WO2003060236A1

WO2003060236A1 - Subsurface layer for athletic turf

Info

Publication number: WO2003060236A1
Application number: PCT/US2002/040639
Authority: WO
Inventors: Stephen L. Linville; Joseph E. Motz; Mark A. Heinlein
Original assignee: Coevin Licensing, L.L.C.
Priority date: 2001-12-21
Filing date: 2002-12-19
Publication date: 2003-07-24
Also published as: US6800339B2; CA2471221A1; US20030118755A1; US20050042032A1; EP1456475A1; AU2002357902A1; US20040028841A1

Abstract

A subsurface layer (44) resides below the surface of an athletic field, on a foundation (46), and provides a selectable degree of shock absorption for the field located above. The subsurface layer (44) includes a subsurface backing (54) and a subsurface particulate fill material (58) of resilient particles, which is preferably retained at a height which corresponds to a desired degree of shock absorption capability for the field. The surface field may be a filled synthetic turf (42) having a plurality of pile filaments (62) extending upwardly from a backing (60) and filled with particulate fill material (64), to create a grass-like appearance, such that the fill material comprises a lower ballast layer (26) of gravel residing on the backing and an layer (30) of resilient particles (31) above the lower layer. The gravel ballast layer (26) provides weight and stability to hold down the synthetic turf, and does not migrate to the surface. The subsurface layer (44) facilitates heating or cooling of the atheletic field, and it also facilitates retrofitting prior installations of other types of fields.

Description

SUBSURFACE LAYER FOR ATHLETIC TURF

Field of the Invention

This invention relates to athletic fields and, more particularly, to a filled

synthetic turf with a subsurface layer having a selected degree of shock absorption

capability, as well as improved stability, drainage and adaptability for retrofit installations.

Background of the Invention

Natural grass turf has traditionally been cultivated on playing surfaces for

athletic games or events, hi addition to providing an aesthetically appealing surface, natural

grass turf provides inherent resiliency and cushioning, thereby minimizing the risk of injury

due to an athlete's impact with the turf. Natural grass turf coverings have traditionally been

used for "high impact" sports such as American football. Typically, athletes participating

in these high impact sports desire a surface with a high degree of resiliency, as provided by

natural grass turf.

However, maintenance of natural grass turf is expensive and time

consuming. Natural grass does not grow well within shaded areas, like those within indoor

or partially enclosed stadiums. In addition, "heavy traffic" locations on the playing field are

susceptible to wear or deterioration due to continuous or excessive wear. These worn areas may become muddy and slippery after the natural grass dies, increasing the likelihood of injury.

Therefore, various types of synthetic turf have been developed for use as athletic playing surfaces, particularly for indoor stadiums. Generally, these synthetic turfs decrease the maintenance expense and increase the durability of the playing surface, compared to natural turf. Synthetic turf generally comprises a flexible backing and a plurality of grass-like pile filaments or fibers extending upwardly from the backing. The flexible backing is typically laid on a foundation or compacted substrate, such as crashed stone or other stabilized material. Most earlier forms of synthetic turf relied solely on the backing and the pile filaments or fibers as the playing surface. ASTROTURF synthetic turf is one example of such an artificial turf. However, in more recent years there has been a movement in the industry toward synthetic turfs which look and feel more like natural grass.

To achieve this look and feel of natural grass, the pile filaments have generally increased in length, so as to more closely resemble natural grass. To give the synthetic turf a desired degree of resiliency and stability, a granular fill material is typically placed between or among the upstanding pile filaments of the synthetic turf. This granular fill material extends upwardly from the upper surface of the backing to a height below the tops of the pile filaments, thereby leaving the upper portions of the pile filaments exposed to create a playing surface which looks like natural grass. The granular fill material helps maintain the filaments of the synthetic turf in a substantially upright condition. hi the past this granular fill material has been sand, crushed slag particles, resilient foam, crumb rubber particles, sand or several different combinations of two or more of these materials. The most typical of these infill materials for synthetic turfs has been sand, because it is readily available at a relatively low cost, and it provides enough weight to hold down the backing during and after installation. This hold down aspect remains important even after installation, because filled synthetic turfs are subject to large temperature fluctuations, which results in contraction and expansion of the turf backing. A fill with at least one layer of sand stabilizes the backing of the synthetic turf and provides weight to minimize lateral movement of the backing.

