EP1991738A2

EP1991738A2 - Method and apparatus for an improved synthetic turf system

Info

Publication number: EP1991738A2
Application number: EP07705656A
Authority: EP
Inventors: John Gilman; Jean PRÉVOST
Original assignee: Fieldturf Tarkett Inc
Current assignee: Tarkett Inc
Priority date: 2006-02-27
Filing date: 2007-02-27
Publication date: 2008-11-19
Also published as: CA2642806A1; CN101426979A; RU2008138537A; WO2007096770A2; ZA200807441B; JP2009528459A; WO2007096770A3

Abstract

A method and system for a synthetic turf system (10) includes a plurality of fibers (14) operatively attached to a backing member (12). An infill layer of particulate material (16) is positioned near the backing member (12) and dispersed among the plurality of fibers (14) wherein a cleansing component (18) is operatively attached to the fibers and/or infill layer.

Description

METHOD AND APPARATUS FOR AN IMPROVED SYNTHETIC TURF SYSTEM

RELATED APPLICATIONS

[Para 1] The present invention claims priority benefit of the filing date of U.S. Provisional Patent Application Serial No. 60/777,099, filed February 27, 2006; the contents of which are expressly incorporated herein by reference.

FIELD OF THE INVENTION

[Para 2] The present invention is directed toward a synthetic surface; and more particularly, to a synthetic turf system.

BACKGROUND OF THE INVENTION [Para 3] The utilization of synthetic turf surfaces to replace natural grass surfaces is well known. Natural grass surfaces generally require a great deal of maintenance, do not stand up well to wear, and do not grow well in partly or fully enclosed environments. In contrast, synthetic turf surfaces require less maintenance, stand up much better to wear, and can be used in closed environments. Today's synthetic turf systems are also more aesthetic than those used in the past. For these reasons, synthetic turf systems are increasingly being utilized in place of natural grass surfaces in many applications; such as, indoor and outdoor recreational facilities, airports, and home and industrial landscaping.

[Para 4] Some synthetic turf surfaces include fibers or ribbons of various materials representing blades of natural grass that extend vertically from a backing member or mat. The backing member is generally placed above a prepared surface, such as compacted soil, rocks, stones, etc., and combinations thereof. A layer of particulate material — frequently referred to as infill — may be placed over the backing member and interspersed among the fibers, wherein the fibers extend through and above the infill. The infill layer may include several courses of particulate material comprising hard and resilient particles, e.g., sand, rubber, and combinations thereof; and is also capable of providing a level of resiliency to the synthetic turf system. If more resiliency is desired, the backing member can be placed over a layer of padding material.

[Para 5] A synthetic turf system is frequently utilized as a playing surface in many sporting events that include human, as well as animal, participants. Some event participants may have existing lacerations and abrasions to their skin; or may incur such minor injuries during the course of play upon direct contact with other participants or the playing surface . itseii. in addition, a participant's bodily fluid — perspiration or saliva, etc. — may contact the playing surface during play. Obviously, such an environment can promote the growth — or support the existence — of odor causing agents, bacteria, and viruses; and participants are at risk of contacting such microorganisms. Although the periodic cleaning of the playing surface is generally included in a scheduled maintenance program, a desire exists to further deter the proliferation of these microbes and improve the clean up of synthetic turf systems. [Para 6] The present invention is intended to address these as well as other issues.

SUMMARY OF THE INVENTION [Para 7] The present invention is directed to a synthetic turf system having an antimicrobial cleansing component that is responsive to a light source. The synthetic turf system further includes a backing member having a plurality of fibers or ribbons — representing blades of natural grass — operatively attached thereto and an infill layer located proximate the backing member and dispersed among the plurality of fibers. [Para 8] In a further aspect of the present invention, the cleansing component includes a photocatalyst. The photocatalyst is incorporated in a portion of at least one of the plurality of fibers and infill layer. That is, the photocatalyst is operatively attached to, or integrated within, a portion of at least one of the plurality of fibers and/or the infill layer. [Para 9] Another aspect of the present invention is directed to a method for improving the hygienic environment of a synthetic turf system including a plurality of fibers operatively attached to a backing member and having an infill layer of particulate material proximate the backing member and dispersed among the plurality of fibers. The method comprises the steps of selecting a photocatalyst for application to at least a portion of the synthetic turf system, and operatively incorporating the photocatalyst to a portion of the synthetic turf system.

