NATURAL FIBER COATED ARTIFICIAL TURF INFILL

Abstract

The method includes providing a base composition including a natural fiber, at least one first type of pigment, and a fluid binding agent. The fluid binding agent includes at least one type of polymer component. The natural fiber includes any one of hemp fiber, burlap fiber, sisal fiber, elephant grass, cotton, coconut fiber, and combinations thereof. The method further includes mixing the base composition. The method further includes adding water and a catalyst to the base composition during the mixing of the base composition to cure the fluid binding agent and the at least one first type of pigment into a base coating of the natural fiber.

Claims

1. A method of manufacturing artificial turf infill (202, 202, 202), wherein the method comprises: providing (800) a base composition comprising a natural fiber (500), at least one first type of of pigment, and a fluid binding agent, wherein the fluid binding agent comprises at least one type of polymer component, wherein the natural fiber comprises any one of the following: hemp fiber, burlap fiber, sisal fiber, elephant grass, cotton, coconut fiber, and combinations thereof; mixing (802) the base composition; adding (804) water and a catalyst to the base composition during the mixing of the base composition to cure the fluid binding agent and the at least one first type of of pigment into a base coating (502) of the natural fiber.

2. The method of manufacturing artificial turf infill of claim 1, wherein the natural fiber consists of any one of the following: hemp fiber, burlap fiber, sisal fiber, elephant grass, cotton, coconut fiber, and combinations thereof.

3. The method of manufacturing artificial turf infill of claim 1, wherein the method further comprises: providing (900) a subsequent composition comprising the natural fiber with the base coating, a at least one second type of of pigment, and the fluid binding agent; mixing (902) the subsequent composition; adding (904) water and the catalyst to the subsequent composition during the mixing of the subsequent composition to cure the fluid binding agent and the at least one second type of of pigment into a subsequent coating of the natural fiber; an providing (906) the natural fiber with the subsequent coating as artificial turf infill (202).

4. The method of manufacturing artificial turf infill of claim 3, wherein any one of the following: the at least one first type of of pigment is identical with the at least one second type of of pigment, and the at least one first type of of pigment is a different color from the at least one second type of of pigment.

5. The method of manufacturing artificial turf infill of claim 3 or 4, wherein the natural fiber with the base coating and the subsequent coating is re-coated at least one time by performing the following sequence: providing (1000) a subsequent composition (1222) by adding at least one additive and the fluid binding agent to the natural fiber; mixing (1002) the subsequent composition; and adding (1004) water and the catalyst to the subsequent composition during the mixing of the subsequent composition to cure the fluid binding agent and the at least one additive into a further coating, wherein the natural fiber with the further coating is provided as the artificial turf infill (202).

6. The method of manufacturing artificial turf infill of claim 5, wherein the at least one additive further comprises any one of the following: the at least one first type of pigment, the at least one second type of pigment, a flame retardant, aluminum trihydrate, magnesium hydroxide, an intumescent component, ammonium polyphosphate, exfoliated graphite, methylcellulose, zeolite, an antibacterial agent, silver, chitosan, an IR reflective pigment, a hindered amine light stabilizer, an anti-freeze additive, a de-icing additive, sodium chloride, potassium chloride, sodium formate, potassium formate, and combinations thereof.

7. The method of manufacturing artificial turf infill of any one of the preceding claims, wherein the natural fiber comprises fibers less than 5 mm long, more preferably less than 1.5 mm long.

8. The method of manufacturing artificial turf infill of any one of the preceding claims, wherein the at least one first type of pigment and/or the at least one second type of pigment comprises any one of the following: an inorganic pigment, an organic pigment, iron oxide, copper phthalo green complex, Chromium(III) oxide, a Copper Phthalocyanine pigment, a nickel azopigment, titanium oxide, and combinations thereof.

9. The method of manufacturing artificial turf infill of any one of the preceding claims, wherein the polymer component comprises any one of the following: at least one type of monomer, at least one type of partially polymerized polymer, and combinations thereof.

10. The method of manufacturing artificial turf infill of any one of the preceding claims, wherein the polymer component is cured into at least one type of polyurethane by the water and catalyst.

11. The method of manufacturing artificial turf infill of any one of the preceding claims, wherein the fluid binding agent comprises a liquid polyurethane component.

