Patent Abstract:
A turf cutter device, an infill extractor/collector device, and a turf wind-up device are used to facilitate the cost-effective removal of an infilled synthetic turf and the subsequent installation of a new turf at the same site, with minimal subsurface disruption. An infill extractor/collector device mounted on a motorized vehicle moves a relatively narrow strip of filled artificial turf from the surface, in front of the vehicle, and directs the strip to an infill removal station. The infill removal station inverts the strip and redirects the strip back toward the front of the vehicle, after agitating the strip to extract the infill. After redirecting the strip toward the front of the vehicle, the vehicle drives over the unfilled strip. Meanwhile, the extractor/collector device moves the extracted infill rearwardly to a bag located in a trailer. The turf cutter device is used prior to infill extraction, while the turf wind up device may be used before or after infill extraction, depending on whether infill extraction takes place at the field or at a remote site, respectively.

Full Description:
RELATED APPLICATION 
     This application claims priority, under Section 120 and/or Section 371, to PCT patent Application No. PCT/US2012/033829 entitled “Apparatus And Methods For Facilitating The Removal Of Existing Turf And Installing New Turf,” filed on Apr. 16, 2012, which in turn claims priority to U.S. Provisional Patent Application No. 61/606,808, filed Mar. 5, 2012, entitled “Devices And Methods For Removing Synthetic Turf;” to U.S. Provisional Patent Application No. 61/475,508, filed Apr. 14, 2011, entitled “Device And Method for Removing Synthetic Turf,” and also to presently pending U.S. patent application Ser. No. 13/206,723, filed Aug. 10, 2011, entitled “Method And Device For Installing Synthetic Turf,” all of which are expressly incorporated by reference herein, in their entireties. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates to infilled synthetic turf, and particularly to apparatus and methods for removing an existing infilled synthetic turf and extracting and collecting the particulate infill. The present invention also contemplates the facilitated installation of a new infilled synthetic turf. 
     BACKGROUND OF THE INVENTION 
     Synthetic turf continues to gain popularity, as an athletic field surface for professional teams, college teams, high school teams, and even public parks. Current types of athletic turf simulate natural grass very well, while eliminating the typical costs associated with maintaining a natural turf, such as watering, mowing, fertilizing, and even replacing the worn turf when bare spots occur. 
     There are any number of reasons why a synthetic turf may need to be replaced, including decreased playability, loss of aesthetic appeal, warranty expiration, or perhaps even safety concerns. Regardless of the one or more reasons that may apply to any specific synthetic turf, there comes a time when the synthetic turf must be removed from the site, and in all likelihood, another synthetic turf put down in its place. 
     Owners of synthetic fields have become accustomed to virtual round-the-clock use of their synthetic turf athletic fields. For this and other reasons, it is important that the removal of an existing synthetic turf, and its replacement with a new synthetic turf, occur as efficiently as possible. Also, the components of a removed synthetic turf are often reused or recycled for other purposes. Therefore, it is also desirable to remove a synthetic field in a manner that readily facilitates such reuse or recycling. 
     One conventional process for removing synthetic turf has typically involved using a bobcat with claw attachments to simply rip and tear through the seams of the existing turf, to literally eat through the field so that it can be stripped from the site. In such instances, it is difficult or time consuming to reuse or recycle the ripped out turf. Also, the use of a bobcat in this manner, to tear out an existing synthetic turf, will inevitably disrupt the carefully compacted and leveled subsurface that resides beneath the synthetic turf. In such instances where the subsurface is disrupted, the subsurface will need to be reconstructed prior to the placement of a new synthetic turf on the same site. This replacement or reconstruction of the subsurface adds to the time and costs associated with installing a new synthetic turf. 
     Most infilled synthetic turfs use an infill of sand, rubber, or a combination of sand and rubber. The particulate nature of such infill materials, and the weight thereof, can lead to complications in removing the synthetic turf. Moreover, the particulate infill is valuable, and may have a useful lifetime that is longer than the useful lifetime of the synthetic turf fibers. 
     Others have tried different methods or devices for removing a synthetic turf from a site. For instance, a product called TurfMuncher, apparently being commercialized by a company called Field Away, is shown and described at www.fieldaway.com. Another existing device is referred to as the CarpetEater, and can be found at www.carlrennen.nl. The device shown at this site seems to be the subject of EP 2 387 875, entitled “Infill Removal Device For Removing Infill From A Strip Of Artificial Turf.” 
     The state of the art can further be understood via the following patent references: 1) U.S. Patent Publication No. 2010/0001115, entitled “Apparatus And Method For Handling an Artificial Turf Arranged On A Base;” 2) U.S. Patent Publication No. 2012/0006930, entitled “Artificial Turf Remover And Infill Separator, And Method Of Use Thereof;” 2) U.S. Patent Publication No. 2010/0319510, entitled “Apparatus For Collecting Artificial Turf For Recycling;” 4) WO2010/094576, entitled “Recycling Of Artificial Turf;” and 5) Japanese Patent Publication No. JP200000831482. The above-referenced U.S. &#39;510 publication provides a good general description of some of the practical problems associated with removing a synthetic turf. 
     For one reason or another, the state of the art has not yet adequately addressed the practical concerns associated with removing an infilled synthetic turf and installing a new turf. 
     SUMMARY OF THE INVENTION 
     It is an object of the present invention to reduce the time and cost associated with removing an existing infilled synthetic turf and/or replacing the existing turf with a new turf. 
     It is another object of the present invention to facilitate the reuse and/or recycling of components of an existing infilled synthetic turf. 
     It is still another object of the present invention to minimize the disruption caused to the prepared subsurface during the removal of an existing infilled artificial infill synthetic turf and/or the installation of a new infilled synthetic turf, and also to protect any surrounding susceptible surfaces. 
     It is still another object of the present invention to simplify the procedures associated with, and the equipment used in, removing an existing infilled synthetic turf and/or installing a new infilled synthetic turf. 
