Artificial turf with improved tuft-lock
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Artificial turf experiences poor adhesion between yarn and backing, leading to yarn pull-off under continuous stresses, which affects the durability of the turf.
Innovation Solution
Stretched filaments are developed using a blend of functionalized polymers with amine or imide groups and non-functionalized polyolefins, enhancing adhesion to polyurethane backings by increasing polarity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional non-functionalized polyolefin yarns are used, then the manufacturing process is simple and cost-effective, but the adhesion between yarn and polyurethane backing is poor, leading to yarn pull-off under stress
Solution Approach 1:
The patent applies composite materials by creating a yarn from a blend of functionalized polymer (containing amine or carboxyl groups) and non-functionalized polyolefin. The functionalized polymer component provides polar groups that enhance adhesion to the polyurethane backing, while the non-functionalized polyolefin maintains the basic structural properties. This composite approach resolves the contradiction by achieving improved adhesion (reliability) through the functionalized component without completely abandoning the simplicity and cost-effectiveness of conventional polyolefin systems.
Solution Approach 2:
The patent applies parameter changes by modifying the chemical composition parameters of the yarn material. Specifically, it introduces functionalized polymers with specific polar groups (amine or carboxyl) at controlled concentrations (typically 1-20% by weight) into the polyolefin matrix. This parameter modification enables the yarn to form stronger chemical interactions with the polyurethane backing through hydrogen bonding or other polar interactions, thereby improving adhesion while maintaining processability.
2Reliability
If functionalized polymer blend is used to improve adhesion, then the adhesion to polyurethane backing increases, but the manufacturing complexity and cost increase
Solution Approach 1:
The patent optimizes the concentration parameter of the functionalized polymer in the blend to balance adhesion improvement with manufacturing feasibility. By limiting the functionalized polymer content to 1-20% by weight (with preferred ranges of 5-15%), the patent achieves sufficient adhesion enhancement while keeping the manufacturing process manageable and costs controlled. This parameter optimization resolves the contradiction between improved reliability and ease of manufacture.
Solution Approach 2:
The patent applies local quality by concentrating the functionalized polymer at the yarn surface or interface regions where contact with the backing occurs, rather than uniformly distributing it throughout the entire yarn volume. This can be achieved through surface treatment or selective placement during tufting. The functional groups are thus localized where they are most needed for adhesion, maximizing their effectiveness while minimizing the overall amount of functionalized polymer required, thereby reducing manufacturing complexity and cost.
3Duration of action of stationary object
If yarn and backing are subjected to continuous stresses, then the artificial turf remains in use, but poor adhesion causes yarn filaments to pull off, reducing durability
Solution Approach 1:
The patent uses composite materials with functionalized polymer components that provide enhanced interfacial bonding between the yarn and polyurethane backing. The polar groups (amine or carboxyl) in the functionalized polymer form strong chemical interactions with the polyurethane, creating a more robust interface that can withstand continuous mechanical stresses during the service life of the artificial turf. This composite structure directly addresses the contradiction by improving both durability (through extended service life) and reliability (through stress-resistant adhesion).
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 enhanced adhesion improves the durability and tenacity of the artificial turf, allowing it to withstand stresses without yarn pull-off, thereby extending its lifespan.
Implementation Method 1
the functionalized polymer enhances the polarity, thus increasing the adhesion of the filament to the polyurethane backing
Data Source
Figure 1A
Figure 1B
Figure 2
AI summary
Embodiments of the present disclosure are directed to stretched filaments comprising a non-functionalized polyolefin and at least one functionalized polymer. The functionalized polymer is a propylene-based plastomer or elastomer having one or more functional groups grafted on the propylene-based plastomer or elastomer. The one or more functional groups is selected from the group consisting of amine groups and imide groups. The at least one functionalized polymer has a DSC melting point from 100° C to 130° C. When the stretched filament is stretched to a stretch ratio of 5, the stretched filament has a tenacity greater than 0.90 cN/dtex