Articles comprising nonwoven material formed using airlay system

Abstract

Described is a shock absorbing pad that includes a composite nonwoven pad. The composite nonwoven pad is formed from a nonwoven blend of fiber and a heat set binder. Top and bottom surfaces composite nonwoven pad can, in cross section, have a plurality of local maxima and minima. The profile of the composite nonwoven pad can provide advantageous shock absorbing performance characteristics.

Description

Attorney Docket No. 19133.0394P1ARTICLES COMPRISING NONWOVEN MATERIAL FORMED USING AIRLAY SYSTEM CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority’ to. and the benefit of the filing date of, U.S.Provisional Patent Application No. 63 / 749,758, filed January 27, 2025, the entirety of which is hereby incorporated by reference herein.FIELD

[0002] This disclosure relates to nonwoven underlayments, and, in particular, nonwoven underlayments having three-dimensional geometries for providing certain performance characteristics.BACKGROUND

[0003] Nonwoven fiber pads used with artificial turf can have many benefits. However, due to the nature of non-woven fiber, conventional nonwoven fiber pads are unable to absorb high forces at a similar capacity as that of other materials (e.g. rubber or foam). Accordingly, artificial turf systems without rubber or foam underlayments conventionally require infill to achieve certain performance metrics, such as shock absorption. However, artificial turf systems having areas with too little infill or insufficiently resilient infill can provide insufficient shock absorption.SUMMARY

[0004] Disclosed herein, in one aspect, is a shock absorbing pad having a first axis, a second axis perpendicular to the first axis, and a third axis perpendicular to the first axis and the second axis. The shock absorbing pad can comprise a composite nonwoven pad. The composite nonwoven pad can comprise a nonwoven blend of fiber and a heat set binder. The composite nonwoven pad can have a top surface and a bottom surface spaced apart along the third axis. The composite nonwoven pad can have a thickness defined as a spacing bet een the top surface and the bottom surface parallel to the third axis. In a cross-sectional plane perpendicular to the second axis the top surface can have a plurality of local minima and a plurality of local maxima; the bottom surface can have a plurality of local minima and aAttorney Docket No. 19133.0394P1plurality of local maxima; a top surface maximum axis is parallel to the first axis and intersects a first local maximum of the plurality of local maxima of the top surface; a bottom surface maximum axis is parallel to the first axis and intersects a first local minimum of the plurality of local minima of the bottom surface, and the thickness measured parallel to the third axis at the first local maxima of the top surface can be less than a distance measured parallel to the third axis between the top surface maximum axis and the bottom surface maximum axis.

[0005] In another aspect, an artificial turf system includes an artificial turf comprising a primary backing layer having a face side and a back side. The artificial turf further comprises a plurality of turf fibers extending through the backing layer such that a face side portion of the turf fibers extends from the face side of the backing layer. The artificial turf system further comprises a shock absorbing pad as disclosed herein. The back side of the primary backing layer of the artificial turf overlies the top surface of the composite nonwoven pad.

[0006] Additional advantages of the invention will be set forth in part in the description that follows, and in part will be obvious from the description, or may be learned by practice of the invention. The advantages of the invention will be realized and attained by means of the elements and combinations particularly pointed out in the appended claims. It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the invention, as claimed.BRIEF DESCRIPTION OF THE DRAWINGS

[0007] The patent or application file contains at least one drawing executed in color. Copies of this patent or patent application publication with color drawing(s) will be provided by the Office upon request and payment of the necessary fee.

[0008] FIG. 1 shows a perspective view of a shock absorbing pad as disclosed herein.

[0009] FIG. 2 is a cross-section of the shock absorbing pad of FIG. 1.

[0010] FIG. 3 is a cross-section of the shock absorbing pad of FIG. 1 in another embodiment.

[0011] FIG. 4 is a geometric representation of a surface of a shock absorbing pad in some exemplary aspects.Attorney Docket No. 19133.0394P1

[0012] FIG. 5 is a schematic exploded view of an artificial turf system having a shock absorbing pad as disclosed herein.

[0013] FIG. 6 is a schematic illustration of a composite nonwoven pad of the shock absorbing pad of FIG. 1.

[0014] FIG. 7 is a schematic view of a nonwoven blend of fiber and heat set binder being formed into a nonwoven composite.

[0015] FIG. 8 is a schematic view of a nonwoven blend of fiber and heat set binder being formed into a nonwoven composite.

[0016] FIG. 9 is a schematic view of a nonw oven blend of fiber and heat set binder being formed into a nonwoven composite.

[0017] It should be understood that the drawings may be exaggerated to show certain features, and relative dimensions of the shock absorbing pad need not be proportional to those shown in the drawings.

[0018] It should be understood that the drawings provided herein are not necessarily to scale. Rather, the draw ings are formatted to help aid the understanding of certain features disclosed herein. For example, the relative sizes of the depicted tufts and backing materials shown in the figures are not necessarily indicative of what would be seen in the tufted articles disclosed herein.DETAILED DESCRIPTION

[0019] The disclosed system and method may be understood more readily by reference to the following detailed description of particular embodiments and the examples included therein and to the Figures and their previous and following description.

[0020] It is to be understood that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the scope of the present invention which will be limited only by the appended claims.

[0021] It must be noted that as used herein and in the appended claims, the singular forms “a,” "an." and “the” further include plural references unless the context clearly dictatesAttorney Docket No. 19133.0394P1otherwise. Thus, for example, reference to “a local maximum” constitutes disclosure of a single local maximum and also constitutes disclosure of a plurality of local maxima, and so forth.

[0022] “Optional” or “optionally” means that the subsequently described event, circumstance, or material may or may not occur or be present, and that the description includes instances where the event, circumstance, or material occurs or is present and instances where it does not occur or is not present.

[0023] Ranges may be expressed herein as from “about” one particular value, and / or to “about” another particular value. When such a range is expressed, also specifically contemplated and considered disclosed is the range from the one particular value and / or to the other particular value unless the context specifically indicates otherwise. Similarly, when values are expressed as approximations, by use of the antecedent “about,” it will be understood that the particular value forms another, specifically contemplated embodiment that should be considered disclosed unless the context specifically indicates otherwise. It will be further understood that the endpoints of each of the ranges are significant both in relation to the other endpoint, and independently of the other endpoint unless the context specifically indicates otherwise. Finally, it should be understood that all of the individual values and subranges of values contained within an explicitly disclosed range are also specifically contemplated and should be considered disclosed unless the context specifically indicates otherwise. The foregoing applies regardless of whether in particular cases some or all of these embodiments are explicitly disclosed.

[0024] Optionally, in some aspects, when values are approximated by use of the antecedents “about,” “substantially,” or “generally,” it is contemplated that values within up to 15%, up to 10%, up to 5%, or up to 1% (above or below) of the particularly stated value or characteristic can be included within the scope of those aspects.

[0025] As used herein, the term “polymer” can comprise any suitable polymer such as, for example, a polyamide, a polyester, polylactic acid, polyurethane, polyvinyl chloride, polyolefin, acrylonitrile butadiene styrene, polystyrene, biopolymers, or a combination thereof. The polymer disclosed herein can be used to make the nonwoven material disclosed herein.Attorney Docket No. 19133.0394P1

[0026] The term “polyamide,’' as utilized herein, is defined to be any long-chain polymer in which the linking functional groups are amide (-CO-NH-) linkages. The term polyamide is further defined to include copolymers, terpolymers and the like as well as homopolymers and also includes blends of two or more polyamides. In one example, the polyamide can comprise one or more of nylon 6, nylon 66, nylon 10, nylon 612, nylon 12, nylon 11, or any combination thereof. In another example, the polyamide can comprise nylon 6 or nylon 66. In yet another example, the polyamide is nylon 6. In a yet further example, the polyamide is nylon 66.