12. The method of manufacturing artificial turf infill of claim 11, wherein the liquid polyurethane component comprises an NCO terminal polymer, which may comprise a pre-polymer, a polymeric isocyanate, an oligomeric isocyanate, a monomer, and a mixture thereof.

13. The method of manufacturing artificial turf infill of claim 11 or 12, wherein the liquid polyurethane component comprises an aromatic diisocyanate of the group of toluene diisocyanate and/or 2,2-Methylene diphenyl diisocyanate and/or 2,4-Methylene diphenyl diisocyanate and/or 4,4-Methylene diphenyl diisocyanate.

14. The method of manufacturing artificial turf infill of claim 11, 12, or 13, wherein the liquid polyurethane component comprises an aliphatic diisocyanate of the group hexamethylene diisocyanate, isophorone diisocyanate, and/or 1,4-cyclohexyldiisocyanate.

15. The method of manufacturing artificial turf infill of any one of claims 11 through 14, wherein the liquid polyurethane component comprises an methylene diphenyldiisocyanate isomer mixture.

16. The method of manufacturing artificial turf infill of any one of claims 11 through 15, wherein the liquid polyurethane component comprises a hydroxyl component, wherein the hydroxyl component is selected from the group of polyether polyol or polyester polyol.

17. The method of manufacturing artificial turf infill of claim 16, wherein the hydroxyl component is based on a polyetherpolyol with a molecular weight between 500 and 10000, preferably the molecular weight is between 1500 and 6000, and more preferably the molecular weight is between 2000 and 4000.

18. The method of manufacturing artificial turf infill of any one of the preceding claims, wherein the catalyst belongs to any one of the following groups: a secondary amine catalyst, a tertiary amine catalyst, and a metal organic catalyst.

19. The method of manufacturing artificial turf infill of any claim 3 through 18 with reference to claim 3, wherein the method further comprises drying the subsequent composition before providing the natural fiber as the artificial turf infill.

20. The method of manufacturing artificial turf infill of any one of the preceding claims, wherein the method is at least partially performed in a flow reactor.

21. The method of manufacturing artificial turf infill of any one of claims 1 through 19, wherein the method is at least partially performed as a batch process.

22. A method of manufacturing artificial turf (200), wherein the method further comprises: installing (300) an artificial turf carpet (100), wherein the artificial turf carpet comprises multiple artificial turf fiber tufts (104); and providing (302) the artificial turf by spreading a layer of artificial turf infill (202, 202, 202) between the multiple artificial turf fiber tufts, wherein the artificial turf infill comprises natural fiber (500), wherein the natural fiber comprises any one of the following: hemp fiber, burlap fiber, sisal fiber, elephant grass, cotton, coconut fiber, and combinations thereof, wherein the natural fiber comprises at least one outer coating (502, 600, 700), wherein the at least one outer coatings comprise at least one first type of pigment and a binding agent, wherein the binding agent comprises at least one type of polyurethane polymer.

23. Artificial turf infill (202, 202, 202), wherein the artificial turf infill comprises natural fiber (500), wherein the natural fiber comprises any one of the following: hemp fiber, burlap fiber, sisal fiber, elephant grass, cotton, coconut fiber, and combinations thereof, wherein the natural fiber comprises at least one outer coating (502, 600, 700), wherein the at least one outer coating comprises at least one first type of pigment and a binding agent, wherein the binding agent comprises at least one type of polyurethane polymer.

24. The artificial turf infill of claim 23, wherein the at least one outer coating comprises openings (504) that expose the natural fiber.

25. An artificial turf, wherein the artificial turf comprises: an artificial turf carpet (100), wherein the artificial turf carpet comprises multiple artificial turf fiber tufts (104); and the artificial turf infill (202, 202, 202) according to claim 23 or 24.

26. The artificial turf of claim 25, wherein the artificial turf further comprises a sprinkler system (400).

27. The method of manufacturing artificial turf infill of any one of claims 1 through 21, wherein the base coating comprises first openings (504) that expose the natural fiber.

28. The method of manufacturing artificial turf infill of any one of claims 27 and 3 through 21 with reference to claim 3, wherein the subsequent coating comprises second openings (504) that expose the natural fiber.

29. The method of manufacturing artificial turf infill of claims 28 and 27, wherein a number of the first openings is bigger than a number of the second openings.

30. The method of manufacturing artificial turf infill of any of claims 27 through 29, wherein a portion of the first openings is covered by the subsequent coating.

