BR112020012956A2 - artificial peat system - Google Patents

Abstract

The present disclosure provides an artificial peat system (10) that includes a primary support layer (12) and a shock absorbing component (20). The primary support layer (12) has a plurality of artificial peat yarns (14) projecting upwardly from the primary support layer (12). The shock-absorbing component (20) consists of a sheet of 3DRLM three-dimensional random loop material (30). The 3DRLM sheet (30) is in contact with the primary support layer (12). The shock-absorbing component (20) includes (i) a damping layer (40) and (ii) a shock absorber (50). The 3DRLM (30) in the damping layer (40) has an apparent density greater than the apparent density of 3DRLM (30) in the shock absorber (50).

Description

“ARTIFICIAL TURF SYSTEM” BACKGROUND

[1] Interest in artificial peat in recent years has been explosive. Artificial peat (also known as "pitch") is increasingly used to replace natural grass on playing surfaces, particularly on sports fields and playgrounds. Artificial peat also finds application in landscaping and leisure environments.

[2] In "third generation artificial peat" or "3G peat", the blades of artificial grass (the "pile") are supported by a thin layer of sand and a filling of rubber crumbs. The height of the pile varies from 40 millimeters (mm) to 65 mm, depending on the main sport to be practiced on the surface. Most 3G fields consist of polyethylene (PE) yarns tufted on a primary support. Typically, the tuft beam is obtained by applying a secondary coating of polyurethane (PU) or a secondary coating of styrene-butadiene-latex. The padding is then spread between the yarn fibers to stabilize the vertical position of the fiber, provide traction to the players and contribute to the shock absorption of the In combination with proper padding, a layer of PU shock foam is also installed in the system to optimize shock absorption.

[3] Artificial peat systems are used in contact sports fields to improve player safety and game consistency. A significant feature of artificial peat is its ability to absorb shocks. The shock-absorbing element of the artificial peat includes the filling material and the shock absorber. However, the use of these components has a number of disadvantages.

[4] Filling is disadvantageous because Filling requires constant maintenance - uniform distribution of filling granules is necessary to reduce the risk of injury to the player. In addition, the shock absorption capacity of the fill decreases over time, requiring filling of the fill and increasing the cost.

[5] The use of rubber granules and / or filler sand, alone or in combination with a PU shock absorber, makes it difficult to recycle existing artificial peat systems, which leads to incineration or disposal costs.

[6] The technique recognizes the need for alternative artificial peat systems with improved shock absorption capacity alone or in combination with improved recycling capacity.

SUMMARY

[7] The present disclosure provides an artificial peat system. In one embodiment, the artificial peat system includes a primary support layer and a shock absorbing component. The primary support layer has a plurality of artificial peat strands projecting upwardly from the primary support layer. The artificial peat system also includes a shock-absorbing component. The shock-absorbing component consists of a sheet of three-dimensional random loop material (3DRLM). The 3DRLM sheet is in contact with the primary support layer. The shock-absorbing component includes (i) a damping layer and (ii) a shock absorber. The 3DRLM in the damping layer has an apparent density higher than the apparent density of 3DRLM in the shock absorber.

[8] An advantage of the present disclosure is an artificial peat system with a 3DRLM shock absorber component which is a single unitary component, whereby the shock absorber is an integral part of the damping layer. The integration of shock absorber and damping in a single unitary shock absorber component eliminates the need for a secondary backing layer.

[9] An advantage of the present disclosure is an artificial peat system with an integrated shock absorber and a damping layer that reduces the amount of padding material needed for the player's safety.

[10] An advantage of the present disclosure is an artificial peat system that is readily recyclable.

BRIEF DESCRIPTION OF THE DRAWINGS

[11] Figure 1 is a perspective sectional view of an artificial peat system according to one embodiment of the present disclosure.

[12] Figure 1A is an enlarged view of area 1A of Figure

1.

[13] Figure 2 is a perspective view of a shock absorbing component in accordance with an embodiment of the present disclosure.

DEFINITIONS

[14] All references to the Periodic Table of Elements in this document must refer to the Periodic Table of Elements published and copyrighted by CRC Press, Inc., 2003. In addition, any references to a Group or Groups must be the Groups or Groups reflected in this Periodic Table of the Elements using the IUPAC system to enumerate groups. Unless stated otherwise, implied from context or routine in the technique, all components and percentages are based on weight. For the purposes of patent practice in the United States, the contents of any patent, patent application or publication referenced herein are incorporated into this document for reference in its entirety (or the equivalent US version thereof is hereby incorporated as a reference). of reference).

[15] The numerical ranges disclosed in this document include all values including the lower to the upper value. For ranges that contain explicit values (for example, 1, or 2, or 3 to 5, or 6, or 7) any sub-range between any two explicit values is included (for example, 1a2; 2a6; 5a7; 3a7; 5Sa6betc. ).

[16] Unless otherwise stated or implied from context or routine in the technique, all components and percentages are based on weight, and all test methods are current as of the filing date of this disclosure.

[17] "Blend", "blend of polymers" and similar terms are a composition of two or more polymers. Such a mixture can be miscible or not. This mix can be separated by phases or not. This mix may contain one or more domain configurations or not, as determined from transmission electronic spectroscopy, light scattering, x-ray scattering and any other method known in the art. Blends are not laminates, but one or more layers of a laminate can contain a blend.

[18] "Composition" and similar terms is a mixture of two or more materials. Pre-reaction, reaction and post-reaction mixtures are included in compositions, among which the latter will include reaction products and by-products, as well as unreacted components of the reaction mixture and decomposition products, if any, formed from the one or more components of the pre-reaction or reaction mixture.

[19] The terms "which comprises", "which includes", "which has" and its derivatives are not intended to exclude the presence of any additional component, step or procedure, regardless of whether it is specifically disclosed or not. In order to avoid any doubt, all compositions claimed using the term "comprise" may include any additive, adjuvant or additional compound, polymeric or not, unless stated otherwise. In contrast, the term, “which essentially consists of” excludes any other component, step or procedure from the scope of any following quote, except those that are not essential to operability. The term “consisting of” excludes any component, step or procedure not specifically outlined or listed.

[20] An “ethylene-based polymer” is a polymer that contains more than 50 weight percent of polymerized ethylene monomer (based on the total weight of polymerizable monomers) and, optionally, can contain at least one comonomer. The ethylene-based polymer includes ethylene homopolymer and ethylene copolymer (meaning units derived from ethylene and one or more comonomers). The terms "ethylene-based polymer" and "polyethylene" are used interchangeably. Non-limiting examples of ethylene-based polymer (polyethylene) include low density polyethylene (LDPE) and linear polyethylene. Non-limiting examples of linear polyethylene include linear low density polyethylene (LLDPE), ultra low density polyethylene (ULDPE), very low density polyethylene (VLDPE), multi-component ethylene-based copolymer (EPE), multi-block copolymer ethylene / a-olefin (also called olefin block copolymer (OBC)), single site catalyzed low density linear polyethylene (M-LLDPE), substantially linear, or linear, plastomers / elastomers, and high density polyethylene (HDPE) ). In general, polyethylene can be produced in gas-phase fluidized bed reactors, liquid-phase slurry process reactors or process reactors in liquid-phase solution, using a heterogeneous catalyst system, such as Ziegler- Natta, a homogeneous catalyst system, comprising ligand structures and Group 4 transition metals, such as metallocene, metal centered without metallocene, heteroaryl, heterovalent aryloxyether, phosphinimine and the like. Combinations of heterogeneous and / or homogeneous catalysts can also be used in single or double reactor configurations.

[21] “High density polyethylene” (or “HDPE”) is an ethylene homopolymer or an ethylene / a-olefin copolymer with at least one C4-Cio a-olefin comonomer or C4-Cg a-olefin comonomer and a density greater than 0.94 g / cm ?, or 0.945 g / cm ?, or 0.95 g / cm ?, or 0.955 g / cm? at 0.96 g / cm ?, or 0.97 g / in? or 0.98 gdem ?. HDPE can be a monomodal copolymer or a multimodal copolymer. A "monomodal ethylene copolymer" is an ethylene / C4-C10 α-olefin copolymer that has a distinct peak in a gel permeation chromatography (GPC) that shows the molecular weight distribution. A "multimodal ethylene copolymer" is an ethylene / Ca-C10 α-olefin copolymer that has at least two distinct peaks in a GPC that shows the molecular weight distribution. Multimodal includes copolymer with two peaks (bimodal), as well as copolymer with more than two peaks. Non-limiting examples of HDPE include DOW '' High Density Polyethylene (HDPE) resins (available from The Dow Chemical Company), ELITETY enhanced polyethylene resins (available from The Dow Chemical Company), bimodal CONTINUUMTY polyethylene resins (available with The Dow Chemical Company), LUPOLENTY (available from LyondellBasell), as well as HDPE products from Borealis, Ineos and ExxonMobil.