[0027] As defined herein, the term “polyolefin’" refers to any class of polymers produced from a simple olefin (also called an alkene with the general formula CnH2n) as a monomer. The polyolefin can comprise, for example, polyethylene, polypropylene, both homopolymer and / or copolymers, poly(l-butene), poly(3-methyl-l-butene), or poly(4- methyl-1 -pentene) and the like, as well as combinations or mixtures of two or more of the foregoing. In one example, the polyolefin can comprise polyethylene or polypropylene. In another example, the polyolefin can comprise polyethylene. In yet another example, the polyolefin can comprise polypropylene.

[0028] As used herein, the term “polyester’" refers to a category of polymers that contain the ester functional group in their main chain. Polyesters disclosed herein include naturally occurring chemicals, such as in the cutin of plant cuticles, as well as synthetics produced through step-growth polymerization. An non-limiting example of polyesters includes any long-chain synthetic polymer composed of at least 85% by weight of an ester of a substituted aromatic dicarboxylic acid, including but not restricted to substituted terephthalic units, p(-R-O-CO- CeH4-CO-O-)x and parasubstituted hydroxy-benzoate units, p(-R-O-CO-CeH4-O)x. In certain examples, the polyesters comprise polyethylene terephthalate (PET) homopolymer and copoly mers, polypropylene terephthalate (PPT) homopolymer and copolymers and polybutylene terephthalate (PBT) homopolymer and copolymers, and the like, including those that contain comonomers such as cyclohexanedimethanol, cyclohexanedicarboxylic acid, isophthalic acid, and the like.

[0029] As defined herein, the term “polyurethane"’ refers to any class of polymers composed of a chain of organic units joined by carbamate (urethane. R1-O-CO-NR2-R3. wherein Ri, R2, and R3 are the same or different) links.Attorney Docket No. 19133.0394P1

[0030] As defined herein, the term "polystyrene" refers to any class of synthetic polymers produced from a simple styrene as a monomer. It is understood that the term “polystyrene” includes isotactic, atactic, and syndiotactic polystyrenes. In some specific aspects, described are also co-polystyrenes including a high-impact polystyrenes (HIPS), acrylonitrile butadiene styrene (ABS) or copolymer of styrene with acrylonitrile (SAN), or copolymer of sty rene with maleic acid (SMA).

[0031] Unless defined otherwise, all technical and scientific terms used herein have the same meanings as commonly understood by one of skill in the art to which the disclosed apparatus, system, and method belong.

[0032] Throughout the description and claims of this specification, the word “comprise” and variations of the word, such as “comprising” and “comprises,” means “including but not limited to,” and is not intended to exclude, for example, other additives, components, integers or steps. In particular, in methods stated as comprising one or more steps or operations it is specifically contemplated that each step comprises what is listed (unless that step includes a limiting term such as “consisting of”), meaning that each step is not intended to exclude, for example, other additives, components, integers or steps that are not listed in the step.

[0033] As used herein, “specified fiber” is understood to mean fiber that has never been used in another article. That is, the “specified fiber” is fiber that is not being repurposed in its fiber form after previously being used in another article. As is understood in the art, airlay systems are conventionally used to form junk fiber -that is, fiber that has been used for another purpose and then is repurposed in its fiber form - into nonwoven material.Therefore, “specified fiber” should be understood to be fiber that is not junk fiber (i.e. fiber that has previously been used in another article). It is contemplated that the “specified fiber” can comprise recycled polymer. For example, the recycled polymer can come from fiber that is recycled from another article and spun into a new fiber to serve as specified fiber.

[0034] Referring to FIGS. 1-3 and 6, disclosed herein is a shock absorbing pad 10 having a first axis 12, a second axis 14 perpendicular to the first axis, and a third axis 16 perpendicular to the first axis and the second axis. The shock absorbing pad 10 comprises a composite nonwoven pad 20 having a nonwoven blend of fiber 22 and a heat set binder 24. The composite nonwoven pad 20 has a top surface 30 and a bottom surface 32 spaced along theAttorney Docket No. 19133.0394P1third axis 16. The composite non woven pad 20 has a thickness, t, defined as a spacing between the top surface 30 and the bottom surfaces 40 parallel to the third axis 16. In a cross-sectional plane 18 perpendicular to the second axis 14, the top surface 30 has a plurality of local maxima 32 and a plurality of local minima 34. Similarly, the cross-sectional plane 18 perpendicular to the second axis 14, the bottom surface 40 has a plurality of local maxima 42 and a plurality of local minima 44. In the cross-sectional plane 18, a top surface maximum axis 50 can intersect a first local maximum 32a of the top surface 30, and bottom surface minimum axis 52 can intersect a first local minimum 44a of the bottom surface 40. The thickness, t, of the composite nonwoven pad 20 at the first local maximum 32a can be less than a distance, d, measured parallel to the third axis 16 between the top surface maximum axis 50 and the bottom surface minimum axis 52.

[0035] Accordingly, it is contemplated that the local maxima 32 of the top surface 30 and the local minima 44 of the bottom surface 40 are not aligned along the first axis 12. In some aspects, the thickness, t, can remain consistent, or substantially consistent, across the composite nonwoven pad 20. For example, the local maxima and minima 32, 34 of the top surface 30 can be aligned with the local maxima and minima 42, 44 of the bottom surface 40 along the first axis 12, and undulations of the top and bottom surfaces can have similar or identical amplitudes. In other aspects, the thickness, t, of the composite nonwoven pad 20 can differ at different locations across the composite nonwoven pad 20. For example, the undulations of the top and bottom surfaces 30, 40 can have different amplitudes and / or the local maxima and minima of the top surface can be offset from the local maxima and minima, respectively, of the bottom surface along the first axis 12. In some optional aspects, the thickness, t, of the pad can be from about 0.5 mm to about 10 mm, or from about 1 mm to about 8 mm, or from about 1 mm to about 4 mm, or from about 4 mm to about 8 mm, or from about 2 mm to about 6 mm.

[0036] In some aspects, the composite nonwoven pad 20 can comprise plurality of alternating ridges 60 and troughs 62 that are spaced along the first axis 12 and extend along the second axis 14. The ridges 60 can define the local maxima 32 of the top surface 30 in the cross-sectional plane 18, and the troughs 62 can define the local minima in the cross-sectional plane. The ridges 60 can be arcuate ridges, and the troughs 62 can be arcuate troughs. In some aspects, in the at least one cross-sectional plane 18, the top surface 30 and the bottom surface 40 can have wavy (e.g., undulating) profiles. For example, in exemplary aspects, inAttorney Docket No. 19133.0394P1the at least one cross-sectional plane 18, the top surface 30 and the bottom surface 40 can have generally sinusoidal profdes.

[0037] In some aspects, respective local maxima of the top surface and the bottom surface can overlie each other (e.g., within 5 mm, or within 4 mm, or within 3 mm, or within 2 mm, or within 1 mm). Likewise, respective local minima of the top surface and the bottom surface can overlie each other (e.g., within 5 mm, or within 4 mm, or within 3 mm. or within 2 mm, or within 1 mm). In this way, optionally, the composite nonwoven pad 20 can have a corrugated profde.

[0038] Referring to FIG. 4, in additional aspects, the top surface 30 of the composite nonw oven pad 20 can comprise a plurality of alternating of peaks 64 and valleys 66 spaced along both the first and second axes 12, 14. For example, the peaks 64 can correspond to local maxima of the top surface 30 along the cross-sectional plane 18 perpendicular to the second axis 14 and a cross-sectional plane 19 perpendicular to the first axis 12. The lower surface can have similar peaks and valleys. In some optional aspects, the peaks and valleys of the lower surface 32 (FIG. 2) can be aligned with the peaks and valleys of the top surface along the first and second axes 12, 14. In some aspects, the peaks 64 and valleys 66 can be evenly spaced along the first axis 12. In other aspects, the peaks 64 and valleys 66 can be unevenly spaced along the first axis 12. In some aspects, the peaks 64 and valleys 66 can be evenly spaced along the second axis 14. In other aspects, the peaks 64 and valleys 66 can be unevenly spaced along the second axis 14. Optionally, the peaks 64 and valleys 66 can be aligned along the first axis 12 so that a plane perpendicular 18 to the second axis 14 intersects sequential peaks and valleys. In other aspects, the peaks 64 and valleys 66 need not be aligned along either of the first axis 12 or the second axis 14. Optionally, the peaks 64 can extend to approximately the same height along the third axis 16, as disclosed with reference to FIG. 2. In other aspects, the peaks 64 can extend to different respective heights along the third axis 16. Similarly, the valleys 66 can extend to the same depth along the third axis 16 or different respective depths.

