Many sports, such as soccer, tennis, and football, are now played on artificial turf sports fields. Artificial turf sports fields generally require less maintenance and can be played on much more intensively than the natural turf sports fields. To give the artificial turf sports field a playing characteristics that resembles a natural turf field, polymer granules are often spread between the artificial turf fibers that not only provide a softer, shock-absorbing playing surface on which players are less prone to injury, but also provide improved playing characteristics. Unfortunately, however, a problem remains in that it is often difficult to maintain the desired shock absorption, energy restitution, and vertical ball rebound properties over an extended period of time. For example, WO 2006/092337 describes a polymer granule that has a cylindrical shape with a length/diameter ratio from 0.8 to 1.2 and having a substantial uniform particle size. However, the use of such polymer granules as infill material in artificial turf structures has a number of drawbacks. During use, for instance, the infill granules can become loose and fly above the turf system surface. This is generally known as “splash” of the infill as the movement of the infill granules resembles the splash of an object hitting a puddle of water. As a result, areas containing little infill may form in places where the field is played on very intensively, such as near the goal of a soccer field. Not only does this inconsistent distribution have an impact on the quality of play, but it can also potentially lead to an increased risk of injury. To maintain consistency, the turf must be routinely inspected and maintained, which is a time-consuming and costly manual process.
As such, a need currently exists for an infill material for use in artificial turf system that is capable of more consistently remaining in place during use.
In accordance with one embodiment of the present invention, an artificial turf system is disclosed that comprises an artificial turf carpet comprising synthetic fibers and a plurality of infill granules disposed between the synthetic fibers. The infill granules have a curved shape and a length of about 5 millimeters or more. Further, the granules comprise a polymer composition that includes a polymer matrix, the polymer matrix including at least one thermoplastic elastomer.
In accordance with another embodiment of the present invention, an artificial turf infill is disclosed that comprises a plurality of infill granules. At least 50% of the granules have a curved shape, length of about 5 millimeters or more, and cross-sectional width of from about 1 to about 10 millimeters. Further, the granules comprise a polymer composition having a Shore A hardness of from about 20 to about 100 as determined in accordance with ASTM D2240-15e1, wherein the polymer composition includes a polymer matrix containing at least one thermoplastic elastomer that includes a styrenic block copolymer, vinyl acetate polymer, polyester, polyurethane, polyolefin, natural rubber, nitrile-butadiene copolymer, polyisoprene, butyl rubber, or a combination thereof.
Other features and aspects of the present invention are set forth in greater detail below.
A full and enabling disclosure of the present invention, including the best mode thereof to one skilled in the art, is set forth more particularly in the remainder of the specification, including reference to the accompanying figures, in which:
It is to be understood by one of ordinary skill in the art that the present discussion is a description of exemplary embodiments only, and is not intended as limiting the broader aspects of the present invention.
Generally speaking, the present invention is directed to infill granules for use in an artificial turf system, such as a soccer field, football field, tennis court, field hockey field, rugby field, track, etc. By selectively controlling the particular material and geometry of the granules, the present inventors have discovered that they can be particularly well suited for use as an infill material that is less susceptible to splash during use of the turf system. The granules, for example, are formed to have a curved or bent shape and a relatively large length.
Referring to
The manner in which the granule is curved may also vary as is known to those skilled in the art. In the illustrated embodiment, for instance, the bending point 306 of the granule 300 is also the midpoint between the two ends 302 and 304. However, this is by no means required and the granule 300 may generally be curved at one or more points along its length. Furthermore, it should also be understood that the granule 300 need not be curved in only one direction as shown in
In addition to the overall geometry, the material used to form the granules may also be selectively controlled to help achieved the desired infill properties. More particularly, the granules are formed from a polymer composition that includes a thermoplastic elastomer. The polymer composition typically has a Shore A hardness of from about 20 to about 100, in some embodiments from about 30 to about 90, in some embodiments from about 40 to about 85, and in some embodiments, from about 50 to about 80, such as determined in accordance with ASTM D2240-15e1. Suitable thermoplastic elastomers may include, for instance, styrenic block copolymers, vinyl acetate polymers (e.g., ethylene vinyl acetate), polyesters (e.g., copolyetheresters), polyurethanes, polyolefins (e.g., ethylene-propylene copolymers, ethylene-propylene-diene terpolymers, etc.), natural rubbers, nitrile-butadiene copolymers, polyisoprene, butyl rubber (e.g., halogenated butyl rubber), and so forth.
