Patent Application
20160213081
The present disclosure relates generally to synthetic grass, and more particularly to a synthetic grass system with vertical grass blades forming a matrix that encapsulates an infill having at least a lower layer of smaller resilient particles and a substantially segregated upper layer of larger resilient particles.
Synthetic turf systems are popular replacements for natural grass. Previous synthetic turf systems used infill materials spread between the synthetic “grass” fibers in an attempt to provide a safer surface. The previous systems used a high percentage of sand infill. However, these systems become hard and less shock absorbent over time, and the sand is abrasive to both the athlete and the turf system. This leads to increased player injuries and a shortened life span of the turf system.
Angular sands used in these types of infill will also migrate to the bottom of the turf system and clog the perforations in the turf system, thereby reducing the percolation rate of the turf system over time.
Other conventional systems use resilient infill, such as “crumb rubber”—rubber from used tires ground into small particles. However, sun on the black rubber infill can cause very hot surface temperatures. The crumb rubber infill also has the potential for off gassing of odors that is sometimes unpleasant to athletes and spectators. Also, the black particles are aesthetically offensive.
Therefore, there is a long-felt but unresolved need for a synthetic grass that provides an improved safe playing surface while also preventing hot surface temperatures and avoiding undesirable odors.
Briefly described, and according to one embodiment, aspects of the present disclosure generally relate to synthetic grass. According to some aspects of the present disclosure, a synthetic turf system includes synthetic grass and a plurality of layers of infill material. In one embodiment, an upper layer of infill particles generally “sit” on top of a lower layer of smaller particles. Because the smaller particles will tend to become more densely packed, the larger particles will tend to remain on top of the smaller particles. In certain embodiments, the upper layer is treated with a light colorant (e.g., dyed), such as green, yellow, white, etc. Depending on field and environmental conditions, the coloring may reduce surface temperatures by up to 30% compared to conventional infills.
It is an object of the present disclosure to provide an infill that will retain its properties throughout use without compaction of the infill and with a reduced requirement for periodic brushing of the surface.
It is a further object of the present disclosure to provide a multi-layer (e.g., two-layer or more) infill system that will significantly reduce surface temperature throughout use, be cost-effective to produce, and will comprise infill layers that remain substantially segregated when in use to achieve certain performance properties.
It is a further object of the present disclosure to provide a multi-layer infill system that will eliminate unwanted odors, reduce the chance of bacterial growth on the field and eliminate any “fly out” of the resilient particles. It is a further object of the present disclosure to provide an aesthetically pleasing colored (e.g., green) surface at a significantly reduced cost.
To overcome the issues and challenges described in the background above and to accomplish the objects recited herein, the present disclosure attempts to utilize at least two layers of infill particles—an upper layer comprising larger particles (which, in certain embodiments, will be treated with a colorant to exhibit certain heat-reduction properties) and a lower layer of traditional particles (not color treated). Thus, the present technology can obtain the benefits of treating the upper particles with a colorant to keep the turf cool during high heat seasons, but also avoid significant additional cost by limiting the amount of colored (and generally more expensive) particles needed for infill.
In one embodiment, a synthetic grass system, comprising: a backing layer; a plurality of generally upstanding synthetic grass blades affixed to the backing layer; and at least two layers of infill particles generally interspersed amongst the plurality of generally upstanding synthetic grass blades, the at least two layers of infill particles comprising: an upper layer of particles; and a lower layer of particles, wherein the lower layer of particles are generally smaller in size as compared to the upper layer of particles.
In one embodiment, a process of providing a synthetic grass system comprising the steps of: providing a backing layer; providing a plurality of generally upstanding synthetic grass blades affixed to the backing layer; distributing a first lower layer of particles utilizing a uniform pattern of spreading with a mechanical spreader; distributing a second upper layer of particles utilizing a uniform pattern of spreading with a mechanical spreader; wherein the upper layer of particles are generally larger in size as compared to the lower layer of particles.
