Cork Granule Coating for Synthetic Turf Infill
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Solution Overview
Problem
Natural cork infill materials in synthetic turf experience issues with low specific gravity, leading to flotation and volatility, especially during rainfall and strong winds, causing uneven distribution and loss of material, which existing granule coating systems fail to adequately address.
Innovation Solution
A process involving the use of a wax coating substance, specifically natural or synthetic waxes with a melting point between 60°C and 140°C, is applied to cork granules to increase their specific gravity, maintaining the physical and mechanical properties of cork while enhancing its weight and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If natural cork granules are used as infill material, then eco-sustainability and natural properties are improved, but specific gravity is too low causing flotation and volatility during rainfall and strong winds
Solution Approach 1:
The patent applies composite materials by coating natural cork granules with a resinous substance. This creates a composite structure where the cork core maintains its natural eco-sustainable properties while the resin coating increases specific gravity and prevents flotation and volatility during extreme weather conditions.
Solution Approach 2:
The patent changes the physical parameter of specific gravity by applying a resinous coating to the cork granules. The coating substance has a higher specific gravity than natural cork, and when applied, it increases the overall specific gravity of the granule from approximately 0.10-0.20 g/cm³ to a higher value, thereby preventing flotation during rainfall and strong winds.
2Quantity of substance
If granule coating systems are used to increase specific gravity, then flotation and volatility are reduced, but the increase in specific gravity is not sufficient and additional substances are needed making the solution less ecological
Solution Approach 1:
The patent uses a resinous coating substance with specific physical properties (melting point between 60°C and 140°C, penetration index between 4 mm and 80 mm at 25°C) that provides sufficient specific gravity increase on its own, eliminating the need for additional flame retardant and anti-mold substances, thus maintaining ecological sustainability.
3Quantity of substance
If coating substances are applied to cork granules, then specific gravity increases, but the physical and mechanical properties of cork may be altered
Solution Approach 1:
The patent carefully controls the coating process by selecting a resinous substance with a melting point between 60°C and 140°C, which allows the coating to be applied without excessive heat that could damage cork's cellular structure. The penetration index range (4 mm to 80 mm at 25°C) ensures the coating penetrates adequately to provide gravity increase while maintaining cork's natural compressibility and mechanical properties.
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 coated cork granules achieve a significant increase in specific gravity, preventing flotation and volatility, maintaining eco-sustainability and ensuring effective performance in sports surfaces without altering their physical properties, and facilitating easier separation and recycling.
Implementation Method 1
a process involving the use of a wax coating substance, specifically natural or synthetic waxes with a melting point between 60°C and 140°C, is applied to cork granules to increase their specific gravity
Implementation Method 2
maintaining the physical and mechanical properties of cork while enhancing its weight and stability
Data Source
AI summary
Process for the manufacture of filler material for synthetic turf, comprising the phases of: - having cork material in granular form with a predetermined initial specific gravity, - having a mass of a coating substance with a melting point of between 90 °C and 140 °C and a penetration index of between 4 and 80 mm at 25 °C, - heating said mass of coating substance until it reaches the melting point, - joining said mass of coating substance to said mass of cork, - mixing said cork material in granular form with said mass of coating substance to obtain filler material for synthetic turf with a predetermined final specific gravity, - allowing said filler material to cool down. Fill material for synthetic turf and coating substance combinable with cork are also disclosed.