Treated Walnut Shell Infill For Artificial Turf

Abstract

An infilled artificial turf surface [18] includes a particulate infill [24] with at least a top layer [28] that comprises a mixture of Black walnut shell particles [30] and English walnut shell particles [32], the walnut shell particles [30, 32] having been treated so as to eliminate or substantially remove tree nut allergens that are known to activate allergies in some humans. Preferably, treatment occurs via heat treatment in a rotary furnace, which also rounds and smoothes the particles [30, 32]. Particularly if used in the top layer [28] of a particulate infill [24] of an artificial turf surface [18], the shape and size and proportion of the Black walnut shell particles [30] and the English walnut shell particles [32] provide stability for the resulting turf surface [18], while also being able to absorb water applied thereto, thereby to hold moisture and to provide evaporative cooling of the artificial turf surface [18] for up to about five hours.

Claims

1. An artificial turf comprising: a base; a backing located above the base, the backing having a primary and grass-like fibers extending upwardly therefrom; a particulate infill residing on the primary and providing lateral support for the grass-like fibers; and the particulate infill including a top layer of treated walnut shell particles, the treated walnut shell particles having been treated so as to substantially eliminate tree nut allergens therefrom.

2. The artificial turf of claim 1 wherein the top layer further comprises: a mixture of treated English walnut shell particles and treated Black walnut shell particles.

3. The artificial turf of any prior claim 2 wherein the mixture comprises about 25-75% English walnut shell particles and about 75-25% Black walnut shell particles, by volume.

4. The artificial turf of claim 3 wherein the top layer consists essentially of the mixture of treated English walnut shell particles and treated Black walnut shell particles.

5. The artificial turf of claim 4 wherein at least some of the treated walnut shell particles are at least partially coated with a green pigment.

6. The artificial turf of claim 4 wherein the treated English walnut shell particles have a sieve size of 6-30 and the treated Black walnut shell particles have a sieve size of 6-30, but preferably each has a sieve size of 8-20.

7. The artificial turf of claim 1 and further comprising: a lower layer of particulate infill residing below the top layer, the lower layer including sand.

8. A method of cooling an artificial turf comprising: spreading a top layer of treated walnut shell particles on an existing infill, the walnut shell particles including a preferred mixture of treated Black walnut shell particles and treated English walnut shell particles; and thereafter, as desired, applying water to the artificial turf so as moisten the top layer of treated walnut shell particles, thereby to enable evaporative cooling to occur so as to reduce the temperature of the artificial turf.

9. The method of claim 8 wherein the preferred mixture comprises about 25-75% English walnut shell particles and about 75-25% Black walnut shell particles, by volume.

10. A particulate infill material for an infilled artificial turf, made according to the process comprising: selecting walnut shell particles generally of a preferred desired size and shape; and treating the selected walnut shell particles so as to substantially eliminate tree nut allergens therefrom.

11. The particulate infill of claim 10 wherein the treating comprises immersing and agitating the walnut shell particles within a buffering solution.

12. The particulate infill of claim 11 wherein the buffering solution is sodium bicarbonate.

13. The particulate infill of claim 12 wherein the sodium bicarbonate solution is 25 milli Moles.

14. The particulate infill of claim 13 wherein the treating further comprises: including within the buffering solution at least one or more additional substances so as to affect at least one of color, durability, and resistance to rotting, of the walnut shell particles.

15. The particulate infill of claim 10 wherein the Black walnut shell particles are generally rounded in shape and of a restricted size profile and the English walnut shell particles are of a restricted size profile but more elongated than the Black walnut shell particles, thereby to enable a mixture of the particles to achieve a stable top layer that is more locked in place and less likely to roll or to mound, compared to a top layer of uniformly sized and shaped infill particles.

16. The particulate infill of claim 10 wherein the allergen level of the walnut shell particles is less than 10 ppm.

17. The particulate infill of claim 10 wherein the treating further comprises heat treating via a rotary furnace, or via a fluidized bed drier, or other source of heat and/or agitation, using time or temperature parameters so as to achieve an allergen level of less than 1.0 ppm.

18. The particulate infill of claim 17 wherein the particles are heated at 390 F. for a duration of 30 minutes.

19. The particulate infill of claim 17 wherein the treating also causes smoother particles (less abrasive) and a moisture context below 10%.

