Methods and systems for manufacturing yarns for synthetic turf
Inactive Publication Date: 2008-08-28
NEXCEL SYNTHETICS
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- Summary
- Abstract
- Description
- Claims
- Application Information
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Benefits of technology
[0018]According to another aspect, the drawing component includes a drawing oven for heating the single strand synthetic yarns and a plurality of drawing rollers adapted to pull and stretch the yarns. In one aspect, the drawing oven heats the single strand synthetic yarns to a temperature of about 90° C. to about 110° C. The yarns are heated in this way so that they may be stretched and shaped by the plurality of drawing rollers. The heated stretching of the yarns creates a smooth finish on yarns, and additionally rounds or radiuses the edges and corners of the yarns. This heated stretching provides a natural seal or finish on the single strand synthetic yarns giving the yarns a higher resilience and more natural look and feel as compared to other synthetic yarns used for synthetic turf.
[0031]According to a further aspect, the plurality of single strand synthetic yarns are drawn at a draw ratio of about 6:1. In one aspect, the yarns are heated to a temperature of about 90° C. to about 110° C. while being drawn. The yarns are heated in this way so that they may be stretched and shaped during the drawing process. The heated stretching of the yarns creates a smooth finish on the yarns, and additionally rounds or radiuses the edges and corners of the yarns. This heated stretching provides a natural seal or finish on the single strand synthetic yarns giving the yarns a higher resilience and more natural look and feel as compared to other synthetic yarns used for synthetic turf. Additionally, in some aspects, the single strand synthetic yarns are cooled after being drawn. In one aspect, the yarns are cooled to a temperature of about 25° C.
Problems solved by technology
While the fibrillating process may be cheap and easy, there are several disadvantages associated with synthetic turf made from fibrillated “grass” blades.
Because of the violent method in which the plastic sheets are cut, the resulting blades of “grass” have sharp or rough edges, which are undesirable because they present a more abrasive surface that can cause injury or irritation if someone slides or falls on the turf.
Also, because of the forceful manner in which these plastic sheets are punctured and slit, the deterioration of the fibers begins as soon as the fibers are put into use.
These brushing machines further break apart and tear the fibers, and typically accelerate the overall weakening of the turf.
Additionally, because the strands of “grass” are lumped together into sections, and are not individual and discrete, the fibrillated synthetic turf lacks the look and feel of real grass.
However, because the monofilament fibers are straight and upright when installed as synthetic turf, the rubber and sand used as infill around the base of the fibers can blow away or be kicked around by players on the turf because there is nothing keeping the infill in place.
This loss or displacement of infill is commonly referred to as “flyout.” Over time, flyout of infill results in a non-uniform, abrasive playing surface, which is highly undesirable.
Additionally, because each strand of monofilament fiber must be individually extruded, it can be difficult to easily and efficiently manufacture large quantities of the fibers.
Method used
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[0047]The present invention is more particularly described in the following examples that are intended as illustrative only since numerous modifications and variations therein will be apparent to those skilled in the art. Various embodiments of the invention are now described in detail. Referring to the drawings, like numbers indicate like components throughout the views. As used in the description herein and throughout the claims that follow, the meaning of “a”, “an”, and “the” includes plural reference unless the context clearly dictates otherwise. Also, as used in the description herein and throughout the claims that follow, the meaning of “in” includes “in” and “on” unless the context clearly dictates otherwise.
[0048]The terms used in this specification generally have their ordinary meanings in the art, within the context of the invention, and in the specific context where each term is used.
[0049]Certain terns that are used to describe the invention are discussed below, or elsew...
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Abstract
Systems and methods for manufacturing synthetic yarns for synthetic turf. The systems and methods include rollers for advancing a plastic sheet forward through a manufacturing process. The plastic sheet is cooled and heated on opposing sides by alternating temperature rollers to pre-form the plastic sheet such that subsequent synthetic yarns made from the sheet will have a curled shape. The plastic sheet is then cut longitudinally by a plurality of slitting blades along the length of the sheet to form a plurality of single strand synthetic yarns. A drawing device then draws and stretches the single strand synthetic yarns to a desired width and thickness, wherein the drawing device includes a drawing oven for heating the yarns, and a plurality of drawing rollers for pulling and stretching the heated yarns. The final product drawn yarns comprise sealed, smooth yarns with desirable rounded edges and a curled tip.
Description
CROSS REFERENCE TO RELATED APPLICATION[0001]This application claims the benefit under 35 U.S.C. §119(e) of U.S. Provisional Patent No. 60 / 891,387, filed Feb. 23, 2007, and entitled “Method and Apparatus for Manufacturing Yarns for Synthetic Turf,” which is incorporated herein by reference in its entirety.FIELD OF THE PRESENT INVENTION[0002]The present invention relates generally to manufacturing yarns for synthetic turf. More particularly, the present invention relates to methods, devices, and systems for manufacturing yarns for synthetic turf that are resilient, retain infill, and have improved appearance and texture.BACKGROUND OF THE PRESENT INVENTION[0003]Synthetic turf is a surfacing material used to imitate grass. It is generally used in areas where grass cannot grow, or in areas where grass maintenance is impossible or undesired. Synthetic turf may be used in several applications, including indoor and outdoor synthetic putting greens, golf short game facilities, indoor practic...
Claims
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Login to View More IPC IPC(8): D01D5/00D02J1/22D02G3/00
CPCD01D5/22D01D5/23D10B2505/202D02G3/445D02J1/22D01D5/426
InventorPRICE, JOSEPH C.
OwnerNEXCEL SYNTHETICS