US20240159000A1

US20240159000A1 - Corn cob based infill material for synthetic turf fields

Info

Publication number: US20240159000A1
Application number: US18/506,218
Authority: US
Inventors: Tina Kramer Ferrand; Eric HABIB; Jason Smollett
Original assignee: Tarkett Sports Canada Inc
Current assignee: Tarkett Sports Canada Inc
Priority date: 2022-11-11
Filing date: 2023-11-10
Publication date: 2024-05-16
Also published as: WO2024098157A1

Abstract

An infill composition for artificial turf fields comprising at least one layer of particles comprising ligneous-belt corn-based particles, the ligneous-belt corn-based particles include a particle size distribution of ligneous-belt corn-based particles with an initial dry size of 0.5 to 5 mm and a final size of 0.6 to 7 mm to after wetting. The infill composition can be installed according to a method of spreading a layer of ligneous-belt corn-based particles over a carpet that is on a base of compacted stone, wherein the layer of ligneous-belt corn-based particles consists of dry particles; watering the layer of ligneous-belt corn-based particles such that the dry particles are expanded after the watering; brushing the layer of ligneous-belt corn-based particles; and decompacting the layer of ligneous-belt corn-based particles such that the ligneous-belt corn-based particles are evenly distributed over the carpet.

Description

CROSS REFERENCE TO RELATED APPLICATION

This application claims the benefit of U.S. Provisional Patent Application Ser. No. 63/424,645, entitled “CORN COB BASED INFILL MATERIAL FOR SYNTHETIC TURF FIELDS” filed on Nov. 11, 2022. The entirety of the above-noted application is incorporated by reference herein.

BACKGROUND

Artificial turf fields are composed of three primary components—from bottom to top: Shock pad, carpet, and infill. These components are generally assembled on top of a base of compacted stone. The shock pad is optional and serves to convey much of the shock absorption performance of the turf field, required for the safety of those playing on the surface in the case of impact with the surface. The carpet serves to mimic the blades of grass and root zone, conveying the softness and traction of the surface as well as many of the ball interaction properties. The infill is generally constituted of at least two layers, the bottom layer of which serves to weight down and stabilize the carpets that it is laid onto, whereas the top layers serve as an additional interface layer to those playing on the field, conveying surface softness, friction, traction, and much of the mechanical properties of the field that are felt directly by the players.
The bottom, stabilizing infill is most often sand, serves to weigh down the turf carpet and keep it in place, as well as providing a more compact and solid base that conveys much traction to the overall turf assembly. Other materials have also previously been used as stabilizing infill, but these remain limited in their pervasiveness due to the good performance, widespread availability, and low price of sand for this purpose.
The upper layers of infill have most often comprised styrene-butadiene rubber (SBR) particles due to the ready availability of end-of-life rubber from car tires, and in many places in the world this continues to be the most commonly used infill material due to shock absorption properties, and its ease of combination with other materials into a complete system. Other types of rubber, such as ethylene propylene diene monomer (EPDM) rubber are also used for this purpose as they are generated as waste from other industries; these can be processed into performance infill to convey advantageous properties; other thermoplastics such as polyvinyl chloride (PVC) have also been used to similar effect. Composite materials can be used that combine thermoplastics, elastomers, reinforcements and/or fillers to obtain further properties that are difficult to obtain with monolithic materials.
Rising environmental and sustainability concerns have more recently led to the use of alternate materials to replace plastic and rubber infill materials. One approach to these environmental issues has been to produce biodegradable plastic infill materials to alleviate these concerns. However, these materials are difficult and expensive to produce with the desired properties and in the quantities required.
The other main approach to mitigate the environmental issues has been to use biological—microbial-, plant- or animal-derived—materials as infills. Cork has been the most common of this type of material used as a performance infill. Cork can provide mechanical performance characteristics, but its low density makes cork expensive to transport and can also lead to it floating off the fields in the case of heavy rain. Cork also includes relatively low wear resistance and limited availability due to long production times and limited growth region. Pulverized olive pits provide mechanical resistance, and are available at low cost, but exhibit a high coefficient of friction that is oftentimes adverse to player comfort. Coconut coir has good mechanical performance but requires constant watering to maintain its properties and performance. Mixed organic materials have also been used as performance infills. Conventional organic infills using corn cobs have been used in the past, either alone, or in combination with other materials in an attempt to offset some of its perceived drawbacks. The previous use of corn used a granulated version of the full cob, and in consequence led to rapid darkening and degradation of the material, as well as an undesirable effect of attracting wildlife to the field.

