Artificial turf having alloy fibers and the method of manufacture thereof

Abstract

An apparatus and a method are described for the present disclosure relating to artificial turf products. The present disclosure includes an artificial turf product comprised of a polyolefin, polyamide, and a binding agent. The three components are mixed together to form a homogenous alloy within an artificial turf fiber. The binding agent allows the polyolefin and the polyamide to combine to create the homogenous alloy. The binding agent may be maleic anhydride, maleic acid, a modified polar star-like high polypropylene, or any other binding agent disclosed herein. To create the homogenous alloy, the unhomogenized mixture of polyolefin, polyamide, and the binding agent is heated. Once the mixture is heated, it may go through an extrusion process. The present disclosure provides a new material in artificial turf products.

Description

CROSS REFERENCE TO RELATED APPLICATION

[0001] This disclosure claims the benefit of and priority to U.S. Provisional Application Ser. No. 63 / 771,414, filed on Mar. 13, 2025.TECHNICAL FIELD

[0002] This disclosure is directed generally to artificial turf and the fibers that are bundled together to form the artificial turf.BACKGROUND ART

[0003] Artificial turf is an article of manufacture typically composed of synthetic man-made fibers that are generally woven onto a backing surface. Artificial turf is made to look and feel similar to natural grass. Artificial turf is commonly used for sports fields, golf courses, pet parks, playgrounds, personal yards, amongst many other uses. Artificial turf may be different colors, length, and density depending on the desired use of the artificial turf.

[0004] Artificial turf is beneficial because it is low maintenance compared to real / natural grass. Artificial turf remains green, does not need to be mowed, and overall, there is not a demanding level of upkeep to maintain artificial turf looking new. Furthermore, artificial turf is beneficial because it is more durable than natural grass and can handle high traffic areas, often without damaging the appearance of the turf. Artificial turf is pet friendly and does not require any chemical treatments to make it grow the way grass does making it an environmentally friendly option as well.

[0005] Currently, the fibers that are used in artificial turf are typically made from either polyethylene or nylon. Artificial turf fibers made from polyethylene are not as durable in comparison to nylon fibers, but the polyethylene fibers are hydrophobic, which means that they are a little softer and water does not permeate the turf fiber, so they do not expand when they are wet. On the other hand, artificial turf made from nylon is more durable, but they are hydrophilic, which means that they receive water, so they expand and contract when they become wet and dry respectively. Nylon turf fibers tend to be a little stiffer because of their hydrophilic nature.

[0006] There are artificial turf products currently that have a sheathed or sheath configuration comprised of a nylon core with a polyethylene sheath or coating. The purpose of having the nylon core with the polyethylene sheath or coating is to have a more durable inner portion of the turf fiber while maintaining the softness of the turf fiber that is made from polyethylene. Although the sheath and core variations of artificial turf fibers are beneficial, it is not without its drawbacks. For example, sheath and core fibers are difficult to manufacture due to the disparate materials (i.e., nylon and polyethylene) that do not mix together. As such, specialty tools are required for manufacture. Furthermore, because the two disparate materials are distinct, there is a chance for them to separate, which then loses the benefits of the sheath and core.SUMMARY OF THE INVENTION

[0007] It has been determined that there is a need to create an artificial turf that is durable yet soft. The present disclosure addresses this need, along with solving the separation problems of sheath and core fibers, by providing an alloy blend for an artificial turf fiber composed of at least two disparate materials, such as nylon and polyethene, that were previously unable to be blended into an alloy and used as a turf fiber. By creating an alloy blend in the form of a turf fiber, aspects of the present disclosure are able to provide an artificial turf product with alloy fibers that maximizes the benefits and advantages of softness and durability.

[0008] In one aspect, an exemplary embodiment of the present disclosure may provide an artificial turf product comprising: a backing layer; at least one artificial turf fiber formed from a homogenous alloy, and the at least one turf fiber is attached to the backing layer; wherein the homogenous alloy comprises: a polyolefin; a polyamide; and a binding agent.

[0009] In another aspect, an exemplary embodiment of the present disclosure may provide the artificial turf product, wherein the polyolefin, polyamide, and the binding agent sum to the 100 parts by weight, and wherein the binding agent comprises at least one of (i) maleic acid and (ii) maleic anhydride. The artificial turf product, wherein the polyolefin is in a range of about 60 to 70 parts by weight of the total parts by weight. The artificial turf product, wherein the polyolefin is polyethylene that is about 65 parts by weight. The artificial turf product, wherein the polyamide is nylon, wherein the nylon is in a range of about 25 to 40 parts by weight. The artificial turf product, wherein the binding agent is a modified polar star-like high polypropylene, wherein the propylene is manufactured by a continuous reactive process at molten phase and characterized by a fork-like or star-like molecular-structure. The artificial turf product, wherein the binding agent comprises: polypropylene ranging from about 80 to 99 parts by weight of the binding agent; The artificial turf product, wherein the binding agent comprises: a free radical initiator having T½ of at least a minute at temperatures higher than 100° C., wherein the free radical initiator is in a range of about 0.01 to 2 parts by weight of the binding agent. The artificial turf product, wherein the binding agent comprises: one or more branching nucleus monomers having two or more vinyl or allyl reactive groups, wherein the branching nucleus monomers are in a range of about 0.1 to 20 parts by weight of the binding agent, wherein the branching nucleus monomer is adapted to form at least one branch point when grafted onto polypropylene. The artificial turf product, wherein the binding agent comprises: one or more monomers having at least one vinyl or allyl reactive group, wherein the one or more monomers are in a range from 0.1 to about 20 parts by weight of the binding agent. The artificial turf product, wherein the binding agent comprises: unsaturated acid monomer having at least one vinyl or allyl reactive groups, and one or more carboxylic acid or anhydride or ester group, wherein the unsaturated acid monomer is in a range of about 0.1 to 5 parts by weight of the binding agent. The artificial turf product, wherein the unsaturated acid monomer having at least one vinyl or allyl reactive group is maleic acid. The artificial turf product, wherein the binding agent is in a range of about 1 to 10 parts by weight. The artificial turf product, wherein the binding agent is maleic anhydride. The artificial turf product, wherein the maleic anhydride is in a range of about 1 to 10 parts by weight. The artificial turf product, wherein the artificial turf fiber has a Gmax measurement in a range of about 1 unit of gravity to 165 units of gravity. The artificial turf product, wherein the artificial turf fiber has a Gmax measurement in a range of about 70 units of gravity to 115 units of gravity. The artificial turf product, further comprising a color agent.

[0010] In one aspect, an exemplary embodiment of the present disclosure may provide a method of manufacturing a turf product comprising: adding a polyolefin, a polyamide, and a binding agent into a mixer; heating a mixture of the polyolefin, the polyamide, and the binding agent; creating an alloy of the polyolefin, the polyamide, and the binding agent in response to heating the mixture; extruding the alloy into at least one fiber adapted to form a portion of artificial turf; effecting the at least one fiber to be attached to a backing layer; and effecting an artificial turf product to be formed in response the at least one fiber being attached to the backing layer.

[0011] This exemplary embodiment or another exemplary embodiment of the present disclosure may provide that the polyolefin, the polyamide, and the binding agent remain in separate mixers before combining the polyolefin, polyamide, and binding agent into the mixer. This exemplary embodiment or another exemplary embodiment of the present disclosure may provide that the polyolefin is polyethylene, wherein the polyethylene is heated to a temperature in a range of about 115° C. to 135° C. This exemplary embodiment or another exemplary embodiment of the present disclosure may provide that the polyamide is nylon, wherein the nylon is heated to a temperature in a range of about 220° C. to 270° C. This exemplary embodiment or another exemplary embodiment of the present disclosure may provide that the binding agent is heated to a temperature in a range of about 50° C. to 135° C. This exemplary embodiment or another exemplary embodiment of the present disclosure may provide that the binding agent produces an alloy of materials that are otherwise incompatible. This exemplary embodiment or another exemplary embodiment of the present disclosure may provide that the at least one fiber is extruded from a die extruder. This exemplary embodiment or another exemplary embodiment of the present disclosure may provide that after extrusion, the at least one fiber is shaped as at least one blade of artificial turf.

[0012] In another aspect, an exemplary embodiment of the present disclosure may provide a method of manufacturing a turf product comprising: adding a polyolefin and a binding agent into a first mixer; heating the polyolefin and the binding agent; adding a polyamide to a second mixer; heating the polyamide; combining the heated polyolefin and binding agent with the heated polyamide; forming a homogenous alloy in response to combining the heated polyolefin and binding agent with the heated polyamide; extruding the homogenous alloy to create an artificial turf fiber; effecting the artificial turf fiber to be attached to a backing layer; and effecting an artificial turf product to be formed in response the artificial turf fiber being attached to the backing layer.

[0013] This exemplary embodiment or another exemplary embodiment of the present disclosure may include adding, automatically, more polyolefin to the second mixer when the computer-monitored sensors detects the level of polyolefin is low. This exemplary embodiment or another exemplary embodiment of the present disclosure may include adding, automatically, more polyamide to the first mixer when the computer-monitored sensors detects the level of polyamide is low. This exemplary embodiment or another exemplary embodiment of the present disclosure may include adding, automatically, more binding agent to the first mixer when the computer-monitored sensors detects the level of binding agent is low.

[0014] In yet another aspect, an exemplary embodiment of the present disclosure may provide a method of manufacturing an artificial turf product comprising: receiving a fiber composed of an alloy comprising a polyolefin, a polyamide, and a binding agent; attaching the fiber to a backing layer; arranging the fiber attached to the backing layer as a tuft or blade of artificial turf in an artificial turf product.

[0015] This exemplary embodiment or another exemplary embodiment of the present disclosure may provide the binding agent that allows the polyolefin and the polyamide to combine to create the homogenous alloy. The binding agent may be maleic anhydride, maleic acid, a modified polar star-like high polypropylene, or any other binding agent disclosed herein. To create the homogenous alloy, the unhomogenized mixture of polyolefin, polyamide, and the binding agent is heated to create the alloy blend. Once the mixture is heated, it may go through an extrusion process. The present disclosure provides a new material in artificial turf products.BRIEF DESCRIPTION OF THE DRAWINGS

[0016] One or more exemplary embodiment(s) of the present disclosure is set forth in the following description, is shown in the drawings and is particularly and distinctly pointed out and set forth in the appended claims. The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate various example configurations and methods, and other example embodiments of various aspects of the invention. It will be appreciated that the illustrated element boundaries (e.g., boxes, groups of boxes, or other shapes) in the figures represent one example of the boundaries. One of ordinary skill in the art will appreciate that in some examples one element may be designed as multiple elements or that multiple elements may be designed as one element. In some examples, an element shown as an internal component of another element may be implemented as an external component and vice versa. Furthermore, elements may not be drawn to scale.

[0017] FIG. 1 is an environmental side elevation view of a section of artificial turf according to one exemplary embodiment of the present disclosure.

[0018] FIG. 2 is an exploded side elevation view of one artificial turf fiber.

[0019] FIG. 3 is a cross-section view of the artificial turf fiber taken along line 3-3 in FIG. 2.

[0020] FIG. 4 is an operational elevation view of the mixing of the materials to make the artificial turf.

[0021] FIG. 5A is a flowchart of a method of manufacturing an artificial turf product according to one aspect of the present disclosure.

[0022] FIG. 5B is a second flowchart for another method of manufacturing an artificial turf product according to another aspect of the present disclosure.

[0023] FIG. 5C is a third flowchart for another method of manufacturing an artificial turf product according to one aspect of the present disclosure.

[0024] Similar numbers refer to similar parts throughout the drawings.DETAILED DESCRIPTION

[0025] FIG. 1 depicts a section or portion of artificial turf 10 according to one exemplary aspect of the present disclosure. Artificial turf 10 comprises synthetic fibers arranged in a tufted manner that collectively define artificial grass, and the synthetic fibers are fabricated from, formed from, extruded from, or otherwise comprise an alloy compound to create soft yet durable artificial grass. The alloy that is used to create the synthetic or artificial turf fiber will be described in greater detail herein.

[0026] Artificial turf 10 may comprise tufts 12 that are defined by a plurality of artificial grass fibers 14 made from the alloy. The alloy enables the artificial grass fibers to be soft yet durable. The artificial grass fibers 14 may be connected to a backing layer 16. In the present disclosure the artificial grass fibers 14 may be connected to the backing layer 16 by the artificial grass fibers 14 being woven through the backing layer 16 to form tufts 12.

[0027] Tufts 12 include a plurality of artificial grass fibers 14, and the number of fibers 14 may be designer-selected, manufacturer-selected or a variable number of artificial grass fibers 14 depending on the application-specific needs of artificial turf 10. In FIG. 1, one of the tufts 12 is comprised of eight artificial grass fibers 14, but this number may vary depending on the desired density and / or thickness of the artificial turf 10. The artificial turf 10 will be denser as more artificial turf fibers 14 are present in the turf 10.

[0028] FIG. 1 depicts the backing layer 16, which may be any type of commercially known backing layer or material used in the artificial turf industry. The backing layer 16 is used to secure the artificial grass fibers 14 to define the tufts 12. The artificial grass fibers 14 may be woven, sewn or otherwise pulled through the backing layer 16 to form tufts 12. There may be any number of tufts 12 that are pulled through the backing layer 16 to form artificial turf 10. The more tufts 12 that are attached to the backing layer 16 will result in a denser artificial turf 10.

[0029] FIG. 2 depicts one exemplary artificial grass fiber 14 according to a non-limiting and exemplary aspect of the present disclosure. The artificial grass fiber 14 includes a top end 18 spaced apart from a bottom end 20 with the fiber body extending therebetween. Artificial grass fiber 14 further includes a first surface 22 and a second surface 24 which are connected by the top end 18 and the bottom end 20. Top end 18 and bottom end 20 may be spaced apart to any desired length, making the artificial grass fiber 14 longer. First surface 22 and second surface 24 may be spaced apart to any desired width to make artificial grass fiber 14 any width. Artificial grass fiber 14 may be formed from or extruded from an alloy that comprises at least three elements or compounds that are homogenously formed together. In one exemplary embodiment artificial grass fiber 14 comprises the compounds of an alloy blend of a polyolefin 26, a polyamide 28, and a binding agent 30, as shown in FIG. 3.

[0030] FIG. 3 depicts a cross section of a body portion of the grass fiber being formed from homogenous alloy 32. In one exemplary embodiment, the alloy 32 may include or comprise polyolefin 26, polyamide 28, and the binding agent 30. In another exemplary embodiment, the alloy 32 may consist of or consist essentially of polyolefin 26, polyamide 28, and the binding agent 30. In one particular embodiment of alloy 32, the polyolefin 26 is polyethylene, the polyamide 28 is nylon, and the binding agent 30 is either maleic anhydride or maleic acid. One exemplary binding agent is BondyRam® that is manufactured by Polyram Plastic Industries Ltd.

[0031] Polyethylene is a polymer made from the polymerization of ethylene monomers. There are several types of polyethylene, including low-density polyethylene (LDPE), high-density polyethylene (HDPE), and linear low-density polyethylene (LLDPE), and of which could be utilized in alloy 32 for manufacture or production of fiber 14. The chemical formula for polyethylene is (C2H4)n, where n represents the number of repeating ethylene units in the polymer chain. Each ethylene unit includes two carbon atoms and four hydrogen atoms. The structure is typically depicted as a long chain of repeating-CH2—CH2-units.

[0032] Nylon is a polymer made from the polymerization of two monomers, hexamethylenediamine and adipic acid. The nylon is made from hexamethylenediamine and adipic acid, called Nylon 6,6, which is the most common form of nylon and of which could be utilized in alloy 32 for manufacture or production of fiber 14. There is another common form of nylon called Nylon 6. Nylon 6 is made from a single monomer called caprolactam. The chemical formula for nylon is (C12H22N2O10)n, where n represents the number of repeating units of nylon. The structure is typically depicted as a long chain of repeating (—CH2)6—NH—CO—(CH2)4—CO—NH—) units.

[0033] Maleic anhydride is the dehydrated form of maleic acid. Maleic anhydride is made from the oxidation of hydrocarbons. Maleic anhydride is typically made from butane, the most common form, or benzene. Maleic anhydride from butane could be utilized in alloy 32 for manufacture or production of fiber 14. The chemical formula for maleic anhydride is (C4H4O3). Maleic Acid is an organic compound with the chemical formula (C4H4O4). It is the cis-isomer of butenedioic acid and has two carboxyl groups. Maleic anhydride is grafted onto the backbone of a polymer, such as polypropylene or polyethylene. This may be done through a process called reactive extrusion, where the polymer and maleic anhydride are mixed and heated together in an extruder. The maleic anhydride groups introduce polar functionalities to the non-polar polymer, making it more compatible with other polar materials like polyamides or fillers. The modified polymer can better adhere to other materials, which is useful in composite materials and multi-layer structures. The modification can improve the strength, toughness, and durability of the polymer.

[0034] Although this exemplary embodiment details the binding agent 30 as a maleic anhydride, other binding agents could be utilized that effectuate the combination of polyolefin 26 and polyamide 28 into the homogenous alloy 32. For example, in another embodiment, the binding agent 30 is a modified polar star-like high polypropylene. The modified polar star-like high propylene is manufactured by a continuous reactive process at molten phase and characterized by a fork-like and / or star-like molecular-structure, comprising: polypropylene ranging from about 80 to 99 parts by weight of the binding agent; a free radical initiator having half life (T½) of at least a minute at temperatures higher than 100° C., wherein the free radical initiator is in a range of about 0.01 to 2 parts by weight of the binding agent; one or more branching nucleus monomers having two or more vinyl or allyl reactive groups, wherein the branching nucleus monomers are in a range of about 0.1 to 20 parts by weight of the binding agent, wherein the branching nucleus monomer is adapted to form at least one branch point when grafted onto polypropylene; and one or more monomers having at least one vinyl or allyl reactive group, wherein the one or more monomers are in a range from 0.1 to about 20 parts by weight; and unsaturated acid monomer having at least one vinyl or allyl reactive groups and one or more carboxylic acid or anhydride or ester group, wherein the unsaturated acid monomer is in a range of about 0.1 to 5 parts by weight.

[0035] As mentioned previously, the alloy 32 may be a homogenous alloy blend of the polyolefin 26 and polyamide 28, which is effectuated by the binding agent 30. When the binding agent 30 is a maleic anhydride, the binding agent 30 enables the two previously incompatible compounds or elements to be combined into a homogenous alloy due to maleic anhydride's ability to graft onto the polymer, polyethylene or any other polyolefin. This homogenous blend was previously not able to be accomplished and previously required the cone a sheath method. Binding agent 30 allows for the homogeneous alloy to be achieved which provides the optimal combination of the polyolefin 26 and the polyamide 28. The alloy 32 in artificial grass fibers 14 solves the long felt need to create an artificial turf that is soft yet durable.

[0036] The alloy 32 of the present disclosure allows for a softer yet durable artificial fiber 14 for turf 10 because it combines the benefits of both polyolefin 26 and polyamide 28 in a homogenous mixture, the combination of which is effectuated by binding agent 30. The softness of the alloy 32 in artificial turf 10 may be measured by using an angle measurement tool having a ruler to measure the units of gravity, wherein the less the ruler moves is an indication that the turf is softer. Another method of testing the softness of the alloy 32 in artificial turf 10 is by using an accelerometer measurement to determine how quickly it decelerates.

[0037] Another method for determining the quality and performance of fiber 14 formed from alloy 32 is the Fiber Performance Index (FPI). The FPI evaluates the fibers' characteristics, including their softness, durability, resilience, and resistance to environmental factors. A portion of the FPI evaluation is the tear test measures the cross tenacity of the fiber, which is an indicator of its durability. By applying a controlled force to the fiber until it breaks, this test quantifies the fiber's ability to withstand mechanical stress. High tenacity fibers are less likely to tear under heavy use, making them ideal for high-traffic areas. This test ensures that the fibers can endure the wear and tear associated with regular use, thereby extending the lifespan of the artificial turf. Another portion of the FPI evaluation is the recovery test that assesses the fiber's resilience after compression. In this test, the fiber is subjected to a compressive force and then allowed to recover. The degree to which the fiber returns to its original shape is measured, providing insight into its ability to maintain its structure and appearance over time. Resilient fibers contribute to the overall aesthetic and functional quality of the turf, as they resist matting and flattening, which are common issues in high-use areas. Another portion of the FPI evaluation is the UV test evaluates the fiber's resistance to ultraviolet (UV) radiation. Exposure to UV rays can degrade the polymer structure of the fibers, leading to discoloration, brittleness, and reduced performance. This test involves exposing the fibers to simulated sunlight and measuring the extent of degradation over time. Fibers with high UV resistance maintain their color and structural integrity longer, ensuring the turf remains visually appealing and functional despite prolonged exposure to sunlight. Another portion of the FPI evaluation is the feel test specifically measures the softness of the fiber, an essential factor for user comfort. This test employs a method adapted from the consumer goods industry, where tactile properties are important. By quantifying the softness, the feel test provides a standardized measure that can be used to compare different fibers. Soft fibers enhance the user experience, making the turf more comfortable for activities such as walking, playing, and lying down. In performing the FPI evaluation on fibers 14 for turf 10, the fibers should have a score ranging from 80 to 100 to ensure that fibers 14 excel in durability, resilience, UV resistance, and softness.

[0038] Turf 10 shock absorbency or impact attenuation may further be measured by determining the ‘Gmax’ of the surface. The turf 10 would have a Gmax measuring in a range of about 1 unit of gravity to 165 units of gravity. The alloy 32 further allows the artificial turf 10 to be durable. The artificial turf 10 may be denser without becoming too hard. The more artificial grass fibers 14 within tufts 12 that are in artificial turf 10 the denser the artificial turf 10 becomes and the more durable the turf may be. Alloy 32 provides the benefits of both polyolefin 26 and polyamide 28 when it is combined into a homogenous mixture as shown in FIG. 3 by alloy 32.

[0039] As mentioned previously, current instantiations of artificial turf fibers have been made from polyethylene alone, nylon alone, or a sheathed arrangement of both (i.e., the sheath formed from two disparate materials connected together but non-homogenously). There has not been success in making alloy 32 in artificial turf. The alloy 32 may be comprised of polyethylene and nylon which have not been previously homogenized in artificial turf fiber before. The present disclosure addresses the long felt need to improve artificial turf 10. The homogenous alloy is fully blended uniformly through the entirety of at least one artificial turf fiber such that there is no inner core and no outer sheath.

[0040] Having thus described one or more exemplary configurations of the artificial turf 10 with artificial grass fibers 14 formed from alloy 32, reference will be made to the method of manufacture of artificial grass fiber 14 from alloy 32 or the method of manufacturing artificial turf 10 from fibers 14 composed of alloy 32.

[0041] FIG. 4 depicts a mixing assembly 34. The mixing assembly 34 includes a first dispenser 36, a second dispenser 38, a third dispenser 40, a mixer 42, a heater 52, and a die extruder 56.

[0042] In accordance, an aspect of the present disclosure, mixing assembly 34 allows for the combination of polyolefin 26 and polyamide 28 to create a homogenous mixture for artificial turf 10 because of the presence of binding agent 30. The artificial turf 10 includes a homogenous mixture of polyolefin 26, polyamide 28, and binding agent 30 that collectively form alloy 32 and allow for the artificial turf 10 to have fewer downsides than if either of these compounds were utilized to create an artificial turf fiber. As mentioned previously, in one exemplary embodiment the polyolefin 26 is polyethylene and the polyamide 28 is nylon. One of the downsides of purely nylon turf is that the turf is hydrophilic which means they receive water and are a little stiffer while polyethylene does not receive water because it is hydrophobic, so they do not change in size, and they are a little softer. The combination of polyethylene and nylon into an alloy 32 advances artificial turf 10 to be more stable and better suited for different types of environments.

[0043] FIG. 4 depicts that the first dispenser 36 houses, stores or retains polyolefin 26 (typically in a pelletized or granular form), the second dispenser 38 houses, stores or retains polyamide 28 (typically in a pelletized or granular form), and the third dispenser 40 houses, stores or retains binding agent 30 (typically in a pelletized or granular form). Each of dispensers 36, 38, and 40 are in rheological communication with mixer 42. The rheological flow of a solid particles from the dispensers 36, 38, and 40 into mixer 42 may be accomplished through any known manner of tubing, piping, or valves. The dispensers may be in electrical communication with production control logic to meter the flow of the solid particulate matter in each respective dispenser 36, 38, and 40 into mixer 42. When the respective particulate matter in each respective dispenser 36, 38, and 40, the rheology or flow of solid particulate matter may be effectuated in any known manner, such as via pneumatics or gravitational forces.

[0044] After the particulate materials that are transferred into the mixer 42 from their respective dispensers 36, 38, and 40, the mixer 42 then holds a mixed but unhomogenized mixture 44. Unhomogenized mixture 44 contains polyolefin 26, polyamide 28, and binding agent 30 that are mixed together. An arrow 46 shows the polyolefin 26 being added to the unhomogenized mixture 44 in the mixer 42. An arrow 48 shows the polyamide 28 being added to the unhomogenized mixture 44 in the mixer 42. An arrow 50 shows the binding agent 30 being added to the unhomogenized mixture 44 in the mixer 42.

[0045] The mixer 42 is in rheological communication with the heater 42. The unhomogenized mixture 44 is transferred into the heater 52 as shown by an arrow 54. The unhomogenized mixture 44 is heated to melt the particulate matter (e.g., polyolefin 26, polyamide 28, and binding agent 30). Once the mixture is melted, it becomes homogenous, thereby creating an alloy 32 of melted material. The melted homogenous material is extruded through the die extruder 56 as shown by an arrow 58. The die extruder 56 will then extruded artificial grass fiber 14 through a die plate as shown by arrow 60. The shape and configuration of the die plate in extruder 56 may have any configuration depending on the design-specific or manufacturer-specific requirements, shapes or cross-sectional arrangements of fiber 14.

[0046] In operation, mixing assembly 34 is operated to create the alloy 32 including polyolefin 26 and polyamide 28 via binding agent 30. In one exemplary embodiment the polyolefin 26 may be added to the first dispenser 36; the polyamide 28 may be added to the second dispenser 38; and the binding agent 30 may be added to the third dispenser 40. The first dispenser 36, second dispenser 38, and third dispenser 40 may release their contents into the mixer 42 as shown by arrows 42, 44, and 46 respectively. Once polyolefin 26, polyamide 28, and binding agent 30 are in the mixer the three compounds are transferred to the heater 52 as shown by arrow 54. Inside the heater the contents will be heated to their melting point and will go through the heater 52 to the die extruder 56 as shown by arrow 58.

[0047] In one exemplary embodiment, the melting point for the polyolefin 26 may be within a range from about 100° C. to about 180° C. The melting point for the polyamide may be within a range from about 170° C. to about 270° C. Once the alloy 32 is transferred to the die extruder 56, the die extruder 56 will produce at least one artificial grass fiber 14 as shown by arrow 56. In this exemplary embodiment, the heater 52 shows a helical device to stir the unhomogenized mixture 44, but the heater 52 may have any stirring mechanism or it may have no stirring mechanism at all within the heater 52.

[0048] FIG. 4 depicts the exemplary embodiment, in which the die extruder 56 produces five artificial grass fibers 14 at one time. However, this is solely for illustrative purposes, and it is to be understood that the die extruder 56 may produce any number turf fibers 14 during extrusion. In this exemplary embodiment the pressure inside the die extruder 56 may range from 10 psi to 2,500 psi. In yet another exemplary embodiment the pressure may range from 250 psi to 1,500 psi.

[0049] FIG. 4 depicts the exemplary embodiment of the mixing assembly 34 as having three dispensers, namely first dispenser 36, second dispenser 38, and third dispenser 40, However, in another exemplary embodiment polyolefin 26, polyamide 28, and binding agent 30 may be added directly to the mixer 42. In another exemplary embodiment the polyolefin 26 and polyamide 28 may be premixed and there may only be two dispensers (i.e., a first mixer holding the polyolefin 26 and polyamide 28, and a second mixer holding the binding agent). In another exemplary embodiment the polyolefin 26 and the binding agent 30 may be premixed and there may only be two dispensers (i.e., a first mixer holding the polyolefin 26 and the binding agent 30, and a second mixer holding the polyamide 28). In yet another exemplary embodiment the polyamide 28 and the binding agent 30 may be premixed and there may only be two dispensers (i.e., a first mixer holding the polyamide 28 and the binding agent 30, and a second mixer holding the polyolefin 26).

