a
defined region within the artificial turf that is characterized by
a particular color. For example, all face yarn fibers contained in
a subregion can have the same color that is different from the
color of the face yarn fibers contained in all subregions adjacent
to that subregion. For example, an artificial turf may comprise a
color pattern that corresponds to the flag of the United States.
This pattern would consist of 7 red subregions and 6 white
subregions having the form of stripes that represent the 13
founding states, a blue subregion in the upper left corner and 50
additional subregions within the blue subregion in the form of
white stars that symbolize states of the USA. Hence, the color
pattern representing the flag of the USA would consist of 63
subregions, and any artificial turf comprising this pattern would
comprise at least 64 subregions (any subregion of the artificial
turf not covered by the flag corresponds to the 64th
subregion).
[0041] A "pigment" as used herein is a material that changes the
color of reflected or transmitted light as the result of
wavelength-selective absorption. According to preferred
embodiments, a pigment is a material that humans have chosen and
developed for coloring other materials. In particular, the
materials used as pigments can have special properties that make
them useful for coloring other materials, e.g., a high-tinting
strength relative to the materials it colors, chemical stability in
solid form at ambient temperatures, thermal stability at increased
process temperature (e.g., the temperature used in the extrusion
process), etc. A pigment can be an inorganic or organic chemical
substance.
[0042] A "texturized fiber" as used herein is a fiber that was
subjected to a texturizing process. A texturizing process is the
process by which fibers, in particular synthetic fibers, are
modified to change their texture--the physical appearance of the
fiber. Texturizing techniques can include bulking (where
thermoplastic fibers are twisted, heat-set, and untwisted) or
crimping and coiling, among others. Some texturizing approaches
take advantage of the thermoplastic nature of synthetic fibers and
use it to set texturized features in place. These modifications
will also affect the eventual fabric and fibers may be folded,
looped, coiled, or crinkled. Texturizing can reduce the "synthetic"
appearance of a finished good comprising a textured fiber.
[0043] A "nucleating agent" as used herein is a substance adapted
to promote the crystallization of polymers, in particular of
semicrystalline polymers. This effect can be achieved by presenting
a heterogeneous surface to the polymer melt. Nucleation starts with
small, nanometer-sized areas where, as a result of heat motion,
some chains or their segments occur parallel. Those seeds can
either dissociate, if thermal motion destroys the molecular order,
or grow further, if the grain size exceeds a certain critical
value. Crystallization of polymers is a process associated with
partial alignment of their molecular chains. These chains fold
together and form ordered regions called lamellae, which compose
larger spheroidal structures named spherulites.
[0044] A "layered surface structure" as used herein is a manmade
flooring structure comprising at least two layers. The term
"manmade" includes "machine-made" and means that the layered
surface structure is not merely a soil structure that has formed
naturally. The layered surface structured can be fabricated at the
use site, e.g., by installing each of the multiple layers at the
use site one after another. Alternatively, the layered surface
structure can be fabricated at a plant and can then be transported
to and installed at the use site. Mixed approaches are also
possible. For example, it is possible to clean and level the base
layer at the use site, which may consist of soil or sand. Then,
multilayered surface structure tiles that may have been
manufactured in a plant can be applied on top of the leveled base
layer and connected with each other. Finally, one or more coatings
may be applied. Then, multilayered surface structure tiles that may
have been manufactured in a plant can be applied on top of the
leveled base layer and connected with each other. Finally, one or
more coatings may be applied. Alternatively, different parts of the
multilayer surface structure are produced in different factories
and are then combined and installed at the use site. For example, a
first company may manufacture display tiles comprising one or more
electronic display devices and a second company may manufacture
artificial turf. The display tiles are installed at the use site
and connected with each other to form the display layer. Then, the
artificial turf is applied on top of the display layer, thereby
forming the layered surface structure.
[0045] A "carrier" as used herein is a material that is adapted for
integrating fibers, e.g., artificial turf fibers, into the
material, thereby providing mechanical stability to the fibers. For
example, the carrier can be a sheet-like structure, e.g., a mesh of
natural and/or synthetic fibers.