[22] An "interpolymer" is a polymer prepared by the polymerization of at least two different monomers. This generic term includes copolymers, commonly used to refer to polymers prepared from two different monomers, and polymers prepared from more than two different monomers, for example, terpolymers, tetrapolymers, etc.

[23] "Low density polyethylene" (or "LDPE") includes ethylene homopolymer, or an ethylene / a-olefin copolymer comprising at least one C3-C10 a-olefin, preferably C3a-Ca a-olefin , which has a density of 0.915 g / one hundred? at 0.940 g / cm? and contains long chain branching with wide MWD. LDPE is typically produced by polymerizing free radicals at high pressure (tubular reactor or autoclave with free radical initiator). Non-limiting examples of LDPE include MarFlex'y (Chevron Phillips), LUPOLENTY (LyondellBasell), as well as LDPE products from Borealis, Ineos, ExxonMobil and others.

[24] “Linear low density polyethylene” (or “LLDPE”) is a linear ethylene / a-olefin copolymer that contains heterogeneous short chain branch distribution comprising units derived from ethylene and units derived from at least one comonomer of C3-C10 a-olefin or at least one C4-Cs a-olefin comonomer, or at least one C-Cs a-olefin comonomer. LLDPE is characterized by little, if any, long chain branching, in contrast to conventional LDPE. LLDPE has a density of 0.910 g / cm ?, or 0.915 g / em ?, or 0.920 g / cm ?, or 0.925 g / em? at 0.930 g / cm ?, or 0.935 g / cm ?, or 0.940 g / cm ?. Non-limiting examples of LLDPE include TUFLINTY low density linear polyethylene resins (available from The Dow Chemical Company), Dowlex '"polyethylene resins (available from Dow Chemical Company), and Marlex'" polyethylene (available from Chevron Phillips).

[25] “Ultra low density polyethylene” (or “ULDPE”) and “very low density polyethylene” (or “VLDPE”), each, is a linear ethylene / a-olefin copolymer that contains chain branch distribution heterogeneous short comprising units derived from ethylene and units derived from at least one C3-C10 α-olefin comonomer or at least one C4-Cg α-olefin comonomer or at least one Cs-Cs α-olefin comonomer. Both ULDPE and VLDPE have a density of 0.885 g / cm ?, or 0.90 g / em? to 0.915 glem ?. Non-limiting examples of ULDPE and VLDPE include ATTANE'Y ultra low density polyethylene resins (available from The Dow Chemical Company) and FLEXOMER'Y very low density polyethylene resins (available from The Dow Chemical Company).

[26] “Multi-component ethylene-based copolymer” (or “EPE”) comprises units derived from ethylene and units derived from at least one C3-C10 α-olefin comonomer, or at least one C4-Cs comonomer at -olefin, or at least one Cs-Cs a-olefin comonomer, as described in USP patent references 6,111,023; USP

5,677,383; and USP 6,984,695. EPE resins have a density of 0.905 g / em ?, or 0.908 g / cm ?, or 0.912 g / cm ?, or 0.920 g / cm? at 0.926 g / cm ?, or 0.929 g / cm ?, or 0.940 g / cm? or 0.962 g / em ?. Non-limiting examples of EPE resins include ELITETY enhanced polyethylene (available from The Dow Chemical Company), advanced technology resins ELITE AT'Y (available from The Dow Chemical Company), SURPASSTY polyethylene (PE) resins (available from Nova Chemicals), and SMART'Y (available from SK Chemicals Co.).

[27] "Single site catalyzed low density linear polyethylenes" (or "M-LLDPE") are linear ethylene / a-olefin copolymers that contain homogeneous short chain branch distribution comprising ethylene-derived units and derivative units of at least one C3-C10 α-olefin comonomer, or at least one C4-Csg α-olefin comonomer, or at least one Cs-Cg α-olefin comonomer. Does m-LLDPE have a density of 0.913 g / cm ?, or 0.918 g / cm ?, or 0.920 g / cm? at 0.925 g / in? or 0.940 glem ?. Non-limiting examples of m-LLDPE include metallocene PE EXCEEDTY

(available from ExxonMobil Chemical), m-LLDPE LUFLEXENY (available from LyondellBasell) and m-LLDPE ELTEX'Y PF (available from Ineos Olefins & Polymers).

[28] “Ethylene plastomers / elastomers” are substantially linear or linear ethylene / a-olefin copolymers that contain homogeneous short chain branch distribution comprising units derived from ethylene and units derived from at least one C3 —- C10 comonomer a-olefin, or at least one C4-Cs a-olefinay comonomer or at least one C6-Cs a-olefin comonomer. Plastomers / ethylene elastomers have a density of 0.870 g / cm ?, or 0.880 g / cm ?, or 0.890 g / cm? at 0.900 g / cm ?, or 0.902 g / in ?, or 0.904 g / cm3, or 0.909 g / cm3, or 0.910 g / cm? or 0.917 g / em ?. Non-limiting examples of ethylene plastomers / elastomers include AFFINITY'Y plastomers and elastomers (available from The Dow Chemical Company), EXACT'Y plastomers (available from ExxonMobil Chemical), Tafmer '"(available from Mitsui), Nexlene' ”(Available from SK Chemicals Co.) and Lucene'Y (available from LG Chem Ltd.).

[29] An "olefin-based polymer" as used herein is a polymer that contains more than 50 weight percent of polymerized olefin monomer (based on a total amount of polymerizable monomers) and, optionally , can contain at least one comonomer. Non-limiting examples of olefin-based polymer include ethylene-based polymer and propylene-based polymer.

[30] A “polymer” is a compound prepared by polymerisation monomers, whether of the same or a different type, which in the polymerized form provide the multiple and / or repetitive “units” or “mer units” that form a polymer. The generic term polymer, therefore, encompasses the term homopolymer, used, in general, to refer to polymers prepared from only one type of monomer, and the term copolymer used, in general, to refer to polymers prepared to from at least two types of monomers. This also covers all forms of copolymer, for example, random, block etc. The terms "ethylene polymer / a-olefin" and "propylene polymer / a-olefin" indicate the copolymer, as described above, prepared from the polymerization of ethylene or propylene, respectively, and one or more a-olefin monomers It is found that although a polymer is often referred to as “produced from“ one or more specified monomers, “based on“ a specified monomer or type of monomer, “containing” a specified monomer content, or similar, in this context, the term “monomer” is understood to refer to the remaining polymerization of the specified monomer and not to the unpolymerized species. In general, the polymers in this document are cited as based on “units” which are the polymerized form of a corresponding monomer.

[31] A "propylene-based polymer" is a polymer that contains more than 50 weight percent polymerized propylene monomer (based on the total amount of polymerizable monomers) and, optionally, can contain at least one comonomer.

TEST METHODS

[32] Apparent density. A sample material is cut into a 38 cm x 38 cm (15 inch x 15 inch) square piece. The volume of this part is calculated from the thickness measured at four points. The division of weight by volume gives the apparent density (an average of four measurements is made) with reported values in grams per cubic centimeter, g / em ?.

[33] Ball rebound: A ball is launched at 2 meters and the height of its rebound from the surface is calculated. The results are reported in meters (m).

[34] Flexion stiffness. Flexural stiffness is measured in accordance with DIN 53121, with compression molded plates 550 µm thick, using a Frank-PTI Flexion Tester. The samples are prepared by compression molding of resin granules according to ISO 293. The conditions for compression molding are chosen according to ISO 1872 - 2007. The average cooling rate of the foundry is 15 º * C / min Bending stiffness is measured in a 2-point bending configuration at room temperature with an amplitude of 20 mm, a sample width of mm and a bending angle of 40 °. The flexion is applied at 6º / second (s) and the force readings are obtained from 6 to 600 s after the flexion is complete. Each material is evaluated four times with results reported in Newton's millimeters (Nmm ”).

