High density synthetic turf system

Abstract

Disclosed herein is a synthetic turf system comprising a high-density blend of fully texturized, semi-texturized, and tape yams tufted through a primary backing to form a blended yarn distribution having a continuous density gradient throughout the turf system's vertical profile. The system is characterized by a high filament density achieved through multiple yam ends per tuft (increased ply count), which is enhanced by the fibrillation of the tape yarns. The high-density blend of fully texturized, semi-texturized, and fibrillated tape yams, combined with the disclosed spatial and mechanical integration, provides a three-dimensional, load-distributive blend of fibers with variable flex, crimp, and surface texture. The overlap between the compression ratios of the different types of yarns results in a vertically continuous, mechanically blended turf layer, with fiber compression profiles that mimic the fibrous gradation of natural grass root and canopy structures.

Description

HIGH DENSITY SYNTHETIC TURF SYSTEMInventors: Dr. Colin Young and Charles Dawson Applicant: TenCate Grass Holding B.V.CROSS REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority benefit to U.S. Serial No. 63 / 692,503, filed September 9, 2024, which is incorporated by reference herein in its entirety.BACKGROUND

[0002] Synthetic turf, also known as artificial grass or artificial turf, is a surface made from synthetic fibers designed to mimic the look and feel of natural grass. It was originally developed for use in sports arenas, particularly those where maintenance of natural grass is challenging such as indoor stadiums. The first major installation occurred in 1966 in the Astrodome in Houston, Texas. The success of synthetic turf in the Astrodome led to its widespread adoption in various sports facilities around the world. The growth of adoption in sports has been rapid, covering a wide range of sporting types and abilities levels (from elite professional stadiums to amateur parks and recreation grounds and everything in-between). In the past 20 years, synthetic turf has found a wider range of applications covering not only sporting applications, but also recreational and domestic uses often grouped as landscape or outdoor living segments.

[0003] Since the 1970s, significant technological advancements in synthetic turf have been made. The latest innovations in synthetic sports surfaces have focused on enhancing player safety, environmental sustainability, and playing characteristics. The goal of these developments was to better emulate well-maintained natural grass. Modem synthetic turf systems typically comprise the following subcomponents: (i) a “pile” made up of synthetic fibers or yarns designed to replicate grass blades; (ii) woven or non-woven fabric backing material (including secondary coating to affix the fibers1#104238420v 14to the backing, typically PU or latex); and (iii) performance infill material — such as crumb rubber, sand, organic materials, thermoplastic elastomers, etc. — that functions as a soil surrogate to provide cushioning, grip / traction and stability, and synthetic fiber support.

[0004] Turf fibers are typically manufactured from thermoplastic polymers such as polyethylene (PE), polypropylene (PP), or, less commonly, nylon (polyamide). These materials are selected for durability, softness, flexibility, and resistance to environmental degradation. Fiber production begins with extrusion, in which polymer pellets are melted and forced through a shaped die. The die geometry determines the cross-section of the strand, which may be flat, diamond, ridged, or otherwise contoured. The extrudate is cooled, subjected to one or more post-extrusion processing steps (e.g., drawing, annealing, heat-setting, etc.), and wound for further use. Extrusion may produce monofilament yarns, formed as single solid strands, or tape yams, produced as wide films that may he slit or fibrillated. Yam types and configuration are selected for their natural appearance, resilience, and coverage depending on the application. Following extrusion, texturizing may be applied to impart a curled or crimped structure. Methods include hot-air jet texturing, false-twist texturing, and gear or stuffer-box crimping. Texturizing increases bulk, improves resilience, reduces glare, and enables fibers to better interlock with or encapsulate particulate infill. It also contributes to the creation of a thatch-like layer at the base of the pile, which stabilizes the upright fibers and can reduce or eliminate the need for performance infill in certain systems. On the other hand, non-texturized straight yarns are typically used for the “face” layer of the artificial turf system, which provides the primary surface appearance and texture of the turf.2#104238420v 14

[0005] Yam performance is evaluated using standardized tests. Crimp properties are measured under ASTM D3936. Dtex (decitex) — a measure of linear density of a yam — is determined by ISO 2060. Dtex measurements of yams quantify the yam thickness / weight, which directly affects yam stiffness, durability, and feel. A higher dtex indicates a thicker, heavier yam, while a lower dtex indicates a finer, lighter yarn. Typical dtex values of yarns used with artificial turf systems are in the 800 to 3,000 dtex range and they are formed together into a ply or number or filament typically 4 to 6 ends. Tape yarn widths generally range from 0.8 to 3.5 mm with thicknesses of 70-300 microns (ASTM D1777). Tensile strength and elongation at break, usually 20- 100%, are assessed according to ASTM D2256 or ISO 2062. Durability, including UV resistance and color stability, is measured by accelerated weathering tests such as ISO 4892 or ASTM G154.

[0006] After extrusion, yams are wound onto bobbins (i.e., cylindrical spools) that supply yarn to the tufting machine. Each bobbin usually carries one continuous length of yarn, although multiple strands can be combined and fed together through a single tufting needle. The number of strands introduced into each tuft is known as the ply count. A single-ply configuration inserts one strand per tuft, while two-ply introduces two strands, and higher counts such as six- or eight-ply introduce multiple strands simultaneously. Higher ply counts generally produce a denser, thicker pile with greater visual coverage and durability, though they also increase material consumption. The yarns in multi-ply systems may be lightly twisted together or laid parallel before tufting, depending on design. Bobbin weights typically range between about 8 and 25 kilograms depending on yam thickness and length, and a full creel — the frame that holds and organizes the bobbins for feeding into the machine — may accommodate several hundred to more than one thousand bobbins, depending on machine gauge and3#104238420v 14ply configuration. Although ply count itself is not formally defined in standards, its effect on mass per unit area is indirectly regulated under specifications such as ISO 8543 and ASTM D5848.

[0007] Tufting is the process of stitching yam loops through a primary backing, which are then cut to form upright fibers resembling individual grass blades. The tufting machine operates with hundreds of needles across the backing width. Several parameters govern the characteristics of the finished turf. The gauge is the spacing between adjacent needles, typically ranging from 3 / 16 inch to 3 / 4 inch. Sports turf is often manufactured at a 3 / 8-inch to 3 / 4-inch gauge. Stitch rate is another important variable, defined as the number of stitches inserted per unit length along the row, usually between about 3 to 6.5 stitches per inch. Higher stitch rates result in more tufts and therefore denser coverage. Pile height, which refers to the length of yarn from the base of the backing to the tip of the cut fiber, also varies by application. Sports turf typically employs pile heights of 30 to 60 millimeters (1.5-2.5 inches) while some application for turf may range from 10 millimeters to 70 millimeters (1.25-2.5 inches). Shorter pile heights have typically been used for fast ball-roll applications such as field hockey or tennis. The number of yam ends per tuft, determined by ply count, directly affects the pile mass and filament density of the system.

[0008] After tufting, the yam loops must be permanently secured to the primary backing by applying a secondary backing. The reverse side of the tufted fabric is coated with an adhesive, most commonly styrene-butadiene rubber (SBR) latex or polyurethane (PU). The coated fabric is then passed through a heated oven or curing chamber, which sets the adhesive and locks the tufts into place. In many products, a secondary layer such as nonwoven polypropylene or polyester is laminated onto the adhesive layer to improve dimensional stability and resistance to shrinkage or4#104238420v 14expansion. Once the backing has been fixed, the finished turf is rolled into large rolls for storage, transport, and eventual installation. The pile mass, representing the yarn component alone, is typically between 800 and 2,500 g / m2, while the total weight of the finished product, including backings and coating, generally falls in the range of 1,800 to 3,500 g / m2. Turf is manufactured in various roll widths, with the most common roll widths for sports applications being twelve (12) feet (Europe) and fifteen (15) feet (United States).