[0039] In the cross-sectional plane 18 a top surface minimum axis 54 parallel to the first axis intersects a first local minima 34a of the plurality of local minima 34 of the top surface 30. In some aspects, a distance measured parallel to the third axis 16 between the top surface maximum axis 50 and the top surface minimum axis 54 is at least 1 mm. In further aspects, aAttorney Docket No. 19133.0394P1distance measured parallel to the third axis 16 between the top surface maximum axis 50 and the top surface minimum axis 54 is at least 2 mm. For example, in some aspects, adjacent local maxima 32 and local minima 34 of the top surface 30 can be spaced along the third axis by respective distances each from about 1 mm to about 4 mm, or from 1.5 mm to about 3 mm, or about 2 mm. In additional aspects, the adjacent local maxima 32 and local minima 34 of the top surface 30 can be spaced along the third axis by respective distances each from about from about 1 mm to about 25 mm, or from about 1 mm to about 5 mm. or from about 5 mm to about 40 mm, or from about 5 mm to about 10 mm, or from about 10 mm to about 20 mm, or from about 10 mm to about 40 mm, or from about 20 mm to about 40 mm.

[0040] In the cross-sectional plane 18 a bottom surface minimum axis 56 parallel to the first axis intersects a first local minima 44a of the plurality of local minima 44 of the bottom surface 40. In some aspects, a distance measured parallel to the third axis 16 between the bottom surface maximum axis 56 and the top surface minimum axis 52 is at least 1 mm. In some aspects, the distance measured parallel to the third axis 16 between the bottom surface maximum axis 56 and the top surface minimum axis 52 is at least 2 mm. For example, in some aspects, adjacent local maxima 42 and local minima 44 of the bottom surface 40 can be spaced along the third axis 16 by respective distances each from about 1 mm to about 4 mm, or from 1.5 mm to about 3 mm, or about 2 mm.

[0041] In various aspects, spacing along the third axis 16 between adjacent local maxima 32 and local minima 34 of the top surface can be substantially the same as that of corresponding axially aligned adjacent local minima 44 and local maxima 42 of the bottom surface. For example, in some aspects, a spacing between the bottom surface maximum axis 56 and the top surface minimum axis 52 can be substantially identical to a distance measured parallel to the third axis between the top surface maximum axis 50 and the top surface minimum axis 54.

[0042] Referring to FIG. 2, in some aspects, the local maxima and local minima of the upper and lower surfaces can all extend to substantially the same height along the third axis 16. In other aspects, and referring to FIG. 3, each local minimum and local maximum can extend to different heights along the third axis 16 in the cross-sectional plane 18 (FIG. 1).Accordingly, along the first axis 12. in the cross-sectional plane 18. the top surface 30 can have an absolute maximum 33. In some aspects, the first local maximum 32a can be theAttorney Docket No. 19133.0394P1absolute maximum 33 of the top surface 30. Accordingly, the absolute maximum 33 can extend to the top surface maximum axis 50. Similarly, an absolute minimum 35 can extend to the top surface minimum axis 54. As should be understood, the absolute maximum can be at the highest point of the top surface (or bottom surface) along the third axis 16 in the cross-sectional plane 18. Similarly, the absolute minimum can be at the lowest point of the top surface (or bottom surface) along the third axis 16 in the cross-sectional plane 18. The remaining local maxima and minima can be positioned between the top surface maximum axis 50 and the top surface minimum axis 54. Similarly, along the first axis 12, in the cross-sectional plane 18 (FIG. 1), the bottom surface 40 can have an absolute maximum 43 that extends to the bottom surface maximum axis 56 and an absolute minimum 45 that extends to the bottom surface minimum axis 52. Accordingly, the first local minimum 44b of the bottom surface 40 can be the absolute minimum 45 of the bottom surface 40. The remaining local maxima and minima can be positioned between the bottom surface maximum axis 56 and the bottom surface minimum axis 52. In some optional aspects, and as illustrated in FIG.3, the thickness of the composite nonwoven pad 20 can be consistent in the cross-sectional plane 18. In other aspects, the thickness can vary. Accordingly, the absolute maximum and absolute minimum of the top and bottom surfaces need not be in the same positions along the first axis.

[0043] Referring to FIGS. 1-2, the shock absorbing pad 10 can have any suitable dimensions. In exemplary aspects, the shock absorbing pad 10 can have a length along the first axis 12 and a width along the second axis 14. In some aspects, the length can be from about 36 inches to about 60 inches (e.g., about 48 inches), and the width can be from about 18 inches to about 24 inches (e.g., about 20 inches). Optionally, in these aspects, the shock absorbing pad 10 can be provided as a panel. In additional aspects, the shock absorbing pad 10 can be provided as a roll.

[0044] In various aspects, the ridges 60 and troughs 62 can extend continuously across the dimension of the shock absorbing pad 10 along the second axis 14. In other aspects, the ridges 60 and troughs 62 can extend at least 50%, at least 60%, at least 70%, at least 80%, at least 90% of the dimension of the shock absorbing pad 10 along the second axis 14.Accordingly, the ridges 60 and troughs 62 can extend along the second axis 14 for at least 10 inches, or at least 20 inches, or at least 40 inches or at least 48 inches.Attorney Docket No. 19133.0394P1

[0045] In various aspects, in the cross-sectional plane 18, the plurality of local maxima 32 of the top surface 30 can comprise at least five, at least ten, or at least twenty local maxima. In further aspects, the plurality of local minima 44 of the top surface 40 can comprise at least five, at least ten, or at least twenty local maxima. In further aspects, in the cross-sectional plane 18, the top surface 30 can have at least 4, or from about 5 to about 20, or about 10 local maxima and local minima per foot. Similarly, in the cross-sectional plane 18, the bottom surface 30 can have at least 4, or from about 5 to about 20, or about 10 local maxima and local minima per foot. The plurality of local maxima 32 of the top surface 30 can comprise at least five, at least ten, or at least twenty local maxima. In further aspects, the plurality of local minima 44 of the top surface 40 can comprise at least five, at least ten, or at least twenty' local minima. In some aspects, the composite nonwoven pad 20 can have, in the cross-sectional plane 18, from about 12 to about 50 local maxima 32 per meter. In some aspects, the composite nonwoven pad 20 can have, in the cross-sectional plane 18, from about 8 to about 100 local maxima 32 per meter. In additional aspects, adjacent local minima and maxima (peak-to-trough) can be spaced along the first axis 12 by a spacing from about 1 cm to about 4 cm. In some aspects, adjacent local minima and maxima can be spaced along the first axis 12 by a spacing from about 1 cm to about 8 cm. In some aspects, adjacent local minima and maxima can be spaced along the first axis 12 by a spacing from about 2 cm to about 8 cm. In some aspects, adjacent local minima and maxima can be spaced along the first axis 12 by a spacing from about 2 cm to about 4 cm. In some aspects, adjacent local minima and maxima can be spaced along the first axis 12 by a spacing from about 0.5 cm to about 15 cm. In additional aspects, adjacent local minima and maxima can be spaced along the first axis 12 by a spacing from about 1 cm to about 4 cm. In some aspects, adjacent local minima and maxima can be spaced along the first axis 12 by a spacing from about 1 cm to about 8 cm. In some aspects, adjacent local minima and maxima can be spaced along the first axis 12 by a spacing from about 2 cm to about 8 cm. In some aspects, adjacent local minima and maxima can be spaced along the first axis 12 by a spacing from about 2 cm to about 4 cm. In some aspects, adjacent local minima and maxima can be spaced along the first axis 12 by a spacing from about 0.5 cm to about 15 cm. In additional aspects, adjacent local maxima (peak-to-peak) can be spaced along the first axis 12 by a spacing from about 2 cm to about 8 cm. In some aspects, adjacent local maxima can be spaced along the first axis 12 by a spacing from about 2 cm to about 16 cm. In some aspects, adjacent local maxima can be spaced along the first axis 12 by a spacing from about 4 cm to about 16 cm. In someAttorney Docket No. 19133.0394P1aspects, adjacent local maxima can be spaced along the first axis 12 by a spacing from about 4 cm to about 8 cm. In some aspects, adjacent local maxima can be spaced along the first axis 12 by a spacing from about 1 cm to about 30 cm.