Description

BRIEF DESCRIPTION OF THE DRAWING(S)

[0032] FIG. 1 is a cross sectional view of an infilled artificial turf according to a preferred embodiment of the invention, with a lower layer of sand infill and a top layer comprising a mixture of treated walnut shell particles, wherein the mixture preferably consists essentially of Black walnut shell particles and English walnut shell particles.

[0033] FIGS. 2 and 3 are, respectively, plan views of Black walnut shell particles of the type that are preferably used with the present invention, namely rounded particles with a sieve size of 8/12, and English walnut shell particles of the type that are preferably used with the present invention, namely angular particles with a sieve size of 8/12.

DETAILED DESCRIPTION OF THE DRAWINGS

[0034] Because walnut shell particles comprise natural organic materials, the use of walnut shell particles as a top layer of an infilled artificial turf presents no new or unnatural health risk to athletes using the artificial turf, or to the surrounding environment, compared to infills which use crumb rubber. Also, compared to other organic infill materials, it is believed that walnut shell particles are generally cooler when dry, and that when they are wet the walnut shell particles have a more prolonged evaporative cooling effect. This means that a walnut shell infill is more versatile, because it performs reasonably well over a wider range of moisture conditions, from dry to completely wet.

[0035] Moreover, the preferred mixture of two types of walnut shell particles, according to the present invention, is believed to be more consistent, stable, and uniform than currently existing infill materials, and also more durable and longer lasting than other existing organic infills. As a result, it is also believed that the preferred mixture of walnut shell particles will result in an artificial turf surface that more closely mimics natural grass.

[0036] One reason for these beliefs is reflected by the teachings of the Reddick U.S. patents, particularly U.S. Pat. No. 7,858,148, which emphasizes the importance of infill particles that are relatively hard, and located within and among the grass-like fibers of an infill, such that any resilience for the turf is supplied below the horizontally oriented backing of the turf, by an underlying pad, preferably of foam.

[0037] For example, FIG. 1 shows a cross sectional view of an exemplary artificial turf 10 according to a preferred embodiment of the present invention. More specifically, FIG. 1 shows a pad 14 which resides on a compacted base, or foundation 16. The base 16 is generally understood by those skilled in the art. The pad 14 may be of the type disclosed in U.S. Pat. No. 8,568,840. The actual components of what is commonly referred to as an artificial turf surface 18 reside above the pad 14, and include a horizontally oriented backing 20, often called a primary, to which grass-like fibers 22 are secured, typically by tufting. The grass-like fibers 22 extend upwardly from the primary 20. A particulate infill 24 resides on the primary 20 amongst the grass-like fibers 22, the infill 24 supporting the fibers 22 in a generally upright condition. The infill 24 preferably includes a lower layer 26 of relatively heavy and dense particulate, such as sand, as shown in FIG. 1. The lower layer 26 of sand provides weight and ballast which helps to hold down the artificial component. The infill also includes a top layer 28 of walnut shell particles, as shown in FIG. 1. The grass-like fibers 22 extend well above the top layer of the walnut shell particles.

[0038] FIGS. 2 and 3 show the types of walnut shell particles included in the top layer. More specifically, FIG. 2 shows relatively round Black walnut shell particles, with a size range of 8/12 sieve. Thus, these particles are generally within a restricted size range. Similarly, FIG. 3 shows generally angularly shaped English walnut shell particles 32 which also have a size range of 8/12 sieve, and thus are also within a restricted size range. However, because of the inherent differences in the nature of English walnut particles 32 compared to Black walnut particles 30, the English walnut particles 32 are more angular.

[0039] When mixed, these two different types of walnut shell particles 30, 32 retain their relatively hard outer surface and texture, but they also tend to achieve a locked in relationship. In contrast to the infills taught in the above-cited U.S. Pat. No. 6,551,689 to Prevost, which teaches a resilient infill, due to the inclusion of rubber particles in the infill mixture, and in Meredith U.S. Pat. No. 5,041,320, which teaches rubber coated sand that is compressible, the infill shown in the FIG. 1 embodiment has two distinct layers 26, 28, and each of the two layers 26, 28 is neither resilient nor compressible. Rather, for each layer 26, 28, the discrete infill particles are relatively hard and non-compressible, and the layers of such particles are also non-resilient and non-compressible in the aggregate.

