Patent Publication Number: US-2021189662-A1

Title: Artifical grass

Description:
FIELD OF THE INVENTION 
     The present invention relates generally to an artificial grass product and a method for making the same. 
     SUMMARY OF THE INVENTION 
     In an embodiment, the invention is directed to a face spinneret and/or nylon face fiber having a certain shape and dimension which impart improved characteristics to the fiber, such a softer feel and a reduced sheen. In another embodiment, the invention is directed to a thatch spinneret and/or nylon thatch fiber having a certain shape and dimension which impart improved characteristics to the fiber, such a softer feel and a reduced sheen. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       A full and enabling disclosure of the present invention, including the best mode thereof directed to one of ordinary skill in the art, is set forth in the specification, which makes reference to the appended drawings, in which: 
         FIG. 1  is a perspective view of a yarn of artificial grass in accordance with one embodiment of the invention; 
         FIG. 2  is a perspective view of a yarn of artificial grass in accordance with another embodiment of the invention; 
         FIG. 3  is a top view of a spinneret of the invention, the yarn shown in  FIG. 1  having the same cross-sectional shape; 
         FIG. 4  is a top view of a spinneret of the invention, the yarn shown in  FIG. 2  having the same cross-sectional shape; 
         FIG. 5  is a perspective view of an artificial grass product, including yarns and backing, in connection with an embodiment of the present invention; and 
         FIG. 6  is a perspective view of an artificial grass product, including yarns and backing, in connection with an embodiment of the present invention. 
     
    
    
     Elements illustrated in the figures are not necessarily drawn to scale. Repeat use of reference characters in the present specification and drawings is intended to represent the same or analogous features or elements of the invention. 
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS 
     Reference will now be made in detail to embodiments of the invention, one or more examples of which are illustrated in the accompanying drawings. Each example is provided by way of explanation of the invention, not limitation of the invention. In fact, it will be apparent to those skilled in the art that modifications and variations can be made in the present invention without departing from the scope or spirit thereof. For instance, features illustrated or described as part of one embodiment may be used on another embodiment to yield a still further embodiment. Thus, it is intended that the present invention covers such modifications and variations as come within the scope of the appended claims and their equivalents. 
     In an embodiment, the artificial grass product of the present invention comprises nylon. Nylon has a high melt temperature and is resilient under deformation (i.e. it tends to retain its deformed shape). However, nylon typically does not inherently have a soft, grass-like feel underfoot and has a sheen that causes it to appear too shiny and unnatural. Accordingly, polypropylene and polyethylene are typically utilized for artificial grass products. Alternatively, currently, nylon may be chemically modified to provide a product with a softer feel and a more natural appearance. Though hard work and ingenuity, however, the present inventor has developed a nylon artificial grass product which has a soft feel and a natural appearance without chemical modification of the nylon itself. In an embodiment, the nylon yarns of the present invention achieve their characteristics and advantages due to their physical form, shape, and dimensions. 
     In an embodiment, the artificial grass product of the present invention at least partially comprises nylon. In an embodiment, artificial grass product of the present invention comprises 100% nylon. In an embodiment, the nylon has not been chemically modified. In an embodiment, the invention comprises both face fibers and thatch fibers and both the face fibers and the thatch fibers of the invention comprise nylon. 
     In an embodiment, the fibers of the artificial grass product of the invention are produced via a specific spinneret profile (exemplary embodiments shown in  FIGS. 3 and 4 ), to provide a yarn with a soft feel and a reduction in sheen. In an embodiment, the fibers of the artificial grass product of the invention are provided with particular dimensions that aid in improving the feel and appearance of the turf. In a further embodiment, the face fibers and the thatch fibers of the invention have different textures and optionally different heights. In an embodiment, neither the face fiber nor the thatch fiber of the invention is flat. 
     Referring to the drawings,  FIGS. 1 and 2  illustrate embodiments of fibers of the present invention. In an embodiment, the fiber  10  shown in  FIG. 1  may be utilized as a face fiber and the fiber  20  shown in  FIG. 2  may be utilized as a thatch fiber. As shown, each fiber  10 ,  20  may have a first or front longitudinal face  12 ,  22 , a second or rear longitudinal face  18 ,  28 , a top surface  16 ,  26 , and two ends  14 ,  24 . In an embodiment, the fibers  10 ,  20  are extruded as a monofilament and the monofilament ribbon is cut in discrete lengths to form the fibers. For example, the top surface  16 ,  26  may represent a position where the ribbon was cut into a fiber. 