[0046] The composite nonwoven pad 20 can comprise first and second side edges 70, 72 that are spaced along the second axis 14 and extend between the top and bottom surfaces 30, 40 on opposite sides 71. 73 of the nonwoven pad 20. In some aspects, the first side edge 70 can define a first connector 74, and the second side edge 72 can define a second connector 76.

[0047] The composite nonwoven pad 20 can further comprise third and fourth side edges 80, 82 that are spaced along the first axis 12 and extend between the top and bottom surfaces 30, 40 on opposite ends 81, 83 of the nonwoven pad 20. In some aspects, the third side edge 80 can define a third connector 84, and the fourth side edge 82 can define a fourth connector 86.

[0048] In some aspects, the first and second connectors 74, 76 can be interlocking profiles. That is, the first connector 74 can interlock with another composite nonwoven pad having an identical profile to that of the second connector. For example, the interlocking profiles can be one of a tongue and groove (e.g., optionally, a dovetail connection, such as, for example, a puzzle piece profile having a widened distal end and a narrowed neck portion). Similarly, the third and fourth connectors 84, 86 can be interlocking profiles. In additional aspects, the nonwoven pad 20 can be configured to engage an adjacent nonwoven pad via a butt joint or a lap joint.

[0049] In some aspects, the nonwoven blend of fiber 22 can comprise specified fiber.Optionally, the fiber of the nonwoven blend of fiber 22 can comprise at least 20%, at least 40%, at least 60%, at least 80%, at least 90 specified fiber. In further aspects, all, or substantially all of the fiber of the nonwoven blend of fiber 22 can comprise specified fiber. In some aspects, the fiber (e.g., specified fiber) can comprise polymer, wherein the polymer is 100% virgin polymer. In further aspects, the specified fiber can be formed entirely from 100% virgin polymer. In other aspects, the specified fiber can comprise recycled polymer. In exemplary aspects, the content (e.g., material) of the specified fiber can range from 0% recycled content to 100% recycled content, e.g.. from 0% to 50% recycled content, or from 50% to 100% recycled content, or from 20% to 80% recycled content.Attorney Docket No. 19133.0394P1

[0050] In some aspects, the fiber 22 (e.g., specified fiber) can comprise a polyamide, a polyester, polylactic acid, polyurethane, polyvinyl chloride, polyolefin, acrylonitrile butadiene styrene, polystyrene, biopolymers, or a combination thereof. In exemplars’ aspects, the fiber (e g., specified fiber) can be at least 90% polyester, for example, 100% polyester. In one example, the polyester can be polyethylene terephthalate (PET).

[0051] In some aspects, the composite nonwoven pad 20 can comprise about 20% to about 60% reclaimed artificial turf material, about 5% to about 35% specified fiber, about 10% to about 40% heat set binder, and about 5% to about 20% foam (e.g., optionally, polyurethane foam, polyethylene foam, or polypropylene foam). In some aspects, the foam can be recycled. For example, the foam can comprise (or be) recycled polyurethane foam, recycled polyethylene foam, or recycled polypropylene foam. In further aspects, the composite nonwoven pad 20 can comprise about 40% to about 60% reclaimed artificial turf material, about 15% to about 25% specified fiber, about 20% to about 40% heat set binder, and about 5% to about 15% foam (e.g.. optionally, polyurethane foam, polyethylene foam, or polypropylene foam). In some aspects, the reclaimed artificial turf material can comprise one or more of a face fiber, a primary backing fiber, an infill material, and an adhesive backing material. In some aspects, the reclaimed artificial turf material comprises a thermoset polymer, a thermoplastic polymer, or a combination thereof.

[0052] In some aspects, the composite nonwoven pad 20 can further comprise at least one performance additive. For example, the at least one performance additive can be a virgin polymeric material, high denier fibers, a low melt fiber, a resilient material, foam chips, rubber chips, cork, wood chips, silica sand, adhesive material, binder fibers, or any combination thereof.

[0053] In some aspects, the composite nonwoven pad can further comprise at least one reclaimed carpet material. For example, the reclaimed carpet material can comprise a postconsumer carpet material, a post-industrial carpet material, or a combination thereof. In further aspects, the reclaimed artificial turf material can comprise a polyolefin, polyamide, polystyrene, polyurethane, polyester, polyvinyl chloride, polyacrylic. or any combination thereof. In additional aspects, the reclaimed artificial turf material can comprise a polyolefin. The polyolefin can comprises a polyethylene, polypropylene, or a combination thereof. In further aspects, the reclaimed artificial turf can comprise a polyamide. For example, theAttorney Docket No. 19133.0394P1polyamide can be nylon 6, nylon 6,6, nylon 1,6, nylon 12, nylon 6,12, or a combination thereof. The reclaimed artificial turf can comprise a polyester. The polyester can comprise polyethylene terephthalate, polypropylene terephthalate, polybutylene terephthalate, or any combination thereof. In aspects in which the polyester comprises the polyethylene terephthalate, the fibers comprising the polyethylene terephthalate has a denier count of about 2 dpf to about 100 dpf.

[0054] The blend of fiber 22 can have a first melting point, and at least a portion of the heat set binder 24 can have a second melting point that is lower than the first melting point. In this way, during a heating step, the heat set binder 24, or the portion thereof having the second melting point, can soften (e.g., melt) to bind to the other fibers to form the composite nonwoven pad 20 (e.g., as a densified fiber batt). For example, referring to FIGS. 7 and 8, in some aspects the heating step can comprise heating the blend of fiber 22 and the heat set binder 24 at a first temperature for a first period of time. In further aspects, the heated blend of fiber 22 can be subjected to pressure with a surface 142 of a press 140. The surface 142 of the press 140 can have a surface temperature that is less than the first melting point.Subjecting the heated fiber batt to the surface of the press can form the composite non woven pad 20.

[0055] In one aspect, the first melting point can be at least 20 °C higher than the second melting point. For example, the first melting point can be at least 40 °C higher than the second melting point. In another example, the first melting point can be at least 60 °C higher than the second melting point. In another example, the first melting point can be at least 80 °C higher than the second melting point. In another example, the first melting point can be at least 100 °C higher than the second melting point. In another example, the first melting point can be at least 120 °C higher than the second melting point. In another example, the first melting point can be at least 140 °C higher than the second melting point. In another example, the first melting point can be at least 160 °C higher than the second melting point. In another example, the first melting point can be at least 180 °C higher than the second melting point. In another example, the first melting point is from about 20 °C to about 250 °C higher than the second melting point. In another example, the first melting point is from about 60 °C to about 250 °C higher than the second melting point. In another example, the first melting point is from about 60 °C to about 200 °C higher than the second melting point.Attorney Docket No. 19133.0394P1In another example, the first melting point is from about 100 °C to about 200 °C higher than the second melting point.

