EP3553225A1 - Gazon artificiel avec fil de face texturé et fil en chaume texturé - Google Patents

Gazon artificiel avec fil de face texturé et fil en chaume texturé Download PDF

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Publication number
EP3553225A1
EP3553225A1 EP18167363.3A EP18167363A EP3553225A1 EP 3553225 A1 EP3553225 A1 EP 3553225A1 EP 18167363 A EP18167363 A EP 18167363A EP 3553225 A1 EP3553225 A1 EP 3553225A1
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EP
European Patent Office
Prior art keywords
fibers
texturized
polymer
yarn
carrier
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Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
EP18167363.3A
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German (de)
English (en)
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EP3553225B1 (fr
Inventor
Stephan Sick
Bernd Jansen
Dirk Schmitz
Ivo LOHR
Stefan HALLY
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Apt Asia Pacific Pty Ltd
Polytex Sportbelage Produktions GmbH
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Apt Asia Pacific Pty Ltd
Polytex Sportbelage Produktions GmbH
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Priority to EP18167363.3A priority Critical patent/EP3553225B1/fr
Publication of EP3553225A1 publication Critical patent/EP3553225A1/fr
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    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N7/00—Flexible sheet materials not otherwise provided for, e.g. textile threads, filaments, yarns or tow, glued on macromolecular material
    • D06N7/0063—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf
    • D06N7/0065—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf characterised by the pile
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06C—FINISHING, DRESSING, TENTERING OR STRETCHING TEXTILE FABRICS
    • D06C13/00—Shearing, clipping or cropping surfaces of textile fabrics; Pile cutting; Trimming seamed edges
    • D06C13/04—Shearing lace or embroidery, e.g. cutting loose threads
    • E—FIXED CONSTRUCTIONS
    • E01—CONSTRUCTION OF ROADS, RAILWAYS, OR BRIDGES
    • E01C—CONSTRUCTION OF, OR SURFACES FOR, ROADS, SPORTS GROUNDS, OR THE LIKE; MACHINES OR AUXILIARY TOOLS FOR CONSTRUCTION OR REPAIR
    • E01C13/00—Pavings or foundations specially adapted for playgrounds or sports grounds; Drainage, irrigation or heating of sports grounds
    • E01C13/08—Surfaces simulating grass ; Grass-grown sports grounds

Definitions

  • the invention relates to the field of synthetic surfaces and the production thereof, and more particularly to artificial turf.
  • 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.
  • 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.
  • 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, like regular mowing, scarifying, fertilizing, and watering.
  • Some artificial turf types are known which comprise a combination of fibers of two different lengths.
  • US patent application US 6,299,959 B1 describes synthetic grass having both surface forming non-textured fibers and textured thatch zone forming fibers to add resilience and to lock in rubber granules which are distributed more densely near the base of the fibers.
  • the covering rubber like particles are used to stabilize the synthetic surface fibers in their upright position.
  • the lack of rigidity of the pile yarn fibers and the tufting-induced tilt of the pile yarn fibers in one direction may alone or in combination result in inhomogeneous and unpredictable movement of any object that rolls or slides along the surface of the artificial turf. This movement behavior is considered highly undesirable in almost all types of application scenarios, in particular in any kinds of ball sports like soccer, golf, or the like.
  • the invention relates to an artificial turf comprising textured thatch yarn fibers, textured face yarn fibers, and a carrier.
  • the face yarn fibers are integrated in the carrier such that the thatch yarn fibers protrude from the carrier by a shared thatch yarn fiber height (L2).
  • the thatch yarn fibers are integrated in the carrier such that the face yarn fibers protrude from the carrier by a shared face yarn fiber height (L3).
  • the face yarn fiber height is larger than the thatch yarn fiber height.
  • Said features may be advantageous for multiple reasons.
  • an artificial turf may allow for predictable, straight movement trajectories of a ball.
  • the tilt of the fibers generated by the tufting process is "randomized".
  • the texturized face yarn fibers still have a tufting-induced tilt, but as they are texturized, the direction of the tilt of all face yarn fiber is randomized such that no net effect of the tilt of the fibers on the movement of a ball is observable.
  • the texturization-induced randomization of the orientation of the thatch yarn fibers and of the face yarn fibers reduces the light reflection on the surface of the artificial turf fibers. This is desirable for acquiring high-quality photographs (e.g. of children playing on ground made of artificial turf) and TV broadcasts of soccer games and other types of sport.
  • the rigidity of the face yarn fibers is increased even if no infill is present or if the height of the infill layer is lower than the height of the face yarn fibers. This may allow providing an artificial turf that is particularly robust against wear and tear.
  • an artificial turf is provided with a "thatch yarn zone” and a "face yarn zone” whose fibers respectively have a defined, common length.
  • a defined, particular pile height is created by cutting non-texturized fibers which do not change their length after the cutting.
  • embodiments of the invention use texturized fibers for generating the face yarn fibers of a particular, defined, common length. This is not trivial, because texturized fibers may have an inhomogeneous distribution of their mass and of other relevant parameters which may have an impact on their length when being cut.
  • the thatch yarn fibers and face yarn fibers protrude in the same direction, respectively generate a "layer" or "zone” of a predefined height.
  • all face yarn fibers have basically the same length (measured from the point where the fiber is integrated in the carrier and the end of the fiber protruding from the carrier).
  • at least 90%, more preferably at least 99% of the thatch yarn fibers have a thatch yarn length that differs from a median thatch yarn fiber length not more than +/- 10%.
  • at least 90%, more preferably at least 99% of the face yarn fibers have a face yarn length that differs from a median face yarn fiber length not more than +/- 10%.
  • the first and second texturized fibers respectively have a molecular memory of a textured state, wherein a textured state can be, for example, a curled, crumpled and/or wrinkled state.