In one embodiment, a synthetic grass system comprising: a backing layer; a plurality of generally upstanding synthetic grass blades affixed to the backing layer; and at least two layers of infill particles generally interspersed amongst the plurality of generally upstanding synthetic grass blades and resting on the backing layer, the at least two layers of infill particles comprising: an upper layer of particles, wherein the upper layer of particles comprises resilient particles treated with a colorant and substantially sized in a range of about 8-16 mesh, and a lower layer of particles, wherein the lower layer of particles comprises particles not treated with a colorant and substantially sized in a range of about 16-20 mesh.
According to one aspect of the present disclosure, the synthetic grass system, wherein the particles of the upper layer are treated with a light colorant sufficient to exhibit heat-reduction properties. Further, the synthetic grass system, wherein the particles of the upper layer are dyed green. Further, the synthetic grass system, wherein the particles of the lower layer are not treated with a colorant. Further, the synthetic grass system, wherein the upper layer comprises a light color. Further, the synthetic grass system, wherein the lower layer comprises resilient particles. Further, the synthetic grass system, wherein the resilient particles of the lower layer are selected from the group consisting of: crumb rubber, micronized rubber power, and elastomer material. Further, the synthetic grass system, wherein the upper layer comprises resilient particles. Further, the synthetic grass system, wherein the resilient particles of the upper layer are selected from the group consisting of: crumb rubber, micronized rubber power, and elastomer material. Further, the synthetic grass system, wherein the lower layer comprises sand. Further, the synthetic grass system, wherein the difference in size between the particles of the upper layer and particles of the lower layer is sufficient for the particles of the upper layer to substantially settle on top of the particles of the lower layer. Further, the synthetic grass system, wherein the lower layer of particles comprises particles substantially sized in the range of 10-20 mesh. Further, the synthetic grass system, wherein a majority of the particles comprising the lower layer of particles are sized in the range of about 16-20 mesh. Further, the synthetic grass system, wherein a majority of the particles comprising the upper layer of particles are sized in the range of about 8-16 mesh.
According to one aspect of the present disclosure, the process of providing a synthetic grass system, wherein the particles of the upper layer are treated with a light colorant sufficient to exhibit heat-reduction properties. Further, the process of providing a synthetic grass system, wherein the particles of the upper layer are dyed green.
These and other aspects, features, and benefits of the claimed invention(s) will become apparent from the following detailed written description of the preferred embodiments and aspects taken in conjunction with the following drawings, although variations and modifications thereto may be effected without departing from the spirit and scope of the novel concepts of the disclosure.
The accompanying drawings illustrate one or more embodiments and/or aspects of the disclosure and, together with the written description, serve to explain the principles of the disclosure. Wherever possible, the same reference numbers are used throughout the drawings to refer to the same or like elements of an embodiment, and wherein:
For the purpose of promoting an understanding of the principles of the present disclosure, reference will now be made to the embodiments illustrated in the drawings and specific language will be used to describe the same. It will, nevertheless, be understood that no limitation of the scope of the disclosure is thereby intended; any alterations and further modifications of the described or illustrated embodiments, and any further applications of the principles of the disclosure as illustrated therein are contemplated as would normally occur to one skilled in the art to which the disclosure relates. All limitations of scope should be determined in accordance with and as expressed in the claims.
Aspects of the present disclosure generally relate to synthetic grass. According to some aspects of the present disclosure, a synthetic turf system includes synthetic grass and a plurality of layers of infill material. In one embodiment, an upper layer of infill particles generally “sit” on top of a lower layer of smaller particles. Because the smaller particles will tend to become more densely packed, the larger particles will tend to remain on top of the smaller particles. In certain embodiments, the upper layer is treated with a light colorant (e.g., dyed), such as green, yellow, white, etc. Depending on field and environmental conditions, the coloring may reduce surface temperatures by up to 30% compared to conventional infills.
Synthetic turf systems may be used for sports fields, track facilities, golf courses, landscaping, and other indoor or outdoor facilities.
