Turf Nail Modular System

Abstract

A modular artificial turf nail system comprising a plurality of border members defining a perimeter of an area to be covered with artificial turf (a field), at least one of the border members having—ends adapted to engage adjacent members, a nail edge defined near an upper edge adapted to receive fasteners affixing turf to the member adjacent to a perimeter edge of the member; at least one fastener affixing at least one border member in place by passing through a receiver defined in the border member; aggregate material within the area defined by the plurality of border members and optionally impact attenuating safety material disposed thereon to create a desired level; and turf attached to the border members by a plurality of fasteners penetrating at least one member's nail edge.

Description

FIELD OF THE INVENTION

The present invention relates generally to systems for installing artificial turf. The installations may be either excavated or elevated, but in either case the area to receive turf—the field—is defined and a border is created around the perimeter to which the turf will be attached.

BACKGROUND

There are two primary types of artificial turf installation most relevant to the present invention: excavated and elevated. Each of them have similar challenges, and the present invention can address both types. However, the present invention is preferably applied to elevated installations, and one of its chief benefits (i.e., minimizing excavation) is achieved primarily in that context.

EXCAVATED

Previously, artificial turf was generally installed at ground level. The entire area to be covered by turf (“field” or “turf area”) is typically excavated and around the perimeter, a border area is also excavated beyond the turf area. Most, if not all, of the excavated soil has to be transported from the area incurring added costs. The turf area is rendered smooth and uniform during and after excavation, sometimes with native soil, but often will fill material such as sand or other well-known aggregate materials. Using concrete border as an example, the concrete border that will define the turf area is excavated, leveled, formed up and poured at or near ground level. Once the concrete is in place, the turf area is usually leveled at an elevation that will, once the turf is installed, be at substantially the same elevation as the concrete border and the surrounding ground level. The same basic installation method may be used for wood or plastic edging. That is, the native soil is excavated then the wood or plastic edging around the perimeter is installed, then the appropriate levels are established with turf installed and affixed to the edging.

A flexible material that may be referred to as bender board was sometimes used for excavated installations (and also potentially for elevated installations). It comprised a dimensional member having a flexible structure, the “bender board.” The bender board was affixed to the material defining the perimeter of the area covered with turf, typically concrete. The turf was then attached to the bender board with fasteners.

ELEVATED

Elevated installations involved creating a border defining the area to receive turf with some retaining material such as wood or stone. In a typical installation, landscape timbers define the outer perimeter. Bender board would be attached to the timbers, and the turf nailed to the bender board. Where the perimeter is defined by landscape timbers, the turf could be nailed to a top edge of the timber, but such an installation have an unattractive appearance because the edge of the turf would be visible. The bender board is typically mounted below the elevation of the material defining the perimeter such that when the turf is affixed to it, the upper surface of the turf is at the same elevation as the surrounding perimeter material. Similar construction would be used if the border was constructed from retaining wall stones, blocks or poured concrete; the perimeter would be defined by the stone or rock, bender board attached, and the turf would be nailed to the bender board.

Problems with prior art systems include the time and expense of removing native materials in an excavated installation and, to a lesser extent, even in an elevated installation. For elevated installations, it is typically still necessary to remove some native soil so that the landscape timbers or stones are slightly below ground level to affix them in place. Affixing bender board to concrete is difficult and unreliable, and the level has to be carefully measured and site-built requiring additional expense and presenting a risk of uneven installation. As such, there is a need to address the previously discussed challenges. Similarly, the elevation to which fill material must be added must also be measured and carefully marked, for example, by a chalk line along the perimeter and/or bender board. Installation of concrete as a perimeter material is very expensive, and landscape timbers are subject to rot. Stones as a perimeter member can be dislocated and present an ongoing maintenance issue.

