Indexed Synthetic Turf Tufting for Waste-Free Custom Installation

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Solution Overview

Problem

Synthetic turf customization is labor-intensive and generates significant waste due to on-site cutting and installation of different colored turf pieces, leading to durability issues and increased costs.

Innovation Solution

A system and method for manufacturing customized synthetic turf using an indexing system that affixes tags to backing material, allowing precise tufting and robotic installation of colored yarn, eliminating the need for on-site customization and reducing waste.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If synthetic turf is customized on-site by cutting and installing different colored turf pieces, then design customization is achieved, but labor intensity increases and waste is generated

Engineering Contradiction:

Improvedesign customizationVSAvoidlabor intensity

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

The patent applies preliminary action by pre-marking the backing material with registration marks and pre-programming the tufting machine with design patterns before manufacturing. This allows the synthetic turf to be customized during manufacturing rather than requiring labor-intensive on-site cutting and installation, thereby reducing labor intensity while maintaining design customization capability

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent replaces the manual mechanical process of on-site cutting and piece-by-piece installation with an automated tufting machine system that can precisely place colored yarn according to programmed designs. This mechanical substitution eliminates the need for labor-intensive on-site customization while achieving the same design customization outcome

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Adaptability or versatility

If synthetic turf is customized on-site by cutting out pieces, then design customization is achieved, but material waste increases

Engineering Contradiction:

Improvedesign customizationVSAvoidmaterial waste

Core Design Contradiction:

Adaptability or versatilityVSLoss of substance

Solution Approach 1:

The patent uses preliminary action by pre-marking the backing material with registration marks and pre-programming the tufting machine with design patterns before manufacturing. This allows precise placement of colored yarn only where needed, eliminating the material waste generated by cutting out pieces during on-site installation

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent applies local quality by inserting colored yarn only in specific locations where design elements are required, rather than cutting out entire pieces of turf. This localized approach to customization minimizes material waste while achieving the desired design effect

Inventive Principle:

Principle #3Local quality

3Adaptability or versatility

If synthetic turf is customized on-site by cutting and installing pieces, then design customization is achieved, but installation time increases

Engineering Contradiction:

Improvedesign customizationVSAvoidinstallation time

Core Design Contradiction:

Adaptability or versatilityVSLoss of time

Solution Approach 1:

The patent applies preliminary action by pre-marking the backing material with registration marks and pre-programming the tufting machine with design patterns before manufacturing. This allows the synthetic turf to be fully customized during manufacturing, eliminating time-consuming on-site cutting and piece-by-piece installation

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent merges the customization process with the manufacturing process by using the tufting machine to both manufacture the synthetic turf and incorporate design elements in a single integrated operation. This eliminates the separate customization step that would otherwise occur on-site, reducing installation time

Inventive Principle:

Principle #5Merging (Combining)

4Adaptability or versatility

If synthetic turf is customized on-site by cutting pieces, then design customization is achieved, but durability decreases

Engineering Contradiction:

Improvedesign customizationVSAvoiddurability

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The patent applies preliminary action by pre-marking the backing material with registration marks and pre-programming the tufting machine with design patterns before manufacturing. This ensures that all yarn insertions are made during manufacturing under controlled conditions, avoiding the durability issues that arise from on-site cutting and installation

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent replaces the manual cutting and installation process with an automated tufting machine system that securely anchors colored yarn during manufacturing. This mechanical substitution ensures consistent quality and durability by eliminating the variable conditions of on-site customization

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS12480242B2System and method for customized synthetic turf design, manufacturing and installation

Publication Date: 2025.11.25 SEATON REED J

AI summary

A system for manufacturing synthetic turf is disclosed that includes an indexing system configured to affix an indexing device to a backing material, a tufting machine configured to receive the backing material and yarn and to fabricate the synthetic turf by tufting the yarn in the backing material and a controller configured to read the indexing device and to post-process the synthetic turf as a function of the indexing device.