US20170175343A1

US20170175343A1 - Method and system for rescuing playability of synthetic turf

Info

Publication number: US20170175343A1
Application number: US15/382,033
Authority: US
Inventors: Christopher des Garennes; John F. Paddock; William F. Reardon; Tony Leonard
Original assignee: DRYJECT Inc
Current assignee: DRYJECT Inc
Priority date: 2015-12-16
Filing date: 2016-12-16
Publication date: 2017-06-22
Also published as: WO2017106733A1

Abstract

A system and method of rescuing playability of synthetic turf are disclosed. The system and method include kicking out infield material, mixing existing infield material with fresh infield material, injecting the mixed infield material, and kicking the bent and depressed turf fibers back to an upright position. The system and method also include performing the injecting pivoting the injectors in multiple directions. The system and method further include mixing water absorbent polymer particles with the mixed infield material and injecting into the turf. The system and method further include applying liquid materials to the fibers and material of the synthetic turf. The system and method further include injecting disinfectants into the turf.

Description

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Patent Application No. 62/268,252 filed Dec. 16, 2015, which is incorporated by reference as if fully set forth.

FIELD OF INVENTION

This application generally relates to the field of turf maintenance, ornamental horticulture, nursery growers, agriculture and more specifically, to the rescue of synthetic turf that is highly trafficked.

BACKGROUND

Synthetic turf fields have become more common. Synthetic turf fields, also known as artificial turf, provide a surface of synthetic fibers made to look like natural grass. These fields may be in arenas and neighborhoods for sports that were originally or are normally played on grass. These fields are also now being used on residential lawns and commercial applications as well. These fields are beneficial because of maintenance-artificial turf stands up to heavy use, such as in sports, and requires no irrigation or trimming. Abundant sunlight is not needed to keep these fields looking nice. Domed, covered, and partially covered stadiums, arenas and other fields may require artificial turf because of the difficulty of getting grass enough sunlight to stay healthy. However, these fields do have drawbacks that need to be addressed including limited life, compaction periodic cleaning requirements, and heightened health and safety concerns including issues with increased temperatures.
These fields have been used for approximately 50 years and there are more than 11,000 of these fields in use in the United States alone with hundreds more being installed and renovated each year. Over this time the fields have developed from the first generation turf systems that include short-pile fibers without infill to second generation and third generation turf systems that feature longer fibers and sand infills, and infills that are mixtures of sand and granules of recycled rubber, respectively.
However, these fields do have drawbacks set forth above. Proper treatment and maintenance of these fields creates a higher quality product, improved lifetime and provides for a more aesthetically appealing landscape, and safer field of play, all which creates a highly attractive and desirable area for play. Therefore, a need exists for minimizing the negative effects and properly treating these fields.

SUMMARY

A system and method of rescuing playability of synthetic turf are disclosed. The system and method include kicking out infield material via injection of high pressure liquid, mixing existing infield material with fresh infield material, and kicking the bent and depressed turf fibers back to an upright position. The system and method include injecting by pivoting the injectors in multiple directions. The system and method include mixing water absorbent polymer particles with the mixed infield material and injecting into the turf. The system and method include applying liquid materials to the fibers and material of the synthetic turf. The system and method include injecting disinfectants into the turf. The system and method may include injecting the liquid at a pressure from 2200 to 2500 psi and/or 2500 to 3250 psi. The system and method may be performed using 3×1, 3×2, and/or 3×3 spacing. The injecting may occurs at an angle of between 15 and 0 degrees, an angle of less than 25 degrees, and/or at an angle in the range of approximately 8 to 11 degrees. The system and method may include mixing that occurs within the field profile and/or prior to injection. The injection may cause the kicking of bent and depressed fibers.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing summary, as well as the following detailed description of the preferred embodiments, will be better understood when read in conjunction with the appended drawings. For the purpose of illustrating the invention, there is shown in the drawings embodiments which are presently preferred. It should be understood, however, that the invention is not limited to the precise arrangements shown.

FIG. 1 depicts synthetic turf;

FIG. 2 illustrates a side exploded view of the synthetic turf of FIG. 1;

FIG. 3 is a schematic view of a system for injecting an additive in or on the field surface in accordance with a disclosed embodiment;

FIG. 4 is a perspective view of a rotating carriage with an encoder disc in accordance with a disclosed embodiment;

FIG. 5 is a schematic side view of the system of FIG. 3 on a movable platform in accordance with a disclosed embodiment;

FIG. 6 is a flow diagram of a method in accordance with a disclosed embodiment; and

FIG. 7 illustrates a method for de-compacting and disinfecting the turf.

To facilitate understanding, identical reference numerals have been used, where possible, to designate identical elements that are common in the figures. The figures are not drawn to scale and may be simplified for clarity. It is contemplated that elements and features of one embodiment may be beneficially incorporated in other embodiments without further recitation.

