Pre-Cut Synthetic Turf Grids

Abstract

My invention modifies synthetic turf in its traditional solid roll turf form for distribution and sale by adding a manual or machine design cutting process to change the overall look and shape of the finished turf material offering a new and improved method of design and application allowing seamless integration and use with other materials for hardscape installations.

Claims

1) A synthetic turf system configured for placement atop a supporting sub-base, said synthetic turf system configured to simulate an elongate walkway, and comprising: A) an elongate turf layer configured to be manipulated into an uninstalled form such as by rolling or folding and also configured to be manipulated into an installed form such as by unrolling or unfolding when in said placement atop said supporting surface, said elongate turf layer itself comprising: 1) an elongate substantially planar backing layer having an upper side and a lower side, said lower side configured for placement atop said supporting sub-base; and 2) a plurality of elongate turf fibers, wherein each of said elongate turf fibers has one end attached proximate said elongate substantially planar backing layer, and each fiber also has a free end extending from said upper side of said elongate substantially planar backing layer, such that said elongate turf fibers extend in a generally coparallel manner such that they and said elongate substantially planar backing layer combine to simulate said elongate turf layer, wherein said elongate turf layer defines a plurality of cut-out voids extending completely through said elongate turf layer, B) a plurality of elements each configured to be placed into a corresponding one of said plurality of cut-out voids and atop said supporting sub-base, such that said turf layer combines with said plurality of elements to provide a finished product simulating an elongate walkway.

2) The synthetic turf system as claimed in claim 1, wherein said elongate turf layer in subsection A is configured to be manipulated into an uninstalled form by rolling and also configured to be manipulated into an installed form such as by unrolling.

3) The synthetic turf system as claimed in claim 2, wherein said cut-out voids are arranged in a recognizable repeating pattern.

4) The synthetic turf system as claimed in claim 1, wherein said cut-out voids are arranged in a recognizable repeating pattern.

5) The synthetic turf system as claimed in claim 1, wherein said elongate turf layer in subsection A replicates the look of grass.

6) The synthetic turf system as claimed in claim 1, wherein said elongate turf layer in subsection A is tufted polypropylene.

7) The synthetic turf system as claimed in claim 1, wherein said plurality of elements in subsection B are pavers, stones, bricks, tiles, or wood members.

8. A method of manufacturing a synthetic turf system configured for placement atop a supporting sub-base, said method comprising A) providing an elongate turf layer configured to be manipulated into an uninstalled form such as by rolling or folding and also configured to be manipulated into an installed form such as by unrolling or unfolding when in said placement atop said supporting surface, said elongate turf layer itself comprising: 1) an elongate substantially planar backing layer having an upper side and a lower side, said lower side configured for placement atop said supporting sub-base; and 2) a plurality of elongate turf fibers, wherein each of said elongate turf fibers has one end attached proximate said elongate substantially planar backing layer, and each fiber also has a free end extending from said upper side of said elongate substantially planar backing layer, such that said elongate turf fibers extend in a generally coparallel manner such that they and said elongate substantially planar backing layer combine to simulate said elongate turf layer, wherein said elongate turf layer defines a plurality of cut-out voids extending completely through said elongate turf layer, B) providing a plurality of elements each configured to be placed into a corresponding one of said plurality of cut-out voids and atop said supporting sub-base, such that said turf layer combines with said plurality of elements to provide a finished product simulating an elongate walkway.

9) The method of manufacturing a synthetic turf system as claimed in claim 9, wherein said elongate turf layer provided in subsection A is configured to be manipulated into an uninstalled form by rolling and also configured to be manipulated into an installed form such as by unrolling.

10) The method of manufacturing a synthetic turf system as claimed in claim 9, wherein said cut-out voids are provided to be arranged in a recognizable repeating pattern.

11) The method of manufacturing a synthetic turf system as claimed in claim 8, wherein said cut-out voids are provided to be arranged in a recognizable repeating pattern.

12) The method of manufacturing a synthetic turf system as claimed in claim 8, wherein said elongate turf layer provided in subsection A replicates the look of grass.

13) The method of manufacturing a synthetic turf system as claimed in claim 8, wherein said elongate turf layer provided in subsection A is tufted polypropylene.

14) The method of manufacturing a synthetic turf system as claimed in claim 8, wherein said plurality of elements provided in subsection B are pavers, stones, bricks, tiles, or wood members.