SUMMARY

The following presents a simplified summary to provide a basic understanding of some aspects of the disclosed subject matter. This summary is not an extensive overview. It is not intended to identify key/critical elements or to delineate the scope of the claimed subject matter. Its sole purpose is to present some concepts in a simplified form as a prelude to the more detailed description presented later.
There remains a need for environmentally friendly and ultimately biodegradable infill materials that present good mechanical properties and mechanical resistance, while presenting high availability, easy transportation, and low cost.
In aspects, a ligneous-belt corn-based infill employs a shock pad to achieve a desired and/or proper shock absorption on the turf. The ligneous-belt corn-based infill is most often installed over a layer of sand wherein the sand acts as a stabilizing infill. As a stabilizing infill, the sand performs as a ballast layer that weighs down the turf carpets and mitigates movement.
In other aspects, an infill composition for artificial turf fields comprises at least one layer of ligneous-belt corn-based particles. The ligneous-belt corn-based particles include a particle size distribution of ligneous-belt corn-based particles with an initial dry size of approximately 0.5 to 5 mm and a final size of approximately 0.6 to 7 mm after wetting. The infill can be installed according to a method of spreading a layer of ligneous-belt corn-based particles over a carpet that is on a base of compacted stone, wherein the layer of ligneous-belt corn-based particles includes or otherwise consists of dry particles. Thereafter, the layer of ligneous-belt corn-based particles are sufficiently watered such that the dry particles are expanded after absorption. The layer of ligneous-belt corn-based particles are brushed and the layer of ligneous-belt corn-based particles are de-compacted such that the ligneous-belt corn-based particles are evenly distributed over the carpet of the turf system. As previously stated, a shock pad is most often employed to achieve a desired shock absorption of the pad.
To the accomplishment of the foregoing and related ends, certain illustrative aspects of the claimed subject matter are described herein in connection with the following description and the annexed drawings. These aspects indicate various ways in which the subject matter may be practiced, all of which are intended to be within the scope of the disclosed subject matter. Other advantages and novel features may become apparent from the following detailed description when considered in conjunction with the drawings.
These and other systems, methods, objects, features, and advantages of the present disclosure will be apparent to those skilled in the art from the following detailed description of the preferred embodiment and the drawings.
All documents mentioned herein are hereby incorporated in their entirety by reference. References to items in the singular should be understood to include items in the plural, and vice versa, unless explicitly stated otherwise or clear from the text. Grammatical conjunctions are intended to express any and all disjunctive and conjunctive combinations of conjoined clauses, sentences, words, and the like, unless otherwise stated or clear from the context.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a turf carpet system having an infill made of corn-based material in accordance with some embodiments of the present disclosure.

FIG. 2 illustrates a turf carpet system having an infill made of corn-based material and sand in separate layers in accordance with some embodiments of the present disclosure.

FIG. 3 illustrates a turf carpet system having an infill made of corn-based material and sand in a mixed layer in accordance with some embodiments of the present disclosure.