[0050] In one or more of the exemplary embodiments, the heater 52 heats the contents of the mixed particulate material to a temperature within the range of from about 115° C. to about 265° C. In some examples, the polyolefin 26 is heated to a temperature within the range of about 115° C. to 135° C.; the polyamide 28 to a temperature within the range of about 220° C. to about 320° C.; and / or the binding agent 30 to a temperature within the range of about 50° C. to 155° C. In another exemplary embodiment there may be another dispenser to add a coloring agent to the unhomogenized mixture 44.

[0051] In yet another exemplary embodiment, the first dispenser 36, second dispenser 38, and third dispenser 40 may all be heated separately to melt the polyolefin 26, polyamide 28, and binding agent 30, respectively. In this exemplary embodiment the melted polyolefin 26, polyamide 28 and binding agent 30 could then be transferred from their disparate and individually melted states, and then into mixer 42. The pre-melted material may then be mixed in mixer 42 to create the homogenous alloy 32 and then transferred to die extruder 56 for extrusion of fiber 14.

[0052] Having thus described the exemplary aspects of methods of manufacture or methods of operation for artificial turf 10, reference will now be made to various manufacturing examples. As used herein, the term “parts by weight” or “weight percent” refers to the weight of ingredients (i.e., particulate materials) in the mixer 42 of the total unhomogenized mixture 44 prior to creating the alloy 32, regardless of whether those ingredients were stored independently in dispensers 36, 38, and 40 or pre-mixed in two or fewer dispensers. However, it is to be understood that once these materials or ingredients are homogenized, such as via melting, the homogenous alloy 32 may have the same ratios, parts by weight, or weight percent in a fully homogenous form.

[0053] Some exemplary embodiments may have, within unhomogenized mixture 44, the polyolefin 26 present within a range of approximately 10 to 65 parts by weight, the polyamide 28 present within a range of approximately 10 to 65 parts by weight, and the binding agent 30 present within a range of 0.05 to 30 parts by weight. Total parts by weight refers to the sum of the individual weights of all ingredients in the mixture 44.Example One

[0054] Example One provides, within the mixture 44, polyethylene at about 65 parts by weight (which may be transferred into mixer 42 from the first dispenser 36), nylon at about 25 parts by weight (which may be transferred into mixer 42 from the second dispenser 38), and maleic anhydride at about 10 parts by weight (which may be transferred into mixer 42 from the third dispenser 38). In this example, the particulate materials are combined and mixed together via the mixer 42.

[0055] During a period of time, such as about 1 to 5 minutes, the mixture may be subjected to a pressure in the range of about 250 psi to 1,500 psi and heated to a temperature in a range of about 115° C. to about 300° C. Heating and subjecting to pressure may occur in the same period of time, sequential periods of time, or overlapping periods of time. Heating may occur in mixer 42 or in the dispenser. Subjecting to pressure may occur in the mixer 42 or in the die extruder 56. This results in the polyethylene, nylon, and maleic anhydride becoming a homogenous and melted mixture.

[0056] The homogenous mixture that will result in homogenous alloy 32 is transferred to the die extruder. The homogenous mixture is extruded through the openings in the die plate of the die extruder 56. The extrusion of the allow results in an elongated fiber 14 that may be spooled onto a reel. The extruded fiber may be spooled or stored on a roll.

[0057] After a roll of fiber 14 is created, the roll of spooled homogenous fiber 14 may be provided to a manufacturer. The manufacturer may utilize any known turf-making machine to create the artificial turf 10 from the fibers 14 composed of alloy 32. Once the application of the fibers 14 to the backing layer 16 has been completed, the fibers may be cut to a suitable length for use as artificial turf, such as a length within a range from about 5 mm to about 150 mm.Example Two

[0058] Example Two provides, within the mixture 44, polyethylene at about 55 parts by weight (which may be transferred into mixer 42 from the first dispenser 36), nylon at about 35 parts by weight (which may be transferred into mixer 42 from second dispenser 38), and maleic anhydride at about 10 parts by weight (which may be transferred into mixer 42 from the third dispenser 40). In this example, the particulate materials are combined and mixed together via the mixer 42.

[0059] During a period of time, such as about 1 to 5 minutes, the mixture may be subjected to a pressure in the range of about 250 psi to 1,500 psi and heated to a temperature in a range of about 115° C. to 300° C. Heating and subjecting to pressure may occur in the same period of time, sequential periods of time, or overlapping periods of time. Heating may occur in mixer 42 or in the dispenser. Subjecting to pressure may occur in the mixer 42 or in the die extruder 56. This results in the polyethylene, nylon, and maleic anhydride becoming a homogenous and melted mixture.

[0060] The homogenous mixture that will result in homogenous alloy 32 is transferred to the die extruder 56. The homogenous mixture is extruded through the opening in the die plate of the die extruder. The extrusion of the alloy results in an elongated fiber that may be spooled onto a reel. The extruded fiber may be spooled or stored on a roll.

[0061] After a roll of fiber 14 is created, the roll of spooled homogenous fiber 14 may be provided to a manufacturer. The manufacturer may utilize any known turf-making machine to create the artificial turf 10 from the fibers 14 composed of alloy 32. Once the application of the fibers 14 to the backing layer 16 has been completed, the fibers may be cut to a suitable length for use as artificial turf, such as a length within a range from about 5 mm to about 150 mm.Example Three

[0062] Example Three provides, within the mixture 44, polyethylene at about 45 parts by weight (which may be transferred into mixer 42 from first dispenser 36), nylon at about 50 parts by weight (which may be transferred into mixer 42 from the second dispenser 38), and maleic anhydride at about 5 parts by weight (which may be transferred into mixer 42 from the third dispenser 40). In this example, the particulate materials are combined and mixed together via the mixer 42.

[0063] During a period of time, such as about 1 to 5 minutes the mixture may be subjected to a pressure in the range of about 250 psi to 1,500 psi and heated to a temperature in a range of about 115° C. to 300° C. Heating and subjecting to pressure may occur in the same period of time, sequential periods of time, or overlapping periods of time. Heating may occur in mixer 42 or in the dispenser. Subjecting to pressure may occur in the mixer 42 or in the die extruder 56. This results in the polyethylene, nylon, and maleic anhydride becoming a homogenous and melted mixture.

[0064] The homogenous mixture that will result in homogenous alloy 32 is transferred to the die extruder 56. The homogenous mixture is extruded through the opening in the die plate of the die extruder. The extrusion of the alloy results in an elongated fiber that may be spooled onto a reel. The extruded fiber may be spooled or stored on a roll.

[0065] After a roll of fiber 14 is created, the roll of spooled homogenous fiber 14 may be provided to a manufacturer. The manufacturer may utilize any known turf-making machine to create the artificial turf 10 from the fibers 14 composed of alloy 32. Once the application of the fibers 14 to the backing layer 16 has been completed, the fibers may be cut to a suitable length for use as artificial turf, such as a length within a range from about 5 mm to about 150 mm.Example Four

[0066] Example Four provides, within the mixture 44, polyethylene at about 30 parts by weight (which may be transferred into mixer 42 from first dispenser 36), nylon at about 60 parts by weight (which may be transferred into mixer 42 from the second dispenser 38), and maleic anhydride at about 10 parts by weight (which may be transferred into mixer 42 from the third dispenser 40). In this example, the particulate materials are combined and mixed together via the mixer 42.

[0067] During a period of time, such as about 1 to 5 minutes the mixture may be subjected to a pressure in the range of about 250 psi to 1,500 psi and heated to a temperature in a range of about 115° C. to 300° C. Heating and subjecting to pressure may occur in the same period of time, sequential periods of time, or overlapping periods of time. Heating may occur in mixer 42 or in the dispenser. Subjecting to pressure may occur in the mixer 42 or in the die extruder 56. This results in the polyethylene, nylon, and maleic anhydride becoming a homogenous and melted mixture.

[0068] The homogenous mixture that will result in homogenous alloy 32 is transferred to the die extruder 56. The homogenous mixture is extruded through the opening in the die plate of the die extruder 56. The extrusion of the alloy results in an elongated fiber that may be spooled onto a reel. The extruded fiber may be spooled or stored on a roll.

[0069] After a roll of fiber 14 is created, the roll of spooled homogenous fiber 14 may be provided to a manufacturer. The manufacturer may utilize any known turf-making machine to create the artificial turf 10 from the fibers 14 composed of alloy 32. Once the application of the fibers 14 to the backing layer 16 has been completed, the fibers may be cut to a suitable length for use as artificial turf, such as a length within a range from about 5 mm to about 150 mm.Example Five

[0070] Example Five provides, within the mixture 44, polyethylene at about 45 parts by weight (which may be transferred into mixer 42 from the first dispenser 36), nylon at about 45 parts by weight (which may be transferred into mixer 42 from the second dispenser 38), and maleic anhydride at about 10 parts by weight (which may be transferred into mixer 42 from the third dispenser 40). In this example, the particulate materials are combined and mixed together via the mixer 42.

[0071] During a period of time, such as about 1 to 5 minutes the mixture may be subjected to a pressure in the range of about 250 psi to 1,500 psi and heated to a temperature in a range of about 115° C. to 300° C. Heating and subjecting to pressure may occur in the same period of time, sequential periods of time, or overlapping periods of time. Heating may occur in mixer 42 or in the dispenser. Subjecting to pressure may occur in the mixer 42 or in the die extruder 56. This results in the polyethylene, nylon, and maleic anhydride becoming a homogenous and melted mixture.

[0072] The homogenous mixture that will result in homogenous alloy 32 is transferred to the die extruder 56. The homogenous mixture is extruded through the opening in the die plate of the die extruder 56. The extrusion of the alloy results in an elongated fiber that may be spooled onto a reel. The extruded fiber may be spooled or stored on a roll.

[0073] After a roll of fiber 14 is created, the roll of spooled homogenous fiber 14 may be provided to a manufacturer. The manufacturer may utilize any known turf-making machine to create the artificial turf 10 from the fibers 14 composed of alloy 32. Once the application of the fibers 14 to the backing layer 16 has been completed, the fibers may be cut to a suitable length for use as artificial turf, such as a length within a range from about 5 mm to about 150 mm.Example Six

[0074] Example Six provides, within the mixture 44, polyethylene at about 50 parts by weight (which may be transferred into mixer 42 from the first dispenser 36), nylon at about 49 parts by weight (which may be transferred into mixer 42 from the second dispenser 38), and maleic anhydride at about 1 part by weight (which may be transferred into mixer 42 from the third dispenser 40). In this example, the particulate materials are combined and mixed together via the mixer 42.

[0075] During a period of time, such as about 1 to 5 minutes, the mixture may be subjected to a pressure in the range of about 250 psi to 1,500 psi and heated to a temperature in a range of about 115° C. to 300° C. Heating and subjecting to pressure may occur in the same period of time, sequential periods of time, or overlapping periods of time. Heating may occur in mixer 42 or in the dispenser. Subjecting to pressure may occur in the mixer 42 or in the die extruder 56. This results in the polyethylene, nylon, and maleic anhydride becoming a homogenous and melted mixture.

[0076] The homogenous mixture that will result in homogenous alloy 32 is transferred to the die extruder 56. The homogenous mixture is extruded through the opening in the die plate of the die extruder 56. The extrusion of the alloy results in an elongated fiber that may be spooled onto a reel. The extruded fiber may be spooled or stored on a roll.

[0077] After a roll of fiber 14 is created, the roll of spooled homogenous fiber 14 may be provided to a manufacturer. The manufacturer may utilize any known turf-making machine to create the artificial turf 10 from the fibers 14 composed of alloy 32. Once the application of the fibers 14 to the backing layer 16 has been completed, the fibers may be cut to a suitable length for use as artificial turf, such as a length within a range from about 5 mm to about 150 mm.Example Seven

[0078] Example Seven provides, within the mixture 44, polyethylene at about 60 parts by weight and maleic anhydride at about 10 parts by weight (which may be transferred into mixer 42 from the first dispenser 36) and nylon at about 30 parts by weight (which may be transferred to mixer 42 from the second dispenser 38). Example Two includes a coloring agent (which may be transferred into mixer 42 from the third dispenser 40). In this example, the particulate materials are combined and mixed together via the mixer 42.

[0079] During a period of time, such as about 1 to 5 minutes, the mixture may be subjected to a pressure in the range of about 250 psi to 1,500 psi and heated to a temperature in a range of about 115° C. to 300° C. Heating and subjecting to pressure may occur in the same period of time, sequential periods of time, or overlapping periods of time. Heating may occur in mixer 42 or in the dispenser. Subjecting to pressure may occur in the mixer 42 or in the die extruder 56. This results in the polyethylene, nylon, maleic anhydride, and coloring agent becoming a homogenous and melted mixture.

[0080] The homogenous mixture that will result in homogenous alloy 32 is transferred to the die extruder 56. The homogenous mixture is extruded through the opening in the die plate of the die extruder 56. The extrusion of the alloy results in an elongated fiber that may be spooled onto a reel. The extruded fiber may be spooled or stored on a roll.

[0081] After a roll of fiber 14 is created, the roll of spooled homogenous fiber 14 may be provided to a manufacturer. The manufacturer may utilize any known turf-making machine to create the artificial turf 10 from the fibers 14 composed of alloy 32. Once the application of the fibers 14 to the backing layer 16 has been completed, the fibers may be cut to a suitable length for use as artificial turf, such as a length within a range from about 5 mm to about 150 mm.Example Eight

[0082] Example Eight provides, within the mixture 44, polyethylene at about 65 parts by weight and a star like high propylene at about 10 parts by weight (which may be transferred into mixer 42 from the first dispenser 36) and nylon at about 25 parts per weight (which may be transferred into mixer 42 from the second dispenser 38). In this example, the particulate materials are combined and mixed via the mixer 42.

[0083] During a period of time, such as about 1 to 5 minutes, the mixture may be subjected to a pressure in the range of about 250 psi to 1,500 psi and heated to a temperature in a range of about 115° C. to 300° C. Heating and subjecting to pressure may occur in the same period of time, sequential periods of time, or overlapping periods of time. Heating may occur in mixer 42 or in the dispenser. Subjecting to pressure may occur in the mixer 42 or in the die extruder 56. This results in the polyethylene, nylon, and star like high polypropylene becoming a homogenous and melted mixture.

[0084] The homogenous mixture that will result in homogenous alloy 32 is transferred to the die extruder 56. The homogenous mixture is extruded through the opening in the die plate of the die extruder. The extrusion of the alloy results in an elongated fiber that may be spooled onto a reel. The extruded fiber may be spooled or stored on a roll.

[0085] After a roll of fiber 14 is created, the roll of spooled homogenous fiber 14 may be provided to a manufacturer. The manufacturer may utilize any known turf-making machine to create the artificial turf 10 from the fibers 14 composed of alloy 32. Once the application of the fibers 14 to the backing layer 16 has been completed, the fibers may be cut to a suitable length for use as artificial turf, such as a length within a range from about 5 mm to about 150 mm.Example Nine

[0086] Example Nine provides, within the mixture 44, polyethylene at about 65 parts by weight and Bondyram Grade 1001 at about 10 parts per weight (which may be transferred into mixer 42 from the first dispenser 36) and nylon at about 25 parts by weight (which may be transferred into mixer 42 from second dispenser 38). In this example, the particulate materials are combined and mixed together via the mixer 42.

[0087] During a period of time, such as about 1 to 5 minutes, the mixture may be subjected to a pressure in the range of about 250 psi to 1,500 psi. The polyethylene and Bondyram Grade 1001 are heated to a temperature in a range of about 115° C. to 135° C. The melted polyethylene and Bondyram Grade 1001 are added to mixer 42. The nylon is heated to a temperature in the range of about 220° C. to 300° C. and is added to mixer 42. Heating and subjecting to pressure may occur in the same period of time, sequential periods of time, or overlapping periods of time. Heating may occur in mixer 42 or in the dispenser. Subjecting to pressure may occur in the mixer 42 or in the die extruder 56. This results in the melted polyethylene, nylon, and Bondyram Grade 1001 becoming a homogenous and melted mixture.

[0088] The homogenous mixture that will result in homogenous alloy 32 is transferred to the die extruder 56. The homogenous mixture is extruded through the opening in the die plate of the die extruder 56. The extrusion of the alloy results in an elongated fiber 14 that may be spooled onto a reel. The extruded fiber 14 may be spooled or stored on a roll.

[0089] After a roll of fiber 14 is created, the roll of spooled homogenous fiber 14 may be provided to a manufacturer. The manufacturer may utilize any known turf-making machine to create the artificial turf 10 from the fibers 14 composed of alloy 32. Once the application of the fibers 14 to the backing layer 16 has been completed, the fibers may be cut to a suitable length for use as artificial turf, such as a length within a range from about 5 mm to about 150 mm.Example Ten

[0090] Example Ten, provides within the mixture 44, polyethylene at about 65 parts by weight and Bondyram Grade 1010 at about 10 parts per weight (which may be transferred into mixer 42 from the first dispenser 36) and nylon at about 25 parts by weight (which may be transferred into mixer 42 from the second dispenser 38). In this example, the particulate materials are combined and mixed together via the mixer 42.

[0091] During a period of time, such as about 1 to 5 minutes, the mixture may be subjected to a pressure in the range of about 250 psi to 1,500 psi. The polyethylene and Bondyram Grade 1010 are heated to a temperature in a range of about 115° C. to 135° C. The melted polyethylene and Bondyram Grade 1010 are added to mixer 42. The nylon is heated to a temperature in the range of about 220° C. to 300° C. and is added to mixer 42. Heating and subjecting to pressure may occur in the same period of time, sequential periods of time, or overlapping periods of time. Heating may occur in mixer 42 or in the dispenser. Subjecting to pressure may occur in the mixer 42 or in the die extruder 56. This results in the melted polyethylene, nylon, and Bondyram Grade 1010 becoming a homogenous and melted mixture.

[0092] The homogenous mixture that will result in homogenous alloy 32 is transferred to the die extruder 56. The homogenous mixture is extruded through the opening in the die plate of the die extruder 56. The extrusion of the alloy results in an elongated fiber 14 that may be spooled onto a reel. The extruded fiber may be spooled or stored on a roll.

[0093] After a roll of fiber 14 is created, the roll of spooled homogenous fiber 14 may be provided to a manufacturer. The manufacturer may utilize any known turf-making machine to create the artificial turf 10 from the fibers 14 composed of alloy 32. Once the application of the fibers 14 to the backing layer 16 has been completed, the fibers may be cut to a suitable length for use as artificial turf, such as a length within a range from about 5 mm to about 150 mm.Example Eleven

[0094] Example Eleven provides, polyethylene at about 65 parts by weight and Bondyram Grade 1101 at about 5 parts per weight (which may be transferred into mixer 42 from the first dispenser 36) and nylon at about 30 parts by weight (which may be transferred into mixer 42 from the second dispenser 38). In this example, the particulate materials are combined and mixed together via the mixer 42.

[0095] During a period of time, such as about 1 to 5 minutes, the mixture may be subjected to a pressure in the range of about 250 psi to 1,500 psi the polyethylene and Bondyram Grade 1101 are heated to a temperature in a range of about 115° C. to 135° C. The melted polyethylene and Bondyram Grade 1101 are added to mixer 42. The nylon is heated to a temperature in the range of about 220° C. to 300° C. and is added to mixer 42. Heating and subjecting to pressure may occur in the same period of time, sequential periods of time, or overlapping periods of time. Heating may occur in mixer 42 or in the dispenser. Subjecting to pressure may occur in the mixer 42 or in the die extruder 56. This results in the melted polyethylene, nylon, and Bondyram Grade 1101 becoming a homogenous and melted mixture.

[0096] The homogenous mixture that will result in homogenous alloy 32 is transferred to the die extruder 56. The homogenous mixture is extruded through the opening in the die plate of the die extruder 56. The extrusion of the alloy results in an elongated fiber 14 that may be spooled onto a reel. The extruded fiber may be spooled or stored on a roll.

[0097] After a roll of fiber 14 is created, the roll of spooled homogenous fiber 14 may be provided to a manufacturer. The manufacturer may utilize any known turf-making machine to create the artificial turf 10 from the fibers 14 composed of alloy 32. Once the application of the fibers 14 to the backing layer 16 has been completed, the fibers may be cut to a suitable length for use as artificial turf, such as a length within a range from about 5 mm to about 150 mm.Example Twelve

[0098] Example Twelve provides, within the mixture 44, polyethylene at about 60 parts by weight and Bondyram Grade 1001CN at about 10 parts per weight (which may be transferred into mixer 42 from first dispenser 36) and nylon at about 30 parts by weight (which may be transferred into mixer 42 from the second dispenser 38). In this example. The particulate materials are combined and mixed together via the mixer 42.

[0099] During a period of time, such as about 1 to 5 minutes, the mixture may be subjected to a pressure in the range of about 250 psi to 1,500 psi. The polyethylene and Bondyram Grade 1001CN are heated to a temperature in a range of about 115° C. to 135° C. The melted polyethylene and Bondyram Grade 1001CN are added to mixer 42. The nylon is heated to a temperature in the range of about 220° C. to 300° C. and is added to mixer 42. Heating and subjecting to pressure may occur in the same period of time, sequential periods of time, or overlapping periods of time. Heating may occur in mixer 42 or in the dispenser. Subjecting to pressure may occur in the mixer 42 or in the die extruder 56. This results in the melted polyethylene, nylon, and Bondyram Grade 1001CN becoming a homogenous and melted mixture.

[0100] The homogenous mixture that will result in homogenous alloy 32 is transferred to the die extruder 56. The homogenous mixture is extruded through the opening in the die plate of the die extruder 56. The extrusion of the alloy results in an elongated fiber 14 that may be spooled onto a reel. The extruded fiber may be spooled or stored on a roll.

[0101] After a roll of fiber 14 is created, the roll of spooled homogenous fiber 14 may be provided to a manufacturer. The manufacturer may utilize any known turf-making machine to create the artificial turf 10 from the fibers 14 composed of alloy 32. Once the application of the fibers 14 to the backing layer 16 has been completed, the fibers may be cut to a suitable length for use as artificial turf, such as a length within a range from about 5 mm to about 150 mm.Example Thirteen

[0102] Example Thirteen provides, within the mixture 44, polyethylene at about 65 parts by weight and Bondyram Grade 1001LE at about 10 parts per weight (which may be transferred into mixer 42 from the first dispenser 36) and nylon at about 25 parts by weight (which may be transferred into mixer 42 from the second dispenser 38). In this example, the particulate materials are combined and mixed together via the mixer 42.

[0103] During a period of time, such as about 1 to 5 minutes, the mixture may be subjected to a pressure in the range of about 250 psi to 1,500 psi the polyethylene and Bondyram Grade 1001LE are heated to a temperature in a range of about 115° C. to 135° C. The melted polyethylene and Bondyram Grade 1001LE are added to mixer 42. The nylon is heated to a temperature in the range of about 220° C. to 300° C. and is added to mixer 42. Heating and subjecting to pressure may occur in the same period of time, sequential periods of time, or overlapping periods of time. Heating may occur in mixer 42 or in the dispenser. Subjecting to pressure may occur in the mixer 42 or in the die extruder 56. This results in the melted polyethylene, nylon, and Bondyram Grade 1001LE becoming a homogenous and melted mixture.

[0104] The homogenous mixture that will result in homogenous alloy 32 is transferred to the die extruder 56. The homogenous mixture is extruded through the opening in the die plate of the die extruder 56. The extrusion of the alloy results in an elongated fiber 14 that may be spooled onto a reel. The extruded fiber may be spooled or stored on a roll.

[0105] After a roll of fiber 14 is created, the roll of spooled homogenous fiber 14 may be provided to a manufacturer. The manufacturer may utilize any known turf-making machine to create the artificial turf 10 from the fibers 14 composed of alloy 32. Once the application of the fibers 14 to the backing layer 16 has been completed, the fibers may be cut to a suitable length for use as artificial turf, such as a length within a range from about 5 mm to about 150 mm.Example Fourteen

[0106] Example Fourteen provides, within the mixture 44, polyethylene at about 60 parts by weight and Bondyram Grade 1001MP at about 10 parts per weight (which may be transferred into mixer 42 from the first dispenser 36) and nylon at about 30 parts by weight (which may be transferred into mixer 42 from the second dispenser 38). In this example, the particulate materials are combined and mixed together via the mixer 42.

[0107] During a period of time, such as about 1 to 5 minutes, the mixture may be subjected to a pressure in the range of about 250 psi to 1,500 psi. The polyethylene and Bondyram Grade 1001MP are heated to a temperature in a range of about 115° C. to 135° C. The melted polyethylene and Bondyram Grade 1001MP are added to mixer 42. The nylon is heated to a temperature in the range of about 220° C. to 300° C. and is added to mixer 42. Heating and subjecting to pressure may occur in the same period of time, sequential periods of time, or overlapping periods of time. Heating may occur in mixer 42 or in the dispenser. Subjecting to pressure may occur in the mixer 42 or in the die extruder 56. This results in the melted polyethylene, nylon, and Bondyram Grade 1001MP becoming a homogenous and melted mixture.

[0108] The homogenous mixture that will result in homogenous alloy 32 is transferred to the die extruder 56. The homogenous mixture is extruded through the opening in the die plate of the die extruder 56. The extrusion of the alloy results in an elongated fiber that may be spooled onto a reel. The extruded fiber may be spooled or stored on a roll.

[0109] After a roll of fiber 14 is created, the roll of spooled homogenous fiber 14 may be provided to a manufacturer. The manufacturer may utilize any known turf-making machine to create the artificial turf 10 from the fibers 14 composed of alloy 32. Once the application of the fibers 14 to the backing layer 16 has been completed, the fibers may be cut to a suitable length for use as artificial turf, such as a length within a range from about 5 mm to about 150 mm.Example Fifteen

[0110] Example Fifteen provides, within the mixture 44, polyethylene at about 55 parts by weight and Bondyram Grade 1201 at about 10 parts per weight (which may be transferred into mixer 42 from the first dispenser 36) and nylon at about 35 parts by weight (which may be transferred into mixer 42 from the second dispenser 38). In this example, the particulate materials are combined and mixed together via the mixer 42.

[0111] During a period of time, such as about 1 to 5 minutes, the mixture may be subjected to a pressure in the range of about 250 psi to 1,500 psi. The polyethylene and Bondyram Grade 1201 are heated to a temperature in a range of about 115° C. to 135° C. The melted polyethylene and Bondyram Grade 1201 are added to mixer 42. The nylon is heated to a temperature in the range of about 220° C. to 300° C. and is added to mixer 42. Heating and subjecting to pressure may occur in the same period of time, sequential periods of time, or overlapping periods of time. Heating may occur in mixer 42 or in the dispenser. Subjecting to pressure may occur in the mixer 42 or in the die extruder 56. This results in the melted polyethylene, nylon, and Bondyram Grade 1201 becoming a homogenous and melted mixture.

[0112] The homogenous mixture that will result in homogenous alloy 32 is transferred to the die extruder 56. The homogenous mixture is extruded through the opening in the die plate of the die extruder 56. The extrusion of the alloy results in an elongated fiber 14 that may be spooled onto a reel. The extruded fiber may be spooled or stored on a roll.

[0113] After a roll of fiber 14 is created, the roll of spooled homogenous fiber 14 may be provided to a manufacturer. The manufacturer may utilize any known turf-making machine to create the artificial turf 10 from the fibers 14 composed of alloy 32. Once the application of the fibers 14 to the backing layer 16 has been completed, the fibers may be cut to a suitable length for use as artificial turf, such as a length within a range from about 5 mm to about 150 mm.Example Sixteen

[0114] Example Sixteen provides, within the mixture 44, polyethylene at about 60 parts by weight and Bondyram Grade 2102 at about 5 parts per weight (which may be transferred into mixer 42 from first dispenser 36) and nylon at about 35 parts by weight (which may be transferred into mixer 42 from the second dispenser 38). In this example, the particulate materials are combined and mixed together via the mixer 42.