"ºC (NMR) NUCLEAR MAGNETIC RESONANCE

SAMPLE PREPARATION

[35] Samples are prepared by adding approximately 2.7 g of a 50/50 mixture of tetrachloroethane-d2 / orthodichlorobenzene which is 0.025 M in chromium acetylacetonate (relaxation agent) to a sample at 0.21 g in a tube of 10 mm NMR. The samples are dissolved and homogenized by heating the tube and its contents to 150 ºC.

[36] Data Acquisition Parameters

[37] Data is collected using a 400 MHz Bruker spectrometer, equipped with a high temperature Bruker Dual DUL CryoProbe. The data is obtained using 320 transients per data file, a 7.3 s pulse repetition delay (6 s delay + 1.3 Ss acquisition time), 90 degree excitation angles and decoupling reverse batch with a sample temperature of 125 ° C. All measurements were made on non-rotating samples in the locked mode. The samples are homogenized immediately before insertion into the heated NMR Sample changer (130 ºC) and are allowed to thermally equilibrate in the probe for 15 minutes before data acquisition. CRYSTALLIZATION ELECTION FRACTIONING METHOD (CEF)

[38] Comonomer distribution analysis is performed with Crystallization Elution Fractionation (CEF) (PolymerChar, Spain) (Monrabal et al, Macromol. Symp. 257.71 to 79 (2007)). Orthodichlorobenzene (ODCB) with 600 ppm of antioxidant butylated hydroxytoluene (BHT) is used as a solvent. Sample preparation is done with a self-sampler at 160 ºC for 2 hours under agitation at 4 mg / ml (unless otherwise specified). The injection volume is 300 µm. The temperature profile of CEF is: crystallization at 3 ºC / min from 110 ºC to 30 ºC, thermal equilibrium at 30 ºC for 5 minutes, elution at 3 ºC / min from 30 ºC to 140 ºC. The flow rate during crystallization is 0.052 ml / min. The flow rate during elution is 0.50 ml / min. The data is collected at a data point / second. The CEF column is packed by the Dow Chemical Company with 125 µm + 6% glass beads (MO-SCI Specialty Products) with 0.32 cm (74 inch) stainless steel tubes. The glass beads are washed with acid by MO-SCI Specialty with the order from the Dow Chemical Company. The column volume is 2.06 ml. Column temperature calibration is performed using a mixture of Linear Polyethylene of Standard Reference Material NIST 1475a (1.0 mg / ml) and Eicosane (2 mg / ml) in ODCB. The temperature is calibrated by adjusting the elution heating rate so that the NIST 1475a linear polyethylene has a temperature peak at 101.0 ° C and Eicosane has a temperature peak of 30.0 ° C. The resolution of the CEF column is calculated with a mixture of linear polyethylene NIST 1475a (1.0 mg / ml) and hexacontane (Fluka, purum,> 97.0%, 1 mg / ml). A separation of NIST 1475a hexacontane and polyethylene reference line is obtained. The hexacontane area (from 35.0 to 67.0 ºC) for the NIST 1475a area from 67.0 to 110.0 ºC is 50 to 50, the amount of soluble fraction below 35.0 ºC is < 1.8% by weight. The resolution of the CEF column is defined in the following equation: Resolution - NIST 1475a peak temperature - Hexacontane peak temperature NIST 1475a half height width + Hexacontane half height width

[39] where the column resolution is 6.0.

[40] Density is measured according to ASTM D 792 with reported values in grams per cubic centimeter, or g / cm ?.

[41] Differential Scanning Calorimetry (DSC). Differential Scanning Calorimetry (DSC) can be used to measure the melting and crystallization behavior of a polymer over a wide temperature range. For example, TA Instruments' 01000 DSC, equipped with an RCS (refrigerated cooling system) and a self-sampler is used to perform this analysis. During the test, a 50 ml / min nitrogen purge gas flow is used. Each sample is pressed by melting in a thin film at about 175 ºC; the molten sample is then cooled to room temperature (approximately 25 ºC). The film sample is formed by pressing a “0.1 to 0.2 gram” sample at 175 ºC at 10.34 Mpa (1,500 psi) and 30 seconds to form a “0.254 mm to 0.508 mm ( 0.1 to 0.2 mil in thickness) ”. A specimen of 3 to 10 mg and 6 mm in diameter was extracted from the cooled, weighed polymer, placed in a light aluminum container (about 50 mg) and closed with crimp. The analysis was then carried out to determine its thermal properties. The thermal behavior of the sample is determined by grading the sample temperature up and down to create a heat flow versus temperature profile. First, the sample was quickly heated to 180 ºC and kept isothermal for five minutes in order to remove its thermal history. Then, the sample was cooled to -40 ºC at a cooling rate of 10 * ºC / minute and kept isothermal at -40 “C for five minutes. The sample was then heated to 150 ºC (this is the “second heating” elevation) at a heating rate of 10 º * C / minute. The cooling and second heating curves are recorded. The cooling curve is analyzed by defining the end points of the baseline since the start of crystallization to -20 ºC. The heat curve is analyzed by establishing reference parameters of -20ºC until the end of the fusion. The values determined are peak melting temperature (Tm), peak crystallization temperature (Tc), initial crystallization temperature (initial Tc), heat of melting (Hf) (in Joules per gram),% crystallinity calculated for samples polyethylene using:% crystallinity for PE = ((Hf) / (292 J / g)) x 100 and the% crystallinity calculated for polypropylene samples using:% crystallinity for PP = ((Hf) / 165 J / g)) x 100. The melting heat (Hf) and the melting peak temperature are reported from the second heat curve. The peak crystallization temperature and the initial crystallization temperature are determined from the cooling curve.

[42] Elastic recovery. Resin pellets are compression molded following ASTM D4703, Annex A1, Method C, to a thickness of approximately 0.127 to 0.254 mm (5 to 10 mil). Geometry microtensile test specimens, as detailed in ASTM D1708, are drilled from the molded sheet. The test specimens are conditioned for 40 hours prior to testing in accordance with Procedure A of Practice D618.

[43] The samples are tested on a screw-driven tensile tester using flat rubber-faced claws. The handle separation is adjusted to 22 mm, equal to the measurement length of microtensile specimens. The sample is extended to 100% deformation at a rate of 100% / min and maintained for 30 s. The crosshead is then returned to the original handle separation at the same rate and maintained for 60 s. The sample is then subjected to deformation to 100% at the same tensile rate of 100% / min.

[44] Elastic recovery can be calculated as follows: Elastic Recovery (Initial Applied Deformation - Permanent Settlement) = Applied Miciar Deformation || 00%

[45] Energy restitution: A mass with an attached spring falls into the peat. Energy restitution is given by comparing the energy of the falling mass before and after impact on the test specimen. Results are reported as a percentage (%).

[46] Indentation load deflection (ILD) is a measure of firmness for a material. In general, the higher the ILD value, the firmer the material; the lower the ILD value, the less firm the material. ILD measurement is performed in the direction of the sample thickness. The test protocol is in accordance with ASTM D 3574.

[47] For the ILD test, a square bottom plate and a round top plate are aligned with their coincident centers. The bottom plate is 33.02 x 33.02 cm (13 x 13 inch) and the diameter of the upper plate is 20.32 cm (8 inches). Each test specimen is 30.48 centimeters x 30.48 centimeters (12 inches x 12 inches).

[48] The ILD test is performed on an Instron material test system in the control-displacement mode. The bottom plate remains stationary and the top plate is driven to move up or down like an indentator. The indentator is lowered towards the bottom plate until the load cell starts to register some compression, which means that there is physical contact between the two plates. The position of the indentador is recorded as the origin of the. With the test specimen on the bottom plate, the indentator is lowered again until the load cell registers about 4.5 N of compressive force. The position of the indentador is recorded as d. The specimen thickness is the difference between the two readings (d - do).

[49] The test procedure consists of two steps: pre-bending and actual DPI measurements. In the pre-flexion stage, the indentator is introduced into the specimen between 75% and 80% of the thickness for two cycles (based on the initial thickness measurement obtained with the protocol specified in the paragraph above). The loading / unloading rate is 250 mm / min. Then, the specimen is left in recovery for 6 minutes before the start of the second stage. The purpose of pre-bending is to eliminate structural hysteresis for accurate thickness measurement. In the second step, the thickness of the specimen is measured again. The indentator is programmed to compress the specimen to 25% of the thickness (based on the second thickness measurement). The indentator maintains its position for 60 seconds to allow the specimen to relax until the strength reading is recorded as 25% ILD. The indentator continues to move downwards, for another 40% of thickness, reaching 65% of the specimen's thickness. The position is held for 60 seconds before the 65% ILD is recorded. The charge / discharge rate is 50 mm / min.