31. The method of manufacturing artificial turf infill of any one of claims 5 through 21 and 27 through 30 with reference to claim 5, wherein the further coating comprises third openings (504) that expose the natural fiber.

32. The method of manufacturing artificial turf infill of claims 31 and 29, wherein the number of the second openings is bigger than a number of the third openings.

33. The method of manufacturing artificial turf infill of claims any one of claims 1 through 21 and 27 through 32 with reference to claims 27 and 3, wherein a portion of the first openings is covered by the subsequent coating.

34. The method of manufacturing artificial turf infill of claims any one of claims 1 through 21 and 27 through 33 with reference to claims 28 and 5, wherein a portion of the second openings is covered by the further coating.

35. The method of manufacturing artificial turf infill of claims 28 and 31, wherein a number of the second openings is bigger than a number of the third openings.

36. The artificial turf infill of claim 23 or 24, wherein the at least one outer coating comprises openings (504) that expose the natural fiber.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0073] In the following embodiments of the invention are explained in greater detail, by way of example only, making reference to the drawings in which:

[0074] FIG. 1 illustrates an example of an artificial turf carpet;

[0075] FIG. 2 illustrates an example of artificial turf;

[0076] FIG. 3 shows a flow chart which illustrates a method of manufacturing artificial turf;

[0077] FIG. 4 illustrates an example of an artificial turf which incorporates a sprinkler system;

[0078] FIG. 5 illustrates an example of an artificial turf infill;

[0079] FIG. 6 illustrates a further example of an artificial turf infill;

[0080] FIG. 7 illustrates a further example of an artificial turf infill;

[0081] FIG. 8 shows a flow chart which illustrates a further method of manufacturing artificial turf infill;

[0082] FIG. 9 shows a flow chart which illustrates a further method of manufacturing artificial turf infill;

[0083] FIG. 10 shows a flow chart which illustrates a further method of manufacturing artificial turf infill;

[0084] FIG. 11 illustrates an example of a batch reactor; and

[0085] FIG. 12 illustrates an example of a flow reactor.

DETAILED DESCRIPTION

[0086] Like numbered elements in these figures are either equivalent elements or perform the same function. Elements which have been discussed previously will not necessarily be discussed in later figures if the function is equivalent.

[0087] FIGS. 1 and 2 illustrate the manufacture of an artificial turf using an artificial turf carpet and artificial turf infill. In FIG. 1 an artificial turf carpet 100 can be seen. The artificial turf carpet 100 comprises a backing 102. The artificial turf carpet 100 shown in FIG. 1 is a tufted artificial turf carpet in this example. The artificial turf carpet is formed by artificial turf fiber tufts 104 that are tufted into the backing 102. The artificial turf fiber tufts 104 are tufted in rows. There is row spacing 106 between adjacent rows of tufts. The artificial turf fiber tufts 104 also extent a distance above the backing 102. The distance that the fibers 104 extend above the backing 102 is the pile height 108. In FIG. 1 it can be seen that the artificial turf carpet 100 has been installed by placing or attaching it to the ground 110 or a floor.

[0088] FIG. 2 illustrates an artificial turf 200 manufactured from the artificial turf carpet 100 of FIG. 1. To manufacture the artificial turf 200 a infill 202 made up of natural fibers with at least one outer coating is used. The at least one outer coating comprises at least one type of pigment and a binding agent, wherein the binding agent comprises at least one type of polyurethane polymer. The natural fiber may for example be any one of the following: hemp fiber, burlap fiber, sisal fiber, elephant grass, cotton, coconut fiber, and combinations thereof. FIG. 2 shows the artificial turf carpet 200 after artificial turf infill 202 has been spread out and distributed between the artificial turf fiber tufts 204.

[0089] FIG. 3 shows a flowchart which illustrates a method of manufacturing the artificial turf 200 shown in FIG. 2. First in step 300 the artificial turf carpet 100 is installed on a surface. The artificial turf comprises multiple artificial turf fiber tufts. Next in step 302 the artificial turf 200 is provided by spreading a layer of the artificial turf infill 202 between the multiple artificial turf fiber tufts 104. The artificial turf infill comprises natural fiber. The natural fiber comprises any one of the following: hemp fiber, burlap fiber, sisal fiber, elephant grass, cotton, coconut fiber, and combinations thereof. The natural fiber comprises at least one outer coating. The at least one outer coating comprises at least one type of pigment and a binding agent. The binding agent comprises at least one type of polyurethane polymer.