[0115] During a period of time, such as about 1 to 5 minutes, the mixture may be subjected to a pressure in the range of about 250 psi to 1,500 psi. The polyethylene and Bondyram Grade 2102 are heated to a temperature in a range of about 115° C. to 135° C. The melted polyethylene and Bondyram Grade 2102 are added to mixer 42. The nylon is heated to a temperature in the range of about 220° C. to 300° C. and is added to mixer 42. Heating and subjecting to pressure may occur in the same period of time, sequential periods of time, or overlapping periods of time. Heating may occur in mixer 42 or in the dispenser. Subjecting to pressure may occur in the mixer 42 or in the die extruder 56. This results in the melted polyethylene, nylon, and Bondyram Grade 2102 becoming a homogenous and melted mixture.

[0116] The homogenous mixture that will result in homogenous alloy 32 is transferred to the die extruder 56. The homogenous mixture is extruded through the opening in the die plate of the die extruder 56. The extrusion of the alloy results in an elongated fiber that may be spooled onto a reel. The extruded fiber may be spooled or stored on a roll.

[0117] After a roll of fiber 14 is created, the roll of spooled homogenous fiber 14 may be provided to a manufacturer. The manufacturer may utilize any known turf-making machine to create the artificial turf 10 from the fibers 14 composed of alloy 32. Once the application of the fibers 14 to the backing layer 16 has been completed, the fibers may be cut to a suitable length for use as artificial turf, such as a length within a range from about 5 mm to about 150 mm.Example Seventeen

[0118] Example Seventeen provides, within the mixture 44, polyethylene at about 60 parts by weight and Bondyram Grade 2103 at about 10 parts per weight (which may be transferred into mixer 42 from the first dispenser 36) and nylon at about 30 parts by weight (which may be transferred into mixer 42 from second dispenser 38). In this example, the particulate materials are combined and mixed together via the mixer 42.

[0119] During a period of time, such as about 1 to 5 minutes, the mixture may be subjected to a pressure in the range of about 250 psi to 1,500 psi. The polyethylene and Bondyram Grade 2103 are heated to a temperature in a range of about 115° C. to 135° C. The melted polyethylene and Bondyram Grade 2103 are added to mixer 42. The nylon is heated to a temperature in the range of about 220° C. to 300° C. and is added to mixer 42. Heating and subjecting to pressure may occur in the same period of time, sequential periods of time, or overlapping periods of time. Heating may occur in mixer 42 or in the dispenser. Subjecting to pressure may occur in the mixer 42 or in the die extruder 56. This results in the melted polyethylene, nylon, and Bondyram Grade 2103 becoming a homogenous and melted mixture.

[0120] The homogenous mixture that will result in homogenous alloy 32 is transferred to the die extruder 56. The homogenous mixture is extruded through the opening in the die plate of the die extruder 56. The extrusion of the alloy results in an elongated fiber that may be spooled onto a reel. The extruded fiber may be spooled or stored on a roll.

[0121] After a roll of fiber 14 is created, the roll of spooled homogenous fiber 14 may be provided to a manufacturer. The manufacturer may utilize any known turf-making machine to create the artificial turf 10 from the fibers 14 composed of alloy 32. Once the application of the fibers 14 to the backing layer 16 has been completed, the fibers may be cut to a suitable length for use as artificial turf, such as a length within a range from about 5 mm to about 150 mm.Example Eighteen

[0122] Example Eighteen provides, within the mixture 44, polyethylene at about 55 parts by weight and Bondyram Grade 7003 at about 10 parts per weight (which may be transferred to mixer 42 from the first dispenser 36) and nylon at about 35 parts by weight (which may be transferred to mixer 42 from second dispenser 38). In this example, the particulate materials are combined and mixed together via the mixer 42.

[0123] During a period of time, such as about 1 to 5 minutes, the mixture may be subjected to a pressure in the range of about 250 psi to 1,500 psi. The polyethylene and Bondyram Grade 7003 are heated to a temperature in a range of about 115° C. to 135° C. The melted polyethylene and Bondyram Grade 7003 are added to mixer 42. The nylon is heated to a temperature in the range of about 220° C. to 300° C. and is added to mixer 42. Heating and subjecting to pressure may occur in the same period of time, sequential periods of time, or overlapping periods of time. Heating may occur in mixer 42 or in the dispenser. Subjecting to pressure may occur in the mixer 42 or in the die extruder 56. This results in the melted polyethylene, nylon, and Bondyram Grade 7003 becoming a homogenous and melted mixture.

[0124] The homogenous mixture that will result in homogenous alloy 32 is transferred to the die extruder 56. The homogenous mixture is extruded through the opening in the die plate of the die extruder 56. The extrusion of the alloy results in an elongated fiber that may be spooled onto a reel. The extruded fiber may be spooled or stored on a roll.

[0125] After a roll of fiber 14 is created, the roll of spooled homogenous fiber 14 may be provided to a manufacturer. The manufacturer may utilize any known turf-making machine to create the artificial turf 10 from the fibers 14 composed of alloy 32. Once the application of the fibers 14 to the backing layer 16 has been completed, the fibers may be cut to a suitable length for use as artificial turf, such as a length within a range from about 5 mm to about 150 mm.Example Nineteen

[0126] Example Nineteen provides, within the mixture 44, polyethylene at about 60 parts by weight and Bondyram Grade 7103 at about 5 parts per weight (which may be transferred into mixer 42 from first dispenser 36) and nylon at about 35 parts by weight (which may be transferred into mixer 42 from second dispenser 38). In this example, the particulate materials are combined and mixed together via the mixer 42.

[0127] During a period of time, such as about 1 to 5 minutes, the mixture may be subjected to a pressure in the range of about 250 psi to 1,500 psi. The polyethylene and Bondyram Grade 7103 are heated to a temperature in a range of about 115° C. to 135° C. The melted polyethylene and Bondyram Grade 7103 are added to mixer 42. The nylon is heated to a temperature in the range of about 220° C. to 300° C. and is added to mixer 42. Heating and subjecting to pressure may occur in the same period of time, sequential periods of time, or overlapping periods of time. Heating may occur in mixer 42 or in the dispenser. Subjecting to pressure may occur in the mixer 42 or in the die extruder 56. This results in the melted polyethylene, nylon, and Bondyram Grade 7103 becoming a homogenous and melted mixture.

[0128] The homogenous mixture that will result in homogenous alloy 32 is transferred to the die extruder 56. The homogenous mixture is extruded through the opening in the die plate of the die extruder 56. The extrusion of the alloy results in an elongated fiber that may be spooled onto a reel. The extruded fiber may be spooled or stored on a roll.

[0129] After a roll of fiber 14 is created, the roll of spooled homogenous fiber 14 may be provided to a manufacturer. The manufacturer may utilize any known turf-making machine to create the artificial turf 10 from the fibers 14 composed of alloy 32. Once the application of the fibers 14 to the backing layer 16 has been completed, the fibers may be cut to a suitable length for use as artificial turf, such as a length within a range from about 5 mm to about 150 mm.Example Twenty

[0130] Example Fifteen utilizes polyethylene at about 65 parts by weight and Bondyram Grade 7107 at about 5 parts per weight (which may be transferred into mixer 42 from first dispenser 36) and nylon at about 30 parts by weight (which may be transferred into mixer 42 from second dispenser 38). In this example, the particulate materials are combined and mixed together via the mixer 42.

[0131] During a period of time, such as about 1 to 5 minutes, the mixture may be subjected to a pressure in the range of about 250 psi to 1,500 psi. The polyethylene and Bondyram Grade 7107 are heated to a temperature in a range of about 115° C. to 135° C. The melted polyethylene and Bondyram Grade 7107 are added to mixer 42. The nylon is heated to a temperature in the range of about 220° C. to 300° C. and is added to mixer 42. Heating and subjecting to pressure may occur in the same period of time, sequential periods of time, or overlapping periods of time. Heating may occur in mixer 42 or in the dispenser. Subjecting to pressure may occur in the mixer 42 or in the die extruder 56. This results in the melted polyethylene, nylon, and Bondyram Grade 7107 becoming a homogenous and melted mixture.

[0132] The homogenous mixture that will result in homogenous alloy 32 is transferred to the die extruder 56. The homogenous mixture is extruded through the opening in the die plate of the die extruder. The extrusion of the alloy results in an elongated fiber that may be spooled onto a reel. The extruded fiber may be spooled or stored on a roll.

[0133] After a roll of fiber 14 is created, the roll of spooled homogenous fiber 14 may be provided to a manufacturer. The manufacturer may utilize any known turf-making machine to create the artificial turf 10 from the fibers 14 composed of alloy 32. Once the application of the fibers 14 to the backing layer 16 has been completed, the fibers may be cut to a suitable length for use as artificial turf, such as a length within a range from about 5 mm to about 150 mm.Example Twenty-One

[0134] Example Twenty-one provides, within the mixture 44, polyethylene at about 60 parts by weight and Bondyram Grade 7108 at about 10 parts per weight (which may be transferred into mixer 42 from the first dispenser 36) and nylon at about 30 parts by weight (which may be transferred into mixer 42 from second dispenser 38). In this example, the particulate materials are combined and mixed together via the mixer 42.

[0135] During a period of time, such as about 1 to 5 minutes, the mixture may be subjected to a pressure in the range of about 250 psi to 1,500 psi. The polyethylene and Bondyram Grade 7108 are heated to a temperature in a range of about 115° C. to 135° C. The melted polyethylene and Bondyram Grade 7108 are added to mixer 42. The nylon is heated to a temperature in the range of about 220° C. to 265° C. and is added to mixer 42. Heating and subjecting to pressure may occur in the same period of time, sequential periods of time, or overlapping periods of time. Heating may occur in mixer 42 or in the dispenser. Subjecting to pressure may occur in the mixer 42 or in the die extruder 56. This results in the melted polyethylene, nylon, and Bondyram Grade 7108 becoming a homogenous and melted mixture.

[0136] The homogenous mixture that will result in homogenous alloy 32 is transferred to the die extruder 56. The homogenous mixture is extruded through the opening in the die plate of the die extruder. The extrusion of the alloy results in an elongated fiber that may be spooled onto a reel. The extruded fiber may be spooled or stored on a roll.

[0137] After a roll of fiber 14 is created, the roll of spooled homogenous fiber 14 may be provided to a manufacturer. The manufacturer may utilize any known turf-making machine to create the artificial turf 10 from the fibers 14 composed of alloy 32. Once the application of the fibers 14 to the backing layer 16 has been completed, the fibers may be cut to a suitable length for use as artificial turf, such as a length within a range from about 5 mm to about 150 mm.Example Twenty-Two

[0138] Example Twenty-two provides, within the mixture 44, polyethylene at about 60 parts by weight and Bondyram Grade 7109 at about 10 parts per weight (which may be transferred into mixer 42 from first dispenser 36) and nylon at about 30 parts by weight (which may be transferred into mixer 42 from second dispenser 38). In this example, the particulate materials are combined and mixed together via the mixer 42.

[0139] During a period of time, such as about 1 to 5 minutes, the mixture may be subjected to a pressure in the range of about 250 psi to 1,500 psi. The polyethylene and Bondyram Grade 7109 are heated to a temperature in a range of about 115° C. to 135° C. The melted polyethylene and Bondyram Grade 7109 are added to mixer 42. The nylon is heated to a temperature in the range of about 220° C. to 300° C. and is added to mixer 42. Heating and subjecting to pressure may occur in the same period of time, sequential periods of time, or overlapping periods of time. Heating may occur in mixer 42 or in the dispenser. Subjecting to pressure may occur in the mixer 42 or in the die extruder 56. This results in the melted polyethylene, nylon, and Bondyram Grade 7109 becoming a homogenous and melted mixture.

[0140] The homogenous mixture that will result in homogenous alloy 32 is transferred to the die extruder 56. The homogenous mixture is extruded through the opening in the die plate of the die extruder 56. The extrusion of the alloy results in an elongated fiber 14 that may be spooled onto a reel. The extruded fiber may be spooled or stored on a roll.

[0141] After a roll of fiber 14 is created, the roll of spooled homogenous fiber 14 may be provided to a manufacturer. The manufacturer may utilize any known turf-making machine to create the artificial turf 10 from the fibers 14 composed of alloy 32. Once the application of the fibers 14 to the backing layer 16 has been completed, the fibers may be cut to a suitable length for use as artificial turf, such as a length within a range from about 5 mm to about 150 mm.Example Twenty-Three

[0142] Example Twenty-three provides, within the mixture 44, polyethylene at about 60 parts by weight and Bondyram Grade 7105 at about 10 parts per weight (which may be transferred into mixer 42 from first dispenser 36) and nylon at about 30 parts by weight (which may be transferred into mixer 42 from second dispenser 38). In this example, the particulate materials are combined and mixed together via the mixer 42.

[0143] During a period of time, such as about 1 to 5 minutes, the mixture may be subjected to a pressure in the range of about 250 psi to 1,500 psi. The polyethylene and Bondyram Grade 7105 are heated to a temperature in a range of about 115° C. to 135° C. the melted polyethylene and Bondyram Grade 7105 are added to mixer 42. The nylon is heated to a temperature in the range of about 220° C. to 265° C. and is added to mixer 42. Heating and subjecting to pressure may occur in the same period of time, sequential periods of time, or overlapping periods of time. Heating may occur in mixer 42 or in the dispenser. Subjecting to pressure may occur in the mixer 42 or in the die extruder 56. This results in the melted polyethylene, nylon, and Bondyram Grade 7105 becoming a homogenous and melted mixture.

[0144] The homogenous mixture that will result in homogenous alloy 32 is transferred to the die extruder 56. The homogenous mixture is extruded through the opening in the die plate of the die extruder 56. The extrusion of the alloy results in an elongated fiber 14 that may be spooled onto a reel. The extruded fiber may be spooled or stored on a roll.

[0145] After a roll of fiber 14 is created, the roll of spooled homogenous fiber 14 may be provided to a manufacturer. The manufacturer may utilize any known turf-making machine to create the artificial turf 10 from the fibers 14 composed of alloy 32. Once the application of the fibers 14 to the backing layer 16 has been completed, the fibers may be cut to a suitable length for use as artificial turf, such as a length within a range from about 5 mm to about 150 mm.Examples Twenty-Four Through One Hundred One

[0146] Examples twenty-four (24) through one hundred one (101) correspond with Table 1 provide below and follow similar fabrication techniques of the previous examples but highlight the exemplary part-by-weight ratios of Polyolefin 26, Polyamide 28, and the binding agent 30 that are possible to fabricate fiber 14.TABLE 1Parts By in Mixture 44ExamplePolyolefinPolyamideBindingNumber2628agent 30241065252510603026156520271560252815553029206515302060203120552532205030332565103425601535255520362550253725453038306553930601040305515413050204230452543304030443564145356324635605473555104835501549354520503540255135353052405915340582544055555405010564045155740402058403525594030306045541614553262455056345451064454015654535206645302567452530685049169504827050455715040107250351573503020745035257550302076502525775020307855441795543280554058155351082553015835525208455202585551530866039187603828860355896030109060251591602020926015259360103094653419565332966530597652510986520159965152010065102510165530

[0147] The parts by weight ratios from Examples 24-101 can be used to create the mixture 44 containing at least the Polyolefin 26, Polyamide 28, and the binding agent 30, but the mixture may include other components as well. If other components are added then the parts by weight ratios of the Polyolefin 26, Polyamide 28, and the binding agent 30 would decrease relative to the balance of the mixture 44. The mixture 44 may be heated for a period of time and then subjected to pressure, which may occur in the mixer 42 or in the die extruder 56. Heating and subjecting to pressure may occur in the same period of time, sequential periods of time, or overlapping periods of time.

[0148] This creates in the homogenous mixture that will result in homogenous alloy 32 is transferred to the die extruder 56. The homogenous mixture is extruded through the opening in the die plate of the die extruder 56. The extrusion of the alloy results in an elongated fiber 14 that may be spooled onto a reel. The extruded fiber may be spooled or stored on a roll.

[0149] After a roll of fiber 14 is created, the roll of spooled homogenous fiber 14 may be provided to a manufacturer. The manufacturer may utilize any known turf-making machine to create the artificial turf 10 from the fibers 14 composed of alloy 32. Once the application of the fibers 14 to the backing layer 16 has been completed, the fibers may be cut to a suitable length for use as artificial turf, such as a length within a range from about 5 mm to about 150 mm.

[0150] The foregoing examples 1-101 demonstrate that mixing the polyolefin 26 (which may be polyethylene or another polyolefin), the polyamide 28 (which may be nylon or another polyamide), and the binding agent 30 can be used to make alloy 32 which can be used in the production of artificial turf 10 with the benefits of both polyethylene artificial turf and nylon artificial turf. Any of the above examples 1-101 (or various combinations of interposing values between the listed values) may be used to result in the alloy 32 containing polyethylene and nylon for artificial turf.

[0151] Regardless of the aforementioned Examples 1-101 that result in fiber 14, after the artificial grass fibers 14 are created the fibers may be spooled. Once the fibers are on a spool, reel or roll they can be transported to a manufacturer where they will assemble artificial turf 10. The artificial grass fibers 14 may be tufted, sewn, or chemically bonded to the backing layer 16. During the tufting process, the artificial grass fibers 14 formed from alloy 32 are fed through the backing layer using a tufting machine. The tufting machine may push the artificial grass fibers are pushed through the backing layer and anchored to the backing layer by a stitching method. Once the artificial turf fibers are tufted through the backing layer the end user may direct the manufacturer of their desired length, and the manufacturer may cut the artificial turf 10 to the desired length of the end user.

[0152] Regardless of the aforementioned examples that result in fiber 14 having a homogenous cross section of alloy 32, the artificial turf 10 may assembled by combining multiple artificial grass fibers 14 to make a tuft 12. The top end 18 of artificial grass fiber 14 within tufts 12 are pulled through the backing layer 16 leaving the bottom end 20 of artificial grass fiber 14 contacting the backing layer. In another exemplary embodiment, individual artificial grass fiber 14 may be pulled through the backing layer 16. In yet another exemplary embodiment the bottom end 20 of artificial grass fiber 14 may be secured to the backing layer 16 by a mechanical connection (e.g., sewing, stapling, or any other mechanical means), a chemical connection (e.g., adhesive or other bonding), or a non-mechanical and non-chemical connection).

[0153] FIG. 5A depicts a method flow chart for manufacturing a turf product shown generally as 100. Method 100 includes adding a polyolefin 26, a polyamide 28, and a binding agent 30 into a mixer, which is shown generally at 112. Method 100 includes heating a mixture of the polyolefin, the polyamide, and the binding agent, which is shown generally at 114. Method 100 includes creating an alloy of the polyolefin 26, the polyamide 28, and the binding agent 30 in response to heating the mixture, which is shown generally at 116. Method 100 includes extruding the alloy into at least one fiber adapted to form a portion of artificial turf, which is shown generally at 118. Method 100 includes effecting the at least one fiber to be attached to a backing layer, which is shown generally at 120. Method 100 includes effecting an artificial turf product to be formed in response the at least one fiber being attached to the backing layer, which is shown generally at 122.

[0154] FIG. 5B depicts a second method flow chart for a method of manufacturing a turf product is shown generally as 200. Method 200 includes adding a polyolefin and a binding agent into a first mixer, which is shown generally at 212. Method 200 includes heating the polyolefin and the binding agent, which is shown generally at 214. Method 200 includes adding a polyamide to a second mixer, which is shown generally at 216. Method 200 includes heating the polyamide, which is shown generally at 218. Method 200 includes combining the heated polyolefin and binding agent with the heated polyamide, which is shown generally at 220. Method 200 includes forming a homogenous alloy in response to combining the heated polyolefin and binding agent with the heated polyamide, which is shown generally at 222. Method 200 includes extruding the homogenous alloy to create an artificial turf fiber, which is shown generally at 224. Method 200 includes effecting the artificial turf fiber to be attached to a backing layer, which is shown generally at 226. Method 200 includes effecting an artificial turf product to be formed in response the artificial turf fiber being attached to the backing layer, which is shown generally at 228.

[0155] FIG. 5C depicts a flowchart of a method for manufacturing a turf product shown generally as 300. Method 300 includes receiving a fiber composed of an alloy comprising a polyolefin, a polyamide, and a binding agent, which is shown generally at 312. Method 300 includes attaching the fiber to a backing layer, which is shown generally at 314. Method 300 includes arranging the fiber attached to the backing layer as a tuft or blade of artificial turf in an artificial turf product, which is shown generally at 316.

[0156] The extrusion device of the present disclosure may additionally include one or more sensors to sense or gather data pertaining to the surrounding environment or operation of the mixing assembly. Some exemplary sensors capable of being electronically coupled with the device of the present disclosure (either directly connected to the device of the present disclosure or remotely connected thereto) may include but are not limited to: accelerometers sensing accelerations experienced during rotation, translation, velocity / speed, location traveled, elevation gained; gyroscopes sensing movements during angular orientation and / or rotation, and rotation; altimeters sensing barometric pressure, altitude change, terrain climbed, local pressure changes, submersion in liquid; impellers measuring the amount of fluid passing thereby; global positioning sensors sensing location, elevation, distance traveled, velocity / speed; audio sensors sensing local environmental sound levels, or voice detection; photo / light sensors sensing ambient light intensity, ambient, day / night, UV exposure; TV / IR sensors sensing light wavelength; temperature sensors sensing machine or motor temperature, ambient air temperature, and environmental temperature; radar sensors; lidar sensors; ultrasonic sensors; magnetic sensors, image sensors; and moisture sensors sensing surrounding moisture levels.

[0157] If sensors are utilized to gather data relating to the device of the present disclosure, then sensed data may be evaluated and processed with artificial intelligence (AI). Analyzing data gathered from sensors using artificial intelligence involves the process of extracting meaningful insights and patterns from raw sensor data to produce refined and actionable results. Raw data is gathered from various sensors, for example those which have been identified herein or others, capturing relevant information based on the intended analysis. This data is then preprocessed to clean, organize, and structure it for effective analysis. Features that represent key characteristics or attributes of the data are extracted. These features serve as inputs for AI algorithms, encapsulating relevant information essential for the analysis. A suitable AI model, such as machine learning or deep learning (regardless of whether it is supervised or unsupervised), is chosen based on the nature of the data and the desired analysis outcome. The model is then trained using labeled or unlabeled data to learn the underlying patterns and relationships. The model is fine-tuned and optimized to enhance its performance and accuracy. This process involves adjusting parameters, architectures, and algorithms to achieve better results. The trained model is used to make predictions or inferences on new, unseen data. The model processes the extracted features and generates refined output based on the patterns it has learned during training. The results produced by the AI model are refined through post-processing techniques to ensure accuracy and relevance. These refined results are then interpreted to extract meaningful insights and derive actionable conclusions. Feedback from the refined results is used to improve the AI model iteratively. The process involves incorporating new data, adjusting the model, and enhancing the analysis based on real-world feedback and evolving requirements. Further, AI results can be used to alter the operation of the device, assembly, or system of the present disclosure based on feedback. For example, AI feedback can be used to improve the efficiency of the device of the present disclosure by responding to predicted changes in the environment or predicted changes to the device, such as how much binding agent to include in the unhomogenized mixture, or if more polyolefin or polyamide is needed more quickly than if only sensed by one or more of the sensors.

[0158] A sensor model may be employed, once trained, in the extruder device of the present disclosure. In one embodiment, the extruder device can be used to teach a sensor model to predict sensor data for a specific scenario. Alternatively, sensor models can be utilized to generate the data to train the AI. The sensor model can be trained for any type of sensor, such as those types of sensors described above, and / or other sensor types. The elements described herein may be implemented as discrete or distributed components in any suitable combination and location. The various functions described herein may be conducted by hardware, firmware, and / or software. For example, a processor may perform various functions by executing instructions stored in memory.

[0159] The AI model and / or sensor model can include a deep neural network (DNN), convolutional neural network (CNN), another neural network (NN) or the like and can support generative learning. For example, the sensor model can include a generative adversarial network (GAN), a variational autoencoder (VAE), and / or another type of DNN, CNN, NN or machine learning model (e.g., natural language processing (NLP)). Generally, the sensor model can accept some encoded representation of a scene as input using any number of data structures and / or channels (e.g., concatenated vectors, matrices, tensors, images, etc.).

[0160] In a particular embodiment, the device of the present disclosure can use the sensors to acquire a representation of the real-world environment (e.g., a physical environment) at a given point in time. Data from these sensors may be used to generate a representation of a scene or scenario, which may then be used to teach a sensor model. For example, the extruder device can detect when levels of any of the polyolefin, polyamide, or binding agent need to be adjusted. For example, a representation of a scene can be derived from sensor data, properties of objects in the scene or surrounding environment such as positions or dimensions (e.g., maps that detail movement of the materials through the production of fiber 14), classification data identifying objects in the scene or surrounding environment, properties or classification data of components of the device of the present disclosure, or some combination thereof. Generally, the sensor model learns to predict sensor data from a representation of the scene, environment or operation of the device of the present disclosure.

[0161] The sensor model architecture can be selected to fit the shape of the desired input and output data. Examples of architectures (e.g., DNNs) include, but are not limited to, perceptron, feed-forward, radial basis, deep feed-forward, recurrent, long / short term memory, gated recurrent unit, autoencoder, variational autoencoder, convolutional, deconvolutional, and generative adversarial. Some DNN architectures, such as a GAN, can include a convolutional neural network (CNN) that accepts and evaluates an input image and may include multiple input channels, which may be used to accept and evaluate multiple input images and / or input vectors.

[0162] In one embodiment, training data for the sensor model may be generated using real-world (e.g., physical environment) data. To collect real-world training data, the device of the present disclosure may collect sensor data by fusing sensors as the vehicle traverses a real-world environment. The sensors of the device of the present disclosure may include, for example, one or more global navigation satellite systems sensors (e.g., Global Positioning System sensors (GPS)), RADAR sensors, ultrasonic sensors, LIDAR sensors, inertial measurement unit (IMU) sensors (e.g., accelerometer(s), gyroscope(s), magnetic compass(es), magnetometer(s), etc.), ego-motion sensors, microphones, stereo cameras, wide-view cameras (e.g., fisheye cameras), infrared cameras, surround cameras (e.g., 360 degree cameras), long-range and / or mid-range cameras, speed sensors (e.g., for measuring the speed of the vehicle), vibration sensors, steering sensors, brake sensors (e.g., as part of the brake sensor system), and / or other sensor types.

[0163] In another embodiment, training data for the sensor model is generated based on simulated or virtual environments. The training data may then be used to train the sensor model for use in real-world autonomous applications, e.g., to control the operation of the device of the present disclosure. The training data may be derived to fit the shape of the input and output data for the sensor model, which may depend on the architecture of the sensor model. For example, sensor data may be used to encode an input scene, input parameters, and / or ground truth sensor data using different data structures and / or channels (e.g., concatenated vectors, matrices, tensors, images, etc.).

[0164] Hyperparameters are settings that govern the training process and behavior of AI models. Exemplary hyperparameters include learning rate, batch size, and regularization parameters. Adjusting these hyperparameters can impact the model's convergence, stability, and generalization capabilities. For example, a higher learning rate may speed up training but risk overshooting optimal solutions, while a lower learning rate ensures precise adjustments but may slow down the process. Similarly, batch size affects gradient estimation and memory usage, influencing the model's ability to learn effectively from the data. The number and type of layers in an AI model define its complexity and capacity to learn from data. Layers can be categorized into input, hidden, and output layers, each serving a specific function. Input layers receive raw data, hidden layers process and extract features, and output layers generate predictions. The depth of the model, determined by the number of hidden layers, allows it to capture intricate patterns and relationships in the data. For instance, DNNs with multiple hidden layers can learn complex representations, while shallow networks may be more suitable for simpler tasks. The architecture of an AI model refers to its overall structure and design, encompassing the arrangement of layers and connections. Different architectures may be tailored to specific types of data and tasks. For example, CNNs are well-suited for image data, leveraging convolutional layers to detect spatial features. Recurrent neural networks (RNNs) and their variants, such as long short-term memory (LSTM) networks, excel in handling sequential data by maintaining temporal dependencies. GANs and VAEs are used for generative tasks, creating new data samples based on learned patterns. The selection of hyperparameters, layers, and architectures directly influences the type of protocol or architecture employed in the AI model. For instance, a protocol designed for real-time data analysis may prioritize low-latency architectures with optimized hyperparameters for rapid inference. Conversely, a protocol for offline batch processing may focus on deep architectures with extensive layers to achieve high accuracy. The choice of architecture also affects the model's ability to handle different data modalities, such as images, text, or sensor data, ensuring that the protocol aligns with the specific requirements of the task.

