Patent Application
20250019910
The application pertains to artificial turf and to a process for manufacturing artificial turf.
Artificial turf is a surface covering comprising artificial turf fibers extending from a first surface of a primary backing, wherein the artificial turf fibers are intended to resemble blades of natural grass as much as possible, in respect of their mechanical properties and/or their visual appearance, depending on the intended use of the artificial turf.
Artificial turf is generally manufactured by tufting artificial turf fibers into a primary backing having a first surface and a second surface, whereby tufts comprising one or more artificial turf fibers are connected to the primary backing. The tufts are connected to the primary backing in a regular pattern. The distance between the tufts in the cross-machine direction of the artificial turf is defined by the gauge of the tufting machine and the distance between the tufts in the machine direction of the artificial turf is defined by the stitch-rate of the tufting machine.
In the last few decades, there have been various developments aimed to improve the artificial turf fibers with respect to their mechanical properties and their visual appearance in order to provide artificial turf resembling natural grass as much as possible.
However, due to the fact that the tufts in artificial turfs are connected to the primary backing along positions in a regular pattern defined by the gauge and the stitch- rate of the tufting machine, such an artificial turf in general can still be distinguished from natural grass surfaces, which by nature have a non-uniform distribution of grass blades.
U.S. Pat. Nos. 3,940,522 A and 7,357,966 B2 disclose artificial turfs comprising two different types of artificial turf fibers, in particular a combination of textured fibers and non-textured fibers, to create some non-uniformity in the visual appearance of artificial turf in an attempt to more closely simulate natural grass.
EP 3 469 142 B1 discloses artificial turf that looks more natural, and which comprises first and second synthetic grass fibers, wherein the height of the first synthetic grass fibers is higher than the height of the second synthetic grass fibers, the first and second synthetic grass fibers being arranged in separate rows. To improve the natural look of the turf, it is further envisaged to omit, by not tufting fibers, certain positions in a given row, for example by means of a computer controlling randomizer. However, even when the artificial turf fibers are omitted at certain positions, most of the positions are tufted with synthetic grass fibers, in order to provide sufficient coverage of the surface of the artificial turf. The tufts are still connected to the primary backing along a regular pattern defined by the gauge and the stitch-rate of the tufting machine, and the artificial turf can still be distinguished from natural grass surfaces, which by nature have a non-uniform distribution of grass blades.
US 2021/0372021 A1 discloses artificial turf which may comprise first tuft sequences formed by a first tufting machine and second tuft sequences formed by a second tufting machine. The second tuft sequences may extend along a second axis that is angled at an oblique angle with respect to the first axis of the first tuft sequences. The second tuft sequences may be positioned between a first tuft sequence and a tuft third sequence. The first tuft sequence can be spaced from the second tuft sequence by the first distance, and the second tuft sequence can be spaced from the third tuft sequence by a second distance, wherein the first distance can be greater than the second distance, or the first distance can be less than the second distance. However, the tufts are still connected to the primary backing along a basic regular pattern within a small distance of the artificial turf, and the artificial turf can still be distinguished quite easily from natural grass surfaces, which by nature have a non-uniform distribution of grass blades.
US 2021/0332534 A1 discloses an artificial turf comprising first tuft lines of tufts on a first spacing and second transverse tuft lines of tufts on a second spacing greater than the first spacing to dispose the second “diverter” tufts intermediate opposing pairs of the first tuft lines that define interstices for receiving infill, in particular for application on steep slopes in landfill applications. The yarn of second tufts defines a second yarn bridge (backstitch) on the bottom side of the backing sheet, wherein the backstitch has a longitudinal axis oriented at an angle to the first tuft lines, which angle is preferably transverse or perpendicular to the first tuft lines. However, the tufts are still connected to the primary backing along a basic regular pattern within a small distance of the artificial turf, and the artificial turf can still be distinguished quite easily from natural grass surfaces, which by nature have a non-uniform distribution of grass blades.
There remains a need for an improved artificial turf which resembles natural grass even more, in particular in respect of the visual appearance of artificial turf.
The object of the invention is thus to provide an artificial turf resembling natural grass better, in particular having improved visual appearance, and to provide a process to manufacture an artificial turf resembling natural grass better, in particular having improved visual appearance.
The object is solved by the artificial turf of claim 1 and by the process of claim 10.
Advantageous further improvements of the artificial turf and of the process for manufacturing the artificial turf are provided by the dependent claims.
An artificial turf comprising a primary backing having a first surface and a second surface, first tufts comprising first artificial turf fibers tufted into the primary backing along the longitudinal direction of the primary backing at a first gauge and a first stitch-rate, the first artificial turf fibers extending to a first length from the first surface of the primary backing, second tufts comprising second artificial turf fibers tufted into the primary backing along the longitudinal direction of the primary backing at a second gauge and a second stitch-rate, the second artificial turf fibers extending to a second length from the first surface of the primary backing, wherein the second gauge is different from the first gauge, and wherein the ratio of the second gauge to the first gauge is not an integer and the ratio of the first gauge to the second gauge is not an integer, enables to provide an improved artificial turf resembling natural grass better, in particular having improved visual appearance, as the tufts are non-uniformly distributed in the artificial turf. The tufts in the artificial turf are not connected to the primary backing along a regular pattern defined by a fixed gauge and fixed stitch-rate of the tufting machine. Due to the fact that the artificial turf comprises first tufts tufted into the primary backing at a first gauge and second tufts tufted into the primary backing at a different second gauge, wherein the ratio of the second gauge to the first gauge is not an integer and the ratio of the first gauge to the second gauge is not an integer, a non-uniform distribution of tufts is obtained in the artificial turf, not only on a small scale of a few tufts, but also on a larger scale within the artificial turf, as the distance between neighbouring tufts varies across the width of the artificial turf over a multitude of tufts.
The first tufts are tufted into the primary backing along the longitudinal direction (also known as machine direction) of the primary backing, enabling to avoid, or at least reduce, problems with tension control in the primary backing as compared to tufting at an angle to the machine direction. The second tufts are also tufted into the primary backing along the longitudinal direction of the primary backing, enabling to avoid, or at least reduce, problems with tension control in the primary backing which has already been tufted with the first tufts, and may therefore be more susceptible for problems with tension control, as compared to tufting at an angle to the machine direction.
In a tufting process, artificial turf fibers, generally comprised in tufting yarns, are tufted into a primary backing by a tufting machine, which comprises a series of tufting needles spaced apart from adjacent needles at a certain distance in the cross-machine direction of the tufting machine. The distance between adjacent tufting needles is understood to be the gauge, which defines the spacing between tufts of artificial turf fibers in the artificial turf, in the cross-machine direction of the artificial turf.
The gauge of a tufting machine, i.e. the distance between two adjacent tufting needles in the cross machine direction of the tufting machine, is customarily defined in inches. The first gauge may have any value which is suitable for artificial turf. The first gauge may, for example, be 3/16 of an inch, ¼ of an inch, 5/16 of an inch, ⅜ of an inch, ⅝ of an inch or ¾ of an inch.
