Synthetic Turf Recycling Agglomeration Extrusion
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Solution Overview
Problem
Current methods for recycling synthetic turf are inadequate due to the difficulty in recycling polyurethane-coated materials and the presence of infill materials like sand and rubber, which are not effectively handled by conventional carpet recycling processes, leading to inefficient reuse and high landfill disposal rates.
Innovation Solution
A method involving agglomeration of synthetic turf fragments into granules, followed by extrusion to form recyclable infill materials such as pellets made from polyethylene, polypropylene, nylon, and polyurethane, allowing for the incorporation of recycled materials back into new synthetic turf products, thereby eliminating the need to separate infill materials before recycling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If conventional carpet recycling processes are used on synthetic turf, then the face fibers can be separated and recycled, but the backing and infill materials cannot be effectively recycled and must be disposed of in landfills
Solution Approach 1:
The patent segments the synthetic turf into three distinct components: face fibers, backing material, and infill materials. Each component is separated through specific processing steps (cutting, agglomeration, screening) and recycled independently through appropriate channels, allowing maximum recovery of valuable materials that would otherwise be wasted together in conventional processes
Solution Approach 2:
The patent extracts and removes infill materials (sand, rubber, organic matter) from the synthetic turf assembly before recycling the remaining components. This extraction allows the infill to be separately managed and the backing/face fiber components to be recycled without contamination, significantly improving overall recycling rates
2Strength
If polyurethane coating is applied to synthetic turf backing, then the face fibers are securely locked in place, but the coated material becomes difficult and costly to recycle
Solution Approach 1:
The patent introduces an intermediary processing step using agglomerators that facilitate the separation of polyurethane-coated backing from face fibers. The agglomerator creates a controlled environment where the coating can be effectively managed during separation, enabling recycling of both the coating and underlying materials that would otherwise be difficult to process
Solution Approach 2:
The patent changes the physical and chemical parameters of the polyurethane coating during recycling processing. By controlling temperature, moisture, and mechanical agitation parameters in the agglomerator, the coating's properties are modified to enable effective separation and recycling, transforming an otherwise non-recyclable material into a recoverable resource
3Reliability
If infill materials are present in synthetic turf, then the turf achieves desired physical properties, but the presence of sand and rubber complicates the recycling process
Solution Approach 1:
The patent extracts infill materials (sand, rubber, organic matter) from the synthetic turf assembly through screening and separation processes. This extraction removes the complicating elements before recycling, simplifying the overall process while maintaining the ability to handle diverse infill compositions without requiring complex specialized equipment
Solution Approach 2:
The patent employs universal recycling processes that can handle multiple types of infill materials (sand, rubber, organic matter) through a single integrated system. The combination of cutting, agglomeration, and screening steps creates a multi-functional process capable of managing diverse infill compositions without requiring separate specialized procedures for each material type
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
Enables the effective recycling and reuse of synthetic turf, allowing recycled materials to make up a significant percentage of the new product, reducing landfill disposal and enhancing the recyclability of synthetic turf systems.
Implementation Method 1
Placed in an agglomerator, the downsized pieces are agglomerated
Implementation Method 2
The agglomerator is a compression molding press
Implementation Method 3
Placed in an extruder, the granules are extruded to form a continuous strand or ribbon
Implementation Method 4
the granules are extruded to form a continuous strand or ribbon
Data Source
AI summary
Disclosed herein is a method for recycling synthetic turf that includes agglomerating a plurality of synthetic turf fragments and extruding the agglomerated material. The method produces a recycled material suitable for use as infill in a synthetic turf. Accordingly, an infill for synthetic turf and a synthetic turf including that infill are also disclosed herein.