Modular Rollup Artificial Turf System
A non-filled artificial turf surface (e.g., field) that can be removed by disconnecting and rolling up a plurality of non-filled artificial turf mats, and reinstalled by unrolling and reconnecting the non-filled artificial turf mats. In a further aspect, the invention is also directed at a method for installing and subsequently removing the non-filled transition artificial turf field in a quick and efficient manner.
This application claims priority to, and the benefit of the filing date, of U.S. Provisional Patent Application No, 62/153,225, filed Apr. 27, 2015, which is incorporated herein by reference in its entirety.
FIELDThis invention relates to artificial turf used for athletic fields. More specifically, this invention relates to a filled artificial turf with enhanced versatility, due to its roll up, unroll capability.
BACKGROUNDSynthetic grass sports surfaces are well known. These surfaces are becoming increasingly popular as replacements for natural grass surfaces in stadiums, playgrounds, golf driving ranges, and other facilities. The synthetic grass surfaces stand up to wear much better than natural grass surfaces, do not require as much maintenance, and can be used in partially or fully enclosed stadiums where natural grass cannot typically be grown.
Most synthetic grass surfaces comprise rows of strips or ribbons of synthetic grass-like material, extending vertically from a backing mat with particulate material infill in between the ribbons on the mat. One or more layers of aggregate material are introduced between the backing mat and on top of a smoothed and compacted subgrade. The surfaces are preferably crowned to promote water drainage. The ribbons of synthetic grass-like material usually extend a short distance above the layer of particulate material and represent blades of grass. The length of these fibers is dictated by the end use of the playing surface. For example, football fields utilize fibers that are longer than golf driving range surfaces. The particulate material usually comprises sand. The particulate matter can also comprise a mixture of sand and other materials, including rubber infill. In these systems, the rubber infill and sand together provide resiliency to the synthetic grass surfaces. In addition, the sand particles add weight to hold down the backing material, thus helping to ensure that the strips of synthetic grass do not move or shift during play. In more recent systems, fields have been produced that utilize 100 percent resilient material as infill. The conventional use of infill in synthetic grass surfaces increases the difficulty of removal and storage of such systems.
For certain sporting facilities or venues, particularly indoor arenas or stadia, the facility can be used for a wide variety of events, including non-sporting events. Some of these events could have adverse effects on a typical artificial turf, due to excessive wear. These adverse effects tend to reduce the playability of, and shorten the effective life of, the artificial turf. Thus, there is a need to accommodate the multi-purpose needs of such facilities, while at the same time minimizing or eliminating any adverse effects on the artificial turf used for sporting events.
It is thus highly desirable to produce a non-filled transition (i.e. non-permanent) synthetic grass surface that is easily installed and removed in the same facility for sporting events that has performance and durability characteristics similar to natural surfaces.
SUMMARYDisclosed herein is a non-filled artificial turf field which can be removed by disconnecting and rolling up a plurality of non-filled artificial turf mats, and reinstalled by unrolling and reconnecting the non-filled artificial turf mats. In a further aspect, disclosed herein is a method for installing and subsequently removing the non-filled transition artificial turf field in a quick and efficient manner.
Because it is contemplated that the non-filled artificial turf mats can be arranged on a floor for a specific activity and then removed and stored when a different activity is to take place on the same floor, it is desirable to provide a system that allows the non-filled artificial turf mats to be easily attached and separated. In some aspects, the system is reusable in that it can permit the non-filled artificial turf mats to be connected and then separated multiple times. In some embodiments in accordance with the invention, the system can allow the non-filled artificial turf mats to be attached to each other and form a substantially contiguous top surface. In other embodiments, the non-filled artificial turf mats can be secured by a connecting system to reduce the likelihood of the mats moving with respect to each other to provide gaps between the non-filled artificial turf mats.
In one aspect, a non-filled artificial turf field can be formed by interconnecting a plurality of non-filled artificial turf mats, wherein each of the non-filled artificial turf mats comprises a turf layer and a foam substrate. In one aspect, the turf layer comprises a plurality of fibrillated yarns tufted within the multilayer backing material. The yarns can be tufted in a wide variety of pile heights, patterns, gauges, and stitch patterns depending upon a desired end use.
The bottommost layer of the multilayer backing material can be coated with an adhesive coating layer that is configured to bind to, and optionally integrate with, at least a portion of the plurality of yarns that is exposed on the bottommost surface of the multilayer backing material. The foam substrate comprising a shock resistant material can be adhered to the bottom of the adhesive layer.