     To achieve one or more of these objects, in a general sense, and according to one preferred embodiment of the invention, the present invention relies on a modified vehicle of the type shown in U.S. Pat. No. 5,307,880, and various implements that are able to connect thereto, so as to enable a high degree of versatility in removing an infilled synthetic turf and replacing it with another. For instance, the invention contemplates a removal process that involves cutting the field into relatively narrow strips, with a cutter device, then extracting and collecting the infill from the strips but placing the strips back onto the subsurface, with an extractor/collector device, followed by winding up the unfilled strips with a turf wind up device. These devices are designed to work with relatively narrow strips of turf, preferably about 45 inches. This relatively narrow width reduces problems associated with overly large and heavy rolls of turf, whether filled or infilled. The relatively narrow width of these strips makes the entire process more manageable, and takes into consideration one presumption, namely, that the artificial turf itself will not be reused as a turf for a large field, i.e., it is worn out and/or not re-usable. 
     According to one aspect of the invention, one or more of these above-described devices may be removably attachable to the motorized vehicle. The ability to removably attach one or more of these device, and the concurrent use of more than one vehicle during the removal of an infilled turf, can reduce the overall time needed to remove the turf. Moreover, each of the devices is operable with the vehicle so as to substantially minimize direct contact with the subsurface, or to eliminate such contact altogether. Preferably, the motorized vehicle is supported on two spaced endless loop treads, so that the force per unit area remains relatively low, due to the even distribution of the weight of the vehicle and the accompanying devices. 
     The shape, configuration, and operation of the extractor/collector causes the accompanying vehicle to be seldom driven on the subsurface. And even if driving on the subsurface does occur, the treads of the vehicle help to evenly distribute this weight, as noted above. Moreover, this same principle applies with respect to cutting an existing turf into strips, when the cutting device is used. That is, the cutting device is also shaped and configured so that it does not require any contact with the subsurface during cutting. Still further, during cutting the cutting device enables the next set of cut lines to be marked, if desired, for the next adjacent rows. 
     Still further, contact with the subsurface can also be avoided when winding up the infilled turf, simply by locating the wind up device at one end of the strip so as to remain stationary during the wind up procedure, to pull the unfilled turf across the subsurface. This is doable because the strip has a width that is relatively low, i.e. about 45 inches, and because it is unfilled so that the weight is relatively low. The advantage of leaving the wind up device stationary is that the subsurface remains untouched as the turf is removed. 
     Also, or in alternative, the use of a relatively narrow width enables an existing field to be, first, cut into strips, and then second, wound up with the strips remaining in a filled condition, and the wind up device remaining stationary and located at the side of the field. Under this scenario, as opposed to on-site infill extraction, the filled strips could be shipped to a processing site for extraction and collection of the infill, most likely from a stationary extractor/collector. This arrangement would facilitate ongoing reprocessing and/or recycling of the infill and the removal of turf in a continuous operation serving multiple fields and/or geographical regions via one fixed regional extractor/collector site. 
     According to one preferred aspect of the invention, the vehicle is easily maneuverable to connect the desired devices. In a typical operation, an existing field is first cut into strips of desired width, using the cutting device. Thereafter, the infill is extracted and collected from the strips, using the extractor/collector device. Then, the unfilled strips are collected using the wind-up device. Because these devices can be removably connected to the same vehicle, the simultaneous use of multiple vehicles will speed up the process. Thus, according to this aspect of the invention, to optimize versatility and interchangeability, all of the devices are removably connectable to one type of motorized vehicle. Thus, if a contractor has two vehicles, any two of the devices can be used at the same time. 
     Alternatively, one of the vehicles may be dedicated for full time use with the extractor/collector device. This alternative approach may be preferred because the power requirements for the extractor/collector device are substantially greater than those of either the cutter device or the wind up device. Moreover, the extractor/collector procedure is more time consuming than the other two procedures. So according to this alternative, i.e., the second preferred embodiment, one higher powered vehicle remains dedicated to the infill extractor/collector, while a separate vehicle is used for cutting and winding up the turf, via interchangeable use of the turf cutter and the turf wind up devices. 
     With respect to infill removal, the extractor/collector has three primary sections, an input section, which includes a ramp, an infill removal section, and an infill collection section. The ramp facilitates initiation of the removal process. That is, due to the shape and orientation of the ramp, an operator has a clear line of sight to the leading edge of the strip of turf to be removed. Also, the apparatus enables the operator to pivotally raise or lower the ramp. Thus, the operator can often maneuver the ramp so as to catch a leading edge of the strip. Alternatively, the leading edge can be fed by hand onto the bottom edge of the ramp. Either way, only a relatively short leading edge of the strip needs to be located on the forward edge of the ramp to initiate removal of the strip. An operator standing on the second, or removal end of the vehicle can easily see the front end of the ramp. 
     Preferably, the ramp includes a forward plate, a belt-type conveyer residing rearward of the plate, and a drive roller which bears against a top surface of the strip as it moves up from the plate to the conveyor. Essentially, the ramp acts as an input section of the extractor. 
     With a first preferred embodiment, the ramp includes an upper pinch roller to aid in directing the strip to the infill removal section. The ramp may also include a lower pinch roller, which may be actively driven, or simply a passive rotating device. The infill removal section includes a housing with one or more agitators, or beaters, which contact the strip to remove infill therefrom as the strip moves therethrough. A downstream roller, located in the housing and downstream of the at least one or more agitators, engages and pulls the strip through the infill removal section, and preferably operates at a speed greater than the ramp roller. This helps to keep tension on the strip. When the trailing edge of the strip reaches the top roller of the ramp, it may be desirable to reverse the rotation of the conveyor pinch roller, thereby to restrain the trailing edge from being pulled prematurely into the infill removal section. 
     According to an additional embodiment, the use of an undulating path for the strip to traverse through the housing of the extractor/collector causes the strip to open up, to close up, and then to reopen. This promotes effective removal of the infill. More specifically, according to this embodiment, the ramp does not need a pinch roller, either at the top or bottom. Rather, the housing includes a plurality of pacing rollers, with spaced engagement teeth, that rotate to pull the strip along the path and toward the agitators located downstream thereof. These pacing rollers control the speed of the strip, and help to restrain the trailing edge thereof. 
     These pacers also invert the strip and direct it forward and toward the first agitator, or rotatable beater, which acts on the strip while in an open condition, then to a tension roller, which closes the strip, and then to a second agitator which again acts on the strip in an open condition. Again, this undulating open/close/open path promotes effective removal of the infill, and collection in the bottom of the infill removal section where it is augered to a conveyor. 
