Patent ID: 7758281
Filing Date: 2010-07-20
Classification: E01C,Y10T

Abstract:
1. A method for forming a synthetic turf sports field comprising: forming a level and substantially smooth subgrade; introducing a geotextile fabric onto said subgrade; introducing a layer of a coarse aggregate material onto said geotextile fabric, said layer having a first thickness; introducing a plurality of first perforated drains within a portion of said coarse aggregate grade, such that said pair of perforated drains overlie said geotextile fabric and said subgrade; fluidically coupling a plurality of drain tiles to each of said plurality of first perforated drains, each of said plurality of drain tiles separated by a first distance; introducing a plurality of secondary perforated drains to said coarse aggregate layer, said plurality of secondary perforated drains disposed entirely above said plurality of first perforated drains, said plurality of secondary perforated drains not fluidly coupled to said plurality of drain tiles; introducing a layer of a fine aggregate material onto said coarse aggregate material; grading and leveling said layer of fine aggregate material to a minimum 95 percent proctor; introducing at least one strip of a synthetic grass material onto said fine aggregate material, each of said at least one strip having a pair of lengthwise edges and a pair of widthwise edges, each of said lengthwise edges being substantially parallel with respect to each other and substantially perpendicular to each of said widthwise edges, said lengthwise edges being longer than said widthwise edges, said synthetic grass material comprising a plurality of layers of a backing material, a polypropylene mesh backing material coupled to a topmost layer of said plurality of layers of said backing material, a plurality of fibrillated synthetic grass strands tufted through said plurality of layers of said backing material and said polypropylene mesh backing material such that said ends of said plurality of fibrillated strands extend above said polypropylene mesh backing material at a first height, and a secondary coating coated to a bottommost one of said plurality of layers of said backing material such that a tufted portion of said plurality of fibrillated synthetic grass strands is contained between said secondary coating and said bottommost one of said plurality of layers of said backing material; fibrillating and standing up said plurality of fibrillated strands on top of said polypropylene mesh backing material, wherein said fibrillated strands therein form a plurality of individual blades; cleaning said plurality of individual blades using a lawn sweeper; introducing a layer of infill onto said strip of said synthetic grass material to a second thickness, wherein said second thickness is less than said first height; and substantially leveling said layer of infill on said strip.