Tufted structure for landscape and sports
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Solution Overview
Problem
Current artificial turfs fail to effectively mimic the volume effect and density of natural grass, and lack adequate shock-absorbing properties, which are crucial for both sports and landscaping applications.
Innovation Solution
A tufted structure with a mechanically bounded layer of fibers, comprising a mixture of natural and synthetic fibers, provides structural support and shock-absorption, allowing for improved drainage and reduced surface compaction, eliminating the need for infill materials and mimicking the root zone of natural grass.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If traditional artificial turf is made with short pile height, narrow gauge, and high stitch rate to eliminate infill, then the turf can be used without infill materials, but it fails to provide adequate shock absorbing properties and volume effect
Solution Approach 1:
The patent introduces a new dimensional element by adding a thick bounded fiber layer (3-15mm) beneath the turf surface, creating a multi-layered structure that provides shock absorption and volume effect without requiring infill materials. This dimensional addition resolves the contradiction between eliminating infill and maintaining shock absorbing properties.
Solution Approach 2:
The patent uses a composite structure combining synthetic turf fibers with a bounded layer of natural and/or synthetic fibers. This composite material approach allows the turf to achieve both infill-free construction and adequate shock absorption, as the bounded fiber layer compensates for the absence of traditional infill materials.
2Manufacturing precision
If artificial turf uses dense fiber arrangement to mimic natural grass appearance, then the volume effect is improved, but drainage capability deteriorates
Solution Approach 1:
The patent applies different fiber densities to different regions: the turf surface layer has high density to mimic natural grass appearance, while the underlying bounded fiber layer has lower density with larger void spaces to facilitate drainage. This local quality differentiation resolves the contradiction between volume effect and drainage capability.
Solution Approach 2:
The patent segments the turf structure into distinct functional layers: a dense surface layer for aesthetic volume effect and a separate bounded fiber layer for drainage and shock absorption. This segmentation allows each layer to optimize its specific function without compromising the other.
3Reliability
If infill materials are used to provide shock absorbency and support, then the turf structure is stabilized, but waste disposal issues arise and environmental friendliness is reduced
Solution Approach 1:
The patent replaces non-recyclable infill materials with a bounded fiber layer that can be removed and recycled along with the turf itself. This approach eliminates the waste disposal problem associated with traditional infill while maintaining structural stability through the engineered fiber boundary layer.
Solution Approach 2:
The patent creates a synthetic copy of the natural grass root zone using the bounded fiber layer, which mimics the structural and functional properties of natural roots without using actual organic materials that would decompose and create waste. This synthetic replication provides long-term stability without environmental degradation.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution enhances the wear and drainage properties of artificial turf, providing a more natural feel and reducing waste disposal issues by using entirely recyclable materials, while ensuring efficient water drainage and structural support.
Implementation Method 1
a bounded layer of fibers, preferably in form of a mechanically bounded layer of fibers
Implementation Method 2
provides structural support and shock-absorption
Implementation Method 3
allowing for improved drainage
Implementation Method 4
reduced surface compaction
Data Source
Figure 1
Figure 2
AI summary
The present invention seeks to provide a tufted structure such as an artificial turf (10), that imitates more closely the root zone, the volume effect, and density of natural grass and that has an improved wear and drainage property. An artificial turf (10) adapted for use in landscape and sports applications comprises a bounded layer of fibers (20) formed as a non-woven matting made of one or more natural and/or synthetic fibers. A plurality of tufts (40) of pile yarn (41 ) is inserted through the bounded layer of fibers (20). A backing (30) is applied at the backside of the bounded layer of fibers (20) enhancing anchoring the tufts (40) to the bounded layer of fibers (20).