     Because the infill conveyor resides on one side of the vehicle, an operator of the vehicle can easily see the infill as it is conveyed rearwardly from the extractor/collector to the trailer. Also, the trailer is offset from the aft end of the vehicle, which also enables the operator to see the infill falling from the conveyor into the bag, or even when the bag is getting too full. 
     The second end of the conveyor includes a downward deflector, to deflect the conveyed infill downward to the bag. This minimizes problems that could otherwise be caused by wind. Also, if desired, the conveyor itself could be covered with a hood, with some or all of the hood being transparent. 
     The use of the conveyor and trailer eliminates the need to drive another motorized vehicle onto the surface in order to collect the extracted infill. The trailer and its accompanying bracket are sized to accommodate the upwardly and rearwardly extending conveyor. This structure causes the extracted and collected infill to be easily and continuously collected in the bags. Preferably, the trailer includes a push mechanism that moves the filled bag from the trailer, and onto the unfilled turf residing behind the trailer. These bags have upper ends that can be moved by a fork lift. Preferably, the wheels of the trailer are large flotation type, to better distribute the weight of the trailer, particularly with the bag therein. 
     The apparatus and methods described herein eliminate the need for large or heavy construction or truck-based equipment, or complicated machinery. Nonetheless, these attachments are sturdy and suitable for rigorous and continuous use, in a user-friendly manner. Also, the attachments are fairly easy to transport and store during periods of non-use. 
     These and other features of the present invention will be readily understood by a person skilled in the art, by reference to the following Figures which show several preferred embodiments of the invention, and the following detailed description which describes those preferred embodiments. 
    
    
     
       DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
         FIG. 1  is an isometric view showing a first preferred embodiment of a vehicle that may be used in conjunction with one or more devices, to cut a synthetic turf field into strips, to separate infill from the strips of synthetic turf for collection, to remove the strips of synthetic turf from the field by winding, and to install new synthetic turf. 
         FIG. 1A  is an isometric view showing the vehicle of  FIG. 1  with a turf cutting device, or attachment, constructed according to a first preferred embodiment of the invention connected thereto, the turf cutting attachment including turf cutters for cutting a strip of synthetic turf. 
         FIG. 2  is an isometric view showing one side of the turf cutting attachment shown in  FIG. 1A , including the position marking assembly. 
         FIG. 3A  is a schematic elevation view showing the vehicle/turf cutting attachment arrangement of  FIG. 1A  adjacent a field of synthetic turf. 
         FIG. 3B  is a schematic elevation view showing the vehicle/turf cutting attachment arrangement of  FIGS. 1A and 3A , the turf being guided toward and cut by a turf cutter. 
         FIG. 4  is a plan view showing a synthetic turf field being cut by the vehicle/turf cutting attachment arrangement of  FIG. 1A . 
         FIG. 5  is a plan view that shows a synthetic turf field as it is cut by the vehicle mounted turf cutting attachment shown in  FIG. 1A  (right side), and which also shows, concurrent therewith, infill being removed from another strip of the synthetic turf by a separate vehicle equipped with an infill extractor/collector device (left side). 
         FIG. 6  is a schematic elevation view showing the vehicle of  FIG. 1  with, connected thereto, an infill extraction and collection device constructed according to a first preferred embodiment of the invention, for removing infill from the synthetic turf. 
         FIG. 7  is a schematic elevation view of the same vehicle and infill extraction and collection device of  FIG. 6 , with the device having a forward insertion plate inserted underneath a portion of synthetic turf to be lifted for infill extraction and collection. 
         FIG. 7A  is a schematic sectional view which shows the internal features of the infill extraction and collection device of  FIGS. 6 and 7 , including the conveyor belt, the driven nipped rollers, the at least one agitator, and the auger. 
         FIG. 7B  is a schematic sectional view which shows a strip of synthetic turf as it travels through the housing of the infill extraction and collection device of  FIGS. 6 ,  7 , and  7 A, as the infill is removed therefrom and collected in the collection bin. 
         FIG. 7C  is a schematic sectional view which shows the rearward components of the structure shown in  FIG. 7 , with the extracted infill being delivered from the collection bin to a collection trailer, according to one preferred embodiment of the invention. 
         FIG. 7D  is a schematic elevation view showing a bag of infill that has been removed from the collection trailer shown in  FIG. 7C . 
         FIG. 7E  schematically shows the structure of an alternative infill extraction and collection device, according to another alternative embodiment of the invention. 
         FIG. 8A  is an isometric view of a turf wind up device constructed according to a first preferred embodiment of the invention, the turf wind up device being suitable for rolling up, or winding up, a strip of synthetic turf. 
         FIG. 8B  is a schematic isometric view of the turf rolling device of  FIG. 8A , as it begins to roll up a strip of synthetic turf. 
         FIG. 8C  is a view similar to that of  FIG. 8B , showing the turf rolling device as it further rolls up the strip of synthetic turf. 
         FIG. 9A  is a schematic elevation view of the turf rolling device of  FIGS. 8A ,  8 B, and  8 C, in combination with a vehicle, according to one aspect of the invention, with the vehicle positioned adjacent a strip of synthetic turf to be wound up. 
         FIG. 9B  is a view similar to  FIG. 9A , showing the vehicle and the turf rolling device as the device begins to roll up the synthetic turf. 
         FIG. 9C  is a view similar to  FIGS. 9A and 9B , showing the strip of synthetic turf nearly completely rolled up by the turf rolling device. 
         FIG. 10  is a plan view showing two moving vehicles, with one moving vehicle operatively connected to a turf wind up device as the device winds up a strip of synthetic turf (left side), and a second moving vehicle operatively connected to an infill extraction and collection device as the device extracts and collects infill from the synthetic turf (right side). 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     In addition to the application referenced above, applicants expressly incorporate herein, by reference, in its entirety, U.S. Pat. No. 5,307,880, entitled “Sod Rollout Machine With Endless Tracks.” 
     The present invention relates to devices and methods pertaining to the installation and removal of synthetic turf from a field, and to removing infill from the synthetic turf. In particular, a vehicle and several attachment devices are provided that are useful for performing steps relating to the installation and removal of synthetic turf, and to removing infill from the synthetic turf. The attachment devices are useful for cutting a synthetic turf field into strips, removing infill from the synthetic turf and collecting the infill, removing the synthetic turf from the field, and for installing new synthetic turf onto the field. The device used for the purpose of removing the infill, i.e., extracting and collecting the infill, connects to both the front (or leading end) of the vehicle and the rear (or trailing end) of the vehicle. As shown in the Figures, synthetic turf is generally indicated by the letter t, infill by the letter i, and the subsurface below the synthetic turf by the letter s. These letter designations are not used throughout this textual description, however, to avoid the excessive repetition that would be created if they were so used. 