U.S. PatentNo.4,044,179 discloses afilled synthetic turf for athletic playing surfaces, wherein the granular fill material is sand with a small amount of moisture retaining material. The problem with the use of sand as the fill is that sand compacts over time and use, resulting in a filled synthetic turf which is harder than desired. Because such playing surfaces are commonly used for high impact sports, the harder the field, the greater the likelihood of injury for the players using the field. Another problem with using sand as the fill material is that sand retains water or moisture, thereby increasing the susceptibility of the filled synthetic turf to mold or mildew.

U.S. Patent No. 4,337,283 discloses a filled synthetic turf for use as an athletic playing surface, the granular fill material being a uniformly mixed combination of sand particles and resilient particles. One inherent problem with the use of such a mixture is that, over time and after repeated use, the resilient particles of the mixture tend to migrate to the top of the fill layer, with the sand tending to settle below the resilient particles. The sand that settles to the bottom of the fill layer tends to compact over time and use. This ultimately results in a layered synthetic turf which is harder and more abrasive than desired.

A further disadvantage of an initially uniform mixture of this type is that the top surface never remains completely mixed. Inevitably the top surface will have some localized regions of abrasive sand particles. This means that the playing surface is not uniform in performance characteristics across its entire surface area. It also means that for some regions of the field, players will inevitably come into contact with the sand particles and may suffer skin abrasions.

U.S. Patent No. 5,958,527 discloses a filled synthetic turf with an infill of sand and resilient particles which are specifically layered, in an effort to overcome the above-described problems of a uniformly mixed sand/rubber infill. More particularly, the granular fill material comprises three separate layers of particles, with sand at the bottom, resilient particles at the top and a mixture therebetween. While this may be an improvement over prior uniformly mixed infills, the improvement tends to be short-lived. Over time and after repeated use, the sand at the bottom of the mixture tends to compact, causing the field to harden and to inhibit the vertical drainage of water off the field through the backing of the filled synthetic turf.

Also, as a synthetic field is used over time, the cleats of athletes tend to churn up and mix the various fill materials. Thus, even if a layered infill is used, eventually this cleat churning will result in some abrasive sand particles finding their way to the surface of the synthetic turf between the pile filaments. This results in upper areas of exposed sand, which means the playing surface lacks uniformity. Also, whenever an athlete falls or contacts the turf, the athlete is susceptible to cuts or abrasions due to the sand. The sand particles located at the surface of the fill material are also abrasive to the pile filaments of the synthetic turf, thereby degrading and/or fibrillating the tops of the pile filaments over time, hi short, based on applicants' present understanding of filled artificial fields, for infills with a mixture of sand and resilient particles, whether uniformly mixed or layered, the resilient effect of the rubber particles is only temporary.

Therefore, it is an object of the present invention to sufficiently hold down the backing of a filled synthetic turf, while eliminating the adverse effects presently associated with the use of sand. It is another obj ect of the present invention to extend the life of the resilient characteristics of a filled synthetic turf, while still maintaining a high degree of directional stability for the synthetic backing.

It is still another object of the present invention to attain a longer lasting, uniforaily resilient athletic playing surface at a relatively low cost, preferably with the playing surface being sufficiently versatile in design to accommodate a number of other diverse structural enhancements, including such enhancements as better drainage, the ability to build in a desired degree of shock absorption, and the ability to more easily retrofit other field installations.

Summary of the Invention

The present invention accomplishes these objects for a filled synthetic turf by a subsurface layer which has a selectable degree of shock absorption capability. This enables the owner or manager of the field to construct a field which has shock absorbency characteristics that are particularly suited for the dominant sport to be played on the field, i other words, the owner or manager can gauge and selectively constract a field with a particular degree of shock absorption.

To do this, the subsurface layer has a flexible subsurface backing with a plurality of subsurface pile filaments extending upwardly to a desired height. A subsurface particulate fill material resides on the subsurface backing to a desired vertical level relative to the desired height of the subsurface pile filaments. The subsurface fill material includes at least some resilient particles, preferably rubber. The subsurface fill material may be layered, with gravel or sand as a lower layer and resilient particles such as rubber particles as an upper layer. It could also be entirely rubber particles. The subsurface particulate fill material is preferably retained, or held in place, at the desired vertical level with a binder, such as a polymeric coating, applied to the subsurface fill material and the subsurface pile filaments in liquid form. Other binders such as latex or urethane could be used to hold the subsurface fill material in place.

The binder may be many different materials applied and activated different ways. In one aspect of the present invention, the binder is a polymeric coating applied to the subsurface fill material and the subsurface pile filaments by spraying. Other binders maybe applied in liquid form such as latex or urethane to hold the subsurface fill material in place. These binders may be activated by the application of heat, water or any other means. Some of these binders may assume a solid particulate form and be mixed in with the subsurface particulate fill material before being activated.