[Para 10] In a still further aspect of the present invention, the photocatalyst is responsive to visible and/or non- visible light.

[Para 11] An object of the present invention is to provide a cleansing capability to a synthetic turf system to combat impurities, micro organisms, and their associated effects. [Para 12] A further object of the present invention is to provide cleansing, disinfecting, and oxidizing properties to a synthetic turf system for improving the hygienic environment thereof.

[Para 13] It is to be understood that the terms "incorporate," "incorporated," "incorporation," etc., as used in this specification generically includes the operative _{-1 1 cc} . _r , . integration and/or affixation of a cleansing component or composition with a portion of the synthetic turf system — more specifically, fiber and/or infill particulate material — by means known to those of ordinary skill in the art of synthetic turf system manufacture. Such processes include, and are not limited to: coating, dipping, spraying, powdering, impregnating, and spinning a composition comprising the cleansing component with an infill particulate material and/or a formable resin-like composition to result in an infill layer or synthetic fiber comprising the cleansing component.

[Para 14] These and other aspects of the present invention will be apparent after consideration of the written description, drawings, and claims herein.

BRIEF DESCRIPTION OF THE DRAWINGS

[Para 15] The present invention will now be described with reference to the drawings wherein:

[Para 16] FIG. 1 is a partial cross-sectional view of the synthetic turf system of the present invention;

[Para 17] FIG. 2 is a partial cross-sectional view of one embodiment of the present invention depicting the infill layer including particulate material having portions of the cleansing component operatively attached thereto;

[Para 18] FIG. 3 is a partial cross-sectional view of another embodiment of the present invention depicting the synthetic fibers having portions of the cleansing component operatively attached thereto;

[Para 19] FIG. 4 is a partial cross-sectional view of another embodiment of the present invention depicting the infill layer including particulate material having portions of cleansing component operatively integrated therewith; and, [Para 20] FIG. 5 is a partial cross-sectional view of another embodiment of the present invention depicting the synthetic fibers having portions of the cleansing component operatively integrated therewith.

DETAILED DESCRIPTION OF THE PRESENT INVENTION [Para 21] While this invention is capable of embodiment in many different forms, there is shown in the drawings and will herein be described in detail one or more embodiments with the understanding that the present disclosure is to be considered as an exemplification of me principles of the present invention and is not intended to be limited to the embodiments illustrated.

[Para 22] It is to be understood that like or analogous elements and/or components referred to herein may be identified throughout the drawings with like reference characters. [Para 23] One embodiment of the present invention is partially shown in FIG. 1 as a synthetic turf system 10 including a backing member 12 placed over a substrate 13. The substrate 13 may comprise a prepared surface such as tamped-down soil, asphalt, a bed of stone or gravel, or combinations thereof. A plurality of fibers 14 are operatively affixed to the backing member 12. The fibers 14 may include various types of synthetic fibers, such as resin, polymer, etc. The fibers 14 are attached to the backing member 12 through any acceptable means known to one of ordinary skill in the art of synthetic turf systems, e.g., glued, melted, stitched, or tufted. A layer of particulate material 16 — often referred to as infill — is disposed above the backing member 12 and interspersed between the plurality of fibers 14. The infill layer of particulate material 16 may include, for example, one or more courses comprising hard, e.g., sand; and resilient, e.g., rubber, cryogenic rubber, and vulcanized rubber; particles, and combinations thereof.

[Para 24] A cleansing component 18 responsive to light is operatively incorporated with the fibers 14 and/or the infill 16. See Figs. 2-5. The cleansing component 18 can be incorporated throughout the entirety of the fibers 14 and/or infill 16, or portions thereof. That is, the cleansing component 18 may only be incorporated to one or more courses of the infill layer, or to portions of the fibers 14 extending above the infill layer.

