Artificial Turf Fiber Structure to Reduce Grain Without Infill
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Solution Overview
Problem
Artificial turf surfaces exhibit grain issues due to fibers being tufted in a specific direction, leading to uneven appearance, inconsistent performance, and difficulty in maintenance, which current methods like alignment and brushing fail to fully address.
Innovation Solution
Manufacture artificial turf using a combination of hot-texturized, low-temperature-texturized, and non-texturized fibers by exposing them to different temperatures to achieve random fiber orientation, forming distinct layers that reduce grain and enhance performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If synthetic fibers are tufted in a specific direction during manufacturing, then the turf structure is stable and easy to install, but grain issues arise causing uneven appearance and inconsistent performance
Solution Approach 1:
The patent applies local quality by creating zones with different fiber orientations within the same turf product. Specifically, it combines a first zone with fibers oriented in a first direction and a second zone with fibers oriented in a second direction (different from the first). This allows different regions of the turf to have optimized properties for their specific functions while collectively eliminating the grain effect that plagues uniform-direction turf.
Solution Approach 2:
The patent segments the turf into multiple zones with distinct fiber orientation characteristics. Rather than using a single uniform fiber direction across the entire product, the turf is divided into segments (zones) where each segment has fibers tufted in different directions. This segmentation approach resolves the grain issue by ensuring that no single grain direction dominates the overall appearance and performance.
2Manufacturing precision
If turf is brushed regularly to maintain uniform appearance, then grain effects are reduced, but maintenance time and cost increase
Solution Approach 1:
The patent applies preliminary action by incorporating the grain-reduction feature directly into the manufacturing process rather than relying on post-installation maintenance. By tufting fibers in multiple directions during production, the turf is pre-configured to resist grain formation, eliminating the need for regular brushing to maintain uniform appearance. This shifts the solution from ongoing maintenance to one-time manufacturing.
3Reliability
If high infill levels are used to support fibers and reduce grain effects, then fiber stability improves, but cost increases and environmental concerns arise from rubber-based infill abrasion
Solution Approach 1:
The patent applies the taking out principle by removing the need for infill material entirely. Instead of using rubber or sand infill to support the fibers and reduce grain effects, the invention achieves fiber stability through the multi-directional tufting configuration itself. The zones with different fiber orientations work together to provide inherent stability without requiring additional infill materials, thereby eliminating the environmental pollution associated with rubber infill abrasion.
4Manufacturing precision
If turf sections are aligned during installation to create uniform appearance, then grain visibility is reduced, but installation time and complexity increase
Solution Approach 1:
The patent applies self-service by making the turf inherently resistant to grain visibility issues through its multi-directional fiber configuration. The product is designed to automatically maintain uniform appearance regardless of installation orientation, eliminating the need for careful alignment during installation. The turf essentially services its own appearance requirements through its intrinsic structural design rather than requiring external alignment efforts.
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 results in an artificial turf with a natural appearance and improved ball slowdown, reduced footing risk, and reduced maintenance needs, without the use of infill, by optimizing fiber lengths and orientations.
Implementation Method 1
exposing the carrier with the texturized and non-texturized fibers to a third temperature, the third temperature being hot enough to cause the hot-texturized fibers to shrink and the low-temperature-texturized fibers to expand
Data Source
Figure 1~2
Figure 3A~3B
Figure 4A~4C
AI summary
Disclosed is a method of manufacturing an artificial turf (200), the method comprising: - manufacturing (222) a hot-texturized yarn by texturizing a first yarn at a first temperature; - manufacturing (224) a low-temperature-texturized yarn by texturizing a second yarn at a second temperature, the second temperature being lower than the first temperature; - integrating (226) the hot-texturized yarn, the low-temperature-texturized yarn and a non-texturized yarn into a carrier (202); - cutting (228) the integrated yarns to form low-temperature-texturized fibers (206), hot-texturized fibers (204) and non-texturized fibers (208) extending from the carrier; - exposing (230) the carrier with the texturized and non-texturized fibers to a third temperature to cause the hot-texturized fibers to shrink and the low-temperature-texturized fibers to expand; and - after exposition to the third temperature, providing (232) the carrier with the texturized and non-texturized fibers as the artificial turf.