NATURAL COMPOSITE INFILL MATERIAL FOR SYNTHETIC TURF

Abstract

An infill composition for artificial turf fields comprising at least one layer of particles comprising curable oil and natural polymers-based particles, the particles can include a particle size distribution of curable oil-based particles with a size of 0.6 to 7 mm to after wetting. The infill composition can be installed according to a method of spreading a layer of curable oil-based particles over a carpet that is on a base of compacted stone, wherein the layer of curable oil-based particles consists of dry particles.

Claims

1. A natural composite granular material for use in artificial turf.

2. A natural composite granular material according to a claim 1, which is made entirely of renewable materials for use in artificial turf.

3. A natural composite granular material according to claim 1, which is made from a blend of natural curative oil or blends thereof, natural hydrophobic polymers or blends thereof, and organic reinforcement or mineral fillers.

4. A natural composite granular material according to claim 3, comprising 30-95% curable oil, 10-40% hydrophobic natural polymer, and 0-50% filler and/or reinforcement based on the weight of the composite material.

5. A natural composite granular material according to claim 3, comprising 60-90% vegetable curable oil, 2-20% hydrophobic polymer, and 0-30% inorganic fillers and/or reinforcement based on the weight of the composite material.

6. A natural composite granular material according to claim 3, wherein the natural curable oil is selected from one or more of linseed oil, tung oil, soybean oil, sunflower oil, safflower oil, poppy seed oil, perilla oil, rapeseed oil, and walnut oil.

7. A natural composite granular material according to claim 3, wherein the natural curable polymer is selected from one or more of carnauba wax, shellac, dammar, copal, rosin such as gum rosin (colophony) or other conifer materials, propolis, mastic and tree gums such as guaiacum, dammaror kauri and gutta percha.

8. A natural composite granular material according to claim 3, wherein the reinforcement is selected from one or more of natural fibers, such as jute, hemp, linen, coconut coir, cotton, regenerated cellulose and bamboo and/or one or more mineral materials such as calcium carbonate, talc, barium sulfate, titanium oxides, silicon dioxides, aluminum oxides, clay, and chalks.

9. A natural composite granular material according to claim 3, wherein the filler is selected from one or more of calcium carbonate, talc, barium sulfate, titanium oxides, silicon dioxides, aluminum oxides, clay, and chalks.

10. A natural composite granular material according to claim 3, wherein the oil is linseed oil, the polymer is rosin and the filler is an inorganic filler.

11. A natural composite granular material according to claim 1, comprising 30-95% linseed oil, 10-40% pine rosin, 0-50% calcium carbonate, and 0-50% talc.

12. A natural composite granular material according to claim 1, wherein the granules have an average size (by sieving) of 0.8-1.25 mm and about 90% by weight have a size>0.5 mm, while most of the granules are smaller than 3.14 mm.

13. A method of using a natural composite granular material as infill for an artificial turf.

14. An artificial turf comprising a layer of a composite granular material which is made from a blend of natural curative oil or blends thereof, natural hydrophobic polymers or blends thereof, and organic reinforcement or mineral fillers.

15. An artificial turf according to claim 14, wherein the layer is made entirely (100% by weight), substantially (e.g., 65% or higher or 75% or higher by weight), primarily (e.g., 50% or higher by weight), or predominantly (e.g., 45% or higher by weight, or a percentage by weight that is higher than the percentage by weight of any other particle or sand in the same layer) of the natural composite granular material.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0012] FIG. 1 illustrates a dish full of the composite infill material in accordance with aspects of the innovation;

[0013] FIG. 2 Illustrates a zoomed-in picture of the natural composite infill particles in accordance with aspects of the innovation;

[0014] FIG. 3 Illustrates a curing reactor setup and flows in accordance with aspects of the innovation; and

[0015] FIG. 4 Illustrates an example turf system assembly in accordance with an aspect of the innovation.

[0016] FIG. 5 illustrates an example turf system assembly in accordance with an aspect of the innovation.

[0017] FIG. 6 illustrates the testing device in accordance with aspects of the innovation.

[0018] FIG. 7 illustrates example test results of the innovation described herein.

[0019] FIG. 8 illustrates example test results of the innovation described herein.

[0020] FIG. 9 illustrates example tested granules post-test as described herein.

DETAILED DESCRIPTION

[0021] Various aspects of the subject disclosure are now described in more detail with reference to the annexed drawings, wherein like numerals generally refer to like or corresponding elements throughout. It should be understood, however, that the drawings and detailed description relating thereto are not intended to limit the claimed subject matter to the particular form disclosed. Instead, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the described and claimed subject matter.

[0022] For the purposes of this description the word natural is used to describe a material that comes from biological or naturally occurring mineral systems, and while it is separated from other materials of a different composition, it is not substantially modified and retains a chemical nature that can be found in the environment without the intervention of man. It is to be understood that natural is to include, but not limited to, unprocessed raw materials as well as those extracted and unmodified. Similarly, the word organic is meant to describe a carbon-based material, as opposed to referring to the method of growing and harvesting the organism.