  • a "molecular memory” means a tendency to turn into a particular state, i.e., the textured state, if the fiber is allowed to do so.
  • the tufting needle may exert a force on the tufted fiber, thereby stretching the fiber and turning the fiber into a stretched, partially or completely "non-texturized" shape. However, as soon as the stretching force has disappeared, e.g.
  • the artificial turf is a playing field surfaces for athletic games such as tennis, football, soccer, baseball, field hockey and golf, or is a landscaping artificial turf.
  • the artificial turf may be a high-usage artificial turf.
  • the invention relates to a method of producing an artificial turf.
  • the method comprises:
  • Said features may be advantageous, as they allow using the same type of polymer material for the first and second fibers.
  • the length difference may be achieved solely by different degrees of texturization of the fibers.
  • different degrees of contraction and thus, different lengths of the fibers in their default state are achieved.
  • This may allow choosing the polymer type freely in dependence on the particular needs of a given use case scenario, and freely defining the respective end length of the thatch yarn fibers and the face yarn fibers by differential texturization of the first and the second fibers.
  • the first and second texturized fibers are made of the same material, e.g.
  • the first and the second texturized fibers are made of different materials which may have identical or different capabilities to contract, e.g. shrink, in response to being exposed to a contraction-inducing condition as described later.
  • the length differences of the first and second fibers are caused, according to embodiments of the invention, solely or partially by texturization of the first and second fibers differently.
  • the length difference may in addition be modulated by differences in the material properties and/or by exposing the tufted fibers to condition which may reduce the length of the first and second fibers differently.
  • embodiments of the invention represent a combination of the alternative A and the alternative B described below.
  • the stretching of the first and second fibers is a reversible stretching and the first and second fibers are adapted to contract, upon being cut, to their respective contracted state whose length is at least partially determined by the degree of their respective texturization.
  • the method further comprises (reversibly) stretching the first and second texturized fibers during and/or after their integration such that they are prevented from contracting to their respective default length, whereby the first fibers are stretched stronger than the second fibers.
  • the method further comprises cutting the stretched first and second texturized fibers at the same length. For example, this can be performed right after or during the tufting process and the first and second texturized fibers may be stretched by the tufting needle(s) while being firmly fixed in the carrier.
  • the stretching of the first and the second fibers is performed such that at least the second fibers are not stretched to their maximum length (i.e., to their fully expanded state) when being cut.
  • the first fibers are not stretched to their maximum length (i.e., to their fully expanded state) when being cut.
  • first fibers being stretched stronger than the second fibers implies that a larger “stretching force” (measured e.g. in Newton) is applied to the first fiber than to the second fiber.
  • the first and second fibers are texturized to identical degree. 10 cm of the non-texturized first fibers may correspond to 5 cm of the texturized first fibers in their default (non-stretched) state. Likewise 10 cm of the non-texturized second fibers may correspond to 5 cm of the texturized second fibers in their default (non-stretched) state.
  • the first and second texturized fibers are tufted in the carrier and a stretching force of 30 Newton is applied to the first fibers and a stretching force of 20 Newton is applied to the second fibers.
  • 5 cm of the texturized first fiber may be (reversibly) stretched into 8 cm stretched texturized first fibers and 5 cm of the texturized second fiber may be (reversibly) stretched into 6.5 cm stretched texturized second fibers.
  • first and second fibers are cut at a cutting height L0 6.5 cm away from the surface of the carrier, the first fibers will contract to their default length corresponding to a thatch yarn height of 3.5 cm and the second fibers will contract to their default length corresponding to a face yarn height of 5 cm.
  • the contraction inducing conditions cause the first and the second texturized fibers to irreversibly contract.
  • Embodiments according to alternative C may have the advantage that the tufting process is facilitated as it may not be necessary to stretch the fibers such that are not in their "default", i.e., contracted", length. Rather, it may be sufficient to cut the tufted fibers at a particular length and then chose the contraction inducing conditions such that a desired length difference between the first and second texturized fibers is achieved.
  • This method may further have the advantage that it is more robust against undesired stretching effects that may be caused by the godets used for transporting the fibers during the fiber production, texturization and tufting process:
  • one fiber should undesirably be textured stronger than desired during the tufting process due to a temperature or rotation speed of one or more godets that deviates from a desired temperature or rotation speed, this may easily be compensated by adjusting the contraction inducing conditions, e.g. raising or decreasing the temperature of an oven used for shrinking the fibers and/or prolonging or shortening the residence time of the artificial turf in the oven.
  • the method further comprises stretching the first and second fibers during and/or after their integration such that they are prevented from contracting to their respective default length.
  • the first fibers are stretched as strongly as the second fibers or are stretched stronger than the second fibers when being cut.
  • the first fibers and second fibers are cut to the same length L0 (cutting length, e.g. length between the surface of the carrier where the fibers are integrated and the cut).
  • Said features may be advantageous as cutting fibers in the stretched state may provide for a more fine-grained control of the resulting length than cutting a non-stretched fiber. This is because the material in a non-stretched, textured fiber is inhomogeneously distributed due to the curling and/or wrinkling of the textured fibers. Therefore, cutting a stretched fiber may ensure that the vast majority of the first fibers will have identical or very similar length and that the vast majority of the second fibers will have identical or very similar length right after the cutting and after the exposing of the fibers to the contraction inducing condition.
  • the first material is a polymer that is identical to a second polymer.
  • the second polymer is used as the second material.
  • the first fibers are texturized stronger than the second fibers.
  • the contraction inducing condition is heat of a temperature adapted to irreversibly contract the stronger texturized first fibers to the thatch yarn fiber height L2 and adapted to irreversibly contract the less texturized second fibers to the face yarn fiber height L3.
  • the first material is different from a second polymer used in the second fibers as the second material.
  • the degree of texturization of the first and second fibers is identical.
  • the first polymer is adapted to contract stronger than the second polymer when heated.