Styrenic block copolymers may, for instance, include one or more monoalkenyl arene blocks (e.g., styrene, methyl styrene, tert-butyl styrene, 1,3 dimethyl styrene, etc.) and one or more conjugated diene blocks (e.g., butadiene, isoprene, pentadiene, hexadiene, or selectively hydrogenated dienes). Particularly suitable styrenic block copolymers include styrene-diene block copolymers (e.g., styrene-butadiene (“SB”), styrene-isoprene (“SI”), styrene-butadiene-styrene (“SBS”), and styrene-isoprene-styrene (“SIS”)) and styrene-olefin block copolymers formed by selective hydrogenation of styrene-diene block copolymers (e.g., styrene-(ethylene-butylene) (“SEB”), styrene-(ethylene-propylene) (“SEP”), styrene-(ethylene-butylene)-styrene (“SEBS”), styrene-(ethylene-propylene)-styrene (“SEPS”), styrene-(ethylene-butylene)-styrene-(ethylene-butylene) (“SEBSEB”), styrene-(ethylene-propylene)-styrene-(ethylene-propylene) (“SEPSEP”), and styrene-ethylene-(ethylene-propylene)-styrene) (“SEEPS”). These block copolymers may have a linear, radial or star-shaped molecular configuration. Likewise, suitable polyolefin elastomers may include ethylene-α-olefin-diene copolymers. The α-olefin constituent of such copolymers may include propylene, 1-butene, 4-methyl-1-pentene, 1-hexene, 1-octene, etc. Propylene is particular suitable such that the resulting copolymer is ethylene-propylene-diene (“EPDM.”). The weight ratio of ethylene to α-olefin may be from about 50:50 to about 90:10, in some embodiments from about 65:35 to about 90:10, and in some embodiments, from about 70:30 to about 85:15. The diene constituent in such copolymers may likewise include 1,4-pentadiene, 1,4-hexadiene, divinylbenzene, dicyclopentadiene, methylenenorbornene, ethylidenenorbornene, vinylnorbornene, etc. (e.g., ethylidenenorbornene). If desired, such copolymer elastomers may also be cured or vulcanized as is known in the art. More particularly, the side chain unsaturation provides for curing by a variety of mechanisms including peroxide, sulfur, and resins.
If desired, other polymers may also be employed in combination with the thermoplastic elastomer(s) in the polymer matrix. Such polymers are generally not elastomeric and may include, for instance, olefin polymers (e.g., ethylene polymers, propylene polymers, etc.), polyamides, polyurethanes, etc. In one embodiment, for instance, a propylene polymer may be employed that has a relatively low melt flow index, such as about 150 grams per 10 minutes or less, in some embodiments about 100 grams per 10 minutes or less, and in some embodiments, from about 1 to about 75 grams per 10 minutes, as determined in accordance with ISO 1133-1:2011 (technically equivalent to ASTM D1238-13) at a load of 2.16 kg and temperature of 230° C. Suitable propylene polymers may include, for instance, propylene homopolymers (e.g., syndiotactic, atactic, isotactic, etc.), propylene copolymers, and so forth. In one embodiment, for instance, a propylene polymer may be employed that is an isotactic or syndiotactic homopolymer. The term “syndiotactic” generally refers to a tacticity in which a substantial portion, if not all, of the methyl groups alternate on opposite sides along the polymer chain. On the other hand, the term “isotactic” generally refers to a tacticity in which a substantial portion, if not all, of the methyl groups are on the same side along the polymer chain. Such homopolymers may have a melting point of from about 160° C. to about 170° C. In yet other embodiments, a copolymer of propylene with an α-olefin monomer may be employed. Specific examples of suitable α-olefin monomers may include ethylene, 1-butene; 3-methyl-1-butene, 3,3-dimethyl-1-butene; 1-pentene; 1-pentene with one or more methyl, ethyl or propyl substituents; 1-hexene with one or more methyl, ethyl or propyl substituents; 1-heptene with one or more methyl, ethyl or propyl substituents; 1-octene with one or more methyl, ethyl or propyl substituents; 1-nonene with one or more methyl, ethyl or propyl substituents; ethyl, methyl or dimethyl-substituted 1-decene; 1-dodecene; and styrene. The propylene content of such copolymers may be from about 60 mole % to about 99 mole %, in some embodiments from about 80 mole % to about 98.5 mole %, and in some embodiments, from about 87 mole % to about 97.5 mole %. The α-olefin content may likewise range from about 1 mole % to about 40 mole %, in some embodiments from about 1.5 mole % to about 15 mole %, and in some embodiments, from about 2.5 mole % to about 13 mole %.