DETAILED DESCRIPTION

Certain terminology is used in the following description for convenience only and is not limiting. The words “front,” “back,” “forward,” “backwards,” “inner,” and “outer” designate directions in the drawings to which reference is made. Additionally, the terms “a” and “one” are defined as including one or more of the referenced item unless specifically noted otherwise. A reference to a list of items that are cited as “at least one of a, b, or c” (where a, b, and c represent the items being listed) means any single one of the items a, b, or c, or combinations thereof. A recitation of “into the field” or the like means to the surface of the field as well as within the field depth unless the context clearly indicated otherwise. The terminology includes the words specifically noted above, derivatives thereof, and words of similar import.
A system and method of rescuing playability of synthetic turf are disclosed. The system and method include kicking out infield material, mixing existing infield material with fresh infield material, injecting the mixed infield material, and kicking the bent and depressed turf fibers back to an upright position. The system and method also include performing the injecting pivoting the injectors in multiple directions. The system and method further include mixing water absorbent polymer particles with the mixed infield material and injecting into the turf. The system and method further include applying liquid materials to the fibers and material of the synthetic turf. The system and method further include injecting disinfectants into the turf.
FIG. 1 depicts synthetic turf 1 in use today. As is shown in FIG. 1, there is a set of fibers 10 that resemble or operate like grass and there are a layer of granules 20 also known as in-fill at the base of the set of fibers.
A side view of the synthetic turf 1 is illustrated in FIG. 2. FIG. 2 depicts the fibers 10 that are abundantly shown in FIG. 1. Fibers 10 may consist of a yarn or fiber (most commonly polyethylene, polypropylene or a blend of the two) of varying thickness, which may be straight 10.1, twisted, curly 10.2 or textured or a combination 10.3 of these types. Most commonly, the yarn is produced in sheets, which are split into thin strips or ribbons and then slit with razors to create multiple strands. The ribbons are then twisted together and tufted through a backing cloth to form the carpet. This type of carpet helps to stabilize and prevent excess movement of the in-fill. Alternatively, some carpets are manufactured from single strands of yarn, known as monofilament. The quantity of yarn used and the distance between the tufts (or stitch gauge) may vary from system to system. Some systems use more yarn or closer tufts; others use more infill. Yarn quantity is expressed in units of tex, a ratio of mass to length, or in weight (ounces per square foot).
A backing cloth 30 or base layer is also illustrated in FIG. 2. A good backing cloth 30 is easily tufted, resists fraying, absorbs coatings, is UV and rot-resistant, and has high dimensional stability. This means that the finished product will not creep or stretch, minimizing line movement.
Once the yarn has been tufted into the backing cloth 30, coatings, including polyurethane and latex coatings, may be applied to the backing to help to hold the tufts in place (called increasing the “tuft bind”) and to increase the dimensional stability of the finished carpet. In some brands, the coatings are applied only to the individual tufts, leaving the areas between the tufts uncoated for drainage. In others, the entire backing is coated and the carpet then is perforated for drainage if designed for outdoor use. If perforated, the size, number and placement of perforations may vary from brand to brand. If carpet is to be used indoors and drainage is unnecessary, it may be ordered without perforations to increase its strength. Once the carpet has been installed, the fibers 10 may be further fibrillated to give them the look and feel of natural grass.
Generally, at the base of the fibers is a layer of granules 20 (in-fill) that is also abundantly evident in FIG. 1. These granules 20 may take many forms including sand and/or rubber, for example. The granules 20 may also be of a myriad of different shapes, such as circular, egg-like, oval, rods, cones, or the like. The type and depth of the granule layer may vary from system to system. This so called “in-fill” holds up the long fibers 10 in the carpet and contributes significantly to the performance characteristics of the turf. Granules 20 material most often are granulated rubber or rubber and sand, either layered or mixed. The rubber may be styrene-butadiene rubber (SBR) granules, black in color and produced from recycled tires, or ethylene propylene terpolymer (EPDM) granules, specifically produced to be granulated and available in black or in colors. Clearly, the components and the construction of synthetic turf systems vary. Depending upon the system, different components may play more or less of a role in the ultimate performance of the system. Some of the components described are incompatible with others.
Over time, because of use and/or environmental reasons, the granules 20 become displaced, compacted, and missing from the synthetic field. Displaced granules 20 may occur from use, weather or the like and may include one area of the field having more granules that another, for example, and may include granule 20 clumping in regions of the field. For example, the center portion of fields tends to receive more traffic during games and as a result the granules 20 originally in this area tend to migrate away from this portion of the field. Displacement of the granules 20 may also occur from rain drainage, or snow removal, for example.
Missing granules 20 constantly occur with use. Every player that plays on the field leaves with granules 20 attached to them. This may include granules 20 in the shoes, socks, shorts, and hair, for example. Use of the field generally causes some portion of the granules 20 to “walk” away.