[0056] Referring to FIG. 6 and 8, in some aspects, the heat set binder 24 can be a low melt fiber. For example, optionally, in these aspects, an entirety7of the heat set binder 24 can comprise polymer having the second melting point. In other exemplary7aspects, and with reference to FIG. 7, the heat set binder 24 can be a bi-component fiber or multi-component fiber. For example, the fibers comprising the first polymer and / or second polymer can be a multi-component fiber. It is understood that in some aspects of the present invention, the multi-component fibers can be defined as “extruding two polymers from the same spinneret with both polymers contained within the same filament.” In some aspects, multi-component fibers can have any cross-sectional shape or geometry that can be contemplated by one of ordinary skill in the art. In some aspects, the multi-component fibers can have cross-section structures that include but are not limited to side-by-side fiber, sheath-core fiber, islands-in-the-sea fiber and segmented-pie cross-section types. It is further understood that in some aspects the sheath and core of the multi-component fiber can comprise the same type of polymer having different melting points. For example, both first polymer and second polymers forming the multi-component fiber can both be a polyester but with different melting points.

[0057] For example, in some aspects, only an outer portion 132 (sheath) of the of the fibers forming the heat set binder 24 has the second melting point, and an inner portion 134 (core) of the of the fibers forming the heat set binder 24 can have a higher melting point than the second melting point. In these aspects, the fibers forming the heat set binder 24 can comprises a sheath and a core provided as a sheath-core configuration. Accordingly, during the heating step, the outer portion 132 of the of the fibers forming the heat set binder 24 can soften and bind to the adjacent fiber (e.g., fiber 22 or other portions of the heat set binder 24), while the inner portion 134 of the heat set binder does not melt. Optionally, the fibers 22 and the fibers forming the heat set binder 24 can be bi-component fiber or multi-component fiber. For example, the fiber 22 and heat set binder 24 can have the same structure. Optionally, in these aspects, the fiber 22 of the composite nonwoven pad 20 can be multicomponent fiber, wherein the portion of the fiber with the second melting point (e.g., the outer portion 132) serves as the heat set binder 24. In other optional aspects, the fiber 22 and the heat set binder can be different fibers. Optionally, in these aspects, the blend of fiber 22 and heat set binderAttorney Docket No. 19133.0394P124 can be entangled prior to the heating step (e.g., via needlepunching). In still other aspects, and with reference to FIG. 9, the heat set binder 24 can be provided as a powder form.Accordingly, in various aspects, the heat sent binder 24 of the composite nonwoven pad 20 can comprise one or more of: single component fiber, multicomponent fiber, or powder. The fiber 22 can comprise one or more of: single component fiber or multicomponent fiber.

[0058] In various optional aspects, the fiber 22 can comprise polypropylene, and the heat set binder 24 can comprise polyethylene. In other optional aspects, the fiber 22 and the heat set binder 24 can comprise polyethylene terephthalate (PET). In still further aspects, the shock absorbing pad 10 can comprise a combination of polyethylene, polypropylene, and polyester. For example, in one aspect, the shock absorbing pad 10 can comprise a combination of bicomponent fiber comprising polyester (optionally, 100% polyester), polyester fiber with a melting temperature so that said polyester fiber is not configured to melt, recycled turf fiber (e.g., comprising polyethylene and polypropylene), and other recycled fibers (e.g., a combination of one or more of: polyethylene, polypropylene, and polyester). In this aspect, the bi-component fiber can serve as the heat-set binder 24. Additionally, the polyethylene can serve as the heat-set binder 24. Optionally, in this example, the mixture of materials can include from about 10% to about 35% bi-component fiber, from about 10% to about 25% polyester fiber not configured to melt, from about 30% to about 70% recycled turf, and from 0 to about 10% other turf. For example, in one embodiment, the shock absorbing pad 10 can comprise about 25% (e.g., 28%) bi-component fiber, about 20% (e.g., 18.5%) polyester fiber that is not heat set binder, about 50% (e.g., 46.5%) recycled turf, and about 5% (e.g., 7%) other recycled fiber.

[0059] In additional aspects, the shock absorbing pad 10 can comprise from 0-100% bi-component fiber. Optionally, for example, the shock absorbing pad 10 can comprise from 10%-75% bi-component fiber, or 20%-50% bi-component fiber. In additional aspects, the shock absorbing pad 10 can comprise from about 10% to about 90% fiber that is not heat set binder 24.

[0060] In another example, the shock absorbing pad 10 can be formed entirely of polyester. For example, the shock absorbing pad 10 can comprise polyester bi-component fiber and polyester fiber with a melting temperature so that said polyester fiber is not configured to melt.Attorney Docket No. 19133.0394P1

[0061] In exemplary' aspects, fibers of the blend of fiber can have a length from about one inch to about six inches, for from about two inches to about four inches, or from about 2.5 inches to about 3.5 inches, or about three inches. It is contemplated that a relatively longer length of the fibers can inhibit mixing of the fibers, thereby providing regions of different colors. In further exemplary' aspects, the fibers of the heat set binder can have a length from about one inch to about six inches, for from about one inches to about three inches, or about two inches, or from about two inches to about four inches. In exemplary aspects, the fibers of the blend of fiber can have a denier from about 1 to about 40, or from about 1 to about 20, or from about 10 to about 20, or about 15. In some exemplary' aspects, the fibers of the blend of fiber 22 can have a denier from about 1 to about 5, or from about 5 to about 10, or from about 5 to about 20. In exemplary aspects, the fibers of the heat set binder 24 can have a denier from about 1 to about 20, or from about 2 to about 6, or about 4. For example, the fibers can comprise bi-component fiber having a length from one inch to six inches, or from about 1.5 inches to about 3 inches. In further aspects, the bi-component fiber can have a denier from about 1 to about 20. For example, the bi-componnet fiber can have a denier from about 1 to about 5, or from about 5 to about 10, or from about 5 to about 20. In additional aspects, the blend of fiber can comprise polyester fiber. The polyester fiber can have a denier from about 5 to about 200. Optionally, in these aspects, the polyester fiber can have a denier from about 10 to about 15, or from about 5 to about 20, or from about 20 to about 200. In further aspects, the polyester fiber can have a length from about 1 / 2 inch to about 6 inches, or from about 1 inch to about 4 inches, or about 2 inches. In additional aspects, the fibers can comprise turf fibers (e.g., recycled turf fibers). Such fibers can have a denier from about 5 to about 4000 (e.g., optionally, from about 5 to about 10, or from 10 to about 200, or from about 20 to about 500, or from about 500 to about 4000). Such turf fibers can be monofilament blades or slit film.

[0062] In some aspects, the shock absorbing pad 10 can have a density' from about 2 lbs / ft3to about 30 lbs / ft3. For example, the shock absorbing pad 10 can have a density of about 9 lbs / ft3.

[0063] In some aspects, when the shock absorbing pad 10 is present as a component in an artificial turf system, the artificial turf system ca exhibit a Gmax value less than about 165 g’s as measured according to ASTM F-355.Attorney Docket No. 19133.0394P1

[0064] In some aspects, when the shock absorbing pad 10 is present as a component in an artificial turf system, the artificial turf system ca exhibit a Head Impact Criterion of less than about 1000 (e.g.. from a 1 meter drop) as measured according to EN 1177 test.

[0065] In some optional aspects, the shock absorbing pad 10 can exhibit a compression set from about 1% to about 30% as measured according to ASTM D-3676 or ASTM D-3574.

[0066] In some aspects, the distance measured along the third axis between the top surface maximum axis and the bottom surface minimum axis decreases at least 5% when a force of 700 N is applied (e.g., using a tensile testing machine). In additional aspects, the distance measured along the third axis between the top surface maximum axis and the bottom surface minimum axis can decrease at least 10%, or at least 15%, or at least 20%, or at least 25% when a force of 700 N is applied. In additional aspects, the distance measured along the third axis between the top surface maximum axis and the bottom surface minimum axis can decrease at least 5%. or at least 10%, or at least 15%, or at least 20%. or at least 25% when a force of 400 N is applied.