[0009] Finished turf products are characterized by parameters including tuft density, filament density, pile height, gauge, stitch rate, pile mass, and total weight. Tuft density, determined by stitch rate and gauge, typically ranges from 8,000 to more than 12,000 tufts per square meter. Filament density represents the total number of yam strands per unit area and is calculated as tuft density multiplied by ply count. Pile height generally varies from 10 to 70 millimeters depending on the application, while gauge and stitch rate determine lateral spacing and coverage. Pile mass, representing the mass of the yarns alone, and total weight, including backing and adhesive, further characterize the finished product. These values directly influence durability, infill retention, and ball-surface interaction. Sports turf typically employs pile heights of 3 / 8 inch-3 / 4 inch with gauges around 3 / 8 inch and stitch rates near 18 (per ten centimeters). These parameters are measured under established standards, including EN 15330- 1 , the FIFA Test Method Handbook, ASTM F2765 for infill systems, ASTM F355 and EN 14808 for shock absorption, and EN 12229 and ASTM D5848 for weight and structural characteristics.

[0010] In many installations, particulate infill is added to the turf surface to enhance performance. Common infill materials include sand, rubber granules, thermoplastic elastomers, and organic particles. Typical infill materials, alone or in5#104238420v 14combination, serve multiple functions, including: as ballast to hold the turf in place and provide stability for the backing; and as a performance enhancer by providing cushioning to reduce impact forces and by helping support fibers so they remain upright during play. For athletic applications, conventionally-used infill contributes to improved traction, ball response, energy restitution, and player safety by moderating impact loads. Accordingly, in most conventional infill systems used on sports fields, a layer of ballast infill, such as sand, is added as ballast and then topped with a layer of performance infill, such as rubber, to provide the safety and performance benefits. A conventional turf system leaves approximately 1 / 2 inch to 3 / 4 inch of fibers exposed above the infill.

[0011] Despite widespread adoption, conventional infilled turf systems present both performance and environmental drawbacks. Infill materials are known for the infamous “rooster tail” that appears when infill is displaced or kicked up during play. Infill materials may migrate, compact, or require replenishment, resulting in uneven playing conditions and increased maintenance. In addition, the abrasive action of conventional sand infill (typically used as a ballast) in conventional volumes accelerates the mechanical wear of plastic fibers, producing microplastic particles that raise health and environmental concerns. Other performance infill materials, such a rubber or thermoplastic elastomers (TPEs), can also fragment into small particles and migrate into the surrounding environment.

[0012] Alternative designs have been developed that reduce or eliminate the use of performance infill. These non-infilled systems (as defined below) rely on higher fiber tuft densities, shorter pile heights, curly or thatch yarns, and / or shock-absorbing pads beneath the turf to achieve performance. In many cases, a limited amount of sand or similar ballast may still be applied as a stabilizing infill to provide dimensional stability.6#104238420v 14However, current generation non-infilled systems have several well-documented critiques when used on sports fields. These include reduced shock absorption, producing a harder underfoot feel compared to natural grass; lower traction, which can result in slippery surfaces; and altered ball interaction, with inconsistent roll and higher rebound than desired. In these systems, the fibers deform / collapse laterally underfoot, causing lateral movement that can cause discomfort to the user. In addition, such prior art systems can accelerate fiber wear and matting, leading to diminished durability and less consistent surface properties over time.

[0013] Accordingly, there remains a need for improved synthetic turf systems that address one or more of these limitations while improving the desirable durability, safety, environmental benefits, and performance properties that make synthetic turf an attractive alternative to natural grass on sports fields.SUMMARY

[0014] The invention disclosed herein is directed to a high-density synthetic turf system featuring a blend of fully texturized, semi-texturized, and tape yarns tufted through a primary backing to form a blended yarn distribution having a continuous density gradient throughout the turf system’s vertical profile. The system is characterized by a high filament density achieved through multiple yam ends per tuft (increased ply count), which is preferentially enhanced by the fibrillation of otherwise single-ply tape yarns to create additional filament ends. The high-density blend of fully texturized, semi-texturized, and fibrillated tape yarns, combined with the disclosed spatial and mechanical integration, provides a three-dimensional, load-distributive blend of fibers with variable flex, crimp, and surface texture. The overlap between the compression ratios of the different types of yams results in a vertically continuous, mechanically blended turf layer, with fiber compression profiles that mimic the fibrous7#104238420v 14gradation of natural grass root and canopy structures. Consequently, the disclosed high- density synthetic turf system is capable of closely mimicking natural grass without the use of performance infill.

[0015] In a particular embodiment exemplifying the principles of the invention, the high-density synthetic turf system features a plurality of yams tufted through the primary backing to provide a synthetic turf system having a filament density greater than 650,000 filaments per square meter (fil / m2). In other embodiments, the synthetic turf system may have a filament density greater than 750,000 fil / m2, greater than 900,000 fil / m2, or greater than and 1,000,000 fil / m2.

[0016] In select embodiments, each tuft of the plurality of yarns comprises a single-ply tape yarn, a semi-texturized monofilament yarn, and a fully-texturized monofilament yam. In other embodiments, each tuft of the plurality of yarns comprises a fibrillated tape yarn, a semi-texturized monofilament yarn, and a fully-texturized monofilament yam. The fibrillated tape yam may be biaxially-drawn and / or slightly curved.

[0017] In select embodiments, the fibrillated tape yam has a ply count in the range of 4 - 8, and most preferably having a ply count of 6. The semi-texturized monofilament yarn may have a ply count in the range of 4 - 8, and most preferably has a ply count of 6. The fully-texturized monofilament yarn may have a ply count in the range of 8 - 12, and most preferably has a ply count of 10.

[0018] In select embodiments, the plurality of yams are provided in relative proportions, wherein the tape yam ranges from 26-32% of the synthetic turf system, wherein the semi-texturized monofilament yarn ranges from 28-34% of the synthetic turf system, and wherein the fully-texturized monofilament yarn ranges from 38-44% of the synthetic turf system.8#104238420v 14

[0019] In select embodiments, the synthetic turf system has a gauge between3 / 16inches and3 / 4inches and a stitch rate of 180 - 240 linear meters, and a tuft density of 20,000 - 25,000 tufts per square meter. Most preferably, the synthetic turf system has a gauge of3 / 8inches, a stitch rate of 210 linear meters, and a tuft density of approximately 22,000 tufts per square meter.

[0020] In select embodiments, the synthetic turf system has a dtex in the range of 14,500-22,500, with the tape yarn having a dtex in the range of 4,000-7,000, the semi-texturized monofilament yam having a dtex in the range of 5,000-7,000, and the fully-texturized monofilament yam has a dtex in the range of 5,500-8,500.

[0021] In select embodiments, the synthetic turf system has a dtex-per-filament ratio in the range of 517-1, 730, with the tape yam having dtex-per-filament ratio in the range of 500-7,000, the semi-texturized monofilament yarn having dtex-per-filament ratio in the range of 625-1 ,250, and with the fully-texturized monofilament yarn having dtex-per-filament ratio in the range of 458-1,250.

[0022] In select embodiments, the synthetic turf system has a pile mass in the range of 3,000 - 4,000 g / m2, with the fibrillated tape yarn having a pile mass in the range of 850 - 900 g / m2, the semi-texturized monofilament yam having a pile mass in the range of 900 - 950 g / m2, and the fully-texturized monofilament yarn having a pile mass in the range of 1,200 - 1,300 g / m2. The synthetic turf system may have a pile height in the range of 30 - 40 mm, and preferably has a pile height of 32-34 mm.

