ARTIFICIAL TURF INFILL

Abstract

The invention provides for a method manufacturing artificial turf infill (602), wherein the method comprises providing (700) an initial composition (1120) comprising a granulate (1006), at least one type of pigment, and a fluid binding agent. The fluid binding agent comprises at least one type of polymer component. The method further comprises mixing (702) the initial composition; adding (704) water and a catalyst to the initial composition during the mixing of the initial composition to cure the fluid binding agent and the at least one type of pigment into an initial coating (200) of the granulate. The method further comprises providing (706) a subsequent composition (1122) comprising the granulate with the initial coating, the at least one type of pigment, and the fluid binding agent. The method further comprises mixing (708) the subsequent composition. The method further comprises adding (710) 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 type of pigment into a subsequent coating (300) of the granulate. The method further comprises providing (712) the granulate with the subsequent coating as artificial turf infill.

Claims

1. A method manufacturing artificial turf infill, wherein the method comprises: providing an initial composition comprising a granulate, at least one first type of pigment, and a fluid binding agent, wherein the fluid binding agent comprises at least one type of polymer component; mixing the initial composition; adding water and a catalyst to the initial composition during the mixing of the initial composition to cure the fluid binding agent and the at least one type of pigment into an initial coating of the granulate; providing a subsequent composition comprising the granulate with the initial coating, at least one second type of pigment, and the fluid binding agent; mixing the subsequent composition; 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 type of pigment into a subsequent coating of the granulate, wherein the initial coating comprises gaps, wherein the subsequent coating comprises gaps; and providing the granulate with the subsequent coating as artificial turf infill.

2. The method of claim 1, wherein the granulate with the initial coating and the subsequent coating is re-coated at least one time by performing the following sequence: providing a subsequent composition by adding at least one additive and the fluid binding agent to the granulate; mixing the subsequent composition; and 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, wherein the granulate with the further coating is provided as the artificial turf infill.

3. The method of claim 2, 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, ade-icing additive, sodium chloride, potassium chloride, sodium formiate, potassium formiate, and combinations thereof.

4. The method of claim 1, wherein the granulate comprises an elastomeric granulate.

5. The method of claim 1, wherein the granulate comprises any one of the following: rubber, an elastomeric polymer, Metallocene Butadiene Rubber, nitrile rubber granulate, natural rubber granulate, styrene-butadiene rubber granulate, ethylene propylene diene monomer rubber granulate, black crumb rubber granulate, acrylonitrile butadiene rubber, a thermoplastic polymer, Styrene Ethylene Butylene Styrene, Styrene Block Copolymers, an elastic foam, elastic polyurethane foam, and combinations thereof.

6. The method of claim 1, wherein the granulate comprises a compression resilient granulate.

7. The method of claim 1, wherein the granulate is any one of the following: natural latex, cork, linoleum, a composite formed from one or more type of solidified vegetable oil and wood flour, a hydrogel of methyl-cellulose, and combinations thereof.

8. The method of claim 1, wherein the granulate has an average diameter between 0.1 mm and 3.0 mm and/or wherein the granulate has a maximum diameter less than 5.0 mm.

9. The method of claim 1, 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, thalo green, chromium(111) oxide, a Copper phythalocyanie pigment, a nickel azopigment, titanium oxide, and combinations thereof.

10. The method of claim 1, 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.

11. The method of claim 1, wherein the polymer component is cured into at least one type of polyurethane by the water and catalyst.

12. The method of claim 1, wherein the fluid binding agent comprises a liquid polyurethane component.

13. The method of claim 12, wherein the liquid polyurethane component comprises an NCO terminal polymer, which may comprise a prepolymer, a polymeric isocyanate, an oligomeric isocyanate, a monomer, and a mixture thereof.

14. The method of claim 12, wherein the liquid polyurethane component comprises an aromatic diisocyanate of the group of toluene diisocyanate and/or methylene-2,2-diisocyanate.

15. The method of claim 12, wherein the liquid polyurethane component comprises an aliphatic disocyanate of the group hexamethylene disiocyanate, isophorone disocyanate, and/or 1,4-cyclohexyldisiocyanate.