Alternatively, a fabric sheet could be laid over the subsurface particulate fill material. This variation of the invention could be helpful if the field were to be used only as a temporary installation, perhaps if the particulate fill material were to be recycled for another use or for a different field. With this particular variation of the present invention, the composition and height of the subsurface particulate fill material, the height of the subsurface pile filaments and/or structure or method used to retain the particulate are selected to achieve a desired degree of shock absorption for the subsurface and for the athletic field located thereabove. In one aspect of the invention, the playing surface may actually be natural grass, supported by the subsurface layer.

For the embodiments of the invention employing a filled synthetic turf as the athletic field playing surface, it is preferred that the filled synthetic turf have a dual- layered particulate fill. This dual layer includes a lower layer of a heavy and relative large particulate such as gravel, to serve as a "ballast" to hold down the backing and an upper layer of resilient particles, such as rubber, residing over the ballast layer, h one aspect of the present invention, the height of the first lower layer is approximately equal to the height of the second upper layer. However, different circumstances for different fields, perhaps depending on the sport for which the field is primarily designated, may result in a desire or a need to have the first lower layer and the second upper layer of different desired heights. There may even be some circumstances where the particulate fill material essentially comprises a generally uniform mixture of ballast particles and resilient particles.

The filled synthetic turf comprises a flexible backing residing on a foundation, a plurality of grass-like pile filaments secured to the backing and extending generally upwardly and a particulate fill material residing on the backing. The foundation may be crushed stone, dirt, asphalt, concrete, a pad or any other supporting surface. If the turf is used outdoors, the backing should be water permeable. The backing may be a single layer of material or multiple layers of material joined together. Also, for drainage purposes one or more drainage members maybe installed over, or comprise part of, the foundation.

A plurality of grass-like pile filaments are secured to the backing and extend generally upwardly therefrom. The pile filaments preferably comprise synthetic ribbons of a selected length. They may be made of nylon, polyethylene or a polyethylene/polypropylene blend or any other suitable material. They may be tufted, adhesively or otherwise joined to the backing. The pile filaments are preferably dyed or colored green so as to resemble the appearance of natural grass. The fill material resides upon the backing and extends upwardly to a desired height which is below the tops of the pile filaments. This gives the field a green appearance, resembling natural grass. In addition, the particulate fill helps to prevent the pile filaments from moving or becoming trampled down.

In one aspect of the present invention, the playing surface may be heated or cooled by conveying heating or cooling upwardly from the subsurface layer and to the playing surface. One way to do this would be to install tubing within the subsurface fill material, above the subsurface backing but below the top ends of the subsurface pile filaments. The tubing would be adapted to be operatively connected to a pump or other fluid supply device, in order to convey heating or cooling fluid within the tube and to selectively heat or cool the subsurface and the filled synthetic turf located above the subsurface. The tubing could be installed in a number of different ways.

The objects and features of the present invention will become more readily apparent from the following detailed description and the accompanying drawings.

Brief Description of the Drawings

Fig. 1 is a cross-sectional view of a filled synthetic turf according to one embodiment of the invention.

Fig. 1A is a cross-sectional view of the filled synthetic turf of Fig. 1, but with a drainage layer residing below the synthetic turf. Fig. IB is a cross-sectional view of a variation of the filled synthetic turf shown in Fig. 1, with the particulate fill being a mixture of gravel and rubber.

Fig. 2A is a cross-sectional view of a first preferred embodiment of the invention, illustrating a filled synthetic turf residing on a subsurface layer which provides a selected degree of shock absorption, and which shows an alternative option of or the invention, a fabric retainer for holding the subsurface layer.

Fig. 2B is a cross-sectional view of a variation of the first preferred embodiment of the invention, illustrating a filled synthetic turf residing on a subsurface layer which is held in place by a binder. Fig. 2C is a cross-sectional view of another variation of the preferred embodiment of the invention, illustrating a filled synthetic turf residing on a subsurface layer which is bound, or retained in place, by a polymeric coating.

Fig. 2D is a cross-sectional view of yet another variation of the preferred embodiment of the invention, illustrating a filled synthetic turf residing on a subsurface layer, but with tubing extending through the subsurface layer to facilitate heating or cooling.

Fig. 3^. is a schematic which shows, in perspective view, a heating/cooling system which may be operatively connected to the tubing shown in Fig. 2D. Fig. 3B is a schematic, similar to Fig. 3 A, which shows a perspective view of another structure for heating an athletic field.