[0165] The device of the present disclosure may include hardware, software and / or firmware responsible for managing the sensor data generated by the sensors. The autonomous hardware, software, and / or firmware being executed may manage different environments using one or more maps (e.g., 3D maps), positioning component(s), and the like. The autonomous hardware, software, and / or firmware may also include components to plan, control, and generally manage the device of the present disclosure. In one example, the autonomous hardware, software, and / or firmware can be installed in and used to control the device of the present disclosure through the environment based on the sensor data, one or more machine learning models (e.g., neural networks), and the like. A training system may use the training data to train the sensor model to predict virtual sensor data for a given scene, environment, or operation of a component.

[0166] The training system can include one or more servers (e.g., a graphics processing unit server) and data stores and may use a cloud-based deep learning infrastructure with artificial intelligence to analyze the sensor data received from the device of the present disclosure and / or stored in the data store. The training system can also incorporate or train up-to-date, real-time neural networks (and / or other machine learning models) for one or more sensor models.

[0167] The extruder device of the present disclosure may include wireless communication logic coupled to sensors on the device. The sensors gather data and provide the data to the wireless communication logic. Then, the wireless communication logic may transmit the data gathered from the sensors to a remote device. Thus, the wireless communication logic may be part of a broader communication system, in which one or several devices, assemblies, or systems of the present disclosure may be networked together to report alerts and, more generally, to be accessed and controlled remotely. Depending on the types of transceivers installed in the device, assembly, or system of the present disclosure, the system may use a variety of protocols (e.g., Wi-Fi®, ZigBee®, MIWI, BLUETOOTH®) for communication. In one example, each of the devices, assemblies, or systems of the present disclosure may have its own IP address and may communicate directly with a router or gateway. This would typically be the case if the communication protocol is Wi-Fi®. (Wi-Fi® is a registered trademark of Wi-Fi Alliance of Austin, TX, USA; ZigBee® is a registered trademark of ZigBee Alliance of Davis, CA, USA; and BLUETOOTH® is a registered trademark of Bluetooth Sig, Inc. of Kirkland, WA, USA).

[0168] In another example, a point-to-point communication protocol like MiWi or ZigBee® is used. One or more of the device of the present disclosure may serve as a repeater, or the devices of the present disclosure may be connected together in a mesh network to relay signals from one device to the next. However, the individual device in this scheme typically would not have IP addresses of their own. Instead, one or more of the devices of the present disclosure communicates with a repeater that does have an IP address, or another type of address, identifier, or credential needed to communicate with an outside network. The repeater communicates with the router or gateway.

[0169] In either communication scheme, the router or gateway communicates with a communication network, such as the Internet, although in some embodiments, the communication network may be a private network that uses transmission control protocol / internet protocol (TCP / IP) and other common Internet protocols but does not interface with the broader Internet, or does so only selectively through a firewall.

[0170] The system that receives and processes signals from the device of the present disclosure may differ from embodiment to embodiment. In one embodiment, alerts and signals from the device of the present disclosure are sent through an e-mail or simple message service (SMS; text message) gateway so that they can be sent as e-mails or SMS text messages to a remote device, such as a smartphone, laptop, or tablet computer, monitored by a responsible individual, group of individuals, or department, such as a maintenance department. Thus, if a particular device of the present disclosure creates an alert because of a data point gathered by one or more sensors, that alert can be sent, in e-mail or SMS form, directly to the individual responsible for fixing it. Of course, e-mail and SMS are only two examples of communication methods that may be used; in other embodiments, different forms of communication may be used.

[0171] In other embodiments, alerts and other data from the sensors on the device of the present disclosure may also be sent to a work tracking system that allows the individual, or the organization for which he or she works, to track the status of the various alerts that are received, to schedule particular workers to repair a particular device of the present disclosure, and to track the status of those repair jobs. A work tracking system would typically be a server, such as a Web server, which provides an interface individuals and organizations can use, typically through the communication network. In addition to its work tracking functions, the work tracker may allow broader data logging and analysis functions. For example, operational data may be calculated from the data collected by the sensors on the device of the present disclosure, and the system may be able to provide aggregate machine operational data for a device of the present disclosure or group of devices of the present disclosure.

[0172] The system also allows individuals to access the device of the present disclosure for configuration and diagnostic purposes. In that case, the individual processors or microcontrollers of the device of the present disclosure may be configured to act as Web servers that use a protocol like hypertext transfer protocol (HTTP) to provide an online interface that can be used to configure the device. In some embodiments, the systems may be used to configure several devices of the present disclosure at once. For example, if several devices are of the same model and are in similar locations in the same location, it may not be necessary to configure the devices individually. Instead, an individual may provide configuration information, including baseline operational parameters, for several devices at once.

[0173] As described herein, aspects of the present disclosure may include one or more electrical, pneumatic, hydraulic, or other similar secondary components and / or systems therein. The present disclosure is therefore contemplated and will be understood to include any necessary operational components thereof. For example, electrical components will be understood to include any suitable and necessary wiring, fuses, or the like for normal operation thereof. Similarly, any pneumatic systems provided may include any secondary or peripheral components such as air hoses, compressors, valves, meters, or the like. It will be further understood that any connections between various components not explicitly described herein may be made through any suitable means including mechanical fasteners, or more permanent attachment means, such as welding or the like. Alternatively, where feasible and / or desirable, various components of the present disclosure may be integrally formed as a single unit.

[0174] Unless explicitly stated that a particular shape or configuration of a component is mandatory, any of the elements, components, or structures discussed herein may take the form of any shape. Thus, although the figures depict the various elements, components, or structures of the present disclosure according to one or more exemplary embodiments, it is to be understood that any other geometric configuration of that element, component, or structure is entirely possible. For example, instead of the artificial grass fiber 14 being generally rectangular in shape, or a cross section of the fiber 14 being generally rectangular, they can be semi-circular triangular, or square, pentagonal, hexagonal, heptagonal, octagonal, decagonal, dodecagonal, diamond shaped or another parallelogram, trapezoidal, star-shaped, oval, ovoid, lines or lined, teardrop-shaped, cross-shaped, donut-shaped, heart-shaped, arrow-shaped, crescent-shaped, any letter shape (i.e., A-shaped, B-shaped, C-shaped, D-shaped, E-shaped, F-shaped, G-shaped, H-shaped, I-shaped, J-shaped, K-shaped, L-shaped, M-shaped, N-shaped, O-shaped, P-shaped, Q-shaped, R-shaped, S-shaped, T-shaped, U-shaped, V-shaped, W-shaped, X-shaped, Y-shaped, or Z-shaped), or any other type of regular or irregular, symmetrical or asymmetrical configuration made from alloy 32.

[0175] Various inventive concepts may be embodied as one or more methods, of which an example has been provided. The acts performed as part of the method may be ordered in any suitable way. Accordingly, embodiments may be constructed in which acts are performed in an order different than illustrated, which may include performing some acts simultaneously, even though shown as sequential acts in illustrative embodiments.

[0176] Any flowchart and / or block diagrams in the Figures illustrate some exemplary architecture, functionality, and operation of possible implementations of systems, methods, and computer program products according to various embodiments of the present disclosure. In this regard, each block in the flowchart or block diagrams may represent a module, segment, or portion of instructions, which comprises one or more executable instructions for implementing the specified logical function(s). In some alternative implementations, the functions noted in the blocks may occur out of the order noted in the Figures. For example, two blocks shown in succession may, in fact, be executed substantially concurrently, or the blocks may sometimes be executed in the reverse order, depending upon the functionality involved. It will also be noted that each block of the block diagrams and / or flowchart illustration, and combinations of blocks in the block diagrams and / or flowchart illustration, can be implemented by special purpose hardware-based systems that perform the specified functions or acts or carry out combinations of special purpose hardware and computer instructions.

[0177] While various inventive embodiments have been described and illustrated herein, those of ordinary skill in the art will readily envision a variety of other means and / or structures for performing the function and / or obtaining the results and / or one or more of the advantages described herein, and each of such variations and / or modifications is deemed to be within the scope of the inventive embodiments described herein. More generally, those skilled in the art will readily appreciate that all parameters, dimensions, materials, and configurations described herein are meant to be exemplary and that the actual parameters, dimensions, materials, and / or configurations will depend upon the specific application or applications for which the inventive teachings is / are used. Those skilled in the art will recognize or be able to ascertain using no more than routine experimentation, many equivalents to the specific inventive embodiments described herein. It is, therefore, to be understood that the foregoing embodiments are presented by way of example only and that, within the scope of the appended claims and equivalents thereto, inventive embodiments may be practiced otherwise than as specifically described and claimed. Inventive embodiments of the present disclosure are directed to each individual feature, system, article, material, kit, and / or method described herein. In addition, any combination of two or more such features, systems, articles, materials, kits, and / or methods, if such features, systems, articles, materials, kits, and / or methods are not mutually inconsistent, is included within the inventive scope of the present disclosure. Thus it is to be clearly understood that present disclosure, including the Figures, describes various features, embodiments, and aspects or instances of inventive matter. It is to be understood that any feature, component, step, or characteristic disclosed in this specification or Figures may be combined with any other disclosed feature to form alternative embodiments, unless explicitly stated otherwise. Individual features should not be viewed as being limited to their originally disclosed embodiments but may be freely combined or rearranged with other features as appropriate to define the scope of the claimed subject matter. Further, the various features, configurations, components, and functionalities discussed herein are intended to provide a “disclosure reservoir” from which any claim language may be derived. To illustrate the flexibility intended by this disclosure reservoir, a first feature, originally described with a second feature, may alternatively be implemented with a third feature, a fourth feature, or both third and fourth features. Similarly, functional components may be substituted or combined in any logical arrangement without departing from the scope of the present disclosure.

[0178] The above-described embodiments can be implemented in any of numerous ways. For example, embodiments of technology disclosed herein may be implemented using hardware, software, firmware or a combination thereof. When implemented in software, the software code or instructions can be executed on any suitable processor or collection of processors, whether provided in a single computer or distributed among multiple computers or in firmware. Furthermore, the instructions or software code can be stored in at least one non-transitory computer readable storage medium.

[0179] Also, a computer or smartphone may be utilized to execute the software code or instructions via its processors may have one or more input and output devices. These devices can be used, among other things, to present a user interface. Examples of output devices that can be used to provide a user interface include printers or display screens for visual presentation of output and speakers or other sound generating devices for audible presentation of output. Examples of input devices that can be used for a user interface include keyboards, and pointing devices, such as mice, touch pads, and digitizing tablets. As another example, a computer may receive input information through speech recognition or in other audible format.

[0180] Such computers or smartphones may be interconnected by one or more networks in any suitable form, including a local area network or a wide area network, such as an enterprise network, and intelligent network (IN) or the Internet. Such networks may be based on any suitable technology and may operate according to any suitable protocol and may include wireless networks, wired networks or fiber optic networks.

[0181] The various methods or processes outlined herein may be coded as software / instructions that are executable on one or more processors that employ any one of a variety of operating systems or platforms. Additionally, such software may be written using any of a number of suitable programming languages and / or programming or scripting tools, and also may be compiled as executable machine language code or intermediate code that is executed on a framework or virtual machine.

[0182] In this respect, various inventive concepts may be embodied as a computer readable storage medium (or multiple computer readable storage media) (e.g., a computer memory, one or more floppy discs, compact discs, optical discs, magnetic tapes, flash memories, USB flash drives, SD cards, circuit configurations in Field Programmable Gate Arrays or other semiconductor devices, or other non-transitory medium or tangible computer storage medium) encoded with one or more programs that, when executed on one or more computers or other processors, perform methods that implement the various embodiments of the disclosure discussed above. The computer readable medium or media can be transportable, such that the program or programs stored thereon can be loaded onto one or more different computers or other processors to implement various aspects of the present disclosure as discussed above.

[0183] The terms “program” or “software” or “instructions” are used herein in a generic sense to refer to any type of computer code or set of computer-executable instructions that can be employed to program a computer or other processor to implement various aspects of embodiments as discussed above. Additionally, it should be appreciated that according to one aspect, one or more computer programs that when executed perform methods of the present disclosure need not reside on a single computer or processor but may be distributed in a modular fashion amongst a number of different computers or processors to implement various aspects of the present disclosure.

[0184] Computer-executable instructions may be in many forms, such as program modules, executed by one or more computers or other devices. Generally, program modules include routines, programs, objects, components, data structures, etc. that perform particular tasks or implement particular abstract data types. Typically, the functionality of the program modules may be combined or distributed as desired in various embodiments. As such, one aspect or embodiment of the present disclosure may be a computer program product including least one non-transitory computer readable storage medium in operative communication with a processor, the storage medium having instructions stored thereon that, when executed by the processor, implement a method or process described herein, wherein the instructions comprise the steps to perform the method(s) or process(es) detailed herein.

[0185] Also, data structures may be stored in computer-readable media in any suitable form. For simplicity of illustration, data structures may be shown to have fields that are related through location in the data structure. Such relationships may likewise be achieved by assigning storage for the fields with locations in a computer-readable medium that convey relationship between the fields. However, any suitable mechanism may be used to establish a relationship between information in fields of a data structure, including through the use of pointers, tags or other mechanisms that establish relationship between data elements.

[0186] All definitions, as defined and used herein, should be understood to control over dictionary definitions, definitions in documents incorporated by reference, and / or ordinary meanings of the defined terms.

[0187] “Logic”, as used herein, includes but is not limited to hardware, firmware, software, and / or combinations of each to perform a function(s) or an action(s), and / or to cause a function or action from another logic, method, and / or system. For example, based on a desired application or needs, logic may include a software controlled microprocessor, discrete logic like a processor (e.g., microprocessor), an application specific integrated circuit (ASIC), a programmed logic device, a memory device containing instructions, an electric device having a memory, or the like. Logic may include one or more gates, combinations of gates, or other circuit components. Logic may also be fully embodied as software. Where multiple logics are described, it may be possible to incorporate the multiple logics into one physical logic. Similarly, where a single logic is described, it may be possible to distribute that single logic between multiple physical logics.

[0188] Furthermore, the logic(s) presented herein for accomplishing various methods of this system may be directed towards improvements in existing computer-centric or internet-centric technology that may not have previous analog versions. The logic(s) may provide specific functionality directly related to structure that addresses and resolves some problems identified herein. The logic(s) may also provide significantly more advantages to solve these problems by providing an exemplary inventive concept as specific logic structure and concordant functionality of the method and system. Furthermore, the logic(s) may also provide specific computer implemented rules that improve existing technological processes. The logic(s) provided herein extends beyond merely gathering data, analyzing the information, and displaying the results. Further, portions or all of the present disclosure may rely on underlying equations that are derived from the specific arrangement of the equipment or components as recited herein. Thus, portions of the present disclosure as it relates to the specific arrangement of the components are not directed to abstract ideas. Furthermore, the present disclosure and the appended claims present teachings that involve more than performance of well-understood, routine, and conventional activities previously known to the industry. In some of the method or process of the present disclosure, which may incorporate some aspects of natural phenomenon, the process or method steps are additional features that are new and useful.

[0189] More particularly, the device of the present disclosure, which may include the logic(s) presented herein, includes the features, components, techniques or processes detailed herein that, as combined, accomplished the desired results detailed herein. These specific elements, configuration or techniques of the device of the present disclosure, some of which may be included in at least one of the appended claims, accomplish these desired results to overcome the then existing problems in the relevant field of computer processor-based systems. Additionally, the features, components, techniques or processes of the device of the present disclosure, are an unconventional arrangement of elements or unconventionally perform a method detailed herein that was unavailable without the unconventional arrangement of elements. These exemplary, yet particular, arrangements provide an improvement over existing technologies that have failed to operate in the manner, and with the efficiency that is taught by the device of the present disclosure.

[0190] The articles “a” and “an,” as used herein in the specification and in the claims, unless clearly indicated to the contrary, should be understood to mean “at least one.” The phrase “and / or,” as used herein in the specification and in the claims (if at all), should be understood to mean “either or both” of the elements so conjoined, i.e., elements that are conjunctively present in some cases and disjunctively present in other cases. Multiple elements listed with “and / or” should be construed in the same fashion, i.e., “one or more” of the elements so conjoined. Other elements may optionally be present other than the elements specifically identified by the “and / or” clause, whether related or unrelated to those elements specifically identified. Thus, as a non-limiting example, a reference to “A and / or B”, when used in conjunction with open-ended language such as “comprising” can refer, in one embodiment, to A only (optionally including elements other than B); in another embodiment, to B only (optionally including elements other than A); in yet another embodiment, to both A and B (optionally including other elements); etc. As used herein in the specification and in the claims, “or” should be understood to have the same meaning as “and / or” as defined above. For example, when separating items in a list, “or” or “and / or” shall be interpreted as being inclusive, i.e., the inclusion of at least one, but also including more than one of a number or list of elements, and, optionally, additional unlisted items. Only terms clearly indicated to the contrary, such as “only one of” or “exactly one of,” or, when used in the claims, “consisting of,” will refer to the inclusion of exactly one element of a number or list of elements. In general, the term “or” as used herein shall only be interpreted as indicating exclusive alternatives (i.e. “one or the other but not both”) when preceded by terms of exclusivity, such as “either,”“one of,”“only one of,” or “exactly one of.”“Consisting essentially of,” when used in the claims, shall have its ordinary meaning as used in the field of patent law.

[0191] As used herein in the specification and in the claims, the phrase “at least one,” in reference to a list of one or more elements, should be understood to mean at least one element selected from any one or more of the elements in the list of elements, but not necessarily including at least one of each and every element specifically listed within the list of elements and not excluding any combinations of elements in the list of elements. This definition also allows that elements may optionally be present other than the elements specifically identified within the list of elements to which the phrase “at least one” refers, whether related or unrelated to those elements specifically identified. Thus, as a non-limiting example, “at least one of A and B” (or, equivalently, “at least one of A or B,” or, equivalently “at least one of A and / or B”) can refer, in one embodiment, to at least one, optionally including more than one, A, with no B present (and optionally including elements other than B); in another embodiment, to at least one, optionally including more than one, B, with no A present (and optionally including elements other than A); in yet another embodiment, to at least one, optionally including more than one, A, and at least one, optionally including more than one, B (and optionally including other elements); etc. As another example, “at least one of: A, B, or B” is intended to cover A, B, C, A-B, A-C, B-C, and A-B-C, as well as any combination with multiple of the same item.

[0192] While components of the present disclosure are described herein in relation to each other, it is possible for one of the components disclosed herein to include inventive subject matter, if claimed alone or used alone. In keeping with the above example, if the disclosed embodiments teach the features of A and B, then there may be inventive subject matter in the combination of A and B, A alone, or B alone, unless otherwise stated herein.

[0193] As used herein in the specification and in the claims, the term “effecting” or a phrase or claim element beginning with the term “effecting” should be understood to mean to cause something to happen or to bring something about. For example, effecting an event to occur may be caused by actions of a first party even though a second party actually performed the event or had the event occur to the second party. Stated otherwise, effecting refers to one party giving another party the tools, objects, or resources to cause an event to occur. Thus, in this example a claim element of “effecting an event to occur” would mean that a first party is giving a second party the tools or resources needed for the second party to perform the event, however the affirmative single action is the responsibility of the first party to provide the tools or resources to cause said event to occur.

[0194] When a feature or element is herein referred to as being “on” another feature or element, it can be directly on the other feature or element or intervening features and / or elements may also be present. In contrast, when a feature or element is referred to as being “directly on” another feature or element, there are no intervening features or elements present. It will also be understood that, when a feature or element is referred to as being “connected”, “attached” or “coupled” to another feature or element, it can be directly connected, attached or coupled to the other feature or element or intervening features or elements may be present. In contrast, when a feature or element is referred to as being “directly connected”, “directly attached” or “directly coupled” to another feature or element, there are no intervening features or elements present. Although described or shown with respect to one embodiment, the features and elements so described or shown can apply to other embodiments. It will also be appreciated by those of skill in the art that references to a structure or feature that is disposed “adjacent” another feature may have portions that overlap or underlie the adjacent feature.

[0195] Spatially relative terms, such as “under”, “below”, “lower”, “over”, “upper”, “above”, “behind”, “in front of”, and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. It will be understood that the spatially relative terms are intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if a device in the figures is inverted, elements described as “under” or “beneath” other elements or features would then be oriented “over” the other elements or features. Thus, the exemplary term “under” can encompass both an orientation of over and under. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly. Similarly, the terms “upwardly”, “downwardly”, “vertical”, “horizontal”, “lateral”, “transverse”, “longitudinal”, and the like are used herein for the purpose of explanation only unless specifically indicated otherwise.

[0196] Although the terms “first” and “second” may be used herein to describe various features / elements, these features / elements should not be limited by these terms, unless the context indicates otherwise. These terms may be used to distinguish one feature / element from another feature / element. Thus, a first feature / element discussed herein could be termed a second feature / element, and similarly, a second feature / element discussed herein could be termed a first feature / element without departing from the teachings of the present disclosure.

[0197] An embodiment is an implementation or example of the present disclosure. Reference in the specification to “an embodiment,”“one embodiment,”“some embodiments,”“one particular embodiment,”“an exemplary embodiment,” or “other embodiments,” or the like, means that a particular feature, structure, or characteristic described in connection with the embodiments is included in at least some embodiments, but not necessarily all embodiments, of the invention. The various appearances “an embodiment,”“one embodiment,”“some embodiments,”“one particular embodiment,”“an exemplary embodiment,” or “other embodiments,” or the like, are not necessarily all referring to the same embodiments. Furthermore, the use of any and all examples or exemplary language (“e.g.,”“such as,” or the like) is intended merely to better illustrate or illuminate the embodiments and does not pose a limitation on the scope of that or those embodiments. No language in this specification should be construed as indicating any unclaimed element as essential to the practice of the disclosed embodiment.

[0198] If this specification states a component, feature, structure, or characteristic “may”, “might”, or “could” be included, that particular component, feature, structure, or characteristic is not required to be included. If the specification or claim refers to “a” or “an” element, that does not mean there is only one of the element. If the specification or claims refer to “an additional” element or “another” element, that does not preclude there being more than one of the additional element or the another element.

[0199] As used herein in the specification and claims, including as used in the examples and unless otherwise expressly specified, all numbers may be read as if prefaced by the word “about” or “approximately,” even if the term does not expressly appear. The phrase “about” or “approximately” may be used when describing magnitude and / or position to indicate that the value and / or position described is within a reasonable expected range of values and / or positions. For example, a numeric value may have a value that is + / −0.1% of the stated value (or range of values), + / −1% of the stated value (or range of values), + / −2% of the stated value (or range of values), + / −5% of the stated value (or range of values), + / −10% of the stated value (or range of values), etc. Any numerical range recited herein is intended to include all sub-ranges subsumed therein. Further, recitation of ranges of values herein are not intended to be limiting, referring instead individually to any and all values falling within that range, unless otherwise indicated herein, and each separate value within such range is incorporated into the specification as if it were individually recited herein.

[0200] Additionally, the method of performing the present disclosure may occur in a sequence different than those described herein. Accordingly, no sequence of the method should be read as a limitation unless explicitly stated. It is recognizable that performing some of the steps of the method in a different order could achieve a similar result.

[0201] In the claims, as well as in the specification above, all transitional phrases such as “comprising,”“including,”“carrying,”“having,”“containing,”“involving,”“holding,”“composed of,” and the like are to be understood to be open-ended, i.e., to mean including but not limited to. Only the transitional phrases “consisting of” and “consisting essentially of” shall be closed or semi-closed transitional phrases, respectively.

[0202] To the extent that the present disclosure has utilized the term “invention” in various titles or sections of this specification, or in the context of those sections, this term has been included as required by the formatting requirements of word document submissions (i.e., docx submissions) pursuant the guidelines / requirements of the United States Patent and Trademark Office and shall not, in any manner, be considered a disavowal of any subject matter.

[0203] In the foregoing description, certain terms have been used for brevity, clearness, and understanding. No unnecessary limitations are to be implied therefrom beyond the requirement of the prior art because such terms are used for descriptive purposes and are intended to be broadly construed.

[0204] Moreover, the description and illustration of various embodiments of the disclosure are examples and the disclosure is not limited to the exact details shown or described.

Examples

example one

[0054]Example One provides, within the mixture 44, polyethylene at about 65 parts by weight (which may be transferred into mixer 42 from the first dispenser 36), nylon at about 25 parts by weight (which may be transferred into mixer 42 from the second dispenser 38), and maleic anhydride at about 10 parts by weight (which may be transferred into mixer 42 from the third dispenser 38). In this example, the particulate materials are combined and mixed together via the mixer 42.

[0055]During a period of time, such as about 1 to 5 minutes, the mixture may be subjected to a pressure in the range of about 250 psi to 1,500 psi and heated to a temperature in a range of about 115° C. to about 300° C. Heating and subjecting to pressure may occur in the same period of time, sequential periods of time, or overlapping periods of time. Heating may occur in mixer 42 or in the dispenser. Subjecting to pressure may occur in the mixer 42 or in the die extruder 56. This results in the polyethylene, nylon...

example two

[0058]Example Two provides, within the mixture 44, polyethylene at about 55 parts by weight (which may be transferred into mixer 42 from the first dispenser 36), nylon at about 35 parts by weight (which may be transferred into mixer 42 from second dispenser 38), and maleic anhydride at about 10 parts by weight (which may be transferred into mixer 42 from the third dispenser 40). In this example, the particulate materials are combined and mixed together via the mixer 42.

[0059]During a period of time, such as about 1 to 5 minutes, the mixture may be subjected to a pressure in the range of about 250 psi to 1,500 psi and heated to a temperature in a range of about 115° C. to 300° C. Heating and subjecting to pressure may occur in the same period of time, sequential periods of time, or overlapping periods of time. Heating may occur in mixer 42 or in the dispenser. Subjecting to pressure may occur in the mixer 42 or in the die extruder 56. This results in the polyethylene, nylon, and male...

example three

[0062]Example Three provides, within the mixture 44, polyethylene at about 45 parts by weight (which may be transferred into mixer 42 from first dispenser 36), nylon at about 50 parts by weight (which may be transferred into mixer 42 from the second dispenser 38), and maleic anhydride at about 5 parts by weight (which may be transferred into mixer 42 from the third dispenser 40). In this example, the particulate materials are combined and mixed together via the mixer 42.

[0063]During a period of time, such as about 1 to 5 minutes the mixture may be subjected to a pressure in the range of about 250 psi to 1,500 psi and heated to a temperature in a range of about 115° C. to 300° C. Heating and subjecting to pressure may occur in the same period of time, sequential periods of time, or overlapping periods of time. Heating may occur in mixer 42 or in the dispenser. Subjecting to pressure may occur in the mixer 42 or in the die extruder 56. This results in the polyethylene, nylon, and male...

CROSS REFERENCE TO RELATED APPLICATION

[0001] This disclosure claims the benefit of and priority to U.S. Provisional Application Ser. No. 63 / 771,414, filed on Mar. 13, 2025.TECHNICAL FIELD

[0002] This disclosure is directed generally to artificial turf and the fibers that are bundled together to form the artificial turf.BACKGROUND ART

[0003] Artificial turf is an article of manufacture typically composed of synthetic man-made fibers that are generally woven onto a backing surface. Artificial turf is made to look and feel similar to natural grass. Artificial turf is commonly used for sports fields, golf courses, pet parks, playgrounds, personal yards, amongst many other uses. Artificial turf may be different colors, length, and density depending on the desired use of the artificial turf.

[0004] Artificial turf is beneficial because it is low maintenance compared to real / natural grass. Artificial turf remains green, does not need to be mowed, and overall, there is not a demanding level of upkeep to maintain artificial turf looking new. Furthermore, artificial turf is beneficial because it is more durable than natural grass and can handle high traffic areas, often without damaging the appearance of the turf. Artificial turf is pet friendly and does not require any chemical treatments to make it grow the way grass does making it an environmentally friendly option as well.

[0005] Currently, the fibers that are used in artificial turf are typically made from either polyethylene or nylon. Artificial turf fibers made from polyethylene are not as durable in comparison to nylon fibers, but the polyethylene fibers are hydrophobic, which means that they are a little softer and water does not permeate the turf fiber, so they do not expand when they are wet. On the other hand, artificial turf made from nylon is more durable, but they are hydrophilic, which means that they receive water, so they expand and contract when they become wet and dry respectively. Nylon turf fibers tend to be a little stiffer because of their hydrophilic nature.