15. A method of installing a synthetic turf system atop a supporting sub-base, said method comprising A) providing an elongate turf layer configured to be manipulated into an uninstalled form such as by rolling or folding and also configured to be manipulated into an installed form such as by unrolling or unfolding when in said placement atop said supporting surface, said elongate turf layer itself comprising: 1) an elongate substantially planar backing layer having an upper side and a lower side, said lower side configured for placement atop said supporting sub-base; and 2) a plurality of elongate turf fibers, wherein each of said elongate turf fibers has one end attached proximate said elongate substantially planar backing layer, and each fiber also has a free end extending from said upper side of said elongate substantially planar backing layer, such that said elongate turf fibers extend in a generally coparallel manner such that they and said elongate substantially planar backing layer combine to simulate said elongate turf layer, wherein said elongate turf layer defines a plurality of cut-out voids extending completely through said elongate turf layer, B) providing a plurality of elements each configured to be placed into a corresponding one of said plurality of cut-out voids and atop said supporting sub-base, such that said turf layer combines with said plurality of elements; C) manipulating said elongate turf layer into an installed form such as by unrolling or unfolding said turf layer such that it is laid in a single thickness atop said supporting sub-base; and D) placing each of said plurality of elements into a corresponding one of said plurality of cut-out voids and atop said supporting sub-base, to provide a finished product simulating an elongate walkway.

16) The method of manufacturing a synthetic turf system as claimed in claim 15, wherein said elongate turf layer provided in subsection A is configured to be manipulated into an uninstalled form by rolling and also configured to be manipulated into an installed form such as by unrolling.

17) The method of manufacturing a synthetic turf system as claimed in claim 15, wherein said cut-out voids are provided to be arranged in a recognizable repeating pattern.

18) The method of manufacturing a synthetic turf system as claimed in claim 15, wherein said elongate turf layer provided in subsection A replicates the look of grass.

19) The method of manufacturing a synthetic turf system as claimed in claim 15, wherein said elongate turf layer provided in subsection A is tufted polypropylene.

20) The method of manufacturing a synthetic turf system as claimed in claim 15, wherein said plurality of elements provided in subsection B are pavers, stones, bricks, tiles, or wood members.

Description

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING

[0010] FIG. 1 is a Top Plan View of pre-cut synthetic turf grid square pattern. The 9 white squares represent the cut-out square turf spaces or voids with no turf and where the other material (paver, stone, brick, tile, or wood tile) would be placed. All the boarder lines represent the grid boarder design and the shaded horizontal line pattern represents what would be the synthetic turf fibers that would replicate the look of grass.

[0011] FIG. 2 is a Bottom Plan View which is comprised of a polypropylene backing that the turf fibers are tufted into forming many rows.

[0012] FIG. 3 is a Left Side Elevation View, Right Side Elevation View, Top Side Elevation View, & Bottom Side Elevation View, which are all identical and represent the synthetic turf fibers or pile height usually between 1 inch to 3 inches tall.

[0013] FIG. 4 is a Top Plan View which is same as FIG. 1 except this example does not have the turf grid boarder around the perimeter.

[0014] FIG. 5 is a Bottom Plan View, same as FIG. 2 except this example does not have the turf grid boarder around the perimeter.

[0015] FIG. 6 is a Left Side Elevation View, Right Side Elevation View, Top Side Elevation View, & Bottom Side Elevation View, which are all Identical and represent the synthetic turf fibers or pile height usually between 1 inch to 3 inches tall.

[0016] FIG. 7 is a Top Plan View of pre-cut synthetic turf grid diagonal pattern with boarder. The white diagonal squares represent the cut-out turf spaces or voids with no turf and where the other material (paver, stone, brick, tile, or wood tile) would be placed. All the boarder lines represent the grid boarder design and the shaded horizontal line pattern represents what would be the synthetic turf fibers that would replicate the look of grass.

[0017] FIG. 8 is a Bottom Plan View of the diagonal pattern with boarder which is comprised of a polypropylene backing that the turf fibers are tufted into forming many rows.

[0018] FIG. 9 is a Top Side Elevation View & Bottom Side Elevation View which are all Identical and represent the synthetic turf fibers or pile height usually between 1 inch to 3 inches tall.

[0019] FIG. 10 is a Left Side Elevation View & Right Side Elevation View which are all Identical and represent the synthetic turf fibers or pile height usually between 1 inch to 3 inches tall.