Detailed Description of the Preferred Embodiments

Fig. 1 illustrates a filled synthetic turf 10 according to the present invention. The filled synthetic turf 10 rests on a foundation 12. The foundation 12 may take any one of many known forms and may include crushed stone or the like, as known in the athletic playing field industry. The filled synthetic turf 10 includes a backing 14 residing on the foundation 12. The backing 14 is preferably made of a flexible, water permeable material, but may be made of any other suitable type of material. If desired, the backing 14 may comprise multiple layers joined together. A plurality of grass-like pile filaments 16 are secured to the backing 14 and extend generally upwardly, tenninating at ends 17. The pile filaments 16 comprise synthetic ribbons of a selected length and maybe made of nylon, polyethylene, a polyethylene/polypropylene blend, or any other appropriate material. The pile filaments 16 maybe tufted to the backing 14, glued to the backing 14, or secured to the backing in other suitable manner. Aparticulate fill material 18 resides on the backing 14 and extends upwardly from the backing 14 to a desired height H. The particulate fill material 18 has a lower surface 19 residing on the backing 14 and an upper surface 20 which is located a distance D below the tops or ends 17 of the pile filaments 16. Thus, each of the pile filaments 16 has a lower portion 22 located inside the particulate fill material 18 and an upper portion

24 located above the particulate fill material 18. The upper portions 24are green and resemble natural grass. The particulate fill material 18 helps stabilize the pile filaments 16 in place and helps prevent the pile filaments 16 from becoming trampled or run-down. As shown in Fig. 1, the particulate fill material 18 has two layers, including a first lower layer 26 of ballast particles 27, such as gravel, located on the backing 14 and extending upwardly from the backing 14 a distance D_x to an upper surface 28. A second upper layer 30 of resilient particles 31 rests on the upper surface 28. The first lower layer 26 provides weight and stability for the synthetic turf and helps hold the backing 14 in its desired location. The second upper layer 30 of resilient particles 31, such as rubber, provides resiliency for the synthetic filled turf 10. The resilient particles 31 are preferably synthetic particles such as rubber particles, commonly referred to as crumb rubber. The second upper layer 30 is of a height D₂ extending from the upper surface 28 of the lower layer 26 to the upper surface 20 of the particulate fill material 18.

In this aspect of the present invention, the particulate fill material 18 is divided into at least two layers: a first lower layer 26 of ballast particles 27 located on top of the backing 14 and a second upper layer 30 of resilient particles 31 residing above the first lower layer 26. The first lower layer 26 comprises particles such as gravel which provide weight for holding the backing in place. According to the United States Golf Association (U.S.G.A.), gravel is defined as particles having a diameter greater than 2 millimeters and sand is defined as particles having a diameter less than 2 millimeters. Fine gravel is defined by the U.S.G.A. as particles having a diameter between 2 and 3.4 millimeters. Although the U.S.G.A. uses diameter to measure particulate size, theparticles of the present invention need not be symmetrical, i.e. have a diameter. They may be irregularly shaped. The ballast particles 27 of the present invention are not intended to be limited to gravel. One type of ballast particle 27 which is suitable for the present invention has the following analysis: 100 percent passing through a 0.5 inch (12 millimeter) sieve; not more than 10 percent passing through a number 10 (2 millimeter) sieve; and not more than 5 percent passing through a number 18 (1 millimeter) sieve.

Fig. 1 A shows a filled synthetic turf 10a similar to that of Fig. 1. However, the foundation 12a is slightly different. The foundation 12a shown in Fig. 1 A has a solid lower portion 32 and an upper portion 34 comprising at least one drainage member 35 extending upwardly from the lower portion 32 a distance D₃. The drainage member 35 is illustrated as a molded plastic sheet having a plurality of indentations 36 and a backing piece 38. One type of drainage member which has been used successfully is manufactured by the Nickelon Corporation of Norcross, Georgia, and sold under the trademark

MIRADRI. This material comes in rolls, and it is rolled over the lower portion 32 during installation, in end to sections laid out in parallel rows.

Fig. IB shows a filled synthetic turf 10b similar to that of Fig. 1. However, in fig. IB the particulate fill material 18b is not divided into layers, but instead is a mixture of ballast particles such as gravel and resilient particles such as crumb rubber. Other particles may be included if desired. The particulate fill material 18b extends upwardly from the backing 14b to a height H, to an upper surface 20b which is located below the tops 17b of the pile filaments 16b.

Figs. 2A through 2D illustrate alternative aspects of the preferred embodiment of the present invention, in which at least one subsurface layer resides below the upper filled synthetic turf used for an athletic field. This subsurface layer provides a selected degree of shock absorption for the playing surface, and this can be determined by the composition and structure of several components, as explained later. Generally, the desired amount of shock absorption of the field will be gauged to correspond to the particular sport for which the playing surface will be used.