DRAWINGS

To describe the manner in which the above-recited and other advantages and features of the disclosure can be obtained, a more particular description of the principles briefly described above will be rendered by reference to specific embodiments thereof which are illustrated in the appended drawings. Understanding that these drawings depict only exemplary embodiments of the disclosure and are not therefore to be considered to be limiting of its scope, the principles herein are described and explained with additional specificity and detail through the use of the accompanying drawings in which:

FIG. 1 shows a typical installation of a modular turf nail system according to the present invention from a cross-sectional side view.

FIG. 2 shows a typical prior art installation with a concrete border, a bender board for attachment of the turf, and a two-layer impact attenuating safety material.

FIG. 3 is a rear view of a border member.

FIG. 4 is a perspective rear view of a border member.

FIG. 5 is a first side view of a border member.

FIG. 6. is a second side view of a border member.

FIG. 7 is a perspective view of a ramp allowing rolling access to the turf.

FIG. 8 is a top view of the ramp.

FIG. 9 is a top view of a border member.

DETAILED DESCRIPTION

Various examples of the disclosure are discussed in detail below. While specific implementations are discussed, it should be understood that this is done for illustration purposes. A person skilled in the relevant art will recognize that other components and configurations can be used without parting from the spirit and scope of the disclosure. Thus, the following description and drawings are illustrative and are not to be construed as limiting. Numerous specific details are described to provide a thorough understanding of the disclosure. However, in certain instances, well-known or conventional details are not described in order to avoid obscuring the description.

The terms used in this specification generally have their ordinary meanings in the art, within the context of the disclosure, and in the specific context where each term is used. Alternative language and synonyms can be used for any one or more of the terms discussed herein, and no special significance should be placed upon whether or not a term is elaborated or discussed herein. In some cases, synonyms for certain terms are provided. A recital of one or more synonyms does not exclude the use of other synonyms. The use of examples anywhere in this specification including examples of any terms discussed herein is illustrative and is not intended to further limit the scope and meaning of the disclosure or of any example term. Likewise, the disclosure is not limited to various embodiments given in this specification.

Additional features and advantages of the disclosure will be set forth in the description that follows, and in part will be obvious from the description, or can be learned by practice of the herein disclosed principles. The features and advantages of the disclosure can be realized and obtained by means of the instruments and combinations particularly pointed out in the appended claims. These and other features of the disclosure will become more fully apparent from the following description and appended claims or can be learned by the practice of the principles set forth herein.

Overview

The present disclosure includes embodiments of a modular artificial turf nail system. The system comprises a plurality of border members defining a perimeter of an area to be covered with artificial turf (a field). Preferably, at least one of the border members has ends adapted to engage adjacent members. A nail edge is defined near an upper edge adapted to receive fasteners affixing turf to the member adjacent to a perimeter edge of the member. At least one stake affixes at least one border member in place by passing through a receiver defined in the border member. Aggregate material is placed within the area defined by the plurality of border members and optionally impact attenuating safety material disposed thereon to create a desired level. Turf is attached to the border members'nail edge by a plurality of fasteners penetrating at least one member's nail edge.

The nail edge may be thicker than the remainder of the body, or it may have an applied layer of a different material to facilitate engagement with fasteners. Additionally, there may be a stability channel disposed below the nail edge providing at least one additional layer of material for secure engagement with a fastener. The stability channel also serves to improve the structural integrity of the member. Additional stability channels may be provided to further enhance the structural integrity of the members.

Members'ends typically define offset projections adapted to engage cooperating projections on adjacent members. The members may be one upper and one lower projection, but they are preferably two jaws on one end, and a single jaw on the other end with the single jaw adapted to be rotatingly received within the pair of jaws on its neighboring member.

Members generally are provided in a standard length, but varying lengths may be provided, or there may be adapters provided so that installers can cut a member to a needed length.

Many optional features are disclosed that enhance the utility of the system. Since the system is generally installed at a level higher than surrounding native soil, a ramp may be provided for rolling access to the field. The outer face of each member may include a decorative finish to enhance the appearance of the installation. Members are expected to by polymeric, and they may be formed by a wide range of methods including injection molding, rotational molding, extrusion blow molding, injection blow molding, or reaction injection molding.

