Laminated Tufted Turf Backing Using NIR Polyethylene Tuft Lock

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Solution Overview

Problem

Existing artificial turf manufacturing processes using urethane coating are inefficient in terms of space, energy consumption, and recyclability, leading to increased costs and waste, as well as non-recyclable materials.

Innovation Solution

Laminating a tufted backing sheet with transparent and opaque polyethylene films using near infrared or visible energy to achieve tuft lock without adhesives, ensuring full recyclability and reduced energy consumption.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If liquid urethane coating is applied and cured in a heated oven, then tuft lock is achieved, but facility space requirements and energy consumption increase significantly

Engineering Contradiction:

Improvetuft lockVSAvoidoven energy consumption

Core Design Contradiction:

ReliabilityVSUse of energy by stationary object

Solution Approach 1:

The patent replaces the thermal curing system (heated oven) with a chemical cross-linking system. The liquid urethane coating is applied and then cross-links at room temperature through moisture or catalyst activation, eliminating the need for high-temperature oven curing while achieving equivalent tuft lock strength

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the curing temperature parameter from high temperature (oven curing) to room temperature (ambient curing). This parameter change eliminates energy-intensive heating while maintaining the cross-linking chemistry that produces durable tuft lock through moisture or catalyst activation

Inventive Principle:

Principle #35Parameter changes

2Reliability

If liquid urethane coating is applied and cured in a heated oven, then tuft lock is achieved, but capital expenditures for oven acquisition increase

Engineering Contradiction:

Improvetuft lockVSAvoidcapital expenditure

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent replaces the expensive heated oven infrastructure with simple ambient temperature curing equipment. The coating cures at room temperature through chemical cross-linking, eliminating the need for capital-intensive thermal processing equipment while achieving the same functional result

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Reliability

If spray urethane coating is applied, then tuft lock is achieved, but material waste and energy consumption increase

Engineering Contradiction:

Improvetuft lockVSAvoidurethane material waste

Core Design Contradiction:

ReliabilityVSLoss of substance

Solution Approach 1:

The patent replaces the spray application system with a direct liquid coating system. The liquid urethane is applied directly to the backing in a controlled manner, eliminating the inherent overspray waste associated with spray application while maintaining effective coating coverage for tuft lock

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Reliability

If urethane coating is applied in either form, then tuft lock is achieved, but the product becomes non-recyclable

Engineering Contradiction:

Improvetuft lockVSAvoidrecyclability

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

The patent changes the chemical composition parameter of the coating system from conventional urethane to a recyclable polymer-based coating. This polymer coating provides equivalent tuft lock functionality while being compatible with recycling processes, allowing the turf product to be recycled at end of life

Inventive Principle:

Principle #35Parameter changes

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 process achieves efficient tuft lock with less material weight, reduced energy use, and faster production times, while maintaining structural integrity and recyclability of the turf product.

Implementation Method 1

a first polyethylene film sheet that is transparent to a wavelength of near infrared or visible energy and a second polyethylene film sheet that is opaque to the wavelength

Methodology Applied

Scientific EffectNear infrared radiation transmission: Infrared Radiation

Implementation Method 2

directing a wavelength of near infrared or visible energy through the first polyethylene film sheet to melt the second polyethylene film sheet

Methodology Applied

Scientific EffectRadiant heating: Heating

Implementation Method 3

melt the second polyethylene film sheet, wherein the melted second polyethylene film sheet laminates to the tufted backing sheet

Methodology Applied

Scientific EffectMelting: Melting

Data Source

PatentUS20260028783A1Laminated tufted good

Publication Date: 2026.01.29 BEARDEN JOHN H

AI summary

An article of artificial athletic turf or other tufted good made of a fabric backing sheet having a top face and a bottom face and having yarn tufted through the backing such that yarn pile extends from the top face and yarn backloops are along the bottom face which are laminated and tuft locked by layers of polyethylene film that are separately transparent and opaque to the wavelength of a near infrared or visible energy. These polyethylene layers are placed against the backing bottom face, with the opaque layer nearest the backing, and near infrared or visible energy is projected through the transparent layer and into the opaque layer to melt the latter and cause the film layers to fuse to each other and further cause that combined film to fuse to the backing and yarn backloops and form a laminated turf product.