In operation, the bottom surface of the mats can be laid on a substrate such as a flooring material, concrete slab, or a leveled aggregate and dirt subgrade. Selected non-filled artificial turf mats can be coupled together utilizing hook and loop fastening systems. To remove the assembled artificial turf field, each non-filled artificial turf mat is simply unhooked from the next adjacent non-filled artificial turf mat and rolled onto a roller
There has thus been outlined, rather broadly, certain embodiments of the invention in order that the detailed description thereof herein may be better understood, and in order that the present contribution to the art may be better appreciated. There are, of course, additional embodiments of the invention that will be described below and which will form the subject matter of the claims appended hereto.
These and other features of the preferred embodiments of the invention will become more apparent in the detailed description in which reference is made to the appended drawings wherein:
The present invention can be understood more readily by reference to the following detailed description, examples, drawing, and claims, and their previous and following description. However, before the present devices, systems, and/or methods are disclosed and described, it is to be understood that this invention is not limited to the specific devices, systems, and/or methods disclosed unless otherwise specified, as such can, of course, vary. It is also to be understood that the terminology used herein is for the purpose of describing particular aspects only and is not intended to be limiting.
The following description of the invention is provided as an enabling teaching of the invention in its best, currently known embodiment. To this end, those skilled in the relevant art will recognize and appreciate that many changes can be made to the various aspects of the invention described herein, while still obtaining the beneficial results of the present invention. It will also be apparent that some of the desired benefits of the present invention can be obtained by selecting some of the features of the present invention without utilizing other features. Accordingly, those who work in the art will recognize that many modifications and adaptations to the present invention are possible and can even be desirable in certain circumstances and are a part of the present invention. Thus, the following description is provided as illustrative of the principles of the present invention and not in limitation thereof.
As used throughout, the singular forms “a,” “an” and “the” include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to “a connecting surface” can include two or more such connecting surfaces unless the context indicates otherwise.
Ranges can be expressed herein as from “about” one particular value, and/or to “about” another particular value. When such a range is expressed, another aspect includes from the one particular value and/or to the other particular value. Similarly, when values are expressed as approximations, by use of the antecedent “about,” it will be understood that the particular value forms another aspect. It will be further understood that the endpoints of each of the ranges are significant both in relation to the other endpoint, and independently of the other endpoint.
As used herein, the terms “optional” or “optionally” mean that the subsequently described event or circumstance may or may not occur, and that the description includes instances where said event or circumstance occurs and instances where it does not.
In one embodiment and as shown in
In one aspect, the turf layer 40 comprises a plurality of fibrillated yarns 42 tufted within a backing material 50. In one aspect, the plurality of fibrillated yarns 42 can comprise at least two different types of yarn (e.g., at least a first type of yarn 42 and a second type of yarn 42″. In one example and not meant to be limiting, a first type of yarn can comprise a 8000 denier, high performance, outdoor, polyethylene, fibrillated tape yarn and a second type of yarn can comprise a 4500 denier, 8-ply, texturized polyethylene yarn. In this aspect, and referencing
The backing material 50 preferably is a multi-layer backing comprising of at least two backing layers. In one aspect, the backing material 50 can optionally comprise at least two nonwoven backing layers, at least one nonwoven backing layer needled to at least one woven backing layer, at least two nonwoven backing layers, at least one woven layer needled to another woven layer, and the like. When the backing material 50 comprises at least two backing layers, it is contemplated that each of the respective at least two backing layers can have the same or different pics counts. One skilled in the art will appreciate that the machine gauge, yarn size, stitch rate and needle size are all factors when considering an appropriate backing material.
In one example and not meant to be limiting, the backing material 50 can comprise two 15 pic, woven, polypropylene primary backings. In operation, the respective polypropylene primary backings are fed individually from two backing stands and into a tufting machine with one on top of the other. The needles conventionally penetrate the backing material 50 with the plurality of fibrillated yarns 42 to create a desired “pile” on the face of the artificial turf mat. In one aspect, it is contemplated that at least two fibrillated yarns of the plurality of fibrillated yarns can be fed to each needle. Due to the large needle size and the large filament size, it is desired that the backing material comprises at least two backing layers.
In a further aspect, the turf layer 40 can comprise an adhesive coating layer 44. In this aspect, the bottommost layer of the backing material 50 can be coated with the adhesive coating layer, which is configured to bind to, and optionally integrate with, at least a portion of the plurality of fibrillated yarns that is exposed on the bottommost surface of the backing material (i.e., the backstitch). In one aspect, it is contemplated that this adhesive coating layer 44 can seal the portion of the plurality of fibrillated yarns that is exposed on the bottommost surface of the backing material to the bottommost layer of the backing material and can add a layer of dimensional stability to the backing. In one aspect, the adhesive layer is applied at about 15 to 30 ounces per square foot, and more preferably about 20 ounces per square foot, onto the bottommost layer of the backing material.