DETAILED DESCRIPTION

Various aspects of the subject disclosure are now described in more detail with reference to the annexed drawings, wherein like numerals generally refer to like or corresponding elements throughout. It should be understood, however, that the drawings and detailed description relating thereto are not intended to limit the claimed subject matter to the particular form disclosed. Instead, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the described and claimed subject matter.
An artificial turf system can use an infill material that includes material derived from the ligneous belt of a corn cob(s). In aspects, a stabilizing layer, such as sand or other sufficient material, is incorporated. Moreover, and most often, a shock pad is employed to achieve a desired shock absorption in accordance with a particular installation/purpose. The infill material conveys many of the mechanical properties that are desired for the use as artificial turf infill and conveys performance advantages over the materials and methods described above.
As stated, the ligneous belt-based corn infill material can be used in combination with a shock pad, carpet, and/or a stabilizing infill layer (e.g., sand) to make up the artificial turf system. The artificial turf system, using the described infill material, exhibits superior mechanical performance, a greater mechanical durability, easy availability and mitigates or otherwise avoids issues of floating away when subjected to large amounts of water.
In addition to its excellent performance on the field, this ligneous belt-based material of the corn cob also exhibits behaviors that utilize and command unique methods for installation. Specifically, the material exhibits a significant amount of expansion upon first exposure to water due to the processing and drying method as an expanding, water absorbing, and resilient infill material.
Installation Process
In some embodiments, e.g., for field installations, the infill material can include a bottom layer of sand and a top layer of the ligneous-belt corn-based infill material. In other embodiments, the ligneous-belt corn-based infill material can be applied alone in a layer. By way of example only, the ligneous-belt corn-based infill material can be used in a single layer, for example, in aspects when the layer is 15 mm or less. Similarly, the ligneous-belt corn-based infill material can be applied in 2 layers, for example, in installments that exceed 15 mm. However, as described herein and throughout, a desired installation includes a stabilizing infill layer (e.g., sand) along with an appropriate shock pad so as to achieve desired performance of the turf.
In some embodiments, the ligneous-belt corn-based infill material is compressed during its production. Therefore, once incorporated into a turf system, the infill material will be expanded via watering so as to regain or recover its original size/volume/shape. Through wetting, the ligneous-belt corn-based infill material can swell (e.g., by approximately 33% in volume) after water is applied to it. Because of that expansion, an initial free pile length can be around 25-30 mm before applying water and expansion. It will be appreciated that the field can be watered naturally by rainfall, irrigation sprinkling the field, use of a water wagon, etc. such that the ligneous-belt corn-based infill material will swell to regain its original volume.
In other embodiments, to prevent that the ligneous-belt corn-based infill material from sticking together, the field can be treated with a brushing and decompaction treatment. This brushing and decompaction treatment can take place after a waiting period, or immediately after applying the water. Of course, if there is no natural rainfall before the first use of the field, or if otherwise desired, the field can be sprinkled either by an irrigation system, by a water wagon or other suitable method. In some embodiments, a minimum amount water that should be applied such as one (1) liter per square meter. In aspects and to fully expand the ligneous-belt corn-based infill material, ideally four (4) liters per square meter, and no more than five (5) liters per square meter for optimal particle expansion. Once the original (or desired) volume has been achieved the field can be maintained as a common field.
In some embodiments, the ligneous-belt corn-based infill material can be of certain example specifications for use. For example, the ligneous-belt corn-based infill material can use a particle size distribution of ligneous-belt corn-based infill particles with an initial dry size of approximately 0.5 to 5 mm and a final (e.g., original or expanded) size of approximately 0.6 to 7 mm after wetting. In some embodiments, the ligneous-belt corn-based infill articles can include a dry bulk density reduction of 20 to 90% after the first time they are wet and expanded at the site of its use.
In yet other embodiments, the ligneous-belt corn-based infill particles can include a bulk density reduction between 30% and 50%. In still other embodiments, the ligneous-belt corn-based infill particles can include a bulk density reduction of 40%. Further, as stated herein, the ligneous-belt corn-based infill material can be used in combination with a stabilizing infill (e.g., sand) and a shock pad. By way of example and not limitation, this combination can achieve a shock absorption of 55% to 70%, vertical deformation of 4 to 11 mm as measured by advanced artificial athlete (AAA), and a critical fall height greater than 1.3 meters, similar to a conventional third generation infilled artificial turf system.