Exemplary Embodiments

Additional features and advantages of the disclosure will be set forth in the description which follows, and in part will be obvious from the description, or can be learned by practice of the herein disclosed principles. The features and advantages of the disclosure can be realized and obtained by means of the instruments and combinations particularly pointed out in the appended claims. These and other features of the disclosure will become more fully apparent from the following description and appended claims, or they can be learned by the practice of the principles set forth herein.

FIG. 1—a Typical Installation of a Turf Nail System According to the Present Invention

FIG. 1 illustrates a typical installation of the turf nail system shown from a cross-sectional ide view. A border member 102 defines an outer edge of the area to be covered with artificial turf—the field. The border member 102 has a nail edge 104 defined near an upper edge 106 of the member 102. The turf 108 is fastened to the nail edge 104 at multiple points along a perimeter of the border member 102. The turf 108 may be fastened by nails, staples, or any other type of well-known fastener. Preferably, the nail edge 104 is at an elevation such that that an upper edge of the turf 108 is adjacent in elevation to the upper edge 106 of the member 102. Since the member 102 is typically constructed of hollow polymeric material, it may be desirable to construct the nail edge of thicker material than is provided for the remainder of the member 102. A further option is to affix onto the nail edge a layer of material to enhance its strength, and the material may be the same polymer of which the remainder of the member 102 is constructed, or it may be a material adapted to more securely engage fasteners.

An impact attenuating safety material 110—a pad—is typically provided below the turf 108. The safety material 110 may be one layer or more than one layer depending on the application. For example, in FIG. 2, a two-layer safety material 110 is shown. The safety material 110 preferably rests on a lower surface 112. The height of the lower surface 112 can be adjusted so that the thickness of the safety material 110 being used provides an upper support surface substantially on the same elevation as the nail edge 104.

Fill material 114 is provided to cover the field to an elevation substantially the same as the lower surface 112. The fill material and the lower surface 124 of the members 102 preferably rest on native soil 116. In an installation where the member and the fill rest on native soil, no excavation is required to prepare the field. However, the field is typically leveled and often grading is provided to accommodate runoff. Additionally, it may be desirable, in addition to leveling, to excavate to some extent to accumulate some native soil to use as fill material. Alternatively, the fill material may be brought in.

The end of the border member 102 shown in FIG. 1 has an upper jaw 118 and a lower jaw 120 defining between them a receiver 122. The receiver 122 is sized and adapted to rotatingly receive therein a projection 302 defined in a cooperating end of a second member 102. Alternatively, each member 102 may have one jaw—an upper and a lower—adapted to engage adjacent cooperating jaws. See, for example, U.S. Pat. No. 12,016,280 to Shepherd et al. Or in a further alternative there could be a plurality of jaws (more than two on one end and more than one on the other).

The length of a member 102 may be fixed, or a range of lengths may be provided to accommodate various installation scenarios. Installation kits could provide primarily members 102 having a standard length—four feet, for example, —while a small number of decreasing lengths of members, for example decreasing in 6″ increments—could also be provided to maximize flexibility in constructing the desired field. Another option to accommodate the need for varying lengths of members is illustrated by the teachings of U.S. Pat. No. 12,016,280 to Shepherd, et al. which teaches a landscape timber system having an adjustable length adapter. In this patent, the standard-length member 102 can be cut to a desired length, and an adapter placed over its cut end to rotatingly engage its adjoining member. Another option for an end of a member 102 is a square end. Square ends would not have any jaws for engaging adjoining members because they would be adapted to serve as the terminal end of a field where it abuts a feature, such as a building.

