Filler composition for artificial turf

Abstract

The present invention relates to a filler composition for artificial turf comprising particles with at least 20% natural rubber and at least one mineral load. These particles may contain between 20 and 80 % natural rubber and between 20 and 60 % mineral load. Furthermore, a plant load may be incorporated, such as rice husks or nutshells, in an amount between 5 and 25 % of the particles in the composition. The invention further relates to a method for preparing this composition.

Description

[0001] DESCRIPTION

[0002] FILL COMPOSITION FOR ARTIFICIAL GRASS

[0003] TECHNICAL SECTOR

[0004] The present invention relates to infill compositions for artificial turf that do not generate microplastics during their useful life.

[0005] BACKGROUND OF THE INVENTION

[0006] Artificial turf has emerged as a versatile and durable solution for numerous applications, from sports fields to recreational areas and landscaping. The evolution of this technology has been driven by the constant quest to replicate the qualities of natural grass. In this context, artificial turf infill has become a crucial component for improving the stability, safety, and aesthetics of these synthetic surfaces.

[0007] To date, the predominant infill used in artificial turf fields is mostly obtained from recycled tires, using petroleum-derived rubbers known as styrene butadiene rubber (SBR). SBR is known for its durability, abrasion resistance, and ability to withstand harsh environmental conditions, making it suitable for use in products requiring strength and flexibility.

[0008] Among the measures adopted by the European Union to limit the manufacture and sale of products that generate polluting particles in the air and water, the restriction on granular infill used in synthetic sports surfaces stands out. The European Commission identifies this type of infill as "the largest source of intentional microplastics in the environment." These microplastic particles come from the degradation of this synthetic infill.

[0009] Among the products affected by the restriction is the granular infill used in synthetic sports surfaces, recognized by the European Commission as "the largest source of intentional microplastics in the environment." Given this scenario and the goal of adopting more sustainable practices, there is an urgent need to develop alternatives. In response, the company is seeking to create a substitute product made from natural rubber, thus helping to mitigate the environmental impact associated with microplastics derived from conventional infill systems on artificial turf fields.

[0010] EXPLANATION OF THE INVENTION

[0011] The present invention focuses on preventing the generation of microplastics in the environment caused by the degradation of artificial turf fields. The formulated composition consists exclusively of environmentally friendly and sustainable elements, thus addressing the environmental problems associated with the generation of microplastics.

[0012] The first aspect of the invention relates to a filler composition for artificial turf comprising particles comprising at least 20% natural rubber and at least one mineral filler.

[0013] The second aspect of the invention relates to a process for preparing a filler composition for artificial turf according to the first aspect of the invention comprising the following steps: i. Providing the rubber and mineral filler in the appropriate proportions;

[0014] i. Optionally, add plant filler and / or auxiliary additive to the previous mixture in the appropriate proportions; iii. Mix the components of step i. or i. until the mixture is homogenized; and iv. Particle the mixture obtained in the previous stage by mechanical means to the desired size.

[0015] The third aspect of the invention relates to the use of the composition according to the first aspect of the invention or prepared by the process of the second aspect of the invention as a filler for artificial turf. PREFERRED EMBODIMENT OF THE INVENTION

[0016] The first aspect of the invention relates to a filler composition for artificial turf comprising particles comprising at least 20% natural rubber and at least one mineral filler.

[0017] Unless otherwise defined, all technical and scientific terms used herein have the same meanings commonly understood by one skilled in the art to which this invention pertains. However, methods and materials similar or equivalent to those described herein may also be used in the practice or testing of the present invention.

[0018] The term "particles" refers to an individual portion or unit of the filler composition. Likewise, the terms particle, granule, or pellet are used interchangeably.

[0019] The term "natural rubber," also known as latex, refers to rubber composed primarily of isoprene polymers generated from natural sources. Natural rubber is generated by a polymerization reaction that occurs naturally, such as Hevea Brasiliensis, for example, and is obtained as an aqueous solution by extraction from the bark. From a chemical perspective, natural rubber is a natural polymer.