[50] Each specimen is tested three times. Between tests, specimens rested for at least 40 minutes as a precaution to allow specimen recovery. ILD results are reported in Newtons (N).

[51] The melt flow rate (MFR) is measured according to ASTM D 1238, Condition of 280 º * C / 2.16 kg (9/10 minutes).

[52] The melt index (MI) is measured in accordance with ASTM D 1238, Condition of 190 ºC / 2.16 kg (9/10 minutes).

[53] The molecular weight distribution (Mw / Mn) is measured using Gel Permeation Chromatography (GPC). In particular, conventional GPC measurements are used to determine the average weight molecular weight (Mw) and the number average molecular weight (Mn) of the polymer and to determine the Mw / Mn. The gel permeation chromatographic system consists of a Polymer Laboratories Model PL-210 instrument or a Polymer Laboratories Model PL-220 instrument. The column and carousel compartments are operated at 140 ºC. Three 10-micron Mixed-B columns from Polymer Laboratories are used. The solvent is 1,2,4 trichlorobenzene. The samples are prepared at a concentration of 0.1 gram of polymer in 50 milliliters of the solvent containing 200 ppm of butylated hydroxytoluene (BHT). The samples are prepared by gently shaking for 2 hours at 160ºC. The injection volume used is 100 microliters and the flow rate is 1.0 ml / minute.

[54] The GPC column set calibration is performed with 21 polystyrene standards of narrow molecular weight distribution with molecular weights in a range of 580 to 8,400,000, arranged in 6 mixtures in “cocktail” with at least a decade of separation between individual molecular weights. The standards are purchased from Polymer Laboratories (Shropshire, UK). Polystyrene standards are prepared in 0.025 grams in 50 milliliters of solvent for molecular weights greater than or equal to 1,000,000 and 0.05 grams in 50 milliliters of solvent for molecular weights less than 1,000,000. The polystyrene standards are dissolved in 80 ºC with gentle agitation for 30 minutes. Mixtures of narrow patterns are performed first and in decreasing order of the highest molecular weight component to minimize degradation. The standard peak molecular weights of polystyrene are converted to molecular weights of polyethylene using the following equation (as described in Williams and Ward, J. Polym. Sci., Polym. Let., 6, 621 (1968)): Mpolipropiteno = 0.645 (Mporstyrene).

[55] Calculations in equivalent molecular weight of polypropylene are performed using Viscotek TriSEC Version 3.0 software.

[56] "Porosity" is the percentage of open volume for 3DRLM. The mass and dimensions of a 3DRLM sample are measured and the bulk density is calculated. The percentage of open volume for the 3DRLM sample is the ratio of the volume of a 3DRLM sample to the volume of a solid polymer of the same mass, using the solid density of the polymer. Porosity results are reported as a percentage (%).

[57] Shock absorption: A mass with an attached spring falls into the artificial peat system. Shock absorption is calculated by comparing the maximum force in the peat with the concrete impact reference. Results are reported as a percentage (%).

[58] Tensile Strength is measured using a hybrid of ASTM D638 (rigid plastics) and ASTM D882 (films). The samples are SAC1 3DRLM shock absorber sheets measuring 203 mm by 31.7 mm (8 inches long and 1.25 inches wide). The gauge length between the test jaws is set to 127 mm (5 inches) and the used traction speed is 50 mm / min.

[59] Vertical deformation: A mass with an attached spring falls on the peat. The vertical deformation is calculated by the displacement of the falling mass in the specimen after its impact on it. The results are presented in millimeters (mm).

DETAILED DESCRIPTION

[60] The present disclosure provides an artificial peat system. In one embodiment, the artificial peat system includes a primary support layer with a plurality of artificial peat strands projecting upwardly from the primary support layer. The artificial peat system also includes a shock-absorbing component. The shock-absorbing component consists of a sheet of three-dimensional random loop material (S9DRLM). The 3DRLM sheet is in contact with the primary support layer. The shock-absorbing component includes (i) a damping layer and (ii) a shock absorber. The 3DRLM in the damping layer has an apparent density higher than the apparent density of 3DRLM in the shock absorber.

[61] Figure 1 shows an embodiment of the present artificial peat system 10 having a primary support layer 12, with a plurality of artificial peat yarns 14 projecting upwardly therefrom. The term "artificial peat", as used herein, is a carpet-like covering with polymer lines substantially vertically or vertically from the artificial peat yarn 14 projecting upward from a substrate which is the primary support layer

12. The artificial peat system 10 also includes a shock absorbing component 20. The shock absorbing component 20 comes into contact with the underside of the primary support layer 12. The shock absorbing component is composed of a material three-dimensional random loop 30. The shock absorber component 20 includes (i) a damping layer 40 and (ii) a shock absorber 50. The shock absorber component 20 is an integral structure, as will be described below.

[62] The "primary support layer" is one or more sheets on which the artificial peat yarn is sewn or woven, so that the artificial peat yarn extends outwardly from the upper side of the primary support layer. The primary support layer can be a polymeric sheet of woven cloth or a polymeric sheet of nonwoven cloth. The primary support layer provides dimensional stability for the artificial peat system.

[63] Non-limiting examples of polymeric material suitable for the primary backing layer include styrene-butadiene rubber (SBR) and propylene-based polymer. In one embodiment, the primary support layer is composed of an olefin-based polymer, such as a propylene-based polymer. In another embodiment, the primary support layer is composed of propylene homopolymer.

[64] The present artificial peat system 10 includes a plurality of artificial peat yarns 14 projecting upwards from the primary support layer 12. The term "artificial peat yarn" or hereinafter "yarn", as herein used, includes fibrillated ribbon yarn, coextruded ribbon yarn, monotape yarn and monofilament yarn. A "fibrillated tape" or "fibrillated tape wire" is a cast extruded film cut into tape (usually about 1 cm wide), stretched film and long slits (fibrillated) in the tape, giving the tape the dimensions of the blades of grass. A "monofilament yarn" is extruded into individual threads or threads with a desired cross-sectional shape and thickness, followed by the yarn orientation and relaxation in hot ovens. The artificial peat wire forms the polymer lines for the artificial peat. Artificial peat requires resilience (return), strength, flexibility, extensibility and durability. Consequently, the artificial peat yarn excludes the yarn for cloths (i.e. woven and / or knitted cloths).

[65] Wire 14 is composed of a polymeric material. Non-limiting examples of polymeric material suitable for the yarn include olefin-based polymer (such as propylene-based polymer and / or ethylene-based polymer), polyester, nylon and combinations thereof. In one embodiment, wire 14 is composed of an ethylene-based polymer.

[66] The artificial peat system 10 includes the shock absorbing component 20. The shock absorbing component 20 is composed of a sheet 22 of three-dimensional random loop material 30. As shown in Figure 2, a “loop material three-dimensional random ”(or“ SDRLM ”) is a mass or structure of a multiplicity of loops 32 formed allowing continuous fibers 34 to wrap, to allow the respective loops to contact each other in a molten state and to be bonded by heat, or otherwise melt-bonded, at most contact points 36. Even when a high stress to cause significant deformation is provided, the S3DRLM 30 absorbs the stress with the entire network structure made up of three-dimensional random loops fused by fusion, deforming; and once the tension is stopped, the elastic resilience of the polymer manifests itself to allow the structure to recover its original shape. When a mesh structure composed of continuous fibers made from a known non-elastic polymer is used as a damping material, plastic deformation is developed and recovery cannot be achieved, thus resulting in low heat resistance durability. When the fibers are not fused at contact points, the shape cannot be retained, and the structure does not completely change its shape, resulting in a fatigue phenomenon due to the concentration of stress, degrading durability and resistance to deformation. In certain embodiments, the fusion link is the state in which all contact points are fused.

[67] A non-limiting method for the production of 3DRLM 30 includes the steps of (a) heating a melted olefin-based polymer to a temperature between 10 ° C and 140 ° C above the melting point of the polymer in a typical melt extruder ; (b) discharge the molten interpolymer downward from a nozzle with multiple holes to form loops allowing the fibers to fall naturally (with the help of gravity). The polymer can be used in combination with a thermoplastic elastomer, non-elastic thermoplastic polymer or a combination thereof.