The second gauge may have any value which is suitable for artificial turf, as long as the second gauge is different from the first gauge, and the ratio of the second gauge to the first gauge is not an integer and the ratio of the first gauge to the second gauge is not an integer. The second gauge may, for example, be 3/16 of an inch (4.76 mm), ¼ of an inch (6.35 mm), 5/16 of an inch (7.94 mm), ⅜ of an inch (9.53 mm), ⅝ of an inch (15.88 mm) or ¾ of an inch (19.05 mm).
In an embodiment of the artificial turf, the second gauge is larger (in inch) than the first gauge to prevent, or at least reduce, the risk that the second tufts cover the first tufts to such an extent that the first tufts are not visible, or only hardly visible, in the artificial turf. It has been observed that, when the number of the first tufts per unit area is higher than the number of the second tufts per unit area, that the visual appearance is further improved, than when the number of the seconds tufts per unit area is higher than the number of the first tufts per unit area.
The stitch-rate of a tufting process, i.e. the number of tufting needle penetrations into the primary backing in the machine direction of the artificial turf, is customarily defined as the number of needle penetrations per 10 cm. The stitch-rate is dependent on the supply speed of the primary backing into the tufting machine and by the frequency at which the needles are reciprocated in the tufting machine. The number of tufting needle penetrations generally equals the number of tufts per 10 cm in the machine direction of the artificial turf, as tufting yarns are customarily continuously supplied to the tufting machine at each needle penetration.
The first stitch-rate may have any value which is suitable for artificial turf. The first stitch-rate may be between 6 stitches per 10 cm and 40 stitches per 10 cm, for example 8 per 10 cm, or 12 per 10 cm, or 14 per 10 cm, or 17 per 10 cm, or 22 per 10 cm, or 28 per 10 cm, or 35 per 10 cm. A higher first stitch-rate may be preferred to increase the number of tufts in the artificial turf and to provide a more densely populated surface in the artificial turf. However, a lower first stitch-rate may be preferred to reduce the amount of raw material needed for the artificial turf fibers in the artificial turf.
The second stitch-rate may have any value which is suitable for artificial turf. The second stitch-rate may be between 6 stitches per 10 cm and 40 stitches per 10 cm, for example 8 per 10 cm, or 12 per 10 cm, or 14 per 10 cm, or 17 per 10 cm, or 22 per 10 cm, or 28 per 10 cm, or 35 per 10 cm. A higher second stitch-rate may be preferred to increase the number of tufts in the artificial turf and to provide a more densely populated surface in the artificial turf. However, a lower second stitch-rate may be preferred to reduce the amount of raw material needed for the artificial turf fibers in the artificial turf.
The artificial turf may comprise the first artificial turf fibers tufted into the primary backing at a first stitch-rate and the second artificial turf fibers tufted into the primary backing at a second stitch-rate, wherein second stitch-rate is equal to the first stitch-rate. Due to the fact that the artificial turf comprises first tufts tufted into the primary backing at a first gauge and second tufts tufted into the primary backing at a different second gauge, wherein the ratio of the second gauge to the first gauge is not an integer and the ratio of the first gauge to the second gauge is not an integer, a non-uniform distribution of tufts is obtained in the artificial turf, even when the second stitch-rate is equal to the first stitch-rate.
The artificial turf may comprise the first artificial turf fibers tufted into the primary backing at a first stitch-rate and the second artificial turf fibers tufted into the primary backing at a second stitch-rate, wherein second stitch-rate is equal to the first stitch-rate, wherein the first tufts and the second tufts are located in different rows to obtain a more non-uniform distribution of tufts in the artificial turf, as the distance between neighbouring tuft varies across the width of the artificial turf over a multitude of tufts.
The rows comprising second tufts may be located equidistantly (along the longitudinal direction of the primary backing) between two rows comprising first tufts, i.e. a row comprising second tufts is located exactly between the preceding row comprising first tufts and the successive row comprising first tufts.
The rows comprising second tufts may be located non-equidistantly (along the longitudinal direction of the primary backing) between two rows comprising first tufts, i.e. a row comprising second tufts is located closer to the preceding row comprising first tufts and further from the successive row comprising first tufts, or is located closer to the successive row comprising first tufts and further from the preceding row comprising first tufts, to obtain a more non-uniform distribution of tufts in the artificial turf.
In an embodiment, the artificial turf may comprise the first artificial turf fibers tufted into the primary backing at a first stitch-rate and the second artificial turf fibers tufted into the primary backing at a second stitch-rate, wherein second stitch-rate is different from the first stitch-rate to obtain an even more non-uniform distribution of tufts in the artificial turf. The artificial turf may comprise any combination of first stitch-rate and second stitch rate. For example, in the artificial turf the first stitch-rate may be 23 stitches per 10 cm and second stitch rate may be 15 stitches per 10 cm, or the first stitch-rate may be 16 stitches per 10 cm and second stitch rate may be 9 stitches per 10 cm.
In an embodiment of the artificial turf, the second stitch-rate is smaller than the first stitch-rate to prevent, or at least reduce, the risk that the second tufts cover the first tufts to such an extent that the first tufts are not visible, or only hardly visible, in the artificial turf. It has been observed that, when the number of the first tufts per unit area is higher than the number of the second tufts per unit area, that the visual appearance is further improved, than when the number of the seconds tufts per unit area is higher than the number of the first tufts per unit area.
In the artificial turf, at least one position defined by the first gauge and the first stitch-rate may omit a first tuft, for example by temporarily stopping the supply of first artificial turf fibers to the respective tufting needle in the tufting machine, to obtain a more non-uniform distribution of first tufts in the artificial turf.
In the artificial turf, at least 1% of the positions defined by the first gauge and the first stitch-rate, or at least 2%, or at least 3%, or at least 4%, or at least 5%, or at least 10%, or at least 20%, or at least 30% of the positions defined by the first gauge and the first stitch-rate may omit a first tuft to obtain an even more non-uniform distribution of first tufts in the artificial turf. In the artificial turf, at most 66% of the positions defined by the first gauge and the first stitch-rate, or at most 50%, or at most 35%, or at most 25%, or at most 20%, or at most 10%, or at most 5%, or at most 2% of the positions defined by the first gauge and the first stitch-rate may omit a first tuft to obtain an even more non-uniform distribution of first tufts in the artificial turf. The positions defined by the first gauge and the first stitch-rate which omit a first tuft may be randomly distributed in the artificial turf, and may be controlled by means of a computer randomizer.
The positions defined by the first gauge and the first stitch-rate which omit a first tuft may be controlled by omitting feeding of tufting yarn to a selection of tufting needles in the first gauge. In the first gauge, omitting feeding of tufting yarn to tufting needles may be selected at regular intervals, or may be selected at random. Preferably, omitting feeding of tufting yarn to tufting needles is selected to at most two neighboring tufting needles at a time, more preferably one tufting needle at a time. The primary backing will be tufted also by these selected tufting needles of the first gauge, but these selected needles will not insert a first tuft.