Fig.2A illustrates a filled synthetic turf 40 having an upper surface layer 42 of filled synthetic turf and a lower subsurface layer 44 resting on a foundation 46 below the upper surface layer 42. The foundation 46 includes a lower portion 48 which is illustrated as being a solidbase, but this maybe crashed stone or any other structurally stable material. Fig. 2A also shows an upper portion 50 which may be one or more drainage members, as described above and shown in Fig. 1A. Alternatively, the foundation 46 maybe uniform like the foundation 12 illustrated in Fig. 1.

In essence, the drainage layer 50 resides between the underlying base structure 48 and the subsurface layer 44. Practically speaking, the drainage layer 50 could be regarded either as an intermediate layer or as part of the foundation, depending on the terminology used by the contractor. This may also depend on whether the field is located indoors or outdoors.

Directly above the drainage layer 50, the subsurface layer 44 comprises a subsurface backing 54 having a plurality of subsurface pile filaments 56 secured thereto and extending upwardly to a desired height H₂. The subsurface pile filaments 56 maybe tufted or secured in any suitable manner to the subsurface backing 54. A subsurface particulate fill material 58 resides on the subsurface backing 54 and extends upwardly a distance about equal to the height H₂ of the subsurface pile filaments 56. The subsurface particulate fill material 58 may be homogenous, as shown, or it may be layered, or a mixture. In any case, the particulate fill 58 should include resilient particles, such as crumb rubber. With further reference to Fig. 2A, the surface layer 42 comprises a filled synthetic turf having a surface backing 60 residing on top of the subsurface layer 44. A plurality of surface pile filaments 62 are tufted or otherwise secured to the surface backing 60. A surface particulate fill 64 resides on the surface backing 60 to a desired vertical height H₃. As shown in Fig. 2A, the surface particulate fill 64 is a homogenous material including at least some resilient particles such as crumb rubber. However, the surface particulate fill 64 may be any known particulate combination. The surface pile filaments 62 have upper end portions 66 extending above an upper surface 68 of the surface particulate fill 64, to form the grass-like surface. To achieve a desired degree of shock absorption, the subsurface layer 44 and more particularly the subsurface pile filaments 56 and/or the particulate 58 may be varied in height. The greater the desired degree of shock absorption, the greater the height of the subsurface layer 44. hi addition, the composition of the subsurface particulate fill material 58 may be modified to obtain the desired degree of shock absorption. For instance, the proportion of crumb rubber to other particulate, such as sand, may be increased, even up to 100% rubber, hi most cases, the level of the particulate 58 and the pile filaments will be about the same height.

Fig. 2 A shows a retainer 84, in this case a geotextile fabric, for holding the particulate 58 at the height H₂. This retainer 84 prevents lateral migration of the particulate, promotes uniform stability and also allows the particulate 58 to be reclaimed for recycling, if that is desired. This may be desirable in circumstances where the field is only used temporarily.

Fig.2B illustrates avariation of the preferred embodiment shown inFig.2A. For simplicity, this variation of the preferred embodiment utilizes the same numbers for corresponding elements as Fig. 2A, but with a "b" designation after the appropriate numeral. Fig.2B also shows filled synthetic turf 40b comprising an upper surface layer 42b and a lower subsurface layer 44b resting directly on a foundation 46b . If desired, a drainage layer may reside on foundation 46b below lower subsurface layer 55b above.

The subsurface layer 44b comprises a subsurface backing 54b having subsurface pile filaments 56b secured thereto and extending upwardly to a desired height

H₄. A subsurface fill material 58b resides on the subsurface backing 54 and extends upwardly to a height H₄, about the height of the subsurface pile filaments 56b. The subsurface fill material 58b includes a first lower layer 70 of gravel extending upwardly from the backing 54b a distance D₄ to an upper surface 72. A second upper layer 74 of resilient particles rests on the upper surface 72 of the first lower layer 70. The first lower layer 70 provides weight and stability for the subsurface layer 42b and helps hold the subsurface backing 54b in its desired location. The second upper layer 74 of resilient particles, such as rubber, provides resiliency for the upper layer of synthetic filled turf. The second upper layer 74 is of a height D₅ extending from the upper surface 72 of the lower layer 70 to the tops of the subsurface pile filaments 56b. hi order to hold the subsurface fill material 58b in place, a binder 75 is mixed therein. The binder 75 is illustrated in Fig. 2B as particles located throughout the second upper layer 74c of the subsurface fill material 58b. The binder 75 may be pellets of latex or polyethylene which are activated by water, heat or any other suitable method. The binder retains the particulate at a desired vertical level equivalent to height H₄.