Compacted granules 20 are caused by environmental forces and play, and are defined as granules 20 that a have begun to break down as a result of the environment, compaction and play. These compacted granules 20 may occur as a result of dust and dirt build-up (fines) between or amongst the granules 20. The dirt and dust may be carried onto the field, or blown by nature, for example. This build-up may fill in voids between the granules 20 causing the field to become compacted and tight. This then may escalate the degradation because the filled in voids provide less space for water to move through the field so water may pool or temporarily pool by draining slower, thereby exaggerating the compaction.
As synthetic turf playing surfaces age they lose granules 20 due to a variety of factors some of which are described above. The granules 20 loss increases the surface hardness and decreases the safety of the field. The ability to add granules 20 once a field has become worn and lost is critical. Normally at the end of a synthetic field's life the field is removed and a new synthetic turf is installed. Being able to add granules 20 back into these fields may add a few years of life to a field. These additional years may save athletic facilities money while also creating a safer playing surface. Therefore having a machine that can add granules 20 at variable rates to synthetic fields and simultaneously reduce compaction, and provide cooling, and disinfecting is essential.
In order to minimize the present shortfalls in artificial fields, practices to care for the turf have developed including dragging or brushing to redistribute infill, brushing to lift pile, brushing and/or vacuuming to remove debris, localized topdressing at heavy wear areas, grooming to relieve compaction of the granules, and removal of moss, algae and/or weeds. Maintenance of synthetic turf today generally consists of topdressing or grooming that is primarily brushing the fibers to aid in their appearance and knap. This may also aid in the displacement of granules 20 by redistributing the granules 20 more evenly. This grooming does very little in improving the compaction of the granules 20 or the missing granules 20.
Other types of maintenance includes vacuuming or otherwise removing the granules 20 and reintroducing new granules 20 or material back into the turf. Grooming may be used after the reintroduction of granules 20 to aid in the placement and levelness of the granules 20.
In an embodiment, an injection system, such as those detailed in U.S. Pat. No. 5,605,105 and U.S. Pat. No. 7,581,684, both of which are incorporated herein by reference as if fully set forth, are used to inject materials including granules 20 and/or polymer into or onto the synthetic field. This technique de-compacts the old and unsafe/unplayable field to de-compact, provide cooling products, and disinfect using high pressure fluid, such as water or air, the high pressure injection with simultaneous injection of dry material granules 20. This method of injecting granules 20 and/or polymer into the field results in thorough and precise distribution with the added benefit of little surface disruption. The high pressure fluid from the injection system may begin or even complete the process of de-compacting the granules 20 remaining in the field. One method and device for inserting granules 20 and/or polymer into the field is described in detail below.
A blend of agents may be applied to retard the expansion of a water absorbent polymer until after the polymer has been delivered to the target area in the field. For example, a cross-linked potassium polyacrylate polymer is blended with the desired additives, such as food grade emulsifiers, stabilizers, preservatives and growth enhancers. The polymer is then coated, such as with vegetable oil and proprietary formula which forms a protective coating that retards the ability of the polymer to absorb water, thus delaying expansion of the polymer into a gel-like substance. The coated polymer may then be formulated into a liquid for injection into the field as set forth herein. Once the polymer has been injected into the field, the protective coating may be washed off either by the process of placing the polymer into the field after some precipitation or irrigation or both, enabling the polymer to absorb water and swell to full capacity.
In an embodiment, the dry polymer particles are 200-800 microns in size to reduce degradation rates. A larger particle size is also desirable because larger particles may absorb more water, resulting in greater and longer lasting benefit to the field. Microbes present in the field consume the particles and do so more quickly with the smaller particles reducing the benefit to the field. Accordingly, the larger particle size may provide a benefit to compensate for microbial activity and extend particle presence in field.
Synthetic turf surface temperature can become elevated during the hottest times of the day. Different cooling techniques have attempted to reduce surface temperatures. Irrigation has been found to reduce surface temperature for a period of 15 to 30 minutes; however, the effect was short lived and surface temperature returned to the previous temperature. Due to durations of athletic events rewetting is not an option to keep surface temperatures reduced. This creates the need for an option to reduce the surface temperature that can keep temperatures reduced for extended periods of time. Polymers that could release moisture over time and keep surface temperatures lower are a possible solution for reducing surface temperatures on synthetic turf. The polymer disclosed herein may include cross-linked polymers and food grade emulsifiers, stabilizers, preservatives, and growth enhancers. The polymer may be formulated into a liquid flowable form with a blend of agents to short-term retard the expansion of the polymer. Once in or on the field, the expansion of the polymer may be retarded until the coating is completely washed off as a result of precipitation or irrigation. The expanded polymer increases the capacity of the field to remain cool and resist temperature changes. This in turn decreases water runoff due to the hydrophilic nature of the polymer. The presence of the water absorbent polymer helps to moderate field temperature and makes aeration more effective. This increases the playability and lifetime of the field.
In an embodiment, larger particle sizes may be used to decrease the rate of degradation of the particles and prevent consumption by microbes, which consume or otherwise breakdown smaller polymer particles more quickly.