The positions defined by the first gauge and the first stitch-rate which omit a first tuft may be controlled by removing a selection of tufting needles in the first gauge. In the first gauge, removing tufting needles may be selected at regular intervals, or may be selected at random. Preferably, removing tufting needles is selected to at most two neighboring tufting needles at a time, more preferably one tufting needle at a time. The primary backing will not be tufted at the positions of the removed selected tufting needles of the first gauge.
In the artificial turf, at least one position defined by the second gauge and the second stitch-rate may omit a second tuft, for example by temporarily stopping the supply of second artificial turf fibers to the respective tufting needle in the tufting machine, to obtain a more non-uniform distribution of second tufts in the artificial turf.
In the artificial turf, at least 1% of the positions defined by the second gauge and the second stitch-rate, o or at least 2%, or at least 3%, or at least 4%, or at least 5%, or at least 10%, or at least 20%, or at least 30% of the positions defined by the second gauge and the second stitch-rate may omit a second tuft to obtain an even more non-uniform distribution of second tufts in the artificial turf. In the artificial turf, at most 66% of the positions defined by the second gauge and the second stitch-rate, or at most 50%, or at most 35%, or at most 25%, or at most 20%, or at most 10%, or at most 5%, or at most 2% of the positions defined by the second gauge and the second stitch-rate may omit a second tuft to obtain an even more non-uniform distribution of second tufts in the artificial turf. The positions defined by the second gauge and the second stitch-rate which omit a second tuft may be randomly distributed in the artificial turf, and may be controlled by means of a computer randomizer.
The positions defined by the second gauge and the second stitch-rate which omit a second tuft may be controlled by omitting feeding of tufting yarn to a selection of tufting needles in the second gauge. In the second gauge, omitting feeding of tufting yarn to tufting needles may be selected at regular intervals, or may be selected at random intervals. Preferably, omitting feeding of tufting yarn to tufting needles is selected to at most two neighboring tufting needles at a time, more preferably one tufting needle at a time. The primary backing will be tufted also by these selected tufting needles of the second gauge, but these selected needles will not insert a second tuft.
The positions defined by the second gauge and the second stitch-rate which omit a second tuft may be controlled by removing a selection of tufting needles in the second gauge. In the second gauge, removing tufting needles may be selected at regular intervals, or may be selected at random. Preferably, removing tufting needles is selected to at most two neighboring tufting needles at a time, more preferably one tufting needle at a time. The primary backing will not be tufted at the positions of the removed selected tufting needles of the second gauge.
The positions which omit a first tuft or omit a second tuft may be independently distributed in the artificial turf.
The first artificial turf fibers in the artificial turf may be any artificial turf fibers suitable for artificial turf.
The first artificial turf fibers in the artificial turf have a first length. The first length may range from 10 mm to 80 mm, and may be for example at least 10 mm, at least 15 mm, at least 20 mm, at least 30 mm, or at least 40 mm, or at least 50 mm or at least 60 mm.
The length of an artificial turf fiber is understood to mean the extension of the artificial turf fiber in a non-textured state. The length of a non-textured artificial turf fiber is determined by measuring the extension of the fiber in a straight line, for example with a ruler. The length of a textured artificial turf fiber is determined by applying a minimum level of tension in the longitudinal direction of the fiber, which is sufficient to align the fiber in a straight line and measuring the extension of the fiber in the straight line.
Artificial turf fibers may extend from the first surface of the primary backing to a height which is equal to the length of the artificial turf fibers, when the artificial turf fibers are non-textured fibers, also known as straight fibers, and when the artificial turf fibers are in an upright orientation. Artificial turf fibers will extend from the first surface of the primary backing to a height which is less than the length of the artificial turf fibers, when the artificial turf fibers are textured fibers or when the (straight) artificial turf fibers are in a non-upright orientation.
The second artificial turf fibers in the artificial turf may be any artificial turf fibers suitable for artificial turf.
The second artificial turf fibers in the artificial turf have a second length. The second length may range from 10 mm to 80 mm, and may be for example at least 10 mm, at least 15 mm, at least 20 mm, at least 30 mm, or at least 40 mm, or at least 50 mm or at least 60 mm.
In the artificial turf, the second length of the second artificial turf fibers may be equal to the first length of the first artificial turf fibers. Due to the fact that the artificial turf comprises first tufts tufted into the primary backing at a first gauge and second tufts tufted into the primary backing at a different second gauge, and the ratio of the second gauge to the first gauge is not an integer and the ratio of the first gauge to the second gauge is not an integer, a non-uniform distribution of tufts is obtained in the artificial turf, thereby resembling natural grass better, even when the second length is equal to the first length, as the distance between neighbouring tuft varies across the width of the artificial turf over a multitude of tufts.
In the artificial turf, the second length of the second artificial turf fibers may be different from the first length of the first artificial turf fibers. In an embodiment of the artificial turf, the second length of the second artificial turf fibers is at least 5 mm larger than the first length of the first artificial turf fibers, preferably at least 10 mm larger, preferably at least 15 mm larger, more preferably at least 20 mm larger, more preferably at least 25 mm larger, more preferably at least 30 mm larger, than the first length of the first artificial turf fibers. The artificial turf resembles natural grass even better as the first artificial turf fibers having a first length and the second artificial turf fibers having a different second length are non-uniformly distributed in the artificial turf.
In the artificial turf, the first artificial turf fibers may have a first color, which may be any color. The first artificial turf fibers may also comprise a first combination of colors. The first color, or first combination of colors, of the first artificial turf fibers may resemble a color of a natural grass blade, for example (a combination of) a green color, a yellow color, and/or a brown color.
In the artificial turf, the second artificial turf fibers may have a second color, which may be any color. The second artificial turf fibers may also comprise a second combination of colors. The second color, or second combination of colors, of the second artificial turf fibers may resemble a color of a natural grass blade, for example (a combination of) a green color, a yellow color, and/or a brown color.
In the artificial turf, the second color, or second combination of colors, of the second artificial turf fibers may be equal to the first color, or first combination of colors, of the first artificial turf fibers. Due to the fact that the artificial turf comprises first tufts tufted into the primary backing at a first gauge and second tufts tufted into the primary backing at a different second gauge, wherein the ratio of the second gauge to the first gauge is not an integer and the ratio of the first gauge to the second gauge is not an integer, a non-uniform distribution of tufts is obtained in the artificial turf, thereby resembling natural grass better, even when the second color is equal to the first color, as the distance between neighbouring tuft varies across the width of the artificial turf over a multitude of tufts.
In the artificial turf, the second color, or second combination of colors, of the second artificial turf fibers may be different from the first color, or first combination of colors, of the first artificial turf fibers to improve the visual appearance of the artificial turf. The artificial turf resembles natural grass even better as the first artificial turf fibers having a first color, or first combination of colors, and the second artificial turf fibers having a different second color, or different second combination of colors are non-uniformly distributed in the artificial turf.