As described above, to achieve a desired degree of shock absorption, the subsurface layer 44b may be varied in height, and the composition of the subsurface particulate fill 58b may also be varied, to accommodate the sport to be played on the surface. Referring to Fig. 2B, the surface layer 42b comprises a filled synthetic turf having a backing 60b and a plurality of surface pile filaments 62b tufted or otherwise secured to the backing 60b in any suitable manner, to extend upwardly to a desired height. A surface particulate fill 64b resides on the surface backing 60b to a desired vertical height H₅. The surface pile filaments 62b have upper portions 66b extending above an upper surface 68b of the surface particulate fill 64b. h the embodiment illustrated in Fig. 2B, the surface particulate fill 64b is a homogenous material, namely resilient particles such as crumb rubber. However, the surface particulate fill 64b maybe layered with other particles, preferably including at least some resilient particles for shock absorption. Fig. 2C illustrates another variation of the preferred embodiment of the invention shown in Fig.2A. For simplicity, this embodiment utilizes the same numbers for corresponding elements as the embodiments illustrated in Figs. 2A and 2B but with a "c" designation after the appropriate numeral.

Fig. 2C shows a filled synthetic turf 40c comprising a foundation 46c, a lower subsurface layer 44c of selected shock absorption capability resting on the foundation

46c, and an upper surface layer 42c of filled synthetic turf. The subsurface layer 44c has a subsurface backing 54c with a plurality of subsurface pile filaments 56c secured thereto and extending upwardly to a desired height H₆. A subsurface fill material 58c resides on the subsurface backing 54c, to a distance equal to the height H₅ of the subsurface pile filaments 56c. The subsurface fill material 58c includes a first lower layer 70c of gravel, which extends upwardly a distance D₆ to an upper surface 72c of the first lower layer 70c, and a second upper layer 74c of resilient particles resting on the upper surface 72c of the first lower layer 70c. The first lower layer 70c provides weight and stability for the subsurface layer and helps hold the subsurface backing 54c in its desired location. The second upper layer 74c of resilient particles, such as rubber, provides resiliency for the upper layer of synthetic filled turf. The second upper layer 74c is of a height D₇ extending from the upper surface 72c of the lower layer 70c to the tops of the subsurface pile filaments 56c. As with the other subsurface layers disclosed, for subsurface layer 44c the composite and depth of the subsurface fill 58c, the height pile and filaments 56c are selected to achieve a desired degree of shock absorbency for the athletic field.

To hold or retain the subsurface fill material in place, a binder 71 is layered on top of the subsurface fill material 58c. The binder 71 is illustrated in Fig. 2C as a polymeric coating layer located on top of the second upper layer 74c. The polymeric coating layer may be a urethane sprayed in liquid form on top of the particulate fill 58c via a nozzle, with the coating thereafter being allowed to set in order to hold the particulate 58c in place, prior to installing the surface layer 42c.

Fig.2C shows the surface layer 42c as a filled synthetic turf having a surface backing 60c residing on subsurface layer 44c. A plurality of surface pile filaments 62c are tufted or otherwise secured to the backing 60c in any suitable manner. A surface particulate fill 64c resides on the surface backing 60b to a desired vertical height H₇. The surface pile filaments 62c each have an upper portion 66c extending above an upper surface 68c of the surface particulate fill 64c.

The surface particulate fill 64c has two layers, a lower layer 76 and an upper layer 78. The surface fill material 64c includes a first lower layer 76 of gravel extending upwardly from surface backing 60c a distance D₈ to an upper surface 77. A second upper layer 78 of resilient particles is located above the upper surface 77. The first lower layer 76 provides weight and stability for the subsurface layer and helps hold the surface backing 60c in its desired location. The second upper layer 78 of resilient particles, such as rubber, provides resiliency for the upper layer 42c of synthetic filled turf. The second upper layer 78 is of a height D₉ extending from the upper surface 77 to an upper surface 68c which is spaced below the tops of the surface pile filaments 62c.

Fig. 2D shows another variation of the invention, which allows heating or cooling of the playing surface from a location below the playing surface. More specifically, hollow tubing 82 extends through the subsurface layer 44. The tubing 82 comprises an exterior wall 84 having a hollow interior 86 such that fluid (not shown) may flow therethrough. The tubing 82 resides within the subsurface fill material above the subsurface backing and below the tops of the subsurface pile filaments. The tubing 82 is adapted to be operatively connected to a pump to convey heated or cooled fluid through the tubing 82 to selectively heat or cool the subsurface, thereby causing the heating or cooling to move upwardly to the surface layer 42.