[0046] A "display element" as used herein is a device or device
component that is adapted to display information and emit light
signals. For example, the electronic device can be an optical
device or an electronic device. Preferably, the display elements
are installed and/or are configured to emit the light signals
selectively or predominantly in an "upward direction," i.e., in the
direction to the artificial turf that lies on top of the display
layer comprising the display elements. A display element can be,
for example, an LED spot, an LED panel, an OLED light source, an
LCD display, or similar. A display element can be configured to
visually represent--alone or in combination with other display
elements contained in the same display layer--a particular piece of
information, e.g., graphical information that specifies the
contours and colors of a logo or other pattern.
[0047] A "display layer" as used herein is a layer of a surface
structure that comprises one or more display elements. In some
embodiments, the display layer comprises or is operatively coupled
to one or more control units of the display elements. The control
units are configured to graphically represent and display
information via the display elements contained in the display layer
to the users of the layered surface structures (i.e., the players)
and preferably also to the audience.
BRIEF DESCRIPTION OF THE DRAWINGS
[0048] In the following, embodiments of the invention are explained
in greater detail, by way of example only, making reference to the
drawings in which:
[0049] FIG. 1 depicts a 3D model of an art artificial turf
according to an embodiment of the invention.
[0050] FIG. 2 depicts a cross-sectional view of an artificial turf
according to an embodiment of the invention.
[0051] FIG. 3 depicts a region of FIG. 2 in greater detail.
[0052] FIG. 4 depicts an artificial turf according to a further
embodiment.
[0053] FIG. 5 depicts an artificial turf according to a further
embodiment.
[0054] FIG. 6 depicts an artificial turf according to a further
embodiment.
[0055] FIG. 7A depicts a flowchart of a method of producing
artificial turf according to an embodiment of the invention.
[0056] FIG. 7B depicts a flowchart of a method of producing a
layered surface structure according to an embodiment of the
invention.
[0057] FIG. 8 depicts tuft rows of an artificial turf according to
an embodiment of the invention.
[0058] FIG. 9 depicts tuft rows of an artificial turf according to
a further embodiment of the invention.
[0059] FIG. 10 depicts a layered surface structure according to an
embodiment of the invention.
[0060] FIG. 1 depicts a virtual 3D model 100 of an art artificial
turf according to an embodiment of the invention. It comprises
straight, non-texturized face yarn fibers 102 having a pile height
L3, and a zone of texturized thatch yarn fibers 104. The thatch
yarn fibers have a height L2 that is shorter than the height L3 of
the face yarn fibers. The difference between the height of the face
yarn fibers and of the thatch yarn fibers is depicted as "L1." The
thatch yarn fibers and face yarn fibers are integrated into a
carrier structure 106, e.g., a fiber mesh. The fiber mesh can be
made of synthetic and/or natural fibers. In some embodiments, the
fiber mesh is created by interweaving the face yarn fibers with
each other such that the forming of the mesh and the integration of
the face yarn fibers is performed in a single operation. According
to other embodiments, the carrier mesh 106 is provided first and
the fibers 102, 104 are integrated into the existing carrier mesh
106 in subsequent steps.
[0061] Optionally, the artificial turf can comprise a backing layer
below the carrier 106 (not shown). The backing layer may consist of
polyurethane (PU) or latex and may be used for firmly fixing the
fibers 102, 104 in the carrier 106.
[0062] In the embodiment depicted in FIG. 1, the artificial turf
further comprises infill 110. The infill can be, for example, an
elastic granulate such as rubber granulate, cork granulate, etc.,
and/or inelastic particles such as sand or zeolite or a mixture
thereof.
[0063] The whole artificial turf comprising the fibers 102, 104,
the carrier 106, the optional filler and the backing (if any) can
be placed on top of a base layer 108. The base layer can also be
referred to as "ground layer" or "substrate layer." For example,
the base layer can be made of concrete, soil, stone, or similar. It
is also possible that the base layer is a manmade flooring layer,
e.g., a layer comprising electronic elements such as LED panels or
other display devices. The manmade layer can also be an elastic
layer, e.g., a PU layer comprising rubber particles.