FIG. 2—Typical Prior Art Installation

FIG. 2 illustrates a typical prior art installation. The installation rests on native soil 116, but in prior art installations, the native soil is typically excavated and concrete 202 is poured to form a boundary for the field A bender board 204 is affixed to the concrete 202 by any of a number of fasteners, but a concrete nail 206 is shown. The turf 208 is then nailed or stapled to the bender board 204. An aggregate 214 is typically placed above the native soil 116, and a safety material 210 is laid on top of the aggregate 214 such that the top surface of the safety material 210 at the same level as the top of the bender board 204. In FIG. 2, the safety material 210 is two layers, but it could be one layer or multiple layers, both in typical prior art installations and in the present invention.

FIGS. 3 and 4—Rear View of Border Member

The end of the border member 102 shown in FIG. 3 has an upper jaw 118 and a lower jaw 120 defining between them a receiver 122 at a first end. The receiver 122 is sized and adapted to rotatingly receive therein a projection 302 defined in a cooperating end of a second member 102. Each border member 102 has both the cooperating jaws 118 and 120 at a first end and a projection 302 adapted to be received between the jaws of a cooperating member. The upper jaw 118 and lower jaw 120 preferably include a peg 310 extending outwardly into the receiver 122. The pegs 310 are adapted to engage cooperating receivers defined within the projection 302. Thus, once the projection 302 is inserted into the receiver 122, the pegs 310 engage the receiver increasing the strength of the connection between adjacent members 102 while allowing them rotational freedom relative one to another.

Each end of a member 102 defines a beveled face 312. Given the rotation point defined by the pegs 310 and the beveled face 312 of each end, each member can rotate through at least 180 degrees relative to its neighbor, and it may rotate through 270 degrees or more. This rotational flexibility gives maximum latitude for creation of the desired shape of the field.

The nail edge 106 is shown above a stability channel 304. The stability channel 304 increases the rigidity of the member 102, and it also provides both an upper surface 314 and a lower surface 316. A fastener used to attach the turf 108 to the member 102 preferably penetrates at least the nail edge 104 and the upper surface 314 thus providing additional stability of connection. Further stability of the connection is provided if the fastener also penetrates the lower surface 316.

Further structural stability of the member may be provided by the inclusion of a second stability channel 306. An analogous structure to the second stability channel 306 may be defined adjacent to the beveled face 312, to wit an end stability channel 322. As with the other stability channels, at least part of its function is to increase the structural integrity of the member 102, and particularly of each of the end sections thereof.

A connector channel 308 defines a hole 402 therethrough to receive a stake. The stake passes through the hole 402 and engages the native soil 116 underneath the member 102. The stake may be any of a well-known type with a point defined to penetrate the soil 116, an elongated shaft, and a head having a diameter larger than its shaft and larger than the hole 402. An upper stake engagement surface 318 is at the upper end of the hole 402 defined through the upper stake engagement surface 318. The member is preferably formed from hollow plastic, so the stake then passes through the hollow body of the member 102. The stake exits from a lower stake engagement surface 320. The upper stake engagement surface 318 preferably is lower than the lower surface 112. The difference between the upper stake engagement surface 318 and the lower surface 112 provides space the head of the spike so that it does not deflect a lower surface of the impact attenuating safety material 110.

The elevation difference between the upper edge 106 and the nail edge 104 of the member 102 can be seen in FIG. 4 and is more clearly illustrated in FIG. 6 as 602. The difference in elevation allows for a more attractive appearance when the member 102 with turf 108 attached is viewed from a side, and it obscures any non-uniformity of the cut of the turf 108 or how it is attached to the nail edge 106.

The upper stake engagement surface 318 defines therethrough a hole 402 that can be seen, and a cutout 404 is defined within the lower surface 112 providing space for the head of the spike. A spike offset 406 extends outward from the member 102 so that the spike is disposed well back from a center of gravity of the member 102. Placing the spike well back from the center of gravity of the member 102 provides additional stability given that the force of the aggregate 114 tends to press on a back of the member 102 tending to rotate it forward.