[0023] An artificial turf system can use an infill material that includes a fully natural composite granular material. In aspects, a stabilizing layer, such as sand or other sufficient material, is incorporated. Moreover, and most often, a shock pad is employed to achieve a desired shock absorption in accordance with a particular installation/purpose. The infill material conveys many of the mechanical properties that are desired for the use as artificial turf infill and conveys performance advantages over the materials and methods described above.

[0024] In aspects, the natural composite granular material is made from a blend of one or many natural curative oils such as siccative oils, one or many hydrophobic and optionally curable natural polymers, and one or many reinforcements or filler, mineral or organic natural materials.

[0025] In embodiments, the natural composite granular material is composed of 30-95% curable oil, 10-40% hydrophobic natural polymer, and 0-50% filler or reinforcement (percentages are based on the weight of the natural composite granular material). In some embodiments, the natural composite granular material is composed of 40-80% curable oil, 15-30% hydrophobic polymer and 5-20% filler or reinforcement. The amount of curable oil is preferably 60-75%. The amount of the hydrophobic polymer is preferably 15-25%.

[0026] The natural curative oils, which are also known as siccative oils used in this composition are oils that polymerize through an oxidation process and harden with exposure to light and oxygen. The curable oils used for this formulation are among linseed oil, tung oil, soybean oil, sunflower oil, safflower oil, poppy seed oil, perilla oil, rapeseed oil, and walnut oil. Linseed oil is particularly and often used.

[0027] The natural hydrophobic or curable polymer are among carnauba wax, shellac, dammar, copal, or resins and terpenoid polymers such as rosin-gum rosin (colophony) or other conifer materials-propolis, mastic, tree gums-guaiacum, dammar, kauri, gutta-percha or other natural polymeric blended materials that are hydrophobic and prone to drying.

[0028] The reinforcements used are among the categories of natural fibers, such as jute, hemp, linen, coconut coir, cotton, regenerated cellulose, bamboo. In most aspects, these must be of a small size, at most 90% length of the granule diameter. Longer fibers convey greater reinforcement of mechanical strength, but increase the abrasiveness of the material, which is deleterious for use in turf. The fillers used are of a mineral nature, and are selected among standard fillers, such as calcium carbonate, talc, barium sulfate, titanium oxides, silicon dioxides, aluminum oxides, clay, and chalks. Calcium carbonate may be from mineral sources or biogenic sources. In case of calcium carbonate from biogenic sources it is possible to provide a composite granular material from 100% renewable materials. Hydrated lime and stearic calcium carbonate, which may be, are also useful. A mix of calcium carbonate and stearic acid also known as stearic calcium carbonate is often employed.

[0029] In an embodiment, the oil is linseed oil, the polymer is rosin and the filler is an inorganic filler. In another embodiment, the natural composite granular material is composed of 30-95, preferably 40-80% linseed oil, 10-40%, preferably 15-30% pine rosin, 0-50%, preferably 0-25% calcium carbonate, and 0-50%, preferably 0-25% talc. In yet another embodiment, the composition comprises 60 to 75%, such as 67% linseed oil, 15 to 25%, such as 20% pine rosin, 8 to 10% calcium carbonate, 3% stearic calcium carbonate and 1% hydrated lime. In a reactor, raw materials are mixed and an oxidation process occurs. Precise setting and monitoring and of air flow and temperature during all oxidation process can be adjusted according to individual needs, whereby the skilled person appreciates that a high air flow and high temperature produces a harder product than a low temperature and a low air flow. Products have a hardness in the order of Shore A 20-40, such as Shore A 30 are preferred.

[0030] In some embodiments, a large amount of siccative oil and mineral filler, and a longer residence time in the reactor could lead to a harder and more durable material more apt for use as stabilizing infill, whereas a mix that is less prone to crosslinking and hardening would better maintain its elastics properties and be more appropriate for use as performance infill.

[0031] Reaction parameters including air flow, shear and mixing rate, reactor blade size and cross-sectional area, overall size, temperature, and residence time also an effect on the properties of the resulting material. Oxidation process can last up to 15 hours and the product obtained has the aspect of crumbs with granules of several sizes.

[0032] Granules obtained from the reactor are then sieved to obtain the required particles size distribution for use in an infill system. In embodiments, particles fall within the range of 0.8-3.15 mm. The granules are produced to have an average particle size in the range of 0.1-5 mm, more preferably a size between 0.3-3 mm, most preferably between 0.8 and 1.25. A fraction wherein 90 wt.-% or more of the granules have size (by sieving) of 0.5 mm or more, is preferred. Granules smaller than 3.15 mm are preferred. The density of the composite granules is in the order of 0.5 g/cm.sup.3 or more, preferably above 0.6 g/cm.sup.3.