[0064] The face yarn fibers in the artificial turf model 100 have a
green color such that natural grass fibers are faithfully
reproduced. The thatch yarn fibers in the 3D model are depicted in
a brighter color in order to better illustrate their height,
position, and texturization. However, FIG. 1 merely depicts a
virtual model. The thatch yarn fibers of an artificial turf
according to embodiments of the invention actually are translucent
and hence cannot be identified as clearly as indicated in the
computer-generated model depicted in FIG. 1.
[0065] FIG. 2 is a photo of a cross-sectional view of an actual
artificial turf 200 according to another embodiment of the
invention. The artificial turf 200 comprises red, non-texturized
face yarn fibers 102 and translucent, colorless, texturized thatch
yarn fibers 104. In addition, the artificial turf comprises infill
granules 110 in the form of rubber granules. The rubber granules
can be coated and the coating can comprise pigments, e.g., dark or
brownish pigments to give the color impression of sand or soil. The
filler material 110 can likewise be, for example, a
sand-rubber-granule mixture. The infill may fill free space between
thatch yarn fibers and/or face yarn fibers. The infill height can
be smaller than the thatch yarn length L2, or can be a height
between L2 and L3. In one embodiment, the upper surface of the
infill layer is one or more cm below the pile height L3. Thanks to
a combination of face yarn fibers and thatch yarn fibers, the
infill granules are stabilized and are protected from being
delocalized by a ball or other object hitting the surface of the
artificial turf.
[0066] The texturization of the thatch yarn fibers may result in a
random orientation of the thatch yarn fibers and an intertwining of
the face yarn fibers and the thatch yarn fibers. This may help to
mechanically fix the infill granules between the thatch yarn
fibers, thereby reducing the loss of infill material that may be
caused by rainfall, wind, and impacting objects, e.g., a ball or a
foot of a player. The thatch yarn fibers depicted in FIG. 2 are not
only translucent but also transparent.
[0067] The thatch yarn fibers can be textured or nontextured.
Likewise, the face yarn fibers can be textured or nontextured
fibers. The texturization of fibers, in particular of the thatch
yarn fibers 104, may provide for a random orientation of the
textured fibers in the artificial turf. This provides an artificial
turf with a more homogeneous surface that increases the
predictability and directional stability of any object rolling or
sliding over the surface of the artificial turf.
[0068] FIGS. 1 and 2 show the texturized thatch yarn fibers 104 in
their relaxed, default state. The length of the fibers in this
state is shorter than in a stretched, expanded state, due to their
texturization.
[0069] The fibers 102, 104 can be monofilaments or split film tapes
or bundles of monofilaments or split film tapes. Preferably, the
fibers of the face yarn are made of a mixture of PE/PA with
compatibilizer as disclosed in EP 3122942. Surprisingly PE/PA
monofilaments have the following advantages in this context: the PE
provides for a soft, elastic surface that protects the skin of the
players from injury. The PA increases the rigidity and thus ensures
that the fibers re-erect after being trampled down. If the fiber is
a textured fiber, the use of a PE/PA mixture or blend may ensure
that the texturing has more long term stability even if subjected
to mechanical stress and weathering (sunshine).
[0070] According to some embodiments, the thatch yarn fibers can be
made of PE monofilaments (in particular LLDPE) or another material
as it is less stressed both mechanically and by weathering.
Moreover, thatch yarn lacking PA may shrink more if exposed to
heat. This effect may be used for generating an artificial turf
with two types of texturized fibers that are adapted to form a
thatch yarn zone of a clearly defined, uniform fiber height L2, and
for generating face yarn fibers having a defined, uniform fiber
height L3 although the face yarn fibers may be texturized.