     Referring first to  FIG. 1 , according to a first preferred embodiment a vehicle for use with the various attachment devices disclosed herein is shown and is indicated generally by the numeral  20 . The vehicle  20  includes a chassis  22  to which all its other components are connected, either directly or indirectly. An upper frame  24  is provided forward of the vehicle&#39;s power-generating components, which are concealed beneath a housing  26 . For example, the vehicle  20  would include a motor, a hydraulic pump system, and transmission components, even though these components are not shown specifically in the Figures. A platform  28  is provided rearward of the frame  24  and the housing  26 , and a user can stand on the platform  28  to ride with the vehicle  20 . A control console  30  is provided with controllers  32  for controlling or operating the vehicle  20 . A handlebar  34  is provided near the control console  30  for a user to grab, such as for support while stepping onto the platform  28 . 
     The vehicle  20  includes endless drive track assemblies  36  having endless loop tracks or treads  38 , which are also referred to as treads. A drive sprocket  40  transfers rotational power to the tracks  38 , which rotate around a series of intermediate rollers  42  and front rollers  44 . The rollers  42 ,  44  are connected to roller plates  46 , which are attached to the chassis  22 . The tracks  38  are separated by a space, or distance d. By using tracks, the vehicle  20  applies less weight per unit area to whatever is beneath it, compared to the weight that would otherwise be applied if conventional wheels and tires were used to support the vehicle. The use of such tracks is advantageous in the context of a synthetic turf field, because such tracks minimize disruption to the subsurface beneath the synthetic turf. 
     The vehicle  20  includes an attachment lift assembly  50  for causing movement of an attachment device, as will become apparent. The attachment lift assembly  50  includes two generally parallel and forwardly-extending arms  52  connected by a transverse brace  54 , which together form a support. The arms  52  include an attachment portion  56  at a forward end thereof and have a plurality of locking pin holes  58 . The arms  52  also include an angled pivot portion  60  at a rearward end thereof. The arms  52  are pivotally connected to the upper frame  24  through pivot brackets  62 , which are positioned near the intersection of the upper frame  24  and the roller plates  46 . The attachment lift assembly  50  further comprises movement actuators  64  for causing movement of each arm  52 . Each movement actuator  64  includes a cylinder  66  having a hydraulically driven piston  68 . The cylinder  66  is connected at a base end  70  to the vehicle  20  near the housing  26 , and at a terminal end  72  to a movement actuator bracket  74 . The movement actuator bracket  74  is connected to, or may be integral with, the arm  52 . It will be appreciated that extension of the piston  68  from the cylinder  66  moves the anus  52  in a generally downward direction, whereas contraction of the piston  68  moves the arms  52  in a generally upward direction. Of course, alternative arrangements for providing an attachment lift assembly are also contemplated, such as where the arms  52  are connected to the roller plates  46 , where the cylinders  66  are connected to the roller plates  46 , and others. The vehicle  20  also includes a counterweight assembly  80  positioned near the forward end of the endless tracks  38 . The counterweight assembly  80  includes a plurality of weight plates  82 , the number of which may be selectively adjusted so that a desired weight balance of the vehicle  20  is achieved, which can be influenced by the weight of the user standing on the platform  28 , the weight of the attachment device connected to the vehicle  20 , and other factors. 
     Referring next to  FIGS. 1A ,  2 ,  3 A, and  3 B,  4 , and  5 , a turf cutting attachment  90  is show that can be connected to the vehicle  20 . The turf cutting attachment  90  is used to cut a synthetic turf field into strips, which strips are subsequently handled as disclosed herein. In particular, the turf cutting attachment  90  includes a widthwise-extending frame  92  having rearwardly extending attachment arms  94  that are configured to mate with the attachment portions  56  of the arms  52  of the vehicle  20 . Each attachment arm  94  includes a locking pin hole  96  configured to receive a locking pin, such as to lock the arms  52  with respect to the arms  94 . Two turf guide and cutting assemblies  98  are mounted on the frame  92  by a mounting bracket  100 . A turf guide  102  extends from each bracket  100  toward the front end of the turf cutting attachment  90 , and includes an angled feed ramp  104  having a distally located tip  106 . A turf cutter  108  is connected to the bracket  100 , and in the embodiment shown includes a circular blade  110  that is driven by a motor  112  and is partially covered by a shroud  114 . The motor  112  is operatively connected to a power source maintained by the vehicle  20 , such as a supply of hydraulic fluid, for example. As the vehicle  20  moves in the forward direction, the angled feed ramp  104  guides the synthetic turf toward the turf cutter  108 , and the blade  110  cuts the turf. In other embodiments, other cutting devices can be used, such as band saws, heat cutting tools, air cutting tools, shears, and the like. It will be appreciated that the distance between the turf cutter  108  is chosen to cut an appropriately-sized strip of synthetic turf. Particularly, the distance between the turf cutting devices  108  is chosen so as to cut strips of synthetic turf that are slightly narrower than the distance d between the tracks  38  of the vehicle  20 . 
     Jack stands  116  can be included with the turf cutting attachment  90  to support the weight thereof, and to prevent excessive weight from being supported by the turf guides  102 , such as near the tips  106 . The jack stands  116  can move up and down with respect to the frame  92 , or could also rotate with respect thereto. 
     The turf cutting attachment  90  also includes position marking assemblies  120  for making a guide mark on a synthetic turf field corresponding to a desired cut line. The position marking assemblies are positioned generally at opposed ends of the frame  92 , and each includes a position adjustable arm  122  extending from the frame  92 . A position marker  124  depends downwardly from the position adjustable arm  122 , and includes a chain portion  126  and a spiked weight  128  at the distal end thereof. The spiked weight  128 , when dragged across a field of synthetic turf, disturbs the turf in a manner that creates a visually perceptible line. The position of the position marker  124  with respect to the frame  92  may be chosen (by adjusting the position of each arm  122 ) so that the line created by the position marker  124  corresponds to a position for the user to make a cut in the synthetic turf using the turf cutting attachment  90 , such as the next cut in the synthetic turf when the user is following a back-and-forth route across a field (in the familiar way that a lawn is mowed, for example). 