Fig. 3A shows, in schematic form, more details of a heating or cooling system, but in this case connected to tubes which reside within the surface layer of particulate. hi other words, the invention contemplates a subsurface tubing circuit located relatively close to the athletic playing surface, to generate heating or cooling which is conveyed upwardly to the playing surface. More specifically, Fig. 3A shows a filled synthetic turf 10 having a lower layer 26 of particulate and an upper layer 30 of particulate fill material. For the sake of simplicity, the numerals used to describe the embodiment shown in Fig. 1 are repeated. Multiple interconnected tubes 86 are operatively connected to a fluid source 88 which contains water or air, for example. A pump 90 or other suitable structure conveys or forces fluid (not shown) from the fluid source 88 into the tubes 86. A heating/cooling system 92 heats or cools the fluid to the appropriate temperature. The tubes 86 may be arranged in any desired configuration, such as a serpentine or herringbone configuration. The tubes 86 are illustrated as residing within the first lower layer 26 of gravel. However, the tubes 86 may reside within the upper layer 30, or within both layers, if desired. Alternatively, if a homogenous particulate fill material is used the tubes maybe located at any desired depth therein. Preferably, if the athletic playing surface has a subsurface layer, the tubes reside within the subsurface layer.

Fig. 3B illustrates another aspect of the present invention, in this case another way to heat a filled synthetic turf 10. To heat the filled synthetic turf 10, the backing 14 of the surface layer is made to incorporate or include accompanying resistive heaters, thereby creating an electric heating grid. A power source 94 supplies electrical energy to the backing 14 to generate heat. This manner of heating may be used with any type of turf having a backing, regardless of the particulate fill material, so long as the backing can be used as an electrical grid. This could be done with the subsurface backing or with the backing of a stabilized natural turf. For all manners of heating or cooling, it is believed that a lower surface layer of gravel will more effectively convey heat upwardly and also retain heat which is generated below. Thus, it is believed that the present invention not only provides effective heating for a playing surface, but also does so in an efficient and cost-effective manner.

In use, the rolls of the subsurface layer are unrolled in side by side rows on a foundation where the athletic playing surface is to be located. The rows are preferably about 8 feet in width, but maybe any desired width of the manufacturer. Adjacent strips are sewn or j oined together along the longitudinal edges thereof, using any conventional j oining method. More particularly, the subsurface backing of the subsurface layer is placed on the foundation and/or on the drainage layer. If a drainage layer is used, the drainage members are unrolled in place on the lower foundation, in end to end fashion and in parallel rows, so as to cover the entire lower foundation. The foundation may be a prepared base, or even an asphalt packing lot, or it may be a stable surface left from a prior athletic field. The present invention is versatile enough to accommodate these various possibilities. A subsurface particulate fill material is then placed on the subsurface backing to a desired vertical height, using a spreader. The subsurface pile filaments are moved or urged into a generally vertical orientation by a brushing with a vehicle-mounted broom device, as is known in the industry. The subsurface layer is filled to the desired fill depth, which will typically match the height of the subsurface pile filaments, and if desired, the subsurface layer is then retained in place, as by the spraying on of a binder in liquid form. Thereafter, the surface layer is installed, using essentially the same steps, but with different fill depths for the surface particulate. That is, the pile filaments of the synthetic turf extend above the upper surface of the fill material. If the tubing circuit is to be located in the subsurface layer, it may be placed on the subsurface backing after initial unrolling of the subsurface, and before any filling of the subsurface.

Alternatively, the tubing maybe installed by routing out the filled subsurface after the liquid binder has been applied and has set. Another option for installing the tubing involves initially burning away, with a heating torch, the subsurface pile filaments in a desired pattern representing the layout for the tubing, then filling the subsurface particulate on the entire subsurface backing, followed by applying vacuum to the "pattern" to remove the particles from the pattern, and then laying the tubing within the vacuumed pattern. Thereafter, the entire subsurface maybe covered, so as to be retained, with a liquid binder or a fabric retainer.

From the above disclosure of the general principles of the present invention and the preceding detailed description of at least one preferred embodiment, those skilled in the art will readily comprehend the various modifications to which this invention is susceptible. Therefore, we desire to be limited only by the scope of the following claims and equivalents thereof.