In one aspect, it is contemplated that the adhesive layer 44 can comprise ECOWORX Broadloom (EBL) extruded coating (SHAW INDUSTRIES GROUP, INC., Dalton, Ga., United States of America), which is configured to lock the backstitch by encapsulation and provides a surface for the underlying foam substrate to adhere. Since the EBL coating is a thermoplastic, as opposed to a standard latex or polyurethane coating, it has good adhesion characteristics. The use of EBL allows for acceptable tuft-binds without a latex pre-coat. In one exemplary aspect, a conventional hot melt methodology can be utilized to apply the adhesive layer thereon the bottommost surface of the backing material. Guidance to EBL can be found in U.S. patent application Ser. Nos. 11/915,553, 12/952,709, 13/036,457, 13/887,866, and 13/953,156, and in U.S. Pat. Nos. 7,338,698, 7,357,971, 7,910,194, 8,283,017, and 8,496,869, each of which is incorporated by reference herein in its entirety.
It is contemplated that latex formulations with very low filler content can also be used as the adhesive layer. Optionally, it is also contemplated that a secondary backing can be adhered to the adhesive layer to facilitate adhesion to the underlying foam substrate by providing more surface area or to create a different surface texture.
In one aspect, the underlying foam substrate 60 can comprise a shock resistant material that can be adhered to the bottom surface of the turf layer. In one exemplary aspect, the underlying foam substrate can comprise a cross-linked, polyethylene foam pad. To meet desired athletic performance and safety requirements, the underlying foam substrate can be between about 0.375 inches to about 0.625 inches in cross-sectional height. Exemplary, non-limiting properties of a suitable cross-linked, polyethylene foam pad can include: a density of about 6 lb/ft3; a tensile strength of about 136 psi; elongation percentage of about 160%; tear resistance of about 39; compressive strength of about: 14 psi (at 10% deflection), about 20 psi (at 25% deflection), about 29 psi (at 40% deflection), and about 37 psi (at 50% deflection); a compression set of about 13%; thermal stability of less than about 0.5% change (24 hours at 158° F.); water absorption of less than 0.07 lb/ft2 (skived); and a working temperature of between about −56° F. to about +210° F.
In various non-limiting examples, versions of the exemplary suitable cross-linked, polyethylene foam substrate 60 were tested and had the properties shown in Table 1.
In exemplary aspects, the desired range for Gmax (surface hardness) can be less than or equal to 100. In further exemplary aspects, the desired range for Force Reduction can be between 55-75%. In still further exemplary aspects, the desired range for vertical deflection can be between about 8 and about 11 mm. As one will appreciate, the characteristics of the disclosed foam substrate 60 can permit compliance with FIFA 1 STAR standards.
In one aspect, the upper surface 62 of the underlying foam substrate 60 can be adhered to the lower surface 45 of the adhesive layer 44. In one exemplary methodology, it is contemplated that the foam substrate can be flame laminated to the turf layer. In this aspect, the upper surface 62 of the foam substrate can be heated by being exposed to a flame to partially melt the top surface of the foam substrate to a desired depth. Subsequently, the bottom surface of the turf layer can be attached to the heated top surface of the foam substrate and the joined turf layer and the foam substrate can then be run between two rollers to compress and bind the respective turf layer and the foam substrate together.
When the joined turf layer and the foam substrate have cooled, the joined materials can be scored, milled and fitted with connection means to form the respective individual non-filled artificial turf mats. In one aspect, the individual non-filled artificial turf mats can have a width of between about 2 feet to about 12 feet. The mats can have any shape, but it is preferred that the mats have a generally rectangular shape with the elongate length exceeding the width.
In another aspect, to aid in rolling up an individual turf mat, each mat 20 can have a plurality of slits 22 defined into the bottom surface of the underlying foam substrate that extend the entire width, or substantially the entire width, of the turf mat. Each slit extends upwardly toward the overlying turf layer to a desired depth in the foam substrate. In various aspects, the slits can extend about 10%, about 20%, about 30%, about 40%, about 50%, about 60%, about 70%, about 80%, about 90%, or about 95% of the cross-sectional height of the foam substrate (moving upwardly from the bottom surface of the mat). In exemplary aspects, it is contemplated that the slits can extend from about 50% to about 99% of the cross-sectional height of the foam substrate. In further exemplary aspects, it is contemplated the slits can extend from about 75% to about 95% of the cross-sectional height of the foam substrate.