     As shown in  FIG. 4 , as the vehicle  20  having the turf cutting attachment  90  makes its way across the field of synthetic turf, the turf is cut into strips (cut turf lines indicated by the letter c), and marked with the position for the next cut line (marked turf line indicated by the letter m). And as shown in  FIG. 5 , in addition to cutting the synthetic turf into strips, the vehicle  20  can be used in with an infill extraction and collection attachment  140 . 
     Referring next to  FIGS. 5 ,  6 ,  7 , and  7 A- 7 E, an infill extraction and collection attachment  140  is shown that can be connected to the vehicle  20 . The infill extraction and collection attachment  140  is used to separate infill from synthetic turf, and to collect the infill. In particular, and as shown in  FIG. 5 , once a field of synthetic turf is cut into strips, the strips are processed by the infill extraction and collection attachment  140 . 
     The infill extraction and collection attachment  140  includes a frame  142  to which its various components are attached. At the forward end thereof, the infill extraction and collection attachment  140  includes a turf conveyor assembly  144 . A hinged insertion plate  146  is at the leading edge thereof, and is for insertion under a portion of synthetic turf. The turf conveyor assembly  144  includes a driven endless conveyor belt  148  for moving and supporting synthetic turf as it moves upwardly at an angle thereon. 
     The turf conveyor assembly  144  includes a heavy roller  150  near its forward end (near the hinged insertion plate  146 ). The heavy roller  150  helps to encourage traction between the synthetic turf and the endless conveyor belt  148 . The heavy roller  150  is passive, and not driven by a motor, though it could be. The turf conveyor assembly also includes a first nipped roller  152  near an upper end thereof and generally away from the heavy roller  150 . The first nipped roller  152  is driven by a motor and positively engages the synthetic turf and feeds it into an extraction and collection assembly  160 , which may also be referred to as an extractor/collector, as it includes an infill removal section. Further, the first nipped roller  152  generally discourages the synthetic turf from entering the extraction and collection assembly  160  faster than rotation of the first nipped roller  152  will allow. 
     A turf conveyor assembly movement actuator  154  is provided for pivotably raising and lowering the turf conveyor assembly  144  (with a raised position being shown in dashed lines in  FIGS. 6 and 7 , for example), and may include a hydraulic cylinder system  156  connected to the frame  142  that operates according to well known principles. 
     The extraction and collection assembly  160  includes a housing  162  that includes side panels  164  and a lid  166 . An entry  168  and exit  170  are defined in forward upper and lower portions of the housing  162 , respectively. The entry  168  may generally be considered an input section and the exit  170  may generally be considered an output section. Synthetic turf being processed by the extraction and collection assembly  160  enters the housing at the entry  168  and exits the housing  162  at the exit  170 . Thus, synthetic turf enters and exits the extraction and collection assembly  160  on the same generally forward side. A guide rail  172  is disposed within the housing  162  that defines and limits the movement of synthetic turf therein. In particular, the guide rail  172  includes a generally flat upper portion  174  connected with a generally flat lower portion  176 , with the portions  174 ,  176  being connected near a rearward end of the housing  162  by a curved transition portion  178 . A second nipped roller  180  is positioned with the housing  162  near the exit  170  and is used to urge synthetic turf out of the housing  162 . When turf exits the housing  162 , it falls under its own weight toward the ground and is guided by an external guide  182  away from the housing  162 . Particularly, the external guide  182  can include a generally cage-like structure that guides the turf away from the infill extraction and collection attachment  140  and back toward the ground. 
     The housing  162  also includes a collection bin  184  for collecting infill that is removed from the synthetic turf, the collection bin having angled walls  186  leading to a trough  188 . The trough  188  includes an opening  190  for removal of the infill therefrom by an auger  192 , as will be explained more fully below. The collection bin  184  can also be referred to generally as an infill collector section. 
     A plurality of infill extractors  200  are provided within the housing  162 . The infill extractors  200  act on the synthetic turf to essentially agitate or beat the synthetic turf so that the infill becomes separated from the turf. Hence the infill extractors can also be referred to as agitators. The infill then falls within the housing  162  into the collection bin  184 . In particular, each infill extractor  200  includes a central shaft  202 , a plurality of arms  204  extending from the central shaft  202 , and a distal shaft  206  associated with each arm  204  and being positioned away from the central shaft  202 , giving each infill extractor an overall triangular cross-sectional shape. While three arms  204  and three distal shafts  206  are shown, other numbers thereof are also contemplated, such as infill extractors having two arms and two distal shafts. The extractors  200  are rotated about their central shafts  202 , and the distal shafts  206  make contact with the synthetic turf. Thereby, infill is dislodged from the synthetic turf and falls in the housing  162  and eventually reaches the collection bin  184 . 
     As synthetic turf enters the extraction and collection assembly housing  162  at the entry  168 , it is directed rearwardly in a generally horizontal orientation. Movement thereof is limited and guided by the guide rail  172 . The synthetic turf is moved rearwardly and around a rearmost infill extractor  200 , which then feeds the synthetic turf horizontally in the opposite direction back toward the front of the housing  162 , so to invert the synthetic turf. The infill extractors  200  can act to both pull the strip of synthetic turf into the extraction and collection assembly  160  and beat the turf so as to remove the infill therefrom. The infill extractors  200  are driven by one or more motors and can rotate in either rotational direction. For example, driving the infill extractors  200  in one direction tends to pull the synthetic turf into the extraction and collection assembly  160  and direct it toward the rearward portion thereof. As the synthetic turf reaches the rearward portion of the extraction and collection assembly  160  and is inverted, rotation of the infill extractors  200  in the same direction directs the synthetic turf toward the front of the extraction and collection assembly  160  and toward the exit  170 . The second nipped roller  180  further directs the synthetic turf out of the housing  162  through the exit  170 . Advantageously, the central shafts  202  of the infill extractors  200  may be inter-connected by a drive assembly  199  so that rotation of one central shaft  202  (a driven shaft) causes rotation of the other central shafts  202 . The drive assembly  199  may include any appropriate linkages, and may be operatively connected to a power source maintained by the vehicle  20 , as will be apparent to a skilled practitioner. Further, the rotation of the central shafts  202  shafts may be set to any appropriate timing. For example, the central shafts  202  may be driven at the same or different rotational rates. Advantageously, the rearward-most infill extractor  200  may be driven at a slower rotational rate than the more forward infill extractors  200  since the rearward-most infill extractor will be under a greater load by virtue of being in contact with a greater portion of the synthetic turf. Also, all three central shafts  202  may be driven at different rates. Moreover, the infill extractors  200  may be set to have any relative rotational position. For example, the rotational position of the triangular-shaped infill extractors  200  may be synchronized so similar respective arms  204  of the triangle shapes occupy the same rotational position. Alternatively, similar respective arms  204  of the triangle shapes may not occupy the same rotational position. Optionally, a cover plate  169  may be provided above the first encountered infill extractor, which is positioned nearest the entry  168  and exit  170 . 