In an example installation method for installing the ligneous-belt corn-based infill material with expansion of the particles, the amount of water and rate of addition can vary based on desired results. The method can control expansion of the water absorbent ligneous-belt corn-based infill material by the amount and rate of addition of water used to expand the ligneous-belt corn-based infill.
A method of installation can include spreading the ligneous-belt corn-based infill material on a field, watering, brushing, decompaction, and redistribution. In an example, the watering can include a mass of water that is equal to twice the mass of dry expanding ligneous-belt corn-based infill material. The watering can include adding the total mass of water via a spreader to distribute the water evenly across the field or surface. The ligneous-belt corn-based infill material can be brushed and de-compacted between multiple water spreading steps.
Another method of installation can include a multiple step process to install the expanding ligneous-belt corn-based infill material. A first layer of expanding ligneous-belt corn-based infill material can be spread evenly across the field. In some embodiments, the mass of the first layer corresponds to 10 to 75% of the total amount of expanding ligneous-belt corn-based infill material. In other embodiments, the mass can be 30% to 60% of the total amount. In yet another embodiment, the mass can be 33% of the total amount. After the first layer is spread on the field, the ligneous-belt corn-based infill material can be watered. In some embodiments, the amount of water used to expand the ligneous-belt corn-based infill material corresponds to 50% to 300% of the dry weight of the ligneous-belt corn-based infill material. In other embodiments, the amount of water can be 175% to 225% of the dry weight. In yet another embodiment, the amount of water can be 200% of the dry weight of the ligneous-belt corn-based infill material. While specific percentages, timeframes and measurements are outlined herein, it is to be appreciated that other aspects can exist that differ from those disclosed. As such, these additional aspects are to be included within the spirit and/or scope of this specification and claims appended hereto.
The method can include a period which the water is spread over the ligneous-belt corn-based infill material for a time period of, for example 2 hours. In some embodiments, the method can include a waiting period of greater than 15 minutes after watering. In other embodiments, the waiting period can be greater than 4 hours before any further actions or steps. The waiting period can be adjusted depending on the weather conditions including the amount of sunshine, wind speed, temperature, and relative humidity of the air.
As disclosed herein, the ligneous-belt corn-based infill material can be brushed after watering. As needed or desired, the ligneous-belt corn-based infill material can be de-compacted. In some embodiments, the ligneous-belt corn-based infill material is preferentially de-compacted with most any suitable de-compactor that does minimal damage to the ligneous-belt corn-based infill material and carpet. In some embodiments, a second or additional layer of dry expanding ligneous-belt corn-based infill material is spread on top of the first or previous layer. The second layer of infill can be expanded with water.
In some embodiments, the dry ligneous-belt corn-based infill material can be hydrated and expanded using water or other liquids containing performance modifying solutes that alter the absorption characteristics, surface properties, or other performance related characteristics of the infill particles. While much of the aforementioned disclosure employs traditional watering techniques for hydration and expansion, other liquids, for example, those that include performance modifying solutes can be employed in conjunction with the ligneous-belt corn-based infill. These alternative aspects are to be included within the spirit and scope of the innovation and claims appended hereto.
In an example installation method, the ligneous-belt corn-based infill materials can be hydrated with water containing dissolved antifungal or antimicrobial compounds that convey those properties to the infill for slow release. Another example, would be hydration with a color dye solution meant to convey a specific color of the infill, as desired for aesthetic or functional purposes such as ultraviolet resistance and increased durability.
Examples of preservative agents that can be employed with the particles include, but are not limited to, Syzygium aromaticum extract oil, Cymbopogon genus extract oils, zinc salts such as zinc chloride, zinc pyrithione, zinc acetate, zinc sulfate; copper salts, such as copper sulfate, copper chloride, copper acetate, copper nitrate, or copper nanoparticles; silver salts, such as silver nitrate, silver chloride, or silver micro- or nanoparticles; chelating compounds, such as citrate salts, 2,3-dimercaptopropanol, and ethylenediaminetetraacetate.
In accordance with principles of the present disclosure, embodiments are directed to using ligneous-belt corn-based particles as a primary portion of the infill for an artificial turf field. Infill, as shown in FIG. 1 , refers to material that is deposited over the turf backing 120 and forms a layer 105 around the turf fibers 125. Infill is interspersed between the turf fibers 125 rising out of the turf backing 120. Infill generally has a depth that covers a portion of the turf fiber (unexposed portion of the turf fiber) leaving part of the turf fiber extending above the infill (exposed portion of the turf fiber). While a stabilizing infill and/or shock pad is not shown in FIG. 1 , it is to be appreciated that these can be employed in embodiments of the innovation as described above and below.