[Para 25] The cleansing component 18 facilitates the cleansing, deodorizing, decontaminating, purifying — and combinations thereof — of the surrounding area by producing an active oxygen on exposure to a light source and utilizes an environmental clean- up material that arises on the surface of fibers 14 — and/or particulate material 16 of the infill — upon receiving light energy. That is, the cleansing component 18 decomposes harmful substances such as NO_x in the atmosphere; sorbs and decomposes odors; kills bacteria; and promotes cleanliness by decomposing oils on the surface of the fiber 14 and/or particulate material 16 that gathers impurities, e.g., dust. [Para 26] The cleansing component 18 is preferably a photocatalyst that generally amplifies or accelerates the functions of the sun, such as: water purification, contamination prevention, anti-bacteria, deodorization, and air purification (dissolving NO_x). When exposed to a light source, the photocatalyst 18 produces surface oxidation to eliminate or reduce harmful substances such as organic or inorganic compounds, and nearby bacteria or viruses.

[Para 27] Some types of photocatalysts 18 capable of being utilized in the present invention are titanium oxide or dioxide, e.g., TiO₂, or ultra fine zinc oxide ZnO; however, other photocatalysts can also be employed, e.g., sulphide-semiconductors, oxide- semiconductors. Titanium oxide is an oxide-semiconductor that can be chemically activated by light. Although titanium oxide is harmless to humans, it is capable of breaking down organic materials drifting into contact with it, and has strong effects on single-celled organisms such as fungi. The anti-bacterial effect of titanium oxide is caused by absorption and decomposition of toxins during the photocatalytic reaction of the titanium oxide.

[Para 28] The strong anti-bacterial effect is brought out upon exposure to light (ultraviolet radiation). During irradiation, a light wavelength suitable for cooperation with the photocatalyst 18 is utilized. The light may include various wavelengths, both visible and non-visible, and it may be emitted from a natural or man-made source, e.g., sun, incandescent lamp, fluorescent lamp, and combinations thereof. Under the influence of light, titanium oxide tends to decompose organic materials. The bactericidal effect (disinfection) by titanium oxide is approximately three times greater than chlorination, and 150% greater than ozonation. [Para 29] The cleansing component 18 may be in various forms, e.g., powder, granule; and may be incorporated with the fiber 14 (or the infill particulate material 16) using any acceptable technique known to one of ordinary skill in the art, e.g., sol-gel process, spraying, coating, dipping, powdering, baking, and spinning.

[Para 30] Referring to Figs. 2 and 3, the cleansing component 18 is incorporated with the fiber 14 and infill particulate material 16 by being adhered to the respective surfaces through the use of a binder such as an adhesive resin or polymer. Adhering the cleansing component 18 to the surface of the fiber 14 is particularly advantageous in applications in which the cleansing component cannot be integral with the fiber. A variety of conventional techniques for adhering the cleansing component 18 to the surface of the fiber 14 can be utilized, such as, spraying or coating the dispersion to the fiber, perhaps with a binder. In some cases where a binder is utilized to adhere the cleansing component 18 to the fiber 14, e.g., in an after-processing step, the "feel" of the resultant fiber may change and affect the fiber's characteristics.

[Para 31] Although the cleansing component 18 may be incorporated with the fiber 14 and/or infill particulate material 16 through affixation to at least some portion that composes me surface oi these elements — and are thus capable to receiving light — it is to be understood that the cleansing component may also be incorporated with these elements by integration throughout the composition of the fibers or the infill particulate material. See Figs. 4 and 5. A variety of conventional techniques for integrating the cleansing component 18 to the fiber 14 can be utilized, such as, impregnating the fiber with a dispersion containing the cleansing component 18, with or without a binder. In one embodiment of the present invention, the cleansing component 18 may be integrated into the fiber 14 by spinning a composition containing the cleansing component and a polymer capable of being formed into a fiber or ribbon. [Para 32] For applications incorporating the cleansing component 18 with a synthetic, semi-synthetic, or regenerated fiber, conventional spinning techniques including a formable polymer can be utilized. The spinning process can be selected in accordance with the type of polymer being implemented, e.g., wet-spinning, dry-spinning, wet-dry spinning, melt- spinning, and other known technologies. Integration of the cleansing component 18 to the fiber 14 is advantageous because the cleansing component is firmly supported within the fiber and its surface.