In the artificial turf, the first artificial turf fibers may have a first cross-sectional shape, which may be any cross-sectional shape suitable for artificial turf. The first cross-sectional shape of the first artificial turf fibers may for example be a rectangular shape, an oval shape, a curved shape, a C-shape, a W-shape, a spine shape, or a propeller shape.
In the artificial turf, the second artificial turf fibers may have a second cross-sectional shape, which may be any cross-sectional shape suitable for artificial turf. The second cross-sectional shape of the second artificial turf fibers may for example be a rectangular shape, an oval shape, a curved shape, a C-shape, a W-shape, a spine shape, or a propeller shape.
In the artificial turf, the second cross-sectional shape of the second artificial turf fibers may be equal to the first cross-sectional shape of the first artificial turf fibers. Due to the fact that the artificial turf comprises first tufts tufted into the primary backing at a first gauge and second tufts tufted into the primary backing at a different second gauge, wherein the ratio of the second gauge to the first gauge is not an integer and the ratio of the first gauge to the second gauge is not an integer, a non-uniform distribution of tufts is obtained in the artificial turf, thereby resembling natural grass better, even when the second cross-sectional shape is equal to the first cross-sectional shape, as the distance between neighbouring tuft varies across the width of the artificial turf over a multitude of tufts.
In the artificial turf, the second artificial turf fibers may have a second cross-sectional shape which is different from the first cross-sectional shape of the first artificial turf fibers to improve the visual appearance and/or the mechanical properties of the artificial turf. The artificial turf resembles natural grass even better as the first artificial turf fibers having a first cross-sectional shape and the second artificial turf fibers having a different second cross-sectional shape are non-uniformly distributed in the artificial turf.
The first artificial turf fibers may have a first cross-sectional size, which may be any cross-sectional size suitable for artificial turf. The first cross-sectional size may be in the range of 150 dtex to 3500 dtex, for example at least 200 dtex, or at least 250 dtex, or at least 500 dtex, or at least 1000 dtex, or at least 1500 dtex, or at least 2000 dtex, or at least 2500 dtex. The first cross-sectional size may be at most 3000 dtex, or at most 2500 dtex, or at most 2000 dtex, or at most 1500 dtex, or at most 1000 dtex, or at most 500 dtex, or at most 250 dtex.
The second artificial turf fibers may have a second cross-sectional size, which may be any cross-sectional size suitable for artificial turf. The second cross-sectional size may be in the range of 150 dtex to 3500 dtex, for example at least 200 dtex, or at least 250 dtex, or at least 500 dtex, or at least 1000 dtex, or at least 1500 dtex, or at least 2000 dtex, or at least 2500 dtex. The first cross-sectional size may be at most 3000 dtex, or at most 2500 dtex, or at most 2000 dtex, or at most 1500 dtex, or at most 1000 dtex, or at most 500 dtex, or at most 250 dtex.
In the artificial turf, the second cross-sectional size of the second artificial turf fibers may be equal to the first cross-sectional size of the first artificial turf fibers. Due to the fact that the artificial turf comprises first tufts tufted into the primary backing at a first gauge and second tufts tufted into the primary backing at a different second gauge, wherein the ratio of the second gauge to the first gauge is not an integer and the ratio of the first gauge to the second gauge is not an integer, a non-uniform distribution of tufts is obtained in the artificial turf, thereby resembling natural grass better, even when the second cross-sectional size is equal to the first cross-sectional size, as the distance between neighbouring tuft varies across the width of the artificial turf over a multitude of tufts.
In the artificial turf, the second artificial turf fibers have a second cross-sectional size which is different from the cross-sectional size of the first artificial turf fibers. The artificial turf resembles natural grass even better as the first artificial turf fibers having a first cross-sectional size and the second artificial turf fibers having a different second cross-sectional size are non-uniformly distributed in the artificial turf. For example, the second artificial turf fibers may have a second cross-sectional size of 3000 dtex and the first artificial turf fibers have a first cross-sectional size of 250 dtex, or vice versa.
In the artificial turf, the first artificial turf fibers may be non-texturized fibers, also known as straight fibers, or the first artificial turf fibers may be texturized fibers.
In the artificial turf, the second artificial turf fibers may be non-texturized fibers, or the second artificial turf fibers may be texturized fibers.
In the artificial turf, the first artificial turf fibers may be non-texturized fibers and the second artificial turf fibers may be non-texturized fibers. Due to the fact that the artificial turf comprises first tufts tufted into the primary backing at a first gauge and second tufts tufted into the primary backing at a different second gauge, wherein the ratio of the second gauge to the first gauge is not an integer and the ratio of the first gauge to the second gauge is not an integer, a non-uniform distribution of tufts is obtained in the artificial turf, thereby resembling natural grass better, even when the first artificial turf fibers are non-texturized fibers and the second artificial turf fibers are non-texturized fibers, as the distance between neighbouring tuft varies across the width of the artificial turf over a multitude of tufts.
In the artificial turf, the first artificial turf fibers may be texturized fibers and the second artificial turf fibers may be texturized fibers. Due to the fact that the artificial turf comprises first tufts tufted into the primary backing at a first gauge and second tufts tufted into the primary backing at a different second gauge, wherein the ratio of the second gauge to the first gauge is not an integer and the ratio of the first gauge to the second gauge is not an integer, a non-uniform distribution of tufts is obtained in the artificial turf, thereby resembling natural grass better, even when the first artificial turf fibers are texturized fibers and the second artificial turf fibers are texturized fibers, as the distance between neighbouring tuft varies across the width of the artificial turf over a multitude of tufts.
In the artificial turf, the first artificial turf fibers may be non-texturized fibers and the second artificial turf fibers may be texturized fibers. The artificial turf resembles natural grass even better as the first artificial turf fibers, which are non-texturized fibers, and the second artificial turf fibers, which are texturized fibers, are non-uniformly distributed in the artificial turf.
The first artificial turf fibers may be texturized fibers having a first texturizing level.
The second artificial turf fibers may be texturized fibers having a second texturizing level.
In the artificial turf, the first artificial turf fibers may be texturized fibers having a first texturizing level and the second artificial turf fibers may be texturized fibers having a second texturizing level, wherein the second texturizing level is equal to the first texturizing level. Due to the fact that the artificial turf comprises first tufts tufted into the primary backing at a first gauge and second tufts tufted into the primary backing at a different second gauge, wherein the ratio of the second gauge to the first gauge is not an integer and the ratio of the first gauge to the second gauge is not an integer, a non-uniform distribution of tufts is obtained in the artificial turf, thereby resembling natural grass better, even when the second texturizing level is equal to the first texturizing level, as the distance between neighbouring tuft varies across the width of the artificial turf over a multitude of tufts.
In the artificial turf, the first artificial turf fibers may be texturized fibers having a first texturizing level and the second artificial turf fibers may be texturized fibers having a second texturizing level, wherein the second texturizing level is different from the first texturizing level. The artificial turf resembles natural grass even better as the first artificial turf fibers having a first texturizing level and the second artificial turf fibers having a different second texturizing level are non-uniformly distributed in the artificial turf.