  • the contraction inducing condition is heat of a temperature adapted to irreversibly contract the first fibers to the thatch yarn fiber height L2 and adapted to irreversibly contract the second fibers to the face yarn fiber height L3.
  • the first material is a first polymer that is different from a second polymer used in the second fibers as the second material.
  • the first polymer is adapted to contract stronger than the second polymer when heated.
  • the first fibers are texturized stronger than the second fibers.
  • the contraction inducing condition is heat of a temperature adapted to irreversibly contract the first fibers to the thatch yarn fiber height L2 and adapted to irreversibly contract the second fibers to the face yarn fiber height L3.
  • the heat is a temperature in the range of 60°C-100°C, more preferentially in the range of 80°C-90°C.
  • the integration of the first and second fibers comprises tufting the first fibers, the second fibers, and one or more further fibers into the carrier.
  • the further fibers can be stitch-in yarn fibers, and/or a lay-in yarn fibers.
  • the carrier can be, for example, an existing mesh, e.g. a synthetic fiber mesh or a plant fiber mesh (e.g. a jute mesh, a sisal mesh, or the like).
  • the carrier can be a mesh generated dynamically by interweaving the first fibers, the second fibers, and/or one or more further fibers with each other such that parts of the first and second fibers form the mesh and other parts of the first and second fibers protrude from the mesh.
  • the first fibers are integrated in the carrier in the form of first rows selectively comprising first dots. Each first dot selectively comprising first fibers.
  • the second fibers are integrated in the carrier in the form of second rows selectively comprising second dots, each second dot selectively comprising second fibers. The first rows and second rows alternate and run in parallel to each other.
  • the first and second rows respectively are zig-zag lines. This may be advantageous as the first and second fibers are distributed more homogeneously in the artificial turf, thus preventing an unpredictable movement pattern of a ball along the artificial turf, preventing the formation of visible "stripes" in the artificial turf and letting the artificial turf appear more "natural”.
  • the exposing of the cut first and second texturized fibers to the contraction inducing condition comprising heating the first and the second rows such that contraction of the first and second fibers is induced.
  • the first rows are heated to higher temperatures than the second rows for inducing a stronger contraction of the first fibers than the second fibers.
  • the first rows can selectively be heated to 130-140°C and the second rows can selectively be heated to 75°C-85°C.
  • the generation of the artificial turf further comprises applying a liquid backing on the side of the carrier opposite to the side from which the first and second fibers protrude.
  • the backing can be a liquid polyurethane reaction mixture or a latex mixture. The backing is applied to prevent, when solidified, detachment of the fibers after extended use of the artificial turf; and an underlayment positioned beneath the backing such that a stable base is provided for the artificial turf.
  • the generation of the artificial turf can comprise, after having tufted the first and second textured fibers in the carrier such that the first and second textured fibers protrude from the upper side of the carrier, applying a liquid backing on the lower side of the carrier.
  • the liquid backing gets in contact with and wets the "U" shaped portions of the tufted fibers.
  • the liquid backing can be, for example, polyurethane (PU) or latex.
  • PU polyurethane
  • the solidification is performed in an oven.
  • the artificial turf is transported, e.g. by a conveyor belt, continuously through the oven.
  • the backing is in liquid state when the artificial turf enters the oven and is in solid or semi-solid state when it leaves the oven.
  • the process of heating the backing for accelerating its solidification is performed in an oven that is adapted to dynamically identify the position of the first and second rows of the artificial turf that is continuously transported through the oven.
  • the oven comprises a plurality of heating elements that can be dynamically aligned with the different tuft rows of the artificial turf such that the heat generated by each of the heating elements selectively and predominantly reaches the one of the tuft rows that was aligned with said heating element.
  • the heating elements can be controlled such that they apply higher temperature to the first rows than to the second rows, thereby inducing a stronger contraction of the first fibers than of the second fibers.
  • the heating elements are positioned such that they apply the heat on the side of the carrier from which the thatch yarn fibers and the face yarn fibers protrude in basically orthogonal direction.
  • the heating is performed in an oven which comprises a plurality of first and second heating elements.
  • the oven further comprises a camera, a controller (e.g. one or more integrated circuits comprising the control logic, or a computer comprising software implementing a control logic) and a positioning element (e.g. robotic arms, a conveyor belt or combinations thereof).
  • the heating comprises:
  • the heating elements can be infrared heating lamps that can be controlled individually.
  • the heating elements can be operatively coupled to the controller and can be configured to receive a control command from the controller, the control command being indicative of a desired temperature that is to be generated by the heating element receiving the control command.
  • Each heating element is adapted to generate a temperature in its respective environment (e.g. within a radius of about 0.5-2 cm around the heating element) and the control command may specify any temperature in a range of 50°C-150°C.
  • the heating elements can be re-positioned relative to each other and relative to a dynamically determined position of the tuft rows at the upper side of the artificial turf.
  • the heating elements are positioned in the oven such that the heat generated by the heating elements is applied selectively or at least predominantly to the tuft row at the upper side of the carrier that was aligned to this heating element.
  • the position of the heating elements is not modified dynamically when the artificial turf is transported through the oven.
  • the heating elements can be fixed or can be re-positionable only when the oven is not in use.
  • the distance and configuration of the heating elements must be adapted to the tuft row distance of the artificial turf that is to be transported through the oven.
  • the adaptation can be performed permanently or in a configuration process that precedes the processing of a particular artificial turf in the oven.
  • the oven may further comprise a heating element positioned below the lower side of the carrier for heating and solidifying the liquid backing.
  • Said features may be advantageous, because they allow applying different contraction inducing conditions on the first and second fibers, respectively, thereby inducing a different degree of contraction (here: shrinkage) of the first and second fibers.
  • energy may be saved as the heat is generated in spatial proximity to the tuft rows where the heat is used to cause the fibers to contract, and the heat is re-used for solidifying the backing.