[0023] In one aspect of the invention, the high-density synthetic turf system is a non-infilled system (i.e., no performance infill) designed for use on sports fields that more closely mimics the performance of natural grass as compared to conventional noninfilled turf systems. In select embodiments, the synthetic turf system includes stabilizing infill disposed among the plurality of yarns and configured to function as a9#104238420v 14ballast for the turf system, but is free of any performance infill. The stabilizing infill preferably is either sand or oolitic aragonite added at a range volume of between 1 and 3.5 Ibs. / sq. ft. and preferably 2 Ibs. / sq. ft.

[0024] In another aspect of the invention, the plurality of yams of the synthetic turf system are constructed and arranged to deform elastically in a generally vertical direction when subjected to a downward force, and to recover substantially to their initial upright orientation when the force is removed, thereby reducing lateral displacement of the yarns relative to the applied load.

[0025] In another aspect of the invention, the plurality of yams of the synthetic turf system are constructed and arranged to exhibit a rotational resistance between 28 - 35 N-m when tested pursuant to EN 15301-1, thereby exhibiting rotational resistance that more closely mimics natural grass as compared to conventional non-infilled artificial turf systems.

[0026] In another aspect of the invention, the plurality of yams of the synthetic turf system are constructed and arranged to exhibit a directional ball roll differential of less than 1 meter when tested in accordance with EN 12235, thereby exhibiting more consistent, natural ball roll as compared to conventional non-infilled artificial turf systems.

[0027] In another aspect of the invention, the plurality of yams of the synthetic turf system are constructed and arranged to exhibit a ball bounce with less than 10% variation in any direction when tested in accordance with EN 12234, thereby exhibiting more consistent, natural ball bounce, as compared to conventional non-infilled artificial turf systems.10#104238420v 14

[0028] In another aspect of the invention, the plurality of yams of the synthetic turf system are constructed and arranged to exhibit improved grip in dry and wet conditions as compared to conventional non-infilled artificial turf systems.

[0029] The above summary is not intended to describe each illustrated embodiment or every possible implementation. These and other features, aspects, and advantages of the present invention will become better understood with regard to the following description, appended claims, and accompanying drawings.BRIEF DESCRIPTION OF THE DRAWINGS

[0030] The accompanying figures, where like reference numerals refer to identical or functionally similar elements throughout the separate views, which are not true to scale, and which, together with the detailed description below, are incorporated in and form part of the specification, serve to illustrate further various embodiments and to explain various principles and advantages in accordance with the present invention:Fig. 1 is a schematic view of various yams suitable for use with the present invention, including: (A) a fully-textured monofilament yarn; (B) a semi-textured monofilament yarn; (C) a non-textured tape yarn; and (D) a fibrillated tape yam;Fig. 2 is a schematic view of a typical yarn bundle utilized with a conventional non-infilled synthetic turf system;Fig. 3 is a schematic view of a first exemplary embodiment of a yarn bundle suitable for use with the artificial turf system of the present invention;11#104238420v 14Fig. 4 is a schematic view of a second exemplary embodiment of a yarn bundle suitable for use with the artificial turf system of the present invention;Fig. 5 is a perspective view of a first exemplary embodiment of an artificial turf system of the present invention, utilizing the yarn bundle of Fig. 3;Fig. 6 is a top view of the artificial turf system of Fig. 5;Fig. 6A is a close-up top view of Fig. 6;Fig. 7 is a perspective view of a second exemplary embodiment of an artificial turf system of the present invention, utilizing the yarn bundle of Fig. 4;Fig. 8 is a top view of the artificial turf system of Fig. 7;Fig. 8A is a close-up top view of Fig. 8;Fig. 9A is a view of a fibrillated tape yam before the fibrils are split;Fig. 9B is a view of the fibrillated tape yarn of Fig. 9A after the fibrils are split;Fig. 10 is an illustration of a soccer ball rolling over the artificial turf system of Fig. 5;Fig. 11 is an illustration of a soccer ball rolling over the artificial turf system of FIG. 7.Fig. 12 is a line graph illustrating the impact of filament density on rotational resistance in dry and wet conditions.12#104238420v 14DETAILED DESCRIPTION

[0031] Detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention, which can be embodied in various forms. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present invention in virtually any appropriately detailed structure. Alternate embodiments may be devised without departing from the spirit or the scope of the invention. Further, the terms and phrases used herein are not intended to be limiting; but rather, to provide an understandable description of the invention. While the specification concludes with claims defining the features of the invention that are regarded as novel, it is believed that the invention will be better understood from a consideration of the following description in conjunction with the drawing figures, in which like reference numerals are carried forward.

[0032] As used herein, the terms “a” or “an” are defined as one or more than one. The term “plurality,” as used herein, is defined as two or more than two. The term “another,” as used herein, is defined as at least a second or more. The terms “comprises,” “comprising,” or any other variation thereof are intended to cover a nonexclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements, but may include, other elements not expressly listed or inherent to such process, method, article, or apparatus. An element proceeded by “comprises” does not, without more constraints, preclude the existence of additional identical elements in the process, method, article, or apparatus that comprises the element. The terms “including,” “having,” or “featuring,” as used herein, are defined as comprising (i.e., open language). The term “coupled,” as used13#104238420v 14herein, is defined as connected, although not necessarily directly, and not necessarily mechanically. As used herein, the term “about” or “approximately” applies to all numeric values, whether or not explicitly indicated. These terms generally refer to a range of numbers that one of skill in the art would consider equivalent to the recited values (i.e., having the same function or result). In many instances these terms may include numbers that are rounded to the nearest significant figure. Relational terms such as first and second, top and bottom, right and left, and the like may be used solely to distinguish one entity or action from another entity or action without necessarily requiring or implying any actual such relationship or order between such entities or actions.

[0033] As used herein, an “infilled turf system” refers to a synthetic turf system in which performance particulate material is deposited among the pile fibers after tufting for the purpose of providing functional performance characteristics, including shock absorption, energy restitution, traction, and fiber support. The particulate material (i.e., performance infill) may include elastomeric, polymeric, or organic granules. Infilled turf systems may also incorporate particulate ballast, such as sand, for dimensional stability in addition to or in place of performance infill.

[0034] As used herein, a “non-infilled turf system” refers to a synthetic turf system that is designed to achieve functional performance without the use of particulate performance infill. A non-infilled turf system may nevertheless include a limited amount of particulate ballast (e.g., sand or mineral infill at 10 to 20 kg / m2or 7.5 mm to 15 mm in thickness) applied for dimensional stability, but such ballast does not materially contribute to performance characteristics such as cushioning, restitution, or traction.14#104238420v 14

[0035] As used herein, a “monofilament yam” refers to a yarn formed as a single, continuous, solid strand of extruded polymer. As used herein, a “tape yarn” refers to a yarn formed from an extruded polymeric fdm that may be slit into narrow, ribbon-like strips. As used herein, a “textured yarn” or “texturized yarn” refers to a yam or fiber that has been processed or designed to have a specific texture, as opposed to being smooth, flat, or straight. The degree and type of texturing can vary and will be distinguished herein based upon the relative length reduction of the yam posttexturization relative to the yarn’s untextured length. As used herein, a “fully- texturized” yarn refers to a yam that has pronounced texturization, displaying a highly curled, non-linear structure and a compression ratio of 30% to 75% relative to the fully extended yarn. As used herein, a “semi-texturized” yarn refers to a yam that has been processed to have less texturization than a fully-texturized yarn, exhibiting a compression ratio of 12.5% to 50% relative to the fully extended yarn. As used herein, a “curved” yam refers to a yarn that has been processed to have a slight curve, exhibiting a compression ratio of 0% to 15%. As used herein, a “fibrillated yam” or “fibrillated tape yam” refers to a tape yarn that has been slit, stretched, or otherwise processed to create a network of interconnected narrow fibrils extending from the tape body, as shown in FIGS. 9A-9B.