[0006] There are artificial turf products currently that have a sheathed or sheath configuration comprised of a nylon core with a polyethylene sheath or coating. The purpose of having the nylon core with the polyethylene sheath or coating is to have a more durable inner portion of the turf fiber while maintaining the softness of the turf fiber that is made from polyethylene. Although the sheath and core variations of artificial turf fibers are beneficial, it is not without its drawbacks. For example, sheath and core fibers are difficult to manufacture due to the disparate materials (i.e., nylon and polyethylene) that do not mix together. As such, specialty tools are required for manufacture. Furthermore, because the two disparate materials are distinct, there is a chance for them to separate, which then loses the benefits of the sheath and core.SUMMARY OF THE INVENTION

[0007] It has been determined that there is a need to create an artificial turf that is durable yet soft. The present disclosure addresses this need, along with solving the separation problems of sheath and core fibers, by providing an alloy blend for an artificial turf fiber composed of at least two disparate materials, such as nylon and polyethene, that were previously unable to be blended into an alloy and used as a turf fiber. By creating an alloy blend in the form of a turf fiber, aspects of the present disclosure are able to provide an artificial turf product with alloy fibers that maximizes the benefits and advantages of softness and durability.

[0008] In one aspect, an exemplary embodiment of the present disclosure may provide an artificial turf product comprising: a backing layer; at least one artificial turf fiber formed from a homogenous alloy, and the at least one turf fiber is attached to the backing layer; wherein the homogenous alloy comprises: a polyolefin; a polyamide; and a binding agent.

[0009] In another aspect, an exemplary embodiment of the present disclosure may provide the artificial turf product, wherein the polyolefin, polyamide, and the binding agent sum to the 100 parts by weight, and wherein the binding agent comprises at least one of (i) maleic acid and (ii) maleic anhydride. The artificial turf product, wherein the polyolefin is in a range of about 60 to 70 parts by weight of the total parts by weight. The artificial turf product, wherein the polyolefin is polyethylene that is about 65 parts by weight. The artificial turf product, wherein the polyamide is nylon, wherein the nylon is in a range of about 25 to 40 parts by weight. The artificial turf product, wherein the binding agent is a modified polar star-like high polypropylene, wherein the propylene is manufactured by a continuous reactive process at molten phase and characterized by a fork-like or star-like molecular-structure. The artificial turf product, wherein the binding agent comprises: polypropylene ranging from about 80 to 99 parts by weight of the binding agent; The artificial turf product, wherein the binding agent comprises: a free radical initiator having T½ of at least a minute at temperatures higher than 100° C., wherein the free radical initiator is in a range of about 0.01 to 2 parts by weight of the binding agent. The artificial turf product, wherein the binding agent comprises: one or more branching nucleus monomers having two or more vinyl or allyl reactive groups, wherein the branching nucleus monomers are in a range of about 0.1 to 20 parts by weight of the binding agent, wherein the branching nucleus monomer is adapted to form at least one branch point when grafted onto polypropylene. The artificial turf product, wherein the binding agent comprises: one or more monomers having at least one vinyl or allyl reactive group, wherein the one or more monomers are in a range from 0.1 to about 20 parts by weight of the binding agent. The artificial turf product, wherein the binding agent comprises: unsaturated acid monomer having at least one vinyl or allyl reactive groups, and one or more carboxylic acid or anhydride or ester group, wherein the unsaturated acid monomer is in a range of about 0.1 to 5 parts by weight of the binding agent. The artificial turf product, wherein the unsaturated acid monomer having at least one vinyl or allyl reactive group is maleic acid. The artificial turf product, wherein the binding agent is in a range of about 1 to 10 parts by weight. The artificial turf product, wherein the binding agent is maleic anhydride. The artificial turf product, wherein the maleic anhydride is in a range of about 1 to 10 parts by weight. The artificial turf product, wherein the artificial turf fiber has a Gmax measurement in a range of about 1 unit of gravity to 165 units of gravity. The artificial turf product, wherein the artificial turf fiber has a Gmax measurement in a range of about 70 units of gravity to 115 units of gravity. The artificial turf product, further comprising a color agent.

[0010] In one aspect, an exemplary embodiment of the present disclosure may provide a method of manufacturing a turf product comprising: adding a polyolefin, a polyamide, and a binding agent into a mixer; heating a mixture of the polyolefin, the polyamide, and the binding agent; creating an alloy of the polyolefin, the polyamide, and the binding agent in response to heating the mixture; extruding the alloy into at least one fiber adapted to form a portion of artificial turf; effecting the at least one fiber to be attached to a backing layer; and effecting an artificial turf product to be formed in response the at least one fiber being attached to the backing layer.

[0011] This exemplary embodiment or another exemplary embodiment of the present disclosure may provide that the polyolefin, the polyamide, and the binding agent remain in separate mixers before combining the polyolefin, polyamide, and binding agent into the mixer. This exemplary embodiment or another exemplary embodiment of the present disclosure may provide that the polyolefin is polyethylene, wherein the polyethylene is heated to a temperature in a range of about 115° C. to 135° C. This exemplary embodiment or another exemplary embodiment of the present disclosure may provide that the polyamide is nylon, wherein the nylon is heated to a temperature in a range of about 220° C. to 270° C. This exemplary embodiment or another exemplary embodiment of the present disclosure may provide that the binding agent is heated to a temperature in a range of about 50° C. to 135° C. This exemplary embodiment or another exemplary embodiment of the present disclosure may provide that the binding agent produces an alloy of materials that are otherwise incompatible. This exemplary embodiment or another exemplary embodiment of the present disclosure may provide that the at least one fiber is extruded from a die extruder. This exemplary embodiment or another exemplary embodiment of the present disclosure may provide that after extrusion, the at least one fiber is shaped as at least one blade of artificial turf.

[0012] In another aspect, an exemplary embodiment of the present disclosure may provide a method of manufacturing a turf product comprising: adding a polyolefin and a binding agent into a first mixer; heating the polyolefin and the binding agent; adding a polyamide to a second mixer; heating the polyamide; combining the heated polyolefin and binding agent with the heated polyamide; forming a homogenous alloy in response to combining the heated polyolefin and binding agent with the heated polyamide; extruding the homogenous alloy to create an artificial turf fiber; effecting the artificial turf fiber to be attached to a backing layer; and effecting an artificial turf product to be formed in response the artificial turf fiber being attached to the backing layer.

[0013] This exemplary embodiment or another exemplary embodiment of the present disclosure may include adding, automatically, more polyolefin to the second mixer when the computer-monitored sensors detects the level of polyolefin is low. This exemplary embodiment or another exemplary embodiment of the present disclosure may include adding, automatically, more polyamide to the first mixer when the computer-monitored sensors detects the level of polyamide is low. This exemplary embodiment or another exemplary embodiment of the present disclosure may include adding, automatically, more binding agent to the first mixer when the computer-monitored sensors detects the level of binding agent is low.

[0014] In yet another aspect, an exemplary embodiment of the present disclosure may provide a method of manufacturing an artificial turf product comprising: receiving a fiber composed of an alloy comprising a polyolefin, a polyamide, and a binding agent; attaching the fiber to a backing layer; arranging the fiber attached to the backing layer as a tuft or blade of artificial turf in an artificial turf product.

[0015] This exemplary embodiment or another exemplary embodiment of the present disclosure may provide the binding agent that allows the polyolefin and the polyamide to combine to create the homogenous alloy. The binding agent may be maleic anhydride, maleic acid, a modified polar star-like high polypropylene, or any other binding agent disclosed herein. To create the homogenous alloy, the unhomogenized mixture of polyolefin, polyamide, and the binding agent is heated to create the alloy blend. Once the mixture is heated, it may go through an extrusion process. The present disclosure provides a new material in artificial turf products.BRIEF DESCRIPTION OF THE DRAWINGS

[0016] One or more exemplary embodiment(s) of the present disclosure is set forth in the following description, is shown in the drawings and is particularly and distinctly pointed out and set forth in the appended claims. The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate various example configurations and methods, and other example embodiments of various aspects of the invention. It will be appreciated that the illustrated element boundaries (e.g., boxes, groups of boxes, or other shapes) in the figures represent one example of the boundaries. One of ordinary skill in the art will appreciate that in some examples one element may be designed as multiple elements or that multiple elements may be designed as one element. In some examples, an element shown as an internal component of another element may be implemented as an external component and vice versa. Furthermore, elements may not be drawn to scale.

[0017] FIG. 1 is an environmental side elevation view of a section of artificial turf according to one exemplary embodiment of the present disclosure.

[0018] FIG. 2 is an exploded side elevation view of one artificial turf fiber.

[0019] FIG. 3 is a cross-section view of the artificial turf fiber taken along line 3-3 in FIG. 2.

[0020] FIG. 4 is an operational elevation view of the mixing of the materials to make the artificial turf.

[0021] FIG. 5A is a flowchart of a method of manufacturing an artificial turf product according to one aspect of the present disclosure.

[0022] FIG. 5B is a second flowchart for another method of manufacturing an artificial turf product according to another aspect of the present disclosure.

[0023] FIG. 5C is a third flowchart for another method of manufacturing an artificial turf product according to one aspect of the present disclosure.

[0024] Similar numbers refer to similar parts throughout the drawings.DETAILED DESCRIPTION

[0025] FIG. 1 depicts a section or portion of artificial turf 10 according to one exemplary aspect of the present disclosure. Artificial turf 10 comprises synthetic fibers arranged in a tufted manner that collectively define artificial grass, and the synthetic fibers are fabricated from, formed from, extruded from, or otherwise comprise an alloy compound to create soft yet durable artificial grass. The alloy that is used to create the synthetic or artificial turf fiber will be described in greater detail herein.

[0026] Artificial turf 10 may comprise tufts 12 that are defined by a plurality of artificial grass fibers 14 made from the alloy. The alloy enables the artificial grass fibers to be soft yet durable. The artificial grass fibers 14 may be connected to a backing layer 16. In the present disclosure the artificial grass fibers 14 may be connected to the backing layer 16 by the artificial grass fibers 14 being woven through the backing layer 16 to form tufts 12.

[0027] Tufts 12 include a plurality of artificial grass fibers 14, and the number of fibers 14 may be designer-selected, manufacturer-selected or a variable number of artificial grass fibers 14 depending on the application-specific needs of artificial turf 10. In FIG. 1, one of the tufts 12 is comprised of eight artificial grass fibers 14, but this number may vary depending on the desired density and / or thickness of the artificial turf 10. The artificial turf 10 will be denser as more artificial turf fibers 14 are present in the turf 10.

[0028] FIG. 1 depicts the backing layer 16, which may be any type of commercially known backing layer or material used in the artificial turf industry. The backing layer 16 is used to secure the artificial grass fibers 14 to define the tufts 12. The artificial grass fibers 14 may be woven, sewn or otherwise pulled through the backing layer 16 to form tufts 12. There may be any number of tufts 12 that are pulled through the backing layer 16 to form artificial turf 10. The more tufts 12 that are attached to the backing layer 16 will result in a denser artificial turf 10.

[0029] FIG. 2 depicts one exemplary artificial grass fiber 14 according to a non-limiting and exemplary aspect of the present disclosure. The artificial grass fiber 14 includes a top end 18 spaced apart from a bottom end 20 with the fiber body extending therebetween. Artificial grass fiber 14 further includes a first surface 22 and a second surface 24 which are connected by the top end 18 and the bottom end 20. Top end 18 and bottom end 20 may be spaced apart to any desired length, making the artificial grass fiber 14 longer. First surface 22 and second surface 24 may be spaced apart to any desired width to make artificial grass fiber 14 any width. Artificial grass fiber 14 may be formed from or extruded from an alloy that comprises at least three elements or compounds that are homogenously formed together. In one exemplary embodiment artificial grass fiber 14 comprises the compounds of an alloy blend of a polyolefin 26, a polyamide 28, and a binding agent 30, as shown in FIG. 3.

[0030] FIG. 3 depicts a cross section of a body portion of the grass fiber being formed from homogenous alloy 32. In one exemplary embodiment, the alloy 32 may include or comprise polyolefin 26, polyamide 28, and the binding agent 30. In another exemplary embodiment, the alloy 32 may consist of or consist essentially of polyolefin 26, polyamide 28, and the binding agent 30. In one particular embodiment of alloy 32, the polyolefin 26 is polyethylene, the polyamide 28 is nylon, and the binding agent 30 is either maleic anhydride or maleic acid. One exemplary binding agent is BondyRam® that is manufactured by Polyram Plastic Industries Ltd.

[0031] Polyethylene is a polymer made from the polymerization of ethylene monomers. There are several types of polyethylene, including low-density polyethylene (LDPE), high-density polyethylene (HDPE), and linear low-density polyethylene (LLDPE), and of which could be utilized in alloy 32 for manufacture or production of fiber 14. The chemical formula for polyethylene is (C2H4)n, where n represents the number of repeating ethylene units in the polymer chain. Each ethylene unit includes two carbon atoms and four hydrogen atoms. The structure is typically depicted as a long chain of repeating-CH2—CH2-units.

[0032] Nylon is a polymer made from the polymerization of two monomers, hexamethylenediamine and adipic acid. The nylon is made from hexamethylenediamine and adipic acid, called Nylon 6,6, which is the most common form of nylon and of which could be utilized in alloy 32 for manufacture or production of fiber 14. There is another common form of nylon called Nylon 6. Nylon 6 is made from a single monomer called caprolactam. The chemical formula for nylon is (C12H22N2O10)n, where n represents the number of repeating units of nylon. The structure is typically depicted as a long chain of repeating (—CH2)6—NH—CO—(CH2)4—CO—NH—) units.

[0033] Maleic anhydride is the dehydrated form of maleic acid. Maleic anhydride is made from the oxidation of hydrocarbons. Maleic anhydride is typically made from butane, the most common form, or benzene. Maleic anhydride from butane could be utilized in alloy 32 for manufacture or production of fiber 14. The chemical formula for maleic anhydride is (C4H4O3). Maleic Acid is an organic compound with the chemical formula (C4H4O4). It is the cis-isomer of butenedioic acid and has two carboxyl groups. Maleic anhydride is grafted onto the backbone of a polymer, such as polypropylene or polyethylene. This may be done through a process called reactive extrusion, where the polymer and maleic anhydride are mixed and heated together in an extruder. The maleic anhydride groups introduce polar functionalities to the non-polar polymer, making it more compatible with other polar materials like polyamides or fillers. The modified polymer can better adhere to other materials, which is useful in composite materials and multi-layer structures. The modification can improve the strength, toughness, and durability of the polymer.

[0034] Although this exemplary embodiment details the binding agent 30 as a maleic anhydride, other binding agents could be utilized that effectuate the combination of polyolefin 26 and polyamide 28 into the homogenous alloy 32. For example, in another embodiment, the binding agent 30 is a modified polar star-like high polypropylene. The modified polar star-like high propylene is manufactured by a continuous reactive process at molten phase and characterized by a fork-like and / or star-like molecular-structure, comprising: polypropylene ranging from about 80 to 99 parts by weight of the binding agent; a free radical initiator having half life (T½) of at least a minute at temperatures higher than 100° C., wherein the free radical initiator is in a range of about 0.01 to 2 parts by weight of the binding agent; one or more branching nucleus monomers having two or more vinyl or allyl reactive groups, wherein the branching nucleus monomers are in a range of about 0.1 to 20 parts by weight of the binding agent, wherein the branching nucleus monomer is adapted to form at least one branch point when grafted onto polypropylene; and one or more monomers having at least one vinyl or allyl reactive group, wherein the one or more monomers are in a range from 0.1 to about 20 parts by weight; and unsaturated acid monomer having at least one vinyl or allyl reactive groups and one or more carboxylic acid or anhydride or ester group, wherein the unsaturated acid monomer is in a range of about 0.1 to 5 parts by weight.

[0035] As mentioned previously, the alloy 32 may be a homogenous alloy blend of the polyolefin 26 and polyamide 28, which is effectuated by the binding agent 30. When the binding agent 30 is a maleic anhydride, the binding agent 30 enables the two previously incompatible compounds or elements to be combined into a homogenous alloy due to maleic anhydride's ability to graft onto the polymer, polyethylene or any other polyolefin. This homogenous blend was previously not able to be accomplished and previously required the cone a sheath method. Binding agent 30 allows for the homogeneous alloy to be achieved which provides the optimal combination of the polyolefin 26 and the polyamide 28. The alloy 32 in artificial grass fibers 14 solves the long felt need to create an artificial turf that is soft yet durable.

[0036] The alloy 32 of the present disclosure allows for a softer yet durable artificial fiber 14 for turf 10 because it combines the benefits of both polyolefin 26 and polyamide 28 in a homogenous mixture, the combination of which is effectuated by binding agent 30. The softness of the alloy 32 in artificial turf 10 may be measured by using an angle measurement tool having a ruler to measure the units of gravity, wherein the less the ruler moves is an indication that the turf is softer. Another method of testing the softness of the alloy 32 in artificial turf 10 is by using an accelerometer measurement to determine how quickly it decelerates.

[0037] Another method for determining the quality and performance of fiber 14 formed from alloy 32 is the Fiber Performance Index (FPI). The FPI evaluates the fibers' characteristics, including their softness, durability, resilience, and resistance to environmental factors. A portion of the FPI evaluation is the tear test measures the cross tenacity of the fiber, which is an indicator of its durability. By applying a controlled force to the fiber until it breaks, this test quantifies the fiber's ability to withstand mechanical stress. High tenacity fibers are less likely to tear under heavy use, making them ideal for high-traffic areas. This test ensures that the fibers can endure the wear and tear associated with regular use, thereby extending the lifespan of the artificial turf. Another portion of the FPI evaluation is the recovery test that assesses the fiber's resilience after compression. In this test, the fiber is subjected to a compressive force and then allowed to recover. The degree to which the fiber returns to its original shape is measured, providing insight into its ability to maintain its structure and appearance over time. Resilient fibers contribute to the overall aesthetic and functional quality of the turf, as they resist matting and flattening, which are common issues in high-use areas. Another portion of the FPI evaluation is the UV test evaluates the fiber's resistance to ultraviolet (UV) radiation. Exposure to UV rays can degrade the polymer structure of the fibers, leading to discoloration, brittleness, and reduced performance. This test involves exposing the fibers to simulated sunlight and measuring the extent of degradation over time. Fibers with high UV resistance maintain their color and structural integrity longer, ensuring the turf remains visually appealing and functional despite prolonged exposure to sunlight. Another portion of the FPI evaluation is the feel test specifically measures the softness of the fiber, an essential factor for user comfort. This test employs a method adapted from the consumer goods industry, where tactile properties are important. By quantifying the softness, the feel test provides a standardized measure that can be used to compare different fibers. Soft fibers enhance the user experience, making the turf more comfortable for activities such as walking, playing, and lying down. In performing the FPI evaluation on fibers 14 for turf 10, the fibers should have a score ranging from 80 to 100 to ensure that fibers 14 excel in durability, resilience, UV resistance, and softness.

[0038] Turf 10 shock absorbency or impact attenuation may further be measured by determining the ‘Gmax’ of the surface. The turf 10 would have a Gmax measuring in a range of about 1 unit of gravity to 165 units of gravity. The alloy 32 further allows the artificial turf 10 to be durable. The artificial turf 10 may be denser without becoming too hard. The more artificial grass fibers 14 within tufts 12 that are in artificial turf 10 the denser the artificial turf 10 becomes and the more durable the turf may be. Alloy 32 provides the benefits of both polyolefin 26 and polyamide 28 when it is combined into a homogenous mixture as shown in FIG. 3 by alloy 32.

[0039] As mentioned previously, current instantiations of artificial turf fibers have been made from polyethylene alone, nylon alone, or a sheathed arrangement of both (i.e., the sheath formed from two disparate materials connected together but non-homogenously). There has not been success in making alloy 32 in artificial turf. The alloy 32 may be comprised of polyethylene and nylon which have not been previously homogenized in artificial turf fiber before. The present disclosure addresses the long felt need to improve artificial turf 10. The homogenous alloy is fully blended uniformly through the entirety of at least one artificial turf fiber such that there is no inner core and no outer sheath.

[0040] Having thus described one or more exemplary configurations of the artificial turf 10 with artificial grass fibers 14 formed from alloy 32, reference will be made to the method of manufacture of artificial grass fiber 14 from alloy 32 or the method of manufacturing artificial turf 10 from fibers 14 composed of alloy 32.

[0041] FIG. 4 depicts a mixing assembly 34. The mixing assembly 34 includes a first dispenser 36, a second dispenser 38, a third dispenser 40, a mixer 42, a heater 52, and a die extruder 56.

[0042] In accordance, an aspect of the present disclosure, mixing assembly 34 allows for the combination of polyolefin 26 and polyamide 28 to create a homogenous mixture for artificial turf 10 because of the presence of binding agent 30. The artificial turf 10 includes a homogenous mixture of polyolefin 26, polyamide 28, and binding agent 30 that collectively form alloy 32 and allow for the artificial turf 10 to have fewer downsides than if either of these compounds were utilized to create an artificial turf fiber. As mentioned previously, in one exemplary embodiment the polyolefin 26 is polyethylene and the polyamide 28 is nylon. One of the downsides of purely nylon turf is that the turf is hydrophilic which means they receive water and are a little stiffer while polyethylene does not receive water because it is hydrophobic, so they do not change in size, and they are a little softer. The combination of polyethylene and nylon into an alloy 32 advances artificial turf 10 to be more stable and better suited for different types of environments.

[0043] FIG. 4 depicts that the first dispenser 36 houses, stores or retains polyolefin 26 (typically in a pelletized or granular form), the second dispenser 38 houses, stores or retains polyamide 28 (typically in a pelletized or granular form), and the third dispenser 40 houses, stores or retains binding agent 30 (typically in a pelletized or granular form). Each of dispensers 36, 38, and 40 are in rheological communication with mixer 42. The rheological flow of a solid particles from the dispensers 36, 38, and 40 into mixer 42 may be accomplished through any known manner of tubing, piping, or valves. The dispensers may be in electrical communication with production control logic to meter the flow of the solid particulate matter in each respective dispenser 36, 38, and 40 into mixer 42. When the respective particulate matter in each respective dispenser 36, 38, and 40, the rheology or flow of solid particulate matter may be effectuated in any known manner, such as via pneumatics or gravitational forces.

[0044] After the particulate materials that are transferred into the mixer 42 from their respective dispensers 36, 38, and 40, the mixer 42 then holds a mixed but unhomogenized mixture 44. Unhomogenized mixture 44 contains polyolefin 26, polyamide 28, and binding agent 30 that are mixed together. An arrow 46 shows the polyolefin 26 being added to the unhomogenized mixture 44 in the mixer 42. An arrow 48 shows the polyamide 28 being added to the unhomogenized mixture 44 in the mixer 42. An arrow 50 shows the binding agent 30 being added to the unhomogenized mixture 44 in the mixer 42.

[0045] The mixer 42 is in rheological communication with the heater 42. The unhomogenized mixture 44 is transferred into the heater 52 as shown by an arrow 54. The unhomogenized mixture 44 is heated to melt the particulate matter (e.g., polyolefin 26, polyamide 28, and binding agent 30). Once the mixture is melted, it becomes homogenous, thereby creating an alloy 32 of melted material. The melted homogenous material is extruded through the die extruder 56 as shown by an arrow 58. The die extruder 56 will then extruded artificial grass fiber 14 through a die plate as shown by arrow 60. The shape and configuration of the die plate in extruder 56 may have any configuration depending on the design-specific or manufacturer-specific requirements, shapes or cross-sectional arrangements of fiber 14.

[0046] In operation, mixing assembly 34 is operated to create the alloy 32 including polyolefin 26 and polyamide 28 via binding agent 30. In one exemplary embodiment the polyolefin 26 may be added to the first dispenser 36; the polyamide 28 may be added to the second dispenser 38; and the binding agent 30 may be added to the third dispenser 40. The first dispenser 36, second dispenser 38, and third dispenser 40 may release their contents into the mixer 42 as shown by arrows 42, 44, and 46 respectively. Once polyolefin 26, polyamide 28, and binding agent 30 are in the mixer the three compounds are transferred to the heater 52 as shown by arrow 54. Inside the heater the contents will be heated to their melting point and will go through the heater 52 to the die extruder 56 as shown by arrow 58.

[0047] In one exemplary embodiment, the melting point for the polyolefin 26 may be within a range from about 100° C. to about 180° C. The melting point for the polyamide may be within a range from about 170° C. to about 270° C. Once the alloy 32 is transferred to the die extruder 56, the die extruder 56 will produce at least one artificial grass fiber 14 as shown by arrow 56. In this exemplary embodiment, the heater 52 shows a helical device to stir the unhomogenized mixture 44, but the heater 52 may have any stirring mechanism or it may have no stirring mechanism at all within the heater 52.

[0048] FIG. 4 depicts the exemplary embodiment, in which the die extruder 56 produces five artificial grass fibers 14 at one time. However, this is solely for illustrative purposes, and it is to be understood that the die extruder 56 may produce any number turf fibers 14 during extrusion. In this exemplary embodiment the pressure inside the die extruder 56 may range from 10 psi to 2,500 psi. In yet another exemplary embodiment the pressure may range from 250 psi to 1,500 psi.

[0049] FIG. 4 depicts the exemplary embodiment of the mixing assembly 34 as having three dispensers, namely first dispenser 36, second dispenser 38, and third dispenser 40, However, in another exemplary embodiment polyolefin 26, polyamide 28, and binding agent 30 may be added directly to the mixer 42. In another exemplary embodiment the polyolefin 26 and polyamide 28 may be premixed and there may only be two dispensers (i.e., a first mixer holding the polyolefin 26 and polyamide 28, and a second mixer holding the binding agent). In another exemplary embodiment the polyolefin 26 and the binding agent 30 may be premixed and there may only be two dispensers (i.e., a first mixer holding the polyolefin 26 and the binding agent 30, and a second mixer holding the polyamide 28). In yet another exemplary embodiment the polyamide 28 and the binding agent 30 may be premixed and there may only be two dispensers (i.e., a first mixer holding the polyamide 28 and the binding agent 30, and a second mixer holding the polyolefin 26).

[0050] In one or more of the exemplary embodiments, the heater 52 heats the contents of the mixed particulate material to a temperature within the range of from about 115° C. to about 265° C. In some examples, the polyolefin 26 is heated to a temperature within the range of about 115° C. to 135° C.; the polyamide 28 to a temperature within the range of about 220° C. to about 320° C.; and / or the binding agent 30 to a temperature within the range of about 50° C. to 155° C. In another exemplary embodiment there may be another dispenser to add a coloring agent to the unhomogenized mixture 44.

[0051] In yet another exemplary embodiment, the first dispenser 36, second dispenser 38, and third dispenser 40 may all be heated separately to melt the polyolefin 26, polyamide 28, and binding agent 30, respectively. In this exemplary embodiment the melted polyolefin 26, polyamide 28 and binding agent 30 could then be transferred from their disparate and individually melted states, and then into mixer 42. The pre-melted material may then be mixed in mixer 42 to create the homogenous alloy 32 and then transferred to die extruder 56 for extrusion of fiber 14.

[0052] Having thus described the exemplary aspects of methods of manufacture or methods of operation for artificial turf 10, reference will now be made to various manufacturing examples. As used herein, the term “parts by weight” or “weight percent” refers to the weight of ingredients (i.e., particulate materials) in the mixer 42 of the total unhomogenized mixture 44 prior to creating the alloy 32, regardless of whether those ingredients were stored independently in dispensers 36, 38, and 40 or pre-mixed in two or fewer dispensers. However, it is to be understood that once these materials or ingredients are homogenized, such as via melting, the homogenous alloy 32 may have the same ratios, parts by weight, or weight percent in a fully homogenous form.

[0053] Some exemplary embodiments may have, within unhomogenized mixture 44, the polyolefin 26 present within a range of approximately 10 to 65 parts by weight, the polyamide 28 present within a range of approximately 10 to 65 parts by weight, and the binding agent 30 present within a range of 0.05 to 30 parts by weight. Total parts by weight refers to the sum of the individual weights of all ingredients in the mixture 44.Example One

[0054] Example One provides, within the mixture 44, polyethylene at about 65 parts by weight (which may be transferred into mixer 42 from the first dispenser 36), nylon at about 25 parts by weight (which may be transferred into mixer 42 from the second dispenser 38), and maleic anhydride at about 10 parts by weight (which may be transferred into mixer 42 from the third dispenser 38). In this example, the particulate materials are combined and mixed together via the mixer 42.