In order to provide at least one context within which the present granules 20 and/or polymer may be inserted or applied, the following description is provided. FIG. 3 schematically shows an embodiment of a system 100 for placing material including the granules and/or polymer or other additives on or in the field. FIG. 5 is a schematic side view of the system of FIG. 3 on a movable platform in accordance with a disclosed embodiment. The system 100 includes a peristaltic pump assembly 102. The peristaltic pump assembly 102 is configured for placing material on or in the field S. The device delivers material, including granules, polymer and disinfectant, at least to the surface S of the field and into the subsurface to a desired depth D (field depth). This depth D may be the distance from the top of surface S to the backing (not shown in FIG. 3 although shown relative to backing 30 in FIG. 2). The peristaltic pump assembly 102 is generally known to include a plurality of rollers 103 supported rotation on a rotating carriage assembly 104. As the carriage 104 rotates as indicated by arrow 105 under the influence of a variable voltage motor 208 (FIGS. 3 and 4), rollers 103 successively compress a resilient tube 106 to urge a material within the tube 106 in the direction of rotation (i.e., corresponding with arrow 105). An axial face of the rotating carriage assembly 104 may include an encoder disc 202. The encoder disc 202 has features 204, for example holes 204, formed around a perimeter of the disc 202 as illustrated in FIG. 4. A sensor 206 (FIG. 3) is positioned to read, or sense, data from the encoder disc 202, for example the number of features 204 passing in a given period of time, and provide that data to a computer control system or controller 108.
A first end 106 a of the resilient tube 106 is fluidly coupled to an additive reservoir 110 containing an additive 111. The first end 106 a resilient tube 106 may be directly coupled to the reservoir 110 or may have one or more intermediate fluid conduits forming inlet line 124. The additive reservoir 110 contains an additive 111 that may comprise one or more miscible or immiscible liquids or one or more solids suspended in one or more liquids, as in a slurry, or other compositions, such as a gel, suitable for pumping via a peristaltic pump.
A second end 106 b of the resilient tube 106 is fluidly coupled to the manifold 112 either directly or through one or more intermediate fluid conduits forming outlet line 126. A check valve 120 is placed in the outlet line 126 between the peristaltic pump 102 and the manifold 112. The check valve 120 is configured to allow flow from the peristaltic pump 102 to the manifold 112 but to prevent or block flow from the manifold to the peristaltic pump 102. The peristaltic pump is controlled to constantly provide an amount of additive to the manifold 112, except for during an injection, discussed below. As the additive 111 flows into the manifold 112, the pressure within the manifold is at or near atmospheric pressure (i.e., 0 pounds per square inch gage) allowing a free flow of the additive. In an embodiment as illustrated, the second end 106 b of the resilient tube 106 is coupled with the manifold at a midpoint L/2 of the length L of the manifold via outlet line 126.
The manifold 112 includes a plurality of nozzles 114. In the non-limiting embodiment illustrated schematically in FIG. 3, eight nozzles 114 are shown evenly spaced along the length L, although spacing need not be even. In other embodiments, a greater or lesser number of nozzles 114 may be used with even or uneven spacing. The nozzles 114 are in direct fluid communication with the interior of the manifold 112 as illustrated. In an embodiment, one or more nozzles 114 may have a valved connection with the manifold 112.
A source of pressurized fluid 116 is in fluid communication with the manifold 112 via pressure line 128. In an embodiment, the point of attachment between the manifold 112 and the source of pressurized fluid 116 is at a midpoint L/2 of the length L of the manifold 112 via pressure line 128. In an embodiment, the source of pressurized fluid 116 is attached to the manifold 112 adjacent to the second end of the resilient tube 106.
The source of pressurized fluid 116 may be an accumulator or other device or structure configured to supply a fluid 117 at a substantially constant pressure. This fluid 117 may include or be disinfectant or other material discussed herein. As used herein, a fluid 117 is a fluid at a pressure greater than the surrounding atmospheric pressure. This pressure is sometimes referred to a gage pressure to distinguish it from the total, or absolute, pressure which includes atmospheric pressure. In some embodiments, the fluid 117 may be at a pressure of up to 4,000 pounds per square inch, for example the pressure of the fluid 117 may range from about 2,000 pounds per square inch to about 4,000 pounds per square inch.
A valve, for example a poppet valve 118, is placed in the pressure line 128 between the source of pressurized fluid 116 and the manifold 112, such as adjacent to the manifold 112. The poppet valve 118 is configured to provide a blast or a jet of fluid 117 to the manifold. Advantageously, the blast or jet of fluid 117 interacts with the additive 111 delivered to the manifold by the second end of the resilient tube 106 b. The interaction of the fluid 117 and the additive 111 in the manifold evenly, or substantially evenly disperses the additive 111 in the fluid 117.
The (gage) pressure within the manifold 112 varies from atmospheric pressure to approximately the pressure of the pressurized fluid source 116. Accordingly, a check valve is not included, as the contents of the manifold will not flow in the direction of the pressurized fluid source 116. However, a check valve may be placed in the pressure line to insure the contents of the manifold do not enter the high pressure source 116.
In an embodiment, a hopper 132 containing a dry filler material 134 may be coupled via line 136 to the nozzles 114 (only shown connected to one nozzle 114 in FIG. 3 for clarity). Dry filler material 134 may include the polymer, rubber, sand or other material discussed herein. As the injected material travels through the nozzles 114, the velocity of flow causes a vacuum in the nozzles 114 behind the flow. This vacuum can be used to draw the dry material 134 into the nozzle 114 and flow in or on the field surface S or ground G by the injection. The flow of the dry material 134 into the nozzles 114 can be controlled by a valve at the hopper 132 or individually by valves at the nozzles 114.
