Irregular Granular Infill for Artificial Grass Stability
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Solution Overview
Problem
Current granular infill materials for artificial grass surfaces, particularly those of thermoplastic origin, face issues with performance, volumetric efficiency, moisture retention, cost, drainage, and environmental impact, as well as stability and durability problems due to their uniform size and shape, and challenges in sourcing and processing vegetable-based materials.
Innovation Solution
A granular infill material composed of a thermoplastic polymeric matrix with a cellulose-based vegetable load, sourced from offcuts and waste materials like wallpaper, offering irregular prismatic shapes and high porosity, which enhances water absorption and volumetric performance, and can be recycled, allowing for customizable characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If uniform shaped granules are used, then manufacturing is simplified, but volumetric performance and stability deteriorate
Solution Approach 1:
The patent applies asymmetry by using granules with irregular prismatic shapes rather than uniform geometric forms. This irregularity allows the granules to interlock more effectively, improving stability and volumetric performance while still being manufacturable through extrusion processes that can accommodate varied cross-sectional geometries.
Solution Approach 2:
The patent applies local quality by varying the cross-sectional geometry of granules at different locations along their length. The granules feature different cross-sectional shapes at different positions, creating local variations that enhance interlocking and stability without requiring complete redesign of the entire granule structure.
2Object-affected harmful factors
If vegetable-based loads are used, then environmental impact improves, but processing difficulty and material availability worsen
Solution Approach 1:
The patent applies parameter changes by carefully controlling the moisture content and thermal parameters during extrusion. By adjusting these parameters, the vegetable-based loads (cellulose, starch, or protein) can be processed without burning or degrading, maintaining their environmental benefits while making the production process feasible.
Solution Approach 2:
The patent applies composite materials by combining thermoplastic polymeric matrices with vegetable-based loads (cellulose, starch, or protein) in a single extrusion process. This creates composite granules that leverage the environmental advantages of vegetable materials while using the processing capabilities of thermoplastics to ensure manufacturability.
3Quantity of substance
If mineral loads are used in thermoplastic granules, then cost reduces, but performance and moisture retention deteriorate
Solution Approach 1:
The patent applies parameter changes by replacing mineral loads with vegetable-based loads and adjusting the moisture content parameters of the granules. This allows the granules to retain moisture effectively while reducing polymer quantity, achieving both cost reduction and improved performance through the natural hygroscopic properties of vegetable materials.
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 granular infill material provides improved stability, moisture retention, and cost-effectiveness while maintaining surface freshness and performance, overcoming the limitations of traditional materials by leveraging the abundance and versatility of cellulose as a raw material.
Implementation Method 1
The granular material has an appreciable granular porosity; the porosity enables obtaining a water absorption that is particularly appreciated
Data Source
Figure 1
AI summary
An artificial grass surface structure (1), in particular for sports fields, comprises a mat (2) with filaments (4) which simulate a grass surface, and at least a filling layer (5) comprising a granular infill material (6) arranged between the filaments (4). The granular infill material for synthetic grass surfaces comprises a plurality of granules (8) comprising a thermoplastic polymeric matrix and a load dispersed in the matrix, where the load includes at least a cellulose-based vegetable component wherein the cellulose is present in a measure of between 20% and 40% in weight.