[0036] The present invention is directed to a high-density, non- infilled synthetic turf system featuring a high-density blend of fully-texturized, semi-texturized, and tape yarns that are spatially and mechanically integrated into the backing material to create a cohesive yarn matrix that more closely mimics natural grass than conventional artificial turf systems. The texturization rate is varied within the monofilament population of fibers, ranging from semi-texturized fibers that provide resilience and loft, to fully-texturized fibers that form a filamentous root-zone analogue. Unlike15#104238420v 14conventional non-filled systems that rely on distinct yarn types to create discrete face and thatch layers having specific functional purposes, the high-density synthetic turf system of the present invention utilizes a uniformly blended fiber network of fully- texturized, semi-texturized, and curved yarns throughout the pile. The disclosed system utilizes controlled texturization to tailor a substantially uniform pile distribution. The result is a mechanically blended turf layer with fiber compression profiles that mimic the fibrous gradation of natural grass root-zone and canopy structures. Surprisingly, the resultant fiber matrix functions as a dynamic traction interface, where the elongation and flex of each yam filament allows partial cleat penetration followed by spring-like capture. This provides not only enhanced grip while maintaining torsional release but also contributes to vertical energy absorption (occurring both during loading and unloading), acting as a distributed micro-resilient layer to moderate peak impact forces and provide a more uniform, consistent shock attenuation. While conventional turf systems may deform horizontally or laterally, the turf system of the present invention deforms in a vertical, linear direction that much more closely imitates natural grass. Additionally, the variance in orientation of the fibers reduces the feeling of slipperiness that is often caused when traditional turf fibers with uniform orientation create a quasiflat surface.

[0037] Exemplary synthetic turf systems embodying features of the present invention are shown in FIGS. 1 and 3-11. The synthetic turf system may comprise: (i) a primary backing material 105, 205, which may be formed from polypropylene woven fabrics, polypropylene or polyester nonwoven fabrics, or any other conventional materials used in the art; and (ii) a plurality of yams tufted into the primary backing material 105, 205, wherein the plurality of yarns comprises a high-density blend of fully texturized, semi-texturized, and tape yarns. In certain embodiments, such as the system16#104238420v 14shown in FIGS. 3, 5-6A, and 10, the synthetic turf system 100 utilizes single-ply tape yarns 160. However, in preferred embodiments, such as the system shown in FIGS. 4, 7-8A, and 11, the synthetic turf system 200 utilizes fibrillated, biaxially-drawn (i.e., has been mechanically stretched in both the longitudinal and transverse directions following extrusion) tape yams 280 that feature a controlled curved geometry. The plurality of yams may be permanently secured to the primary backing by applying a secondary backing layer 110, 210 adhered to the primary backing. Suitable secondary backing materials include styrene-butadiene rubber (SBR) latex, polyurethane (PU), or any other known adhesives suitable for use as backing materials for synthetic turf. The synthetic turf system does not utilize performance infill material. However, the synthetic turf system may optionally include a limited amount of particulate ballast (e.g., mineral infill such as sand, aragonite, etc.) for increased dimensional stability. In a preferred embodiment, the ballast infill comprises oolitic aragonite (CaCCh).

[0038] Referring to FIG. 1 , exemplary embodiments of yarns suitable for use with the present invention are shown, namely: fully-texturized monofilament yarns 20, semi-texturized monofilament yams 40, single-ply, non-texturized tape yarns 60, and curved, fibrillated tape yarns 80. The selection and processing of yams with varying levels of mechanical texturization is a key determinant of pile behavior, system density, and biomechanical response.

[0039] As shown in FIGS. 1 A and IB, fully-texturized yarns 20 display a highly curled, non-linear structure and a compression ratio of 30% to 75% relative to the fully extended yarn, while semi-texturized yams 40 display less curling and exhibit a compression ratio of 12.5% to 50% relative to the fully extended yarn. Unlike traditional straight monofilament yarns that maintain a fixed linear profile, texturized fibers introduce controlled non-linearity, achieved through thermomechanical crimping17#104238420v 14or extrusion modulation, allowing substantial vertical compression under load and during installation. Historically, the successful use of semi-texturized and fully- texturized monofilaments in non-infilled turf systems has been limited to leisure or landscape turf applications, as attempts to utilize texturized yams as a thatch layer in a non-infilled sports field has resulted in unacceptable performance characteristics (specifically low grip / traction and inconsistent ball / surface behavior). However, the high-density blend of the present invention allows the fully-textured and semi-textured yarns to be functional performance elements. The texturization rate, or degree of induced crimp, is varied within the monofilament population ranging from semitexturized fibers that provide resilience and loft within the overall filament matrix, to fully-texturized fibers that form a filamentous root-zone analogue while preserving elongation capacity and responsive mechanical rebound when subjected to dynamic cleat pressure. In a preferred embodiment, the semi -texturized yarn exhibits a compression ratio between 15% and 40% while the fully-texturized yam exhibits a compression ratio between 30% and 60%, with the majority of each type of yarn exhibiting a compression ratio in the middle of its respective range and the outliers creating some overlap between the fully-texturized and semi-texturized yarns.

[0040] An exemplary embodiment of a single-ply tape yarn 60 is shown in FIG. 1C. Single-ply tape yams have widths that generally range from 0.8 to 3.5 mm with thicknesses of 70-300 microns.

[0041] An exemplary embodiment of a fibrillated, biaxially-drawn tape yarn 80 having a controlled curved geometry is shown in FIG. ID. The fibrillation and shaping processes can be achieved using conventional means known in the art. This curve profile, engineered along the primary axis of the fibrillated tape, effectively reduces surface directionality and mitigates the “top-heavy” profile commonly associated with18#104238420v 14standard tape constructions. Conventional fibrillated and non- fibrillated tape yarns can flatten or orient horizontally, forming a film-like sheet at the surface that limits cleat penetration, creates anisotropic rolling resistance, and increases slipperiness of the playing surface. The fibrillated, biaxially-drawn tape yarn is particularly beneficial in its dual contribution to traction and surface resilience. The fibrillation process used in the present invention significantly increases the total number of individual filament ends exposed at the surface and provides enhanced filament surface roughness. In a preferred embodiment, the yarns are fibrillated using linear slits, but a skilled artisan will recognize that the benefits of the present invention may be achieved using a myriad of other fibrillation methods known in the art. The fibrillation and curved-shaping process further enables a natural vertical contraction, representing a height reduction of 0% to 10%. This controlled compaction aligns the fibrillated tape fibers more closely with the semi-texturized monofilament population, resulting in a cohesive and vertically integrated yarn matrix across the pile distribution. Unlike conventional flat tape yams which primarily resist lateral load via surface area and stiffness, the disclosed fibrillated, biaxially-drawn tape yarns leverage axial flexibility and volumetric entanglement to uniformly absorb and return force, while capturing and releasing cleats with greater biomechanical fidelity. Because the fibers deform vertically in response to applied force, minimizing lateral or horizontal, the artificial turf provides a much more natural feel for players and is less prone to slippage caused by conventional turf systems. The uniform vertical absorption and capture of force also contributes to more consistent shock attenuation than conventional turf systems. The combination of applying fibrillation and a curved shape to a biaxially-drawn tape yarn beneficially provides enhanced grip, comfort, and predictability to athletes during play without the use of performance infill.19#104238420v 14

[0042] FIGS. 2-4 provide schematic illustrations comparing the yarns used in traditional non-infill systems to the yarns used in exemplary turf systems of the present invention. As shown in FIG. 2, traditional non-infill systems would typically implement yarns in two discrete layers — with a fully-texturized monofilament 20 forming the thatch layer and a single-ply tape yarn 60 or non-texturized monofilament forming the face layer. As shown in FIG. 3, an exemplary yam bundle utilized in a synthetic turf system of the present invention may utilize three different yarns — a fully-texturized monofilament 20, a semi-texturized monofilament 40, and a non-texturized tape yarn 60. An alternative embodiment of a yam bundle utilized in a synthetic turf system of the present invention is shown in FIG. 4 and comprises a fully-texturized monofilament 20, a semi-texturized monofilament 40, and a curved, fibrillated tape yam 80. In both the FIG. 3 and FIG. 4 yam bundles, the gradation of texturization across yarn types results in a cohesive and vertically integrated yarn matrix, as compared to the separate layers found in conventional non-infill systems.

