Plasma-Activated Artificial Turf Binding
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Solution Overview
Problem
Artificial turfs have limited lifespan due to wear and tear from use and exposure to environmental factors, requiring frequent maintenance and replacement, which is costly and resource-intensive.
Innovation Solution
A system using a dielectric barrier discharge device with two electrodes, a conveyor unit, and a dispensing unit to plasma-activate the backside of a carrier mesh with integrated fibers, enhancing the binding between fibers and the backing layer, thereby increasing the durability and lifespan of artificial turf.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional manufacturing methods are used, then production cost and time are reduced, but binding strength between fibers and backing layer is insufficient
Solution Approach 1:
The dielectric barrier discharge device applies plasma treatment to the backside of the carrier mesh before the backing layer is applied. This preliminary plasma activation creates reactive groups on the fiber surfaces, which significantly enhances the binding strength between the fibers and the subsequent backing layer, resolving the contradiction by preparing the surface in advance for better adhesion.
Solution Approach 2:
The invention replaces conventional mechanical or chemical binding methods with a plasma-based dielectric barrier discharge process. This substitution uses electrical energy to create plasma that chemically activates the fiber surfaces, achieving superior binding strength without the complexity of mechanical fastening systems or extensive chemical treatments.
2Strength
If plasma activation is applied to enhance binding, then binding strength increases, but energy consumption increases
Solution Approach 1:
The dielectric barrier discharge device operates by controlling electrical parameters (voltage, frequency, pulse duration) to optimize plasma generation efficiency. By adjusting these parameters, the system achieves effective fiber activation with minimized energy consumption, balancing the trade-off between binding strength enhancement and energy usage.
Solution Approach 2:
The plasma treatment is applied as periodic pulses rather than continuous exposure. This periodic activation allows the reactive species to effectively treat the fiber surfaces during brief intervals, achieving sufficient binding enhancement while reducing overall energy consumption compared to continuous plasma generation.
3Strength
If plasma treatment is used, then binding strength improves, but manufacturing process complexity increases
Solution Approach 1:
The dielectric barrier discharge device is integrated into the existing turf manufacturing line, combining the plasma treatment step with the continuous production process. The carrier mesh moves continuously through the plasma zone while the backing layer is applied immediately after, merging multiple operations into a streamlined workflow that enhances binding without proportionally increasing overall process complexity.
Solution Approach 2:
The dielectric material in the dielectric barrier discharge device serves as an intermediary that enables plasma generation without direct contact between the electrode and the carrier mesh. This intermediary approach simplifies the device design by eliminating the need for complex electrode positioning and protection systems while still achieving effective plasma treatment.
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 system significantly improves the binding strength between fibers and the backing layer, leading to a more durable and long-lasting artificial turf with reduced maintenance needs and extended lifespan.
Implementation Method 1
a dielectric barrier discharge device including a first electrode and a second electrode; a conveyor unit configured for moving a carrier mesh through an air gap formed between the first electrode and the second electrode... to apply a dielectric barrier discharge to the backside of the carrier mesh as the carrier mesh moves through the air gap for plasma-activating the backside
Data Source
Figure 1
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Figure 4
AI summary
The invention relates to a system (100) for manufacturing an artificial turf (136), including: - a dielectric barrier discharge device (112) including a first electrode (402, 602, 604, 958) and a second electrode (404); - a conveyor unit (108, 110, 107) configured for moving a carrier mesh (960) through an air gap (405) formed between the first electrode and the second electrode, wherein the carrier mesh includes a backside, and wherein the carrier mesh includes fibers integrated such that a portion of the fibers are exposed on the backside; - a control unit (114) configured to control the dielectric barrier discharge device to apply a dielectric barrier discharge to the backside of the carrier mesh as the carrier mesh moves through the air gap for plasma-activating the backside; and - a dispensing unit (116) configured to apply a backing layer to the plasma-activated backside of the carrier mesh for providing the artificial turf.