  • no extra step for generating different fiber length and for solidifying the backing may be required, thereby saving energy and increasing the speed of artificial turf production.
  • the first fibers and the second are integrated in the carrier in the form of rows, whereby each row comprises first and second dots in alternating order ("dot-wise-mixed rows"). Each first dot selectively comprises first fibers and each second dot selectively comprising second fibers.
  • the first fibers and the second are integrated in the carrier in the form of rows, whereby each row comprises a random mixture of first and second fibers ("randomly mixed rows"). Mixed rows may be heated selectively by a single type of heating element as described above, thereby saving energy, but no differential heating can be applied in this case. However, the material of the first and second fibers may have a different shrinkage behavior at high temperatures. Thus, also fibers contained in mixed rows can be exposed to a contraction inducing condition that results in the generation of thatch yarn fibers and face yarn fibers having different, defined lengths.
  • the rows can have a distance to each other in a range of 7.5mm-11.5 mm, preferably in the range of 9mm-10 mm, for example.
  • the method further comprises generating the first texturized fibers by curling, crumpling, and/or wrinkling of a non-texturized monofilament or split-film tape upon itself so that the first texturized fibers are created.
  • Each first texturized fiber does not extend to its full potential height in the absence of a stretching force.
  • the method comprises generating the second texturized fibers by curling, crumpling, and/or wrinkling of a non-texturized monofilament or split-film tape upon itself so that the second texturized fibers are created.
  • Each second texturized fiber does not extend to its full potential height in the absence of a stretching force.
  • the first and second texturized fibers respectively have a molecular memory of a curled, crumpled and/or wrinkled state.
  • the shared thatch yarn fiber height (L2) is in the range of 10 mm to 30mm, preferably in the range of 15 mm to 25 mm.
  • the shared face yarn fiber height (L3) is in the range of 31 mm to 50 mm, preferably in the range of 35 to 45 mm.
  • the first fibers are made of a first polymer and the second fibers are made of a second polymer, the first polymer being adapted to contract stronger than the second polymer in response to being exposed to the contraction inducing condition.
  • the exposing of the cut first and second texturized fibers to the contraction inducing condition comprises heating the first and the second rows such that contraction of the first and second fibers is induced.
  • the first polymer is HDPE (high density polyethylene) and the second polymer is LLDPE (linear low density polyethylene).
  • the first polymer is PE, whereby the PE is free of PA.
  • the second polymer is PE comprising thread-like regions of PA as described, for example, in EP 3122942 .
  • the first polymer is PE comprising thread-like regions of PA as described, for example, in EP 3122942 .
  • the second polymer is polypropylene (PP) or polyamide (PA) or a mixture thereof.
  • the fibers can be heated, for example, in an oven for about 5 minutes to at least 80°C, preferably to 130°C-140°C.
  • Said exemplary combinations of different polymers may allow generating thatch yarn fibers and face yarn fibers having a clearly defined height simply by applying heat as the contraction inducing condition.
  • the polymer type the first fibers are made from shrinks stronger under heat than the polymer type used for generating the second fibers.
  • the first and second fibers are made of the same polymer or of different polymers.
  • the first fibers must be stronger texturized than the second fibers in order to provide for thatch yarn and face yarn fibers having different length.
  • the texturization of the two fibers may also differ.
  • the different shrinkage behaviors of the materials and the differing degree of texturization may both contribute to the length difference of the fibers.
  • the stronger texturization of a fiber the stronger the contraction of the fiber after the cutting of the fiber in stretched state.
  • the first polymer is adapted to contract at least 20%, preferably at least 35% more than the second polymer upon heating the artificial turf fibers to a predefined temperature, e.g. above 80°C.
  • the heating may be performed such that first and second fibers are heated to the same temperature.
  • the heating can be performed in an oven, whereby the oven may in addition be used for hardening a liquid backing having been applied on the lower side of the artificial turf.
  • the shrinkage of artificial turf fibers strongly depends on the type of material (typically a polymer, e.g. a polyolefin) the fiber is made of.
  • the different shrinkage properties of different polymers is partly due to the difference of density of polymers from the melt state and the cooled, rigid state. Shrinkage is a rate, so it is expressed in percent.
  • Semi-crystalline polymers e.g. polybutylene-terephthalate (PBT) or polypropylene (PP) show a higher shrinkage than amorphous polymers (e.g.
  • PS polystyrol
  • PC polycarbonates
  • the bulk polymer is polyethylene (PE) and the thread polymer is polyamide (PA).
  • the bulk polymer is polyethylene (PE) and the thread polymer is polyester.
  • the bulk polymer is polypropylene (PP) and the thread polymer is polyester.
  • the bulk polymer is polypropylene (PP) and the thread polymer is polyamide (PA).
  • Said embodiments may have the advantage of delayed and/or reduced texture reversion of the thatch yarn fibers and/or the pile yarn fibers made from this polymer material.
  • the first fiber and/or the second fiber can comprise (or consists of) a mixture of a bulk polymer and a thread polymer with an optional compatibilizer.
  • the polymer mixture can comprise at least 30 weight percent of the bulk polymer and/or at least 10 weight percent of the thread polymer.
  • the bulk polymer is polyethylene (PE) and a thread polymer being polyamide (PA) and.
  • the thread polymer may comprise at least 90 weight percent of PA.
  • the bulk polymer can comprise at least 90 weight percent of PE.
  • the polymer mixture used for generating the first and/or second fiber can comprise at least 30 weight percent of PE and/or at least 30 weight percent of PA.
  • the thread polymer comprises (or consists of) polyester and the bulk polymer comprises (or consists of) PE.
  • the thread polymer may comprise at least 90 weight percent of polyester.
  • the bulk polymer can comprise at least 90 weight percent of PE.