       FIGS. 3 and 4  illustrate top views of spinnerets used to extrude the fibers illustrated in  FIGS. 1 and 2 , respectively. Thus, in an embodiment, a cross-sectional view of the fibers illustrated in  FIGS. 1 and 2  is the same as or very similar to the illustration of the spinnerets shown in  FIGS. 3 and 4 . 
     Generally speaking, the face spinneret ( FIG. 3 ) and the cross-sectional view of the face fiber  10  of the invention comprises an elongated shape. In an embodiment, the face spinneret and the face fiber  10  do not comprise any linear or planar surfaces, viewed in cross-section. That is, in this embodiment, the perimeter or exterior surface of the yarn  10 , as viewed in cross-section, comprises a continuous arcuate shape, alternating between concave  32  and convex portions  34 . Thus, a convex portion  34  may continue into a concave portion  32 , which may continue into a convex portion  34 , repeating the pattern continuously. In an embodiment, the shape of the perimeter of the face fiber, and the perimeter of the face spinneret, may be described as having a sine curve-like shape. 
     In an embodiment shown in  FIG. 3 , the ends  14  of the face fiber, as viewed in cross-section, may each be convex, extending arcuately outwardly (each, a convex end portion  33 ). Adjacent each side of each convex end portion  33  may be a concave portion  32 . In an embodiment, the convex end portions  33  extend outward in the width direction, away from the centerline A-A of the fiber width  36 . The convex end portions  33  provide a soft feel to the edge of each end  14  of the synthetic grass blade, which is beneficial regardless of whether an individual is walking over a lawn or sliding over the turf in an athletic event. In an embodiment, the line C-C shown in  FIG. 3  may be referred to as the longitudinal direction. In an embodiment, the convex end portions  33  extend outwardly in the longitudinal direction. In an embodiment, the concave portions  32  on either side of each convex end portion  33  transition from the convex end portion  33  to a plurality of convex and concave body portions. 
     As noted, in an embodiment, the face fiber  10  additionally comprises a plurality of convex body portions  34  which extend arcuately outwardly from the first side  12  of the face fiber and which are disposed along the width  36  of the fiber and are disposed at a ninety-degree angle (or approximately at a ninety-degree angle) from that of the convex end portions  33 . In an embodiment, the convex body portions  34  extend outwardly from the first side  12 , perpendicular to the longitudinal direction C-C. In an embodiment, the convex body portions  34  extend in the thickness direction, away from the center C-C of the fiber thickness  38 . 
     In an embodiment, the face fiber  10  additionally comprises concave body portions  32  which may have the same or a similar (but opposite) radius of curvature as the convex portions  34  of the face fiber  10 . In an embodiment, each concave portion  32  is adjacent a convex portion  34  along the first side  12  of the fiber  10 . In an embodiment, each convex portion  34  of the face fiber  10  curves gradually into the adjacent concave portion  32  and vice versa. 
     As shown in  FIG. 3 , the convex portions  34  may be disposed opposite (relative to the width  36  of the face fiber  10 ) another convex portion  34 . That is, line A-A is taken through the width  36  of the face fiber  10  and intersects a convex portion  34  on each side of the width  36 . Likewise, the concave portions  32  may be disposed opposite (relative to the width  36  of the face fiber  10 ) another concave portion  32 . That is, line B-B is taken through the width  36  of the face fiber  10  and intersects a concave portion  32  on each side of the width  36 . In this embodiment, the protrusions (i.e. convex portions  34 ) are not staggered but are, instead, aligned along the width  36  (or the longitudinal direction C-C) of the face fiber  10 . In an embodiment, the cross-section of the face fiber  10 , including its convex and concave portions  32 ,  34 , is symmetrical. In an embodiment, the centerline (shown as A-A in  FIG. 3 ) comprises a convex portion  34  on each side of the width  36 . In an embodiment, the face fiber  10  comprises four convex portions  34  between the centerline A-A and the end  14 , not counting the convex end portion  33 . In an embodiment, the face fiber  10  comprises five concave portions  32  between the centerline A-A and the convex end portion  33 . In an embodiment, the face fiber  10  comprises nine convex portions  34  between the first end and the second end of the fiber. The sine curve-like structure of the perimeter of the yarn  10  provides a soft feel and reduction in luster, providing a more natural appearance and feel. 
