Patterned Tufted Turf Panels Without Seams or Inlay Cutting

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Solution Overview

Problem

Current artificial turf production methods limit variations in pile length and number of stitches, requiring multiple discrete panels for complex installations, leading to inefficiencies and poor field integrity due to manual customization and installation techniques.

Innovation Solution

Tufted articles with patterned regions of varying color, pile height, and yarn density, produced by a system of tufting machines controlled by a controller to form continuous patterns without seams, allowing for seamless integration of graphics and textures.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If conventional tufting specifications are used with fixed machine setups, then production is simplified, but variations in pile length and number of stitches are limited

Engineering Contradiction:

Improvetufting production simplicityVSAvoidpile length and stitch variation

Core Design Contradiction:

Ease of manufactureVSAdaptability or versatility

Solution Approach 1:

The patent implements dynamic adjustment capabilities in the tufting machine that allow pile length and number of stitches to be varied during operation. The machine can change these parameters without stopping, enabling continuous production of turf with varying specifications while maintaining manufacturing efficiency.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The invention changes the operational parameters of the tufting machine dynamically. Pile length is controlled by adjusting needle travel distance, and stitch density is controlled by varying needle penetration frequency. These parameter changes enable production of multiple turf types from a single continuous process.

Inventive Principle:

Principle #35Parameter changes

2Adaptability or versatility

If multiple discrete turf panels are produced and manually customized, then complex installations with multiple colors and textures can be achieved, but significant inefficiencies and high costs occur

Engineering Contradiction:

Improvecolor and texture variationVSAvoidinstallation efficiency

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

The patent merges multiple turf production capabilities into a single continuous tufting process. Instead of producing separate panels for different colors and textures and then assembling them manually, the machine produces a continuous turf with integrated patterned regions that include multiple colors, textures, and graphical elements in one uninterrupted operation.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The invention maintains continuous production action throughout the tufting process. The machine operates without stopping to create varied turf sections, and the backing material moves continuously through the tufting head. This eliminates the need for manual assembly of discrete panels while maintaining design complexity.

Inventive Principle:

Principle #20Continuity of useful action

3Adaptability or versatility

If manual cutting and gluing techniques are used to install graphic elements, then field customization is achieved, but field integrity and quality are compromised

Engineering Contradiction:

Improvefield customization capabilityVSAvoidfield integrity

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The patent incorporates graphical elements and patterned regions directly into the turf during the tufting production process itself. Logos, text, lines, and other graphical features are tufted into the backing material as an integrated part of the manufacturing process, eliminating the need for subsequent manual installation that would compromise field integrity.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The invention replaces the manual mechanical process of cutting and gluing graphics into the field with an automated tufting process. The tufting machine directly forms graphical elements by selectively depositing yarn in desired patterns during production, substituting post-installation customization with integrated manufacturing.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS20260022504A1Patterned tufted articles, surface coverings comprising same, and systems and methods of making and using same

Publication Date: 2026.01.22 COLUMBIA INSURANCE CO

AI summary

A tufted article (e.g., an artificial turf panel) having a backing and a plurality of tufts extending through the backing. The plurality of tufts are distributed among a plurality of patterned regions. Each patterned region has at least one tuft of the plurality of tufts. The tufts of each patterned region differ from the tufts of at least one other patterned region of the tufted article in at least one of color, pile height, yarn type, or yarn density. At least one patterned region creates a longitudinal discontinuity in the color pattern of the tufted article. The tufted article does not have a seam. Complementary side edges of the tufted articles can be secured together to form at least a portion of the surface covering without the need for cutting or the use of inlay components.