System and Method for Forming Artificial Turf Products with a Woven Appearance

Abstract

A system and method for forming synthetic / artificial grass or turf tufted fabric materials in which a series of tufts or artificial / synthetic grass or turf yarns is formed in a backing material. The system generally will include a row of needles mounted along a tufting zone and which are reciprocated through the backing material to deliver a series of yarns into the backing materials. The needles are arranged in needle groups with the needle groups spaced apart along the length of the needle bar. A series of gauge parts, typically including cut-pile hooks, will be aligned with and will engage the needles in order to form cut and pile tufts defining spaced grass / turf tuft formations in the backing material.

Description

FIELD OF THE INVENTION[0001]The present invention generally relates to systems and methods for forming artificial / synthetic sports grass or turf fabric materials or products, and in particular to a method and system for forming artificial / synthetic sports grass or turf fabrics materials or products utilizing tufting systems and processes to form such grass or turf fabric materials or products with a woven appearance.BACKGROUND OF THE INVENTION[0002]Artificial / synthetic grass or turf products have been growing in popularity and demand in recent years, especially for use in indoor stadiums and in geographic areas where grass fields are difficult to maintain due to weather and heavy use conditions. In the past, such synthetic turf products typically have been formed by various methods, including being formed as woven products in which loops of synthetic turf filaments or fibers are woven into a mesh or backing material and the tips of the loops thereafter sheared to create the appearan...

AI Technical Summary

Benefits of technology

[0009]The backing feed control system further typically will monitor the position of the main shaft so as to determine when the needles are leaving the backing material or are at a desired position out of or nearly out of the backing material so as to begin advancement of the backing material and complete the advancement or indexing thereof in sufficient time prior to the needles finishing a downward stroke. The control system also can slow or delay / stop the movement of the backing material as the needles penetrate the backing material to form the tufts of grass or turf yarns as part of such control. In addition, a shift mechanism can be provided to control / cause a transverse movement of the needles as needed to further help avoid “rowing” effects in the finished artificial / synthetic grass or turf fabric material or product.

[0010]The backing feed control system and method of the present invention accordingly will enable the formation of artificial / synthetic grass or turf products utilizing a tufting process and having a substantially woven appearance of dense tuft groups arranged in a balanced, spaced arrangement both laterally across and longitudinally along the length of the backing material. As a result, improved and / or more precise distribution of tufts of the synthetic grass yarns can be provided across the backing material, enabling less yarn weight while providing better support for the tufts against flattening or laying down to avoid rowing effects and provide an enhanced natural grass appearance and feel to the finished artificial / synthetic grass or turf product.

Problems solved by technology

One problem with such woven turf products is a tendency of the turf fibers to flatten in the direction of the weave, especially over continued or extensive use and as the infill material is disturbed.

This leads to a “corn-row” appearance that is less natural looking and tends to reduce the cushioning effects of the turf.

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