     In an embodiment, the yarn shown in  FIG. 1  comprises a face fiber  10  and the face spinneret ( FIG. 3 ) and the face fiber each have a thickness  38  in the range of about 0.001 to 0.100 inches. In another embodiment, the yarn shown in  FIG. 1  comprises a face fiber  10  and the face spinneret and yarn each have a thickness  38  in the range of about 0.025 to 0.033 inches. In still another embodiment, the yarn shown in  FIG. 1  comprises a face fiber  10  and the face spinneret and yarn have a thickness  38  of about 0.025 inches. 
     In an embodiment, the yarn shown in  FIG. 1  comprises a face fiber  10  and the face spinneret and yarn have a width  36  in the range of about 0.070 to 0.250 inches. In an embodiment, the yarn shown in  FIG. 1  comprises a face fiber  10  and the face spinneret and yarn have a width  36  in the range of about 0.109 to 0.180 inches. In yet an embodiment, the yarn shown in  FIG. 1  comprises a face fiber  10  and the face spinneret and yarn have a width  36  of about 0.180 inches. 
     In an embodiment, the yarn shown in  FIG. 2  comprises a thatch fiber  20 . In an embodiment, the thatch fibers  20  provide structural support to the face fibers  10 . In another embodiment, the thatch fibers  20  provide a varied appearance and feel to the turf, simulating the look and feel of natural grass. 
     Generally speaking, a cross-sectional view of the thatch yarn  20  of the invention comprises an elongated shape, though not as elongated as that of the face yarn  10  in an embodiment. In an embodiment, the width of the face yarn  10  may be about one and a half times that of the thatch yarn  20 . In an embodiment, the thatch yarn  20  is different from the face yarn  10  in at least one of thickness, width, and shape configuration. 
     In an embodiment, the thatch yarn  20  comprises a combination of linear or planar surfaces and curved surfaces, when viewed in cross-section. In an embodiment of the thatch spinneret shown in  FIG. 4 , the spinneret and resulting thatch fiber  20  comprise a longitudinal direction shown as G-G and a centerline shown as F-F. At the centerline F-F, the thatch fiber  20  may extend angularly outwardly from the first side  22  of the fiber  20 , the extension being perpendicular to and away from the longitudinal direction G-G. In an embodiment, this first or central angular protrusion  42  may comprise a generally triangular shape or may be a flattened triangle, such that the outermost end of the triangle is flattened and is parallel to the longitudinal direction. In an embodiment, the angle of each side of the central angular protrusion  42  is equal. In an embodiment, a symmetrical central angular protrusion  42  is disposed on the second side  28  of the width of the yarn  20 . In an embodiment, the end  43  of each central angular protrusion  42  comprises the thickest part of the thatch yarn  20 . That is, the central angular protrusion  42  extends further away from the longitudinal direction G-G than any other part of the thatch yarn  20 . 
     In an embodiment, one or more second angular protrusions  44  may extend perpendicular to and away from the longitudinal direction G-G. In an embodiment, a second angular protrusion  44  is disposed adjacent each side of the central angular protrusion  42 , on a first side  22  of the thatch yarn  20 . In an embodiment, the one or more second angular protrusions  44  may comprise triangular shapes or may be flattened triangles, such that the outermost end of the triangle is flattened and is parallel to the longitudinal direction. In an embodiment, the angle of each side of the second angular protrusions  42  is equal. In an embodiment, each of the second angular protrusions  42  has the same size, angles, and dimensions. In an embodiment, one or more second angular protrusions  42  are disposed on the second side  28  of the width of the yarn  20 , symmetrically with those of the first side. In an embodiment, the width of the one or more second angular protrusions  44  may be less than the width of the central angular protrusion  42 . 