[0043] Referring now to FIG. 5, an exemplary embodiment of a synthetic turf system 100 featuring a high-density blend of fully-texturized monofilament yams 120, semi-texturized monofilament yams 140, and single-ply tape yarns 160 is shown. The fully-texturized monofilament yarn 120 functions as a controlled, functional thatch layer, the single-ply, non-texturized tape yam 160 functions as a face layer, and the semi-texturized monofilament yam 140 provides both thatch layer and face layer functionality. In certain embodiments, the fully-texturized monofilament yarn 120 may exhibit the following characteristics: a dtex between 5,500-8,500 g / lOkm; a ply count ranging from 6-14, and preferably 10 ply; and a pile mass between 1,100-1,400 g / m2. In certain embodiments, the semi-texturized monofilament yam 140 may exhibit the following characteristics: a dtex between 5,000-7,000 g / lOkm; a ply count ranging20#104238420v 14from 4-8, and most preferably 6 ply; and a pile mass between 800-1,100 g / m2. In certain embodiments, the single-ply tape yarn 160 may exhibit the following characteristics: a dtex between 4,000-7,000 g / lOkm and a pile mass between 800-900 g / m2. In certain embodiments, the single-ply tape yam 160 may also be a curved singleply tape yam. FIGS. 6 and 6 A show this embodiment of the artificial turf system 100 from the top, demonstrating the density of the yams in the system and the single directionality of the tape yarns 160. Additional characteristics of an exemplary synthetic turf system 100 are summarized in the table below:21#104238420v 14Table 1

[0044] Referring now to FIG. 7, an exemplary embodiment of a synthetic turf system 200 featuring a high-density blend of fully-texturized yarns 220, semitexturized yams 240, and fibrillated, biaxially-drawn, curved tape yarns 280 is shown. The fully-texturized monofilament yam 220 functions as a thatch layer, while the semitexturized monofilament yarn 240 and the fibrillated tape yarn 280 each provide both thatch layer and face layer functionality. Whereas conventional non-infilled turfs are layered systems with defined face and thatch zones, the high-density, non-infilled synthetic turf system 200 features a blended yarn distribution having a continuous density gradient throughout its vertical profile rather than defined layers like in the prior art. The system is characterized by a high filament density achieved through multiple yarn ends per tuft (increased ply count), aided in part by the fibrillation of the tape yarns. This is achieved despite having a relatively low linear density (majority of yarns less than 1 ,000 dtex / filament) and no performance infill to support the yarns. FIGS. 8 and 8A show this embodiment of the artificial turf system 200 from the top. As compared to the embodiment of the artificial turf system 100 shown in FIGS. 5-6A, the turf system 200 has more yams per square inch, and the controlled curvature of the fibrillated tape yarns 180 results in the mixed directionality of the fibers shown in FIGS. 8 and 8 A.

[0045] The non-filled synthetic turf system 200 utilizes controlled curvature or texturization of each yarn element to tailor a substantially uniform pile distribution without reducing overall fiber length or system mass. The high-density blend of fully texturized, semi-texturized, and fibrillated tape yams, combined with the disclosed spatial and mechanical integration, provides a turf system having no fixed thatch layer or a consistent upper “face” layer as used in conventional non-infilled turf systems.22#104238420v 14Rather, the high-density, non-infilled system of the present invention provides a three- dimensional, load-distributive blend of fibers with variable flex, crimp, and surface texture. This blending of fully-texturized, semi-texturized, and curved fibrillated yams within a single matrix enables the construction of surfaces with enhanced traction, cleat conformity, energy absorption, vertical deformation and release, and ball interaction — without reliance on infill materials. The overlap between the compression ratios of the different types of yarns results in a vertically continuous, mechanically blended turf layer, with fiber compression profiles that mimic the fibrous gradation of natural grass root and canopy structures, and the continuous gradient of mechanical properties and introduction of distributed flex delivers enhanced multidirectional cleat engagement and surface grip under rotational load.

[0046] In certain embodiments, the fully- texturized monofilament yam 220 may exhibit the following characteristics: a dtex between 7,500-8,500 g / lOkm; a ply count ranging from 8-12, and most preferably 10 ply; and a pile mass between 1 ,200- 1,300 g / m2. In certain embodiments, the semi-texturized monofilament yarn 240 may exhibit the following characteristics: a dtex between 5,500-6,500 g / lOkm; a ply count ranging from 4-8, and most preferably 6 ply; and a pile mass between 900-1,000 g / m2. In certain embodiments, the fibrillated, curved tape yarn 280 may exhibit the following characteristics: a dtex between 5,000-6,000 g / lOkm; a ply count ranging from between 4-8, and most preferably 6 ply; and a pile mass between 800-900 g / m2. Additional characteristics of the synthetic turf system 200 are summarized in the table below:23#104238420v 14Table 2

[0047] Comparative analysis indicates greater than a 20% increase in fiber ply count per unit area versus embodiments utilizing non-fibrillated tape yams, resulting in a corresponding increase in cleat engagement points per square meter available for player- surface interaction. This enhancement, along with the increased roughness, is especially impactful in cold or wet conditions, where the additional contact improves traction, surface compliance, and cleat capture consistency. Further, by removing directional stiffness and introducing distributed flex, as shown in FIGS. 8-8 A, the system delivers enhanced multidirectional cleat engagement and surface grip, particularly under rotational load.24#104238420v 14EXAMPLES

[0048] The invention disclosed herein is directed to a synthetic turf system featuring a high-density combination of fully-texturized, semi-texturized, and tape yarns. Exemplary embodiments of the present invention were tested against several prior art systems. The experimental results below demonstrate that the synthetic turf system of the present invention out-performs legacy non-filled turf systems and conventional rubber infill systems, more closely simulating natural grass playing surfaces without requiring the usage of performance infill material.Example 1:Embodiment 1- Three-Yam Synthetic Turf System

[0049] Characteristics of an exemplary embodiment of a synthetic turf system 100 featuring a high-density blend of fully-texturized monofilament yams 120, semitexturized monofilament yams 140, and single-ply tape yarns 160 are shown below:25#104238420v 14Table 3The synthetic turf system 100 above exhibits a filament density of 749,606 filaments / m2using a 17-ply strand bundle with an average total dtex / filament ratio of 1,141.Example 2:Embodiment 2- Three-Yarn Synthetic Turf System w / Fibrillated Tape Yarns

[0050] Characteristics of an exemplary embodiment of a synthetic turf system 200 featuring a high-density blend of fully-texturized monofilament yams 220, semitexturized monofilament yarns 240, and curved, fibrillated tape yams 280 are shown below:26#104238420v 14Table 4The synthetic turf system 200 above exhibits a filament density of 970,079 filaments / m2using a 22-ply strand bundle with an average total dtex / filament ratio of 882. The turf system 200 has the same tuft density of 22,047 tufts / m2as Example 1 above, but because of the additional ply added by the fibrillation of the tape yam — providing a total 22-ply strand bundle as compared to the 17-ply strand bundle in the first exemplary embodiment — the filament density significantly increases from 749,606 filaments / m2to 970,079 filaments / m2.Example 3:Rubber Infill Synthetic Turf System (Prior Art)

[0051] Conventional synthetic turf systems used for sports fields typically comprise the following subcomponents: (i) synthetic fibers or yams designed to replicate grass blades; (ii) woven or non-woven fabric backing material (including secondary coating to affix the fibers to the backing, typically PU or latex); and (iii) performance infill material — such as crumb rubber, sand, organic materials, thermoplastic elastomers, etc. — that functions as a soil surrogate to provide cushioning, grip / traction and stability, and synthetic fiber support.