[0090] FIG. 4 shows a further example of the artificial turf 200. In this example an automatic sprinkler system 400 has been integrated into the artificial turf 200. The sprinkler 400 is depicted as spraying water 402 on an upper surface of the artificial turf 200. The use of an artificial sprinkler may be beneficial in combination with the infill component that comprises both the rubber natural fiber and the natural fiber. The natural fiber may absorb water which through evaporation can help to keep the surface of the artificial turf 200 cool.

[0091] FIG. 5 shows an example of an artificial turf infill 202 manufactured from a natural fiber 500. The view in FIGS. 5, 6 and 7 are cross-sectional views. The natural fiber is shown as being partially coated with an outer coating 502. The outer coating 502 is formed from at least one first type of pigment and a binding agent. The binding agent comprises at least one type of polyurethane polymer. The outer coating 502 may provide coloration which may help the artificial turf infill appear more realistic. The outer coating 502 may also help serve to protect and keep the natural fiber 500 from breaking apart prematurely during use. The openings 504 in the outer coating 502 provide access to the atmosphere for the natural fiber 500. This enables the natural fiber 500 to absorb and desorb water. For example when an artificial turf is wetted with for example the sprinkler shown in FIG. 4 the natural fiber can then absorb water. The amount of openings 504 controls how quickly the artificial turf infill 202 will lose its water and its cooling effect.

[0092] FIG. 6 shows a further example of an artificial turf infill 202. The artificial turf infill 202 is again shown as a cross-sectional view of the natural fiber 500. In this example an additional subsequent coating 600 has been applied to the natural turf fiber 500. The subsequent coating 600 is shown as covering some of the openings 504 that were present in FIG. 5. As a result a number of openings is reduced by applying the additional subsequent coating. Thus the process of water absorption and desorption through the openings can be tuned to a desired level by applying the subsequent coating. The subsequent coating 600 also partially covers some of the previously coated base coating 502. As a result the structural integrity, and/or durability, and/or mechanical properties of the coating comprising the outer coating 502 and the subsequent coating 600 can be improved or tuned to a desired level. The subsequent coating 600 may comprise a second type of pigment and the binding agent. The binding agent comprises at least one type of polyurethane polymer again. In some instances the first and at least one second type of of pigments are identical. In other cases they may be two different colors. Using two colors that are the same may enable more uniform color coding of the natural fiber 500. Using two different colors may enable a more lifelike appearance for the natural fiber 500. It can be seen that the number of openings 504 has been greatly reduced. This may provide for a means of controlling how exposed the natural fiber 500 is to the atmosphere. This may enable control of how quickly the artificial turf infill 202 loses water when it is exposed to heat and sunlight. This may have the effect of prolonging the cooling effect.

[0093] FIG. 7 shows a further example of an artificial turf infill 202 as illustrated by showing a further cross-sectional view of the natural fiber 500. The artificial turf fiber 500 displayed in FIG. 7 is similar to that in FIG. 6 except an additional further coating 700 has been coated over the subsequent coating 600 and the base coating 502. It can be seen that the number of openings 504 has again been greatly reduced. If a sufficient number of coatings are used then the artificial turf fiber 500 may be completely encapsulated in coatings. The further coating 700 may comprise at least one pigment and a binding agent where the binding agent comprises at least one type of polyurethane polymer. The further coating, the subsequent coating 600 and/or the base coating 502 in all of the examples shown in 5, 6 and 7 may also comprise various functional additives or components. For example there may be components which are used to provide flame retardants, provide infrared reflection or other properties.

[0094] Such an iterative processing of applying coatings can provide for an effective control of a number of openings and/or areas of the openings. In addition this iterative process can provide for a production of an integral coating of the artificial turf infill which has desired mechanical and/or structural properties and/or required wear and longevity.

[0095] FIG. 8 shows a flowchart which illustrates a method for manufacturing the artificial turf infill 202 illustrated in FIG. 5. First in step 800 a base composition is provided which comprises the natural fiber 500. The base composition further comprises a at least one first type of of pigment which may be a collection of multiple pigments and a fluid binding agent. The fluid binding agent comprises at least one type of polymer component. The natural fiber comprises any one of the following: hemp fiber, burlap fiber, sisal fiber, elephant grass, cotton, coconut fiber, and combinations thereof. Next in step 202 the method further comprises mixing the base composition. Then finally in step 804 the method further comprises adding water and a catalyst to the base composition during the mixing of the base composition to cure the fluid binding agent and the at least one first type of of pigment into a base coating 502 of the natural fiber 500.

