Artificial Turf Embossed Underside to Reduce Heat Deformation
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Solution Overview
Problem
Artificial turf deforms at high temperatures, leading to issues such as rippling and material fatigue, which affect its functionality and lifespan, particularly in recycled materials.
Innovation Solution
A method involving embossing the underside of artificial turf to create recessed areas during the fusion process, allowing the turf to expand when heated, thereby maintaining structural integrity and reducing deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If artificial turf is made with recycled material, then environmental sustainability is improved, but stiffness increases and susceptibility to deformation worsens
Solution Approach 1:
The patent applies local quality by creating recessed areas at specific locations on the underside of the artificial turf where thermal expansion occurs. These localized depressions allow the material to expand into the recesses rather than deforming the visible surface, enabling the turf to maintain dimensional stability while using recycled materials.
Solution Approach 2:
The invention addresses surface deformation by moving the compensation mechanism to another dimension - creating recesses in the underside of the turf rather than trying to prevent expansion at the visible surface. This dimensional shift allows the turf to expand vertically into the recesses while maintaining a flat appearance from above.
2Stability of the object's composition
If additional films are used to prevent deformation, then dimensional stability is improved, but device complexity and material consumption increase
Solution Approach 1:
The patent extracts the need for additional stabilizing films by integrating the deformation compensation function directly into the carrier material structure through embossed recesses. This eliminates the requirement for separate anti-deformation films or layers, simplifying the overall structure while maintaining dimensional stability.
Solution Approach 2:
The invention merges the functions of the carrier material and the deformation compensation mechanism into a single integrated structure. The recesses are formed directly in the carrier material, combining the structural support and thermal expansion management functions into one component, thereby reducing overall complexity.
3Ease of manufacture
If conventional production methods are used, then manufacturing simplicity is maintained, but heat resistance and dimensional stability worsen at high temperatures
Solution Approach 1:
The patent applies preliminary action by forming the recesses in the carrier material before the turf is subjected to high temperatures. This pre-formed structure is designed to accommodate thermal expansion that will occur during use, allowing the turf to resist deformation at high temperatures while maintaining manufacturing simplicity through a single embossing step.
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 method enhances heat resistance and dimensional stability, preventing warping and rippling while reducing material consumption and improving recyclability.
Implementation Method 1
transferring heat from the heated rotating calender roll to the carrier material with the fibers
Implementation Method 2
fusing the connected areas of the fibers with the underside of the carrier material
Implementation Method 3
embossing an underside of the artificial turf, wherein the embossing forms one or more depressed portions of the underside of the artificial turf
Data Source
Figure 1
Figure 2A
Figure 2B
AI summary
A method for manufacturing artificial turf, comprising the steps of: providing a backing material having a top and a bottom; providing a plurality of fibers, each fiber comprising two ends extending from the top of the backing material and a connected region arranged in a loop on the bottom of the backing material; feeding the backing material with the fibers to a heated rotating calender roller; guiding the backing material with the fibers over at least a portion of the surface of the heated rotating calender roller, the connected regions of the fibers and the bottom of the backing material facing the calender roller; and, while guiding the backing material with the fibers over the at least portion of the surface of the heated rotating calender roller, transferring heat from the heated rotating calender roller to the backing material with the fibers.and fusing the connected areas of the fibers with the underside of the backing material to form the artificial turf, as well as embossing an underside of the artificial turf.