16. The method of claim 12, wherein the liquid Polyurethane component comprises an methylenediphenyl-isocyanate isomer mixture.

17. The method of claim 12, wherein the liquid Polyurethane component comprises a hydroxyl component, wherein the hydroxyl. component is selected from the group of polyether polyol or polyester polyol.

18. The method of claim 17, 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.

19. The method of claim 1, wherein the catalyst belongs to any one of the following groups: a secondary amine catalyst, a tertiary amine catalyst, and a metal organic catalyst.

20. The method of claim 1, wherein the method further comprises drying the subsequent composition before providing the granulate as the artificial turf infill.

21. The method of claim 1, wherein the method is at least partially performed in a flow reactor.

22. The method of claim 1, wherein the method is at least partially performed as a batch process, wherein the initial coating is formed on the granulate during an initial batch, and wherein the subsequent coating is formed on the granulate during a subsequent batch.

23. The method of claim 1, wherein any one of the following: the at least one first type of pigment is identical with the at least one second type of pigment, and the at least one first type of pigment is a different color from the at least one second type of pigment.

24. The method of claim 1, wherein the initial coating and the subsequent coating each have a thickness of less than any one of the following: 0.1 mm, 0.075 mm, 0.05 mm, and 0.01 mm.

25. A method of manufacturing artificial turf, wherein the method comprises: installing an artificial turf carpet, wherein the artificial turf carpet comprises multiple artificial turf fiber tufts; and providing the artificial turf by spreading a layer of artificial turf infill between the multiple artificial turf fiber tufts, wherein the artificial turf infill comprises granulate, wherein the granulate comprises at least two outer coatings, wherein one of the at least two outer coatings comprises at least one first type of pigment and a binding agent, wherein the other of the at least two outer coatings comprises at least one second type of pigment and the binding agent, wherein the binding agent comprises at least one type of polyurethane polymer, and wherein the at least two outer coatings each comprise gaps.

26. Artificial turf infill, wherein the artificial turf infill comprises granulate, wherein the granulate comprises at least two outer coatings, wherein one of the at least two outer coatings comprises at least one first type of pigment and a binding agent, wherein the other of the at least two outer coatings comprises at least one second type of pigment and the binding agent, wherein the binding agent comprises at least one type of polyurethane polymer, wherein the at least two outer coatings each comprise gaps.

27. An artificial turf, wherein the artificial turf comprises: an artificial turf carpet, wherein the artificial turf carpet comprises multiple artificial turf fiber tufts; and artificial turf infill spread between the multiple artificial fiber tufts, wherein the artificial turf infill comprises a granulate, wherein the granulate comprises at least two outer coatings, wherein one of the at least two outer coatings comprises at least one first type of pigment and a binding agent, wherein the other of the at least two outer coatings comprises at least one second type of pigment and the binding agent, wherein the binding agent comprises at least one type of polyurethane polymer, and wherein the at least two outer coatings each comprise gaps.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0080] In the following embodiments of the invention are explained in greater detail, by way of example only, making reference to the drawings in which:

[0081] FIG. 1 illustrates a cross sectional coating of a grain of a granulate;

[0082] FIG. 2 illustrates the granule of FIG. 1 after being partially coated with an initial coating;

[0083] FIG. 3 illustrates the granule of FIG. 2 after being partially coated with a subsequent coating;

[0084] FIG. 4 illustrates the granule of FIG. 3 after being partially coated with a subsequent coating;

[0085] FIG. 5 illustrates an example of an artificial turf carpet;

[0086] FIG. 6 illustrates an example of artificial turf;

[0087] FIG. 7 shows a flow chart which illustrates a method of manufacturing artificial turf infill;

[0088] FIG. 8 shows a flow chart which illustrates a further method of manufacturing artificial turf infill;

[0089] FIG. 9 shows a flow chart which illustrates a method of manufacturing artificial turf;

[0090] FIG. 10 illustrates an example of a batch reactor; and

[0091] FIG. 11 illustrates an example of a flow reactor.

DETAILED DESCRIPTION

[0092] 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.