[0071] The thatch yarn fibers and the face yarn fibers can be made
of the same type of polymer, e.g., PE, or of a mixture of miscible
polymers, or a polymer mixture of immiscible polymers. For example,
the polymer mixture used for generating the face yarn or thatch
yarn fibers can be a three-phase system, wherein the polymer
mixture comprises a first polymer, a second polymer, and a
compatibilizer. The first polymer and the second polymer are
immiscible. The first polymer forms polymer beads surrounded by the
compatibilizer within the second polymer as disclosed in EP 3122942
the entirety of which being expressly herein incorporated by
reference. The second polymer may be a PE and the first polymer can
be PA. The polymer mixture used for generating the first fibers to
be turned into thatch yarn fibers can be made of PE that is free of
any PA. The PA beads may provide some stability and rigidity to the
fibers, thereby reducing the ability of the second fibers to
contract, e.g., in response to heat.
[0072] The face yarn fibers and thatch yarn fibers can be
integrated into the carrier, e.g. by gluing, weaving, or tufting
the fibers into the carrier.
[0073] The face yarn fibers 102 define the pile height L3 of the
artificial turf and provide the rolling resistance for the rolling
ball. The thatch yarn fibers 104 serve the purpose of holding or
immobilizing the infill, if any, and prevent or reduce splashing
and limit redistribution of the infill when the artificial turf is
in use, thereby preventing an uneven distribution of the
infill.
[0074] FIG. 3 depicts a region 202 of FIG. 2 in greater detail.
FIG. 3 illustrates that the thatch yarn fibers of some embodiments
are not only translucent, but also transparent, meaning that not
only the color of the face yarn fibers, but also the contours of
the face yarn fibers are visible through a thatch yarn fiber.
[0075] FIG. 4 depicts an artificial turf 400 according to a further
embodiment. The artificial turf 400 comprises non-texturized face
yarn fibers 102 and texturized thatch yarn fibers 104.
[0076] FIG. 5 depicts an artificial turf 500 according to a further
embodiment. The artificial turf 500 comprises texturized face yarn
fibers 102 and texturized thatch yarn fibers 104.
[0077] FIG. 6 depicts an artificial turf 600 according to a further
embodiment. The artificial turf 500 comprises texturized face yarn
fibers 102, texturized thatch yarn fibers 104, and a filler 110
that is mechanically stabilized by the face yarn fibers and the
thatch yarn fibers.
[0078] The side of the carrier 106 from which the fibers 102, 104
protrude is referred to herein as the "upper side" of the
carrier/of the artificial turf, while the other side, where only
u-shaped portions of the fibers forming tuft knots and/or a
secondary backing may be visible, is referred to herein as the
"lower side" of the artificial turf.
[0079] FIG. 7A depicts a flowchart of a method of producing
artificial turf 200, 400, 500, 600, 800, 900 according to an
embodiment of the invention.
[0080] In step 702, a carrier 106 is provided. The carrier can be a
textile carrier, e.g., a fiber mesh made of synthetic and/or
natural fibers. The carrier can be provided by feeding the carrier
into a machine that is configured for integrating fibers into the
carrier. The machine can be, for example, a tufting machine.
[0081] In step 704, translucent thatch yarn fibers 104 are
integrated in the carrier. For example, the thatch yarn fibers can
be tufted, knitted, woven, glued, or otherwise integrated into or
attached to the carrier.
[0082] In step 706, opaque face yarn fibers 102 are integrated in
the carrier. For example, the face yarn fibers can be tufted,
knitted, woven, glued, or otherwise integrated into or attached to
the carrier.
[0083] In some embodiments, the face yarn fibers are integrated
earlier than the thatch yarn fibers. In other embodiments, the
thatch yarn fibers are integrated earlier than the face yarn
fibers. In still other embodiments, the face yarn fibers and the
thatch yarn fibers are integrated basically at the same time. For
example, the thatch yarn fibers and the face yarn fibers can be
tufted into the carrier by different tufting machine or by a
tufting machine comprising two or more different tufting
needles.
[0084] According to embodiments, the integration of the fibers is
performed such that the machine or machine component that performs
the integration of the face yarn fibers replaces the face yarn
having a first color that was previously used for integration by
another face yarn having a second color when the machine crosses a
subregion border of the artificial turf. The machine or machine
component that performs the integration of the thatch yarn fiber
maintains (does not replace) the thatch yarn that was previously
used for integration by another thatch yarn when the machine
crosses a subregion border of the artificial turf.
