A mat for a hybrid lawn

Abstract

A mat for a hybrid lawn with a woven base fabric comprising pile tufts interwoven with weft yarn (5), the ends of the tufts forming synthetic blades of grass, the mat having a warp density of 54 to 72 ends / 10 cm, a weft density of 30 to 80 ends / 10 cm and a pile height of 20 to 140 mm, the total area of ​​the openings in the base fabric being 5% to 15% of the total area of ​​the base fabric of the mat, characterized in that warp threads (1, 2) consist of biodegradable natural fibers with a linear mass of 100 tex to 400 tex, the weft yarn (5) consists of biodegradable natural fibers with a linear mass of 140 tex to 1000 tex and pile yarns (3, 4) consist of biodegradable natural fibers or biodegradable polymer threads with a linear mass of 65 tex to 1200 tex.

Description

TECHNICAL AREA

[0001] The invention relates to a fully biodegradable mat for a hybrid lawn and the hybrid lawn produced therefrom, which contains artificial turf and promotes the growth of natural grass. BACKGROUND

[0002] Lawns are generally divided into natural grass and artificial turf. Natural grass, where the grass grows directly on the ground, offers high levels of comfort, but is prone to damage under heavy use and requires a long recovery time. Artificial turf is made entirely of synthetic materials and typically consists of an artificial mat from which long artificial turf blades protrude, with the spaces between the blades filled with artificial granules. While durable, artificial turf offers less comfort than natural grass.

[0003] Carpet-based hybrid turf, which combines a base mat with artificial turf covered with soil in which natural grass grows, is also popular. The roots of the natural turf grow through the artificial base and permanently bond with it. Over time, the natural turf blades grow beyond the height of the artificial turf blades, providing a similar level of comfort to natural grass. In high-wear areas, such as the goal area of ​​a soccer field, if the natural turf blades become damaged, the artificial turf blades become exposed, reducing comfort but not as much as with damaged natural turf.

[0004] Mats for hybrid turf must have suitable base parameters, including water and air permeability, and must also allow natural grass roots to grow through the base. The simplest known method to ensure suitable base permeability is to perforate the base after installation, but this complicates the installation process.

[0005] A European patent EP 2 698 460 B1 discloses a mat for a hybrid sports or ornamental turf in the form of a woven fabric with a single-sided pile made of synthetic olefin fibers such as polyethylene and / or polypropylene and / or polyester, according to a 3 / 8W or 5 / 12W or 7 / 16W weave structure, comprising tufts interwoven with the weft thread, the ends of the tufts forming artificial turf blades. The mat has 5,000 to 20,000 tufts per square meter, a warp density of 54 to 72 ends / 10 cm, a weft density of 30 to 80 ends / 10 cm, and a pile height of 20 to 140 mm, each tuft being interwoven at least twice over three weft threads, and the total basis weight of the mat is 753 to 2,105 g / m 2 amounts.

[0006] Existing hybrid turf mats face challenges related to installation complexity, subsurface permeability, and integration with natural grass. These issues require the development of alternative hybrid turf mat designs to effectively address these challenges. SUMMARY OF THE INVENTION

[0007] Based on this, the object of the present invention is to provide a fully biodegradable, woven mat for a hybrid lawn with a construction alternative to the known mats for hybrid lawns.

[0008] The use of biodegradable materials for the warp, weft, and pile threads ensures that the mat decomposes naturally over time, thus reducing its environmental impact. This is particularly beneficial in applications where the mat needs to be replaced frequently, such as high-traffic sports fields or ornamental lawns in public areas. Because the mat is biodegradable, it produces no long-term waste, making it an environmentally friendly alternative to conventional synthetic mats.

[0009] The mat according to the invention is suitable for hybrid sports or ornamental turf and consists of a woven material comprising an artificial turf cover and a base through which the roots of natural turf can easily grow. The mat combines the advantages of artificial turf and natural turf, is resistant to adverse weather conditions, and can withstand heavy use. In the event of damage, only the damaged parts need to be replaced. The mat can be used to create turf systems at the end-use site or in a production facility. The mat is extremely flexible even with a natural turf infill layer and can therefore be rolled and transported into ready-to-install hybrid turf rolls.