[0052] In the following example, characteristics of an exemplary embodiment of a conventional rubber-infilled synthetic turf system is compared to Examples 1 and 2 of the high-density synthetic turf system of the present invention:27#104238420v 14Table 5

[0053] In contrast to the high-density synthetic turf system of the present invention, conventional performance infill turf systems utilize rubber infill material to provide the support for the yarns, which exhibit a substantially higher overall pile height when compared to Examples 1 and 2. Additionally, conventional performance infill turf systems typically have much lower overall ply counts and use a lower stitch rate and higher gauge than Examples 1 and 2 of the present invention, which results in a significantly lower number of tufts and filaments per unit area. Consequently, the28#104238420v 14filament densities of Examples 1 and 2 are 25 times (25x) and 32x higher, respectively, than the filament density of the conventional rubber infill system. This lower filament density is necessary for rubber infill systems in order to accommodate the performance infill, which serves as a functional component of the playing surface. Examples 1 and 2 of the present invention also exhibit much lower dtex / filament ratios than conventional rubber infill systems, which gives the turf system of the present invention a softer hand feel and more comfort underfoot, more natural aesthetics due to the use of finer filaments, and better ball roll characteristics due to the increased density of the filament canopy.Example 4:Conventional Non-infilled Synthetic Turf System (Prior Art)

[0054] As previously noted, conventional non-infilled turf systems have been developed in attempts to avoid the downsides associated with rubber-infilled turf systems. Conventional non-infilled turf systems rely on higher fiber tuft densities, shorter pile heights, curly or thatch yarns, and / or prefabricated shock-absorbing pads beneath the turf to achieve performance.

[0055] In the following example, characteristics of an exemplary embodiment of a conventional non-infilled synthetic turf system is compared to Examples 1 and 2 of the high-density synthetic turf system of the present invention:29#104238420v 14Table 6

[0056] Like the high-density synthetic turf system of the present invention, traditional non-infill systems do not use performance infill and instead rely on the turf yarns themselves to provide the necessary structural support. However, traditional noninfill systems typically achieve this structural support by utilizing a very stiff yam with a high linear density (12,000 dtex) for the face layer, and by utilizing a relatively stiff (7,920 dtex) texturized yam for the thatch layer. Both Examples 1 and 2 of the present invention utilize a high-density combination of three distinct yams with much lighter30#104238420v 14linear density at a higher total ply count than that of the traditional non-infill turf. Thus, while the pile mass of Examples 1 and 2 is only about 1.25x higher than the traditional non-infill (2,430 g / m2), the filament densities (749,606 fil / m2and 970,079 fil / m2, respectively) are significantly higher than the traditional non-infill (529,134 fil / m2), creating a much denser and more structurally supportive turf that is still bendable and movable like natural grass. Through the elimination of layered yam stratification and the introduction of a heterogeneous, intermeshed matrix of fiber types distributed throughout the turf pile, a mechanically stable, cleat-engageable matrix is created that mimics the organic soil-canopy interface found in natural grass systems.Example 5:Rotational Resistance Testing-Comparative Analysis

[0057] The rotational resistance test (sometimes called “torque resistance” or “rotational traction”) measures the force required to twist a cleat that is studded in the surface of the turf. The test is typically carried out by pressing a studded test foot or stud plate into the turf under a defined vertical load, rotating the boot, and then measuring the peak torque required to initiate and maintain rotation. The rotational resistance test is designed to simulate the interaction between a player’s foot and the turf, capturing the balance between sufficient grip for performance and controlled release to reduce the risk of injury. Where the torque is too low, the surface of the turf will provide poor grip and feel slippery; where the torque is too high, the turf presents a high risk of foot / ankle / knee injuries due to the higher likelihood that a player’ s foot will get caught in the turf. For reference, the FIFA Quality Programme sets out acceptable ranges of torque for FIFA Quality and FIFA Quality Pro turfs, which typically have a torque range around 25-50 N-m, depending on the category.

[0058] Rotational resistance tests were conducted according to the standards set forth in EN 15301-1. The vertical load was applied at 46 kg to simulate a player’s body31#104238420v 14weight pressing down, and the studded test foot was rotated through 90° at 12 rpm. The torque was measured using the rotational resistance equipment as described in EN 15301-1. The test was performed in both wet and dry conditions and on both new and aged specimens. The specimens were artificially aged through 20,200 cycles of Lisport method (EN 15306), meant to replicate approximately 6 to 10 years of play without intervention. The results of the experiment are provided in Table 7 in Newton meters.Table 7

[0059] In each test, the Conventional Non-Filled System (Example 4) exhibited the lowest grip, often below the 25 N-m threshold of FIFA Quality turfs, demonstrating the non- suitability of traditional non-filled turfs for sports applications. Before the specimens were aged, the 3 -Yam Fibrillated System (Example 2) and the Rubber In- Filled System (Example 3) performed very similarly to natural grass, while the 3-Yarn System (Example 1) exhibited a lower grip that still fell well within the acceptable range. After aging, both the 3 -Yam System (Example 1) and the 3-Yarn Fibrillated System (Example 2) performed very similarly to new natural grass, while the Rubber In-Filled System’s grip increased significantly. Although still within the acceptable range for safety provided by FIFA, this increased grip after aging is one of the reasons players prefer the feel of natural grass over current generation artificial turf systems.

[0060] The 3- Yam Fibrillated System (Example 2) was shown to exhibit rotational resistance most closely mimicking that of natural grass. It is believed that the32#104238420v 14high filament density and open fiber structure at the surface, which creates additional contact points between the cleats and the turf, provided improved rotational traction when compared to the non-fibrillated, 3-Yam System (Example 1). Additionally, 3- Yam Fibrillated System (Example 2) does not exhibit a significant increase in grip after aging, as opposed the Rubber In-Filled System (Example 3) which detrimentally develops more grip than natural grass as it ages (due to infill compaction and consolidation).Example 6:Rotational Resistance Testing-Impact of Filament Density

[0061] Further rotational resistance testing was conducted to evaluate the effect of filament density on turf performance. The 3-Yarn Fibrillated System of Example 2 was utilized for this study, but with fibrillated tape yams having ply counts ranging from 4-8 to produce turf systems with varying filament densities. The experiment was conducted using non-aged turf systems in both wet and dry conditions. The results of the experiments are shown in Table 8 below:Table 8

[0062] The results of this experiment show a steady increase in grip from the 500,000 fil / m2specimen up through the 1.1 million fil / m2specimen, but with increases in grip leveling off around 1 million fil / m2. This relationship is best illustrated by the line graph in Figure 12. Thus, the filament density of the turf exhibits a positive33#104238420v 14correlation with the grip of the turf, with the 1 million fil / m2specimen most closely replicating the grip of natural grass.Example 7:Ball Roll Testing

[0063] The ball roll test measures the distance a standard soccer ball (football) travels across a turf surface when released from a set height and slope. On natural grass, ball roll is consistent in all directions. On turf, however, directional differences can occur due to the lean of the fibers. This effect is especially pronounced in dense systems with higher face yarn content, where the directional lean can create large differences in ball roll depending on the direction of play. For players, this reduces predictability and consistency.