Now referring to the drawings,
To maintain the two (or more) layers of particles, in one embodiment, the upper layer 4 includes larger particles that generally “sit” on top of the smaller particles of the lower layer 3. In particular, because the smaller particles will tend to become more densely packed, the larger particles will tend to remain on top of the smaller particles even during extended use of the synthetic turf. In various embodiments, the lower layer occupies about two-thirds of the total infill depth, the upper layer occupies about one-third of the total infill depth, and the total infill depth reaches to about three-quarters of the height of the grass-like pile elements 2. In other embodiments, the depth of each layer of infill and the total infill depth may vary.
According to the embodiment shown in
In some embodiments, each layer has distinctly different mesh or sieve size. As would be understood by one having ordinary skill in the art, “mesh” refers to a standard test for particle sizing. Particles are placed on a mesh screen with openings of a particular size. When the mesh is shaken, particles larger than the mesh size are retained on the mesh, while smaller particles generally pass through. For example, 10 mesh means there are 10 squares across one linear inch of screen. A larger mesh size therefore represents smaller particle sizes.
As shown in
In some embodiments, the lower layer 3 and upper layer 4 should not be mixed together and should be applied separately in different courses or layers in which the relative proportions and size of the two types of particles differ.
According to one embodiment, the multi-layer infill product described herein comprises the following characteristics (when a two-layer approach is used, as illustrated in
Lower layer 3: between about 10-20 mesh, majority falling between about 16-20 mesh. These particles may be reused infill with all rubber or a mixture of sand and rubber, or some other combination as will occur to one of ordinary skill in the art. In one embodiment, the lower layer 3 comprises 30-70% of total infill by weight. One specific nonlimiting example of the composition of particles in a lower layer 3 is as follows:
In some embodiments, installation of the lower layer 3 should be performed in stages (also called lifts) of approximately 0.5 lbs per square foot of resilient particles utilizing a uniform pattern of spreading by means of a mechanical spreader, each layer should be groomed with a sweeping machine, and sprayed with a solution of diluted fabric softener to eliminate static electricity and allow the particles to slide into place. Upon the final lift of the lower layer 3 particles, the surface should be groomed, sprayed with the fabric softener solution, and blown with air prior to installation of the upper layer 4.
Upper layer 4: between about 8-16 mesh colored rubber or (resilient colored particle) making up the remainder of weight of infill. One specific nonlimiting example of the composition of resilient particles in upper layer 4 is as follows:
Installation of the upper layer 4 should be performed in lifts of approximately 0.5 lbs per square foot of resilient particles utilizing a uniform pattern of spreading by means of a mechanical spreader, each layer should be groomed with a sweeping machine, and sprayed with a solution of fabric softener to eliminate static electricity and allow the particles to slide into place.
After installation, the resultant turf field should be groomed periodically. New fields should be groomed once a week for the first two months. In some embodiments, the brush of a grooming machine should not penetrate the lower layer 3 more than 0.25 inches to avoid mixing of infill. The field should be groomed from sideline to sideline alternating the direction of travel, i.e. towards the home side or visiting side on successive grooming cycles. In some embodiments, a nylon soft bristle drag system should be used, such as one manufactured by Gandy.
The embodiments were chosen and described in order to explain the principles of the claimed inventions and their practical application so as to enable others skilled in the art to utilize the inventions and various embodiments and with various modifications as are suited to the particular use contemplated. Alternative embodiments will become apparent to those skilled in the art to which the claimed inventions pertain without departing from their spirit and scope. Accordingly, the scope of the claimed inventions is defined by the appended claims rather than the foregoing description and the exemplary embodiments described therein.
This application claims the benefit of and priority to U.S. Provisional Patent Application No. 62/106,801, filed Jan. 23, 2015, entitled, “MULTI-LAYER INFILL SYSTEM FOR SYNTHETIC GRASS,” incorporated herein by reference in its entirety.
| Number | Date | Country | |
|---|---|---|---|
| 62106801 | Jan 2015 | US |