[Para 33] Other processes can also be utilized in producing the fiber 14 of the present invention, such as: adding the cleansing component 18 to a material slurry for the fiber polymer; preparing a prepolymer and adding the cleansing component thereto immediately before polycondensation of the prepolymer; and, adding the cleansing component to the formable polymer immediately after the preparation of the polymer while the polymer is still in a liquid state. The cleansing component 18 of the present invention may include a high catalytic activity and may occasionally affect the polymerization process depending on the species of the polymer. [Para 34] In instances where the cleansing component 18 is added in the form of a powder, e.g., a fine particle, to the polymer, coagulation of particles may occur such that formation of the fiber 14 may be difficult; and even if a fiber is formed, its strength may be unacceptably weakened. Therefore, the cleansing component 18 may be added in the form of a slurry obtainable by dispersing the powdery cleansing component 18 into a suitable dispersion medium.

[Para 35] Consequently, the production of a fiber 14 containing the cleansing component 18 incorporated therein is not limited and may be constructed by any acceptably known techniques, including: adding the cleansing component 18 in a polymerizing process of the fiber, or immediately thereafter; adding the cleansing component to the polymer batch ana iormmg the fiber thereafter; or adding the cleansing component to the polymer at any step prior to the polymer being spun out from a spinning nozzle.

[Para 36] Similarly, the production of the infill particulate material 16, e.g., resilient rubber (vulcanized, cryogenic), containing the cleansing component 18 incorporated therein is not limited and may be constructed by any acceptably known techniques. That is, the cleansing component 18 may be operatively integrated within, or attached to, the infill particulate material 16.

[Para 37] Furthermore, the physical configuration of the fiber 14 or the infill particulate material 16 is not limited and may be selected from a wide range of shapes and sizes according to the use of the product. The structure of the fiber 14 may be simple or complex, e.g., a composite (compounded) configuration composed of sections containing different concentrations of the cleansing component 18. In considering the selection of the cleansing component 18, its size and/or amount relative to the size and structure of the fiber 14, or infill particulate material 16, should also be considered so as not to adversely affect light responsiveness and cleansing efficiency of the cleansing component.

[Para 38] It is contemplated that the synthetic turf system 10 of the present invention may also include various conventional additives such as, antioxidants, flame-retardants, antistatic agents, coloring agents, lubricants, antimicrobes, insect-proofing, mold/mildew- proofing agents, ultraviolet ray adsorbents, delustering agents (flatting agents), heat reserving agents and others. Similarly, an adsorbent component, deodorant, and/or antimicrobial metal component, e.g., silver, zinc, copper; can be included to expand the antimicrobial range of the present invention. Additionally, according to the use and species of the selected fiber 14, the fiber may be treated by any additional processing technology, such as fibrillation, false- twisting, interlacing, crimping, mercerization, shrink proofing, crease proofing, hydrophilization, water proofing, and resist styling (resist printing).

[Para 39] While specific embodiments have been illustrated and described, numerous modifications may come to mind without significantly departing from the spirit of the invention, and the scope of protection is only limited by the scope of the accompanying Claims.

Claims

What is claimed is:

1. A synthetic turf system (10) comprising: a backing member (12) ; a plurality of fibers (14) operatively attached to the backing member; an infill layer (16) including a plurality of particulate material proximate the backing member and dispersed among the plurality of fibers; and, a cleansing component (18) operatively attached to at least a portion of the infill layer, wherein the cleansing component is responsive to a light source.

2. The synthetic turf system of Claim 1 wherein the cleansing component being integral with at least a portion of one of the plurality of fibers.