[0093] FIGS. 1-4 illustrate the manufacture of artificial turf infill by examining a single grain or granule 100. The granule 100 could for example be made from an elastomeric compound, a rigid compound, a semi-rigid compound, and/or a compression resilient compound. FIG. 1 shows a grain or granule. For example the grain 100 could be a grain or granule of rubber or a compression, a rigid compound, a semi-rigid compound, or resilient compound. The view shown in FIGS. 1-4 is a cross-sectional view.

[0094] FIG. 2 shows the same grain 100 or granule after it has been coated with an initial coating 200. The initial coating 200 was formed by providing an initial composition of a granulate, which is made up of a large number of grains or granules 100. The initial composition comprised at least one first type of pigment and a fluid binding agent also. The fluid binding agent comprises at least one type of polymer component. The initial composition was then mixed. Next, water and a catalyst were added to the initial composition during the mixing process to cure the fluid binding agent and the at least one first type of pigment into the initial coating 200. As a large number of these granules 100 or grains are mixed they interact with each other and bump into each other occasionally during the process. For this reason there may be holes or defects in the initial coating 200. In FIG. 2 it can be seen that there are a number of gaps 202 in the initial coating 200. These are regions where the grain 100 or granule is coated or is insufficiently coated by the initial coating 200.

[0095] FIG. 3 shows the same grain 100 or granule after it has been coated with a subsequent coating 300. As with the initial coating 200 the subsequent coating 300 does not completely cover all portions of the grain 100 or granule. However, due to the two-step process almost the entire grain 100 or granule 100 is coated. In this example there can only be seen one gap 202. The subsequent coating 300 was formed by providing a subsequent composition comprising the granulate with the initial coating as is shown in FIG. 2 and then combining it with the at least one first type of pigment or at least one second type of pigment and the fluid binding agent. This subsequent composition was then mixed. During the mixing process additional water and a catalyst were added to the subsequent composition to cure the fluid binding agent and the at least one type of pigment into the subsequent coating 300. FIG. 3 illustrates how a two-step coating process may be used to improve the coverage or quality of the coating on a granule that makes up a larger granulate. Granules manufactured, such as is shown in FIG. 3, may be provided as a group to form an artificial turf infill.

[0096] It is also possible to perform further coatings on the grain 100 or granule 100. FIG. 4 shows the grain 100 after a further coating 400 has been applied. This further coating 400 may for example be formed by recoating the granulate, which comprises the grain 100, by adding at least one additive and the fluid binding agent to the granulate. Next, a combination of the granulate and the at least one additive in the fluid binding agent form a subsequent composition. This subsequent composition is then mixed and again, water and a catalyst can be added to cure the fluid binding agent and at least one additive into the further coating 400. It can be seen now that the coverage of the grain 100 or granule is sufficient that there are no longer any gaps visible in this cross-section. The at least one additive could take different forms.

[0097] If it were desired to ensure that there are no gaps in the coatings the at least one pigment could be used again. In other cases additional additives may be added to form a functional further coating 400. For example a flame retardant such as polyurethane oliphatic isocyanates could be added. To provide for the absorption and de-absorption of water, to cool the carpet a zeolite could be added. Also various antibacterial or antifungal agents could be added too. In other examples an infrared reflection agent such as EPDM may be used to reduce the amount of heat absorbed by the artificial turf infill and/or also to help protect it from sunlight.

[0098] FIGS. 5 and 6 illustrate the manufacture of an artificial turf using an artificial turf carpet and artificial turf infill. In FIG. 5 an artificial turf carpet 500 can be seen. The artificial turf carpet 500 comprises a backing 502. The artificial turf carpet 500 shown in FIG. 5 is a tufted artificial turf carpet in this example. The artificial turf carpet is formed by artificial turf fiber tufts 504 that are tufted into the backing 502. The artificial turf fiber tufts 504 are tufted in rows. There is row spacing 506 between adjacent rows of tufts. The artificial turf fiber tufts 504 also extent a distance above the backing 502. The distance that the fibers 504 extend above the backing 502 is the pile height 508. In FIG. 5 it can be seen that the artificial turf carpet 500 has been installed by placing or attaching it to the ground 510 or a floor. To manufacture the artificial turf the artificial turf infill made up of grains or granules such as is shown in FIG. 3 or 4 are spread out on the surface and distributed between the artificial turf fiber tufts 504. FIG. 6 shows the artificial turf carpet 500 after the artificial turf infill 602 has been spread out and distributed between the artificial turf fiber tufts 504. It can be seen that the artificial turf infill 602 is a granulate made up of individual grains 100 or granules such as is depicted in FIG. 3 or 4.