[0020] The term "mineral filler" refers to inorganic solid materials, such as fine mineral particles or powders, used to modify the physical, chemical, or mechanical properties of the resulting composite material. These compounds, when mixed with polymers, can improve their strength, increase their density, and, for example, in the particular case of the invention, when mixed with rubber, act as a rubber elasticity reducer.

[0021] In a preferred embodiment, the particles of the composition comprise between 20 and 80 percent by weight relative to the particles of the composition. In an even more preferred embodiment of the invention, the particles of the composition comprise between 40 and 60 percent by weight relative to the particles of the composition.

[0022] In another preferred embodiment of the composition of the invention, the particles of the composition comprise between 20 and 60 percent by weight with respect to the particles of the composition. In the most preferred embodiment, the particles of the composition comprise between 30 and 50% mineral filler by weight with respect to the particles of the composition. The mineral filler contained in the particles of the composition of the invention is selected from the group consisting of calcium carbonate, silica, talc, kaolin, titanium dioxide, zinc oxide, barite, mica, bentonite, wollastonite, or mixtures thereof.

[0023] Additionally, in another embodiment of the composition of the first aspect of the invention, the particles of the composition comprise plant-based filler. The term "plant-based filler" refers to materials of plant origin used as components in a composition; these are typically fruit hulls and pits, for example, rice hulls or crushed olive pits. The incorporation of plant-based filler into the particles of the composition allows for modulation of their density, allowing them to be adjusted to appropriate values ​​in the field. In another preferred embodiment of the invention, the plant-based filler is selected from fruit hulls, fruit pits, and / or plant-based fibers; preferably, the plant-based filler is selected from rice hulls, walnut shells, peanut shells, almond shells, hazelnut shells, olive pits, corn fibers, coconut fibers, or mixtures thereof.

[0024] In another preferred embodiment of the invention, the particles of the composition of the first aspect of the invention comprise between 5 and 25% by weight of plant filler, preferably between 10 and 20% by weight with respect to the particles of the composition.

[0025] Additionally, the particles of the composition of the first aspect of the invention also comprise an auxiliary additive. The term "auxiliary additive" refers to an additive that facilitates the handling and mixing of the substances in the composition. In this particular case, the adjective "auxiliary" refers to biodegradable polymeric compounds. In the most preferred embodiment, the auxiliary additive is a biodegradable polyester. The adjective "auxiliary" functions as a process aid, facilitating the mixing of the composition and achieving the appropriate particle size, facilitating the overall mechanical process. In addition to their role in handling, these biodegradable polyesters contribute to the environmental sustainability of the product, as they are capable of decomposing in biological environments.In the most preferred embodiment, the particles of the composition of the first aspect of the invention comprise an auxiliary additive selected from the group of polycaprolactone (PCL), polyurethane (Pll), ethylene polybutyl tartrate (PBTE), polyhydroxyalkanoates (PHA), polylactic acid (PLA) or mixtures thereof.

[0026] In another more preferred embodiment of the invention, the particles of the composition of the first aspect of the invention comprise between 3 and 8% by weight of auxiliary additive relative to the particles of the composition. In the most preferred embodiment of the invention, the particles of the composition of the first aspect of the invention comprise approximately 5 percent of the particles of the composition.

[0027] Certain ranges are presented with numerical values ​​preceded by the term "approximately." The term "approximately" is used in this document to provide literal support for the exact number that precedes it, as well as a number close or approximate to the number preceding the term. In determining whether a number is close or approximate to a specifically recited number, the unrecited close or approximate number may be a number that, in the context in which it is presented, provides the substantial equivalent of the specifically recited number.

[0028] In the most preferred embodiment the composition of the first aspect of the invention has a density between 0.95 and 1.5 g / cm 3 .