The system 100 may be used to rescue unplayable fields and add additional usage by de-compacting, cooling, and/or disinfecting the field. Specifically, a 3×1 to 3×3 spacing may be used with a 2500-3250 psi water injection, for example. An angle between 15-0 degrees may be used for injections to provide a clean level surface after injection. Use of angles outside of this range may still provide de-compaction and other benefits, but with lessening efficiency. For example, other angles up to 25 degree may be used with less effective results. Approximately 10 degrees including a range of 8-11 degrees provides measured benefits in de-compaction. Swivel injectors may be used opposite the direction of travel of the device described below. The device may be equipped with ¾ inch suctions lines and a modified hopper for the ¾ inch lines.
The system 100 can be supported on a platform 302 movable with respect to the surface S of the field or field depth as illustrated in FIG. 3. The platform 302 can be designed to be pulled or towed and may be attached to, at a hitch 304, a tractor or other vehicle suitable for towing (not shown). The system 100 has wheels 306 that operate as a free-wheel as the system 100 is towed along the surface S. The platform 304 could also be self-propelled with at least one wheel 306 as a drive wheel.
A sensor 308 may be attached to a wheel 306, either free-wheel or drive wheel, for selectively sensing data corresponding to ground speed. In an embodiment, the data relates to angular displacement corresponding to rotations of a wheel 306 of a known diameter. Between the sensor 308 and the controller 108 is a communication link 310 to facilitate communication of ground speed data between the sensor 308 and the controller 108.
In the non-limiting embodiment illustrated in FIG. 3, the entire system 100 is supported on the platform 302 for ease of illustration only. Some components may be supported for movement over the surface S in a separate vehicle. The communication link 310 may be a wired link, or may be a wireless link connection.
When the output motor 208 rotates the carriage assembly 104, rollers 103 compress the resilient tube 106 within a cavity peristaltic pump 102 to draw the additive 111 from the additive reservoir 110 through the first end portion 106 a and force the additive 111 through the second end 106 b of the resilient tube. In an embodiment, the carriage assembly 104 can rotate in a clockwise (as illustrated) or counter-clockwise direction and additives in the resilient tube 106 can be urged within the flexible tube in the direction of travel of the rollers 103 (i.e., corresponding with arrow 105 in FIG. 3).
The additives 111 are provided or metered out by the peristaltic pump 102 in precision amounts to the injection manifold 112. This is accomplished by mounting an encoder disc 202 on the carriage assembly 104 (FIG. 4). The encoder disc 202 may be formed from a metal, for example stainless steel, with features, such as holes 204 that are sensed by a sensor 206, for example a Hall Effect proximity sensor. As shown in FIG. 4, the sensor 206, for example a proximity sensor, is mounted to the peristaltic pump housing and detects the absence or presence of metal directly in front of it. In an embodiment the proximity sensor 50 reads the revolutions of the encoder disc 202 per a period of time and reports the revolutions to a computer control system, controller 108 via communication link 130. The communication link 130 may be a wired link or a wireless link to facilitate transmission of at least a control signal from the controller 108 to the motor 208. As illustrated in the non-limiting embodiment of FIG. 4, each through hole 204 in the encoder disc 202 represents 1/40 of the peristaltic pump's 102 volume per revolution. For example, if the peristaltic pump's 102 volume per revolution is 0.16 ounces, each hole would be equal to 0.0036 ounce. As illustrated in FIG. 3, the computer sends a control signal, for example a variable output voltage, to the motor 208 to pump the additive material 111 at a given revolution per period of time. In other words, the controller 108 controls the amount of material that is output from the peristaltic pump 102. The desired amount of material output can be pre-set at the controller 108 and may vary from approximately 3 oz. per 1,000 sq. ft. to approximately 365 oz. per 1,000 sq. ft. The peristaltic pump 102 output is controlled by the controller 108 based on data provided by the sensor 206 and the sensor 308. The sensor 308 provides ground speed data to central controller 108.
As shown in FIG. 3, the additives 111 of the peristaltic pump 102 are provided to the injection manifold 112 through a valve, check valve 120, and high pressure fluid, for example water, is injected through a poppet valve assembly 118, adjacent to the valve 120 where the additive materials 111 of the peristaltic pump 102 are provided. When high pressure fluid (e.g., water) is injected into the injection manifold 112, the injection causes the pressure in the manifold 112 to rise. The pressure in the manifold 112 can rise to the same, or substantially the same, pressure as the pressurized fluid source 116. This increase in pressure closes the check valve 120 that allows the additive 111 to flow into the manifold. The pressure within the manifold 112 causes the fluid 117 and the additive 111, mixed under the influence of the fluid 117 jet in the manifold 112, to exit the manifold through the nozzles 114. The nozzles 114 may be in free and open fluid communication with the atmosphere as illustrated, or may include one or more valves to restrict the flow out of the manifold 112.
As the pressure drops in the manifold 112, the check valve moves into an open position and the additives 111 again enter the mixing chamber. Injection of the fluid 117 into the injection manifold 112 stops the movement of the additive into the injection manifold for duration of approximately 0.05 to 0.30 seconds. During this time period, the pressure in the mixing chamber increases from approximately 0 p.s.i. (gage, therefore corresponding to atmospheric pressure) to approximately 4,000 p.s.i. (gage). After each injection of fluid 117 into the manifold 112, the pressure in the manifold 112 decreases to approximately 0 p.s.i.; during this period, between high pressure injections, the additives move into the injection manifold 112. The mixture of additives and high pressure water is pumped into or onto the field as noted below.