FIGS. 5 and 6—Side Views of Border Member

A member 102 is shown in a first side view in FIG. 5. The upper edge 106 is shown, the projection 302 is disposed between it and the lower surface 124. The spike offset 406 defines the back-most portion of the member 102. The end stability channel 322 can be seen.

Similarly, in FIG. 6, the upper edge 106 and the lower surface 124 can be seen, but disposed between them are an upper jaw 118 and a lower jaw 120 with the pegs 310a in the upper jaw and 310b in the lower jaw. There is a stability channel 322, and the spike offset 406 also defines the back-most portion of the member 102.

Three elevation differentials are emphasized in FIG. 6. The first elevation differential 602 is between the upper edge 106 and the nail edge 104. The first elevation differential 602 is not structurally significant, but it rather provides an aesthetic screen for the cut edge of the turf 108 that may be uneven or otherwise unattractive. The second elevation differential 604 is between the nail edge 104 and the lower surface 112, and it is substantially the same thickness as the safety material 110 being used in the particular installation such that an edge of the turf resting on the safety material 110 is naturally at the same elevation as the nail edge 104 for ease of attachment. The third elevation differential 606 is between the lower surface 112 and the stake engagement surface 318. The difference here provides a space for the head of the spike so that its height does not cause displacement of the safety material 110 disposed above the spike.

FIGS. 7 and 8—Ramp and Other Optional Components

FIGS. 7 and 8 illustrate a ramp 800 for use with the present invention that provides rolling access from the lower level of native soil 116 surrounding the field onto the level of the field. The ramp 800 includes a rolling surface 802 preferably bounded on each edge by a siderail 804. The ramp extends from a lower edge 806 up to a upper edge 808 with the former substantially on the same elevation as surrounding native soil 116, and the latter substantially on the same level as the upper edge 106. To affix the ramp in place, there may be attachment points 810 defined in the rolling surface 802, or there may be attachment tabs 812 attached to an edge of the ramp 800. In either case, at least one spike is placed through the relevant attachment means to secure the ramp 800 in place adjacent to and extending perpendicularly out from a member 102.

FIG. 9—Top View of Border Member

FIG. 9 shows a top view of a member 102. The upper edge 106 and the nail edge 104 are visible. The upper engagement surface 318, the hole 402, and the spike offset 406 can be seen relation to one another as can the cutout 404. The lower surface 112 is seen between the two upper engagement surfaces 318.

Interpretation

The above specification and examples provide a complete description of the structure and use of illustrative embodiments. Although certain embodiments have been described above with a certain degree of particularity, or with reference to one or more individual embodiments, those skilled in the art could make numerous alterations to the disclosed embodiments without departing from the scope of this invention. As such, the various illustrative embodiments of the methods and systems are not intended to be limited to the particular forms disclosed. Rather, they include all modifications and alternatives falling within the scope of the claims, and embodiments other than the one shown may include some or all of the features of the depicted embodiment. For example, elements may be omitted or combined as a unitary structure, and/or connections may be substituted. Further, where appropriate, aspects of any of the examples described above may be combined with aspects of any of the other examples described to form further examples having comparable or different properties and/or functions and addressing the same or different problems. Similarly, it will be understood that the benefits and advantages described above may relate to one embodiment or may relate to several embodiments. For example, embodiments of the present methods and systems may be practiced and/or implemented using different structural configurations, materials, ionically conductive media, monitoring methods, and/or control methods.

The claims are not intended to include, and should not be interpreted to include, means-plus-or step-plus-function limitations, unless such a limitation is explicitly recited in a given claim using the phrase(s) “means for” or “step for,” respectively.

Claims

1. A modular artificial turf nail system comprising:

a. a plurality of border members defining a perimeter of an area to be covered with artificial turf, at least one of the border members having i. ends adapted to engage adjacent members, ii. a nail edge defined near an upper edge adapted to receive fasteners affixing turf to the member adjacent to a perimeter edge of the member;

b. at least one fastener affixing at least one border member in place by passing through a receiver defined in the border member;

c. aggregate material within the area defined by the plurality of border members; and

d. turf attached to the border members by a plurality of fasteners penetrating at least one member's nail edge.