The distance between the nozzle surface and the starting conveyors installed in a cooling unit to solidify the fibers, the viscosity of the polymer, the diameter of the orifice and the quantity to be discharged are the elements that determine the diameter of the loop and the fineness of the fibers.

The loops are formed by holding and allowing the melted fibers supplied to reside between a pair of starting conveyors (belts or rollers) placed in a cooling unit (the distance between them being adjustable), placing the loops thus formed in contact by adjusting the distance between the holes for this purpose, in such a way that the ties in contact are connected by heat, or connected by casting in another way, insofar as they form a three-dimensional random loop structure.

Then, the continuous fibers, in which the contact points were connected by heat as the loops form a three-dimensional random loop structure, are taken continuously to a cooling unit for solidification to provide a network structure.

After that, the structure is cut to a desired length and shape.

The method is characterized in that the olefin-based polymer is melted and heated to a temperature between 10 ° C to 140 ° C higher than the melting point of the interpolymer and released downward in a molten state from a nozzle with multiple holes.

When the polymer is discharged at a temperature below 10ºC higher than the melting point, the fiber supplied becomes cold and less fluid to result in insufficient heat binding of the fiber contact points.

[68] Properties, such as the diameter of the loop and the fineness of the fibers that make up the cushioning structure provided here, depend on the distance between the nozzle surface and the take-off conveyor installed in a cooling unit to solidify the interpolymer , melt viscosity of the interpolymer, orifice diameter and the amount of interpolymer to be delivered from it. For example, a decreased amount of the interpolymer to be distributed and a lower melt viscosity at the time of distribution result in less fiber fineness and a smaller average loop diameter of the random loop. In contrast, a shortened distance between the nozzle surface and the withdrawal conveyor installed in the cooling unit to solidify the interpolymer results in a slightly greater fineness of the fiber and a larger average loop diameter of the random loop. These conditions in combination provide the desired fineness of 100 denier to 100,000 denier continuous fibers and an average random loop diameter of no more than 100 mm, or 1 millimeter (mm), or 2 mm, or 10 mm to 25 mm or 50 mm. By adjusting the distance to the aforementioned conveyor, the thickness of the structure can be controlled while the heat-bonded network structure is in a molten state and a structure with a desirable thickness and a flat surface formed by the conveyors can be obtained. Too high a conveyor speed results in failure to heat contact points, since cooling occurs before heat connection. On the other hand, a very slow speed can cause a higher density resulting from the excessively long stay of the melt. In some embodiments, the distance to the conveyor and the speed of the conveyor should be selected in such a way that the desired bulk density from 0.005 to 0.1 g / in? or 0.01 to 0.05 g / em? can be achieved.

[69] In one embodiment, 3DRLM 30 has one, some or all of the properties (i) to (iii) below:

[70] (1) a fiber diameter of 0.1 mm, or 0.5 mm, or 0.7 mm, or 1.0 mm, or 1.5 mm to 2.0 mm, or 2.5 mm , or 3.0 mm; and / or

[71] (ii) a thickness (machine direction) of 0.5 cm, or 1.0 cm, 2.0 cm, or 3.0 cm, or 4.0 cm, or 5.0 cm, or 10 cm, or 20 cm to 50 cm, or 75 cm or 100 cm, or more. It is understood that the thickness of the 3DRLM 30 will vary based on the application of the artificial peat system.

[72] 3DRLM 30 is formed in a three-dimensional geometric shape to form a leaf (that is, a prism). 3DRLM 30 is an elastic material that can be compressed and stretched and returned to its original geometric shape. An “elastic material”, as used in this document, is a rubber-like material that can be compressed and / or stretched and that expands / retracts very quickly to approximately its original shape / length when the force exerting compression and / or the stretch is released. The three-dimensional random loop material 30 has a "neutral state" when no compressive forces and no stretching forces are transmitted to the 3DRLM 30. The three-dimensional random loop material 30 has "a compressed state" when a compressive force is transmitted to the 3DRLM 30. 3DRLM 30. The three-dimensional random loop material 30 has “a stretched state” when a stretching force is transmitted to the 3DRLM 30.

[73] The three-dimensional random loop material 30 is composed of one or more olefin-based polymers. The olefin-based polymer can be one or more ethylene-based polymers, one or more propylene-based polymers and blends thereof.

[74] In one embodiment, the ethylene-based polymer is an ethylene / α-olefin copolymer. The ethylene / a-olefin copolymer can be a random ethylene / a-olefin polymer or a multi-block polymer of ethylene / a-olefin. Α-olefin is a C3-C20 α-olefin, or a Ca4-C12 α-olefin or a C4-Cs α-olefin. Non-limiting examples of suitable α-olefin comonomer include propylene, butene, methyl-1-pentene, hexene, octene, decene, dodecene, tetradecene, hexadecene, octadecene, cyclohexyl-1-propene (allyl cyclohexane), vinyl cyclohexane and combinations thereof.

[75] In one embodiment, the ethylene-based polymer is a homogenously randomized branched ethylene / α-olefin copolymer.

[76] "Random copolymer" is a copolymer in which the at least two different monomers are arranged in a non-uniform order. The term "random copolymer" specifically excludes block copolymers. The term "homogeneous ethylene polymer", as used to describe ethylene polymers, is used in the conventional sense according to the original description by Elston in US Patent 3,645,992, the description of which is incorporated herein by reference, to refer to a ethylene polymer in which the comonomer is randomly distributed within a given polymer molecule and in which substantially all of the polymer molecules have substantially the same molar ratio of ethylene to comonomer. As defined herein, both substantially linear ethylene polymers and homogeneously branched linear ethylene are homogeneous ethylene polymers.

[77] The homogeneously branched random ethylene / alpha-olefin copolymer component may be a random homogeneously branched linear ethylene / alpha-olefin copolymer or a substantially linear homogeneously branched random ethylene / α-olefin copolymer component. The term "substantially linear ethylene / α-olefin copolymer" means that the polymer main chair is replaced with 0.01 long chain / 1,000 carbon branches to 3 long chain branches / 1,000 carbon or 0.01 chain branch long / 1,000 carbons to 1 long chain branch / 1,000 carbons, or 0.05 long chain branch / 1,000 carbons to 1 long chain branch / 1,000 carbons. In contrast, the term "linear ethylene / α-olefin copolymer" means that the polymer main chain has no long chain branches.

[78] The homogeneously branched ethylene / α-olefin copolymers can have the same proportion of ethylene / α-olefin comonomer within all copolymer molecules. The homogeneity of the copolymers can be described by SCBDI (short chain branch distribution index) or CDBI (composition distribution branch index) and is defined as the weight percentage of polymer molecules that have a comonomer content within 50 percent of the median total molar comonomer content. The CDBI of a polymer is readily calculated from data obtained from procedures known in the art, such as, for example, fractionation by elution by increasing the temperature (here abbreviated as "TREF") as described in US Patent 4,798,081 (Hazlitt et al.) Or in US Patent 5,089,321 (Chum et al.) Whose disclosures are incorporated herein by reference. The SCBD | I or CDBI for the homogenously randomized branched ethylene / α-olefin copolymers is preferably greater than about 30 percent, or greater than about 50 percent.

[79] The randomly homogeneously branched α-olefin / ethylene copolymer can include at least one ethylene comonomer and at least one C3-C2o α-olefin or at least one Ca-C12 α-olefin comonomer. For example, and not by way of limitation, C3-C20 α-olefins may include, but are not limited to, propylene, isobutylene, 1-butene, 1-hexene, 4-methyl-1-pentene,

1-heptene, 1-octene, 1-nonene and 1-decene or, in some embodiments, 1-butene, 1-hexene, 4-methyl-1-pentene and 1-octene.

[80] In one embodiment, the homogeneously branched ethylene / α-olefin copolymer consists of ethylene and a C4-C3 α-olefin comonomer and has one, some or all of the following properties (i) to (iii) below :

[81] () a melting index (12) of 1 g / 10 min, or 59/10 min, or 10 g / 10 min, or 20 g / 10 min at 30 g / 10 min, or 40 9 g / 10 min, or 50 g / 10 min and / or

[82] (ii) a density of 0.75 g / cm ?, or 0.880 g / cm ?, or 0.890 g / cm? at 0.90 g / cm ?, or 0.91 g / cm3, or 0.920 g / cm ?, or 0.925 g / cm ?; and / or

[83] (ii) a molecular weight distribution (Mw / Mn) of 2.0, or 2.5, or 3.0 to 3.5, or 4.0.