Claims

We claim:

1. A filled artificial turf playing surface residing over a foundation, the filled artificial turf including a flexible surface backing with a plurality of grass-like pile filaments extending generally upwardly therefrom, and a surface particulate fill layer residing on the surface backing to a desired height, the invention further characterized in that: a subsurface layer resides between the foundation and the backing, the subsurface layer including a flexible subsurface backing residing over the foundation, a plurality of subsurface pile filaments extending generally upwardly from the subsurface backing and a subsurface particulate fill material residing on the subsurface backing to a desired subsurface height, the subsurface particulate fill material including resilient particles, whereby the composition of the subsurface particulate fill material and the desired subsurface height are selected to achieve a desired degree of shock absorption for the filled artificial turf playing surface residing thereabove.

2. The filled artificial turf of claim 1 and further comprising; means for retaining the subsurface particulate fill material at the desired subsurface height.

3. The filled artificial turf of claim 2 wherein the means for retaining further comprises: a binder holding the subsurface particulate fill material and the subsurface pile filaments together in place and holding the subsurface particulate fill material and the subsurface pile filaments to the subsurface backing.

4. The filled artificial turf of claim 3, the binder is a polymeric binder and has been applied in liquid form.

5. The filled artificial turf of claim 1 wherein the means for retaining comprises a fabric residing in contact with and over the top of the subsurface particulate fill material.

6. The filled artificial turf of claim 5 wherein the fabric comprises a flexible geotextile fabric.

7. The filled artificial turf of any one of the previous claims wherein the subsurface particulate fill material comprises rubber particles.

8. The filled artificial turf of any one of the previous claims wherein the surface particulate fill layer includes a lower layer of gravel located on the surface backing.

9. The filled artificial turf of any one of the previous claims and further comprising: a drainage layer residing between the foundation and the subsurface backing.

10. The filled artificial turf of claim 9 wherein the drainage layer further comprises: a plurality of parallel rows of drainage members laid end to end.

11. The filled artificial turf of any of the previous claims and further comprising: means for heating or cooling the filled artificial turf playing surface, said means located below the top of the surface particulate fill layer so that the heating or cooling is conveyed upwardly to the grass-like pile filaments.

12. The filled artificial turf of claim 11 wherein the means for heating or cooling resides within the subsurface layer so that the heating or cooling originates within the subsurface layer prior to being conveyed upwardly.

13. The filled artificial turf of either claim 11 or 12, the means for heating or cooling further comprising: a subsurface tubing circuit residing within the subsurface particulate fill material, the subsurface tubing circuit adapted to convey fluid therein for selectively heating or cooling the subsurface layer and conveying said heating or cooling upwardly.

14. The filled artificial turf of any of the previous claims wherein the subsurface fill material extends upwardly to a vertical level about the same as the desired height of the subsurface pile filaments.

15. The filled artificial turf of any of the previous claims wherein the subsurface layer is water permeable.

16. A method of constructing on a foundation a subsurface for an athletic field, comprising the steps of: placing a subsurface layer on the foundation, the subsurface layer including a subsurface backing with a plurality of subsurface pile filaments extending generally upwardly therefrom; filling a subsurface particulate material on the subsurface backing to a desired vertical level, the subsurface particulate material including resilient particles; retaining the subsurface particulate material on the subsurface backing at the desired vertical level, thereby to hold the subsurface particulate material in place relative to the subsurface backing; and installing a surface layer on the subsurface layer, the surface layer serving as an athletic field, the composition of the subsurface particulate material and the desired vertical level being selected to achieve a desired degree of shock absorption capability for the athletic field.

17. The method of claim 17 wherein the retaining step comprises: spraying a binder on the subsurface particulate material, prior to said installing step .

18. The method of either of claims 16 or 17 and further comprising the step of: installing a drainage layer on the foundation prior to said placing step, the subsurface layer residing on the drainage layer.

19. The method of any one of claims 16-18 wherein the athletic field is natural grass.

20. A filled synthetic turf comprising: a foundation; a backing residing on the foundation; a plurality of grass-like pile filaments secured to the backing and extending generally upwardly therefrom; and a particulate fill material residing on the backing to a desired height, the pile filaments extending above the fill material, the fill material including a first lower layer of gravel located on the backing and a second upper layer of resilient particles, wherein the first lower layer provides weight for holding down the backing and the second upper layer provides resiliency for the synthetic turf.

21. The filled synthetic turf of claim 20 wherein the second upper layer of resilient particles comprises synthetic particles.

22. The filled synthetic turf of claim 20 or 21 wherein the synthetic particles are rubber.

23. The filled synthetic turf of any of claims 20-22 wherein the height of the first lower layer is about equal to the height of the second upper layer.