In operation, the bottom surface of the mats can be laid on a substrate such as a flooring material, concrete slab, or a leveled aggregate and dirt subgrade and married to adjoining mats to create a floating, portable athletic field. The connection means is configured to be suitable for selective joining and separating the artificial turf mats. As one will appreciate, also disclosed herein is method for installing and subsequently removing the transition artificial turf field in a quick and efficient manner.
Because it is contemplated that the non-filled artificial turf mats can be arranged on a floor for a specific activity and then removed and stored when a different activity is to take place on the same floor, it is desirable to provide a system that allows the non-filled artificial turf mats to be easily attached and separated. In some aspects, the system can be reusable in that it can permit the non-filled artificial turf mats to be connected and then separated multiple times. In some embodiments in accordance with the invention, the system can allow the non-filled artificial turf mats to be attached to each other and form a substantially contiguous top surface. In other embodiments, the non-filled artificial turf mats can be secured by connection means for reducing movement between selectively adjoined artificial turf mats and preventing gaps from occurring between the selectively adjoined artificial turf mats. In one aspect, the connection means can comprise the connecting system described in U.S. Pat. Nos. 8,307,600, 8,596,011, 8,733,056, 8,800,233, and 9,278,243, each of which is incorporated herein by reference in its entirety.
Selected non-filled artificial turf mats can be coupled together utilizing hook and loop fastening systems. To remove the assembled artificial turf field, each non-filled artificial turf mat can be unhooked from the next adjacent non-filled artificial turf mat and rolled onto a roller 90 as exemplarily shown in
In another embodiment, as shown in
In one aspect, elongated stripes of attaching material 70 can be adhered to the respective first and second connecting surfaces. The attaching material can be attached to the respective first and second connecting surfaces 65, 67 by any suitable method such as, but not limited to, flame lamination, gluing, double sided tape, and sewing. In one aspect, attaching material 70 provided with an adhesive on the back can also be used. In one exemplary aspect, the attaching material 70 can be, for example, a hook and loop attaching material or other conventional attaching material that is capable of being attached and detached multiple times. In another embodiment, the loop portion of the attaching material can be mounted to the horizontal first connecting surface 65 of the longitudinally extending shoulder member, and the hook portion of the attaching material is mounted on the horizontal second connecting surface 67 of the longitudinally extending shelf member. Alternatively, the hook portion of the attaching material can be mounted to the horizontal first connecting surface 65 of the longitudinally extending shoulder member, and the loop portion of the attaching material is mounted on the horizontal second connecting surface 67 of the longitudinally extending shelf member. One example, and not meant to be limiting, of a hook and loop material is a series of products sold under the trade name VELCRO.
In further exemplary aspects, it is contemplated that the non-filled artificial turf mats can be coupled together utilizing magnetic attraction forces. In these aspects, it is contemplated that the attaching material on the first connecting surface can comprise at least one magnet having a first polarity, while the attaching material on the second connecting surface can comprise at least one magnet having a second polarity that is opposite the first polarity to thereby generate a magnetic attraction between the first and second connecting surfaces when the magnets are sufficiently aligned (or proximate one another). It is further contemplated that each of the first and second connecting surfaces can define receptacles (holes, openings, and the like) for receiving and retaining respective magnets.
In still further exemplary aspects, it is contemplated that the non-filled artificial turf mats can be coupled together utilizing at least one projection defined by one of the first and second connecting surfaces and a corresponding trench defined by the other of the first and second connecting surfaces. In these aspects, the trench can be spaced from an edge of the mat and run substantially parallel to an edge of the mat, and each projection can be configured for selective complementary insertion into the trench. In exemplary aspects, the trench and the at least one projection can have a rectangular cross-sectional shape; however, it is contemplated that any shape, including chamfered and rounded shapes, can be used.
One skilled in the art will appreciate that when non-filled artificial turf mats of the present invention are selectively secured together via exemplary connection means, the turf layers of both of the adjoining mats form the substantially contiguous top or working surface.
As shown in
Although several embodiments of the invention have been disclosed in the foregoing specification, it is understood by those skilled in the art that many modifications and other embodiments of the invention will come to mind to which the invention pertains, having the benefit of the teaching presented in the foregoing description and associated drawings. It is thus understood that the invention is not limited to the specific embodiments disclosed hereinabove, and that many modifications and other embodiments are intended to be included within the scope of the appended claims. Moreover, although specific terms are employed herein, as well as in the claims which follow, they are used only in a generic and descriptive sense, and not for the purposes of limiting the described invention, nor the claims which follow.