  • the polymer mixture can comprise at least 30 weight percent of PE and/or at least 30 weight percent of polyester.
  • the thread polymer comprises (or consists of) polyester and the bulk polymer comprises (or consists of) polypropylene (PP).
  • the thread polymer may comprise at least 90 weight percent of polyester.
  • the bulk polymer can comprise at least 90 weight percent of PP.
  • the polymer mixture can comprise at least 30 weight percent of PP and/or at least 30 weight percent of polyester.
  • the thread polymer comprises (or consists of) PA and the bulk polymer comprises (consists of) PP.
  • the thread polymer may comprise at least 90 weight percent of PA.
  • the bulk polymer can comprise at least 90 weight percent of PP.
  • the polymer mixture can comprise at least 30 weight percent of PP and/or at least 30 weight percent of PA.
  • the SEBS is styrene-ethylene-butylene-styrene.
  • the EVA is ethylene-vinyl acetate.
  • the EPD is polyamide-6 polymer.
  • the EPDM is ethylene propylene diene monomer (M-class) rubber.
  • the polymer mixture may comprise at least 10 weight percent of the compatibilizer. This embodiment may be advantageous, because it can provide for the polymer mixture which utilization results in manufacturing of the textured artificial turf yarn with the aforementioned delayed and/or reduced texture reversion.
  • the polymer mixture is at least a four-phase system as described above and/or further in the text.
  • This mixture can be prepared as described above and further in the text.
  • the third polymer in this mixture may be any one of the following: polyethylene terephthalate (PET) and polybutylene terephthalate (PBT).
  • PET polyethylene terephthalate
  • PBT polybutylene terephthalate
  • the polymer mixture may comprise at least 20 weight percent of the third polymer. Utilization of these polymers and/or the aforementioned concentration of the third polymer may facilitate delaying and/or reducing texture reversion of the textured artificial turf yarn.
  • the method comprises the following steps: extruding the polymer mixture into a monofilament yarn; quenching the monofilament yarn; heating the quenched monofilament yarn; stretching the heated monofilament yarn to deform the polymer beads into threadlike regions and to form the heated monofilament yarn into a stretched monofilament yarn; and texturing the stretched monofilament yarn to form the textured and stretched monofilament yarn to be used as the first and/or the second texturized fiber.
  • This embodiment may be advantageous, because the deformation of the polymer beads into threadlike regions can facilitate delaying and/or reducing texture reversion of the textured artificial turf yarn.
  • the method further comprises adding infill material on the already installed artificial turf such that the infill material fills the space between the thatch yarn fibers and filling at least 20% of the space between the face yarn fibers extending above the ends of the thatch yarn fibers.
  • the infill layer may be as high as the pile height of the turf, but does not have to be so high, because the face yarn fibers are texturized and thus have a high rigidity and resilience and thus may not need the presence of an infill as high as the pile height of the artificial turf in order to stabilize the face yarn fibers.
  • the invention relates to artificial turf generated by a method according to any one of the embodiments and examples described herein.
  • any description of a method step that implicitly corresponds to a feature of the generated artificial turf shall also be considered as a specification of a feature of the resulting artificial turf and its components.
  • an “infill” as used herein is material, typically sand or rubber granules that is added on top of an artificial turf layer and fills the space between fibers for ballast and cushion.
  • Extrusion as used herein is the process of transforming liquid plastic into individual solid fibers by pushing the liquid plastic through a fixed cross sectional profile that is designed to form a monofilament or film that may then be processed to generate an artificial turf yarn fiber.
  • a "thatch yarn” as used herein is yarn used with different colors that is situated below the face yarn to enhance recovery.
  • a “face yarn” is the yarn that forms the pile of the artificial turf and that protrudes from the carrier of the artificial turf farther than any other type of yarn contained in the artificial turf, if any, thereby determining the pile height of the artificial turf.
  • tufting is a sub-process in the manufacturing of artificial turf that comprises pressing (e.g. by using pneumatic force) a U-shaped piece of yarn through a carrier, e.g. a carrier mesh or other form of carrier structure.
  • a carrier e.g. a carrier mesh or other form of carrier structure.
  • the height of the pile is altered solely by cutting the yarn shorter or leaving it longer.
  • artificial turf fibers are stretched while being cut and/or are subjected to contraction inducing condition that modulates the height of first and second fibers differently such that a thatch yarn layer with a homogeneous fiber length and a face yarn layer with a different homogeneous fiber length is generated.
  • the length " L0 " may also be referred to as "cutting length” and is the distance between the point where the first and second texturized fibers are respectively integrated in the carrier and the point where they are cut.
  • a “texturized” fiber as used herein is a fiber that has a molecular memory of a textured state, wherein a textured state can be, for example, a curled, crumpled and/or wrinkled state.
  • the expression "fibers sharing a fiber height” as used herein means that the fibers have identical or basically identical height.
  • the height deviations of the fibers is below 6% of the fiber length, preferably below 2.5% of the fiber length.
  • a fiber that is "stronger texturized" than another fiber is a fiber that, provided that both fibers have the same length in their non-textured, fully expanded state, contracts to a contracted length that is shorter than the contracted length of the other fiber.
  • a fiber that is texturized 10% stronger than another fiber is a fiber that, provided that both fibers have the same length in their non-textured, fully expanded state, contracts to a contracted length that is 10% shorter than the contracted length of the other fiber.
  • the "texture reversion" (or “texturing reversion") of a textured (curled) artificial turf yarn is, as understood herein, a process of smoothing out of the crimps of the textured (curled) artificial turf yarn, when the textured (curled) artificial turf yarn is subjected to a mechanical and/or weathering stress.
  • the mechanical stress can be caused by sportsmen using the artificial turf with the textured (curled) artificial turf yarn.
  • the weathering stress can be caused by weather conditions at place where the artificial turf with the textured (curled) artificial turf yarn is installed.