[0067] In some aspects, the composite nonwoven pad can define a plurality of openings extending from the top surface to the bottom surface. For example, the plurality of openings can be configured to provide a predetermined rate of horizontal drainage of moisture through the nonwoven pad from the top surface to the bottom surface. In some aspects, each opening of the plurality of openings can have a diameter from about 1 mm to about 15 mm. The plurality of openings can cooperate to provide a vertical water drainage capability from 10 inches per hour to 500 niches per hour as determined by ASTM D3385.

[0068] In some aspects, the composite nonwoven pad can be a slab or panel.

[0069] Referring to FIG. 5, an artificial turf system 100 can comprise an artificial turf 110, the artificial turf comprising a primary backing layer 112 having a face side 114 and a back side 116. The artificial turf 110 can further comprise a plurality of turf fibers 120 extending through the backing layer 110 such that a face side portion 122 of the turf fibers extends from the face side 114 of the backing layer 112. The artificial turf system 100 can further comprise a shock absorbing pad 10. The back side 116 of the primary backing layer 112 of the artificial turf 110 overlies the top surface 32 of die composite nonwoven pad 30. In some aspects, the back side 116 can be coupled to the composite nonwoven pad 30 (e g., via adhesive).Attorney Docket No. 19133.0394P1

[0070] In some aspects, the turf system 100 can exhibit a Gmax value less than about 165 g’s as measured according to ASTM F-355.

[0071] In some aspects, the turf system 100 can exhibit a Head Impact Criteria of less than about 1,000 (e.g., from a 1 meter drop) as measured according to EN 1177 test.

[0072] In some aspects, the turf system 100 can exhibit a compression set from about 1% to about 30% as measured according to ASTM D-3676 or ASTM D3574.EXEMPLARY ASPECTS

[0073] In view of the described products, systems, and methods and variations thereof, herein below are described certain more particularly described aspects of the invention. These particularly recited aspects should not however be interpreted to have any limiting effect on any different claims containing different or more general teachings described herein, or that the '‘particular” aspects are somehow limited in some way other than the inherent meanings of the language literally used therein.

[0074] Aspect 1 : A shock absorbing pad having a first axis, a second axis perpendicular to the first axis, and a third axis perpendicular to the first axis and the second axis, the shock absorbing pad comprising:a composite nonwoven pad comprising:a) a nonwoven blend of fiber and a heat set binder;c) a top surface and a bottom surface spaced apart along the third axis, wherein the composite nonwoven pad has a thickness defined as a spacing between the top surface and the bottom surface parallel to the third axis; andwherein in a cross-sectional plane perpendicular to the second axis:i) the top surface has a plurality of local minima and a plurality of local maxima;ii) the bottom surface has a plurality of local minima and a plurality of local maxima;Attorney Docket No. 19133.0394P1iii) a top surface maximum axis is parallel to the first axis and intersects a first local maximum of the plurality of local maxima of the top surface;iv) a bottom surface maximum axis is parallel to the first axis and intersects a first local minimum of the plurality of local minima of the bottom surface; andv) the thickness measured parallel to the third axis at the first local maxima of the top surface is less than a distance measured parallel to the third axis between the top surface maximum axis and the bottom surface maximum axis.

[0075] Aspect 2: The shock absorbing pad of aspect 1, wherein in the cross-sectional plane perpendicular to the second axis:a top surface minima axis is parallel to the first axis and intersects a first local minimum of the plurality of local minima of the top surface; a distance measured parallel to the third axis between the top surface maxima axis and the top surface minima axis is at least 1mm.

[0076] Aspect 3: The shock absorbing pad of aspect 1 or aspect 2, wherein in the cross-sectional plane perpendicular to the second axis:a bottom surface maxima axis is parallel to the first axis and intersects a first local maximum of the plurality of local maxima of the bottom surface;a distance measured parallel to the third axis between the bottom surface maxima axis and the bottom surface minima axis is at least 1 mm.

[0077] Aspect 4: The shock absorbing pad of any one of the preceding aspects, wherein a distance measured parallel to the third axis between the top surface maxima axis and the top surface minima axis is substantially identical to a distance measured parallel to the third axis between the bottom surface maxima axis and the bottom surface minima axis.Attorney Docket No. 19133.0394P1

[0078] Aspect 5: The shock absorbing pad of any one of the preceding aspects, wherein the composite nonwoven pad comprise a plurality of alternating ridges and troughs, wherein the alternating ridges define the plurality of local maxima and minima in the cross-sectional plane, wherein the plurality of alternating ridges extend parallel to the second axis for at least 16 inches.

[0079] Aspect 6: The shock absorbing pad of any one of the preceding aspects, the composite nonwoven pad comprise a plurality of alternating ridges and troughs, wherein the alternating ridges define the plurality of local maxima and minima in the cross-sectional plane, wherein the plurality of alternating ridges extend at least 50% of dimension of the shock absorbing pad along the second axis.

[0080] Aspect 7: The shock absorbing pad of any one of the preceding aspects, wherein the top surface comprises at least five local maxima.

[0081] Aspect 8: The shock absorbing pad of any one of the preceding aspects, wherein the bottom surface comprises at least five local minima.

[0082] Aspect 9: The shock absorbing pad of any one of the preceding aspects, wherein, in the cross-sectional plane, the top surface has at least 4 local maxima per foot.

[0083] Aspect 10: The shock absorbing pad of any one of the preceding aspects, wherein, in the cross-sectional plane, the bottom surface has at least 4 local minima per foot.

[0084] Aspect 11 : The shock absorbing pad of any one of the preceding aspects, wherein in the cross-sectional plane, the top and bottom surfaces of the composite nonwoven pad each wavy profiles.

[0085] Aspect 12: The shock absorbing pad of any one of the preceding aspects, wherein the composite nonwoven pad further comprises:first and second side edges that are spaced along the second axis and extend between the top and bottom surfaces on opposite sides of the composite nonwoven pad, wherein the first side edge defines a first connector, wherein the second side edge defines a second connector.Attorney Docket No. 19133.0394P1

[0086] Aspect 13: The shock absorbing pad of aspect 12, wherein the composite nonwoven pad further comprises:third and fourth side edges that are spaced along the first axis and extend between the top and bottom surfaces on opposite ends of the composite nonwoven pad, wherein the third side edge defines a third connector, wherein the fourth side edge defines a fourth connector.

[0087] Aspect 14: The shock absorbing pad of aspect 12 or aspect 13, wherein the first connector and second connector are interlocking profiles.

[0088] Aspect 15: The shock absorbing pad of aspect 14, wherein the interlocking profiles comprise one of: a tongue and agroove; or a lap joint.

[0089] Aspect 16: The shock absorbing pad of any one of the preceding aspects, wherein the composite nonwoven pad comprises about 20% to about 60% reclaimed artificial turf material, about 5% to about 35% specified fiber, about 10% to about 40% heat set binder, and about 5% to about 20% recycled polyurethane foam. The shock absorbing pad can further comprise at least one performance additive (e.g., a virgin polymeric material, high denier fibers, a low melt fiber, a resilient material, foam chips, rubber chips, cork, wood chips, silica sand, adhesive material, binder fibers, or any combination thereof).

[0090] Aspect 17 : The shock absorbing pad of any one of the preceding aspects, wherein the composite nonwoven pad comprises about 40% to about 60% reclaimed artificial turf material, about 15% to about 25% specified fiber, about 20% to about 40% heat set binder, and about 5% to about 15% foam. The shock absorbing pad can further comprise at least one performance additive (e.g., a virgin polymeric material, high denier fibers, a low melt fiber, a resilient material, foam chips, rubber chips, cork, wood chips, silica sand, adhesive material, binder fibers, or any combination thereof).