Claims
1. An artificial turf system comprising:
- a plurality of artificial turf mats, each artificial turf mat comprising: a turf layer; an underlying foam substrate; and a selective connection means for reducing movement between selectively adjoined artificial turf mats and preventing gaps from occurring between the selectively adjoined artificial turf mats,
- wherein the turf layer of each artificial turf mat does not comprise particulate infill.
2. The artificial turf system of claim 1, wherein the turf layer of each artificial turf mat comprises a plurality of fibrillated yarns and a backing material, wherein the plurality of fibrillated yarns are tufted within the backing material.
3. The artificial turf system of claim 1, wherein the plurality of fibrillated yarns of each artificial turf mat comprises a first type of yarn and a second type of yarn different from the first type of yarn.
4. The artificial turf system of claim 1, wherein the backing material of the turf layer of each artificial turf mat comprises at least two backing layers.
5. The artificial turf system of claim 2, wherein the backing material comprises a bottommost layer, and wherein the turf layer of each artificial turf mat comprises an adhesive coating that coats the bottommost layer of the backing material.
6. The artificial turf system of claim 5, wherein an exposed portion of the plurality of fibrillated yarns extends downwardly through the bottommost layer of the backing material, and wherein the adhesive coating is configured to bind the exposed portion of the plurality of fibrillated yarns to the bottommost layer of the backing material.
7. The artificial turf system of claim 1, wherein the foam substrate of each artificial turf mat comprises a shock resistant material.
8. The artificial turf system of claim 7, wherein the shock resistant material of the foam substrate comprises polyethylene foam.
9. The artificial turf system of claim 5, wherein the foam substrate of each artificial turf mat is adhered to the bottommost layer of the backing material.
10. The artificial turf system of claim 9, wherein the foam substrate of each artificial turf mat is flame-laminated to the bottommost layer of the backing material.
11. The artificial turf system of claim 1, wherein the foam substrate of each artificial turf mat has a bottom surface, and wherein each turf mat comprises a plurality of slits that extend upwardly from the bottom surface of the foam substrate to a desired depth in the foam substrate.
12. The artificial turf system of claim 1, wherein the selective connection means comprises a hook and loop fastening system.
13. The artificial turf system of claim 1, wherein the foam substrate of each artificial turf mat comprises:
- a longitudinally extending shoulder member on a first longitudinal edge of the mat that defines a downwardly facing, substantially horizontal, first connecting surface; and
- a longitudinally extending shelf member on a second, opposing longitudinal edge of the mat that defines an upwardly facing, substantially horizontal, second connecting surface,
- wherein the shoulder member is shaped for a complementary fit with the shelf member.
14. The artificial turf system of claim 13, wherein each artificial turf mat comprises elongated stripes of attaching material that are attached to the respective first and second connecting surfaces.
15. The artificial turf system of claim 14, wherein the attaching material comprises a hook and loop attaching material, wherein a loop portion of the hook and loop attaching material is attached to one of the first and second connecting surfaces, and wherein a hook portion of the hook and loop attaching material is attached to the other of the first and second connecting surfaces.
16. The artificial turf system of claim 14, wherein the attaching material extends over end edges of the shelf member.
17. The artificial turf system of claim 16, wherein the foam substrate has a bottom surface, and wherein the attaching material extends to the bottom surface of the foam substrate.
18. A method of preparing an artificial turf surface, comprising:
- attaching a first connecting surface of a first artificial turf mat to a second connecting surface of a second artificial turf mat, wherein each artificial turf mat comprises: a turf layer; an underlying foam substrate; and attaching material attached to the first and second connecting surfaces of the artificial turf mat, wherein the turf layer of each artificial turf mat does not comprise particulate infill, and
- wherein the attachment of the first connecting surface of the first artificial turf mat to the second connecting surface of the second artificial turf mat reduces movement between the first and second artificial turf mats and prevents gaps from occurring between the first and second artificial turf mats.
19. The method of claim 18, wherein attaching material attached to the first and second connecting surfaces of each artificial turf mat comprises hook and loop attaching material.
20. The method of claim 18, wherein the foam substrate of each artificial turf mat has a bottom surface, wherein each turf mat comprises a plurality of slits that extend upwardly from the bottom surface of the foam substrate to a desired depth in the foam substrate, and wherein the method further comprises rolling up the attached first and second artificial turf mats.
Type: Application
Filed: Apr 26, 2016
Publication Date: Oct 27, 2016
Inventors: GREGORY D. FOWLER (Ringgold, GA), PHIL STRICKLEN (Dalton, GA), LISA PORTER (Ringgold, GA), STEVE KERR (Acworth, GA), CHAD LIND (Flower Mound, TX)
Application Number: 15/138,775