[0064] The ball roll test was conducted according to the EN 12235 standard. In the experiment, a test ball is rolled down a ramp under controlled conditions in two opposite directions, and the distance travelled is recorded. A surface with a short ball roll will hinder natural play, while a longer ball roll makes control difficult for players. The FIFA Quality Programme defines a generally acceptable range of ball roll as between 4-10 m, depending on the category, to replicate natural grass conditions. The results of the experiment are shown in Table 9, with measurements in meters:Table 9

[0065] All five turfs tested exhibited ball roll within the acceptable 4-10 m range in both directions. The Conventional Non-Filled System (Example 4) exhibited34#104238420v 14the worst performance, with a directional difference of 4.4 meters. The Rubber In-FilledSystem (Example 3) and the 3-Yam System (Example 1) both exhibited a noticeable differential between their ball rolls, testing at 1.0 m and 1.7 m respectively. The 3- Yarn Fibrillated System (Example 2) closely mimicked natural grass — with a roll differential of 0.1 m as compared to 0.2 m for natural grass. It is believed that the 3- Y am Fibrillated System (Example 2) demonstrated superior ball roll characteristics due to the fibrillated tape yarns being smaller, more flexible, and slightly curved as compared to the 3- Yarn System (Example 1) that utilizes a non-textured, single-ply tape yarn. Because the fibers of the fibrillated tape yams do not all point in the same direction as with singleply tape yarn, consistent ball roll is achieved in all directions. This effect is illustrated in FIGS. 10 and 11, which show a soccer ball rolling over the 3-Yam System (Example 1) in FIG. 10 as compared to the 3-Yam Fibrillated System (Example 2) in FIG. 11.Example 8:Deformation Testing

[0066] The deformation test measures the movement of a cleat, or boot, when the boot applies pressure to the surface of turf. To conduct the test, reflective markers are attached to a test boot, and then a force is applied through the boot to the surface of the turf. The movement of the boot is measured by an infrared camera, such as the 12 Vicon® Vantage Motion Capture Camera (250 Hz), which uses infrared light to track the positions of the reflective markers. When the pressure is applied, a force plate, such as the 1000 Hz one produced by Kistler®, tracks the location of the center of pressure during movement so that the movement of the boot caused by deformation of the turf — rather than by the applied force — can be isolated. The goal of this testing is to see how the surface of the turf bends during contact. When yams require more force to bend in the vertical direction, it can create a feeling of floating that feels uncomfortable for players. Additionally, when yams are slippery, deformation of the blades can push the35#104238420v 14foot in an unintended direction horizontally, which can lead to discomfort. Thus, in artificial turf, the goal is generally to achieve minimal horizontal and lateral deformation in order to mimic the feel of natural grass.

[0067] The results are shown in Table 10, with amount of deformation in each direction measured in millimeters. The X column measures the deformation of the boot in the left-to-right direction, the Y column measures the deformation of the boot in the front-to-back (toe-to-heel) direction, and the Z column measures the deformation of the boot in the vertical direction. All are measured from the point of first contact with the top of the yarn or blade of grass.Table 10

[0068] The 3- Yam System (Example 1) and the 3- Yarn Fibrillated System (Example 2) exhibited similar vertical deformation — at 14.5 mm 14.3 mm respectively. This vertical deformation was similar to the Rubber In-Filled System (Example 3) and over 2 mm more than the Conventional Non-Filled System (Example 4). The 3- Yarn Fibrillated System (Example 2) exhibited the most similar horizontal deformation as compared to natural grass, with just a 0.1 mm difference between natural grass and the 3- Yam Fibrillated System in both the X and Y directions. These results illustrate that the 3-Yarn Fibrillated System’s integrated fiber structure and non-directional orientation of the tape fibrils allow the boot to settle more naturally into the surface of the turf without unwanted horizontal slip that can raise stability concerns.36#104238420v 14

[0069] Many modifications and other embodiments of the invention set forth herein will come to mind to one skilled in the art having the benefit of the teaching presented in the foregoing description and associated drawings. Therefore, it is to be understood that the inventions are not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.37#104238420v 14

Claims

CLAIMSWhat is claimed is:

1. A synthetic turf system, comprising: a) a primary backing; b) a plurality of yarns tufted through the primary backing to provide a synthetic turf system having a filament density greater than 750,000 filaments per square meter (fil / nr), wherein each tuft of the plurality of yarns comprises:(i) a fibrillated tape yam, wherein the fibrillated tape yarn has a ply count of at least 4;(ii) a semi-texturized monofilament yarn, wherein the semitexturized monofilament yarn has a ply count of at least 4; and(iii) a fully-texturized monofilament yam wherein the fully- texturized monofilament yam has a ply count of at least 8.

2. The synthetic turf system of claim 1 , wherein the synthetic turf system has a filament density greater than 900,000 filaments per square meter.

3. The synthetic turf system of claim 1, wherein the synthetic turf system has a filament density greater than 1 ,000,000 filaments per square meter.

4. The synthetic turf system of any one of claims 1 to 3, wherein the synthetic turf system has a gauge between3 / 16inches and3 / 4inches and a stitch rate of 180 - 240 linear meters.

5. The synthetic turf system of claim 4, wherein the synthetic turf system has a gauge of3 / g inches.

6. The synthetic turf system of claim 4, wherein the fibrillated tape yarn is biaxially drawn to provide a curved fibrillated tape yarn.38#104238420v 147. The synthetic turf system of claim 4, wherein the synthetic turf system has a stitch rate between 200 - 220 linear meters.

8. The synthetic turf system of claim 4, wherein the synthetic turf system has a stitch rate of 210 linear meters.

9. The synthetic turf system of claim 4, wherein the synthetic turf system has a tuft density of 20,000 - 25,000 tufts per square meter.

10. The synthetic turf system of claim 4, wherein the plurality of yarns are provided in relative proportions, wherein the fibrillated tape yarn ranges from 26-32% of the synthetic turf system, wherein the semi-texturized monofilament yarn ranges from 28-34% of the synthetic turf system, and wherein the fully- texturized monofilament yam ranges from 38-44% of the synthetic turf system.

11. The synthetic turf system of claim 4, wherein the synthetic turf system has a dtex in the range of 14,500-22,500, with the fibrillated tape yam having a dtex in the range of 4,000-7,000; with the semi -texturized monofilament yarn having a dtex in the range of 5,000-7,000; and with the fully-texturized monofilament yarn has a dtex in the range of 5,500-8,500.

12. The synthetic turf system of claim 4, wherein the synthetic turf system has a dtex-per- filament ratio in the range of 517 - 1,406, with the fibrillated tape yarn having dtex-per-filament ratio in the range of 500 - 1,750; with the semitexturized monofilament yam having dtex-per-filament ratio in the range of 900-950; and with the fully-texturized monofilament yarn having dtex-per- filament ratio in the range of 1,200-1,300.

13. The synthetic turf system of claim 4, wherein the fibrillated tape yam has a ply count of 6, wherein the semi-texturized monofilament yarn has a ply count of 6, and wherein the fully-texturized monofilament yam has a ply count of 10.39#104238420v 1414. The synthetic turf system of claim 4, wherein the synthetic turf system has a pile height in the range of 30 - 40 mm.