[0099] FIG. 7 shows a flowchart which illustrates a method of manufacturing artificial turf infill 602 such as is depicted in FIGS. 1-3 in the coating of the single grain 100 or granule. First in step 700 an initial composition is provided. The initial composition comprises a granulate, at least one first type of pigment, and a fluid binding agent. The fluid binding agent comprises at least one type of polymer component. Next in step 702 the initial composition is mixed. Next in step 704 during the mixing water and catalyst are added to the initial composition to cure the fluid binding agent and the at least one type of pigment into an initial coating 200 of the granulate. In step 706 a subsequent composition is provided. The subsequent composition comprises the granulate with the initial coating 200, the at least one second type of pigment, and the fluid binding agent. Next in step 708 the subsequent composition is mixed. Next in step 710 water and the 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 second type of pigment into a subsequent coating 300 of the granulate. Finally in step 712 the granulate with the subsequent coating 300 is provided as the artificial turf infill 602.

[0100] FIG. 8 shows a flowchart, which illustrates an alternate method of manufacturing artificial turf infill. The method depicted in FIG. 8 is similar to the method depicted in FIG. 7 with several additional steps. The method in FIG. 8 is identical to FIG. 7 in steps 700-710. After step 710 has been performed, step 800 is performed. Steps 802 and then 804 are performed before step 712 is performed. Steps 800, 802 and 804 are the steps of recoating the granulate after it has been coated with the subsequent coating. First in step 800 a subsequent composition is provided by adding at least one additive and a fluid binding agent to the granulate. Next in step 802, the subsequent composition is mixed. Finally, in step 804, during the mixing in step 802, water and catalyst are added to the subsequent composition during mixing of the subsequent composition to cure the fluid binding agent and at least one additive into the further coating 400. Finally, in step 712, the granulate that has been coated with the initial coating, the subsequent coating, and the further coating 400, is provided as the artificial turf infill 602.

[0101] FIG. 9 shows a flowchart, which illustrates a method of manufacturing artificial turf 600 such as depicted in FIG. 6. First in step 900 an artificial turf carpet 500 is installed. The artificial turf carpet comprises multiple artificial turf fiber tufts 504. Next in step 902, the artificial turf 600 is provided by spreading a layer of artificial turf infill 602 between the multiple artificial turf fiber tufts 504. The artificial turf infill comprises the granulate. The granulate comprises at least two outer coatings 200, 300, 400. Each of the at least two outer coatings 200, 300, 400 comprises at least one type of pigment and a binding agent. The pigments in each of the coatings may be identical or different. The binding agent comprises at least one type of polyurethane polymer.

[0102] FIG. 10 illustrates some equipment which may be used for manufacturing the artificial turf infill 602 and for coating grain or granules 100, such as is illustrated in FIGS. 1-4. FIG. 10 depicts a mixing vat 1000. The mixing vat has a rotatable shaft 1002 that is connected to a number of mixing paddles 1004. The mixing vat 1000 is filled with the granulate 1006. The elastomeric granulate can then be manufactured into artificial turf infill by following the methods illustrated in FIG. 7 or 8. Since water is added with the catalyst for forming each of the initial coating 200, the subsequent coating 300 or the further coating 400 it is not necessary to dry the granulate 1006 between the coating of each of the coatings. The granulate 1006 can be added to the mixing vat 1000 and then at different times the different materials can be added while the rotatable shaft 1002 is turned.

[0103] The apparatus depicted in FIG. 10 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.