[0055] During a period of time, such as about 1 to 5 minutes, the mixture may be subjected to a pressure in the range of about 250 psi to 1,500 psi and heated to a temperature in a range of about 115° C. to about 300° C. Heating and subjecting to pressure may occur in the same period of time, sequential periods of time, or overlapping periods of time. Heating may occur in mixer 42 or in the dispenser. Subjecting to pressure may occur in the mixer 42 or in the die extruder 56. This results in the polyethylene, nylon, and maleic anhydride becoming a homogenous and melted mixture.

[0056] The homogenous mixture that will result in homogenous alloy 32 is transferred to the die extruder. The homogenous mixture is extruded through the openings in the die plate of the die extruder 56. The extrusion of the allow results in an elongated fiber 14 that may be spooled onto a reel. The extruded fiber may be spooled or stored on a roll.

[0057] After a roll of fiber 14 is created, the roll of spooled homogenous fiber 14 may be provided to a manufacturer. The manufacturer may utilize any known turf-making machine to create the artificial turf 10 from the fibers 14 composed of alloy 32. Once the application of the fibers 14 to the backing layer 16 has been completed, the fibers may be cut to a suitable length for use as artificial turf, such as a length within a range from about 5 mm to about 150 mm.Example Two

[0058] Example Two provides, within the mixture 44, polyethylene at about 55 parts by weight (which may be transferred into mixer 42 from the first dispenser 36), nylon at about 35 parts by weight (which may be transferred into mixer 42 from second dispenser 38), and maleic anhydride at about 10 parts by weight (which may be transferred into mixer 42 from the third dispenser 40). In this example, the particulate materials are combined and mixed together via the mixer 42.

[0059] During a period of time, such as about 1 to 5 minutes, the mixture may be subjected to a pressure in the range of about 250 psi to 1,500 psi and heated to a temperature in a range of about 115° C. to 300° C. Heating and subjecting to pressure may occur in the same period of time, sequential periods of time, or overlapping periods of time. Heating may occur in mixer 42 or in the dispenser. Subjecting to pressure may occur in the mixer 42 or in the die extruder 56. This results in the polyethylene, nylon, and maleic anhydride becoming a homogenous and melted mixture.

[0060] The homogenous mixture that will result in homogenous alloy 32 is transferred to the die extruder 56. The homogenous mixture is extruded through the opening in the die plate of the die extruder. The extrusion of the alloy results in an elongated fiber that may be spooled onto a reel. The extruded fiber may be spooled or stored on a roll.

[0061] After a roll of fiber 14 is created, the roll of spooled homogenous fiber 14 may be provided to a manufacturer. The manufacturer may utilize any known turf-making machine to create the artificial turf 10 from the fibers 14 composed of alloy 32. Once the application of the fibers 14 to the backing layer 16 has been completed, the fibers may be cut to a suitable length for use as artificial turf, such as a length within a range from about 5 mm to about 150 mm.Example Three

[0062] Example Three provides, within the mixture 44, polyethylene at about 45 parts by weight (which may be transferred into mixer 42 from first dispenser 36), nylon at about 50 parts by weight (which may be transferred into mixer 42 from the second dispenser 38), and maleic anhydride at about 5 parts by weight (which may be transferred into mixer 42 from the third dispenser 40). In this example, the particulate materials are combined and mixed together via the mixer 42.

[0063] During a period of time, such as about 1 to 5 minutes the mixture may be subjected to a pressure in the range of about 250 psi to 1,500 psi and heated to a temperature in a range of about 115° C. to 300° C. Heating and subjecting to pressure may occur in the same period of time, sequential periods of time, or overlapping periods of time. Heating may occur in mixer 42 or in the dispenser. Subjecting to pressure may occur in the mixer 42 or in the die extruder 56. This results in the polyethylene, nylon, and maleic anhydride becoming a homogenous and melted mixture.

[0064] The homogenous mixture that will result in homogenous alloy 32 is transferred to the die extruder 56. The homogenous mixture is extruded through the opening in the die plate of the die extruder. The extrusion of the alloy results in an elongated fiber that may be spooled onto a reel. The extruded fiber may be spooled or stored on a roll.

[0065] After a roll of fiber 14 is created, the roll of spooled homogenous fiber 14 may be provided to a manufacturer. The manufacturer may utilize any known turf-making machine to create the artificial turf 10 from the fibers 14 composed of alloy 32. Once the application of the fibers 14 to the backing layer 16 has been completed, the fibers may be cut to a suitable length for use as artificial turf, such as a length within a range from about 5 mm to about 150 mm.Example Four

[0066] Example Four provides, within the mixture 44, polyethylene at about 30 parts by weight (which may be transferred into mixer 42 from first dispenser 36), nylon at about 60 parts by weight (which may be transferred into mixer 42 from the second dispenser 38), and maleic anhydride at about 10 parts by weight (which may be transferred into mixer 42 from the third dispenser 40). In this example, the particulate materials are combined and mixed together via the mixer 42.

[0067] During a period of time, such as about 1 to 5 minutes the mixture may be subjected to a pressure in the range of about 250 psi to 1,500 psi and heated to a temperature in a range of about 115° C. to 300° C. Heating and subjecting to pressure may occur in the same period of time, sequential periods of time, or overlapping periods of time. Heating may occur in mixer 42 or in the dispenser. Subjecting to pressure may occur in the mixer 42 or in the die extruder 56. This results in the polyethylene, nylon, and maleic anhydride becoming a homogenous and melted mixture.

[0068] The homogenous mixture that will result in homogenous alloy 32 is transferred to the die extruder 56. The homogenous mixture is extruded through the opening in the die plate of the die extruder 56. The extrusion of the alloy results in an elongated fiber that may be spooled onto a reel. The extruded fiber may be spooled or stored on a roll.

[0069] After a roll of fiber 14 is created, the roll of spooled homogenous fiber 14 may be provided to a manufacturer. The manufacturer may utilize any known turf-making machine to create the artificial turf 10 from the fibers 14 composed of alloy 32. Once the application of the fibers 14 to the backing layer 16 has been completed, the fibers may be cut to a suitable length for use as artificial turf, such as a length within a range from about 5 mm to about 150 mm.Example Five

[0070] Example Five provides, within the mixture 44, polyethylene at about 45 parts by weight (which may be transferred into mixer 42 from the first dispenser 36), nylon at about 45 parts by weight (which may be transferred into mixer 42 from the second dispenser 38), and maleic anhydride at about 10 parts by weight (which may be transferred into mixer 42 from the third dispenser 40). In this example, the particulate materials are combined and mixed together via the mixer 42.

[0071] During a period of time, such as about 1 to 5 minutes the mixture may be subjected to a pressure in the range of about 250 psi to 1,500 psi and heated to a temperature in a range of about 115° C. to 300° C. Heating and subjecting to pressure may occur in the same period of time, sequential periods of time, or overlapping periods of time. Heating may occur in mixer 42 or in the dispenser. Subjecting to pressure may occur in the mixer 42 or in the die extruder 56. This results in the polyethylene, nylon, and maleic anhydride becoming a homogenous and melted mixture.

[0072] The homogenous mixture that will result in homogenous alloy 32 is transferred to the die extruder 56. The homogenous mixture is extruded through the opening in the die plate of the die extruder 56. The extrusion of the alloy results in an elongated fiber that may be spooled onto a reel. The extruded fiber may be spooled or stored on a roll.

[0073] After a roll of fiber 14 is created, the roll of spooled homogenous fiber 14 may be provided to a manufacturer. The manufacturer may utilize any known turf-making machine to create the artificial turf 10 from the fibers 14 composed of alloy 32. Once the application of the fibers 14 to the backing layer 16 has been completed, the fibers may be cut to a suitable length for use as artificial turf, such as a length within a range from about 5 mm to about 150 mm.Example Six

[0074] Example Six provides, within the mixture 44, polyethylene at about 50 parts by weight (which may be transferred into mixer 42 from the first dispenser 36), nylon at about 49 parts by weight (which may be transferred into mixer 42 from the second dispenser 38), and maleic anhydride at about 1 part by weight (which may be transferred into mixer 42 from the third dispenser 40). In this example, the particulate materials are combined and mixed together via the mixer 42.

[0075] During a period of time, such as about 1 to 5 minutes, the mixture may be subjected to a pressure in the range of about 250 psi to 1,500 psi and heated to a temperature in a range of about 115° C. to 300° C. Heating and subjecting to pressure may occur in the same period of time, sequential periods of time, or overlapping periods of time. Heating may occur in mixer 42 or in the dispenser. Subjecting to pressure may occur in the mixer 42 or in the die extruder 56. This results in the polyethylene, nylon, and maleic anhydride becoming a homogenous and melted mixture.

[0076] The homogenous mixture that will result in homogenous alloy 32 is transferred to the die extruder 56. The homogenous mixture is extruded through the opening in the die plate of the die extruder 56. The extrusion of the alloy results in an elongated fiber that may be spooled onto a reel. The extruded fiber may be spooled or stored on a roll.

[0077] After a roll of fiber 14 is created, the roll of spooled homogenous fiber 14 may be provided to a manufacturer. The manufacturer may utilize any known turf-making machine to create the artificial turf 10 from the fibers 14 composed of alloy 32. Once the application of the fibers 14 to the backing layer 16 has been completed, the fibers may be cut to a suitable length for use as artificial turf, such as a length within a range from about 5 mm to about 150 mm.Example Seven

[0078] Example Seven provides, within the mixture 44, polyethylene at about 60 parts by weight and maleic anhydride at about 10 parts by weight (which may be transferred into mixer 42 from the first dispenser 36) and nylon at about 30 parts by weight (which may be transferred to mixer 42 from the second dispenser 38). Example Two includes a coloring agent (which may be transferred into mixer 42 from the third dispenser 40). In this example, the particulate materials are combined and mixed together via the mixer 42.

[0079] During a period of time, such as about 1 to 5 minutes, the mixture may be subjected to a pressure in the range of about 250 psi to 1,500 psi and heated to a temperature in a range of about 115° C. to 300° C. Heating and subjecting to pressure may occur in the same period of time, sequential periods of time, or overlapping periods of time. Heating may occur in mixer 42 or in the dispenser. Subjecting to pressure may occur in the mixer 42 or in the die extruder 56. This results in the polyethylene, nylon, maleic anhydride, and coloring agent becoming a homogenous and melted mixture.

[0080] The homogenous mixture that will result in homogenous alloy 32 is transferred to the die extruder 56. The homogenous mixture is extruded through the opening in the die plate of the die extruder 56. The extrusion of the alloy results in an elongated fiber that may be spooled onto a reel. The extruded fiber may be spooled or stored on a roll.

[0081] After a roll of fiber 14 is created, the roll of spooled homogenous fiber 14 may be provided to a manufacturer. The manufacturer may utilize any known turf-making machine to create the artificial turf 10 from the fibers 14 composed of alloy 32. Once the application of the fibers 14 to the backing layer 16 has been completed, the fibers may be cut to a suitable length for use as artificial turf, such as a length within a range from about 5 mm to about 150 mm.Example Eight

[0082] Example Eight provides, within the mixture 44, polyethylene at about 65 parts by weight and a star like high propylene at about 10 parts by weight (which may be transferred into mixer 42 from the first dispenser 36) and nylon at about 25 parts per weight (which may be transferred into mixer 42 from the second dispenser 38). In this example, the particulate materials are combined and mixed via the mixer 42.

[0083] During a period of time, such as about 1 to 5 minutes, the mixture may be subjected to a pressure in the range of about 250 psi to 1,500 psi and heated to a temperature in a range of about 115° C. to 300° C. Heating and subjecting to pressure may occur in the same period of time, sequential periods of time, or overlapping periods of time. Heating may occur in mixer 42 or in the dispenser. Subjecting to pressure may occur in the mixer 42 or in the die extruder 56. This results in the polyethylene, nylon, and star like high polypropylene becoming a homogenous and melted mixture.

[0084] The homogenous mixture that will result in homogenous alloy 32 is transferred to the die extruder 56. The homogenous mixture is extruded through the opening in the die plate of the die extruder. The extrusion of the alloy results in an elongated fiber that may be spooled onto a reel. The extruded fiber may be spooled or stored on a roll.

[0085] After a roll of fiber 14 is created, the roll of spooled homogenous fiber 14 may be provided to a manufacturer. The manufacturer may utilize any known turf-making machine to create the artificial turf 10 from the fibers 14 composed of alloy 32. Once the application of the fibers 14 to the backing layer 16 has been completed, the fibers may be cut to a suitable length for use as artificial turf, such as a length within a range from about 5 mm to about 150 mm.Example Nine

[0086] Example Nine provides, within the mixture 44, polyethylene at about 65 parts by weight and Bondyram Grade 1001 at about 10 parts per weight (which may be transferred into mixer 42 from the first dispenser 36) and nylon at about 25 parts by weight (which may be transferred into mixer 42 from second dispenser 38). In this example, the particulate materials are combined and mixed together via the mixer 42.

[0087] During a period of time, such as about 1 to 5 minutes, the mixture may be subjected to a pressure in the range of about 250 psi to 1,500 psi. The polyethylene and Bondyram Grade 1001 are heated to a temperature in a range of about 115° C. to 135° C. The melted polyethylene and Bondyram Grade 1001 are added to mixer 42. The nylon is heated to a temperature in the range of about 220° C. to 300° C. and is added to mixer 42. Heating and subjecting to pressure may occur in the same period of time, sequential periods of time, or overlapping periods of time. Heating may occur in mixer 42 or in the dispenser. Subjecting to pressure may occur in the mixer 42 or in the die extruder 56. This results in the melted polyethylene, nylon, and Bondyram Grade 1001 becoming a homogenous and melted mixture.

[0088] The homogenous mixture that will result in homogenous alloy 32 is transferred to the die extruder 56. The homogenous mixture is extruded through the opening in the die plate of the die extruder 56. The extrusion of the alloy results in an elongated fiber 14 that may be spooled onto a reel. The extruded fiber 14 may be spooled or stored on a roll.

[0089] After a roll of fiber 14 is created, the roll of spooled homogenous fiber 14 may be provided to a manufacturer. The manufacturer may utilize any known turf-making machine to create the artificial turf 10 from the fibers 14 composed of alloy 32. Once the application of the fibers 14 to the backing layer 16 has been completed, the fibers may be cut to a suitable length for use as artificial turf, such as a length within a range from about 5 mm to about 150 mm.Example Ten

[0090] Example Ten, provides within the mixture 44, polyethylene at about 65 parts by weight and Bondyram Grade 1010 at about 10 parts per weight (which may be transferred into mixer 42 from the first dispenser 36) and nylon at about 25 parts by weight (which may be transferred into mixer 42 from the second dispenser 38). In this example, the particulate materials are combined and mixed together via the mixer 42.

[0091] During a period of time, such as about 1 to 5 minutes, the mixture may be subjected to a pressure in the range of about 250 psi to 1,500 psi. The polyethylene and Bondyram Grade 1010 are heated to a temperature in a range of about 115° C. to 135° C. The melted polyethylene and Bondyram Grade 1010 are added to mixer 42. The nylon is heated to a temperature in the range of about 220° C. to 300° C. and is added to mixer 42. Heating and subjecting to pressure may occur in the same period of time, sequential periods of time, or overlapping periods of time. Heating may occur in mixer 42 or in the dispenser. Subjecting to pressure may occur in the mixer 42 or in the die extruder 56. This results in the melted polyethylene, nylon, and Bondyram Grade 1010 becoming a homogenous and melted mixture.

[0092] The homogenous mixture that will result in homogenous alloy 32 is transferred to the die extruder 56. The homogenous mixture is extruded through the opening in the die plate of the die extruder 56. The extrusion of the alloy results in an elongated fiber 14 that may be spooled onto a reel. The extruded fiber may be spooled or stored on a roll.

[0093] After a roll of fiber 14 is created, the roll of spooled homogenous fiber 14 may be provided to a manufacturer. The manufacturer may utilize any known turf-making machine to create the artificial turf 10 from the fibers 14 composed of alloy 32. Once the application of the fibers 14 to the backing layer 16 has been completed, the fibers may be cut to a suitable length for use as artificial turf, such as a length within a range from about 5 mm to about 150 mm.Example Eleven

[0094] Example Eleven provides, polyethylene at about 65 parts by weight and Bondyram Grade 1101 at about 5 parts per weight (which may be transferred into mixer 42 from the first dispenser 36) and nylon at about 30 parts by weight (which may be transferred into mixer 42 from the second dispenser 38). In this example, the particulate materials are combined and mixed together via the mixer 42.

[0095] During a period of time, such as about 1 to 5 minutes, the mixture may be subjected to a pressure in the range of about 250 psi to 1,500 psi the polyethylene and Bondyram Grade 1101 are heated to a temperature in a range of about 115° C. to 135° C. The melted polyethylene and Bondyram Grade 1101 are added to mixer 42. The nylon is heated to a temperature in the range of about 220° C. to 300° C. and is added to mixer 42. Heating and subjecting to pressure may occur in the same period of time, sequential periods of time, or overlapping periods of time. Heating may occur in mixer 42 or in the dispenser. Subjecting to pressure may occur in the mixer 42 or in the die extruder 56. This results in the melted polyethylene, nylon, and Bondyram Grade 1101 becoming a homogenous and melted mixture.

[0096] The homogenous mixture that will result in homogenous alloy 32 is transferred to the die extruder 56. The homogenous mixture is extruded through the opening in the die plate of the die extruder 56. The extrusion of the alloy results in an elongated fiber 14 that may be spooled onto a reel. The extruded fiber may be spooled or stored on a roll.

[0097] After a roll of fiber 14 is created, the roll of spooled homogenous fiber 14 may be provided to a manufacturer. The manufacturer may utilize any known turf-making machine to create the artificial turf 10 from the fibers 14 composed of alloy 32. Once the application of the fibers 14 to the backing layer 16 has been completed, the fibers may be cut to a suitable length for use as artificial turf, such as a length within a range from about 5 mm to about 150 mm.Example Twelve

[0098] Example Twelve provides, within the mixture 44, polyethylene at about 60 parts by weight and Bondyram Grade 1001CN at about 10 parts per weight (which may be transferred into mixer 42 from first dispenser 36) and nylon at about 30 parts by weight (which may be transferred into mixer 42 from the second dispenser 38). In this example. The particulate materials are combined and mixed together via the mixer 42.

[0099] During a period of time, such as about 1 to 5 minutes, the mixture may be subjected to a pressure in the range of about 250 psi to 1,500 psi. The polyethylene and Bondyram Grade 1001CN are heated to a temperature in a range of about 115° C. to 135° C. The melted polyethylene and Bondyram Grade 1001CN are added to mixer 42. The nylon is heated to a temperature in the range of about 220° C. to 300° C. and is added to mixer 42. Heating and subjecting to pressure may occur in the same period of time, sequential periods of time, or overlapping periods of time. Heating may occur in mixer 42 or in the dispenser. Subjecting to pressure may occur in the mixer 42 or in the die extruder 56. This results in the melted polyethylene, nylon, and Bondyram Grade 1001CN becoming a homogenous and melted mixture.

[0100] The homogenous mixture that will result in homogenous alloy 32 is transferred to the die extruder 56. The homogenous mixture is extruded through the opening in the die plate of the die extruder 56. The extrusion of the alloy results in an elongated fiber 14 that may be spooled onto a reel. The extruded fiber may be spooled or stored on a roll.

[0101] After a roll of fiber 14 is created, the roll of spooled homogenous fiber 14 may be provided to a manufacturer. The manufacturer may utilize any known turf-making machine to create the artificial turf 10 from the fibers 14 composed of alloy 32. Once the application of the fibers 14 to the backing layer 16 has been completed, the fibers may be cut to a suitable length for use as artificial turf, such as a length within a range from about 5 mm to about 150 mm.Example Thirteen

[0102] Example Thirteen provides, within the mixture 44, polyethylene at about 65 parts by weight and Bondyram Grade 1001LE at about 10 parts per weight (which may be transferred into mixer 42 from the first dispenser 36) and nylon at about 25 parts by weight (which may be transferred into mixer 42 from the second dispenser 38). In this example, the particulate materials are combined and mixed together via the mixer 42.

[0103] During a period of time, such as about 1 to 5 minutes, the mixture may be subjected to a pressure in the range of about 250 psi to 1,500 psi the polyethylene and Bondyram Grade 1001LE are heated to a temperature in a range of about 115° C. to 135° C. The melted polyethylene and Bondyram Grade 1001LE are added to mixer 42. The nylon is heated to a temperature in the range of about 220° C. to 300° C. and is added to mixer 42. Heating and subjecting to pressure may occur in the same period of time, sequential periods of time, or overlapping periods of time. Heating may occur in mixer 42 or in the dispenser. Subjecting to pressure may occur in the mixer 42 or in the die extruder 56. This results in the melted polyethylene, nylon, and Bondyram Grade 1001LE becoming a homogenous and melted mixture.

[0104] The homogenous mixture that will result in homogenous alloy 32 is transferred to the die extruder 56. The homogenous mixture is extruded through the opening in the die plate of the die extruder 56. The extrusion of the alloy results in an elongated fiber 14 that may be spooled onto a reel. The extruded fiber may be spooled or stored on a roll.

[0105] After a roll of fiber 14 is created, the roll of spooled homogenous fiber 14 may be provided to a manufacturer. The manufacturer may utilize any known turf-making machine to create the artificial turf 10 from the fibers 14 composed of alloy 32. Once the application of the fibers 14 to the backing layer 16 has been completed, the fibers may be cut to a suitable length for use as artificial turf, such as a length within a range from about 5 mm to about 150 mm.Example Fourteen

[0106] Example Fourteen provides, within the mixture 44, polyethylene at about 60 parts by weight and Bondyram Grade 1001MP at about 10 parts per weight (which may be transferred into mixer 42 from the first dispenser 36) and nylon at about 30 parts by weight (which may be transferred into mixer 42 from the second dispenser 38). In this example, the particulate materials are combined and mixed together via the mixer 42.

[0107] During a period of time, such as about 1 to 5 minutes, the mixture may be subjected to a pressure in the range of about 250 psi to 1,500 psi. The polyethylene and Bondyram Grade 1001MP are heated to a temperature in a range of about 115° C. to 135° C. The melted polyethylene and Bondyram Grade 1001MP are added to mixer 42. The nylon is heated to a temperature in the range of about 220° C. to 300° C. and is added to mixer 42. Heating and subjecting to pressure may occur in the same period of time, sequential periods of time, or overlapping periods of time. Heating may occur in mixer 42 or in the dispenser. Subjecting to pressure may occur in the mixer 42 or in the die extruder 56. This results in the melted polyethylene, nylon, and Bondyram Grade 1001MP becoming a homogenous and melted mixture.

[0108] The homogenous mixture that will result in homogenous alloy 32 is transferred to the die extruder 56. The homogenous mixture is extruded through the opening in the die plate of the die extruder 56. The extrusion of the alloy results in an elongated fiber that may be spooled onto a reel. The extruded fiber may be spooled or stored on a roll.

[0109] After a roll of fiber 14 is created, the roll of spooled homogenous fiber 14 may be provided to a manufacturer. The manufacturer may utilize any known turf-making machine to create the artificial turf 10 from the fibers 14 composed of alloy 32. Once the application of the fibers 14 to the backing layer 16 has been completed, the fibers may be cut to a suitable length for use as artificial turf, such as a length within a range from about 5 mm to about 150 mm.Example Fifteen

[0110] Example Fifteen provides, within the mixture 44, polyethylene at about 55 parts by weight and Bondyram Grade 1201 at about 10 parts per weight (which may be transferred into mixer 42 from the first dispenser 36) and nylon at about 35 parts by weight (which may be transferred into mixer 42 from the second dispenser 38). In this example, the particulate materials are combined and mixed together via the mixer 42.

[0111] During a period of time, such as about 1 to 5 minutes, the mixture may be subjected to a pressure in the range of about 250 psi to 1,500 psi. The polyethylene and Bondyram Grade 1201 are heated to a temperature in a range of about 115° C. to 135° C. The melted polyethylene and Bondyram Grade 1201 are added to mixer 42. The nylon is heated to a temperature in the range of about 220° C. to 300° C. and is added to mixer 42. Heating and subjecting to pressure may occur in the same period of time, sequential periods of time, or overlapping periods of time. Heating may occur in mixer 42 or in the dispenser. Subjecting to pressure may occur in the mixer 42 or in the die extruder 56. This results in the melted polyethylene, nylon, and Bondyram Grade 1201 becoming a homogenous and melted mixture.

[0112] The homogenous mixture that will result in homogenous alloy 32 is transferred to the die extruder 56. The homogenous mixture is extruded through the opening in the die plate of the die extruder 56. The extrusion of the alloy results in an elongated fiber 14 that may be spooled onto a reel. The extruded fiber may be spooled or stored on a roll.

[0113] After a roll of fiber 14 is created, the roll of spooled homogenous fiber 14 may be provided to a manufacturer. The manufacturer may utilize any known turf-making machine to create the artificial turf 10 from the fibers 14 composed of alloy 32. Once the application of the fibers 14 to the backing layer 16 has been completed, the fibers may be cut to a suitable length for use as artificial turf, such as a length within a range from about 5 mm to about 150 mm.Example Sixteen

[0114] Example Sixteen provides, within the mixture 44, polyethylene at about 60 parts by weight and Bondyram Grade 2102 at about 5 parts per weight (which may be transferred into mixer 42 from first dispenser 36) and nylon at about 35 parts by weight (which may be transferred into mixer 42 from the second dispenser 38). In this example, the particulate materials are combined and mixed together via the mixer 42.

[0115] During a period of time, such as about 1 to 5 minutes, the mixture may be subjected to a pressure in the range of about 250 psi to 1,500 psi. The polyethylene and Bondyram Grade 2102 are heated to a temperature in a range of about 115° C. to 135° C. The melted polyethylene and Bondyram Grade 2102 are added to mixer 42. The nylon is heated to a temperature in the range of about 220° C. to 300° C. and is added to mixer 42. Heating and subjecting to pressure may occur in the same period of time, sequential periods of time, or overlapping periods of time. Heating may occur in mixer 42 or in the dispenser. Subjecting to pressure may occur in the mixer 42 or in the die extruder 56. This results in the melted polyethylene, nylon, and Bondyram Grade 2102 becoming a homogenous and melted mixture.

[0116] The homogenous mixture that will result in homogenous alloy 32 is transferred to the die extruder 56. The homogenous mixture is extruded through the opening in the die plate of the die extruder 56. The extrusion of the alloy results in an elongated fiber that may be spooled onto a reel. The extruded fiber may be spooled or stored on a roll.

[0117] After a roll of fiber 14 is created, the roll of spooled homogenous fiber 14 may be provided to a manufacturer. The manufacturer may utilize any known turf-making machine to create the artificial turf 10 from the fibers 14 composed of alloy 32. Once the application of the fibers 14 to the backing layer 16 has been completed, the fibers may be cut to a suitable length for use as artificial turf, such as a length within a range from about 5 mm to about 150 mm.Example Seventeen

[0118] Example Seventeen provides, within the mixture 44, polyethylene at about 60 parts by weight and Bondyram Grade 2103 at about 10 parts per weight (which may be transferred into mixer 42 from the first dispenser 36) and nylon at about 30 parts by weight (which may be transferred into mixer 42 from second dispenser 38). In this example, the particulate materials are combined and mixed together via the mixer 42.

[0119] During a period of time, such as about 1 to 5 minutes, the mixture may be subjected to a pressure in the range of about 250 psi to 1,500 psi. The polyethylene and Bondyram Grade 2103 are heated to a temperature in a range of about 115° C. to 135° C. The melted polyethylene and Bondyram Grade 2103 are added to mixer 42. The nylon is heated to a temperature in the range of about 220° C. to 300° C. and is added to mixer 42. Heating and subjecting to pressure may occur in the same period of time, sequential periods of time, or overlapping periods of time. Heating may occur in mixer 42 or in the dispenser. Subjecting to pressure may occur in the mixer 42 or in the die extruder 56. This results in the melted polyethylene, nylon, and Bondyram Grade 2103 becoming a homogenous and melted mixture.