[84] In one embodiment, the ethylene-based polymer is a heterogeneously branched random ethylene / α-olefin copolymer.

[85] The heterogeneously ramified random ethylene / a-olefin copolymers differ from the homogeneously ramified random ethylene / a-olefin copolymers mainly in the branching distribution. For example, randomly heterogeneously branched ethylene / α-olefin copolymers have a branching distribution that includes a highly branched portion (similar to very low density polyethylene), a medium branched portion (similar to a medium branching polyethylene) and a essentially linear portion (similar to linear homopolymer polyethylene).

[86] Like the random homogeneously branched random ethylene / α-olefin copolymer, the random heterogeneously branched ethylene / α-olefin copolymer can include at least one ethylene comonomer and at least one C3-C2o α-olefin comonomer or at least one C4-C12 α-olefin comonomer. For example, and not by way of limitation, C3-C20 α-olefins may include, but are not limited to, propylene, isobutylene, 1-butene, 1-hexene, 4-methyl-1-pentene, 1-heptene, 1-octene, 1-nonene and 1-decene or, in some embodiments, 1-butene, 1-hexene, 4-methyl-1-pentene and 1-octene. In one embodiment, the heterogeneously branched ethylene / α-olefin copolymer may comprise more than about 50% by weight of ethylene comonomer, or more than about 60% by weight, or more than about 70% by weight. Weight. Similarly, the heterogeneously branched ethylene / a-olefin copolymer may comprise less than about 50% by weight of a-olefin monomer, or less than about 40% by weight, or less than about 30% by weight.

[87] In one embodiment, the heterogeneously ramified random ethylene / α-olefin copolymer consists of ethylene and a C4-Cs α-olefin comonomer and has one, some or all of the following properties (i) to (iii) below:

[88] () a density of 0.900 g / cm ?, or 0.0910 g / cm ?, or 0.920 g / cm? at 0.930 g / cm ?, or 0.094 g / cm ?;

[89] (ii) a melting index (12) of 1 g / 10 min., Or 59/10 min., Or 10 9 g / 10 min., Or 20 g / 10 min. at 30 g / 10 min., or 40 g / 10 min., or 50 g / 10 min. and / or

[90] (ii) one Mw / Mnde3.00or3.5a4.00or4.5.

[91] In one embodiment, 3DRLM 30 is composed of a mixture of a homogeneously branched randomized branched ethylene / a-olefin copolymer and a heterogeneously branched ethylene / a-olefin copolymer, the mixture having one, some or all the properties (i) - (v) below:

[92] () an Mw / Mn of 2.5, or 3.0 to 3.5, or 4.0, or 4.5;

[93] (ii) a melting index (12) of 3.0 g / 10 min., Or 4.0 9/10 min., Or 5.0 g / 10 min., Or 10 g / 10 min. at 15 g / 10 min., or 20 g / 10 min. or 25 9/10 min .;

[94] (ii) a density of 0.895 g / cm ?, or 0.900 g / cm ?, or 0.910 g / cm ?, or 0.915 g / em? at 0.920 g / em ?, or 0.925 g / em ?; and / or

[95] (iv) a 10 ° / l2 ratio of 59/10 min., Or 7 g / 10 min. at 9/10 min., or 15 g / 10 min .; and / or

[96] (v) a percentage crystallinity of 25%, or 30%, or 35%, or 40% to 45%, or 50% or 55%.

[97] According to the Crystallization Elution Fractionation (CEF), the ethylene / a-olefin copolymer blend can have a weight fraction in a temperature range of 90 ° C to 115 ° C or about 5% at about from 15% by weight, or about 6% to about 12%, or about 8% to about 12%, or more than about 8%, or more than about 9%. In addition, as detailed below, the copolymer blend can have a Comonomer Distribution Constant (CDC) of at least about 100, or at least about 110.

[98] The present ethylene / a-olefin copolymer blend can have at least two or three melting peaks when measured using Differential Scanning Calorimetry (DSC) below a temperature of 130 ° C. In one or more embodiments, the ethylene / α-olefin copolymer blend may include a maximum temperature melting peak of at least 115 ° C, or about 120 ° C, or from about 120 ° C to about 125 ° C or from about 122 ºC to about 124 “ºC. Without being bound by theory, the heterogeneously branched ethylene / a-olefin copolymer is characterized by two melting peaks, and the homogeneously branched ethylene / a-olefin copolymer is characterized by a melting peak, thus making up the three melting peaks .

[99] Additionally, the ethylene / α-olefin copolymer blend may comprise from about 10 to about 90% by weight, or about 30 to about 70% by weight, or about 40 to about 60% by weight of homogeneously branched ethylene / α-olefin copolymer. Similarly, the ethylene / α-olefin copolymer blend can comprise from about 10 to about 90% by weight, about 30 to about 70% by weight, or about 40 to about 60% by weight of the copolymer of heterogeneously ramified ethylene / a-olefin. In a specific embodiment, the mixture of ethylene / a-olefin copolymer can comprise from about 50% to about 60% by weight of the homogeneously ramified ethylene / a-olefin copolymer and 40% to about 50% of the copolymer of ethylene / a-olefin. heterogeneously branched ethylene / α-olefin.

[100] In addition, the strength of the ethylene / α-olefin copolymer blend can be characterized by one or more of the following metrics. One of these metrics is elastic recovery. Here, the ethylene / a-olefin copolymer blend has an elastic recovery, Re, at 100 percent deformation in 1 cycle between 50 to 80%. Additional details regarding elastic recovery are provided in US Patent 7,803,728, which is incorporated herein by reference in its entirety.

[101] The ethylene / α-olefin copolymer blend can also be characterized by its storage module. In some embodiments, the ethylene / a-olefin copolymer blend may have a ratio of storage module at 25 ° C, G '(25 ° C) to a storage module at 100 ° C, G' (100 ° C) of about 20 to about 60, or about 20 to about 50, or about 30 to about 50, or about 30 to about 40.

[102] In addition, the ethylene / a-olefin copolymer blend can also be characterized by a flexural stiffness of at least about 1.15 Nmm at 6 s, or at least about 1.20 Nmm at 6 s , or at least about

1.25 NmMmm at 6 s, or less about 1.35 NmM at 6 s. Without being limited by theory, it is believed that these stiffness values demonstrate how the ethylene / a-olefin copolymer blend will provide cushioning support when incorporated into 3DRLM fibers bonded to form a cushioning network structure.

[103] In one embodiment, the ethylene-based polymer is an ethylene / a-olefin interpolymer composition that has one, some or all of the following properties (i) to (v) below:

[104] (i) a higher DSC temperature melting peak of 90.0 ° C to 115.0 ° C; and / or

[105] (ii) a zero shear viscosity ratio (ZSVR) of 1.40 to 2.10; and / or

[106] (ii)! a density in the range of 0.860 to 0.925 g / cm *; and / or

[107] (iv) a melting index (12) of 1 g / 10 min. at 259/10 min .; and / or

[108] (v) a molecular weight distribution (Mw / Mn) in the range of 2.0 to 4.5.

[109] In one embodiment, 3DRLM 30 is composed of an ethylene / C41-Cs a-olefin copolymer that is an elastomer. An "elastomer", as used herein, refers to a rubber-like polymer that can be stretched to at least twice its original length and which retracts very quickly to approximately its original length when the force exerting the stretch is released . An elastomer has an elastic modulus of about 10,000 psi (68.95 MPa) or less and an elongation generally greater than 200% in the non-crosslinked state at room temperature using the ASTM D638 - 72 method. In one embodiment, 3DRLM is composed of an “ethylene-based elastomer” which is an elastomer composed of at least 50% by weight of ethylene-derived units.

[110] In one embodiment, 3DRLM 30 is composed of an ethylene / C4-Cg a-olefin copolymer with a Comonomer Distribution Constant (CDC) in the range of more than 45 to less than 400, the copolymer of ethylene / C4-C8 a-olefin with a total of less than 120 units of unsaturation / 1,000,000 C (hereinafter “CDC45-ethylene polymer”). Non-limiting examples of suitable CDC45-ethylene copolymer are found in U.S. Patent Nos. * US 8372931 and 8829115, the entire contents of which are incorporated herein by reference.