In the artificial turf, the first artificial turf fibers may comprise a first polymer, which may be any polymer suitable for artificial turf. The first artificial turf fibers may also comprise a first combination of polymers, which can for example enable to create crimps in the first artificial turf fibers, or a helical shape in the first artificial turf fibers. The first artificial turf fibers may for example comprise one or more polyester polymers, one or more polyamide polymers or one or more polyolefin polymers, or any combination thereof. The first artificial turf fibers preferably comprise one or more polyolefin polymers.
In the artificial turf, the second artificial turf fibers may comprise a second polymer, which may be any polymer suitable for artificial turf. The second artificial turf fibers may also comprise a second combination of polymers, which can for example enable to create crimps in the second artificial turf fibers, or a helical shape in the second artificial turf fibers. The second artificial turf fibers may for example comprise one or more polyester polymers, one or more polyamide polymers or one or more polyolefin polymers, or any combination thereof. The second artificial turf fibers preferably comprise one or more polyolefin polymers.
In the artificial turf, the second polymer of the second artificial turf fibers may be equal to the first polymer of the first artificial turf fibers. Due to the fact that the artificial turf comprises first tufts tufted into the primary backing at a first gauge and second tufts tufted into the primary backing at a different second gauge, wherein the ratio of the second gauge to the first gauge is not an integer and the ratio of the first gauge to the second gauge is not an integer, a non-uniform distribution of tufts is obtained in the artificial turf, thereby resembling natural grass better, in particular in respect of mechanical properties, even when the second polymer is equal to the first polymer, as the distance between neighbouring tuft varies across the width of the artificial turf over a multitude of tufts.
In the artificial turf, the second polymer of the second artificial turf fibers may be different from the first polymer of the first artificial turf fibers. The artificial turf resembles natural grass even better, in particular in respect of mechanical properties, as the first artificial turf fibers comprises a first polymer and the second artificial turf fibers comprises a second polymer are non-uniformly distributed in the artificial turf.
In the artificial turf, the first tufts may comprise multiple first artificial turf fibers, preferably 2 to 20 first artificial turf fibers, preferably 2 to 14, more preferably 4 to 9, more preferably 4 to 8 first artificial turf fibers.
In the artificial turf, the second tufts may comprise multiple second artificial turf fibers, preferably 2 to 20 second artificial turf fibers, preferably 2 to 14, more preferably 4 to 9, more preferably 4 to 8 second artificial turf fibers.
In the artificial turf, the number of second artificial turf fibers in the second tufts may be equal to the number of first artificial turf fibers in the first tufts. Due to the fact that the artificial turf comprises first tufts tufted into the primary backing at a first gauge and second tufts tufted into the primary backing at a different second gauge, wherein the ratio of the second gauge to the first gauge is not an integer and the ratio of the first gauge to the second gauge is not an integer, a non-uniform distribution of tufts is obtained in the artificial turf, thereby resembling natural grass better, even when the number of second artificial turf fibers in the second tufts is equal to the number of first artificial turf fibers in the first tufts, as the distance between neighbouring tuft varies across the width of the artificial turf over a multitude of tufts.
In the artificial turf, the number of second artificial turf fibers in the second tufts may be different from the number of first artificial turf fibers in the first tufts. The artificial turf resembles natural grass even better, in respect of visual appearance and/or mechanical properties, as the first tufts comprising multiple first artificial turf fibers and the second tufts comprising multiple second artificial turf fibers, wherein the number of second artificial turf fibers in the second tufts may be different from the number of first artificial turf fibers in the first tufts, are non-uniformly distributed in the artificial turf.
In the artificial turf, the second artificial turf fibers in the second tufts may be different from the first artificial turf fibers in the first tufts in any combination of features discussed herein above.
The first tufts may comprise the first artificial turf fibers and third artificial turf fibers extending to a third length from the first surface of the primary backing.
In the artificial turf, the first tufts may comprise several first artificial turf fibers and several third artificial turf fibers, preferably 2 to 10 first artificial turf fibers and 2 to 10 third artificial turf fibers, more preferably 2 to 4 first artificial turf fibers and 2 to 4 third artificial turf fibers.
The third artificial turf fibers may be non-texturized fibers or low texturized fibers, or the third artificial turf fibers may be texturized fibers.
The third artificial turf fibers may have a third length, a third color or a third combination of colors, a third texturizing level, a third cross-sectional shape and/or a third cross-sectional size, which each may be independently selected, and which each independently may be equal to or different from the first length, the first color or the first combination of colors, the first texturizing level, the first cross-sectional shape and the first cross-sectional size of the first artificial turf fibers, respectively.
The third artificial turf fibers may comprise a third polymer or a third combination of polymers, which may be independently selected, and which may be equal to or different from the first polymer or the first combination of polymers of the first artificial turf fibers.
In the artificial turf, the first tufts may comprise non-textured first artificial turf fibers and textured third artificial turf fibers. The textured third artificial turf fibers may provide support for the non-textured first artificial turf fibers to prevent, or at least reduce the chance, that the first artificial turf fibers will assume an orientation to lie flat in the artificial turf after a certain amount of time, thereby reducing the amount of infill required in the artificial turf.
The second tufts may comprise the second artificial turf fibers and fourth artificial turf fibers extending to a fourth length from the first surface of the primary backing.
In the artificial turf, the second tufts may comprise several second artificial turf fibers and several fourth artificial turf fibers, preferably 2 to 10 second artificial turf fibers and 2 to 10 fourth artificial turf fibers, more preferably 2 to 4 second artificial turf fibers and 2 to 4 fourth artificial turf fibers.
The fourth artificial turf fibers may be non-texturized fibers, or the fourth artificial turf fibers may be texturized fibers.
The fourth artificial turf fibers may have a fourth length, a fourth color or a fourth combination of colors, a fourth texturizing level a fourth cross-sectional shape and/or a fourth cross-sectional size, which each may be independently selected and which each independently may be equal to or different from the second length, the second color or the second combination of colors, the second texturizing level, the second cross-sectional shape and the second cross-sectional size of the second artificial turf fibers, respectively.
The fourth artificial turf fibers may comprise a fourth polymer or a fourth combination of polymers, which may be independently selected, and which may be equal to or different from the second polymer or the second combination of polymers of the second artificial turf fibers.
The first tufts may comprise the first artificial turf fibers, the third artificial turf fibers and fifth artificial turf fibers extending to a fifth length from the first surface of the primary backing.
In the artificial turf, the first tufts may comprise several first artificial turf fibers, several third artificial turf fibers and several fifth artificial turf fibers, preferably 2 to 7 first artificial turf fibers, 2 to 7 third artificial turf fibers and 2 to 7 fifth artificial turf fibers, for example 3 first artificial turf fibers, 3 third artificial turf fibers and 3 fifth artificial turf fibers.