[0085] This may significantly ease and accelerate the process of
integrating fibers when manufacturing artificial turf that
comprises complex patterns of multiple different colors.
[0086] FIG. 7B depicts a flowchart of a method of producing a
layered surface structure 950 as depicted, for example, in FIG.
9.
[0087] In step 750, a display layer 952 comprising one or more
display elements is applied. The display layer can be installed on
a base layer made of a natural material such as soil, wood, or
stone or on top of a base layer made of another type of material
such as concrete, polyurethane, acrylic resin or similar. The
layered structure can be an indoor or an outdoor flooring, e.g., a
playing surface of a sports field or playground. In particular, the
surface structure can be an interactive playing surface, e.g., an
interactive gym floor, soccer floor, golf course, tennis field, or
similar. The application of the display layer can comprise
installing the display elements at the use site, e.g., connecting
the display elements with one or more control units and with a
power source.
[0088] Then in step 752, an artificial turf is applied on top of
the display layer. The artificial turf is an artificial turf as
described herein for embodiments and examples of the invention and
as depicted, for example, in FIGS. 2, 3, 4, 5, 6, 8, and 9. The
artificial turf can be placed directly on top of the display layer.
Alternatively, one or more translucent, preferably transparent
material layers can be applied on top of the display layer before
the artificial turf is applied. For example, a glass layer or a
polymer foil layer can be applied in order to better protect
sensitive electronic components of the display elements from
impacting objects.
[0089] The display elements can be electronic display elements
adapted to visually represent and display information and emit
light signals in the direction to the artificial turf, i.e., in an
upward direction. In some embodiments, the display elements are
configured to emit light in basically all directions. However,
preferably, the display elements are configured to emit the
majority of the light in basically an upward direction to save
energy and costs. It needs to be ensured that at least the players
using the surface structure and also the audience can see the light
intensity and/or color pattern generated by the light emitted by
the display elements.
[0090] FIG. 8 depicts tuft rows 802, 804 of an artificial turf 800
according to an embodiment of the invention. In the depicted
embodiment, texturized face yarn fibers and texturized thatch yarn
fibers are tufted in straight parallel rows. Thatch yarn fiber rows
("B"), 802 and face yarn fiber rows ("A") 804 are alternating in
the plane of the artificial turf. The face yarn fibers are longer
than the thatch yarn fibers. The fibers are integrated into the
carrier mesh by a tufting process, whereby bundles of fibers of the
same type are tufted into the carrier and are then cut. Each row
802, 804 comprises only fibers of one particular type, i.e., either
thatch yarn fibers or face yarn fibers.
[0091] The distance between tufting rows of the same fiber type can
be e.g., 1.9 cm and can be about 0.95 cm between neighboring rows
of face/thatch yarn.
[0092] FIG. 9 depicts another artificial turf 900 wherein
texturized face yarn fibers and texturized thatch yarn fibers are
tufted in parallel, zigzag rows. Thatch yarn fiber rows 902 and
face yarn fiber rows 904 are alternating in the plane of the
artificial turf. Each row comprises only fibers of one particular
type, i.e., either thatch yarn fibers or face yarn fibers.
[0093] Using texturized face yarn fibers reduces the anisotropy of
the roll resistance of the artificial turf. Zigzag rows are
particularly advantageous in this context as they reduce the
anisotropy of the roll resistance of the artificial turf even
more.
[0094] According to further embodiments ("mixed type tuft rows,"
not shown), face yarn fibers and thatch yarn fibers are tufted in
parallel, mixed type (or "mixed") rows. Each row comprises a
mixture of both texturized face yarn fibers and texturized thatch
yarn fibers. For example, each row may comprise a mixture of thatch
yarn fiber bundles and face yarn fiber bundles. Alternatively, each
row may comprise a mixture of face and thatch yarn fibers that are
individually tufted into the carrier. Still alternatively, each row
may comprise tuft bundles respectively comprising a mixture of
thatch yarn fibers and face yarn fibers.