  • the weathering stress comprises at least one of the following: temperature changes, water exposure, snow exposure, icing, light exposure (in particular ultraviolet light exposure).
  • the properties of the textured turf yarn of an artificial turf can degrade throughout its lifetime/utilization due to the texture reversion.
  • the phenomenon of the texture reversion is a newly observed effect, which is not yet reported in the state of art literature.
  • the publication " Ribbon curling via stress relaxation in thin polymer films” discloses an observation that the texturing of the filament made of polymer film remains permanent ("Ribbon curling via stress relaxation in thin polymer films", Proceedings of the National Academy of Sciences of the United States of America, vol. 113, no. 7, pp. 1719-1724, http://www.pnas.org/content/113/7/1719 ).
  • the texture reversion of a fragment of a single textured artificial turf yarn can be assessed by employing the following example method: hanging the fragment, such that the fragment is unfolded by gravity in a vertical direction; measuring a distance D1 between the ends of the hanged fragment; subjecting the fragment to a mechanical and/or weathering stress, which may be caused by utilization of an artificial turf comprising said fragment and said artificial turf backing; performing the following after the subjecting of the fragment to the mechanical and/or weathering stress: hanging the fragment, such that the fragment is unfolded by gravity in the vertical direction; measuring a distance D2 between the ends of the hanged fragment.
  • a first value characterizing the texture reversion can be determined according to the following equation: (D2-D1)/D1.
  • a second value characterizing the texture reversion can be determined according to the following equation: (D2-D1)(/D1*T), wherein T is a time interval between the aforementioned measurements of distances D1 and D2.
  • the first and/or the second value can be used for optimization of manufacturing tools for manufacturing of the textured artificial turf yarn, parameters of processes for manufacturing of the textured artificial turf yarn, phase and/or chemical composition of filaments used as an ingot for manufacturing of the textured artificial turf yarn.
  • the optimization can be targeted towards reduction in the first and/or second value, whereas fragments of different filaments are subjected to the same (test) mechanical and/or weathering stress, wherein the different filaments are manufactured using different tools, different process parameters, and/or different ingots.
  • a similar approach can be implemented using characteristic values of fiber texturing generated using the aforementioned optical means.
  • Figure 1 depicts a cross-sectional view of a state-of-the-art artificial turf 100. It comprises straight, non-texturized face yarn fibers 104 having a pile height L3, and a zone of texturized thatch yarn fibers 106.
  • the thatch yarn fibers have a height L2 that is shorter than the height L3 of the face yarn fibers.
  • L1 The difference between the height of the face yarn fibers and of the thatch yarn fibers is depicted as "L1".
  • Figure 2 depicts a cross-sectional view of an artificial turf 200 according to an embodiment of the invention.
  • the artificial turf 200 comprises texturized thatch yarn fibers 206 having a height L2 and texturized face yarn fibers 204 having a height L3.
  • the thatch yarn fibers are shorter than the face yarn fibers by a length L1.
  • the face yarn fibers and thatch yarn fibers are integrated, e.g. tufted, in a carrier 202, e.g. a mesh made of synthetic or plant-based materials.
  • the artificial turf 200 may comprise a fill layer and/or a backing as depicted, for example, in figure 3 .
  • the face yarn defines the pile height of the artificial turf and provides the rolling resistance for the rolling ball.
  • the thatch yarn serves 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.
  • FIG. 3 depicts a cross-sectional view of an artificial turf 300 according to another embodiment of the invention.
  • the artificial turf 300 comprises a backing 310, e.g. a layer of solidified latex or polyurethane having been added in liquid state onto the lower side of the carrier 202 after the fibers 204, 206 have been tufted into the carrier.
  • the side of the carrier 202 from which the fibers 204, 206 protrude is referred 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 310 may be visible, is referred herein as the "lower side" of the artificial turf.
  • the artificial turf 300 comprises a backing 310, e.g. a layer of hardened latex or polyurethane, that contacts and surrounds the U-shaped fibers on the lower side of the artificial turf, thereby strongly fixing the fibers in the carrier.
  • a backing 310 e.g. a layer of hardened latex or polyurethane
  • the artificial turf 300 comprises a filler material 308, e.g. a sand-rubber-granule mixture.
  • the infill may fill free space between thatch yarn fibers and/or face yarn fibers in the thatch yarn zone as well as in the face yarn zone.
  • the face yarn is texturized, it is not necessary to have an infill height that almost reaches the tips of the face yarn fibers in order to stabilize the fibers. Rather, it may be possible to use an infill layer whose upper surface is one or more cm below the pile height L3. Thanks to a combination of textured 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. Moreover, thanks to the random orientation of the texturized face yarn fibers, an artificial turf with a more homogeneous surface is provided that increases the predictability and directional stability of any object rolling or sliding over the surface of the artificial turf.
  • Figures 2 and 3 show the texturized fibers 204, 206 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.
  • This effect may be used for generating an artificial turf with two types of texturized fibers which 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 also the face yarn fibers are texturized.
  • Figure 4 depicts flowcharts of three alternative methods of producing artificial turf according to embodiments of the invention.
  • Figure 4A depicts a method of producing an artificial turf 200, 300, 500, 520, 530 according to "alternative A" embodiments. This alternative is based on length difference of the thatch yarn fibers and the face yarn fibers which completely or at least partially result from a different degree of texturization of first and second fibers.
  • the first and second fibers can be air texturized, for example, with a venture nozzle adapted to generate a texturizing air jet.
  • a venture nozzle adapted to generate a texturizing air jet.
  • US4282637A describes a Venturi type nozzle for the texturization of yarns.
  • the nozzle includes a hollow body which compressed air is fed, a needle housed therein to which yarn is fed, and a plug.
  • the needle is provided with a longitudinal passage for the yarn.
  • the air passes between the body and the needle, and yarn and air pass through a passage shaped like a Venturi cone in the plug.
