Artificial turf, method for manufacturing artificial turf and method for recycling an artificial turf into polyester granules
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Solution Overview
Problem
Current artificial turf is difficult to recycle and deteriorates over time, posing environmental concerns and requiring separate processing of materials, which complicates recycling and maintenance.
Innovation Solution
Development of fully recyclable artificial turf using polyester or co-polyester fibers and a polyether sulfone adhesive or thermoplastic co-polyester adhesive for tuft withdrawal force enhancement, allowing for complete recycling into polyester granules without material separation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional artificial turf materials (polyamide, polypropylene, polyethylene) are used, then sports properties and comfort are improved, but recyclability deteriorates due to material complexity and degradation
Solution Approach 1:
The patent applies homogeneity by using polyester as a single base material for both the artificial turf fibers and the adhesive coating. This material uniformity enables complete recyclability because all components can be processed together through melting and extrusion without requiring separation, while still achieving the required sports properties through proper formulation and processing parameters
Solution Approach 2:
The patent uses composite materials by combining polyester fibers with a polyester-based adhesive coating that contains specific additives and plasticizers. This composite structure provides the necessary mechanical properties, flexibility, and adhesion strength for sports applications while maintaining compatibility for unified recycling processing
2Adaptability or versatility
If multiple materials are used for artificial turf components, then performance and comfort are enhanced, but recycling complexity increases due to material separation requirements
Solution Approach 1:
The invention uses polyester as a common base material for both the turf fibers and the adhesive coating, creating material homogeneity that eliminates the need for separation during recycling. The coating contains additional components (additives, plasticizers) but these are compatible with polyester processing, allowing all layers to be melted and reprocessed together in a single extrusion step
3Strength
If adhesive coating is applied to enhance tuft withdrawal force, then fiber attachment is improved, but recyclability deteriorates due to material incompatibility
Solution Approach 1:
The adhesive coating is formulated with polyester as its base material, matching the polyester fibers it bonds to. This material homogeneity ensures that the coating and fibers can be simultaneously melted and reprocessed during recycling without compatibility issues, while still providing the necessary adhesion strength through proper formulation with plasticizers and additives
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 solution provides a recyclable artificial turf with improved tuft withdrawal force, meeting sports association standards and enabling up to ten cycles of recycling without property degradation, while being environmentally friendly and reducing maintenance costs.
Implementation Method 1
a coating is provided on the substrate for providing a tuft withdrawal force of the first artificial turf fibers of at least Newtons
Implementation Method 2
The coating is a polyether sulfone adhesive or a thermoplastic co-polyester adhesive
Data Source
AI summary
The present invention generally relates to artificial turf, and more particularly to an artificial turf that is fully recyclable, as well as to a production method for manufacturing such an artificial turf. According to a first aspect of the present description, artificial turf is provided arranged for use as a sports field. The artificial turf comprises at least a substrate, artificial turf fibers and a coating, wherein at least first artificial turf fibers are attached to the substrate, and wherein the substrate is further provided with the coating for providing a tuft withdrawal force of the first artificial turf fibers of at least 30 Newtons. The first artificial turf fibers are made of polyester and/or co-polyester, and the coating is a polyether sulfone adhesive for completely recycling the artificial turf into polyester granules.