[0091] Aspect 18: The shock absorbing pad of aspect 16 or aspect 17, wherein the reclaimed artificial turf material comprises one or more of a face fiber, a primary backing fiber, an infill material, and an adhesive backing material.

[0092] Aspect 19: The shock absorbing pad of any one of the preceding aspects, wherein the composite nonwoven pad further comprises at least one performance additive.Attorney Docket No. 19133.0394P1

[0093] Aspect 20: The shock absorbing pad of aspect 19, wherein the at least one performance additive comprises a virgin polymeric material, high denier fibers, a low melt fiber, a resilient material, foam chips, rubber chips, cork, wood chips, silica sand, adhesive material, binder fibers, or any combination thereof

[0094] Aspect 21: The shock absorbing pad of any one of aspects 16-20, wherein the reclaimed artificial turf material comprises a thermoset polymer, a thermoplastic polymer, or a combination thereof.

[0095] Aspect 22: The shock absorbing pad of any one of aspects 16-21, wherein the composite nonwoven pad further comprises at least one reclaimed carpet material.

[0096] Aspect 23: The shock absorbing pad of aspect 22, wherein the reclaimed carpet material comprises a post-consumer carpet material, a post-industrial carpet material, or a combination thereof.

[0097] Aspect 24: The shock absorbing pad of any one of aspects 16-23, wherein the reclaimed artificial turf material comprises a polyolefin, polyamide, polysty rene, polyurethane, polyester, polyvinyl chloride, poly acrylic, or any combination thereof.

[0098] Aspect 25: The shock absorbing pad of aspect 24, wherein the reclaimed artificial turf material comprises a polyolefin.

[0099] Aspect 26: The shock absorbing pad of aspect 25, wherein the polyolefin comprises a polyethylene, polypropylene, or a combination thereof.

[0100] Aspect 27: The shock absorbing pad of any one of aspects 24-26, wherein the reclaimed artificial turf comprises a polyamide.

[0101] Aspect 28: The shock absorbing pad of aspect 27, wherein the polyamide is nylon 6, nylon 6,6, nylon 1.6. nylon 12, nylon 6,12, or a combination thereof.

[0102] Aspect 29: The shock absorbing pad of any one of aspects 24-26, wherein the reclaimed artificial turf comprises a polyester.Attorney Docket No. 19133.0394P1

[0103] Aspect 30: The shock absorbing pad of aspect 29, wherein the polyester comprises polyethylene terephthalate, polypropylene terephthalate, polybutylene terephthalate, or any combination thereof.

[0104] Aspect 31: The shock absorbing pad of aspect 30, wherein the polyester comprises polyethylene terephthalate, wherein the fiber comprising polyethylene terephthalate has a denier count of about 2 dpf to about 100 dpf.

[0105] Aspect 32: The shock absorbing pad of any one of the preceding aspects, wherein the heat set binder is a low melt fiber.

[0106] Aspect 33: The shock absorbing pad of any one of the preceding aspects, wherein the heat set binder is a bi-component fiber.

[0107] Aspect 34: The shock absorbing pad of any one of the preceding aspects, wherein the shock absorbing pad has a density from about 2 lbs / ft3to about 30 lbs / ft3.

[0108] Aspect 35: The shock absorbing pad of any one of the preceding aspects, wherein when the shock absorbing pad is present as a component in an artificial turf system, the artificial turf system exhibits a Gmax value less than about 165 g’s as measured according to ASTM F-355.

[0109] Aspect 36: The shock absorbing pad of any one of the preceding aspects, wherein when the shock absorbing pad is present as a component in an artificial turf system, the artificial turf system exhibits a Head Impact Criterion of less than about 1000 from a 1 meter drop as measured according to EN 1177 test.

[0110] Aspect 37: The shock absorbing pad of any one of the preceding aspects, wherein the shock absorbing pad exhibits a compression set from about 1% to about 30% as measured according to ASTM D-3676 or ASTM D-3574.

[0111] Aspect 38: The shock absorbing pad of any one of the preceding aspects, wherein the distance measured along the third axis between the top surface maximum axis and the bottom surface minimum axis decreases at least 5 % when a force of 700N is applied using a tensile testing machine.Attorney Docket No. 19133.0394P1

[0112] Aspect 39: The shock absorbing pad of any one of the preceding aspects, wherein the composite nonwoven pad defines a plurality of openings extending from the top surface to the bottom surface.

[0113] Aspect 40: The shock absorbing pad of aspect 39, wherein the plurality of openings are configured to provide a predetermined rate of horizontal drainage of moisture through the nonwoven pad from the top surface to the bottom surface.

[0114] Aspect 41: The shock absorbing pad of aspect 39 or aspect 40, wherein each opening of the plurality of openings has a diameter from about 1 mm to about 15 mm.

[0115] Aspect 42: The shock absorbing pad of any one of the preceding aspects, wherein the plurality of openings cooperate to provide a vertical water drainage capability from 10 inches per hour to 500 inches per hour as determined by ASTM D3385.

[0116] Aspect 43: The shock absorbing pad of any one of the preceding aspects, wherein the composite nonwoven pad is a slab or panel.

[0117] Aspect 44: An artificial turf system comprising:i) an artificial turf comprising:a. a primary backing layer having a face side and a back side;andb. a plurality of turf fibers extending through the backing layer such that a face side portion of the turf fibers extends from the face side of the backing layer, andii) a shock absorbing pad according to any one of the preceding aspects.iii) wherein the back side of the primary backing layer of the artificial turf overlies the top surface of the composite nonwoven pad.

[0118] Aspect 45: The artificial turf system of aspect 44, wherein the turf system exhibits a Gmax value less than about 165 g's as measured according to ASTM F-355.Attorney Docket No. 19133.0394P1

[0119] Aspect 46: The artificial turf system of aspect 44 or aspect 45, wherein the turf system exhibits a Head Impact Criteria of less than about 1,000 from a 1 meter drop as measured according to EN 1177 test.

[0120] Aspect 47: The artificial turf system of any one of aspects 44-46, wherein the turf system exhibits a compression set from about 1% to about 30% as measured according to ASTM D-3676 or ASTM D3574.

Claims

Attorney Docket No. 19133.0394P1CLAIMSThe following is claimed:

1. A shock absorbing pad having a first axis, a second axis perpendicular to the first axis, and a third axis perpendicular to the first axis and the second axis, the shock absorbing pad comprising:a composite nonwoven pad comprising:a) a nonwoven blend of fiber and a heat set binder;c) a top surface and a bottom surface spaced apart along the third axis, wherein the composite nonwoven pad has a thickness defined as a spacing between the top surface and the bottom surface parallel to the third axis; andwherein in a cross-sectional plane perpendicular to the second axis:i) the top surface has a plurality of local minima and a plurality of local maxima;ii) the bottom surface has a plurality of local minima and a plurality of local maxima;iii) a top surface maximum axis is parallel to the first axis and intersects a first local maximum of the plurality of local maxima of the top surface;iv) a bottom surface maximum axis is parallel to the first axis and intersects a first local minimum of the plurality of local minima of the bottom surface; and v) the thickness measured parallel to the third axis at the first local maxima of the top surface is less than a distance measured parallel to the third axis between the top surface maximum axis and the bottom surface maximum axis.

2. The shock absorbing pad of claim 1, wherein in the cross-sectional plane perpendicular to the second axis:a top surface minima axis is parallel to the first axis and intersects a first local minimum of the plurality of local minima of the top surface;a distance measured parallel to the third axis between the top surface maxima axis and the top surface minima axis is at least 1mm.Attorney Docket No. 19133.0394P13. The shock absorbing pad of claim 1, wherein in the cross-sectional plane perpendicular to the second axis:a bottom surface maxima axis is parallel to the first axis and intersects a first local maximum of the plurality of local maxima of the bottom surface; a distance measured parallel to the third axis between the bottom surface maxima axis and the bottom surface minima axis is at least 1 mm.