     Adjacent each second angular protrusions  44 , moving toward the end  24  of the fiber  20  in a cross-sectional dimension, the thatch fiber  20  may comprise one or more convex thatch portions  46 . The convex thatch portions  46  may be continuously curved or may comprise a series of angles which appears to the naked eye to comprise a curvature. For example, the perimeter of the convex thatch portions  46  may comprise a smooth curve or may comprise three of more linear panels which appear to approximate a curve. The middle panel of the convex thatch portions  46  may be flattened and may be parallel with the longitudinal direction G-G, in an embodiment. For example, in an embodiment, the convex thatch portions  46  may comprise half-hexagonal shapes. In an embodiment, the width of the convex thatch portions  46  may be less than the width of the one or more second angular protrusions  44 . 
     Finally, the thatch fiber  20  may comprise a bulbous end portion  48  on each longitudinal end  24  of the fiber. The bulbous end portions  48  may be semi-circular in an embodiment, curving convexly outwardly. In another embodiment, the bulbous end portions  48  may comprise a plurality of angular panels which approximate the appearance of a curvature. For example, the bulbous end portions  48  may be semi-hexagonal or semi-octagonal. In an embodiment, the width of the bulbous end portions  48  may be less than the width of the one or more convex thatch portions  46 . 
     As shown in  FIG. 4 , the apex of each angular protrusion  42 ,  44  on the first side  22  of the fiber  20  may be disposed opposite (relative to the width  47  of the thatch fiber  20 ) the apex of another angular protrusion  42 ,  44  on the second side  28  of the fiber  20 . That is, line F-F, is taken through the width  47  of the thatch fiber  20 , intersects the apex of each central angular protrusion  42  on each side of the width  47 . 
     Likewise, the convex thatch portions  46  on the first side  22  of the fiber  20  may be disposed opposite (relative to the width  47  of the thatch fiber  20 ) another convex thatch portions  46  on the second side  28  of the fiber  20 . That is, line D-D is taken through the width  47  of the thatch fiber  20  and intersects the center of a convex thatch portion  46  on each side of the width  47 . As can be seen, the valleys  45  between each angular protrusion  42 ,  44 , convex thatch portion  46 , and/or bulbous end portions  48  are also aligned and are not staggered, in an embodiment. 
     In this embodiment, the angular protrusions  42 ,  44  and the convex thatch portions  46  are not staggered but are, instead, aligned along the width  47  (or the longitudinal direction G-G) of the thatch fiber  20 . In an embodiment, the cross-section of the thatch fiber  20 , including its angular protrusions  42 ,  44 , convex thatch portions  46 , and bulbous end portions  48 , is symmetrical. In an embodiment, thatch fiber  20  comprises, per longitudinal side, one central angular protrusion  42 , two second angular protrusions  44  on either side of the central angular protrusion  42 , convex thatch portions  46  on either side of the second angular protrusions  44 , and two bulbous end portions  48  on each end  24  of the fiber. The variations in curvature and angularity of the thatch yarn  20  provides a reduction in luster and variance in visual appearance, providing a more natural appearance and feel to the artificial turf product. 
     In an embodiment, the yarn shown in  FIG. 2  comprises a thatch fiber  20  and the thatch spinneret and yarn have a thickness  49  in the range of about 0.001 to 0.100 inches. In another embodiment, the yarn shown in  FIG. 3  comprises a thatch fiber  20  and the thatch spinneret and yarn have a thickness  49  in the range of about 0.025 to 0.033 inches. In still another embodiment, the yarn shown in  FIG. 2  comprises a thatch fiber  20  and the thatch spinneret and yarn have a thickness  49  of about 0.033 inches. 
     In an embodiment, the thickness of the thatch fiber  20  is variable along its width. That is, near the ends  24 , the thatch fiber may be less thick then near the center of the fiber. In the central portion of the thatch fiber  20 , the fiber may be thicker than the remainder of the fiber. In an embodiment, the thickness of the thatch fiber (or its extensions) increases gradually from the ends  24  to the central portion of the fiber. 
     In an embodiment, the yarn shown in  FIG. 2  comprises a thatch fiber  20  and the thatch spinneret and yarn have a width  47  in the range of about 0.070 to 0.250 inches. In an embodiment, the yarn shown in  FIG. 2  comprises a thatch fiber  20  and the thatch spinneret and yarn have a width  47  in the range of about 0.109 to 0.180 inches. In yet an embodiment, the yarn shown in  FIG. 2  comprises a thatch fiber  20  and the thatch spinneret and yarn have a width  47  of about 0.109 inches. 