3. The synthetic turf system of Claim 1 wherein the cleansing component being operatively attached to at least a portion of one of the plurality of fibers.

4. The synthetic turf system of Claim 3 wherein the cleansing component being coated to at least a portion of one of the plurality of fibers.

5. The synthetic turf system of Claim 1 wherein the cleansing component is responsive to visible light.

6. The synthetic turf system of Claim 1 wherein the cleansing component is responsive to non-visible light.

7. The synthetic turf system of Claim 1 wherein the cleansing component is a photocatalyst.

8. The synthetic turf system of Claim 7 wherein the photocatalyst is titanium oxide.

9. The synthetic turf system of Claim 7 wherein the photocatalyst is zinc oxide.

.

IU. The synthetic turf system of Claim 1 wherein the cleansing component being integral with at least a portion of one of the plurality of particulate material of the infill layer.

11. The synthetic turf system of Claim 10 wherein the cleansing component is a photocatalyst.

12. The synthetic turf system of Claim 11 wherein the photocatalyst is titanium oxide.

13. The synthetic turf system of Claim 11 wherein the photocatalyst is zinc oxide.

14. The synthetic turf system of Claim 11 wherein the cleansing component being coated to at least a portion of one of the plurality of particulate material of the infill layer.

15. The synthetic turf system of Claim 14 wherein the cleansing component is a photocatalyst.

16. The synthetic turf system of Claim 14 wherein the photocatalyst is titanium oxide.

17. The synthetic turf system of Claim 14 wherein the photocatalyst is zinc oxide.

18. A synthetic turf system (10) including a plurality of fibers (14) operatively attached to a backing member (12), the synthetic turf system comprising: an infill layer (16) including a plurality of particulate material proximate the backing member and dispersed among the plurality of fibers, wherein a photocatalyst (18) responsive to a light source is operatively attached to at least a portion of the infill layer.

19. The synthetic turf system of Claim 18 wherein the photocatalyst being integral with at least a portion of one of the plurality of fibers.

20. The synthetic turf system of Claim 18 wherein the photocatalyst being coated on at least a portion of one of the plurality of fibers.

21. The synthetic turf system of Claim 18 wherein the photocatalyst is responsive to visible light.

22. The synthetic turf system of Claim 18 wherein the photocatalyst is responsive to non- visible light.

23. The synthetic turf system of Claim 18 wherein the photocatalyst is titanium oxide.

24. The synthetic turf system of Claim 18 wherein the photocatalyst is zinc oxide.

25. The synthetic turf system of Claim 18 wherein the photocatalyst being coated to at least a portion of one of the plurality of particulate material.

26. The synthetic turf system of Claim 18 wherein the particulate material of the infill layer is rubber.

27. A method for improving the hygienic environment of a synthetic turf system (10) including a plurality of fibers (14) operatively attached to a backing member (12) and having an infill layer (16) of particulate material proximate the backing member and dispersed among the plurality of fibers, the method comprising the steps of: selecting a photocatalyst (18) for application to at least a portion of a synthetic turf system; incorporating the selected photocatalyst to a portion of the synthetic turf system; operatively attaching a plurality of fibers to a backing member; and, dispersing a layer of particulate material among the plurality of fibers.

28. The method of Claim 27 further comprising: incorporating the selected photocatalyst to the plurality of fibers.

29. The method of Claim 27 further comprising: integrating the selected photocatalyst to at least a portion of the plurality of fibers.

30. The method of Claim 27 further comprising: attaching the selected photocatalyst to at least a portion of the plurality of fibers.

31. The method of Claim 27 further comprising: incorporating the selected photocatalyst to the layer of particulate material dispersed among the plurality of fibers.

32. The method of Claim 27 further comprising: integrating the selected photocatalyst to at least a portion of the layer of particulate material dispersed among the plurality of fibers.

33. The method of Claim 27 further comprising: attaching the selected photocatalyst to at least a portion of the layer of particulate material dispersed among the plurality of fibers.