[0010] The mat consists of a woven backing fabric consisting of pile tufts interwoven with the weft thread, with the ends of the tufts forming synthetic grass blades. The mat has a warp density of 54 to 72 ends / 10 cm, a weft density of 30 to 80 ends / 10 cm, and a pile height of 20 to 140 mm. The total area of ​​the openings in the backing fabric is 5% to 15% of the total area of ​​the backing fabric of the mat. The warp threads are made of biodegradable natural fibers with a linear mass of 100 tex to 400 tex, the weft threads are made of biodegradable natural fibers with a linear mass of 140 tex to 1000 tex, and the pile threads are made of biodegradable natural fibers or biodegradable polymer threads with a linear mass of 65 tex to 1200 tex.

[0011] The warp and weft threads can be selected to have a shorter biodegradability than the pile threads. Preferably, the warp and weft threads should decompose within 1-2 growing seasons. This ensures that the structural integrity of the mat is maintained during the initial growth phase of the natural turf. While the warp and weft threads decompose, the remaining pile threads continue to provide some structural support for the turf. This gradual decomposition process creates more openings for the unhindered growth of natural turf and improves the integration of the natural and artificial components of the hybrid turf. This property is particularly advantageous compared to fully synthetic mats, which can hinder the growth of natural turf due to their lack of biodegradability.

[0012] The warp threads can be made of cotton (with a biodegradability of 3 months to 2 years) and / or viscose (with a biodegradability of 6 weeks to 2 years). The weft threads can be made of jute (with a biodegradability of 6 months to 2 years) and / or cotton (with a biodegradability of 3 months to 2 years) and / or linen (with a biodegradability of 6 months to 2 years) and / or hemp (with a biodegradability of 6 months to 2 years). The pile threads can be made of naturally dyed cotton fibers (with a biodegradability of 3 months to 2 years) or biodegradable polymer threads (with a biodegradability of 2 years to 6 years).

[0013] If it is necessary to increase the stability of the mat and the resistance of the tufts to pulling out, the underside of the mat can be coated with a water-based fixing dispersion, for example in an amount of 50 to 120 g / m 2Dry matter. The fixing dispersion must also be biodegradable. The fixing dispersion used in the mat can be an aqueous solution of a natural binder, such as starch, with additional additives that enhance the growth of natural grass. This natural binder not only ensures the biodegradability of the mat but also contributes to the health and growth of the natural grass. The additives can contain nutrients and growth promoters that provide the grass with the necessary elements for proper growth. This dual functionality of the fixing dispersion—as a binder and as a growth additive—further increases the ecological benefits and practical usability of the mat.

[0014] The mat's biodegradability also opens up a wide range of possible applications. For example, the mat can be installed in temporary installations such as event venues or seasonal sports fields and allowed to decompose naturally after the event or season. This eliminates costly and labor-intensive removal and disposal processes. Furthermore, the mat can be used in environmentally sensitive areas where the use of non-biodegradable materials would be inappropriate or prohibited.

[0015] The woven mat can have a single-sided pile blanket constructed according to a 3 / 8W, 5 / 12W, or 7 / 16W weave structure. Each pile tuft can be interwoven at least twice over three weft threads. The mat can contain 5,000 to 20,000 pile tufts per m. 2 and the total mass of the mat can be between 753 and 2105 g / m 2 lay.

[0016] Due to its loose structure, the mat provides optimal conditions for the development of the root system of natural grass and is permeable to water and air. The advantageous warp density ensures a loose structure of the mat with a linear pile mass of over 5000 dtex, while simultaneously allowing for openings in the base fabric of the mat. Furthermore, despite its loose nature, the mat retains a cohesive structure even during use.

[0017] The attachment of the tufts, measured as the force required to pull out or break a stalk, can range from 17 to 74 N, depending on the weave structure used and its density. The attachment should be sufficiently strong that the mat does not require additional coating with a fixing dispersion on the underside and maintains its maximum elasticity and permeability to water and air.