[111] In one embodiment, the CDC45-ethylene copolymer has one, some or all of the following properties (i) to (iv) below:

[112] () a density of 0.86 g / cm ?, or 0.87 g / em? at 0.88 g / cm ?, or 0.89 g / cm ?; and / or

[113] (ii) a zero shear viscosity ratio (ZSVR) of at least 2; and / or

[114] (ii) less than 20 vinylidene unsaturation units / 1,000,000 C; and / or

[115] (iv) a bimodal molecular weight distribution.

[116] Figure 2 shows that the shock absorber component 20 includes the shock absorber layer 40 and the shock absorber 50. The shock absorber layer 40 and shock absorber 50 are each composed of 3DRLM 30.

[117] As best seen in Figure 1A and Figure 2, the shock absorber component 20 is a single integral structure, in which the subcomponents, damping layer 40 and shock absorber 50, are essentially inseparable or are inseparable and constitute a single unitary component - that is, the shock-absorbing component 20. The damping layer 40 and the shock absorber 50 are formed simultaneously, in a single extrusion process, so that many fibers (tens, hundreds or thousands) of 3DRLM extend from the damping layer 40 to the shock absorber 50 and vice versa. In other words, the shock absorbing component 20 is an integral structure whereby no intermediate layer and / or no intermediate structure and / or no intermediate composition is present between the damping layer 40 and the shock absorber 50.

[118] The 3DRLM 30 of the shock absorbing component is composed of a plurality of multiple loops. The multiple loops are formed by a plurality of continuous fibers composed of polymeric material, as previously disclosed. At least 2, 3 or 4, 5, 6 or 7 or 8 or 9 or 10 or more continuous fibers 34 extend from shock absorber 50 to damping layer 40 and vice versa. In one embodiment, hundreds or thousands of continuous fibers extend through the damping layer 40 and enter shock absorber 50 and vice versa.

[119] In one embodiment, the shock absorber component 20 includes the shock absorber layer 40, the shock absorber 50 and a second shock absorber layer (not shown) shock absorber

50. The 3DRLM in the second damping layer has an apparent density that is greater than the apparent density of 3DRLM in the shock absorber 50. The damping layer 40 and the second damping layer impact the shock absorber 50. The second layer of shock damping is located opposite the damping layer 40. In other words, the damping layer 40 and the second damping layer are substantially parallel or parallel to each other. The second cushion layer is similar to the cushion layer 40 in that the second cushion layer is composed of the same continuous fibers as the continuous fibers in the shock absorber 50 and / or is composed of the same continuous fibers in the cushion layer 40. A apparent density of the second buffer layer may be the same or different from the apparent density of the buffer layer 40. The thickness of the second buffer layer may be the same or different from the thickness of the buffer layer 40.

[120] In one embodiment, the shock absorber has a thickness, measured in millimeters (mm), which is 2 times, or 3 times, or 10 times, or 15 times to 50 times, or 100 times, or 200 times , or 300 times the thickness of the damping layer. In an additional embodiment, the shock absorber has a thickness of 3 times, or 5 times, or 8 times, or 12 times, or 15 times greater than the thickness of the damping layer.

[121] The 3DRLM in damping layer 40 has an apparent density that is greater than the apparent density of 3DRLM in shock absorber 50. Figure 1A and Figure 2 show that the continuous fibers 34 in damping layer 40 are more densely packed. packaged compared to the loosely packaged continuous fibers 34 in the shock absorber 50. This difference in fiber packaging results in the damping layer 40 having an apparent density that is greater than the apparent density of the shock absorber 50.

[122] In one embodiment, the apparent density of the damping layer 40 is 2 times, or 3 times, or 10 times, or 15 times to 50 times, or 100 times, or 200 times, or 300 times, or 400 times greater than the apparent density of the shock absorber 50. In an additional embodiment, the apparent density of the damping layer 40 is 2 times, or 3 times,

or 5 times, or 8 times to 10 times, or 15 times, or 20 times greater than the apparent density of the shock absorber 50.

[123] In one embodiment, shock absorber 50 has an apparent density of 0.010 g / cm ?, or 0.016 g / cm ?, or 0.020 g / cm ?, or 0.050 glem ?, or 0.070 g / em? , or 0.100 g / cm ?, or 0.150 g / in? at 0.200 g / in ?, or 0.250 g / in ?, or 0.300 g / cm ?, or 0.330 g / cm ?, or 0.400 g / cm ?.

[124] In one embodiment, the damping layer 40 has an apparent density of 0.030 g / cm ?, or 0.032 g / cm ?, or 0.050 g / cm ?, or 0.070 g / cm ?, or 0.100 g / cm? cm3, or 0.159 g / cm? at 0.200 / cm ?, or 0.250 g / cm? 3, or 0.300 g / cm ?, or 0.400, or 0.500 g / cm ?, or 0.600 g / cm ?, or 0.700 g / cm ?, or 0.800 g / cm ?, or 0.900 / cm3, or 0.960 g / cm ?, or 1,000 g / cm ?.

[125] In one embodiment, shock absorber 50 has an apparent density of 0.010 g / cm3, or 0.016 g / cm ?, or 0.020 g / cm ?, or 0.050 g / em ?, or 0.070 g / cm ?, or 0.100 g / cm ?, or 0.150 g / cm? at 0.200 g / cm ?, or 0.250 g / cm ?, or 0.300 g / cm ?, or 0.330 g / cm? or 0.400 gcm? and the damping layer 40 has an apparent density of 0.030 g / cm ?, or 0.032 g / cm ?, or 0.050 g / cm ?, or 0.070 g / em3, or 0.100 g / cm ?, or 0.159 g / em? , at 0.200 / cm ?, or 0.250 g / in ?, or 0.300 g / cm ?, or 0.400, or 0.500 g / cm ?, or 0.600 g / cm ?, or 0.700 g / cm ?, or 0.800 g / cm ?, or 0.900 / cm3, or 0.960 g / cm ?, or 1,000 g / cm? with the proviso that the apparent density of the 3DRLM in the damping layer 40 is greater than the apparent density of the 3DRLM in the shock absorber 50.

[126] The shock absorbing component 20 comes into contact with the primary support layer 12. More specifically, the exposed surface of the damping layer 40 comes into contact with the lower surface of the primary support layer 12. The contact between the damping layer 40 and the primary support layer 12 can be by (i) direct contact or (ii) indirect contact.

[127] In one embodiment, the damping layer 40 comes in direct contact with the bottom surface of the primary support layer 12. The term "direct contact", as used here, is the spatial relationship by which the damping layer 40 touches the bottom of the primary support layer 12, so that no intermediate layer, and / or no intermediate structure and / or no intermediate composition is present between the damping layer 40 and the primary support layer 12.

[128] In one embodiment, the damping layer 40 comes into indirect contact with the lower surface of the primary support layer 12. The term "indirect contact", as used herein, is the spatial relationship by which an intermediate layer and / or an intermediate structure and / or an intermediate composition are present between the damping layer 40 and the primary support layer 12. The intermediate layer / structure / composition may or may not be coextensive with the exposed surface of the damping layer 40. In one embodiment additionally, the cushion layer 40 comes in indirect contact with the lower surface of the primary support layer 12, whereby an adhesive layer is attached, or otherwise bonds, the exposed surface of the cushion layer 40 to the lower surface of the primary support 12.

[129] In one embodiment, the artificial peat system 10 and / or the shock absorbing component 20 is foam-free.

[130] In one embodiment, the shock absorbing component 20 is foam-free.

[131] In one embodiment, the artificial peat system 10 is free of a secondary support layer.

[132] In one embodiment, the artificial peat system 10 includes a filler material 60. The filler is a particulate material and is arranged between the individual peat strands. Padding material 60 performs one, some or all of the following items:

[133] (1) keeps the individual peat strands upright; and / or

[134] (2) protects the primary support layer from direct sunlight, thereby increasing the life span of the primary support layer; and / or

[135] (3) increases the ballast to avoid flattening (matting) ensuring that the individual wires return after heavy traffic.

[136] Non-limiting examples of materials suitable for padding material 60 include sand (silica), coated silica sand, SBR (styrene butadiene rubber), recycled rubber from car tires, EPDM (ethylene-propylene-diene monomer) ), other vulcanized rubbers or recycled track rubber, thermoplastic elastomers (TPEs) and thermoplastic vulcanized (TPVs), ground rubber and any combination thereof.