[0095] FIG. 10 depicts a layered surface structure 950 according to
an embodiment of the invention. The surface structure comprises a
display layer 952 and an artificial turf 960 on top of the display
layer.
[0096] The display layer comprises a plurality of display elements
954, e.g., LED light spots or stripes. Each of the display elements
can be connected to one or more control units, e.g., one or more
remote or local control computers. The control units cause the
display elements to light up to display patterns of different light
intensity and/or color on. These patterns can relate to line
markings for different sports. For example, the display elements
can be LED lights underneath a transparent or translucent layer,
e.g., a glass floor. The dynamic displaying of the line markings
may allow supporting many different types of sports such as tennis,
handball, volleyball, basketball, and badminton by a single playing
surface structure. For example, the display layer can comprise a
plurality of single glass panels layered with foil and comprising
bright LED or OLED spots or stripes whose intensity and/or color
can be controlled by the control unit(s) individually.
[0097] The artificial turf 960 comprises translucent fibers 956.
Preferably, the fibers 956 are transparent fibers, e.g.,
transparent PE fibers that can be texturized or non-texturized
fibers. According to some embodiments, all fibers 956 of the
artificial turf 960 are translucent, e.g., transparent, fibers.
This may have the advantage that the light emitted by the display
layer is not, or not significantly, weakened or absorbed by the
artificial turf. However, this type of artificial turf is not
suited for representing and comprising a graphical pattern, e.g., a
logo, because the fibers basically do not modify the wavelength
composition of the light passing through the fibers. According to
other embodiments, the artificial turf comprises the transparent
fibers 956 in addition to opaque fibers. For example, the
artificial turf 950 can be an artificial turf as described herein
for embodiments and examples of the inventive artificial turf,
e.g., a turf 100, 200, 400, 500, 600, 800, 900 illustrated in FIGS.
1, 2, 4, 5, 6, 8, and 9. This may have the advantage that some
patterns can be generated by the display layer while other patterns
can be generated based on color differences of the opaque face yarn
fibers. For example, the color of the pigments of different face
yarn fibers can be used for defining permanent patterns in the
artificial turf, e.g., line markings or a logo of a club owning the
surface structure 950 while the light emitted selectively by some
display elements of the display layer may define line markings that
may be changed dynamically based on the type of game to be played.
However, it is also possible that the line markings, for example,
are defined permanently via pigment differences of face yarn fibers
and the display elements are used for displaying dynamically
modifiable patterns such as the logo of the invited club, an ad, a
text with information for visitors, or the like.
[0098] The face yarn fibers 102 of the artificial turf 200 may
absorb some of the light emitted by the display elements 954, but a
significant portion of the light will pass through the artificial
turf layer because the translucent thatch yarn fibers ensure that
the light is not completely absorbed or blocked by the face yarn
fibers. The thatch yarn fibers, in particular if textured, will
occupy space and thus ensure that some regions of the artificial
turf allow light to pass through.
LIST OF REFERENCE NUMERALS
[0099] 100 3D model of artificial turf [0100] 102 face yarn fibers
[0101] 104 thatch yarn fibers [0102] 106 carrier [0103] 108 base
layer [0104] 110 filler material [0105] L2 length of thatch yarn
fibers [0106] L3 length of face yarn fibers [0107] L1 difference of
L2 and L3 [0108] 200 artificial turf [0109] 202 selected region of
artificial turf 200 [0110] 400 artificial turf [0111] 500
artificial turf [0112] 600 artificial turf [0113] 702-706 steps
[0114] 750-752 steps [0115] 800 artificial turf [0116] 802 tuft row
comprising thatch yarn fibers [0117] 804 tuft row comprising face
yarn fibers [0118] 900 artificial turf [0119] 902 tuft row
comprising thatch yarn fibers [0120] 904 tuft row comprising face
yarn fibers [0121] 950 layered surface structure [0122] 952 display
layer [0123] 954 display element [0124] 956 translucent fiber
[0125] 960 artificial turf
* * * * *