When employed, additional polymer(s) typically constitute from about 5 wt. % to about 50 wt. %, in some embodiments from about 10 wt. % to about 45 wt. %, and some embodiments, from about 20 wt. % to about 40 wt. % of the polymer matrix employed in the polymer composition. Likewise, the thermoplastic elastomer(s) typically constitute from about 50 wt. % to about 95 wt. %, in some embodiments from about 55 wt. % to about 90 wt. %, and in some embodiments, from about 60 wt. % to about 80 wt. % of the polymer matrix. It should also be understood that depending on the type employed, the thermoplastic elastomers may constitute the entire polymer content (100 wt. %) of the composition. Likewise, in certain embodiments, only the polymer matrix is used to form the granule such that the percentages noted above also correspond to the percentages of the entire granule. Of course, various other materials may also be employed in the granule as known in the art, such as fillers (e.g., calcium carbonate, talc, mica, kaolin clay, etc.), plasticizers (e.g., mineral oil, paraffinic oil, aromatic oil, naphthenic oil, etc.), antioxidants, UV-stabilizers, antistatic agents, waxes, foaming agents, lubricants, flame retardants, pigments, and so forth. Plasticizers may, for instance, constitute from about 5 wt. % to about 40 wt. %, in some embodiments from about 10 wt. % to about 35 wt. %, and in some embodiments, from about 15 wt. % to about 30 wt. % of the polymer composition. Fillers may likewise constitute from about 10 wt. % to about 70 wt. %, in some embodiments from about 20 wt. % to about 65 wt. %, and in some embodiments, from about 40 wt. % to about 60 wt. % of the polymer composition. In such embodiments, the polymer matrix may likewise constitute from about 5 wt. % to about 40 wt. %, in some embodiments from about 10 wt. % to about 35 wt. %, and in some embodiments, from about 15 wt. % to about 30 wt. % of the polymer composition.
Generally speaking, a plurality of infill granules are generally employed in the artificial turf system. Desirably, at least a substantial portion of these granules, if not all, are formed in accordance with the present invention. For example, it is typically desired that about 50% or more, in some embodiments about 60% or more, in some embodiments about 70% or more, in some embodiments from about 80% to 100%, in some embodiments from about 90% to 100%, in some embodiments from about 95% to 100%, and in some embodiments, from about 99% to 100% of the granules employed in the turf system have a cross-sectional width, length, degree of curvature, first curvature angle, and/or second curvature angle within the ranges noted above. For example, from about 90% to 100% (e.g., 100%), and in some embodiments, from about 99% to 100% of the granules typically have a length of about 5 millimeters or more, in some embodiments from about 5 millimeters to about 30 millimeters, and in some embodiments, from about 5 millimeters to about 20 millimeters, and/or a cross-sectional width (e.g., diameter) of from about 1 to about 10 millimeters, in some embodiments from about 1.5 to about 5 millimeters, and in some embodiments, from about 2 to about 4 millimeters. Of course, it is contemplated that the granules may have varying properties. In fact, in certain embodiments, varying the degree of curvature and/or curvature angles in different portions of the granules may actually further reduce the likelihood of splashing. For example, in certain embodiments, a first portion of the granules may have a degree of curvature of from about 0.33 mm−1 to about 1 mm−1, in some embodiments from about 0.50 mm−1 to about 1 mm−1, and in some embodiments, from about 0.75 mm−1 to about 1 mm−1, while a second portion of the granules may have a degree of curvature of from about 1.0 mm−1 to about 3 mm−1, in some embodiments from about 1.5 mm−1 to about 2.5 mm−1, and in some embodiments, from about 1.75 mm−1 to about 2 mm−1. The first portion and the second portion may each constitute from about 25% to about 75%, and in some embodiments, from about 35% to about 65% of the granules.
The granules may be formed by any suitable method as is known in the art. For example, the components used to form the granules (e.g., thermoplastic elastomer, additional polymer(s), additive(s), etc.) may be compounded together and then extruded through orifices of a die plate. The size of the orifices are selected based on the desired cross-sectional width (e.g., diameter) of the granules. Once extruded, the resulting granules may then be cut to the desired length through the use of an underwater pelletizing system, water ring pelletizing system, strand pelletizing system, hot-cut pelletizing system, etc. If desired, the strand cutting may occur after the granules are cooled in a water bath or while under water at the face of the die plate. This process is generally known as “underwater pelletizing.” For example, the granules may be extruded through extrusion orifices in the die plate into a water-filled compartment or chamber. While immersed in the water, the granules may then be cut to the desired length by knives mounted on a hub-like member and driven in rotation by a shaft. The cutting edges of the knives lie flat or substantially so against the flat face of the die plate and wipe across the face of the orifices in a cutting or shearing action as the hub is rotated by the shaft.
The manner in which the granules are employed in an artificial turf system may vary as is known in the art. Referring to
These and other modifications and variations to the present invention may be practiced by those of ordinary skill in the art, without departing from the spirit and scope of the present invention, which is more particularly set forth in the appended claims. In addition, it should be understood that aspects of the various embodiments may be interchanged both in whole or in part. Furthermore, those of ordinary skill in the art will appreciate that the foregoing description is by way of example only, and is not intended to limit the invention so further described in such appended claims.
The present application claims filing benefit of U.S. Provisional Patent Application Ser. No. 62/994,885 having a filing date of Mar. 26, 2020, which is incorporated herein by reference in its entirety.
Number | Date | Country | |
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62994885 | Mar 2020 | US |