     In an embodiment, the yarn shown in  FIG. 1  comprises a face fiber  10  and has a thickness  38  of about 0.025 inches and a width  36  of about 0.180 inches. In an embodiment, the face fiber has a width  36  that is approximately seven times greater than its thickness  38 , at the greatest point of its thickness. In an embodiment, the yarn shown in  FIG. 2  comprises a thatch fiber  20  and the thatch spinneret and yarn have a thickness  49  of about 0.033 inches, at its widest point, and has a width  47  of about 0.109 inches. In an embodiment, the thatch fiber  20  has a width  47  that is approximately three times greater than its thickness  49 , at the greatest point of its thickness. In an embodiment, the face fiber of the invention has a greater width than that of the thatch fiber. In an embodiment, the face fiber of the invention has a lesser thickness width than that of the thatch fiber—that is the face fiber is a thinner fiber than that of the thatch fiber. 
     In an embodiment, the height of the face fibers is greater than the height of the thatch fibers. The height is determined from the upper surface of the backing to the top of the extended fibers, in a normal state of the turf. In an embodiment, the face and thatch fibers are upright-oriented cut-pile fibers and may be arranged in bundles of synthetic grass fibers. In an embodiment, face yarns and thatch yarns may be tufted together in a given bundle of fibers. In other embodiments, face yarn bundles and thatch yarn bundles may be tufted in adjacent, but alternating locations. In still other embodiments, face yarn bundles and thatch yarn bundles may be tufted in seemingly random locations. In such an embodiment, they are not necessarily present in adjacent, alternating positions. 
     Advantageously, the invention having the disclosed shapes, configurations, and dimensions provides good flexing and bending characteristics, a soft feel, a natural look, and durability. In an embodiment, the artificial turf invention described herein may be used on sports fields, artificial residential or commercial lawns, or for any other use known in the art. 
     In an embodiment, the synthetic grass product of the invention comprises at least two yarn ends, the yarn provided on a cone to be tufted through backing as face fabric or thatch fabric tufts. In an embodiment, the synthetic grass product of the invention is a single yarn. In another embodiment, the invention comprises multiple inventive yarns (optionally of varied colors) directed through the same opening of a backing material. Similarly, in an embodiment, the synthetic grass product of the invention comprises a roll or sheet of artificial grass tufted through a backing. In an embodiment, the backed synthetic grass product of the invention comprises face fiber tufts and thatch fiber tufts. In an embodiment, face fiber tufts are disposed adjacent thatch fiber tufts in the backing. 
     In an embodiment, the face fiber tufts comprise a plurality of filaments or strands. In an embodiment, the face fiber tufts comprise a plurality of filaments or strands which are different colors. In an embodiment, the thatch fiber tufts comprise a plurality of filaments or strands. In an embodiment, the thatch fiber tufts comprise a plurality of filaments or strands which are different colors. In an embodiment, a plurality of yarns (face or thatch) are tufted through the same opening in the backing material. In an embodiment, the melting point of the synthetic grass product of the invention is above 420 degrees Fahrenheit. 
     In an embodiment, the backed turf product of the invention has a pile height of at least about 0.6 inch. In another embodiment, the backed turf product of the invention has a pile height of at least about 1.0 inch. In an embodiment, the extruded ribbons of the invention may comprise between about 300 and 2500 denier. In another embodiment, the extruded ribbons of the invention may comprise between about 600 and 2000 denier. 
     Method: 
     In an embodiment, the method includes, not necessarily in this order, the following steps: extruding a pellet through a spinneret to form an extended ribbon; optionally, combining the extended ribbon with a blend of other extruded ribbons; cutting the extended ribbon(s) to create a yarn that has a specified length; and tufting the yarns into a backing material. In an embodiment, the pellet is a nylon material. In an embodiment pellets of varied colors are used to create ribbons and, thereby, yarns having differing colors. The backing material may include a foam pad and/or a subsurface in some embodiments. A fill material may be added on top of the backing if desired. While the invention is described as being tufted, the inventive yarns may alternatively be used in a woven or knitted artificial grass product. 
     The accompanying figures are provided for explanatory purposes. The components that are illustrated are not necessarily drawn to scale. Many modifications and other embodiments of the inventions set forth herein will come to mind to one skilled in the art to which these inventions pertain having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is to be understood that the inventions are not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.