The fifth artificial turf fibers may have a fifth length, a fifth color or a fifth combination of colors, a fifth texturizing level, a fifth cross-sectional shape and/or a fifth cross-sectional size, which each may be independently selected, and which each independently may be equal to or different from the first length and/or third length, the first and/or third color or the first and/or third combination of colors, the first and/or third texturizing level, the first and/or third cross-sectional shape and the first and/or third cross-sectional size of the first and/or third artificial turf fibers, respectively.
The fifth artificial turf fibers may comprise a fifth polymer or a fifth combination of polymers, which may be independently selected, and which may be equal to or different from the first and/or third polymer or the first and/or third combination of polymers of the first and/or third artificial turf fibers.
In the artificial turf, the first tufts may comprise non-textured first and/or third artificial turf fibers and textured fifth artificial turf fibers. The textured fifth artificial turf fibers may provide support for the non-textured first and/or third artificial turf fibers to prevent, or at least reduce the chance, that the first and/or third artificial turf fibers will assume an orientation to lie flat in the artificial turf after a certain amount of time, thereby reducing the amount of infill required in the artificial turf.
The second tufts may comprise the second artificial turf fibers, the fourth artificial turf fibers and sixth artificial turf fibers extending to a sixth length from the first surface of the primary backing.
In the artificial turf, the second tufts may comprise several second artificial turf fibers, several fourth artificial turf fibers and several sixth artificial turf fibers, preferably 2 to 7 second artificial turf fibers, 2 to 7 fourth artificial turf fibers and 2 to 7 sixth artificial turf fibers, for example 3 second artificial turf fibers, 3 fourth artificial turf fibers and 3 sixth artificial turf fibers.
The sixth artificial turf fibers may have a sixth length, a sixth color or a sixth combination of colors, a sixth texturizing level, a sixth cross-sectional shape and/or a sixth cross-sectional size, which each may be independently selected, and which each independently may be equal to or different from the second length and/or fourth length, the second and/or fourth color or the second and/or fourth combination of colors, the second and/or fourth texturizing level, the second and/or fourth cross-sectional shape and the second and/or fourth cross-sectional size of the second and/or fourth artificial turf fibers, respectively.
The sixth artificial turf fibers may comprise a sixth polymer or a sixth combination of polymers, which may be independently selected, and which may be equal to or different from the second and/or fourth polymer or the second and/or fourth combination of polymers of the second and/or fourth artificial turf fibers.
In the artificial turf, the second tufts may comprise non-textured second and/or fourth artificial turf fibers and textured sixth artificial turf fibers. The textured sixth artificial turf fibers may provide support for the non-textured second and/or fourth artificial turf fibers to prevent, or at least reduce the chance, that the second and/or fourth artificial turf fibers will assume an orientation to lie flat in the artificial turf after a certain amount of time, thereby reducing the amount of infill required in the artificial turf.
In the artificial turf, the second tufts may comprise non-textured second artificial turf fibers and textured fourth artificial turf fibers. The textured fourth artificial turf fibers may provide support for the non-textured second artificial turf fibers to prevent, or at least reduce the chance, that the second artificial turf fibers will assume an orientation to lie flat in the artificial turf after a certain amount of time, thereby reducing the amount of infill required in the artificial turf.
The artificial turf may comprise an infill, which may for example be sand, a natural infill, such as for example cork particles, coconut shell particles and the like, or a polymeric infill.
In an embodiment, the artificial turf does not comprise an infill, in particular in an artificial turf wherein the first tufts comprise non-textured first or low texturized artificial turf fibers (also known as semi-texturized artificial turf fibers), and textured third artificial turf fibers, and/or the second tufts comprise non-textured or low texturized second artificial turf fibers and textured fourth artificial turf fibers.
The artificial turf resembles natural grass better, in respect of the visual appearance and/or mechanical properties, and may be used in any artificial turf application. The artificial turf may for example be used as a sports field, as a playground, as a residential lawn or as an artificial turf in landscaping applications. Due to the improved visual appearance of the artificial turf, the artificial turf may advantageously be used as a residential lawn or as an artificial turf in landscaping applications.
The first tufts may comprise the first artificial turf fibers, the third artificial turf fibers, the fifth artificial turf fibers and seventh artificial turf fibers extending to a seventh length from the first surface of the primary backing.
The seventh artificial turf fibers may have a seventh length, a seventh color or a seventh combination of colors, a seventh texturizing level, a seventh cross-sectional shape and/or a seventh cross-sectional size, which each may be independently selected, and which each independently may be equal to or different from the first length and/or third and/or fifth length, the first and/or third and/or fifth color or the first and/or third and/or fifth combination of colors, the first and/or third and/or fifth texturizing level, the first and/or third and/or fifth cross-sectional shape and the first and/or third and/or fifth cross-sectional size of the first and/or third and/or fifth artificial turf fibers, respectively.
The seventh artificial turf fibers may comprise a seventh polymer or a seventh combination of polymers, which may be independently selected, and which may be equal to or different from the first and/or third and/or fifth polymer or the first and/or third combination of polymers of the first and/or third and/or fifth artificial turf fibers.
The second tufts may comprise the second artificial turf fibers, the fourth artificial turf fibers, the sixth artificial turf fibers and eight artificial turf fibers extending to an eight length from the first surface of the primary backing.
The eight artificial turf fibers may have a eight length, a eight color or a eight combination of colors, a eight texturizing level, a eight cross-sectional shape and/or a eight cross-sectional size, which each may be independently selected, and which each independently may be equal to or different from the second length and/or fourth and/or sixth length, the second and/or fourth and/or sixth color or the second and/or fourth and/or sixth combination of colors, the second and/or fourth and/or sixth texturizing level, the second and/or fourth and/or sixth cross-sectional shape and the second and/or fourth and/or sixth cross-sectional size of the second and/or fourth and/or sixth artificial turf fibers, respectively.
The eight artificial turf fibers may comprise an eight polymer or an eight combination of polymers, which may be independently selected, and which may be equal to or different from the second and/or fourth and/or sixth polymer or the second and/or fourth and/or sixth combination of polymers of the second and/or fourth and/or sixth artificial turf fibers.
A process for manufacturing an artificial turf comprising the steps of providing a primary backing having a first surface and a second surface, tufting first artificial turf fibers into the primary backing along the longitudinal direction of the primary backing in a first tufting step at a first gauge and a first stitch-rate to extend from the first surface of the primary backing to a first length to form first tufts, tufting second artificial turf fibers into the primary backing along the longitudinal direction of the primary backing in a subsequent second tufting step at a second gauge and a second stitch-rate to extend from the first surface of the primary backing to second length to form second tufts, characterized in that the second gauge in the second tufting step is different from the first gauge in the first tufting step, and wherein the ratio of the second gauge to the first gauge is not an integer and the ratio of the first gauge to the second gauge is not an integer, enables to provide an improved artificial turf resembling natural grass better, in particular having improved visual appearance, as the tufts are non-uniformly distributed in the artificial turf, not only on a small scale of a few tufts, but also on a larger scale within the artificial turf, as the distance between neighbouring tufts varies across the width of the artificial turf over a multitude of tufts.