During the period when the check valve 120 is closed and the pressure in the manifold 112 is elevated, the carriage assembly 104 of peristaltic pump 102 continues to turn as controlled by the variable voltage motor 208. The second end portion 106 b of the resilient tube 106 or the outlet line 126, or both the resilient tube 106 and the outlet line 126, acts as an accumulator for the additive materials 111 pumped during that time period.
The mixture of additives 111 and fluid 117 is injected in or on the surface S to the ground G under high pressure through nozzles 114. The velocity of the fluid 117 moving through the nozzles 114 allows the mixture to be forced into the field profile from depths D of approximately 1 to 12 inches.
FIG. 6 is a flow diagram representing a method 400 for placing an additive onto or into the field surface according to a disclosed embodiment. At 402 data related to ground speed of the system 100 is sensed by a sensor, for example sensor 308, which may include an encoder disc mounted to a wheel 306 and a proximity sensor fixed to the movable platform 302. The data is communicated to the controller 108 where the data may be stored.
At 404, the ground speed of the system 100 including at least the manifold 112 and nozzles 114 is calculated at the controller 108 from the data received.
At 406, an area per unit time covered by the nozzle assembly 114 at the calculated ground speed is calculated at the controller 108.
The controller 108 determines at 408 the amount of additive 111 required at the nozzles 114 in order to apply a predetermined amount of additive per unit area to the field.
At 410, the controller 108 provides a control signal, for example a variable voltage, via the communications link 130 to the peristaltic pump 102 to deliver the determined amount of an additive 111 to the manifold 112. Under the pressure generated by the peristaltic pump 102 in outlet line 106 b, the check valve 120 is caused to open, allowing the determined amount of additive 111 to be delivered to the manifold 112.
At 412, poppet valve 118 opens and a fluid 117 is introduced to the manifold 112. As the fluid 117 enters the manifold, the check valve 120 is urged to close and the manifold become pressurized to the same, or substantially the same, pressure as the fluid 117. The fluid 117 enters the manifold 112 as a jet or a blast and distributed the additive within the manifold 112.
At 414, the pressurized manifold forces the mixture of fluid and additive through the nozzles 114 and injects the mixture of fluid and additive onto or into the field surface. The sequence can be repeated for a set number of cycles programmed into the controller 108.
The method for rescuing poor quality synthetic fields is a combination or any one or more of the three unique techniques that have been introduced herein including de-compacting, cooling, and disinfecting using new granules and/or polymer.
As discussed, the system and method may utilize existing U.S. Pat. No. 5,605,105 and U.S. Pat. No. 7,581,684 using modifications so that a new and different service is made available to existing synthetic turf that extends the playability, safety, etc. of the field for an extended period of time. This extended period of time is much greater than any existing maintenance service presently being offered in the industry.
The machine and service may use high pressure water, air or combination or water and air, with a special swivel kit that modifies the manifold, venture suction, to provide pulsing injections at 3×1 to 3×3 spacing as described. The result of this and other modifications is that a compacted failing turf is de-compacted cabled, and disinfected for a long period of time or use.
A method 500 for de-compacting and disinfecting the infield is illustrated in FIG. 7. Method 500 includes the kicking out of infield material at step 505. The kicking out of material may be by the injection blast. The injection blast may be set at an angle and pulse rate. An angle between 15-0 degrees may be used for injections to provide a clean level surface after injection. Use of angles outside of this range may still provide de-compaction and other benefits, but with lessening efficiency. For example, other angles up to 25 degree may be used with less effective results. Approximately 10 degrees including a range of 8-11 degrees provides measured benefits in de-compaction.
At step 510 the mixing of the existing de-compacted, decomposed and deteriorated infield material with new fresh clean infield material occurs. This mixing may occur in the hopper, for example. New infield material is injected at step 515. This new infield material may be completely new infield material that mixes with the old infield material upon injection or application, or it may be a mixture of new and old infield material for injection or application. The use of water at 2200 to 2500 psi to carry the infield material into the field profile may cause the mixing of the new (and old) injected infield material with current used material. This injection may occur at a rate up to 12 cubic feet per 1000 square feet of treated area. Kicking the bent and depressed turf fibers back to an upright position at step 520. The kicking of the turf fibers may occur simultaneously with the injection of step 515 allowing the back fill of the treated field with new material to realign the fibers, as well. This creates a stabilized effect and foundation to hold fibers in the upright position. The kicking of step 520 may be performed by the injection manifold with 7-32 injectors set at a predetermined angle. Pivoting the injectors in multiple directions at step 525 allows the machine to operate in multiple directions. For example, the injectors may be pivoted in two directions allowing the machine to operate in two directions. Swivel injectors may be used opposite the direction of travel of the device described below.
