An underlayment layer is configured to support an artificial turf assembly. The underlayment layer comprises plurality of panels, each panel comprising a core with a top side and a bottom side. The top side has a plurality of top projections. The top projections form top side water drainage channels. The panels have edges, with the edges of one panel abutting the edges of adjacent panels, thereby forming a drainage path between adjacent panels. The panel edges have vertical support extensions that extend into the drainage paths between adjacent panels. The vertical support extensions have an upper surface for supporting an artificial turf assembly overlying the turf underlayment layer, and the panel edges having one or more complementary indentations corresponding to vertical support extensions of adjacent panels. When the panels move toward each other, thereby closing drainage paths between adjacent panels, the vertical support extensions are received in the corresponding indentations.

Disclosed are methods for making shock absorbing pads utilizing reclaimed artificial turf and reclaimed carpet materials. It is demonstrated that the artificial turf systems comprising inventive pads exhibit improved Head Impact Criteria (HIC) and cradle-to-cradle score.

The present invention relates to a face spinneret and/or nylon face fiber having a certain shape and dimension which impart improved characteristics to the fiber, such a softer feel and a reduced sheen. In another embodiment, the invention is directed to a thatch spinneret and/or nylon thatch fiber having a certain shape and dimension which impart improved characteristics to the fiber, such a softer feel and a reduced sheen.

The invention comprises a method of making synthetic turf. The method comprises applying an ethylene-vinyl acetate copolymer adhesive to a first primary surface of a tufted primary backing to form a coating thereon and wherein the primary backing is tufted with a plurality of synthetic filaments to form a face pile extending outwardly from a second primary surface of the synthetic turf opposite the first primary surface and heating the ethylene-vinyl acetate copolymer adhesive to a temperature above its melting point so that the ethylene-vinyl acetate copolymer adhesive melts and at least partially flows into the primary backing. The method also comprises heating a linear low-density polyethylene film to a temperature below the softening point of the film and pressing the heated linear low-density polyethylene film into contact with the polymer coated first primary surface of the tufted primary backing. The method further comprises allowing the ethylene-vinyl acetate copolymer adhesive and the linear low-density polyethylene film to cool, whereby the linear low-density polyethylene film is adhered to the tufted primary backing.

An artificial grass product has 100% nylon face fabric which forms blades of grass when tufted. This grass shows a melt temperature exceeding 400 degrees Fahrenheit, at least about 100 degrees hotter than prior art materials. The thatch can be made of similar materials for at least some embodiments. When coupled with multiple yarns extending from common penetrations, quite durable and attractive products can be provided. Furthermore, resiliency in excess of 10% over prior art polyethylene or polypropylene grass products can be experienced with at least some embodiments.

An artificial turf system comprises a resilient layer, an artificial grass layer comprising a substrate and pile fibers upstanding from the substrate and an infill layer. The infill layer comprises smooth, hard granules having a mean size of between 1.8 mm and 10 mm disposed on the substrate and interspersed between the pile fibers. The smooth, hard granules provide improved characteristics in terms of foot release.

Disclosed are methods for making shock absorbing pads utilizing reclaimed artificial turf and reclaimed carpet materials. It is demonstrated that the artificial turf systems comprising inventive pads exhibit improved Head Impact Criteria (HIC) and cradle-to-cradle score.

Disclosed are artificial turfs having a nonwoven backing layer and a plurality of turf fibers extending through the nonwoven backing layer such that a face side portion of the turf fibers extends from the face side of the nonwoven backing layer and a back side portion of the turf fibers extends from the back side of the nonwoven backing layer, wherein at least a portion of the back side portion of turf fibers are bonded to themselves. Also disclosed herein are the methods of making the same.

An underlayment layer is configured to support an artificial turf assembly. The underlayment layer comprises plurality of panels, each panel comprising a core with a top side and a bottom side. The top side has a plurality of top projections. The top projections form top side water drainage channels. The panels have edges, with the edges of one panel abutting the edges of adjacent panels, thereby forming a drainage path between adjacent panels. The panel edges have vertical support extensions that extend into the drainage paths between adjacent panels. The vertical support extensions have an upper surface for supporting an artificial turf assembly overlying the turf underlayment layer, and the panel edges having one or more complementary indentations corresponding to vertical support extensions of adjacent panels. When the panels move toward each other, thereby closing drainage paths between adjacent panels, the vertical support extensions are received in the corresponding indentations.

Disclosed is an artificial turf. In the present disclosure, nylon is used as the main material. Through selecting straight fibers and curve fibers with certain cross-sectional shapes, lengths and widths and using the straight fiber and curve fiber together, the obtained grass fibers not only have relatively good temperature resistance, but also good handfeed, wear resistance, anti-aging performance, grass fiber resilience, trampling resistance and grass uprightness.