The process comprises the step of tufting first artificial turf fibers into the primary backing along the longitudinal direction of the primary backing in a first tufting step, enabling to avoid, or at least reduce, problems with tension control in the primary backing as compared to tufting at an angle to the machine direction or longitudinal direction of the primary backing. The second tufts are also tufted into the primary backing along the longitudinal direction of the primary backing, enabling to avoid, or at least reduce, problems with tension control in the primary backing which has already been tufted with the first tufts, and may therefore be more susceptible for problems with tension control, as compared to tufting at an angle to the machine direction.
In a tufting process, artificial turf fibers, generally comprised in tufting yarns, are tufted into a primary backing by a tufting machine, which comprises a series of tufting needles spaced apart from adjacent needles at a certain distance in the cross-machine direction of the tufting machine. The distance between adjacent tufting needles is understood to be the gauge, which defines the spacing between tufts of artificial turf fibers in the artificial turf, in the cross-machine direction of the artificial turf.
The process may comprise the step of tufting the second artificial turf fibers into the primary backing in the subsequent second tufting step at a second gauge and a second stitch-rate, wherein the second gauge is different from the first gauge in the first tufting step, and wherein the ratio of the second gauge to the first gauge is not an integer and the ratio of the first gauge to the second gauge is not an integer, and wherein the second stitch-rate is equal to the first stitch-rate in the first tufting step, wherein the alignment of the stitch-rate in the subsequent second tufting step is such that the first tufts and the second tufts are located in different rows. The alignment of the stitch-rate in the subsequent second tufting step may be such that the rows comprising second tufts may be located equidistantly between two rows comprising first tufts, i.e. a row comprising second tufts is located exactly between the preceding row comprising first tufts and the successive row comprising first tufts. In the process, the tufting needles will insert the rows of second tufts exactly between the preceding row comprising first tufts and the successive row comprising first tufts. The alignment of the stitch-rate in the subsequent second tufting step may also be such that the rows comprising second tufts may be located non-equidistantly between two rows comprising first tufts, i.e. a row comprising second tufts is located closer to the preceding row comprising first tufts and further from the successive row comprising first tufts, or is located closer to the successive row comprising first tufts and further from the preceding row comprising first tufts, to obtain a more non-uniform distribution of tufts in the artificial turf. In the process, the tufting needles will insert the rows of second tufts somewhere between the preceding row comprising first tufts and the successive row comprising first tufts.
The process may comprise the step of tufting the second artificial turf fibers into the primary backing in the subsequent second tufting step at a second gauge and a second stitch-rate, wherein the second gauge is different from the first gauge in the first tufting step and the second stitch-rate is different from the first stitch-rate in the first tufting step to obtain a more non-uniform distribution of tufts in the artificial turf.
In an embodiment of the process, the second gauge is larger than the first gauge to prevent, or at least reduce, the risk that the second tufts cover the first tufts to such an extent that the first tufts are not visible, or only hardly visible, in the artificial turf. It has been observed that, when the number of the first tufts per unit area is higher than the number of the second tufts per unit area, that the visual appearance is further improved, than when the number of the seconds tufts per unit area is higher than the number of the first tufts per unit area.
In an embodiment of the artificial turf, the second stitch-rate is smaller than the first stitch-rate to prevent, or at least reduce, the risk that the second tufts cover the first tufts to such an extent that the first tufts are not visible, or only hardly visible, in the artificial turf. It has been observed that, when the number of the first tufts per unit area is higher than the number of the second tufts per unit area, that the visual appearance is further improved, than when the number of the seconds tufts per unit area is higher than the number of the first tufts per unit area.
In the process, the first artificial turf fibers may have a first length, a first color or a first combination of colors, a first texturizing level, a first cross-sectional shape and/or a first cross-sectional size, as provided herein above.
In the process, the first artificial turf fibers may be non-texturized fibers or low texturized, as provided herein above.
In the artificial turf, the first artificial turf fibers may comprise a first polymer or a first combination of polymers, as provided herein above.
In the process, the second artificial turf fibers may have a second length, a second color or a second combination of colors, a second texturizing level, a second cross-sectional shape and/or a second cross-sectional size, as provided herein above.
In the process, the second artificial turf fibers may be non-texturized fibers or low texturized, as provided herein above.
In the artificial turf, the second artificial turf fibers may comprise a second polymer or a second combination of polymers, as provided herein above.
The process may comprise the step of tufting first artificial turf fibers and third artificial turf fibers into the primary backing in the first tufting step at a first gauge and a first stitch-rate, to extend the first artificial turf fibers from the first surface of the primary backing to a first length and to extend the third artificial turf fibers from the first surface of the primary backing to a third length to form first tufts comprising first artificial turf fibers and third artificial turf fibers.
In the process, the third artificial turf fibers may have a third length, a third color or a third combination of colors, a third texturizing level, a third cross-sectional shape and/or a third cross-sectional size, which each may be independently selected and which each independently may be equal to or different from the first length, the first color or the first combination of colors, the first texturizing level, the first cross-sectional shape and the first cross-sectional size of the first artificial turf fibers, respectively, as provided herein above.
In the process, the third artificial turf fibers may comprise a third polymer or a third combination of polymers, which may be independently selected, and which may be equal to or different from the first polymer or the first combination of polymers of the first artificial turf fibers, as provided herein above.
In the process, the first artificial turf fibers may be non-textured or low texturized first artificial turf fibers and the third artificial turf fibers may be textured third artificial turf fibers. The textured third artificial turf fibers may provide support for the non-textured first artificial turf fibers to prevent, or at least reduce the chance, that the first artificial turf fibers will assume an orientation to lie flat in the artificial turf after a certain amount of time, thereby reducing the amount of infill required in the artificial turf.
The process may comprise the step of tufting second artificial turf fibers and fourth artificial turf fibers into the primary backing in the subsequent second tufting step at a second gauge and a second stitch-rate, to extend the second artificial turf fibers from the first surface of the primary backing to a second length and to extend the fourth artificial turf fibers from the first surface of the primary backing to a fourth length to form second tufts comprising second artificial turf fibers and fourth artificial turf fibers.
In the process, the fourth artificial turf fibers may have a fourth length, a fourth color or a fourth combination of colors, a fourth texturizing level, a fourth cross-sectional shape and/or a fourth cross-sectional size, which each may be independently selected and which each independently may be equal to or different from the second length, the second color or the second combination of colors, the second texturizing level, the second cross-sectional shape and the second cross-sectional size of the second artificial turf fibers, respectively, as provided herein above.
In the process, the fourth artificial turf fibers may comprise a fourth polymer or a fourth combination of polymers, which may be independently selected, and which may be equal to or different from the second polymer or second combination of polymers of the second artificial turf fibers, as provided herein above.