     Some of the infill loosens as the synthetic turf moves rearwardly toward the rear of the housing  162 , while most of the infill falls out upon beating of the synthetic turf as it moves forwardly, in the inverted position. The infill removed from the synthetic turf in the extraction and collection assembly  160  is collected in the collection bin  184  near the bottom of the housing  162 . 
     After being fed into the extraction and collection assembly  160 , being inverted, and being beaten by the infill extractors  200 , the turf is directed via the external guide  182  to a position under the infill extraction and collection attachment  140  and between the tracks  38  of the vehicle  20 . Particularly, the second nipped roller  180  is positioned near the exit  170  of the extraction and collection assembly  160  and pulls the synthetic turf so as to direct it out of the extraction and collection assembly  160 . The second nipped roller may be driven, with the rotational rate of the second nipped roller  180  being slightly greater than the rotational rate of the first nipped roller  152  so as to maintain a tension in the synthetic turf when it is in the extraction and collection assembly  160 . Of course, the nipped rollers  152 ,  180  may be driven at any relative rate, including at the same rate. The nipped rollers  152 ,  180  may also be referred to as pinch rollers, or guide rollers. 
     Thus, the first nipped roller  152  directs synthetic turf into the extraction and collection assembly  160  and the second nipped roller  180  directs synthetic turf out of the extraction and collection assembly  160 . As mentioned, the infill extractors  200  can rotate in a direction that encourages movement of the synthetic turf through the extraction and collection assembly  160  from the entry  168  to the exit  170 . Advantageously, the rotational direction of the infill extractors  200  may be controlled by a user for the efficient movement of the synthetic turf through the extraction and collection assembly  160 . For example, while the infill extractors  200  generally move in a direction that encourages the synthetic turf to move through the extraction and collection assembly  160  from the entry  168  to the exit  170 , the direction of the infill extractors  200  may also be reversed. Since the second nipped roller  180  pulls the synthetic turf through the extraction and collection assembly  160  and pushes it out of the exit  170 , the synthetic turf will continue to advance between the entry  168  and the exit  170  in the extraction and collection assembly  160 , even if the direction of rotation of the infill extractors  200  is working against such movement. Reversing the direction of the infill extractors  200  may be beneficial near the end of a strip of synthetic turf in order to alter the speed at which the synthetic turf exits the extraction and collection assembly  160  and to prevent the synthetic turf from travelling too quickly therethrough. Thus, the invention contemplates structure for restraining a trailing edge of a strip of synthetic turf from being pulled prematurely into the extraction and collection assembly  160 . Such structure may also include pacing rollers or pull devices, as will be discussed below. A control system is operatively connected to the infill extractors  200  and to at least one of the nipped rollers  152 ,  180 , and is adapted to rotate the infill extractors  200  at a higher speed than the at least one of the nipped rollers  152 ,  180 . 
     As the vehicle  20  moves along a field of synthetic turf, a strip of the synthetic turf is fed into the entry  168  of the extraction and collection assembly  160  and then replaced back onto the subsurface at the lower front end of the extraction and collection assembly  160 , but with the infill removed therefrom. Advantageously, and because the strip of synthetic turf fits between the tracks  38  of the vehicle  20 , the vehicle  20  does not disturb the ground or subsurface beneath the turf. 
     Notably, the vehicle  20  drives on the synthetic turf adjacent the strip of turf where infill is being removed from, so that the vehicle  20  is not driving directly on the subsurface below the synthetic turf. This greatly assists in minimizing the need for repair or rework of the subsurface, so that a new field can be put in as quickly and as efficiently as possible. 
     It is to be understood that the length of the strip removed from the surface is, when placed back on the surface in an unfilled condition, displaced from its original position along the path traversed by the vehicle. This is due to the fact that a certain length of strip is “taken up” within the apparatus. If it is desirable to eliminate all contact between the vehicle and the subsurface, a “dummy” lead section can be attached to the forward end of the strip, with this lead section being the same width as the strip and of a length needed to traverse the path from the front end of the ramp along the path through the extractor/collector and to the front of the extractor/collector, so that there will be no portion of uncovered subsurface as the vehicle moves over the strip. 
     As mentioned, the collection bin  184  includes a trough  188  having an opening  190  therein. Infill collected in the trough  188  is moved toward the opening  190  by an auger  192 , and exits through the opening  190  and is directed to an elongated infill mover, in this case an endless conveyor belt  194  of an infill conveyor assembly  196 . The opening  190  may be located near an end of the collection bin  184 , for example. The conveyor belt  194  of the conveyor assembly  196  is upwardly and rearwardly directed, and may include a plurality of spaced partitions  198  for holding infill. The conveyor belt  194  directs the infill from the collection bin  184  toward an infill collection device, which in the embodiments shown is in the form of an infill collection trailer  201 . A downward deflector is positioned at the terminal end of the conveyor belt to deflect the conveyed infill downward to the infill collection trailer below. Alternatively, the elongated infill mover may use an auger to move the infill from the collector bin  184  to the collector trailer  201 . 
