Two-Step Coating Process for Artificial Turf Infill Granules
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Solution Overview
Problem
Existing artificial turf infill materials often have incomplete surface coverage, leading to defects and reduced durability and aesthetic appeal, as they do not effectively mimic the natural appearance of real turf.
Innovation Solution
A method involving a two-step coating process for granular materials used in artificial turf infill, where an initial and subsequent coating with polyurethane-based binders and pigments are applied to achieve nearly complete surface coverage, enhancing both the appearance and durability of the infill.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a single-step coating process is used for artificial turf infill, then the manufacturing process is simple and fast, but the surface coverage is incomplete leading to defects and reduced aesthetic appeal
Solution Approach 1:
The coating process is divided into two distinct steps: a first coating step applying a preliminary layer of binder and pigment, and a second coating step applying an additional layer. This segmentation allows each step to contribute to overall surface coverage, with the second step filling in gaps from the first step, thereby achieving nearly complete coverage while maintaining a manageable process structure
Solution Approach 2:
The first coating step serves as a preliminary action that prepares the infill surface by applying an initial layer of binder and pigment. This preliminary coating creates a base layer that the second coating step can build upon, ensuring that subsequent pigment and binder adhere properly and achieve complete surface coverage
2Reliability
If existing infill materials are used, then the manufacturing cost is low and process is simple, but the durability and wear qualities are reduced due to incomplete surface coverage
Solution Approach 1:
The manufacturing process is segmented into multiple coating steps, where each step contributes to building a durable, fully coated infill product. The first step applies a base layer and the second step completes the coverage, ensuring superior durability and wear qualities compared to single-step processes
Solution Approach 2:
The coating process continues through multiple sequential steps rather than stopping after a single application. The second coating step immediately follows the first, maintaining continuous useful action to achieve complete surface coverage and enhanced durability without interrupting the manufacturing flow
3Manufacturing precision
If existing infill materials with incomplete coating are used, then the production time is short and manufacturing is fast, but the aesthetic appeal and natural appearance are reduced
Solution Approach 1:
The coating process is segmented into two steps that can be efficiently executed in sequence. The first step applies a preliminary coating and the second step completes the surface uniformity, achieving nearly complete coverage and natural appearance while maintaining reasonable production speed through optimized process flow
Solution Approach 2:
The second coating step applies an additional layer of binder and pigment that may exceed the minimum required for complete coverage. This excessive action ensures that all gaps and defects from the first step are fully addressed, achieving uniform surface appearance while the efficient process design minimizes the time penalty
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 a more uniformly coated and durable artificial turf infill with improved wear qualities and a natural, earth-like appearance, reducing defects and enhancing the overall performance and visual appeal of the turf.
Implementation Method 1
a one-pack type or two-pack type polyurethane resin which gels at least from a liquid state in 60 seconds or more and cures through the gelling process
Implementation Method 2
adding water and a catalyst to the initial composition during the mixing of the initial composition to cure the fluid binding agent and the at least one type of pigment into an initial coating of the granulate
Data Source
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AI summary
The invention provides for a method manufacturing artificial turf infill (602), wherein the method comprises providing (700) an initial composition (1120) comprising a granulate (1006), at least one type of pigment, and a fluid binding agent. The fluid binding agent comprises at least one type of polymer component. The method further comprises mixing (702) the initial composition; adding (704) water and a catalyst to the initial composition during the mixing of the initial composition to cure the fluid binding agent and the at least one type of pigment into an initial coating (200) of the granulate. The method further comprises providing (706) a subsequent composition (1122) comprising the granulate with the initial coating, the at least one type of pigment, and the fluid binding agent. The method further comprises mixing (708) the subsequent composition. The method further comprises adding (710) water and the catalyst to the subsequent composition during the mixing of the subsequent composition to cure the fluid binding agent and the at least one type of pigment into a subsequent coating (300) of the granulate. The method further comprises providing (712) the granulate with the subsequent coating as artificial turf infill.