[0020] FIG. 11 is a Top Plan View of pre-cut synthetic turf grid circle pattern. The white circles represent the cut-out turf spaces or voids with no turf and where the other material (paver, stone, brick, tile, or wood tile) would be placed. All the boarder lines represent the grid boarder design and the shaded horizontal line pattern represents what would be the synthetic turf fibers that would replicate the look of grass.

[0021] FIG. 12 is a Bottom Plan View which is comprised of a polypropylene backing that the turf fibers are tufted into forming many rows.

[0022] FIG. 13 is a Top Side Elevation View, & Bottom Side Elevation View, which are all Identical and represent the synthetic turf fibers or pile height usually between 1 inch to 3 inches tall.

[0023] FIG. 14 is a Left Side Elevation View & Right Side Elevation View which are all Identical and represent the synthetic turf fibers or pile height usually between 1 inch to 3 inches tall.

[0024] FIG. 15 is a Top Plan View of pre-cut synthetic turf freeform grid circle pattern. The white circles represent the cut-out turf spaces or voids with no turf and where the other material (paver, stone, brick, tile, or wood tile) would be placed. All the boarder lines represent the grid boarder design and the shaded horizontal line pattern represents what would be the synthetic turf fibers that would replicate the look of grass.

[0025] FIG. 16 is a Bottom Plan View which is comprised of a polypropylene backing that the turf fibers are tufted into forming many rows.

[0026] FIG. 17 is Top Side Elevation View, & Bottom Side Elevation View, which are all Identical and represent the synthetic turf fibers or pile height usually between 1 inch to 3 inches tall.

[0027] FIG. 18 is a Left Side Elevation View & Right Side Elevation View which are all Identical and represent the synthetic turf fibers or pile height usually between 1 inch to 3 inches tall.

DETAILED DESCRIPTION OF THE INVENTION

[0028] Pre-cut synthetic turf grids are used in architectural and landscape designs for hardscapes most commonly used to make grass and paver, stone, brick, tile, or wood patterned walkways, patios, driveways, walls and fence installations.

[0029] Traditional synthetic turf is currently only manufactured and distributed in solid rolls between 12 to 15 wide and usually sold by the length or total square foot. It is typically sold and installed by specialty turf contractors and there are usually large minimums of square footage required for a professional installation job. Any special designs or patterns including walkway grids with lots of additional cutting and seaming labor is an additional premium charge and only attempted by highly experienced experts.

[0030] Pre-cut synthetic turf grids eliminate all the complicated cutting, fitting, seaming, & gluing of traditional synthetic turf designs by manufacturing and distributing an already pre-sized, patterned, & factory pre-cut by hand or machine synthetic turf grid product (See Drawings FIGS. 1,4 & 7).

[0031] Pre-cut synthetic turf grids are made using a standard piece of synthetic turf finished goods. Pre-cut pieces of synthetic turf grids can be manufactured from a traditional 12 or 15 wide standard size roll, either in place on the roll or by cutting smaller sections from the standard roll. When cutting by hand, either on the roll, or a smaller piece section, the desired working length or piece size of the turf material is rolled out onto floor or work table with the underside, usually comprised of a polypropylene backing, facing up. Next, the square, circle, rectangle or diagonal shape grid pattern design template made from wood, plastic or metal and sized accordingly per a standard specification is applied to the turf backing or underside (See Drawings FIGS. 2,5 & 8 for finished product underside). Then each pattern shape is manually cut out and removed by hand following the template with a carpet cutting tool creating a pattern of turf spaces or voids.

[0032] If using a CNC machine, the standard roll of turf or section of turf piece size is loaded into the CNC machine and the specific design template CAD file would be initiated and used to drive the CNC machine and the grid pattern would be cut automatically (CNC knives or laser cutting machine). When pre-cut by machine using a CAD file, the final design can be more intricate and easily modified per specification or need (See Drawings FIG. 1 showing design with boarder & FIG. 4 showing design without boarder). The excess synthetic turf pieces are removed by hand or machine creating a pattern of turf spaces or voids, then turf is folded or rolled by hand or machine and packaged accordingly for distribution or sale.

[0033] The pre-cut synthetic turf grids allow a DIYer or any type of contractor to install for example; a beautifully designed & complex walkway by simply rolling out or unfolding the pre-cut synthetic turf grid on top of an already properly prepared sub-base and finished by installing the corresponding sized paver, stone, brick, tile, or wood pieces in the already cut out turf spaces or voids to form the finished product. Depending on the desired finished aesthetic and application, the final turf height (See Drawings FIG. 3) may need to be adjusted, secured and infill added by standard synthetic turf installation methods not being claimed.