[0040] Because of the relatively uniform size of the walnut shell particles, this preferred mixture in the top layer 28 will not cause excessive rolling, as would otherwise be caused by uniformly sized and shaped particles, such as ball bearings. But at the same time, these two distinct shapes will also resist mounding. Still further, it is believed that a top layer 28 of this preferred mixture will retain these above-described properties for a relatively long duration, at least compared to other currently available infills which include coconut or other organic particles. In fact, it is believed that the infill layer 28 of the present invention may even last up to at least about 8 years, the typical life span of the artificial turf surface 18. Thus, it is believed that an artificial turf surface 18 of the type shown in FIG. 1 will retain a relatively constant G-Max rating for an extended period of time, i.e., during the duration of its useful life. Applicant is currently aware of only one other infill product, its own ENVIROFILL product, which enables an infilled artificial turf surface to achieve this goal.

[0041] The types of walnut shell particles 30, 32 used with this invention will naturally include tree allergens, i.e., proteins, which may cause an allergic reaction in a human who suffers from nut allergies. And the conventional processing of walnuts, to separate the shell particles from the walnut meat, will generally result in shell particles that have some residual walnut meat thereon. To eliminate potential concerns associated with this condition, the walnut shell particles 30, 32 are treated prior to use. Preferably, the two types of walnut shell particles 30, 32 are mixed together and then treated as a mixture. As noted above, any one of a number of treatment procedures may be used.

[0042] Preferably, the walnut shell particles 30, 32 are sized and sieved before the treatment procedure, to achieve the desired size range, which may be the same as those shown in FIGS. 2 and 3. The mixture ratio, by volume, contemplates a range of 25-75% English walnut shell particles 32 and 75-25% Black walnut shell particles 30, although a 50/50 mixture, by volume, is currently believed to be the optimum mixture.

[0043] One effective treatment method includes immersing the walnut shell particles 30, 32, separately or mixed, in a buffering solution comprising water and an effective amount of sodium bicarbonate, which preferably may be about 25 milli Moles.

[0044] Another effective treatment method comprises heat treatment of the particles 30, 32 in a rotary furnace, during which the heating/tumbling provides a number of additional benefits, besides the removal of allergens. More specifically, the use of a rotary furnace results in rounding of the particles, i.e. the smoothing of the otherwise sharp edges. This process also reduces the odor of the particles, from a strong, loamy aroma to a mild, roasted aroma. Further, this process removes dust (compared to the raw material), produces a richer color that looks more like natural dirt, and also produces a moisture content below 10%, a level that will not propagate mold during storage. Applicant tested various temperature/time parameters, as shown in a report by Vulcan Systems, a Division of Worldwide Recycling Equipment Sales, LLC, entitled Final Test Report: 16PS0205. This report describes the use of various heat and time parameters for the heating and tumbling, and it is expressly incorporated by reference herein, in its entirety.

[0045] As a result of these test efforts, applicant currently believes that the best results are achieved by heating the particles 30, 32 in a rotary furnace set with a temperature in the range of 360-400 F., but more preferably at 390 F., for a duration of 30 minutes. The goal with the test was to achieve an allergen level of less than 10 ppm. With the preferred parameters of 390 F. and 30 minutes, applicant achieved a result of 0.27 ppm. Other sources of heat and/or agitation could also prove to be suitable, such as a fluidized bed drier.

[0046] Those skilled in the art will understand and appreciate that this specification is intended to explain the details of the present invention in the context of the exemplary embodiments disclosed herein. Those same persons of skill in the art will also understand that this specification is not intended to limit the scope of the present invention to the presently disclosed details, or to be used to limit the scope of the following claims. Further, those skilled in the art will recognize that the recitation of objects of the invention in this specification is intended to describe the inventor's current understanding of the deficiencies of the known prior art, so as to inform and enhance the reader's overall understanding of this specification, not to serve as a requirement for each of the following claims. In other words, those skilled in the art should recognize that applicant does not intend that each of the appended claims will achieve every one of the above-stated objectives.