[0018] The coherence of the mat, which is particularly important for heavy-duty applications such as sports fields, can be achieved by interlacing the binding yarn and the filling yarn between the pile threads. At least one working yarn, forming the pile, can be arranged between interlaced sets of three to six warp threads. Such an interlaced arrangement of sets of three and six threads ensures optimal stability of the mat's weft threads while ensuring sufficient permeability for water and air within the mat, which can be at least 100,000 mmH2O / hour.

[0019] The openings in the base can be evenly distributed and of a uniform size, for example at least 25 mm 2 , so that per square centimeter of the base of the mat in its initial state, ie before laying on the field, openings with an area of ​​0.5 to 4 mm 2may be present. The openings in the mat can enlarge as grass roots grow through them, causing the threads surrounding the opening to move sideways under the force of the grass roots, which is possible due to the loose structure of the mat.

[0020] To further stabilize the mat for hybrid turf, the mat may include incorporated pile yarns, preferably located between the working pile yarn and the filling warp, which improve the dimensional stability of the mat. The linear mass of the working pile yarn, which forms the top layer of the mat, is 80% to 120% of the linear mass of the incorporated pile yarn.

[0021] Preferably, staple fibers with a total linear mass of more than 5000 dtex, preferably more than 6000 dtex and particularly preferably more than 10000 dtex can be used.

[0022] Multi-colored yarns can be used for the pile, for example, several shades of green, creating artificial turf tufts with a color similar to natural grass. Therefore, the pile threads can consist of at least two filaments. For example, the in-place pile thread can be formed from three filaments with a linear mass of 2000 dtex each, and the working pile thread can be formed from three filaments with a linear mass of 2000 dtex each, resulting in a total linear mass of the pile of 6000 dtex.

[0023] The use of the yarn incorporated in the base results in a mat with stable dimensions, suitable parameters such as water and air permeability and a high uniformity of openings per square centimeter, which allows the mat to be used for the production of hybrid sports or ornamental turf.

[0024] Finally, the mat is used to form a hybrid lawn by placing it on a substrate (e.g., soil or sand) and covering its top with an infill layer of grass seeds. As the grass seeds germinate, the grass roots grow toward the ground through the openings in the base layer, and the blades of natural grass grow on the mat between the artificial blades. The infill layer can consist of any known permeable cultivation material, such as natural or synthetic sand, pozzolan, incineration ash, organic particles, synthetic particles such as rubber particles, or mixtures thereof. BRIEF DESCRIPTION OF THE CHARACTERS

[0025] Additional details and further advantages of the invention are described below with reference to preferred embodiments, to which the present invention is not limited, and in conjunction with the accompanying drawings.

[0026] It shows schematically: Fig. 1 a mat according to a first embodiment, which is manufactured according to a 3 / 8W weave structure, Fig. 2 a mat according to a second embodiment, which is manufactured according to a 7 / 16W weave structure, and Fig. 3 a bottom side of a mat according to a third embodiment, which is made with a 7 / 16W weave structure. DETAILED DESCRIPTION OF THE EMBODIMENTSFirst Embodiment - Fig. 1.

[0027] The mat is constructed as a woven 3 / 8W weave and is particularly suitable for non-professional recreational areas, especially in water-scarce regions. The mat consists of: working pile yarns and incorporated pile yarns made of 400 tex naturally dyed cotton fibers; weft yarns made of 280 tex jute; and binding and filling warp yarns made of 200 tex cotton. The mat has a weft density of 36 threads / 10 cm and the length of the yarn in a single tuft is 86 mm with a pile height of 35 mm.

