Artificial Turf Infill Reuse and Elastic Binding Composition

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Solution Overview

Problem

Artificial turf systems face wear and tear due to usage and environmental factors, leading to the need for frequent replacement and resulting in waste and increased costs, as existing methods do not effectively reuse or rejuvenate worn-out turf components.

Innovation Solution

A method and system for manufacturing new artificial turf by collecting infill from existing turf, mixing it with a binding agent to create an elastic binding composition, and applying this composition over a base layer or existing turf to support a new layer of artificial turf fibers, reducing waste and production costs while maintaining elasticity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If artificial turf is replaced frequently due to wear, then the playing surface quality is maintained, but waste increases and costs increase

Engineering Contradiction:

Improveplaying surface qualityVSAvoidwaste

Core Design Contradiction:

ReliabilityVSLoss of substance

Solution Approach 1:

The patent recovers and reuses infill material from worn artificial turf by collecting it, processing it through screening and cleaning, and reintroducing it into the turf system. This prevents the infill from becoming waste while maintaining the playing surface quality through rejuvenation rather than complete replacement

Inventive Principle:

Principle #34Discarding and recovering

Solution Approach 2:

The patent changes the physical state and properties of the infill material through processing steps including screening to remove contaminants, cleaning to eliminate debris, and potential re-coating or treatment. These parameter changes restore the infill's functional properties, enabling its reuse and reducing waste

Inventive Principle:

Principle #35Parameter changes

2Reliability

If artificial turf is replaced frequently due to wear, then the playing surface quality is maintained, but manufacturing costs increase

Engineering Contradiction:

Improveplaying surface qualityVSAvoidmanufacturing costs

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent recovers valuable infill material from worn turf systems, processing and reusing it to rejuvenate the turf rather than requiring complete replacement. This significantly reduces manufacturing and installation costs while maintaining playing surface quality through cost-effective refurbishment

Inventive Principle:

Principle #34Discarding and recovering

Solution Approach 2:

The system enables self-service turf maintenance by collecting and reprocessing the infill material on-site or through centralized facilities. The processed infill is then reintroduced to rejuvenate the turf, creating a self-sustaining cycle that reduces dependency on expensive new material purchases

Inventive Principle:

Principle #25Self-service

3Loss of substance

If infill is collected and reused, then waste is reduced and costs decrease, but the complexity of the manufacturing process increases

Engineering Contradiction:

Improvewaste reductionVSAvoidmanufacturing process complexity

Core Design Contradiction:

Loss of substanceVSDevice complexity

Solution Approach 1:

The patent divides the turf system into separable components, specifically isolating the infill material from the turf fibers and backing. This segmentation enables independent processing of the infill through screening and cleaning operations, simplifying the overall complexity by treating only the infill rather than the entire turf system

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent introduces intermediary processing steps including screening mechanisms and cleaning systems that act as mediators between the collected infill and its reuse. These intermediary devices handle the complex tasks of contaminant removal and material preparation, isolating the complexity from the core rejuvenation process

Inventive Principle:

Principle #24Intermediary (Mediator)

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

This approach allows for the partial reuse of worn-out turf, reducing waste and costs by creating a new, elastic artificial turf system with improved mechanical force distribution, leading to a more durable and cost-effective solution without compromising on elasticity or appearance.

Implementation Method 1

mixing the collected rubber granulates and a binding agent for generating an elastic binding composition

Methodology Applied

Scientific EffectAdhesion: Adhesive

Data Source

PatentUS20240125057A1Method for manufacturing an artificial turf system and the system therein

Publication Date: 2024.04.18 APT ADVANCED POLYMER TECH CORP

AI summary

A method for manufacturing an artificial turf system provides for collecting infill from an existing artificial turf, wherein the collected infill comprises collected rubber granulates, mixing the collected rubber granulates and a binding agent for generating an elastic binding composition, applying the elastic binding composition over a base layer or over an optional existing artificial turf on top of the base layer, and applying a new artificial turf over the elastic binding composition, and the artificial turf system generated therein.