[0104] FIG. 11 illustrates an example of a flow reactor 1100. The example shown in FIG. 11 is illustrative and is not drawn to scale. The flow reactor 1100 comprises a rotatable shaft 1102 that is connected to a screw conveyor 1104. The screw conveyor 1104 is similar to an Archimedes screw, which is mounted horizontally. The flow reactor 1100 can be shown as being filled with granulate 1006. The granulate 1006 comprises grains or particles 100 such as is shown in FIGS. 1-4. As the rotatable shaft 1102 is turned, it causes the granulate 1006 to move through the flow reactor 1100. It also causes the granulate 1006 to be mixed. At an entrance there is an inlet 1108 for adding granulate 1006. This may be done on a continual basis as the shaft 1102 is rotated. This causes the granulate to go to a first inlet for at least one pigment and fluid binding agent. At this first inlet 1110 the at least one pigment and the fluid binding agent are added to the granulate 1006 and become mixed with it as the shaft 1102 is rotated. When they are thoroughly mixed, the granulate 1006 and the at least one pigment and the fluid binding agent form an initial composition 1120. This initial composition 1120 is then transported beneath a first inlet for water and catalyst 1112. The water and catalyst may be added on a continual or intermittent basis at this inlet 1112.

[0105] As the initial composition 1120 is transported further along the flow reactor 1100 fluid binding agent and at least one pigment cure into the initial coating 200 such as depicted in FIG. 2. After the initial coating 200 is formed, the initial composition 1120 is transported underneath the second inlet for at least one pigment and fluid binding agent. At this point more of the pigment and fluid binding agent are added and the initial composition 1120 becomes the subsequent composition 1122. The pigments used for the initial composition and the subsequent composition may be identical or they may be different.

[0106] The subsequent composition 1122 is mixed and transported underneath the second inlet for water and catalyst 1116. The water and catalyst are then mixed with the subsequent composition 1122 and over time are further transported to the end of the flow reactor 1100. By the time the subsequent composition 1122 has reached the end of the flow reactor 1100 the subsequent coating 300 has formed on the grains or particles of the granulate 1006 such as depicted in FIG. 3. At the very end, then the granulate 1006 exits the flow reactor 1100 at an outlet 1117. The granulate 1006 at this point is then artificial turf infill 602. The artificial turf infill 602 is then shown as entering into an optional dryer 1118.

[0107] It is clear from FIG. 11 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 1100 can simply be increased. This may involve moving the granulate at a different rotational rate or possibly even making the flow reactor 1100 longer.

LIST OF REFERENCE NUMERALS

[0108] 100 grain or granule [0109] 200 initial coating [0110] 202 gap [0111] 300 subsequent coating [0112] 400 further coating [0113] 500 artificial turf carpet [0114] 502 backing [0115] 504 artificial turf fiber tufts [0116] 506 row spacing [0117] 508 pile height [0118] 510 ground or floor [0119] 600 artificial turf [0120] 602 artificial turf infill [0121] 700 providing an initial composition comprising a granulate [0122] 702 mixing the initial composition [0123] 704 adding water and a catalyst to the initial composition during the mixing of the initial composition to cure the fluid binding agent and the at least one first type of pigment into an initial coating of the granulate [0124] 706 providing a subsequent composition comprising the granulate with the initial coating [0125] 708 mixing the subsequent composition [0126] 710 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 pigment into a subsequent coating of the granulate [0127] 712 providing the granulate with the subsequent coating as artificial turf infill [0128] 800 providing a subsequent composition by adding at least one additive and the fluid binding agent to the granulate [0129] 802 mixing the subsequent composition [0130] 804 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 [0131] 900 installing an artificial turf carpet with multiple artificial turf fiber tufts [0132] 902 providing the artificial turf by spreading a layer of artificial turf infill between the multiple artificial turf fiber tufts [0133] 1000 mixing vat [0134] 1002 rotatable shaft [0135] 1004 mixing paddles [0136] 1006 granulate [0137] 1100 flow reactor [0138] 1102 rotatable shaft [0139] 1104 screw conveyor [0140] 1108 inlet for granulate [0141] 1110 first inlet for at least one pigment and fluid binding agent [0142] 1112 first inlet for water and catalyst [0143] 1114 second inlet for at least one pigment and fluid binding agent [0144] 1116 first inlet for water and catalyst [0145] 1117 outlet [0146] 1118 dryer [0147] 1120 initial composition