  • Mutually facing portions of the needle head and of the plug have frusto-conical surfaces.
  • the nozzle is adapted to produce a texturization effect on the yarn.
  • the stretched first and second fibers are cut at the same length L0.
  • the "same length” here means the length of the fibers in fully expanded state.
  • a tufting needle used for tufting the fibers may comprise or be coupled to a knife or a scissor adapted for automatically cutting the tufted, maximally stretched first and second fibers at the same length.
  • the cut first and second fibers are allowed to contract to their respective default (contracted) lengths.
  • the contraction is induced by the molecular memory of the fibers that causes the fibers to contract into the curled state defined during the texturization of the respective fibers.
  • the contracted first texturized fibers provide texturized thatch yarn fibers 206 protruding from the carrier by a shared thatch yarn fiber height L2.
  • the contracted second texturized fibers provide texturized face yarn fibers 204 protruding from the carrier by a shared face yarn fiber height L3.
  • the face yarn fiber height is larger than the thatch yarn fiber height.
  • Figure 4B depicts a method of producing an artificial turf 200, 300, 500, 520, 530 according to "alternative B" embodiments.
  • This alternative is based on length differences of the thatch yarn fibers and the face yarn fibers which completely or at least partially result from different degrees of reversibly stretching the first and second fibers, whereby the first fibers are reversibly stretched stronger in step 430 than are the second texturized fibers.
  • the first and second fibers may be made of the same material or of different materials.
  • the first and second fibers may be texturized to the same degree or the first fibers may be texturized stronger than the second fibers.
  • Alternative B is characterized in that the length difference of the face yarn fibers and of the thatch yarn fibers are solely or at least partially generated by the stronger reversibly stretching of the first than of the second fibers in sep 430. All other steps correspond to the steps described for alternative A, whereby in step 402 it is also possible to use first and second fibers having the same degree of texturization.
  • first texturized fibers made of a first materiel and second texturized fibers made of a second material are integrated in a carrier 202.
  • the fibers can be integrated by a respective tufting needle in a tufting process.
  • the first and second texturized fibers are integrated such that the first and second texturized fibers protrude from the carrier in the same direction.
  • the first material is adapted to contract stronger than the second material upon being exposed to a contraction inducing condition.
  • step 424 the integrated first and second texturized fibers are cut at the same cutting length L0 as described already for alternative A.
  • the cut first and second texturized fibers are exposed to a defined contraction inducing condition.
  • the contraction inducing conditions causes the first and the second texturized fibers to contract.
  • the contraction inducing condition may be heat of 80°C or higher, as described with reference to figure 7 .
  • the contraction inducing condition may be chosen differently for the first and second fibers.
  • the first fiber may be heated to higher temperatures and/or for a longer duration than the second texturized fibers, thereby causing the first texturized fibers to contract stronger than the second texturized fibers.
  • the contracted first fibers provide texturized thatch yarn fibers 206 protruding from the carrier by a shared thatch yarn fiber height L2.
  • the contracted second fibers provide texturized face yarn fibers 204 protruding from the carrier by a shared face yarn fiber height L3.
  • the face yarn fiber height is larger than the thatch yarn fiber height.
  • the method of producing artificial turf according to embodiments of the invention can comprise combinations of the steps of both methods, thereby providing a better control of the length difference of the textured thatch yarn fibers and the texturized face yarn fibers.
  • Figure 5 depicts three alternative ways how first and second textured fibers can be integrated in a carrier 202.
  • Figure 5A depicts an artificial turf 500 wherein texturized face yarn fibers and texturized thatch yarn fibers are tufted in straight parallel rows. Thatch yarn fiber rows ("B"), 502 and face yarn fiber rows ("A") 504 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 202 by a tufting process, whereby bundles of fibers of the same type are tufted into the carrier and are then cut. Each row 502, 504 comprises only fibers of one particular type, i.e., either thatch yarn fibers or face yarn fibers.
  • 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.
  • Figure 5B depicts another artificial turf 520 wherein texturized face yarn fibers and texturized thatch yarn fibers are tufted in parallel, zig-zag rows. Thatch yarn fiber rows 508 and face yarn fiber rows 506 are alternating in the plane of the artificial turf. Each row 506, 508 comprises only fibers of one particular type, i.e., either thatch yarn fibers or face yarn fibers.
  • 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.
  • Figure 5C depicts another artificial turf 530 wherein face yarn fibers and thatch yarn fibers are tufted in parallel, mixed type (or "mixed") rows 510, 512
  • Each row comprises a mixture of both texturized face yarn fibers and texturized thatch yarn fibers.
  • each row may comprise a mixture of thatch yarn fiber bundles and face yarn fiber bundles.
  • each row may comprise a mixture of face and thatch yarn fibers which are individually tufted into the carrier.
  • each row may comprise tuft bundles respectively comprising a mixture of thatch yarn fibers and face yarn fibers.
  • Figure 6 depicts the process of tufting, stretching and cutting textured fibers according to embodiments of the invention.
  • a first tufting needle (not shown) can tuft a first texturized fiber 602 into a carrier 202.
  • the first fiber is stretched.
  • the stretched, expanded first fiber is at least 10%, more preferably at least 20%, more preferably at least 50% longer than in its default, contracted state.
  • the stretching can be performed, for example, by a plurality of godets 608 within or external to the tufting needle which apply a pulling force on the tufted first fiber in basically orthogonal direction away from the carrier 202.
  • a second tufting needle (not shown) can tuft a second texturized fiber 604 into the carrier 202.
  • the second fiber is stretched.
  • the stretched, expanded second fiber is at least 10%, more preferably at least 20%, more preferably at least 50% longer than in its default, contracted state.
  • the stretching can be performed, for example, by a plurality of godets 610 within or external to the tufting needle which apply a pulling force on the tufted second fiber in basically orthogonal direction away from the carrier 202.