Method 500 may also include mixing water absorbent polymer particles with additives for inclusion with the fibers and material at step 530. This mixing may include blending a water absorbent polymer with food grade emulsifier, stabilizers, preservatives and growth enhancers to form a polymer blend, coating the polymer blend with an agent to retard absorption of water, and formulating the coated polymer blend into a liquid. This liquid may then be applied at step 535 to the fibers and material before, during or after injection at step 515. Step 535 of injecting a water absorbent polymer blend into or onto the field may aid in lowering the temperature of the playing surface. Injecting at step 535 may be performed by mixing the liquid with water and injecting into the field structure, for example.
Method 500 may also include injecting disinfectants at step 540. The disinfectants may be applied at step 540 to the fibers and material before, during or after injection at steps 515 and/or 535. The disinfecting of step 540 simultaneously with injecting of step 515 of dry infield materials and kicking at step 505 out of old worn deteriorated, infected infield material may result in much better coverage and results in application of the disinfectant. The combination may create a much greater zone of treatment, better coverage (top to bottom) compared to existing topical and other existing service options. The disinfecting results in much more complete disinfecting of the total turf area. This new zone of treatment is deep into the previously hard, compacted and impenetrable areas of the infield material down to the turf backing.
The kicking out of step 505 in conjunction with the injection of step 515 with high volumes of new infield material may dilute the broken down failing existing infield material as a percentage of all the infield material. This will result in less compaction, higher infiltration rates and safer turf. The injection of new infield material at step 515 in combination with the existing material as a routine maintenance program to synthetic turf 1-5 times per year will result in significant turf life extension. In 6-10 hours this injection service can accomplish turf rescue that replenishes the turf to a safe level (G MAX numbers of approximately 165) at substantially less labor, energy, and cost of other field maintenance services. This extends the life of the turf thus postponing the turf replacement investment for a period of time.
The use of the present process and apparatus produced improved playing surfaces. Testing has been performed using to determine the influence of the system on the addition of crumb rubber into a synthetic surface that is near end-of-life and to determine if a polymer added by the process described herein may lower synthetic turf surface temperatures.
The testing is performed using Astroturf GameDay 360 (a blend of monofilament and slit film) synthetic turf installed over a gravel base. Prior to treatment applications the test field received 300 simulated traffic events using the Baldtree traffic simulator (BTS). Surface hardness measurements for the test field ranged between 200-206 GMAX with the F355 Apparatus A device, and 149-155 GMAX with the Clegg Impact Soil Tester. The test field was not within compliance for the ASTM (200 GMAX with F355), Synthetic Turf Council (165 GMAX with F355), and NFL (100 GMAX with Clegg) surface hardness thresholds, respectively. All plots were groomed using a brush to standup the turf fibers prior to rescue treatments. The presently described recue treatment is performed using the described apparatus using a 3″×2″ spacing to incorporate either crumb rubber and/or sand infill.
Surface hardness was collected using the F355 Apparatus A (F355) and Clegg Impact Surface Tester (CIST). The F355 is the current ASTM and STC standard device for measuring surface hardness on synthetic turf. The CIST was also used due to its common use on natural turf athletic fields, and its current use for testing all surfaces on National Football League Stadiums. Additionally, it has been reported that infill depth is highly correlated to surface hardness. Therefore, infill depth was collected every time surface hardness data were taken. With increasing traffic, infill depths decreased likely due to walk-off rubber and infill compaction (settling) from simulated traffic events as described hereinabove.
Results indicate that the treatment with two passes of crumb rubber using the described process and apparatus provided a decrease in surface hardness with new results of 151 GMAX. Two passes of crumb rubber (177 GMAX) significantly (P<0.001) reduced the surface hardness for 150 simulated traffic events.
One pass of crumb rubber injection only (174 GMAX) significantly (P<0.001) reduced the surface hardness for 100 simulated traffic events compared to the brushing only (167 GMAX) treatment.
Injection of sand (172 GMAX) did not reduce surface hardness compared to the brushing alone (165 GMAX) treatment. The two passes of crumb rubber treatment reduced surface hardness below the STC's acceptable surface hardness threshold of 165 GMAX. The two passes injecting crumb rubber significantly reduced surface hardness below the acceptable STC 165 GMAX threshold of these acceptable values were maintained over 100 simulated traffic events
Similar results were found to the F355 for surface hardness data. Results indicated that with two passes of crumb rubber treatment significantly (P<0.001) decreased the surface hardness to 59 GMAX. The treatment with one crumb rubber injection (112 GMAX) pass was effective at significantly (P<0.001) decreasing the surface hardness; however, it did not have as large of a reduction as the treatment with two passes of crumb rubber injection (96 GMAX). The two pass crumb rubber injection (96 GMAX) treatment was the only treatment that went below the NFL's acceptable surface hardness threshold of 100 GMAX.
The treatment with two passes of injecting crumb rubber reduced surface hardness below the acceptable NFL 100 GMAX threshold. Through 150 simulated events, the treatment with two passes of crumb rubber significantly (P<0.001) reduced surface hardness of a worn synthetic turf surface greater than all other treatments.
Having thus described various methods, configurations, and features of the present poppet valve in detail, it is to be appreciated and will be apparent to those skilled in the art that many physical changes, only a few of which are exemplified in the detailed description above, could be made in the apparatus and method without altering the inventive concepts and principles embodied therein. The present embodiments are therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are therefore to be embraced therein.