     At the terminal end of the conveyor belt  194 , infill falls into the infill collection trailer  201 . The infill collection trailer  201  generally connects with the infill extraction and collection attachment  140  via a hitch  203 , and is pulled behind the vehicle  20 . The hitch  203  could alternatively connect the trailer  201  to the vehicle  20 . The trailer  201  includes a bottom surface  205 , side walls  207 , and a front wall  208 , with a collection space  210  generally defined therebetween. There is no rear wall, which allows for the efficient removal of infill from the trailer  201 . An upper framework  212  extends from the walls  207 ,  208  and includes upwardly extending arms  214  joined by connecting arms  216 . Retaining levers  218  are provided on the upper framework  212  for holding the straps or handles  220  of a large bag  222 , which is suspended in the trailer  201 . The upper framework  212  and the retaining levers  218  form a sort of bracket configured to carry a container for infill, such as the bag  222 , and to maintain it in an open conduction. The infill can be collected in the bag  222 , which may subsequently be removed from the trailer  201 . To that end, the trailer  201  includes a ram  224 , or push mechanism, for pushing the large bag  222  therefrom. The ram  224  includes a movement actuator  226 , such as a cylinder  228  having a hydraulically activated piston  230  attached to the ram  224 . Extension of the piston  230  pushes a bag  222  out of the trailer  201 , which bag  222  may then be lifted and removed by suitable equipment (a fork of a fork-lift is shown). Of course, the handles  220  of the bag  222  would first be removed from the retaining levers  218  before attempting to remove the bag  222  from the trailer  201 . The bag  222  can be removed from the trailer  201  after the trailer  201  reaches a pre-defined weight and/or volume limit for the bag  222 , and the trailer  201  can include necessary measuring devices therefor. Also, the trailer  201  includes large and soft pneumatic tires  232 . 
     The conveyor assembly  196  that moves the infill from the collection bin  184  to the infill collection trailer  201  may be selectively activated by a user, such as to momentarily suspend operation of the conveyor track  194  (or perhaps the auger  192 ). The collection bin  184  can be sufficiently sized so as not to require continuous augering and removal of infill therefrom, in order to allow the conveyor assembly  196  or the auger  192  to be momentarily suspended. Thereby, replacement or adjustment of the bag  222  in the trailer  201  can be achieved without suspending the entire operation. 
       FIG. 7E  depicts components of an infill extraction and collection assembly  160 ′ according to an alternative embodiment of an infill extraction and collection attachment. A turf conveyor assembly  144 ′ used in association therewith does not include a nipped roller, as in the first nipped roller  152  of the embodiment discussed above. Furthermore, the synthetic turf does not follow a similarly shaped path as provided by the guide rail  172  of the embodiment discussed above. Rather, the synthetic turf follows a partially generally sinusoidal pathway defined by a partially generally sinusoidal shaped guide rail  172 . As synthetic turf enters the extraction and collection assembly  160 ′ at an entry  168 ′, a first pacing roller  201  having a plurality of spaced engagement teeth engages the upper surface of the synthetic turf and urges the synthetic turf further into the extraction and collection assembly  160 ′. A first infill extractor  200 ′ that is substantially similar to the infill extractor  200  discussed above contacts the synthetic turf on the lower surface thereof, and further urges the synthetic turf along its pathway and begins to beat the synthetic turf, thereby dislodging the infill therefrom. As the synthetic turf goes past the first infill extractor  200 ′, a second pacing roller  201  engages the upper surface of the synthetic turf and pushes it further along its pathway. The synthetic turf is contacted by a third pacing roller  201  that engages the upper surface of the synthetic turf as the synthetic turf is being inverted. A fourth pacing roller  201  positioned generally below the first infill extractor  200  further engages the synthetic turf, and in this location the synthetic turf is completely inverted. A tension roller  203  is positioned after the fourth pacing roller  201  and engages the inverted upper surface of the synthetic turf. A second infill extractor  200  follows the tension roller  203  and contacts the synthetic turf on the inverted lower surface thereof. Finally, the guide rail  172 ′ guides the synthetic turf out of the extraction and collection assembly  160 ′ through an exit  170 ′, and directs the synthetic turf back toward the ground, in a similar manner as the embodiment discussed above. The pacing rollers can be passive or driven, and if driven can be driven at any speed, including different speeds for different pacing rollers  201 . Further, the tension roller  203  may also be passive or driven, and can be driven at any speed with respect to infill extractors  200 ′ or the pacing rollers  201 . Further still, the infill extractors  200 ′ are driven, and may be driven at any appropriate speed with respect to one another or with respect to the pacing rollers  201  or the tension roller  203 . 
     Referring next to  FIGS. 8A-8C ,  9 A- 9 C, and  10 , a turf rolling attachment  240  is shown that can be connected to the vehicle  20 . The turf rolling attachment  240  is useful for removing synthetic turf from a field. Because of the movement involved, the turf rolling attachment  240  can also be referred to as a wind up attachment. 
     The turf rolling attachment  240  includes a frame  242  having attachment arms  244  for mating with the attachment arms  52  of the vehicle  20 . Widthwise-extending and adjustable position arms  246  are attached to the frame  24 . A position adjustment actuator  248  is provided for moving the arms  246  in the widthwise direction, and may include a hydraulic cylinder arrangement  250  that operates according to well known principles. Extension arms  252  are connected to the arms  246  and extend in a generally forward direction. First portions  254  thereof extend generally parallel with the attachment arms  244 , and second portions  256  thereof extend from the first portions  254  in a further forward, but downward direction. Turf rolling assemblies  258  are located near a distal end of the second portions  256  away from the first portions  254 . Each turf rolling assembly includes a hub  260  that is rotatably moveable with respect to the second portion  256 . Tines  262  extend from each hub  260  toward the other hub  260 , the tines being configured to grab and hold a portion of synthetic turf. A rotational movement actuator, such as a motor  264 , is provided for rotating each hub  260 . The hubs  260  may be rotated in either direction. 
     A strip of synthetic turf is placed around one or more of the tines  262 , and the motor  264  can then rotate the hub  260 , thereby rolling the synthetic turf up and into a roll, as shown. The distance between the respective turf rolling assemblies  258  can be adjusted. For example, before rolling a strip of synthetic turf, the arms  246  are moved into an appropriately-spaced orientation so the strip of synthetic turf fits between, but properly engages, the turf rolling assemblies  258 . Once the strip of synthetic turf is rolled up, the arms  246  may again be moved, to move the turf rolling assemblies  258  away from each other, thereby releasing the roll of synthetic turf from the turf rolling attachment  240 . 
