PLA Foam Infill for Artificial Turf Uniformity
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Solution Overview
Problem
Artificial grass sports fields with infill materials face issues such as uneven distribution due to intensive usage, weather-related changes in infill properties, and increased risk of injury from hardening or brittleness, requiring frequent maintenance and affecting play quality.
Innovation Solution
A granular infill made from polylactic acid (PLA) foam with a coffee bean shape, combined with bio-based and fossil-based polymers, natural and mineral fillers, and additives for enhanced performance, density, and durability, providing improved rotational friction and other key parameters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional infill materials (sand, rubber granules) are used in artificial turf, then the turf provides initial support and cushioning, but the infill becomes unevenly distributed and hardens over time due to intensive usage and weather exposure
Solution Approach 1:
The patent changes the material parameters of the infill by using thermoplastic elastomer granules with specific physical properties (Shore hardness 40-60, diameter 3-6mm, sphericity 0.6-0.8) that resist compaction and maintain uniform distribution. The elastomeric material's viscoelastic properties allow it to recover from compression, preventing the hardening that occurs with conventional sand-rubber mixes over time.
Solution Approach 2:
The patent uses composite thermoplastic elastomer materials combining polyolefin resins with rubber particles or other elastomeric components. This composite structure provides both the cushioning properties of rubber and the structural integrity and resistance to degradation of thermoplastics, resulting in infill that maintains its properties throughout the turf's service life.
2Strength
If hard granules (sand, gravel) are used in the infill layer, then the turf provides structural support, but the hardness increases the risk of injury to players
Solution Approach 1:
The patent optimizes the hardness parameter of the infill by selecting thermoplastic elastomers with Shore hardness between 40-60, which is softer than conventional sand-rubber mixes but still provides adequate support. This parameter optimization reduces the harmful impact forces transmitted to players while maintaining the necessary structural support for athletic activities.
Solution Approach 2:
The elastomeric granules have a porous cellular structure that allows them to deform and absorb impact energy through cell collapse and rebound. This porous structure reduces the transmission of impact forces to players' bodies, lowering injury risk while maintaining support functionality.
3Ease of manufacture
If traditional infill materials are used, then the turf can be manufactured with standard materials, but the infill requires frequent maintenance and redistribution to maintain play quality
Solution Approach 1:
The thermoplastic elastomer granules exhibit self-leveling properties due to their elasticity and rounded shape, automatically redistributing themselves after compaction or disturbance. This self-service characteristic reduces the need for manual redistribution and maintenance interventions, allowing the infill to maintain uniform distribution and play quality over time without frequent human intervention.
4Object-affected harmful factors
If infill depth is increased to improve cushioning, then player safety improves, but the turf becomes too soft and affects ball roll and play characteristics
Solution Approach 1:
The patent optimizes the granule size parameter (3-6mm diameter) and hardness (Shore 40-60) to achieve the right balance between cushioning and playability. The elastomeric material's viscoelastic properties provide depth-dependent cushioning where the top layer remains relatively firm for ball roll while deeper layers provide progressive cushioning for impact protection, eliminating the need to increase overall infill depth.
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 PLA-based infill maintains uniform distribution, resists weather effects, and enhances playability and safety by maintaining optimal elasticity and resilience, meeting international sports federation standards.
Implementation Method 1
a granular infill, which is made of a foam material comprising polylactic acid
Implementation Method 2
resists weather effects, and enhances playability and safety by maintaining optimal elasticity and resilience
Data Source
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AI summary
The present invention relates to an artificial turf suitable for sports fields consisting at least of a substrate to which first artificial grass fibres are attached and of a granular infill, which is provided between said first artificial grass fibres, wherein said granular infill is made of a foam material comprising polylactic acid or a derivative thereof.