  • the tufting process is illustrated for individual fibers. However, the tufting process can likewise be performed for bundles of fibers.
  • the stretched texturized first and second fibers 602, 604 or one or more bundles thereof are cut, preferably in a single cutting operation at the same length L0 above the carrier as indicated by the scissor and the dotted lines.
  • the cut first fiber 602 contracts to its default state, thereby providing a texturized thatch yarn fiber 602' having a height L2 above the carrier structure 202'.
  • stretched, texturized first and second fibers 602, 604 may be cut when respectively being in fully expanded state.
  • the texturized look of the expanded fibers 602, 604 in figure 6 is just for illustration that the first and second fibers are texturized and have a "molecular memory" of a texturized fiber.
  • the fibers When the fibers are expanded to their maximum expandable length, they may still have a slightly wrinkled appearance, but in many cases the fully expanded fibers will have the same or a similar appearance as a non-texturized fiber.
  • the tufted face yarn fiber 604' and the tufted thatch yarn fiber 602' have different lengths in their default, contracted state, but have identical lengths if stretched to their completely expanded state.
  • the thatch yarn fiber length L1 in default, contracted state can be about 20 mm and the face yarn fiber length L3 in default, contracted state can be about 40 mm.
  • the first and the second fibers are made of the same material.
  • the length difference of the face yarn and the thatch yarn is obtained solely based on the different degrees of texturization of the first and second fibers, because stronger texturization results in a stronger contraction of the fibers upon being cut, and in a shorter length in the contracted default state of a fiber.
  • the first and second texturized fibers can be made of the same type of polymer, e.g. polyethylene (PE), or of a mixture of miscible polymers, or a polymer mixture of immiscible polymers.
  • PE polyethylene
  • the polymer mixture used for generating the second fibers to be turned into face yarn fibers is at least 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 EP3122942 the entirety of which being expressly herein incorporated by reference.
  • the second polymer may be a PE and the first polymer can be polyamide (PA).
  • PAs beads may provide some stability and rigidity to the second fibers, thereby reducing the ability of the second fibers to contract, e.g. in response to heat.
  • Figure 7 depicts a block diagram of an oven 700 adapted to heat fibers contained in different tuft rows differently.
  • the artificial turf may be generated in a fully or semi-automated process.
  • the carrier may be transported, via godets and/or conveyor belts, to a tufting unit where first and second fibers are tufted into the carrier as illustrated, for example, in figures 5 and 6 .
  • the cutting of the tufted fibers may be performed in the tufting unit.
  • the carrier comprising the tufted fibers is transported further to a further unit where the liquid backing is applied on the lower part of the artificial turf.
  • the backing can be applied via a "knife over roll" technique and/or can be sprayed on the backing.
  • the liquid backing is allowed to wet the U-shaped portions of the fibers at the lower side of the carrier and may even be allowed to partially penetrate the openings of the carrier 202, e.g. a carrier mesh. Then, the artificial turf with the still liquid backing is transported automatically into the oven 700.
  • the oven comprises a camera 706 adapted to continuously capture images of the turf that is currently transported through and processed in the oven.
  • the oven further comprises a plurality of heating elements 702, 704 and a controller.
  • the Heating elements may comprise first heating elements 702 and second heating elements 704.
  • the oven may further comprise one or more positioning elements 710 that are interoperatively coupled with the controller 708 and are adapted to position the individual heating elements and the tufting rows 502, 504 relative to each other such that first heating elements are selectively aligned to first rows and second heating elements are selectively aligned to second rows.
  • the controller 708 is configured to control the first and second heating elements such that the first heating elements generate a higher temperature than the second heating elements.
  • the texturized artificial turf fibers in the first rows contract stronger in response to the heat than the second fibers.
  • the first texturized fibers provide the texturized thatch yarn fibers and the second texturized fibers provide the texturized face yarn fibers.
  • the stronger heat-induced contraction of the first fiber may alone or in combination with differences in the degree of texturization contribute to the length difference of the face yarn fibers and the thatch yarn fibers.
  • the first heating elements generate heat that is adapted to selectively or predominantly heat the first tuft rows 502 to about 130-140 °C.
  • the second heating elements generate heat that is adapted to selectively or predominantly heat the second tuft rows 504 to about 80 °C, thereby causing the first texturized fibers in the first rows to shrink stronger than the fibers in the second rows.
  • the first texturized fibers in the first rows can be of a material that shrinks stronger at a given temperature than the material of the second fibers.
  • the material of the first texturized fiber can be pure PE and the material of the second texturized fibers can be a mixture of PE/PA.
  • the first fibers can be made of PE (in particular LLDPE) or a similar material as it is less stressed both mechanically and by weathering. Moreover, in some embodiments, the first texturized fibers in the first tuft rows are texturized stronger than the texturized fibers in the second rows.

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Road Paving Structures (AREA)
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CN114381984A (zh) * 2020-10-21 2022-04-22 青岛青禾人造草坪股份有限公司 一种人造草坪
EP4012082A2 (fr) * 2020-11-23 2022-06-15 Don & Low Limited Améliorations apportées ou se rapportant à des surfaces artificielles
DE202021105122U1 (de) 2021-09-23 2023-01-03 Smg Sportplatzmaschinenbau Gmbh Messvorrichtung für Kunstrasen

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Publication number Priority date Publication date Assignee Title
CN114381984A (zh) * 2020-10-21 2022-04-22 青岛青禾人造草坪股份有限公司 一种人造草坪
EP4012082A2 (fr) * 2020-11-23 2022-06-15 Don & Low Limited Améliorations apportées ou se rapportant à des surfaces artificielles
DE202021105122U1 (de) 2021-09-23 2023-01-03 Smg Sportplatzmaschinenbau Gmbh Messvorrichtung für Kunstrasen

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