[0029] In a preferred embodiment, the particles of the composition according to the first aspect of the invention have a size between 1 and 8 mm, more preferably between 1.5 and 3 mm. The particle size is determined by methods known and customary in the art, for example, by sieving.

[0030] In the compositions of the invention, at least 40% by weight of the components of the composition are of renewable origin. The term "renewable origin" refers to those derived from natural sources that can be regenerated or replaced in a relatively short period of time. Some examples of these materials are polymers of natural origin, minerals, or products resulting from the agricultural industry, such as nutshells or similar, wood, or natural fibers, such as cotton, linen, or hemp. In another preferred embodiment of the invention, the particles of the composition of the invention comprise at least 20% natural rubber, at least one mineral filler, at least one plant-based filler, and at least one auxiliary additive.In another even more preferred embodiment of the invention, the particles of the composition of the invention consist of at least 20% natural rubber, at least one mineral filler, at least one plant-based filler, and at least one auxiliary additive. In another even more preferred embodiment of the invention, the particles of the composition of the invention comprise between 40 and 60% by weight of natural rubber, between 30 and 50% of at least one mineral filler, between 10 and 20% of at least one plant-based filler, and approximately 5% of at least one auxiliary additive. All percentages are expressed as percentages by weight relative to the particles unless otherwise specified.

[0031] The second aspect of the invention relates to a process for preparing a filler composition for artificial turf according to the first aspect of the invention comprising the following steps: i. Providing the natural rubber and at least one mineral filler in the appropriate proportions;

[0032] i. Optionally, add at least one plant filler and / or at least one auxiliary additive to the previous mixture in the appropriate proportions; iii. Mix the components of step i. or step ¡i. until the mixture is homogenized; and iv. Particle the mixture obtained in the previous stage by mechanical means to the desired size.

[0033] In a preferred embodiment, in the process for preparing an artificial turf infill composition according to the invention, the particles obtained in the embodiment of step iv. have a size between 1 and 8 mm. In the most preferred embodiment of the second aspect of the invention, the particles resulting from step iv. have a size between 1.5 and 3 mm.

[0034] The mechanical means used for the particularization of the mixture obtained in step i. or ¡i., are mechanical means known to the person skilled in the art, some of which may be, but are not limited to, extrusion and cutting, crushing, or similar.

[0035] In a preferred embodiment, in the process for preparing an artificial turf infill composition according to the invention, the mixing of the components of step iii. is carried out in a Banbury-type mixer.

[0036] The third aspect of the invention relates to the use of the composition according to the first aspect of the invention or prepared by the process of the second aspect of the invention as an artificial turf infill.

[0037] Having adequately described the nature of the present invention, as well as the methods for implementing it, it is not considered necessary to explain it in detail so that any person skilled in the art can understand its scope and the advantages derived from it. It is specified that, within its essence, it may be carried out in other embodiments that differ in detail from those provided as examples, and that they are also covered by the requested protection, as long as they do not alter, change, or modify its fundamental principle.

[0038] EXAMPLES

[0039] By way of illustrative, but not limiting, example, various embodiments of infill compositions for artificial turf, as well as the processes used in their preparation, are described below. These descriptions provide a more detailed and specific view of the formulations and methods, serving as representative, but not restrictive, examples of the wide variety of compositions and processes that can be applied in the manufacture of sustainable infills for synthetic sports surfaces. The composition of Example 1 is mixed and homogenized using a Banbury-type mixer-kneader. It is then shear extruded in air to obtain particles between 4 mm and 8 mm in size.

[0040] The composition of Example 2 is mixed and homogenized using a Banbury-type mixer-kneader. The mixture is then passed through a calender to obtain a thin sheet, which is then ground to obtain 3 mm to 6 mm particles.

[0041] Example 3

[0042] The composition of Example 3 is mixed and homogenized using a Banbury-type mixer-kneader. The mixture is then passed through a calender to obtain a thin sheet, which is then ground to obtain 1- to 3-mm particles.

