Coconut Shell Granular Infill for Biodegradable Synthetic Turf

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Solution Overview

Problem

Current rubber crumb infill materials in synthetic sports fields are not environmentally friendly, pose health concerns, and are non-biodegradable, necessitating a safer and more sustainable alternative that meets performance standards.

Innovation Solution

Coconut shell crumb is used as a replacement for rubber crumb infill, processed into particles of specific sizes to ensure compatibility and safety, utilizing a method involving shredding and screening to produce coconut crumb infill that meets the standards set by the Synthetic Turf Council.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If rubber crumb infill material is used in synthetic sports fields, then shock absorption and traction are provided, but environmental friendliness deteriorates and health safety worsens

Engineering Contradiction:

ImprovesafetyVSAvoidenvironmental harm

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent changes the material parameter from synthetic rubber crumb to natural coconut shell crumb, transforming the infill material's composition while maintaining its functional properties. This parameter change resolves the contradiction by providing a biodegradable, non-carcinogenic alternative that retains shock absorption and traction capabilities while eliminating environmental and health hazards

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent converts the previously harmful rubber crumb material into a beneficial natural alternative. By using coconut shell crumb, the solution transforms the problem of non-biodegradable synthetic material into a benefit of using renewable, biodegradable natural material that improves environmental sustainability while maintaining field performance

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

2Reliability

If rubber crumb infill material is used, then field performance is maintained, but biodegradability deteriorates

Engineering Contradiction:

ImproveperformanceVSAvoidbiodegradability

Core Design Contradiction:

ReliabilityVSDuration of action of stationary object

Solution Approach 1:

The patent changes the temporal parameter of material durability by switching from permanent synthetic rubber to biodegradable coconut shell crumb. This parameter change enables the infill material to naturally decompose over time, resolving the contradiction between maintaining field performance and achieving biodegradability

Inventive Principle:

Principle #35Parameter changes

3Object-affected harmful factors

If coconut shell crumb is used as infill material, then environmental friendliness improves and safety enhances, but manufacturing complexity increases

Engineering Contradiction:

Improveenvironmental safetyVSAvoidprocessing complexity

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The patent applies segmentation by breaking down coconut shells into crumb-sized particles through mechanical processing. This segmentation transforms the raw coconut shell material into the required infill particle size, resolving the contradiction by creating a processed product that meets performance standards while maintaining environmental benefits

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent replaces the need for complex chemical treatments or synthetic material production with a simpler mechanical processing system. By using mechanical shredding and screening of coconut shells, the solution reduces manufacturing complexity compared to synthetic rubber production while achieving the desired infill material properties

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS12084817B2Coconut hard shell granular infill for synthetic sport fields

Publication Date: 2024.09.10 GENUS IND LLC

AI summary

Coconut crumb can serve as an infill material on synthetic turf fields in the place of tire crumb. The crumbs are less than 10 mm big and have smooth corners and edges. The process of producing the coconut crumb involves successive grinding or milling processes that reduce the inner hard shell of the coconut to particles of an appropriate size for infill, while screening out the unwanted material from being included in the infill.