[0028] The mat is manufactured by interlacing the filling warp 1 and the binding warp 2 with the working pile yarn 3, the incorporated pile yarn 4 and the weft yarn 5. The filling warp 1, the binding warp 2, the weft yarn 5 and the incorporated pile yarn 4 form the base fabric. The working pile yarn 3 forms artificial turf tufts, with each tuft being interlaced three times (as in Fig. 1) or seven times (as shown in Fig. 2) is interwoven with the threads of the weft yarn 5 and two ends of the working pile yarn 3. The mat is produced by double-sided weaving, whereby two mats are produced in a single operation: an upper and a lower mat, which are then separated by a cutting device integrated into the weaving machine. In double-sided weaving, both fabrics consist of weft threads 5, threads of the binding warp 2, threads of the filling warp 1, threads of the incorporated pile yarn 4, and threads of the working pile yarn 3, wherein the threads of the working pile yarn 3 in the upper and lower fabric layers are alternately interwoven by threads of the weft yarn 5 according to a W-weave structure, wherein each artificial turf comprises two ends of the working pile yarn 3. Second embodiment - Fig. 2

[0029] The mat is constructed as a woven fabric with a 7 / 16W weave structure, suitable for professional soccer pitches and other heavy-duty applications. The mat consists of: working pile yarns 3 and incorporated pile yarns 4 made of 1000 tex biodegradable polymer; weft yarns 5 made of 800 tex cotton; binding warp yarns 2 and filling warp yarns 1 made of 300 tex viscose. The mat has a weft density of 36 ends / 10 cm and the length of the yarn in a single tuft is 120 mm with a pile height of 50 mm. Third embodiment - Fig. 3

[0030] Fig.Figure 3 shows the distribution of individual threads, viewed from the underside of the mat made with a 7 / 16W weave structure. The mat has a yarn configuration including a binding warp 2, a filling warp 1, a working pile yarn 3, and an incorporated pile yarn 4 interlaced with a weft yarn 5. Each yarn of the incorporated pile yarn 4 is located between the working pile yarn 3 and the filling warp 1 yarn, with the incorporated pile yarn 4 interlaced with the weft yarn 5 in the same manner as the filling warp 1 yarns. The working pile yarn 3 is interwoven with the weft yarn 5 in the same way as the yarns of the binding warp 2. The filling warp 1 and the binding warp 2 form an arrangement of interchangeably arranged sets of three and six warp threads, between which working pile yarns 3 and incorporated pile yarns 4 are arranged in the warp direction.The set of six warp threads, seen from the left in the figure, comprises in sequence: two filling warp threads 1a, 1b, one binding warp thread 2c, one filling warp thread 1d, one binding warp thread 1e, and one filling warp thread 1f. The set of six warp threads provides stability to the mat and maintains the position of the weft yarn 5 threads across the entire fabric surface. The set of three warp threads consists of one filling warp thread 1g, one binding warp thread 2h, and one filling warp thread 1i. The set of warp threads enables a total mat base mass of over 256 g / m2 while maintaining high permeability to water, air, and grass roots. Other embodiments

[0031] The mat may further comprise a configuration of two yarns: the working pile yarn 3 and the incorporated pile yarn 4, the incorporated pile yarn 4 being optional. The pile yarns may extend in the warp direction between sets of three and six warp threads. The working pile yarn 3 may be interwoven with threads of the weft yarn 5 through a 7 / 16W weave structure. The ends of the working pile yarn 3 extending outside the fabric form artificial turf knobs, each knob being formed by two parallel yarns of the working pile yarns 3 extending in a row of pile yarns in the warp direction and whose ends are brought out of the fabric on the same weft yarn 5 (not shown in the drawing). The knobs thus formed form uniform rows in the warp direction, with the knobs of one pile in one row being offset from the knobs of parallel adjacent rows (i.e.the consecutive studs of the artificial turf do not form parallel rows in the direction of the shot), which allows for a more even distribution of the studs on the mat surface.