2. The system of claim 1 each border member having a fixed length and, at each end thereof, at least one offset projection adapted to alternatively engage at least one cooperating projection from adjacent members.

3. The system of claim 2 the projections defining cooperating members allowing rotation through at least 180 degrees for adjoining members relative to one another.

4. The system of claim 2 adding an adjustable length adapter having: whereby the length of a member can be changed, by sliding the adjustable length adapter over a cut end of a member, or lengthened, by sliding the adapter over an uncut member.

a. a length less than a border member;

b. an open end adapted to securely and slidingly receive a border member; and

c. an opposite end defining a projection to engage an adjacent border member,

5. The system of claim 1, the border member defining a lower surface below the nail edge, the lower surface adapted to engage an impact attenuating safety material installed beneath the turf at an elevation that, when added to a thickness of the safety material, supports the turf at a desired height to engage the nail edge and whereby the lower surface provides an integral indicator of the proper elevation for aggregate.

6. The system of claim 5, the receiver disposed below the lower surface whereby the fastener, when installed, does not interfere with the safety material engaging the lower surface.

7. The system of claim 1, the nail edge having a thickness adapted to securely engage fasteners affixed thereto.

8. The system of claim 7, at least one border member further defining a stability channel lower than the nail edge, the stability channel having an upper and lower surface whereby a fastener can penetrate the nail edge and one or both of the upper and lower surfaces to provide increased security of engagement of the fastener.

9. The system of claim 1, each border member defining an upper edge above the nail edge whereby a clean, finished appearance.

10. The system of claim 9, each member defining a decorative outside face whereby a more aesthetically pleasing appearance is presented.

11. The system of claim 1 where each member is formed by a method selected from injection molding, rotational molding, extrusion blow molding, injection blow molding, or reaction injection molding.

12. The system of claim 1 the ends adapted to engage adjacent members define therethrough a channel adapted to receive a fastener that more securely connects adjacent members.

13. The system of claim 12 in which the fastener also passes into the ground below whereby additional stability is provided to the system.

14. The system of claim 1 further including at least one ramp adapted to facilitate rolling access to the turf from a lower level.

15. The system of claim 1 where at least one member is provided having a square end for terminal engagement of a feature.

16. The system of claim 1 where the nail edge is thicker than the material from which the remainder of the member is constructed.

17. The system of claim 16 where additional thickness and engagement of the nail edge is provided by affixing a layer of a different material to the nail edge.

18. A modular artificial turf nail system comprising:

a. a plurality of border members defining a perimeter of an area to be covered with artificial turf, at least one of the border members having i. ends adapted to engage adjacent members, ii. a nail edge defined near an upper edge adapted to receive fasteners affixing turf to the member adjacent to a perimeter edge of the member, iii. at least one border member and further defining a stability channel enhancing the structural integrity of the member, the stability channel lower than the nail edge, the stability channel having an upper and lower surface whereby a fastener can penetrate the nail edge and one or both of the upper and lower surfaces to provide increased security of engagement of the fastener, iv. the border member defining a lower surface below the nail edge, the lower surface adapted to engage an impact attenuating safety material installed beneath the turf at an elevation that, when added to a thickness of the safety material, supports the turf at a desired height to engage the nail edge and whereby the lower surface provides an integral indicator of the proper elevation for aggregate; and v. each border member having a fixed length and, at each end thereof, at least one offset projection adapted to alternatively engage at least one cooperating projection from adjacent members, the projections defining cooperating members allowing rotation through at least 180 degrees for adjoining members;

b. at least one fastener affixing at least one border member in place by passing through a receiver defined in the border member;

c. aggregate material within the area defined by the plurality of border members; and

d. turf attached to the border members by a plurality of fasteners penetrating at least one member's nail edge.