Claims

What is claimed is:

1. A method of rescuing playability of synthetic turf, the method comprising:

kicking out infield material via injection of high pressure liquid;

mixing existing infield material with fresh infield material; and

kicking the bent and depressed turf fibers back to an upright position.

2. The method of claim 1 wherein the injecting is performed by pivoting the injectors in multiple directions.

3. The method of claim 1 further comprising mixing water absorbent polymer particles with the mixed infield material and injecting into the turf.

4. The method of claim 1 further comprising applying liquid materials to the fibers and material of the synthetic turf.

5. The method of claim 1 further comprising injecting disinfectants into the turf.

6. The method of claim 1 wherein the liquid is injected at a pressure from 2200 to 2500 psi.

7. The method of claim 1 wherein the liquid is injected at a pressure from 2500 to 3250 psi.

8. The method of claim 1 wherein the injection occurs using 3×1 spacing.

9. The method of claim 1 wherein the injection occurs using 3×2 spacing.

10. The method of claim 1 wherein the injection occurs using 3×3 spacing.

11. The method of claim 1 wherein the injection occurs at an angle of between 15 and 0 degrees.

12. The method of claim 1 wherein the injection occurs at an angle of less than 25 degrees.

13. The method of claim 1 wherein the injection occurs at an angle in the range of approximately 8 to 11 degrees.

14. The method of claim 1 wherein the injection is from an injection manifold with 7 to 32 injectors.

15. The method of claim 1 wherein the mixing occurs within the field profile.

16. The method of claim 1 wherein the mixing occurs prior to injection.

17. The method of claim 1 wherein the injection causes the kicking of bent and depressed fibers.

18. A system for rescuing the playability of synthetic turf, the system comprising:

a manifold including a plurality of nozzles distributed along a length;

a peristaltic pump assembly that comprises a motor that rotates a carriage assembly, an encoder disc, a sensor, an inlet line fluidly coupled to an additive reservoir, and an outlet line coupled to the manifold;

a pressurized fluid source fluidly coupled to the manifold, wherein when the pressurized fluid is injected into the manifold, the pressure in the manifold increases and the pressurized fluid mixes with an additive delivered from the additive reservoir; and

a ground speed sensor; and

a computer control system in communication with the peristaltic pump assembly and the ground speed indicator,

wherein the computer control system controls an output of the peristaltic pump to be proportional to the ground speed sensed and wherein the increased pressure in the manifold causes the pressurized fluid within the manifold to exit through the plurality of nozzles to inject the pressurized fluid and the additive to be injected into the soil by creating fractures in the soil, and

wherein the additive includes new infield material.

19. The system of claim 18 wherein the additive includes disinfectant.

20. The system of claim 18 wherein the water absorbent polymer particles.