4. The shock absorbing pad of claim 1, wherein a distance measured parallel to the third axis betw een the top surface maxima axis and the top surface minima axis is substantially identical to a distance measured parallel to the third axis between the bottom surface maxima axis and the bottom surface minima axis.

5. The shock absorbing pad of claim 1, wherein the composite nonwoven pad comprise a plurality of alternating ridges and troughs, wherein the alternating ridges define the plurality’ of local maxima and minima in the cross-sectional plane, w herein the plurality’ of alternating ridges extend parallel to the second axis for at least 16 inches.

6. The shock absorbing pad of claim 1. the composite nonw oven pad comprise a plurality’ of alternating ridges and troughs, wherein the alternating ridges define the plurality of local maxima and minima in the cross-sectional plane, wherein the plurality of alternating ridges extend at least 50% of dimension of the shock absorbing pad along the second axis.

7. The shock absorbing pad of claim 1, wherein the top surface comprises at least five local maxima.

8. The shock absorbing pad of claim 1, wherein the bottom surface comprises at least five local minima.

9. The shock absorbing pad of claim 1, w herein, in the cross-sectional plane, the top surface has at least 4 local maxima per foot.

10. The shock absorbing pad of claim 1. wherein, in the cross-sectional plane, the bottom surface has at least 4 local minima per foot.

11. The shock absorbing pad of claim 1, wherein in the cross-sectional plane, the top and bottom surfaces of the composite nonwoven pad each wavy profiles.

12. The shock absorbing pad of claim 1, wherein the composite nonw oven pad further comprises:first and second side edges that are spaced along the second axis and extend between the top and bottom surfaces on opposite sides of the composite nonw oven pad.Attorney Docket No. 19133.0394P1wherein the first side edge defines a first connector, wherein the second side edge defines a second connector.

13. The shock absorbing pad of claim 12, wherein the composite nonwoven pad further comprises:third and fourth side edges that are spaced along the first axis and extend between the top and bottom surfaces on opposite ends of the composite nonwoven pad, wherein the third side edge defines a third connector, wherein the fourth side edge defines a fourth connector.

14. The shock absorbing pad of claim 12, wherein the first connector and second connector are interlocking profiles.

15. The shock absorbing pad of claim 14, wherein the interlocking profiles comprise one of: a tongue and a groove; or a lap joint.

16. The shock absorbing pad of claim 1, wherein the composite nonwoven pad comprises about 20% to about 60% reclaimed artificial turf material, about 5% to about 35% specified fiber, about 10% to about 40% heat set binder, and about 5% to about 20% foam.

17. The shock absorbing pad of claim 1. wherein the composite nonwoven pad comprises about 40% to about 60% reclaimed artificial turf material, about 15% to about 25% specified fiber, about 20% to about 40% heat set binder, and about 5% to about 15% foam.

18. The shock absorbing pad of claim 16, wherein the reclaimed artificial turf material comprises one or more of a face fiber, a primary backing fiber, an infill material, and an adhesive backing material.

19. The shock absorbing pad of claim 1. wherein the composite nonwoven pad further comprises at least one performance additive.

20. The shock absorbing pad of claim 19, wherein the at least one performance additive comprises a virgin polymeric material, high denier fibers, a low melt fiber, a resilient material, foam chips, rubber chips, cork, wood chips, silica sand, adhesive material, binder fibers, or any combination thereof.

21. The shock absorbing pad of claim 16, wherein the reclaimed artificial turf material comprises a thermoset polymer, a thermoplastic polymer, or a combination thereof.

22. The shock absorbing pad of claim 16, wherein the composite nonwoven pad further comprises at least one reclaimed carpet material.Attorney Docket No. 19133.0394P123. The shock absorbing pad of claim 22, wherein the reclaimed carpet material comprises a postconsumer carpet material, a post-industrial carpet material, or a combination thereof.

24. The shock absorbing pad of claim 16, wherein the reclaimed artificial turf material comprises a polyolefin, polyamide, polystyrene, polyurethane, polyester, polyvinyl chloride, polyacrylic, or any combination thereof.

25. The shock absorbing pad of claim 24. wherein the reclaimed artificial turf material comprises a polyolefin.

26. The shock absorbing pad of claim 25, wherein the polyolefin comprises a polyethylene, polypropylene, or a combination thereof.

27. The shock absorbing pad of claim 24, wherein the reclaimed artificial turf comprises a polyamide.

28. The shock absorbing pad of claim l, wherein the polyamide is nylon 6, nylon 6,6, nylon 1,6, nylon 12, nylon 6,12, or a combination thereof.

29. The shock absorbing pad of claim 24, wherein the reclaimed artificial turf comprises a polyester.

30. The shock absorbing pad of claim 29, wherein the polyester comprises polyethylene terephthalate, polypropylene terephthalate, polybutylene terephthalate, or any combination thereof.

31. The shock absorbing pad of claim 30, wherein the polyester comprises polyethylene terephthalate, wherein the fiber comprising polyethylene terephthalate has a denier count of about 2 dpf to about 100 dpf.

32. The shock absorbing pad of claim 1, wherein the heat set binder is a low melt fiber.

33. The shock absorbing pad of claim 1, wherein the heat set binder is a bi-component fiber.

34. The shock absorbing pad of claim 1, wherein the shock absorbing pad has a density from about 2 lbs / ft3to about 30 lbs / ft3.

35. The shock absorbing pad of claim 1. wherein when the shock absorbing pad is present as a component in an artificial turf system, the artificial turf system exhibits a Gmax value less than about 165 g’s as measured according to ASTM F-355.

36. The shock absorbing pad of claim 1, wherein when the shock absorbing pad is present as a component in an artificial turf system, the artificial turf system exhibits a Head Impact Criterion of less than about 1000 from a 1 meter drop as measured according to EN 1177 test.Attorney Docket No. 19133.0394P137. The shock absorbing pad of claim 1, wherein the shock absorbing pad exhibits a compression set from about 1% to about 30% as measured according to ASTM D-3676 or ASTM D-3574.

38. The shock absorbing pad of claim 1. wherein the distance measured along the third axis between the top surface maximum axis and the bottom surface minimum axis decreases at least 5 % when a force of 700N is applied using a tensile testing machine.

39. The shock absorbing pad of claim 1, wherein the composite nonwoven pad defines a plurality of openings extending from the top surface to the bottom surface.

40. The shock absorbing pad of claim 39, wherein the plurality of openings are configured to provide a predetermined rate of horizontal drainage of moisture through the nonwoven pad from the top surface to the bottom surface.

41. The shock absorbing pad of claim 39, wherein each opening of the plurality of openings has a diameter from about 1 mm to about 15 mm.

42. The shock absorbing pad of claim 1. wherein the plurality of openings cooperate to provide a vertical water drainage capability from 10 inches per hour to 500 inches per hour as determined by ASTM D3385.

43. The shock absorbing pad of claim 1, wherein the composite nonwoven pad is a slab or panel.

44. An artificial turf system comprising:ii) an artificial turf comprising:a. a primary backing layer having a face side and a back side; and b. a plurality of turf fibers extending through the backing layer such that a face side portion of the turf fibers extends from the face side of the backing layer, andii) a shock absorbing pad according to any one of the preceding claims, iii) wherein the back side of the primary backing layer of the artificial turf overlies the top surface of the composite nonwoven pad.

45. The artificial turf system of claim 44, wherein the turf system exhibits a Gmax value less than about 165 g’s as measured according to ASTM F-355.

46. The artificial turf system of claim 44, wherein the turf system exhibits a Head Impact Criteria of less than about 1,000 from a 1 meter drop as measured according to EN 1177 test.

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