[0096] FIG. 9 shows a flowchart which illustrates a method of manufacturing artificial turf infill 202 shown in FIG. 6. The method of FIG. 9 includes the steps 800, 802, and 804 from FIG. 8. The method after performing step 804 further comprises providing a subsequent composition comprising the natural fiber 500 with the base coating 502. The subsequent composition further comprises a at least one second type of of pigment which may be the same or different than the at least one first type of of pigment and the fluid binding agent. The at least one second type of of pigment may also be a single pigment or formed from a collection of different pigments. Next in step 902 the method further comprises mixing the subsequent composition. Next the method further comprises the step 904 of adding water and the catalyst to the subsequent composition during the mixing of the subsequent composition to cure the fluid binding agent and the at least one second type of of pigment into a subsequent coating 600 of the natural fiber 500. The method then further comprises 906 providing the natural fiber with the subsequent coating as the artificial turf infill 202.

[0097] FIG. 10 shows a flowchart which illustrates a method of manufacturing an artificial turf infill 202 such as illustrated in FIG. 7. The method illustrated in FIG. 10 uses the artificial turf infill 202 illustrated in FIG. 6. The method in FIG. 10 also includes the method steps of FIG. 9. After step 906 is performed the method further comprises providing 1000 a subsequent composition by adding at least one additive and the fluid binding agent to the natural fiber. The method then proceeds to step 1002 where the subsequent composition is mixed. Then finally in step 1004 water and catalyst are added to the subsequent composition during the mixing of the subsequent composition to cure the fluid binding agent and the at least one additive into a further coating 700 of the natural fiber. The method may end in step 1004 where the resulting artificial turf 202 infill is provided. However, the addition of the subsequent coatings may be performed multiple times. The arrow going from step 1004 to 1000 indicates that this process may be repeated as many times as is desired. This step may be performed multiple times to add additional properties to the artificial turf infill such as greater coverage of openings 504 or even adding additional colors or functional coatings which may for instance be used to provide flame retardants, infrared reflective, antibacterial properties or even antifungal properties.

[0098] FIG. 11 illustrates some equipment which may be used for manufacturing the artificial turf infill 202, 202, 202 as depicted in FIGS. 5 through 7. The mixing vat can be used to perform any of the methods shown in FIGS. 8 through 10. FIG. 11 depicts a mixing vat 1100. The mixing vat has a rotatable shaft 1102 that is connected to a number of mixing paddles 1104. The mixing vat 1100 is filled with natural fibers 500. The natural fiber 500 can then be manufactured into artificial turf infill 202 by forming an base composition. The base composition comprises the the natural fiber 500, optionally at least one first type of pigment, and a fluid binding agent. The fluid binding agent, may for example, comprises at least one type of polymer component. Next in step the base composition is mixed. During this step, the mixing water and catalyst are added to the base composition to cure the fluid binding agent and the optional at least one type of pigment into an outer coating 502 that bonds to the surface of the natural fibers 500. Likewise, the artificial turf infills 202 and 202 as depicted in FIGS. 6 and 7 can be performed by using the methods depicted in FIGS. 9 and 10.

[0099] The apparatus depicted in FIG. 11 may be used for manufacturing the artificial turf infill as batches. It is also possible to manufacture the artificial turf infill as a continuous process using a flow reactor.

[0100] FIG. 12 illustrates an example of a flow reactor 1200. The example shown in FIG. 12 is illustrative and is not drawn to scale. The flow reactor 1200 comprises a rotatable shaft 1202 that is connected to a screw conveyor 1204. The screw conveyor 1204 is similar to an Archimedes screw, which is mounted horizontally. The flow reactor 1200 is shown as being filled with natural fiber 500. As the rotatable shaft 1202 is turned, it causes the natural fiber 500 to move through the flow reactor 1200. At an entrance there is an inlet 1208 for the natural fiber 500. This may be done on a continual basis as the shaft 1202 is rotated. This causes the natural fiber 500 to go to a first inlet 1210 for fluid binding agent and optionally at least one first type of pigment. At inlet 1210 the at least one at least one first type of of pigment and the fluid binding agent are added to the natural fiber 504 and become mixed with it as the shaft 1202 is rotated. When they are thoroughly mixed, the natural fiber 1204 and the rubber natural fiber 1206 and the at least one first type of pigment and the fluid binding agent form an base composition 1220. This base composition 1220 is then transported beneath a first inlet for water and catalyst 1212. The water and catalyst may be added on a continual or intermittent basis at this inlet 1212.