[0120] The homogenous mixture that will result in homogenous alloy 32 is transferred to the die extruder 56. The homogenous mixture is extruded through the opening in the die plate of the die extruder 56. The extrusion of the alloy results in an elongated fiber that may be spooled onto a reel. The extruded fiber may be spooled or stored on a roll.

[0121] After a roll of fiber 14 is created, the roll of spooled homogenous fiber 14 may be provided to a manufacturer. The manufacturer may utilize any known turf-making machine to create the artificial turf 10 from the fibers 14 composed of alloy 32. Once the application of the fibers 14 to the backing layer 16 has been completed, the fibers may be cut to a suitable length for use as artificial turf, such as a length within a range from about 5 mm to about 150 mm.Example Eighteen

[0122] Example Eighteen provides, within the mixture 44, polyethylene at about 55 parts by weight and Bondyram Grade 7003 at about 10 parts per weight (which may be transferred to mixer 42 from the first dispenser 36) and nylon at about 35 parts by weight (which may be transferred to mixer 42 from second dispenser 38). In this example, the particulate materials are combined and mixed together via the mixer 42.

[0123] During a period of time, such as about 1 to 5 minutes, the mixture may be subjected to a pressure in the range of about 250 psi to 1,500 psi. The polyethylene and Bondyram Grade 7003 are heated to a temperature in a range of about 115° C. to 135° C. The melted polyethylene and Bondyram Grade 7003 are added to mixer 42. The nylon is heated to a temperature in the range of about 220° C. to 300° C. and is added to mixer 42. Heating and subjecting to pressure may occur in the same period of time, sequential periods of time, or overlapping periods of time. Heating may occur in mixer 42 or in the dispenser. Subjecting to pressure may occur in the mixer 42 or in the die extruder 56. This results in the melted polyethylene, nylon, and Bondyram Grade 7003 becoming a homogenous and melted mixture.

[0124] The homogenous mixture that will result in homogenous alloy 32 is transferred to the die extruder 56. The homogenous mixture is extruded through the opening in the die plate of the die extruder 56. The extrusion of the alloy results in an elongated fiber that may be spooled onto a reel. The extruded fiber may be spooled or stored on a roll.

[0125] After a roll of fiber 14 is created, the roll of spooled homogenous fiber 14 may be provided to a manufacturer. The manufacturer may utilize any known turf-making machine to create the artificial turf 10 from the fibers 14 composed of alloy 32. Once the application of the fibers 14 to the backing layer 16 has been completed, the fibers may be cut to a suitable length for use as artificial turf, such as a length within a range from about 5 mm to about 150 mm.Example Nineteen

[0126] Example Nineteen provides, within the mixture 44, polyethylene at about 60 parts by weight and Bondyram Grade 7103 at about 5 parts per weight (which may be transferred into mixer 42 from first dispenser 36) and nylon at about 35 parts by weight (which may be transferred into mixer 42 from second dispenser 38). In this example, the particulate materials are combined and mixed together via the mixer 42.

[0127] During a period of time, such as about 1 to 5 minutes, the mixture may be subjected to a pressure in the range of about 250 psi to 1,500 psi. The polyethylene and Bondyram Grade 7103 are heated to a temperature in a range of about 115° C. to 135° C. The melted polyethylene and Bondyram Grade 7103 are added to mixer 42. The nylon is heated to a temperature in the range of about 220° C. to 300° C. and is added to mixer 42. Heating and subjecting to pressure may occur in the same period of time, sequential periods of time, or overlapping periods of time. Heating may occur in mixer 42 or in the dispenser. Subjecting to pressure may occur in the mixer 42 or in the die extruder 56. This results in the melted polyethylene, nylon, and Bondyram Grade 7103 becoming a homogenous and melted mixture.

[0128] The homogenous mixture that will result in homogenous alloy 32 is transferred to the die extruder 56. The homogenous mixture is extruded through the opening in the die plate of the die extruder 56. The extrusion of the alloy results in an elongated fiber that may be spooled onto a reel. The extruded fiber may be spooled or stored on a roll.

[0129] After a roll of fiber 14 is created, the roll of spooled homogenous fiber 14 may be provided to a manufacturer. The manufacturer may utilize any known turf-making machine to create the artificial turf 10 from the fibers 14 composed of alloy 32. Once the application of the fibers 14 to the backing layer 16 has been completed, the fibers may be cut to a suitable length for use as artificial turf, such as a length within a range from about 5 mm to about 150 mm.Example Twenty

[0130] Example Fifteen utilizes polyethylene at about 65 parts by weight and Bondyram Grade 7107 at about 5 parts per weight (which may be transferred into mixer 42 from first dispenser 36) and nylon at about 30 parts by weight (which may be transferred into mixer 42 from second dispenser 38). In this example, the particulate materials are combined and mixed together via the mixer 42.

[0131] During a period of time, such as about 1 to 5 minutes, the mixture may be subjected to a pressure in the range of about 250 psi to 1,500 psi. The polyethylene and Bondyram Grade 7107 are heated to a temperature in a range of about 115° C. to 135° C. The melted polyethylene and Bondyram Grade 7107 are added to mixer 42. The nylon is heated to a temperature in the range of about 220° C. to 300° C. and is added to mixer 42. Heating and subjecting to pressure may occur in the same period of time, sequential periods of time, or overlapping periods of time. Heating may occur in mixer 42 or in the dispenser. Subjecting to pressure may occur in the mixer 42 or in the die extruder 56. This results in the melted polyethylene, nylon, and Bondyram Grade 7107 becoming a homogenous and melted mixture.

[0132] The homogenous mixture that will result in homogenous alloy 32 is transferred to the die extruder 56. The homogenous mixture is extruded through the opening in the die plate of the die extruder. The extrusion of the alloy results in an elongated fiber that may be spooled onto a reel. The extruded fiber may be spooled or stored on a roll.

[0133] After a roll of fiber 14 is created, the roll of spooled homogenous fiber 14 may be provided to a manufacturer. The manufacturer may utilize any known turf-making machine to create the artificial turf 10 from the fibers 14 composed of alloy 32. Once the application of the fibers 14 to the backing layer 16 has been completed, the fibers may be cut to a suitable length for use as artificial turf, such as a length within a range from about 5 mm to about 150 mm.Example Twenty-One

[0134] Example Twenty-one provides, within the mixture 44, polyethylene at about 60 parts by weight and Bondyram Grade 7108 at about 10 parts per weight (which may be transferred into mixer 42 from the first dispenser 36) and nylon at about 30 parts by weight (which may be transferred into mixer 42 from second dispenser 38). In this example, the particulate materials are combined and mixed together via the mixer 42.

[0135] During a period of time, such as about 1 to 5 minutes, the mixture may be subjected to a pressure in the range of about 250 psi to 1,500 psi. The polyethylene and Bondyram Grade 7108 are heated to a temperature in a range of about 115° C. to 135° C. The melted polyethylene and Bondyram Grade 7108 are added to mixer 42. The nylon is heated to a temperature in the range of about 220° C. to 265° C. and is added to mixer 42. Heating and subjecting to pressure may occur in the same period of time, sequential periods of time, or overlapping periods of time. Heating may occur in mixer 42 or in the dispenser. Subjecting to pressure may occur in the mixer 42 or in the die extruder 56. This results in the melted polyethylene, nylon, and Bondyram Grade 7108 becoming a homogenous and melted mixture.

[0136] The homogenous mixture that will result in homogenous alloy 32 is transferred to the die extruder 56. The homogenous mixture is extruded through the opening in the die plate of the die extruder. The extrusion of the alloy results in an elongated fiber that may be spooled onto a reel. The extruded fiber may be spooled or stored on a roll.

[0137] After a roll of fiber 14 is created, the roll of spooled homogenous fiber 14 may be provided to a manufacturer. The manufacturer may utilize any known turf-making machine to create the artificial turf 10 from the fibers 14 composed of alloy 32. Once the application of the fibers 14 to the backing layer 16 has been completed, the fibers may be cut to a suitable length for use as artificial turf, such as a length within a range from about 5 mm to about 150 mm.Example Twenty-Two

[0138] Example Twenty-two provides, within the mixture 44, polyethylene at about 60 parts by weight and Bondyram Grade 7109 at about 10 parts per weight (which may be transferred into mixer 42 from first dispenser 36) and nylon at about 30 parts by weight (which may be transferred into mixer 42 from second dispenser 38). In this example, the particulate materials are combined and mixed together via the mixer 42.

[0139] During a period of time, such as about 1 to 5 minutes, the mixture may be subjected to a pressure in the range of about 250 psi to 1,500 psi. The polyethylene and Bondyram Grade 7109 are heated to a temperature in a range of about 115° C. to 135° C. The melted polyethylene and Bondyram Grade 7109 are added to mixer 42. The nylon is heated to a temperature in the range of about 220° C. to 300° C. and is added to mixer 42. Heating and subjecting to pressure may occur in the same period of time, sequential periods of time, or overlapping periods of time. Heating may occur in mixer 42 or in the dispenser. Subjecting to pressure may occur in the mixer 42 or in the die extruder 56. This results in the melted polyethylene, nylon, and Bondyram Grade 7109 becoming a homogenous and melted mixture.

[0140] The homogenous mixture that will result in homogenous alloy 32 is transferred to the die extruder 56. The homogenous mixture is extruded through the opening in the die plate of the die extruder 56. The extrusion of the alloy results in an elongated fiber 14 that may be spooled onto a reel. The extruded fiber may be spooled or stored on a roll.

[0141] After a roll of fiber 14 is created, the roll of spooled homogenous fiber 14 may be provided to a manufacturer. The manufacturer may utilize any known turf-making machine to create the artificial turf 10 from the fibers 14 composed of alloy 32. Once the application of the fibers 14 to the backing layer 16 has been completed, the fibers may be cut to a suitable length for use as artificial turf, such as a length within a range from about 5 mm to about 150 mm.Example Twenty-Three

[0142] Example Twenty-three provides, within the mixture 44, polyethylene at about 60 parts by weight and Bondyram Grade 7105 at about 10 parts per weight (which may be transferred into mixer 42 from first dispenser 36) and nylon at about 30 parts by weight (which may be transferred into mixer 42 from second dispenser 38). In this example, the particulate materials are combined and mixed together via the mixer 42.

[0143] During a period of time, such as about 1 to 5 minutes, the mixture may be subjected to a pressure in the range of about 250 psi to 1,500 psi. The polyethylene and Bondyram Grade 7105 are heated to a temperature in a range of about 115° C. to 135° C. the melted polyethylene and Bondyram Grade 7105 are added to mixer 42. The nylon is heated to a temperature in the range of about 220° C. to 265° C. and is added to mixer 42. Heating and subjecting to pressure may occur in the same period of time, sequential periods of time, or overlapping periods of time. Heating may occur in mixer 42 or in the dispenser. Subjecting to pressure may occur in the mixer 42 or in the die extruder 56. This results in the melted polyethylene, nylon, and Bondyram Grade 7105 becoming a homogenous and melted mixture.

[0144] The homogenous mixture that will result in homogenous alloy 32 is transferred to the die extruder 56. The homogenous mixture is extruded through the opening in the die plate of the die extruder 56. The extrusion of the alloy results in an elongated fiber 14 that may be spooled onto a reel. The extruded fiber may be spooled or stored on a roll.

[0145] After a roll of fiber 14 is created, the roll of spooled homogenous fiber 14 may be provided to a manufacturer. The manufacturer may utilize any known turf-making machine to create the artificial turf 10 from the fibers 14 composed of alloy 32. Once the application of the fibers 14 to the backing layer 16 has been completed, the fibers may be cut to a suitable length for use as artificial turf, such as a length within a range from about 5 mm to about 150 mm.Examples Twenty-Four Through One Hundred One

[0146] Examples twenty-four (24) through one hundred one (101) correspond with Table 1 provide below and follow similar fabrication techniques of the previous examples but highlight the exemplary part-by-weight ratios of Polyolefin 26, Polyamide 28, and the binding agent 30 that are possible to fabricate fiber 14.TABLE 1Parts By in Mixture 44ExamplePolyolefinPolyamideBindingNumber2628agent 30241065252510603026156520271560252815553029206515302060203120552532205030332565103425601535255520362550253725453038306553930601040305515413050204230452543304030443564145356324635605473555104835501549354520503540255135353052405915340582544055555405010564045155740402058403525594030306045541614553262455056345451064454015654535206645302567452530685049169504827050455715040107250351573503020745035257550302076502525775020307855441795543280554058155351082553015835525208455202585551530866039187603828860355896030109060251591602020926015259360103094653419565332966530597652510986520159965152010065102510165530

[0147] The parts by weight ratios from Examples 24-101 can be used to create the mixture 44 containing at least the Polyolefin 26, Polyamide 28, and the binding agent 30, but the mixture may include other components as well. If other components are added then the parts by weight ratios of the Polyolefin 26, Polyamide 28, and the binding agent 30 would decrease relative to the balance of the mixture 44. The mixture 44 may be heated for a period of time and then subjected to pressure, which may occur in the mixer 42 or in the die extruder 56. Heating and subjecting to pressure may occur in the same period of time, sequential periods of time, or overlapping periods of time.

[0148] This creates in the homogenous mixture that will result in homogenous alloy 32 is transferred to the die extruder 56. The homogenous mixture is extruded through the opening in the die plate of the die extruder 56. The extrusion of the alloy results in an elongated fiber 14 that may be spooled onto a reel. The extruded fiber may be spooled or stored on a roll.

[0149] After a roll of fiber 14 is created, the roll of spooled homogenous fiber 14 may be provided to a manufacturer. The manufacturer may utilize any known turf-making machine to create the artificial turf 10 from the fibers 14 composed of alloy 32. Once the application of the fibers 14 to the backing layer 16 has been completed, the fibers may be cut to a suitable length for use as artificial turf, such as a length within a range from about 5 mm to about 150 mm.

[0150] The foregoing examples 1-101 demonstrate that mixing the polyolefin 26 (which may be polyethylene or another polyolefin), the polyamide 28 (which may be nylon or another polyamide), and the binding agent 30 can be used to make alloy 32 which can be used in the production of artificial turf 10 with the benefits of both polyethylene artificial turf and nylon artificial turf. Any of the above examples 1-101 (or various combinations of interposing values between the listed values) may be used to result in the alloy 32 containing polyethylene and nylon for artificial turf.

[0151] Regardless of the aforementioned Examples 1-101 that result in fiber 14, after the artificial grass fibers 14 are created the fibers may be spooled. Once the fibers are on a spool, reel or roll they can be transported to a manufacturer where they will assemble artificial turf 10. The artificial grass fibers 14 may be tufted, sewn, or chemically bonded to the backing layer 16. During the tufting process, the artificial grass fibers 14 formed from alloy 32 are fed through the backing layer using a tufting machine. The tufting machine may push the artificial grass fibers are pushed through the backing layer and anchored to the backing layer by a stitching method. Once the artificial turf fibers are tufted through the backing layer the end user may direct the manufacturer of their desired length, and the manufacturer may cut the artificial turf 10 to the desired length of the end user.

[0152] Regardless of the aforementioned examples that result in fiber 14 having a homogenous cross section of alloy 32, the artificial turf 10 may assembled by combining multiple artificial grass fibers 14 to make a tuft 12. The top end 18 of artificial grass fiber 14 within tufts 12 are pulled through the backing layer 16 leaving the bottom end 20 of artificial grass fiber 14 contacting the backing layer. In another exemplary embodiment, individual artificial grass fiber 14 may be pulled through the backing layer 16. In yet another exemplary embodiment the bottom end 20 of artificial grass fiber 14 may be secured to the backing layer 16 by a mechanical connection (e.g., sewing, stapling, or any other mechanical means), a chemical connection (e.g., adhesive or other bonding), or a non-mechanical and non-chemical connection).

[0153] FIG. 5A depicts a method flow chart for manufacturing a turf product shown generally as 100. Method 100 includes adding a polyolefin 26, a polyamide 28, and a binding agent 30 into a mixer, which is shown generally at 112. Method 100 includes heating a mixture of the polyolefin, the polyamide, and the binding agent, which is shown generally at 114. Method 100 includes creating an alloy of the polyolefin 26, the polyamide 28, and the binding agent 30 in response to heating the mixture, which is shown generally at 116. Method 100 includes extruding the alloy into at least one fiber adapted to form a portion of artificial turf, which is shown generally at 118. Method 100 includes effecting the at least one fiber to be attached to a backing layer, which is shown generally at 120. Method 100 includes effecting an artificial turf product to be formed in response the at least one fiber being attached to the backing layer, which is shown generally at 122.

[0154] FIG. 5B depicts a second method flow chart for a method of manufacturing a turf product is shown generally as 200. Method 200 includes adding a polyolefin and a binding agent into a first mixer, which is shown generally at 212. Method 200 includes heating the polyolefin and the binding agent, which is shown generally at 214. Method 200 includes adding a polyamide to a second mixer, which is shown generally at 216. Method 200 includes heating the polyamide, which is shown generally at 218. Method 200 includes combining the heated polyolefin and binding agent with the heated polyamide, which is shown generally at 220. Method 200 includes forming a homogenous alloy in response to combining the heated polyolefin and binding agent with the heated polyamide, which is shown generally at 222. Method 200 includes extruding the homogenous alloy to create an artificial turf fiber, which is shown generally at 224. Method 200 includes effecting the artificial turf fiber to be attached to a backing layer, which is shown generally at 226. Method 200 includes effecting an artificial turf product to be formed in response the artificial turf fiber being attached to the backing layer, which is shown generally at 228.

[0155] FIG. 5C depicts a flowchart of a method for manufacturing a turf product shown generally as 300. Method 300 includes receiving a fiber composed of an alloy comprising a polyolefin, a polyamide, and a binding agent, which is shown generally at 312. Method 300 includes attaching the fiber to a backing layer, which is shown generally at 314. Method 300 includes arranging the fiber attached to the backing layer as a tuft or blade of artificial turf in an artificial turf product, which is shown generally at 316.

[0156] The extrusion device of the present disclosure may additionally include one or more sensors to sense or gather data pertaining to the surrounding environment or operation of the mixing assembly. Some exemplary sensors capable of being electronically coupled with the device of the present disclosure (either directly connected to the device of the present disclosure or remotely connected thereto) may include but are not limited to: accelerometers sensing accelerations experienced during rotation, translation, velocity / speed, location traveled, elevation gained; gyroscopes sensing movements during angular orientation and / or rotation, and rotation; altimeters sensing barometric pressure, altitude change, terrain climbed, local pressure changes, submersion in liquid; impellers measuring the amount of fluid passing thereby; global positioning sensors sensing location, elevation, distance traveled, velocity / speed; audio sensors sensing local environmental sound levels, or voice detection; photo / light sensors sensing ambient light intensity, ambient, day / night, UV exposure; TV / IR sensors sensing light wavelength; temperature sensors sensing machine or motor temperature, ambient air temperature, and environmental temperature; radar sensors; lidar sensors; ultrasonic sensors; magnetic sensors, image sensors; and moisture sensors sensing surrounding moisture levels.

[0157] If sensors are utilized to gather data relating to the device of the present disclosure, then sensed data may be evaluated and processed with artificial intelligence (AI). Analyzing data gathered from sensors using artificial intelligence involves the process of extracting meaningful insights and patterns from raw sensor data to produce refined and actionable results. Raw data is gathered from various sensors, for example those which have been identified herein or others, capturing relevant information based on the intended analysis. This data is then preprocessed to clean, organize, and structure it for effective analysis. Features that represent key characteristics or attributes of the data are extracted. These features serve as inputs for AI algorithms, encapsulating relevant information essential for the analysis. A suitable AI model, such as machine learning or deep learning (regardless of whether it is supervised or unsupervised), is chosen based on the nature of the data and the desired analysis outcome. The model is then trained using labeled or unlabeled data to learn the underlying patterns and relationships. The model is fine-tuned and optimized to enhance its performance and accuracy. This process involves adjusting parameters, architectures, and algorithms to achieve better results. The trained model is used to make predictions or inferences on new, unseen data. The model processes the extracted features and generates refined output based on the patterns it has learned during training. The results produced by the AI model are refined through post-processing techniques to ensure accuracy and relevance. These refined results are then interpreted to extract meaningful insights and derive actionable conclusions. Feedback from the refined results is used to improve the AI model iteratively. The process involves incorporating new data, adjusting the model, and enhancing the analysis based on real-world feedback and evolving requirements. Further, AI results can be used to alter the operation of the device, assembly, or system of the present disclosure based on feedback. For example, AI feedback can be used to improve the efficiency of the device of the present disclosure by responding to predicted changes in the environment or predicted changes to the device, such as how much binding agent to include in the unhomogenized mixture, or if more polyolefin or polyamide is needed more quickly than if only sensed by one or more of the sensors.

[0158] A sensor model may be employed, once trained, in the extruder device of the present disclosure. In one embodiment, the extruder device can be used to teach a sensor model to predict sensor data for a specific scenario. Alternatively, sensor models can be utilized to generate the data to train the AI. The sensor model can be trained for any type of sensor, such as those types of sensors described above, and / or other sensor types. The elements described herein may be implemented as discrete or distributed components in any suitable combination and location. The various functions described herein may be conducted by hardware, firmware, and / or software. For example, a processor may perform various functions by executing instructions stored in memory.

[0159] The AI model and / or sensor model can include a deep neural network (DNN), convolutional neural network (CNN), another neural network (NN) or the like and can support generative learning. For example, the sensor model can include a generative adversarial network (GAN), a variational autoencoder (VAE), and / or another type of DNN, CNN, NN or machine learning model (e.g., natural language processing (NLP)). Generally, the sensor model can accept some encoded representation of a scene as input using any number of data structures and / or channels (e.g., concatenated vectors, matrices, tensors, images, etc.).

[0160] In a particular embodiment, the device of the present disclosure can use the sensors to acquire a representation of the real-world environment (e.g., a physical environment) at a given point in time. Data from these sensors may be used to generate a representation of a scene or scenario, which may then be used to teach a sensor model. For example, the extruder device can detect when levels of any of the polyolefin, polyamide, or binding agent need to be adjusted. For example, a representation of a scene can be derived from sensor data, properties of objects in the scene or surrounding environment such as positions or dimensions (e.g., maps that detail movement of the materials through the production of fiber 14), classification data identifying objects in the scene or surrounding environment, properties or classification data of components of the device of the present disclosure, or some combination thereof. Generally, the sensor model learns to predict sensor data from a representation of the scene, environment or operation of the device of the present disclosure.

[0161] The sensor model architecture can be selected to fit the shape of the desired input and output data. Examples of architectures (e.g., DNNs) include, but are not limited to, perceptron, feed-forward, radial basis, deep feed-forward, recurrent, long / short term memory, gated recurrent unit, autoencoder, variational autoencoder, convolutional, deconvolutional, and generative adversarial. Some DNN architectures, such as a GAN, can include a convolutional neural network (CNN) that accepts and evaluates an input image and may include multiple input channels, which may be used to accept and evaluate multiple input images and / or input vectors.

[0162] In one embodiment, training data for the sensor model may be generated using real-world (e.g., physical environment) data. To collect real-world training data, the device of the present disclosure may collect sensor data by fusing sensors as the vehicle traverses a real-world environment. The sensors of the device of the present disclosure may include, for example, one or more global navigation satellite systems sensors (e.g., Global Positioning System sensors (GPS)), RADAR sensors, ultrasonic sensors, LIDAR sensors, inertial measurement unit (IMU) sensors (e.g., accelerometer(s), gyroscope(s), magnetic compass(es), magnetometer(s), etc.), ego-motion sensors, microphones, stereo cameras, wide-view cameras (e.g., fisheye cameras), infrared cameras, surround cameras (e.g., 360 degree cameras), long-range and / or mid-range cameras, speed sensors (e.g., for measuring the speed of the vehicle), vibration sensors, steering sensors, brake sensors (e.g., as part of the brake sensor system), and / or other sensor types.

[0163] In another embodiment, training data for the sensor model is generated based on simulated or virtual environments. The training data may then be used to train the sensor model for use in real-world autonomous applications, e.g., to control the operation of the device of the present disclosure. The training data may be derived to fit the shape of the input and output data for the sensor model, which may depend on the architecture of the sensor model. For example, sensor data may be used to encode an input scene, input parameters, and / or ground truth sensor data using different data structures and / or channels (e.g., concatenated vectors, matrices, tensors, images, etc.).

[0164] Hyperparameters are settings that govern the training process and behavior of AI models. Exemplary hyperparameters include learning rate, batch size, and regularization parameters. Adjusting these hyperparameters can impact the model's convergence, stability, and generalization capabilities. For example, a higher learning rate may speed up training but risk overshooting optimal solutions, while a lower learning rate ensures precise adjustments but may slow down the process. Similarly, batch size affects gradient estimation and memory usage, influencing the model's ability to learn effectively from the data. The number and type of layers in an AI model define its complexity and capacity to learn from data. Layers can be categorized into input, hidden, and output layers, each serving a specific function. Input layers receive raw data, hidden layers process and extract features, and output layers generate predictions. The depth of the model, determined by the number of hidden layers, allows it to capture intricate patterns and relationships in the data. For instance, DNNs with multiple hidden layers can learn complex representations, while shallow networks may be more suitable for simpler tasks. The architecture of an AI model refers to its overall structure and design, encompassing the arrangement of layers and connections. Different architectures may be tailored to specific types of data and tasks. For example, CNNs are well-suited for image data, leveraging convolutional layers to detect spatial features. Recurrent neural networks (RNNs) and their variants, such as long short-term memory (LSTM) networks, excel in handling sequential data by maintaining temporal dependencies. GANs and VAEs are used for generative tasks, creating new data samples based on learned patterns. The selection of hyperparameters, layers, and architectures directly influences the type of protocol or architecture employed in the AI model. For instance, a protocol designed for real-time data analysis may prioritize low-latency architectures with optimized hyperparameters for rapid inference. Conversely, a protocol for offline batch processing may focus on deep architectures with extensive layers to achieve high accuracy. The choice of architecture also affects the model's ability to handle different data modalities, such as images, text, or sensor data, ensuring that the protocol aligns with the specific requirements of the task.

[0165] The device of the present disclosure may include hardware, software and / or firmware responsible for managing the sensor data generated by the sensors. The autonomous hardware, software, and / or firmware being executed may manage different environments using one or more maps (e.g., 3D maps), positioning component(s), and the like. The autonomous hardware, software, and / or firmware may also include components to plan, control, and generally manage the device of the present disclosure. In one example, the autonomous hardware, software, and / or firmware can be installed in and used to control the device of the present disclosure through the environment based on the sensor data, one or more machine learning models (e.g., neural networks), and the like. A training system may use the training data to train the sensor model to predict virtual sensor data for a given scene, environment, or operation of a component.

[0166] The training system can include one or more servers (e.g., a graphics processing unit server) and data stores and may use a cloud-based deep learning infrastructure with artificial intelligence to analyze the sensor data received from the device of the present disclosure and / or stored in the data store. The training system can also incorporate or train up-to-date, real-time neural networks (and / or other machine learning models) for one or more sensor models.

[0167] The extruder device of the present disclosure may include wireless communication logic coupled to sensors on the device. The sensors gather data and provide the data to the wireless communication logic. Then, the wireless communication logic may transmit the data gathered from the sensors to a remote device. Thus, the wireless communication logic may be part of a broader communication system, in which one or several devices, assemblies, or systems of the present disclosure may be networked together to report alerts and, more generally, to be accessed and controlled remotely. Depending on the types of transceivers installed in the device, assembly, or system of the present disclosure, the system may use a variety of protocols (e.g., Wi-Fi®, ZigBee®, MIWI, BLUETOOTH®) for communication. In one example, each of the devices, assemblies, or systems of the present disclosure may have its own IP address and may communicate directly with a router or gateway. This would typically be the case if the communication protocol is Wi-Fi®. (Wi-Fi® is a registered trademark of Wi-Fi Alliance of Austin, TX, USA; ZigBee® is a registered trademark of ZigBee Alliance of Davis, CA, USA; and BLUETOOTH® is a registered trademark of Bluetooth Sig, Inc. of Kirkland, WA, USA).

[0168] In another example, a point-to-point communication protocol like MiWi or ZigBee® is used. One or more of the device of the present disclosure may serve as a repeater, or the devices of the present disclosure may be connected together in a mesh network to relay signals from one device to the next. However, the individual device in this scheme typically would not have IP addresses of their own. Instead, one or more of the devices of the present disclosure communicates with a repeater that does have an IP address, or another type of address, identifier, or credential needed to communicate with an outside network. The repeater communicates with the router or gateway.