Infill 105 helps support the turf fibers 125 in an upright position and is used to provide traction and shock absorption. As described in detail above, in some embodiments, the infill 105 comprises a specially designed layer of engineered ligneous-belt corn-based particles. The infill 105 can be installed using a method of spreading the ligneous-belt corn-based infill material on a field, watering, brushing, de-compaction, and redistribution.
Further, the infill 105 can use a particle size distribution of ligneous-belt corn-based infill particles with an initial dry size of 0.5 to 5 mm and a final size of 0.6 to 7 mm that expands to after wetting. In some embodiments, the ligneous-belt corn-based particles can include a dry bulk density reduction of 20% to 90% after the first time they are wet and expanded at the site of its use. In other embodiments, the ligneous-belt corn-based particles can include a bulk density reduction between 30% and 50%. In another embodiment, the ligneous-belt corn-based infill particles can include a bulk density reduction of 40%. In other embodiments, the ligneous-belt corn-based infill material can be used in combination with a shock pad in order to achieve a desired shock absorption. For example, this combination of infill and shock pad can achieve a shock absorption of 57% or more than a conventional carpet or infill artificial turf system.
As a general matter, various types of infill arrangements are contemplated. For example, two layer, three layers, or other arrangements are contemplated. For convenience, the present description primarily discusses two and three layer embodiments. Embodiments of the present disclosure are directed to providing corn-based infill solutions. The materials that are discussed are primarily sand (as a stabilizing infill) and ligneous-belt corn-based infill material but it should be understood that other materials can be included or substituted.
As described herein, in accordance with embodiments of the innovation, the infill material is directed to having the ligneous-belt corn-based particles, in effect, replace crumb rubber infill materials. As such, the infill is devoid or substantially devoid of crumb rubber or similar materials. For example, in such embodiments, one layer of the infill (e.g., one of the multiple layers in the infill) can be made entirely (100% by weight), substantially (e.g., 65% or higher or 75% or higher by weight), primarily (e.g., 50% or higher by weight), or predominantly (e.g., 45% or higher by weight, or a percentage by weight that is higher than the percentage by weight of any other particle or sand in the same layer) of the ligneous-belt corn-based particles. In some embodiments, the infill can be only one layer, and the only layer can be made entirely (100% by weight), substantially (e.g., 65% or higher or 75% or higher by weight), primarily (e.g., 50% or higher by weight), or predominantly (e.g., 45% or higher by weight, or a percentage by weight that is higher than the percentage by weight of any other particle or sand in the layer) of the ligneous-belt corn-based particles. It is to be understood and appreciated that the ligneous-belt corn-based particles can provide shock absorbency and traction. It is possible for the infill layer to include other organic materials or other materials in addition to or in place of those described herein.
The infill may include or comprise ligneous-belt corn-based particles in a particular size range for dry application and expansion of particles after wetting. The range of sizes can include a size distribution of corn infill particles with an initial dry size of 0.5 to 5 mm and a final size of 0.6 to 7 mm to after wetting. The ligneous-belt corn-based particles can include a dry bulk density reduction of 20% to 90% after the first time they are wet and expanded at the site of its use, more preferably a bulk density reduction between 30% and 50%, or 40%. In some embodiments, the infill may comprise sand (e.g., in a layer) that is in a particular size range. The range of sieve-sizes for sand may be from 20 to 50 (e.g., 0.841 mm-0.297 mm).
The infill may comprise the aforementioned ligneous-belt corn-based particles and sand (as a stabilizing layer) in separate layers (one overlaying the other) or intermixed as shown in FIGS. 2-3 respectively. FIG. 2 depicts illustrative infill 205 comprising ligneous-belt corn-based particles and sand in separate layers. The first layer 210 (sequentially in the order of layers from bottom to top, where bottom is closest to the ground) is preferably a sand layer. In a second layer 215, the infill may comprise ligneous-belt corn-based particles of a desired engineered size and distribution. The second layer 215 may comprise the aforementioned ligneous-belt corn-based particles, the aforementioned fine sand, or a combination thereof. When the second layer 215 includes both the ligneous-belt corn-based particles and the sand, the ligneous-belt corn-based particles and the sand are preferably intermixed. FIG. 3 depicts illustrative infill 305 comprising a layer 310 of ligneous-belt corn-based particles and sand intermixed.
While specific embodiments are shown and described herein, it is contemplated that alternative embodiments exist that employ alternative materials, mixtures, proportions, sizes, etc. without departing from the spirit and/or scope of the innovation as described in detail. These alternative embodiments are to be included within the spirit and scope of the innovation as described and claimed herein.

