Artificial Grass Mat with Fine Pile Distribution
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing methods for producing artificial grass mats face challenges in achieving uniform distribution of pile yarns, leading to material inefficiency and increased downtime due to the difficulty in handling thick yarns, which results in higher raw material consumption and operational disruptions.
Innovation Solution
The artificial grass mat is produced using a double-face weaving method with pile-warp yarns of less than 5,000 dtex density, distributed in a W bond structure, where each burl has two pile legs bound over multiple weft yarns, and the yarns are offset in the warp direction to improve spread and reduce material usage, while also incorporating monofilament or textured yarns for enhanced performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If thick filaments with fibre density of 6,000 to 14,000 dtex are used to achieve good pile occupation, then the artificial grass blades can support a ball effectively and have an attractive appearance, but the yarns become difficult to handle, leading to increased downtime and operational disruptions
Solution Approach 1:
The patent divides the thick filament into multiple thinner filaments (each less than 5,000 dtex, preferably 1,000-3,000 dtex) that are bundled together to form the pile yarn. This segmentation makes the yarns easier to handle during weaving while maintaining the required pile occupation and ball support capabilities through the combined structure of multiple filaments per tuft.
2Ease of operation
If the distance between pile rows and piles is set to at least 10 mm to prevent stud entanglement, then the filling can be easily released, but the number of pile tufts per square meter is limited to at most 10,000, reducing material efficiency
Solution Approach 1:
The patent changes the critical parameter from pile spacing to filament density within the pile yarn. By using multiple thinner filaments (each <5,000 dtex) bundled together, the invention achieves both adequate spacing (≥10 mm) for stud release and high filament density within each tuft for material efficiency and attractive appearance.
3Quantity of substance
If high density of tufting needles and stitches is used to increase pile tuft density, then the artificial grass blades are densely distributed, but the needles heat up during the tufting process, making further improvement difficult
Solution Approach 1:
The patent replaces the mechanical tufting process with a weaving process. Instead of using tufting needles that mechanically punch and heat up, the invention uses a weaving loom to interlace pile-warp yarns with ground-warp and weft yarns, achieving dense pile distribution without the thermal limitations of needle-based tufting.
4Ease of manufacture
If pile-warp yarns with density of less than 5,000 dtex are used, then the yarns are easier to handle and distribute uniformly, but more yarns are needed to achieve the same pile occupation, increasing raw material consumption
Solution Approach 1:
The patent creates a composite structure by bundling multiple thinner filaments (each <5,000 dtex) together to form a pile yarn with equivalent or greater total density. This composite approach maintains ease of handling during weaving while achieving the required pile occupation and visual appearance through the combined effect of multiple filaments.
Data Source
Figure 1~3
AI summary
The present invention relates, on the one hand, to an artificial grass mat comprising a ground fabric and a number of artificial grass blades protruding from the ground fabric, at least one of the artificial grass blades being formed from a pile-warp yarn (1-6; 7-10; 15-18) having a density of less than 5,000 dtex. On the other hand, the present invention relates to a method for the production of an artificial grass mat of this type. The artificial grass mat according to the invention is suitable both for deployment in the practising of sport, such as for example football, tennis, hockey, golf and the like, and for deployment for other uses, such as for example domestic and garden applications, as a decorative landscape element.