[0043] Example 4

[0044] The composition of Example 4 is mixed and homogenized using a Banbury-type mixer-kneader. The mixture is then passed through a calender to obtain a thin sheet, which is then ground to obtain 1- to 3-mm particles.

[0045] Example 5

[0046] The composition of Example 4 is mixed and homogenized using a Banbury-type mixer-kneader. The mixture is then passed through a calender, and the resulting sheet is subsequently ground using a cryogenic crusher to a size smaller than 1 mm.

[0047] The composition of Example 4 is mixed and homogenized using a Banbury-type mixer-kneader. A water shear extruder is then used to shear and homogenize the shear into particles approximately 4 mm in size.

Claims

CLAIMS 1. Filler composition for artificial turf comprising particles comprising at least 20% by weight of natural rubber relative to the particles of the composition and at least one mineral filler.

2. The composition according to the preceding claim, wherein the particles of the composition comprise between 20 and 80% by weight of natural rubber with respect to the composition, preferably between 40 and 60% by weight with respect to the particles of the composition.

3. The composition according to any of the preceding claims, wherein the particles of the composition comprise between 20 and 60% by weight of mineral filler with respect to the particles of the composition, preferably between 30 and 50% by weight with respect to the particles of the composition.

4. The composition according to any of the preceding claims, wherein the particles of the composition additionally comprise a plant filler.

5. The composition according to the preceding claim, wherein the vegetable filler is selected from fruit shells, fruit stones and / or fiber of vegetable origin, preferably the vegetable filler is selected from rice husk, walnut shell, peanut shell, almond shell, hazelnut shell, olive stone, corn fibers, coconut fiber or mixtures thereof.

6. The composition according to claims 4 or 5, wherein the particles of the composition comprise between 5 and 25% by weight of plant filler with respect to the particles of the composition, preferably comprising between 10 and 20% by weight with respect to the particles of the composition.

7. The composition according to any of the preceding claims, wherein the mineral filler is selected from calcium carbonate, silica, talc, kaolin, titanium dioxide, zinc oxide, barite, mica, bentonite, wollastonite or mixtures thereof.

8. The composition according to any of the preceding claims, where the particles of the composition comprise an auxiliary additive, preferably comprising between 3 and 8% by weight relative to the particles of the composition.

9. The composition according to the preceding claim, wherein the auxiliary additive is a biodegradable polymer from the polyester family, preferably the auxiliary additive is selected from polycaprolactone (PCL), polyurethane (Pll), ethylene polybutyl tartrate (PBTE), polyhydroxyalkanoates (PHA), polylactic acid (PLA) or mixtures thereof.

10. The composition according to any of the preceding claims, wherein the composition has a density between 0.95 and 1.5 g / cm3.

11. The composition according to any of the preceding claims, wherein the particles of the composition have a size between 1 and 8 mm, preferably between 1.5 and 3 mm.

12. The composition according to any of the preceding claims, wherein at least 40% by weight of the components of the composition are of renewable origin.

13. Process for the preparation of a filler composition for artificial turf according to any of claims 1 to 12 comprising the steps: i. Providing the rubber and mineral filler in the appropriate proportions; i. Optionally, add plant filler and / or auxiliary additive to the previous mixture in the appropriate proportions; iii. Mix the components of step i. or i. until the mixture is homogenized; and iv. Particle the mixture obtained in the previous stage by mechanical means to the desired size.

14. The process for preparing a filler composition for artificial turf according to the preceding claim, wherein the particles obtained in the particularization of step iv. have a size between 1 and 8 mm, preferably between 1.5 and 3 mm.

15. The process for preparing an artificial turf infill composition according to the preceding claim, wherein step iii. is carried out in a Banbury-type mixer.

16. Use of the composition according to claims 1 to 12 or prepared by the process according to claims 13 to 15 as an artificial turf infill.

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