15. The synthetic turf system of claim 14, wherein the synthetic turf system has a pile height of 32 mm.

16. The synthetic turf system of claim 4, wherein the synthetic turf system has a pile mass in the range of 3,000 - 4,000 g / m2, with the fibrillated tape yam having a pile mass in the range of 850 - 900 g / m2; with the semi-texturized monofilament yarn having a pile mass in the range of 900 - 950 g / m2; and with the fully-texturized monofilament yam having a pile mass in the range of 1 ,200 - 1,300 g / m2.

17. The synthetic turf system of claim 4, further comprising stabilizing infill disposed among the plurality of yarns.

18. The synthetic turf system of claim 15, wherein the stabilizing infill is selected from the group consisting of sand and oolitic aragonite.

19. The synthetic turf system of claim 15, wherein the synthetic turf system is free of any performance infill disposed among the yarns.

20. A synthetic turf system, comprising: a) a primary backing; b) a plurality of yarns tufted through the primary backing to provide a synthetic turf system having a filament density greater than 650,000 filaments per square meter (fil / m2), wherein each tuft of the plurality of yarns comprises:(i) a tape yarn;(ii) a semi-texturized monofilament yarn, wherein the semitexturized monofilament yarn has a ply count of at least 4; and40#104238420v 14(iii) a fully-texturized monofilament yam wherein the fully- texturized monofilament yam has a ply count of at least 8.

21. The synthetic turf system of claim 20, wherein the tape yam is a single-ply tape yarn.

22. The synthetic turf system of claim 22, wherein the tape yam is a fibrillated, biaxially-drawn tape yarn having a ply count in the range of 4 - 8.

23. The synthetic turf system of any one of claims 20 to 22, wherein the synthetic turf system has a filament density greater than 750,000 filaments per square meter.

24. The synthetic turf system of claim 22, wherein the synthetic turf system has a filament density greater than 900,000 filaments per square meter.

25. The synthetic turf system of any one of claims 20 to 22, wherein the synthetic turf system has a gauge between3 / 16inches and3 / 4inches and a stitch rate of 180 - 240 linear meters.

26. The synthetic turf system of claim 25, wherein the synthetic turf system has a gauge of3 / 8inches.

27. The synthetic turf system of claim 25, wherein the synthetic turf system has a stitch rate of 200 - 220 linear meters.

28. The synthetic turf system of claim 25, wherein the synthetic turf system has a stitch rate of 210 linear meters.

29. The synthetic turf system of claim 25, wherein the synthetic turf system has a tuft density of 20,000 - 25,000 tufts per square meter.

30. The synthetic turf system of claim 25, wherein the plurality of yarns are provided in relative proportions, wherein the tape yam ranges from 26-32% of the synthetic turf system, wherein the semi-texturized monofilament yarn41#104238420v 14ranges from 28-34% of the synthetic turf system, and wherein the fully- texturized monofilament yam ranges from 38-44% of the synthetic turf system.

31. The synthetic turf system of claim 20, wherein the synthetic turf system has a dtex in the range of 14,500-22,500, with the tape yarn having a dtex in the range of 4,000-7,000; with the semi-texturized monofilament yarn having a dtex in the range of 5,000-7,000; and with the fully-texturized monofilament yarn has a dtex in the range of 5,500-8,500.

32. The synthetic turf system of claim 20, wherein the synthetic turf system has a dtex-per- filament ratio in the range of 517-1,730, with the tape yarn having dtex-per-filament ratio in the range of 500-7,000; with the semi-texturized monofilament yarn having dtex-per-filament ratio in the range of 625-1,250; and with the fully-texturized monofilament yarn having dtex-per-filament ratio in the range of 458-1,250.

33. The synthetic turf system of claim 22, wherein the fihrill ated tape yam has a ply count of 6, wherein the semi-texturized monofilament yarn has a ply count of 6, and wherein the fully-texturized monofilament yam has a ply count of 10.

34. The synthetic turf system of claim 25, wherein the synthetic turf system has a pile height in the range of 30 - 40 mm.

35. The synthetic turf system of claim 25, wherein the synthetic turf system has a pile height of 32 mm.

36. The synthetic turf system of claim 25, wherein the synthetic turf system has a pile mass in the range of 3,000 - 4,000 g / m2, with the fibrillated tape yam having a pile mass in the range of 850 - 900 g / m2; with the semi-texturized monofilament yarn having a pile mass in the range of 900 - 950 g / m2; and with42#104238420v 14the fully-texturized monofilament yam having a pile mass in the range of 1 ,200 - 1,300 g / m2.

37. The synthetic turf system of claim 4, further comprising stabilizing infill disposed among the plurality of yarns.

38. The synthetic turf system of claim 15, wherein the stabilizing infill is selected from the group consisting of sand and oolitic aragonite.

39. The synthetic turf system of claim 15, wherein the synthetic turf system is free of any performance infill disposed among the yarns.

40. A synthetic turf system, comprising: a) a primary backing; b) a plurality of yarns tufted through the primary backing to provide a synthetic turf system having a filament density between 750,000 filaments / m2and 1,300,000 filaments / m2, wherein each tuft comprises: (i) a fihrillated tape yarn having a ply count between 2 and 8 and comprising 26-32% of the synthetic turf system; (ii) a semi-texturized monofilament yarn having a ply count between 4 and 8 and comprising 28-34% of the synthetic turf system; and (iii) a fully-texturized monofilament yam having a ply count between 8 and 12 and comprising 38-44% of the synthetic turf system; and c) wherein the synthetic turf system has: a gauge between3 / 16inches and 3 / 4inches; a stitch rate between 180 - 240 linear meters; and a tuft density between 20,000 - 25,000 tufts / m2; and d) wherein the plurality of yams are configured to deform elastically in a generally vertical direction when subjected to a downward force and to43#104238420v 14recover substantially to their initial upright orientation when the force is removed.

41. A non-infilled synthetic turf system, comprising: a) a primary backing; b) a plurality of yarns tufted through the primary backing to provide a synthetic turf system having a filament density greater than 750,000 filaments / m2, wherein each tuft of the plurality of yarns comprises: (i) a curved, fibrillated tape yarn; (ii) a semi-texturized monofilament yarn; and (iii) a fully-texturized monofilament yam; c) wherein the plurality of yams are configured to deform elastically along their vertical axis when subjected to a downward force and to recover substantially to their initial upright orientation when the force is removed.

42. A non-infilled synthetic turf system, comprising: a) a primary backing; b) a plurality of yams tufted through the primary backing to provide a noninfilled synthetic turf system having a filament density greater than 750,000 filaments / m2, wherein each tuft comprises: (i) a curved, fibrillated tape yarn; (ii) a semi-texturized monofilament yam; and (iii) a fully-texturized monofilament yarn having; and c) wherein the non-infilled synthetic turf system exhibits a rotational resistance between 28 - 35 N m when tested pursuant to EN 15301-1.

43. A non-infilled synthetic turf system, comprising: a) a primary backing;44#104238420v 14b) a plurality of yams tufted through the primary backing to provide a noninfilled synthetic turf system having a filament density greater than 750,000 filaments / m2, wherein each tuft comprises: (i) a curved, fibrillated tape yarn; (ii) a semi-texturized monofilament yam; and (iii) a fully-texturized monofilament yarn having; and c) wherein the non-infilled synthetic turf system exhibits a directional ball roll differential of less than 1 meter when tested in accordance with EN 12235.

44. The non-infilled synthetic turf system of any one of claims 41 to 43, further comprising stabilizing ballast disposed among the plurality of yams.

45. The non-infilled synthetic turf system of claim 44, wherein the stabilizing infill is selected from the group consisting of sand and oolitic aragonite.45#104238420v 14

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