[0169] In either communication scheme, the router or gateway communicates with a communication network, such as the Internet, although in some embodiments, the communication network may be a private network that uses transmission control protocol / internet protocol (TCP / IP) and other common Internet protocols but does not interface with the broader Internet, or does so only selectively through a firewall.

[0170] The system that receives and processes signals from the device of the present disclosure may differ from embodiment to embodiment. In one embodiment, alerts and signals from the device of the present disclosure are sent through an e-mail or simple message service (SMS; text message) gateway so that they can be sent as e-mails or SMS text messages to a remote device, such as a smartphone, laptop, or tablet computer, monitored by a responsible individual, group of individuals, or department, such as a maintenance department. Thus, if a particular device of the present disclosure creates an alert because of a data point gathered by one or more sensors, that alert can be sent, in e-mail or SMS form, directly to the individual responsible for fixing it. Of course, e-mail and SMS are only two examples of communication methods that may be used; in other embodiments, different forms of communication may be used.

[0171] In other embodiments, alerts and other data from the sensors on the device of the present disclosure may also be sent to a work tracking system that allows the individual, or the organization for which he or she works, to track the status of the various alerts that are received, to schedule particular workers to repair a particular device of the present disclosure, and to track the status of those repair jobs. A work tracking system would typically be a server, such as a Web server, which provides an interface individuals and organizations can use, typically through the communication network. In addition to its work tracking functions, the work tracker may allow broader data logging and analysis functions. For example, operational data may be calculated from the data collected by the sensors on the device of the present disclosure, and the system may be able to provide aggregate machine operational data for a device of the present disclosure or group of devices of the present disclosure.

[0172] The system also allows individuals to access the device of the present disclosure for configuration and diagnostic purposes. In that case, the individual processors or microcontrollers of the device of the present disclosure may be configured to act as Web servers that use a protocol like hypertext transfer protocol (HTTP) to provide an online interface that can be used to configure the device. In some embodiments, the systems may be used to configure several devices of the present disclosure at once. For example, if several devices are of the same model and are in similar locations in the same location, it may not be necessary to configure the devices individually. Instead, an individual may provide configuration information, including baseline operational parameters, for several devices at once.

[0173] As described herein, aspects of the present disclosure may include one or more electrical, pneumatic, hydraulic, or other similar secondary components and / or systems therein. The present disclosure is therefore contemplated and will be understood to include any necessary operational components thereof. For example, electrical components will be understood to include any suitable and necessary wiring, fuses, or the like for normal operation thereof. Similarly, any pneumatic systems provided may include any secondary or peripheral components such as air hoses, compressors, valves, meters, or the like. It will be further understood that any connections between various components not explicitly described herein may be made through any suitable means including mechanical fasteners, or more permanent attachment means, such as welding or the like. Alternatively, where feasible and / or desirable, various components of the present disclosure may be integrally formed as a single unit.

[0174] Unless explicitly stated that a particular shape or configuration of a component is mandatory, any of the elements, components, or structures discussed herein may take the form of any shape. Thus, although the figures depict the various elements, components, or structures of the present disclosure according to one or more exemplary embodiments, it is to be understood that any other geometric configuration of that element, component, or structure is entirely possible. For example, instead of the artificial grass fiber 14 being generally rectangular in shape, or a cross section of the fiber 14 being generally rectangular, they can be semi-circular triangular, or square, pentagonal, hexagonal, heptagonal, octagonal, decagonal, dodecagonal, diamond shaped or another parallelogram, trapezoidal, star-shaped, oval, ovoid, lines or lined, teardrop-shaped, cross-shaped, donut-shaped, heart-shaped, arrow-shaped, crescent-shaped, any letter shape (i.e., A-shaped, B-shaped, C-shaped, D-shaped, E-shaped, F-shaped, G-shaped, H-shaped, I-shaped, J-shaped, K-shaped, L-shaped, M-shaped, N-shaped, O-shaped, P-shaped, Q-shaped, R-shaped, S-shaped, T-shaped, U-shaped, V-shaped, W-shaped, X-shaped, Y-shaped, or Z-shaped), or any other type of regular or irregular, symmetrical or asymmetrical configuration made from alloy 32.

[0175] Various inventive concepts may be embodied as one or more methods, of which an example has been provided. The acts performed as part of the method may be ordered in any suitable way. Accordingly, embodiments may be constructed in which acts are performed in an order different than illustrated, which may include performing some acts simultaneously, even though shown as sequential acts in illustrative embodiments.

[0176] Any flowchart and / or block diagrams in the Figures illustrate some exemplary architecture, functionality, and operation of possible implementations of systems, methods, and computer program products according to various embodiments of the present disclosure. In this regard, each block in the flowchart or block diagrams may represent a module, segment, or portion of instructions, which comprises one or more executable instructions for implementing the specified logical function(s). In some alternative implementations, the functions noted in the blocks may occur out of the order noted in the Figures. For example, two blocks shown in succession may, in fact, be executed substantially concurrently, or the blocks may sometimes be executed in the reverse order, depending upon the functionality involved. It will also be noted that each block of the block diagrams and / or flowchart illustration, and combinations of blocks in the block diagrams and / or flowchart illustration, can be implemented by special purpose hardware-based systems that perform the specified functions or acts or carry out combinations of special purpose hardware and computer instructions.

[0177] While various inventive embodiments have been described and illustrated herein, those of ordinary skill in the art will readily envision a variety of other means and / or structures for performing the function and / or obtaining the results and / or one or more of the advantages described herein, and each of such variations and / or modifications is deemed to be within the scope of the inventive embodiments described herein. More generally, those skilled in the art will readily appreciate that all parameters, dimensions, materials, and configurations described herein are meant to be exemplary and that the actual parameters, dimensions, materials, and / or configurations will depend upon the specific application or applications for which the inventive teachings is / are used. Those skilled in the art will recognize or be able to ascertain using no more than routine experimentation, many equivalents to the specific inventive embodiments described herein. It is, therefore, to be understood that the foregoing embodiments are presented by way of example only and that, within the scope of the appended claims and equivalents thereto, inventive embodiments may be practiced otherwise than as specifically described and claimed. Inventive embodiments of the present disclosure are directed to each individual feature, system, article, material, kit, and / or method described herein. In addition, any combination of two or more such features, systems, articles, materials, kits, and / or methods, if such features, systems, articles, materials, kits, and / or methods are not mutually inconsistent, is included within the inventive scope of the present disclosure. Thus it is to be clearly understood that present disclosure, including the Figures, describes various features, embodiments, and aspects or instances of inventive matter. It is to be understood that any feature, component, step, or characteristic disclosed in this specification or Figures may be combined with any other disclosed feature to form alternative embodiments, unless explicitly stated otherwise. Individual features should not be viewed as being limited to their originally disclosed embodiments but may be freely combined or rearranged with other features as appropriate to define the scope of the claimed subject matter. Further, the various features, configurations, components, and functionalities discussed herein are intended to provide a “disclosure reservoir” from which any claim language may be derived. To illustrate the flexibility intended by this disclosure reservoir, a first feature, originally described with a second feature, may alternatively be implemented with a third feature, a fourth feature, or both third and fourth features. Similarly, functional components may be substituted or combined in any logical arrangement without departing from the scope of the present disclosure.

[0178] The above-described embodiments can be implemented in any of numerous ways. For example, embodiments of technology disclosed herein may be implemented using hardware, software, firmware or a combination thereof. When implemented in software, the software code or instructions can be executed on any suitable processor or collection of processors, whether provided in a single computer or distributed among multiple computers or in firmware. Furthermore, the instructions or software code can be stored in at least one non-transitory computer readable storage medium.

[0179] Also, a computer or smartphone may be utilized to execute the software code or instructions via its processors may have one or more input and output devices. These devices can be used, among other things, to present a user interface. Examples of output devices that can be used to provide a user interface include printers or display screens for visual presentation of output and speakers or other sound generating devices for audible presentation of output. Examples of input devices that can be used for a user interface include keyboards, and pointing devices, such as mice, touch pads, and digitizing tablets. As another example, a computer may receive input information through speech recognition or in other audible format.

[0180] Such computers or smartphones may be interconnected by one or more networks in any suitable form, including a local area network or a wide area network, such as an enterprise network, and intelligent network (IN) or the Internet. Such networks may be based on any suitable technology and may operate according to any suitable protocol and may include wireless networks, wired networks or fiber optic networks.

[0181] The various methods or processes outlined herein may be coded as software / instructions that are executable on one or more processors that employ any one of a variety of operating systems or platforms. Additionally, such software may be written using any of a number of suitable programming languages and / or programming or scripting tools, and also may be compiled as executable machine language code or intermediate code that is executed on a framework or virtual machine.

[0182] In this respect, various inventive concepts may be embodied as a computer readable storage medium (or multiple computer readable storage media) (e.g., a computer memory, one or more floppy discs, compact discs, optical discs, magnetic tapes, flash memories, USB flash drives, SD cards, circuit configurations in Field Programmable Gate Arrays or other semiconductor devices, or other non-transitory medium or tangible computer storage medium) encoded with one or more programs that, when executed on one or more computers or other processors, perform methods that implement the various embodiments of the disclosure discussed above. The computer readable medium or media can be transportable, such that the program or programs stored thereon can be loaded onto one or more different computers or other processors to implement various aspects of the present disclosure as discussed above.

[0183] The terms “program” or “software” or “instructions” are used herein in a generic sense to refer to any type of computer code or set of computer-executable instructions that can be employed to program a computer or other processor to implement various aspects of embodiments as discussed above. Additionally, it should be appreciated that according to one aspect, one or more computer programs that when executed perform methods of the present disclosure need not reside on a single computer or processor but may be distributed in a modular fashion amongst a number of different computers or processors to implement various aspects of the present disclosure.

[0184] Computer-executable instructions may be in many forms, such as program modules, executed by one or more computers or other devices. Generally, program modules include routines, programs, objects, components, data structures, etc. that perform particular tasks or implement particular abstract data types. Typically, the functionality of the program modules may be combined or distributed as desired in various embodiments. As such, one aspect or embodiment of the present disclosure may be a computer program product including least one non-transitory computer readable storage medium in operative communication with a processor, the storage medium having instructions stored thereon that, when executed by the processor, implement a method or process described herein, wherein the instructions comprise the steps to perform the method(s) or process(es) detailed herein.

[0185] Also, data structures may be stored in computer-readable media in any suitable form. For simplicity of illustration, data structures may be shown to have fields that are related through location in the data structure. Such relationships may likewise be achieved by assigning storage for the fields with locations in a computer-readable medium that convey relationship between the fields. However, any suitable mechanism may be used to establish a relationship between information in fields of a data structure, including through the use of pointers, tags or other mechanisms that establish relationship between data elements.

[0186] All definitions, as defined and used herein, should be understood to control over dictionary definitions, definitions in documents incorporated by reference, and / or ordinary meanings of the defined terms.

[0187] “Logic”, as used herein, includes but is not limited to hardware, firmware, software, and / or combinations of each to perform a function(s) or an action(s), and / or to cause a function or action from another logic, method, and / or system. For example, based on a desired application or needs, logic may include a software controlled microprocessor, discrete logic like a processor (e.g., microprocessor), an application specific integrated circuit (ASIC), a programmed logic device, a memory device containing instructions, an electric device having a memory, or the like. Logic may include one or more gates, combinations of gates, or other circuit components. Logic may also be fully embodied as software. Where multiple logics are described, it may be possible to incorporate the multiple logics into one physical logic. Similarly, where a single logic is described, it may be possible to distribute that single logic between multiple physical logics.

[0188] Furthermore, the logic(s) presented herein for accomplishing various methods of this system may be directed towards improvements in existing computer-centric or internet-centric technology that may not have previous analog versions. The logic(s) may provide specific functionality directly related to structure that addresses and resolves some problems identified herein. The logic(s) may also provide significantly more advantages to solve these problems by providing an exemplary inventive concept as specific logic structure and concordant functionality of the method and system. Furthermore, the logic(s) may also provide specific computer implemented rules that improve existing technological processes. The logic(s) provided herein extends beyond merely gathering data, analyzing the information, and displaying the results. Further, portions or all of the present disclosure may rely on underlying equations that are derived from the specific arrangement of the equipment or components as recited herein. Thus, portions of the present disclosure as it relates to the specific arrangement of the components are not directed to abstract ideas. Furthermore, the present disclosure and the appended claims present teachings that involve more than performance of well-understood, routine, and conventional activities previously known to the industry. In some of the method or process of the present disclosure, which may incorporate some aspects of natural phenomenon, the process or method steps are additional features that are new and useful.

[0189] More particularly, the device of the present disclosure, which may include the logic(s) presented herein, includes the features, components, techniques or processes detailed herein that, as combined, accomplished the desired results detailed herein. These specific elements, configuration or techniques of the device of the present disclosure, some of which may be included in at least one of the appended claims, accomplish these desired results to overcome the then existing problems in the relevant field of computer processor-based systems. Additionally, the features, components, techniques or processes of the device of the present disclosure, are an unconventional arrangement of elements or unconventionally perform a method detailed herein that was unavailable without the unconventional arrangement of elements. These exemplary, yet particular, arrangements provide an improvement over existing technologies that have failed to operate in the manner, and with the efficiency that is taught by the device of the present disclosure.

[0190] The articles “a” and “an,” as used herein in the specification and in the claims, unless clearly indicated to the contrary, should be understood to mean “at least one.” The phrase “and / or,” as used herein in the specification and in the claims (if at all), should be understood to mean “either or both” of the elements so conjoined, i.e., elements that are conjunctively present in some cases and disjunctively present in other cases. Multiple elements listed with “and / or” should be construed in the same fashion, i.e., “one or more” of the elements so conjoined. Other elements may optionally be present other than the elements specifically identified by the “and / or” clause, whether related or unrelated to those elements specifically identified. Thus, as a non-limiting example, a reference to “A and / or B”, when used in conjunction with open-ended language such as “comprising” can refer, in one embodiment, to A only (optionally including elements other than B); in another embodiment, to B only (optionally including elements other than A); in yet another embodiment, to both A and B (optionally including other elements); etc. As used herein in the specification and in the claims, “or” should be understood to have the same meaning as “and / or” as defined above. For example, when separating items in a list, “or” or “and / or” shall be interpreted as being inclusive, i.e., the inclusion of at least one, but also including more than one of a number or list of elements, and, optionally, additional unlisted items. Only terms clearly indicated to the contrary, such as “only one of” or “exactly one of,” or, when used in the claims, “consisting of,” will refer to the inclusion of exactly one element of a number or list of elements. In general, the term “or” as used herein shall only be interpreted as indicating exclusive alternatives (i.e. “one or the other but not both”) when preceded by terms of exclusivity, such as “either,”“one of,”“only one of,” or “exactly one of.”“Consisting essentially of,” when used in the claims, shall have its ordinary meaning as used in the field of patent law.

[0191] As used herein in the specification and in the claims, the phrase “at least one,” in reference to a list of one or more elements, should be understood to mean at least one element selected from any one or more of the elements in the list of elements, but not necessarily including at least one of each and every element specifically listed within the list of elements and not excluding any combinations of elements in the list of elements. This definition also allows that elements may optionally be present other than the elements specifically identified within the list of elements to which the phrase “at least one” refers, whether related or unrelated to those elements specifically identified. Thus, as a non-limiting example, “at least one of A and B” (or, equivalently, “at least one of A or B,” or, equivalently “at least one of A and / or B”) can refer, in one embodiment, to at least one, optionally including more than one, A, with no B present (and optionally including elements other than B); in another embodiment, to at least one, optionally including more than one, B, with no A present (and optionally including elements other than A); in yet another embodiment, to at least one, optionally including more than one, A, and at least one, optionally including more than one, B (and optionally including other elements); etc. As another example, “at least one of: A, B, or B” is intended to cover A, B, C, A-B, A-C, B-C, and A-B-C, as well as any combination with multiple of the same item.

[0192] While components of the present disclosure are described herein in relation to each other, it is possible for one of the components disclosed herein to include inventive subject matter, if claimed alone or used alone. In keeping with the above example, if the disclosed embodiments teach the features of A and B, then there may be inventive subject matter in the combination of A and B, A alone, or B alone, unless otherwise stated herein.

[0193] As used herein in the specification and in the claims, the term “effecting” or a phrase or claim element beginning with the term “effecting” should be understood to mean to cause something to happen or to bring something about. For example, effecting an event to occur may be caused by actions of a first party even though a second party actually performed the event or had the event occur to the second party. Stated otherwise, effecting refers to one party giving another party the tools, objects, or resources to cause an event to occur. Thus, in this example a claim element of “effecting an event to occur” would mean that a first party is giving a second party the tools or resources needed for the second party to perform the event, however the affirmative single action is the responsibility of the first party to provide the tools or resources to cause said event to occur.

[0194] When a feature or element is herein referred to as being “on” another feature or element, it can be directly on the other feature or element or intervening features and / or elements may also be present. In contrast, when a feature or element is referred to as being “directly on” another feature or element, there are no intervening features or elements present. It will also be understood that, when a feature or element is referred to as being “connected”, “attached” or “coupled” to another feature or element, it can be directly connected, attached or coupled to the other feature or element or intervening features or elements may be present. In contrast, when a feature or element is referred to as being “directly connected”, “directly attached” or “directly coupled” to another feature or element, there are no intervening features or elements present. Although described or shown with respect to one embodiment, the features and elements so described or shown can apply to other embodiments. It will also be appreciated by those of skill in the art that references to a structure or feature that is disposed “adjacent” another feature may have portions that overlap or underlie the adjacent feature.

[0195] Spatially relative terms, such as “under”, “below”, “lower”, “over”, “upper”, “above”, “behind”, “in front of”, and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. It will be understood that the spatially relative terms are intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if a device in the figures is inverted, elements described as “under” or “beneath” other elements or features would then be oriented “over” the other elements or features. Thus, the exemplary term “under” can encompass both an orientation of over and under. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly. Similarly, the terms “upwardly”, “downwardly”, “vertical”, “horizontal”, “lateral”, “transverse”, “longitudinal”, and the like are used herein for the purpose of explanation only unless specifically indicated otherwise.

[0196] Although the terms “first” and “second” may be used herein to describe various features / elements, these features / elements should not be limited by these terms, unless the context indicates otherwise. These terms may be used to distinguish one feature / element from another feature / element. Thus, a first feature / element discussed herein could be termed a second feature / element, and similarly, a second feature / element discussed herein could be termed a first feature / element without departing from the teachings of the present disclosure.

[0197] An embodiment is an implementation or example of the present disclosure. Reference in the specification to “an embodiment,”“one embodiment,”“some embodiments,”“one particular embodiment,”“an exemplary embodiment,” or “other embodiments,” or the like, means that a particular feature, structure, or characteristic described in connection with the embodiments is included in at least some embodiments, but not necessarily all embodiments, of the invention. The various appearances “an embodiment,”“one embodiment,”“some embodiments,”“one particular embodiment,”“an exemplary embodiment,” or “other embodiments,” or the like, are not necessarily all referring to the same embodiments. Furthermore, the use of any and all examples or exemplary language (“e.g.,”“such as,” or the like) is intended merely to better illustrate or illuminate the embodiments and does not pose a limitation on the scope of that or those embodiments. No language in this specification should be construed as indicating any unclaimed element as essential to the practice of the disclosed embodiment.

[0198] If this specification states a component, feature, structure, or characteristic “may”, “might”, or “could” be included, that particular component, feature, structure, or characteristic is not required to be included. If the specification or claim refers to “a” or “an” element, that does not mean there is only one of the element. If the specification or claims refer to “an additional” element or “another” element, that does not preclude there being more than one of the additional element or the another element.

[0199] As used herein in the specification and claims, including as used in the examples and unless otherwise expressly specified, all numbers may be read as if prefaced by the word “about” or “approximately,” even if the term does not expressly appear. The phrase “about” or “approximately” may be used when describing magnitude and / or position to indicate that the value and / or position described is within a reasonable expected range of values and / or positions. For example, a numeric value may have a value that is + / −0.1% of the stated value (or range of values), + / −1% of the stated value (or range of values), + / −2% of the stated value (or range of values), + / −5% of the stated value (or range of values), + / −10% of the stated value (or range of values), etc. Any numerical range recited herein is intended to include all sub-ranges subsumed therein. Further, recitation of ranges of values herein are not intended to be limiting, referring instead individually to any and all values falling within that range, unless otherwise indicated herein, and each separate value within such range is incorporated into the specification as if it were individually recited herein.

[0200] Additionally, the method of performing the present disclosure may occur in a sequence different than those described herein. Accordingly, no sequence of the method should be read as a limitation unless explicitly stated. It is recognizable that performing some of the steps of the method in a different order could achieve a similar result.

[0201] In the claims, as well as in the specification above, all transitional phrases such as “comprising,”“including,”“carrying,”“having,”“containing,”“involving,”“holding,”“composed of,” and the like are to be understood to be open-ended, i.e., to mean including but not limited to. Only the transitional phrases “consisting of” and “consisting essentially of” shall be closed or semi-closed transitional phrases, respectively.

[0202] To the extent that the present disclosure has utilized the term “invention” in various titles or sections of this specification, or in the context of those sections, this term has been included as required by the formatting requirements of word document submissions (i.e., docx submissions) pursuant the guidelines / requirements of the United States Patent and Trademark Office and shall not, in any manner, be considered a disavowal of any subject matter.

[0203] In the foregoing description, certain terms have been used for brevity, clearness, and understanding. No unnecessary limitations are to be implied therefrom beyond the requirement of the prior art because such terms are used for descriptive purposes and are intended to be broadly construed.

[0204] Moreover, the description and illustration of various embodiments of the disclosure are examples and the disclosure is not limited to the exact details shown or described.

Examples

example one

[0054]Example One provides, within the mixture 44, polyethylene at about 65 parts by weight (which may be transferred into mixer 42 from the first dispenser 36), nylon at about 25 parts by weight (which may be transferred into mixer 42 from the second dispenser 38), and maleic anhydride at about 10 parts by weight (which may be transferred into mixer 42 from the third dispenser 38). In this example, the particulate materials are combined and mixed together via the mixer 42.

[0055]During a period of time, such as about 1 to 5 minutes, the mixture may be subjected to a pressure in the range of about 250 psi to 1,500 psi and heated to a temperature in a range of about 115° C. to about 300° C. Heating and subjecting to pressure may occur in the same period of time, sequential periods of time, or overlapping periods of time. Heating may occur in mixer 42 or in the dispenser. Subjecting to pressure may occur in the mixer 42 or in the die extruder 56. This results in the polyethylene, nylon...

example two

[0058]Example Two provides, within the mixture 44, polyethylene at about 55 parts by weight (which may be transferred into mixer 42 from the first dispenser 36), nylon at about 35 parts by weight (which may be transferred into mixer 42 from second dispenser 38), and maleic anhydride at about 10 parts by weight (which may be transferred into mixer 42 from the third dispenser 40). In this example, the particulate materials are combined and mixed together via the mixer 42.

[0059]During a period of time, such as about 1 to 5 minutes, the mixture may be subjected to a pressure in the range of about 250 psi to 1,500 psi and heated to a temperature in a range of about 115° C. to 300° C. Heating and subjecting to pressure may occur in the same period of time, sequential periods of time, or overlapping periods of time. Heating may occur in mixer 42 or in the dispenser. Subjecting to pressure may occur in the mixer 42 or in the die extruder 56. This results in the polyethylene, nylon, and male...

example three

[0062]Example Three provides, within the mixture 44, polyethylene at about 45 parts by weight (which may be transferred into mixer 42 from first dispenser 36), nylon at about 50 parts by weight (which may be transferred into mixer 42 from the second dispenser 38), and maleic anhydride at about 5 parts by weight (which may be transferred into mixer 42 from the third dispenser 40). In this example, the particulate materials are combined and mixed together via the mixer 42.

[0063]During a period of time, such as about 1 to 5 minutes the mixture may be subjected to a pressure in the range of about 250 psi to 1,500 psi and heated to a temperature in a range of about 115° C. to 300° C. Heating and subjecting to pressure may occur in the same period of time, sequential periods of time, or overlapping periods of time. Heating may occur in mixer 42 or in the dispenser. Subjecting to pressure may occur in the mixer 42 or in the die extruder 56. This results in the polyethylene, nylon, and male...

Claims

1. An artificial turf product comprising:a backing layer;at least one artificial turf fiber formed from a homogenous alloy, and the at least one turf fiber is attached to the backing layer and tufted as artificial grass;wherein the homogenous alloy comprises:a polyolefin;a polyamide; anda binding agent.

2. The artificial turf product of claim 1, wherein the homogenous alloy is fully blended uniformly through the entirety of at least one artificial turf fiber such that there are no inner core and no outer sheath.

3. The artificial turf product of claim 1, wherein the polyolefin, polyamide, and the binding agent sum to a 100 total parts by weight, and wherein the binding agent comprises at least one of (i) maleic acid and (ii) maleic anhydride.

4. The artificial turf product of claim 3, wherein the polyolefin is in a range of about 10 to 70 parts by weight of the total parts by weight.

5. The artificial turf product of claim 4, wherein the polyolefin is polyethylene that is about 65 parts by weight of the total parts by weight.

6. The artificial turf product of claim 3, wherein the polyamide is in a range of about 25 to 40 parts by weight of the total parts by weight.

7. The artificial turf product of claim 6, wherein the polyamide is nylon.

8. The artificial turf product of claim 1, wherein the binding agent is a modified polar star-like high polypropylene, wherein the propylene is manufactured by a continuous reactive process at molten phase and characterized by a fork-like or star-like molecular-structure.

9. The artificial turf product of claim 8, wherein the binding agent comprises:polypropylene ranging from about 80 to 99 parts by weight of the binding agent;10. The artificial turf product of claim 8, wherein the binding agent comprises:a free radical initiator having a half-life (T½) of at least a minute at temperatures higher than 100° C., wherein the free radical initiator is in a range of about 0.01 to 2 parts by weight of the binding agent.

11. The artificial turf product of claim 8, wherein the binding agent comprises:one or more branching nucleus monomers having two or more vinyl or allyl reactive groups, wherein the branching nucleus monomers are in a range of about 0.1 to 20 parts by weight of the binding agent, wherein the branching nucleus monomer is adapted to form at least one branch point when grafted onto polypropylene.

12. The artificial turf product of claim 8, wherein the binding agent comprises:one or more monomers having at least one vinyl or allyl reactive group, wherein the one or more monomers are in a range from 0.1 to about 20 parts by weight of the binding agent.

13. The artificial turf product of claim 8, wherein the binding agent comprises:unsaturated acid monomer having at least one vinyl or allyl reactive groups, and one or more carboxylic acid or anhydride or ester group, wherein the unsaturated acid monomer is in a range of about 0.1 to 5 parts by weight of the binding agent.

14. The artificial turf product of claim 13, wherein the unsaturated acid monomer having at least one vinyl or allyl reactive group is maleic acid.

15. The artificial turf product of claim 13, wherein the binding agent is in a range of about 0.1 to 30 parts by weight of the total parts by weight.

16. The artificial turf product of claim 13, wherein the binding agent is in a range of about 1 to 10 parts by weight of the total parts by weight.

17. The artificial turf product of claim 1, wherein the binding agent is maleic anhydride, and wherein the maleic anhydride is in a range of about 1 to 10 parts by weight of the total parts by weight.

18. The artificial turf product of claim 1, wherein the artificial turf fiber has a Gmax measurement in a range of about 1 unit of gravity to 165 units of gravity.

19. The artificial turf product of claim 18, wherein the artificial turf fiber has a Gmax measurement in a range of about 70 units of gravity to 115 units of gravity.

20. An artificial turf fiber that is to be attached to a backing layer and tufted into artificial grass, the artificial turf fiber comprising:a homogenous alloy that comprises:a polyolefin, wherein the polyolefin is in a range of about 10 to 70 parts by weight of a total parts by weight;a polyamide, wherein the polyamide is in a range of about 25 to 40 parts by weight of the total parts by weight; anda binding agent, wherein the binding agent is in a range of about 0.1 to 30 parts by weight of the total parts by weight;wherein the polyolefin, polyamide, and the binding agent sum to 100 for the total parts by weight; andwherein the homogenous alloy is fully blended uniformly through the entirety of the artificial turf fiber such that there are no inner core and no outer sheath.

Images