In the process, the second artificial turf fibers may be non-textured or low texturized second artificial turf fibers and the fourth artificial turf fibers may be textured fourth artificial turf fibers. The textured fourth artificial turf fibers may provide support for the non-textured second artificial turf fibers to prevent, or at least reduce the chance, that the second artificial turf fibers will assume an orientation to lie flat in the artificial turf after a certain amount of time, thereby reducing the amount of infill required in the artificial turf.
The process may comprise the step of tufting first artificial turf fibers, third artificial turf fibers and fifth artificial turf fibers into the primary backing in the first tufting step at a first gauge and a first stitch-rate, to extend the first artificial turf fibers from the first surface of the primary backing to a first length, to extend the third artificial turf fibers from the first surface of the primary backing to a third length and to extend the fifth artificial turf fibers from the first surface of the primary backing to a fifth length to form first tufts comprising first artificial turf fibers, third artificial turf fibers and fifth artificial turf fibers.
In the process, the fifth artificial turf fibers may have a fifth length, a fifth color or a fifth combination of colors, a fifth texturizing level, a fifth cross-sectional shape and/or a fifth cross-sectional size, which each may be independently selected and which each independently may be equal to or different from the first and/or third length, the first and/or third color or the first and/or third combination of colors, the first and/or third texturizing level, the first and/or third cross-sectional shape and the first and/or third cross-sectional size of the first and/or third artificial turf fibers, respectively, as provided herein above.
In the process, the fifth artificial turf fibers may comprise a fifth polymer or a fifth combination of polymers, which may be independently selected, and which may be equal to or different from the first and/or third polymer or the first and/or third combination of polymers of the first and/or third artificial turf fibers, as provided herein above.
In the process, the first and/or third artificial turf fibers may be non-textured first and/or third artificial turf fibers and the fifth artificial turf fibers may be textured fifth artificial turf fibers. The textured fifth artificial turf fibers may provide support for the non-textured first and/or third artificial turf fibers to prevent, or at least reduce the chance, that the first and/or third artificial turf fibers will assume an orientation to lie flat in the artificial turf after a certain amount of time, thereby reducing the amount of infill required in the artificial turf.
The process may comprise the step of tufting second artificial turf fibers, fourth artificial turf fibers and sixth artificial turf fibers into the primary backing in the second tufting step at a second gauge and a second stitch-rate, to extend the second artificial turf fibers from the first surface of the primary backing to a second length, to extend the fourth artificial turf fibers from the first surface of the primary backing to a fourth length and to extend the sixth artificial turf fibers from the first surface of the primary backing to a sixth length to form second tufts comprising second artificial turf fibers, fourth artificial turf fibers and sixth artificial turf fibers.
In the process, the sixth artificial turf fibers may have a sixth length, a sixth color or a sixth combination of colors, a sixth texturizing level, a sixth cross-sectional shape and/or a sixth cross-sectional size, which each may be independently selected and which each independently may be equal to or different from the second and/or fourth length, the second and/or fourth color or the second and/or fourth combination of colors, the second and/or fourth texturizing level, the second and/or fourth cross-sectional shape and the second and/or fourth cross-sectional size of the second and/or fourth artificial turf fibers, respectively, as provided herein above.
In the process, the sixth artificial turf fibers may comprise a sixth polymer or a sixth combination of polymers, which may be independently selected, and which may be equal to or different from the second and/or fourth polymer or the second and/or fourth combination of polymers of the second and/or fourth artificial turf fibers, as provided herein above.
In the process, the second and/or fourth artificial turf fibers may be non-textured second and/or fourth artificial turf fibers and the sixth artificial turf fibers may be textured sixth artificial turf fibers. The textured sixth artificial turf fibers may provide support for the non-textured second and/or fourth artificial turf fibers to prevent, or at least reduce the chance, that the second and/or fourth artificial turf fibers will assume an orientation to lie flat in the artificial turf after a certain amount of time, thereby reducing the amount of infill required in the artificial turf.
Artificial turfs were provided by providing a primary backing, tufting the primary backing in a first tufting step at a first gauge of ⅜ inch, and tufting the primary backing in a second tufting step at a second gauge of ⅝ inch.
The primary backing was tufted in the first tufting step at a first stitch rate of 12 per 10 cm to 16 per 10 cm. The primary backing was tufted in the second tufting step at a second stitch rate of 8 per 10 cm to 12 per 10 cm.
The length of the artificial turf fibers in the first tufting step was 20 mm or 25 mm. The length of the artificial turf fibers in the second tufting step was 50 mm, 55 mm, 60 mm, or 65 mm.
In the first tufting step, two tufting yarns were fed to the tufting needles, a tufting yarn of 4050 dtex/6 fibers comprising 3 non-texturized first artificial turf fibers and 3 non-texturized third artificial turf fibers, wherein the first cross sectional shape of the first artificial turf fibers is a small wave shape and the third cross sectional shape of the third artificial turf fibers is a wide wave shape, and wherein the first color of the first artificial turf fibers is cactus green and the third color of the third artificial turf fibers is dark green, and a tufting yarn of 3200 dtex/8 fibers comprising 6 texturized fifth artificial turf fibers and 2 texturized seventh artificial turf fibers, wherein the fifth cross sectional shape of the fifth artificial turf fibers is a lense shape and the seventh cross sectional shape of the seventh artificial turf fiber is the same lense shape, and wherein the fifth color of the fifth artificial turf fibers is pine green and the seventh color of the seventh artificial turf fibers is beige.
The first polymer of the first artificial turf fibers is a polyethylene. The third polymer of the third artificial turf fibers is a polyethylene. The fifth polymer of the fifth artificial turf fibers is a polypropylene. The seventh polymer of the seventh artificial turf fibers is a polypropylene.
In the second tufting step, two tufting yarns were fed to the tufting needles, a tufting yarn of 6800 dtex/8 fibers comprising 4 non-texturized second artificial turf fibers and 4 non-texturized fourth artificial turf fibers, wherein the second cross sectional shape of the second artificial turf fibers is a C-shape and the fourth cross sectional shape of the fourth artificial turf fibers is the same C-shape, and wherein the second color of the second artificial turf fibers is lime green and the fourth color of the fourth artificial turf fibers is field green, and a tufting yarn of 6000 dtex/12 fibers comprising 6 texturized sixth artificial turf fibers and 6 texturized eight artificial turf fibers, wherein the sixth cross sectional shape of the sixth artificial turf fibers is a diamond shape and the eight cross sectional shape of the eight artificial turf fiber is the same diamond shape and wherein the sixth color of the sixth artificial turf fibers is green and the eight color of the eight artificial turf fibers is straw beige.
The second polymer of the second artificial turf fibers is a polyethylene. The fourth polymer of the fourth artificial turf fibers is a polyethylene. The sixth polymer of the sixth artificial turf fibers is a polypropylene. The eight polymer of the eight artificial turf fibers is a polypropylene.
| Number | Date | Country | Kind |
|---|---|---|---|
| 23185486.0 | Jul 2023 | EP | regional |