[0032] The incorporated pile yarn 4 can extend between the threads of the working pile yarns 3 and between the sets of six or three warp threads such that each yarn of the incorporated pile yarn 4, extending parallel along a yarn of the working pile yarn 3 and the set of six threads of the weft yarn 5, changes its position at the point 6 where two working pile yarns 3 protrude and extends parallel between the following working pile yarn 3 and the set of three warp threads. Such an arrangement of the piles in the fabric ensures the dimensional stability of the mat. LIST OF REFERENCE SYMBOLS 1 filling chain 1a filling warp thread 1b Filling warp thread 1d filling warp thread 1st binding warp thread 1f filling warp thread 1g filling warp thread 1i filling warp thread 2 binding chain 2c binding warp thread 2h binding warp thread 3 working pile yarn 4 incorporated pile yarn 5 weft yarn 6 Place where two working pile yarns (3) protrude QUOTES CONTAINED IN THE DESCRIPTION

[0000] This list of documents submitted by the applicant was generated automatically and is included solely for the convenience of the reader. This list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions. Cited patent literature

[0000] EP 2 698 460 B1

[0005]

Claims

[1] A mat for a hybrid lawn comprising a woven base fabric comprising pile nubs interwoven with weft yarn (5), wherein the ends of the nubs form synthetic grass blades, wherein the mat has a warp density of 54 to 72 ends / 10 cm, a weft density of 30 to 80 ends / 10 cm and a pile height of 20 to 140 mm, wherein the total area of ​​the openings in the base fabric is 5% to 15% of the total area of ​​the base fabric of the mat, characterized by , that warp threads (1, 2) are made of biodegradable natural fibers with a linear mass of 100 tex to 400 tex, the weft yarn (5) is made of biodegradable natural fibers with a linear mass of 140 tex to 1000 tex, and pile yarns (3, 4) are made of biodegradable natural fibers or biodegradable polymer threads with a linear mass of 65 tex to 1200 tex. [2] The mat according to claim 1, wherein the warp threads (1, 2) consist of cotton and / or viscose. [3] The mat according to claim 1 or 2, wherein the weft yarn (5) consists of one or more of the following materials: jute, cotton, linen and hemp yarn. [4] The mat according to any one of claims 1 to 3, wherein the pile yarns (3, 4) consist of naturally dyed cotton and / or biodegradable polymer. [5] The mat according to one or more of the preceding claims, characterized by that one underside of the mat is coated with a biodegradable, water-based dispersion containing natural grass nutrients and / or growth promoters. [6] The mat according to one or more of the preceding claims, characterized by , that the weft yarn (5), the warp threads (1; 2) and the pile yarns (3, 4) are movable to form openings with a size of at least 25 mm 2 to form. [7] The mat according to one or more of the preceding claims, characterized bythat the mat has at least one opening with an area of ​​0.5 mm 2 up to 4 mm 2 per square centimeter of the area of ​​the base fabric of the mat. [8] The mat according to one or more of the preceding claims, characterized by , that the mat further comprises a working pile yarn (3) and / or an incorporated pile yarn (4). [9] The mat according to claim 8, characterized by , that each yarn of the incorporated pile thread (4) is arranged between the working pile thread (3) and a filler chain (1) of the warp threads (1; 2). [10] The mat according to claim 8 or 9, characterized by , that the total linear mass of the working pile yarns (3) is 80% to 120% of the linear mass of the incorporated pile yarns (4). [11] The mat according to one or more of claims 8 to 10, characterized by , that the working pile yarn (3) consists of at least two filaments. [12] The mat according to one or more of claims 8 to 11, characterized by , that at least one working pile yarn (3) is arranged between interwoven sets of three and six warp threads (1, 2), in particular the filling warp (1) and / or the binding warp (2). [13] The mat according to claim 12, characterized by , that between the intertwined sets of three and six warp threads (1, 2), in particular the filling warp (1) and / or the binding warp (2), a further incorporated pile yarn (4) is arranged. [14] The mat according to claim 12, characterized by , that the set of three warp threads includes a filler warp thread (1g), a binding warp thread (2h) and a filler warp thread (1i) in succession, and the set of six warp threads includes two filler warp threads (1a, 1b), a binding warp thread (2c), a filler warp thread (1d), a binding warp thread (1e) and a filler warp thread (1f) in succession. [15] The mat according to claim 12, characterized by, that the pile tufts in each row are offset from the pile tufts of parallel adjacent rows.

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