[0101] As the base composition 1220 is transported further along the flow reactor 1200 fluid binding agent and at least one pigment cure into the outer coating 502 such as depicted in FIG. 5. At this point, the artificial turf infill 202 has been formed.

[0102] In some examples the flow reactor may additional inlets so that additional layers or coatings can be applied. FIG. 7 also depicts optional inlets 1214 and 1216. After the outer coating 502 is formed, the base composition 1220 is transported underneath the second inlet 1214 for at least one pigment and fluid binding agent. At this point more of the pigment and fluid binding agent are added and the base composition 1220 becomes the subsequent composition 1222. The pigments used for the base composition and the subsequent composition may be identical or they may be different.

[0103] The subsequent composition 1222 is mixed and transported underneath the second inlet for water and catalyst 1216. The water and catalyst are then mixed with the subsequent composition 1222 and over time are further transported to the end of the flow reactor 1220. By the time the subsequent composition 1222 has reached the end of the flow reactor 1200 the subsequent coating 600 has formed on the natural fibers 500. At the very end, then the artificial turf infill 202 exits the flow reactor 1200 at an outlet 1217. The the natural fiber 500 is then artificial turf infill 202. The artificial turf infill 202 is then shown as entering into an optional dryer 1218.

[0104] It is clear from FIG. 12 that the flow reactor may also be extended. For example if it is desired to put a third or fourth or even more coatings, the number of inlets in the flow reactor 1200 can simply be increased. This may involve moving the natural fiber at a different rotational rate or possibly even making the flow reactor 1200 longer.

LIST OF REFERENCE NUMERALS

[0105] 100 artificial turf carpet [0106] 102 backing [0107] 104 artificial turf fiber tufts [0108] 106 row spacing [0109] 108 pile height [0110] 110 ground or floor [0111] 200 artificial turf [0112] 202 artificial turf infill [0113] 202 artificial turf infill [0114] 202 artificial turf infill [0115] 300 installing an artificial turf carpet [0116] 302 providing the artificial turf by spreading a layer of artificial turf infill between the multiple artificial turf fiber tufts [0117] 400 sprinkler [0118] 402 water [0119] 500 natural fiber [0120] 502 base coating [0121] 504 opening [0122] 600 subsequent coating [0123] 700 further coating [0124] 800 providing a base composition comprising a natural fiber, a at least one first type of of pigment, and a fluid binding agent [0125] 802 mixing the base composition [0126] 804 adding water and a catalyst to the base composition during the mixing of the base composition to cure the fluid binding agent and the at least one first type of of pigment into a base coating of the natural fiber [0127] 900 providing a subsequent composition comprising the natural fiber with the base coating, a at least one second type of of pigment, and the fluid binding agent [0128] 902 mixing the subsequent composition [0129] 904 adding water and the catalyst to the subsequent composition during the mixing of the subsequent composition to cure the fluid binding agent and the at least one second type of of pigment into a subsequent coating of the natural fiber [0130] 906 providing the natural fiber with the subsequent coating as artificial turf infill [0131] 1000 providing a subsequent composition by adding at least one additive and the fluid binding agent to the natural fiber [0132] 1002 mixing the subsequent composition [0133] 1004 adding water and the catalyst to the subsequent composition during the mixing of the subsequent composition to cure the fluid binding agent and the at least one additive into a further coating [0134] 1100 mixing vat [0135] 1102 rotatable shaft [0136] 1104 mixing paddles [0137] 1200 flow reactor [0138] 1202 rotatable shaft [0139] 1204 screw conveyor [0140] 1208 inlet for natural fiber [0141] 1210 first inlet for at least one pigment and fluid binding agent [0142] 1212 first inlet for water and catalyst [0143] 1214 second inlet for at least one pigment and fluid binding agent [0144] 1216 first inlet for water and catalyst [0145] 1217 outlet [0146] 1218 dryer [0147] 1220 base composition [0148] 1222 subsequent composition