Use in Turf Systems

[0033] The natural composite infill material is to be used as stabilizing infill or performance infill layer in an artificial turf system.

[0034] In aspects, a natural composite infill employs a shock pad to achieve a desired and/or proper shock absorption on the turf. The curable oil-based infill is most often installed over a layer of sand wherein the sand acts as a stabilizing infill. As a stabilizing infill, the sand performs as a ballast layer that weighs down the turf carpets and mitigates movement.

[0035] In other aspects, an infill composition for artificial turf fields comprises at least one layer of natural composite infill particles. As previously stated, a shock pad is most often employed to achieve a desired shock absorption of the field.

[0036] To the accomplishment of the foregoing and related ends, certain illustrative aspects of the claimed subject matter are described herein in connection with the following description and the annexed drawings. These aspects indicate various ways in which the subject matter may be practiced, all of which are intended to be within the scope of the disclosed subject matter. Other advantages and novel features may become apparent from the following detailed description when considered in conjunction with the drawings.

[0037] As stated, the natural composite infill material can be used in combination with a shock pad, carpet, and/or a stabilizing infill layer (e.g., sand) to make up the artificial turf system. The artificial turf system, using the described infill material, exhibits superior mechanical performance, a greater mechanical durability, easy availability and mitigates or otherwise avoids issues of floating away when subjected to large amounts of water.

[0038] As a general matter, various types of infill arrangements are contemplated. For example, two layer, three layers, or other arrangements are contemplated. For convenience, the present description primarily discusses two and three layer embodiments. Embodiments of the present disclosure are directed to providing natural composite infill solutions. The materials that are discussed are primarily sand (as a stabilizing infill) and natural composite infill material but it should be understood that other materials can be included or substituted.

[0039] As described herein, the infill material is directed to having the natural composite particles, in effect, replace crumb rubber infill materials. As such, the infill is devoid or substantially devoid of crumb rubber or similar materials. For example, in such embodiments, one layer of the infill (e.g., one of the multiple layers in the infill) can be made entirely (100% by weight), substantially (e.g., 65% or higher or 75% or higher by weight), primarily (e.g., 50% or higher by weight), or predominantly (e.g., 45% or higher by weight, or a percentage by weight that is higher than the percentage by weight of any other particle or sand in the same layer) of the natural composite particles. In some embodiments, the infill can be only one layer, and the only layer can be made entirely (100% by weight), substantially (e.g., 65% or higher or 75% or higher by weight), primarily (e.g., 50% or higher by weight), or predominantly (e.g., 45% or higher by weight, or a percentage by weight that is higher than the percentage by weight of any other particle or sand in the layer) of natural composite particles. It is to be understood and appreciated that the natural composite particles can provide shock absorbency and traction. It is possible for the infill layer to include other organic materials or other materials in addition to or in place of those described herein.

[0040] The infill may comprise the aforementioned natural composite particles and sand (as a stabilizing layer) in separate layers (one overlaying the other) or intermixed as shown in FIG. 4. FIG. 4 depicts illustrative infill 205 comprising particles and sand in separate layers in accordance with aspects of the innovation. The first layer 210 (sequentially in the order of layers from bottom to top, where bottom is closest to the ground) is preferably a sand layer. In a second layer 215, the infill may comprise particles in accordance the innovation described herein of a desired engineered size and distribution. The second layer 215 may comprise the aforementioned particles, the aforementioned fine sand, or a combination thereof. When the second layer 215 includes both the innovative particles and the sand, the innovative particles and the sand are preferably intermixed. FIG. 5 depicts illustrative infill 305 comprising a layer 310 of innovative particles and sand intermixed.

[0041] While specific embodiments are shown and described herein, it is contemplated that alternative embodiments exist that employ alternative materials, mixtures, proportions, sizes, etc. without departing from the spirit and/or scope of the innovation as described in detail. These alternative embodiments are to be included within the spirit and scope of the innovation as described and claimed herein.

Example

[0042] A composite granular material with a grain size of 0.5-2.5 mm (determined by sieving) and a density of 0.612 g/cm.sup.3 with a composition as set forth in Table 1 was tested according to EN 15330-5:

TABLE-US-00001 TABLE 1 Linseed Oil 65-75% Pine rosin 15-25% Calcium carbonate 8-12% Hydrated Lime 1-2% Stearic Calcium carbonate 2-4%

[0043] The test was conducted with the device shown in FIG. 6. The studded rollers are moved over the artificial turf. The results are shown in FIGS. 7 and 8. The composite granulate material described above resists 4500 cycles, whereby the minimum requirement in this test is only 500 cycles. At 4500 cycles, 63% of the grains are within the declared values. At 5000 cycles only 56% are within the declared values (requirement est60%). FIG. 9 illustrates the tested material after 4500 cycles.