Claims

What is claimed is:

1. An artificial turf comprising:

at least one layer of particles comprising ligneous-belt corn-based particles that expand upon wetting;

a stabilizing infill beneath the at least one layer of particles comprising ligneous-belt corn-based particles; and

a shock pad beneath the stabilizing infill.

2. The artificial turf of claim 1, wherein the stabilizing infill is sand.

3. The artificial turf of claim 1, further comprising a second layer of particles comprising ligneous-belt corn-based particles that expand upon wetting.

4. The artificial turf of claim 1, wherein the wetting employs water for hydration.

5. The artificial turf of claim 1, wherein the wetting employs a liquid that includes performance modifying solutes.

6. The artificial turf of claim 1, wherein the wetting employs water that includes antifungal or antimicrobial compounds.

7. The artificial turf of claim 1, wherein the wetting employs hydration with a color dye solution that conveys a specific color of the infill.

8. The artificial turf of claim 7, wherein the color dye solution provides desired aesthetic or functional purposes such as ultraviolet resistance or increased durability.

9. The artificial turf of claim 1, wherein the ligneous-belt corn-based particles include a particle size distribution of ligneous-belt corn-based particles with an initial dry size of 0.5 to 5 mm and a final size of 0.6 to 7 mm to after wetting.

10. The artificial turf of claim 1, wherein the artificial turf achieves a shock absorption of 55% to 70%, vertical deformation of 4 to 11 mm as measured by advanced artificial athlete (AAA).

11. A method of installing an artificial turf field, comprising:

spreading a layer of ligneous-belt corn-based particles over a carpet that is on a stabilizing infill base, wherein the layer of ligneous-belt corn-based particles includes dry particles;

wetting the layer of ligneous-belt corn-based particles such that the dry particles are expanded after the wetting;

brushing the layer of ligneous-belt corn-based particles; and

decompacting the layer of ligneous-belt corn-based particles such that the ligneous-belt corn-based particles are evenly distributed over the carpet.

12. The method of installing an artificial turf field of claim 11, wherein the ligneous-belt corn-based particles are compacted prior to the act of spreading.

13. The method of installing an artificial turf field of claim 11, wherein the ligneous-belt corn-based particles regain original shape post-wetting.

14. The method of installing an artificial turf field of claim 11, wherein the act of wetting is effected via rain, irrigation system or water wagon.

15. The method of installing an artificial turf field of claim 11, wherein the act of wetting employs between approximately four and five liters of liquid per square meter for particle expansion.

16. The method of installing an artificial turf field of claim 11, wherein the amount of liquid used to expand the ligneous-belt corn-based infill material corresponds to 50% to 300% of the dry weight of the ligneous-belt corn-based particles.

17. The method of installing an artificial turf field of claim 11, wherein the stabilizing infill base includes compacted stone or sand.

18. The method of installing an artificial turf field of claim 11, further comprising spreading a second layer of ligneous-belt corn-based particles over the layer of ligneous-belt corn-based particles, wherein the second layer of ligneous-belt corn-based particles includes dry particles.

19. The method of installing an artificial turf field of claim 11, wherein the wetting employs a liquid that includes a preservative agent, wherein the preservative agent is at least one of Syzygium aromaticum extract oil, Cymbopogon genus extract oils, zinc salts such as zinc chloride, zinc pyrithione, zinc acetate, zinc sulfate; copper salts, such as copper sulfate, copper chloride, copper acetate, copper nitrate, or copper nanoparticles; silver salts, such as silver nitrate, silver chloride, or silver micro- or nanoparticles; chelating compounds, such as citrate salts, 2,3-dimercaptopropanol, and ethylenediaminetetraacetate.

20. The method of installing an artificial turf field of claim 11, wherein the wetting employs a liquid that includes antifungal or antimicrobial compounds or a color dye solution that conveys a specific color to enhance ultraviolet resistance or increased durability of the artificial turf field.