     The turf rolling attachment  240  may be used with the vehicle  20  held stationary or with the vehicle  20  moving. For example, the vehicle  20  may be parked on the sidelines and off of the synthetic turf to be removed, and the synthetic turf is pulled by the turf rolling attachment  240  and rolled up. Advantageously, this approach allows the synthetic turf to be removed without driving the vehicle  20  over the subsurface below the synthetic turf, thereby limiting or eliminating any damage to the subsurface that would have to be repaired before a new synthetic turf is installed. Also, the turf rolling attachment may be used with the vehicle  20  driving across the field as the strip of synthetic turf is rolled up. 
     As shown in  FIG. 10 , after the infill is removed from synthetic turf by the infill extraction and collection attachment, it can be rolled up by the turf rolling attachment. 
     A roll of synthetic turf may be removed from the turf removal attachment and transported for reconditioning, recycling, or other disposal. Advantageously, the infill is removed from a strip of synthetic turf before it is removed from a field, but such is not required as the infill can be removed away from the field, such as at an off-site location, as discussed above. 
     Further, the vehicle  20  can be used in accordance with the teachings relating to the devices and methods disclosed in U.S. Patent Publication No. 2012/0067996, which is hereby incorporated by reference in its entirety. Particularly, the frame 16 of the &#39;996 publication can be used as an attachment device that can be connected to the vehicle  20  for unrolling a roll of turf onto a field. In particular, the frame 16, along with the spindle 18 holding a roll 20 of synthetic turf, all of the &#39;996 publication, can be used with the vehicle  20  herein as a turf installation attachment, and can be used for installing a new synthetic turf onto a field. Methods for using the vehicle  20  in conjunction with the frame 16 of the &#39;996 publication will be evident from the teachings of the &#39;996 publication. 
     Thus, when it is time to remove a synthetic turf field, the vehicle and attachment devices disclosed herein can be used. Particularly, the vehicle  20  can be used with the turf cutting attachment  90  to cut a synthetic turf field into strips. Then, the vehicle  20  can be used with the infill extraction and collection attachment  140  to remove the infill from the strips of synthetic turf. The infill can be collected, saved for subsequent use, or handled in any other way. Once the infill has been removed from the synthetic turf, the vehicle  20  can be used with the turf rolling attachment  240  to remove the strips of synthetic turf from the field, either with the vehicle  20  held stationary, or by driving the vehicle  20  across the field as the strips are rolled up. The vehicle  20  and the attachment devices disclosed herein allow the synthetic turf to be removed with minimal disruption of the underlying subsurface. 
     Alternatively, the vehicle  20  can be used with the turf cutting attachment  90  to cut a synthetic turf field into strips. The strips can then be rolled up using the vehicle  20  and the turf rolling attachment  240 . Infill contained within the strips of synthetic turf can be removed at an off-site location, or the strips can be otherwise handled. For example, an off-site stationary device can include an infill extraction and collection component similar to the infill extraction and collection attachment assembly  160  disclosed herein. 
     Synthetic turf and infill recovered as disclosed herein can be handled in any desired manner. For example, the synthetic turf may be recycled, discarded, or reused. Likewise, the infill may be recycled, discarded, or reused. 
     The extraction and collection assembly  160  can also be used in circumstances other than in association with a motorized vehicle of the type shown in the Figures. For example, the extraction and collection assembly  160  can be mounted at a fixed off-site location for stationary operation. The strips of filled synthetic turf can be fed into the stationary extraction and collection assembly  160 , at the extractor/collector site, and the infill removed therefrom. For example, strips of infilled synthetic turf may be removed from a distant field and then transferred to the extractor/collector site to recover the infill. Synthetic turf that exits the stationary extraction and collection assembly  160  can be further processed, such as rolled up into a roll or fed into a shredding machine, for example. The infill removed from the synthetic turf can be further processed, as well, or disposed of, as appropriate. Thus, the stationary extractor/collector site may be capable of serving an entire geographical region. 
     According to one aspect of the invention, the extraction and collection assembly  160  disclosed herein has the capability for directly engaging a leading edge of a strip of synthetic turf, such as at the edge of a field. In contrast, prior art devices have required that a lead-up strip be attached to synthetic turf, so that the lead-up strip can be fed into the prior art devices before the synthetic turf. The attachment of a lead-up strip to synthetic turf requires a user to physically connect the lead-up strip to the synthetic turf, and such lead-up strips can take several feet or yards of material. The present invention makes the use of such a lead-up strip unnecessary, and thereby saves time and resources that would otherwise be required by a lead up strip. 
     While chain and sprocket drive mechanisms are shown in association with the various devices in the figures, belts, pulleys, and other associated drive mechanisms are also considered appropriate and may be used in alternative embodiments. 
     Thus, by using the devices and methods disclosed herein, the present invention enables a synthetic turf to be cut into strips, the infill removed (i.e., extracted and collected) from the synthetic turf, the synthetic turf removed from a field, and a new synthetic turf installed in a relatively short time window. Advantageously, the present invention contemplates removal of a synthetic turf in a manner that does not disrupt the subsurface beneath the synthetic turf, or does so only to a small extent. The present invention contemplates removing the infill at the site and collecting the infill at the site in an infill collection trailer, or removing the infill at an off-site extractor/collector location. The removed infill can be reused, recycled, or disposed of as circumstances dictate. Also, the removed turf can be transported to a reconditioning, recycling, or disposal facility. 
     This specification shows and describes several preferred embodiments of the invention. However, those skilled in the art will appreciate that the disclosed embodiments are susceptible to a reasonable amount of modification and/or permutation, without departing from the overall scope of the invention. For instance, the dimensions of the components shown and described, and/or the relationships of those dimensions to other components may vary, as needed, in order to apply the general principles of the present invention to the actual circumstances at hand. Moreover, it is to be understood that the recitation of “objects of the invention” in this specification is not intended to be construed as an admission that others have recognized the same problems or perceived the same limitations in the state of the art, as recognized by the present inventors. Moreover, the recitation of the objects of the invention is also not intended to require each of the following claims to achieve all of the above-stated objects. Rather, the recitation of the objects of the invention in this specification is intended merely to help explain the story behind the present invention, and to explain why the present invention represents an advance in the state of the art over existing technology. Accordingly, the inventors intend that the scope of the appended claims are not to be limited by the specific details shown or described herein, or by the “objects” described above.

Technology Classification (CPC): 8