[137] Non-limiting examples of other materials suitable for filler material 60 include organic material, such as natural cork, fibers ground from the outer shell of the coconut and any combination thereof.

[138] In one embodiment, the artificial peat system includes a drainage component 70. The drainage component allows water to be removed from the artificial peat and prevents the artificial peat strands from becoming saturated with water. Non-limiting examples of suitable drainage components include stone-based drainage systems, EXCELDRAIN Sheet 100, EXCELDRAIN Sheet 200 and EXCELDRAIN EX-T STRIP (available from American Wick Drain Corp., Monroe, North Carolina).

[139] In one embodiment, the shock absorbing component 20 has dimensions of 305 mm x 305 mm x 54 mm (shock absorber 48 mm, damping layer 6 mm) (hereinafter SAC1, as shown in Table 1) . SAC1 has one, some or all of the following properties (1) to (D):

[140] (i) a tensile strength of the shock absorber of 10 N, or 30 N, or 40 N to 80 N, or 300 N, or 500 N; and / or

[141] (ii) tensile strength of a shock absorbing component of 30 N, or 50 N, or 100 N to 250 N, or 600 N, or 800 N; and / or

[142] (iii) an ILD shock absorber (25%) of N, or 30 N, or 60 N to 130 N, or 400 N, or 500 N; and / or

[143] (iv) an ILD shock absorbing component (25%) of 30 N, or 50 N, or 100 N to 250 N, or 600 N, or 800 N; and / or

[144] (v) an ILD shock absorber (65%) of 50 N, or 100 N, or 200 N to 300 N, or 400 N, or 600 N; and / or

[145] (vi) an ILD shock absorbing component (65%) of 75 N, or 150 N, or 250 N to 700 N, or 1,000 N, or 1,200 N; and / or

[146] (vii) a shock absorber porosity of 80%, or 90%, or 93% to 99.5%, or 97%, or 99%; and / or

[147] (viii) a porosity of the damping layer of 0%, or greater than 0%, or 50%, or 70% to 80%, or 90%, or 95%; and / or

[148] (ix) a porosity of the shock absorbing component of 80%, or 85%, or 90%, 95%, or 99%, or 99.5%.

[149] The present artificial peat system 10 advantageously provides the following benefits.

[150] (1) Improved drainage. The open loop structure of the damping layer 40 and the shock absorber 50 provides a high drainage capacity of rainwater vertically and horizontally due to the open three-dimensional structure of the shock absorbing component 20 composed of 3DRLM 30.

[151] (2) Reduction in filling. The shock-absorbing component 20 increases the shock absorption and elasticity of the artificial peat system 10, reducing the amount of filler material 60 required. Reducing the use of filling material allows for less maintenance work, less risk of injury due to the inhomogeneous distribution of granules and reduces the cost of the general artificial peat system.

[152] (3) Improved recyclability. An all-polyolefin artificial peat system is made possible by the current artificial peat system with the inclusion of (i) the primary support layer 12 which is a propylene-based polymer, (ii) the shock absorbing component 20 which is composed of an ethylene-based polymer, and (ii) an elastomeric polymer filler that is an ethylene-based polymer. The “all polyolefin” 10 artificial peat system can be recycled in a single polymer stream, instead of treating the polyethylene yarn, the secondary PU / SB latex support separately, as is the case with existing artificial peat - that is , artificial peat with SBR / sand filling and a polyurethane shock absorber.

[153] (4) Reduction in manufacturing cost. The integration of shock absorber 50 and damping layer 40 in a single integral shock absorber component 20 eliminates the production step of applying a secondary support layer to the system, creating production efficiency and lowering the current overall cost. artificial peat system 10.

[154] By way of example, and not by way of limitation, some modalities of the present disclosure will now be described in detail in the Examples below.

EXAMPLES

1. MATERIALS

[155] A shock-absorbing component with a damping layer integrated into the shock absorber is produced on a C-ENG line (Duralastic, USA). The Forming Shock Absorption Component has the structure of the Shock Absorption Component 20 shown in Figure 2 with damping layer 40 and shock absorber 50. The 3DRLM of the Forming Shock Absorption Component is continuous fibers composed of an ethylene copolymer / α-olefin octene with a density of 0.905 g / cm2.

[156] Table 1 below provides the properties of the formant shock-absorbing component (hereinafter referred to as SAC1). TABLE 1 - SAC PROPERTIES Nominal dimensions = 305 mm x 305 mm x 54 mm SAC1 SAMPLE Mass (e) Thickness (mm) Volume (in) Density (g / cm ') Porosity (%) Shock absorption component 310.1 5a 5016.8 0.0618 93.17% Shock absorber 187.9 48 4459.3 0.0421 95.34% Support layer 122.2 6 5574 0.2192 75.78% “3DL control sample 0, 0626 93.08% solid PE 0.905 0.00%

2. TEST

[157] The performance of SAC1 is compared to a control (comparative sample or CS). The control sample is the shock absorber shown in Table 1 above. In other words, the control sample is composed of the same 3DRLM as the SAC, the difference is that the control sample is only the shock absorber; the control sample has a damping layer cut and physically removed. The SAC1 includes the shock absorber and the damping layer.

[158] The control sample and the SAC1 sample are prepared for ILD tests and tensile strength tests. The sample for the shock absorbing component is 381 mm x 381 mm x 54 mm. From this sample, a test sample is cut to dimensions 305 mm x 305 mm x 54 mm for compression testing. The compression test is not destructive. After the shock absorption component compression test, the specimens are prepared for the tensile strength test. Four samples are cut from the 381 mm x 381 mm x 54 mm sample of the shock absorbing component. The specimens used for the tensile test are 203 mm long and 32.7 mm wide. The tensile test is a destructive test. Two of these traction specimens are measured for the shock absorber component (damping layer integrated with the shock absorber). For the other two traction specimens, the damping layer is cut from the shock absorber and the shock absorber alone (control) is subjected to the tensile test.

[159] The results are provided in Table 2 below.

TABLE 2. TEST AND ILD TEST RESULTS AND E) compression compression traction (N) [Control CS * [87.6 ——— j2B | 6 | * shock absorber only, damping layer removed from shock absorbing component

[160] The applicant found that the 3DRLM shock absorber component with integral shock absorber layer (ie SAC1) unexpectedly exhibits better shock absorption (ILD 65%, 424 in SAC1 vs 228 in the control) and an improved tensile strength (158 N in SAC1 vs 66 N in control) when compared to the 3DRLM shock absorber only.

[161] It is intended, - specifically, that this disclosure is not limited to the modalities and illustrations contained in this document, but includes modified forms of these modalities, including parts of the modalities and combinations of elements of different modalities, as included in the scope of the claims Next.

Claims (10)

CLAIMS 1 Artificial peat system characterized by the fact that it comprises: a primary support layer with a plurality of artificial peat strands projecting upwards from the primary support layer; a shock-absorbing component composed of a sheet of three-dimensional random loop material (3DRLM) and in contact with the primary support layer the shock-absorbing component comprising ()) a damping layer; and (ii) a shock absorber; and the 3DRLM in the damping layer has an apparent density greater than the apparent density of 3DRLM in the shock absorber. 2. Artificial peat system according to claim 1, characterized by the fact that the damping layer is part of shock absorber. 3. Artificial peat system according to claim 2, characterized by the fact that the 3DRLM comprises a plurality of multiple loops formed by a plurality of continuous fibers composed of polymeric material; and at least two continuous fibers extend from the shock absorber to the damping layer. 4, Artificial peat system, according to claim 1, characterized by the fact that the shock absorber has a thickness, measured in millimeters, from 2 to 300 times greater than the thickness of the damping layer. 5. Artificial peat system according to claim 4, characterized by the fact that the apparent density of the damping layer is 2 to 400 times greater than the apparent density of the shock absorber. 6. Artificial peat system according to claim 1, characterized by the fact that the shock absorber has an apparent density of 0.010 g / cm? at 0.400 g / cm2. 7. Artificial peat system according to claim 6, characterized by the fact that the damping layer has an apparent density of 0.030 g / cm? to 1,000 g / cm ?. 8. Artificial peat system according to claim 1, characterized by the fact that 3DRLM is composed of an ethylene-based polymer. 9 Artificial peat system according to claim 1, characterized by the fact that it comprises a filling material. 10. Artificial peat system according to claim 9, characterized by the fact that the peat yarn, the primary support layer, the 3DRLM and the filling material are composed of an olefin-based polymer.