ES2708132T3 - Artificial turf comprising an agglomerate filler - Google Patents

Abstract

An artificial turf surface (100, 200, 800, 1000) comprising: an artificial turf carpet (102) with a stack (104), wherein the artificial turf carpet comprises a backing (106); wherein the artificial turf carpet further comprises artificial turf fibers (108), wherein the artificial turf fibers are knotted (110) to the back, wherein the artificial turf fibers form the pile, wherein the artificial turf fibers They are fixed to the backrest; and filling artificial turf (114) distributed within the pile, characterized in that the surface of the artificial turf has been manufactured according to the method of any one of claims 16 to 22, thereby comprising the filling of artificial turf, shaped grains irregular (116), wherein the irregularly shaped grains comprise an agglomerate, wherein the agglomerate comprises at least one type of non-elastomeric thermoplastic, wherein at least a portion of the grains has fibrous extensions (302).

Description

DESCRIPTION

Artificial turf comprising an agglomerate filler

Field of the invention

The invention relates to artificial turf, in particular to artificial turf with stuffing and also to artificial turf filler.

Background and related technique

Artificial lawns are known as a carpet structure that resembles natural grass. The structure consists of a fabric in which the fibers are inserted in tufts and fixed in the lower part of the fabric. The fibers are monofilament or twisted threads of polyethylene or other thermoplastic materials. The fabrics are woven polypropylene products and the fixing material which bonds the fibers to the fabric are mixtures of SBR gratings and fillers such as calcium carbonate or polyurethane based adhesives.

Artificial turfs are used as sports fields, while carpets are spread over a substructure of rubber granules that act as a shock absorbing layer or on a substructure comprising an elastic layer (layer e). The structure of the carpet is filled with sand and rubber granules to keep the structure in place so that the carpet does not slide and the fibers remain in vertical position. The stuffing material is also known as filler or stuffing material. Typically, SBR rubber or EPDM rubber, both elastomeric materials in irregular granular form, is used. SBR rubber is commonly obtained from used tires.

An advantage of using artificial grass is that it eliminates the need to take care of a surface of grass or landscaping, such as mowing the lawn regularly, scarifying, fertilizing and watering. Irrigation can be difficult, for example, due to regional restrictions on water use. In other climatic zones, the regrowth of the grass and the reformation of a closed grass cover are slow in comparison with the damage produced in the surface of the natural grass to the jugary / or to exercise in the field. Artificial turf fields, although they do not require similar attention and effort to be maintained, may require some maintenance, such as having to clean up dirt and debris and having to be brushed regularly. This can be done to help the fibers lift up after they have been stepped on during play or exercise. Throughout the typical use time of 5 to 15 years, it can be beneficial if a field of artificial grass sports can withstand heavy mechanical wear, can resist ultraviolet rays, thermal cycles or thermal aging, product interactions chemicals and various environmental conditions. Therefore, it is beneficial that the artificial grass has a long useful life, is durable and maintains its characteristics to play and superficial, as well as its appearance during all the time of use.

The filling of synthetic grass plays a predominant role with respect to the mechanical properties of the complete structure of the grass. These properties determine the cushioning of a bouncing ball and the effects of running or jumping athletes. It is also desirable that the upper structure of a lawn does not cause injuries to athletes, such as burns, scratches, abrasions of the skin, etc. The filling of synthetic grass with sand alone has an energy-wasting effect, comparable to running on dry sand on a beach. To avoid such uncomfortable attitudes, filler systems are commonly used. At least two layers form such filling systems, in which the sand layer is first spread over the top of the carpet (the opposing side of the backrest) and a second layer or elastomeric material is spread over the sand. The elastomeric material usually consists of ground rubber, while the particles are thicker than the grains of sand. The thickness of a filling system is such that only a small proportion of the grass fibers exceed the height of the filling layer. The complete structure thus resembles freshly cut natural grass.

FIFA (Federation Internationale de Football Associaton) has established quality standards in its "Quality Concept for Football Turf, Handbook of Requirements", January 2012 issue. This manual describes the standards as well as the test methods. Synthetic grass filler systems, the following criteria are applied:

Force reduction: 60% - 70%

Vertical deformation: 4 m m -10 mm

resistance to rotation: 30 Nm - 45 Nm

all in dry and humid conditions and after simulated wear.

According to FIFA regulations, the tests are carried out with the so-called advanced artificial athlete -T rip le A, a wear meter and a resistance to rotation meter.

The artificial grass or the artificial grass is a surface formed by fibers that is used to replace the grass. The structure of the artificial grass is designed in such a way that the artificial grass has an aspect similar to grass. Typically, artificial grass is used as a surface for sports such as soccer, football, rugby, tennis, golf, on the playing fields or in the training camps. In addition, artificial grass is often used for landscaping applications.

Artificial grass can be manufactured using carpet making techniques. For example, artificial grass fibers that look like grass blades may be knotted or attached to a backing. Many times the artificial grass filling is arranged between the artificial grass fibers. The artificial grass filling is a granular material that covers the lower part of the artificial grass fibers. The use of artificial grass filler can have several advantages. For example, artificial grass filling can help the artificial grass fibers stay upright. The artificial grass filling can also absorb the impact when walking or running and provides an experience similar to being on real grass. Artificial grass filling can also help keep the artificial grass carpet flat and in place by ballasting it.

The patent application of the E.E. U.U. US 2010/0151158 discloses a method for recycling synthetic grass including agglomerating a plurality of synthetic grass fragments and extruding the agglomerated material. The method produces a recycled material to be used as a synthetic grass filler. The agglomerate is extruded and can have a spherical, cylindrical, oval or soccer ball shape. The pellets can also be of an irregular shape. The irregular shape can be used to help tight packing of the granules.

Compendium

The invention provides an artificial grass surface, a method and the use of an agglomerate as a filler for artificial turf. The embodiments are set forth in the dependent claims.

The examples may provide an artificial grass filler that is made at least partially from an agglomerate comprising one or more non-elastomeric thermoplastics. The agglomerate is formed in irregularly shaped grains. A "grain" as used herein encompasses a small part or portion of a material that is hard.

Normally, non-elastomeric thermoplastics are too hard and narrow to be used as artificial turf fill. However, their formation in grains that have fibrous extensions makes them flexible. When the grains are distributed in the artificial grass pile, the grains tend to be packaged loose due to the fibrous extensions. This produces gaps or free spaces between the grains, which makes the resulting filling more elastic, although it has been manufactured with non-elastomeric thermoplastics.

In several examples, the agglomerate may be formed by one or more non-elastomeric thermoplastics and an additional additive, such as a pigment powder.

In some examples, the artificial grass filling is made at least partially from an agglomerate of at least two non-elastomeric thermoplastics.

In other examples, the material used to form the artificial grass filler is provided as agglomerate. Then an extrusion process is used to form the material in the beads with fibrous extensions.

In one aspect, the invention provides an artificial grass surface comprising an artificial grass mat with a pile. The artificial grass carpet comprises a backrest. The artificial grass carpet also comprises artificial grass fibers. The artificial grass fibers are knotted to the support. The grass fibers of artificial grass form the pile. The artificial grass fibers are fixed to the backrest.

The surface of the artificial grass also comprises an artificial grass filling that is distributed inside the pile. The artificial grass filling can also be described as being distributed among the artificial grass fibers. The artificial grass filling comprises irregularly shaped grains. The grains comprise an agglomerate comprising at least one type of non-elastomeric thermoplastic.

At least a portion of the grains have fibrous extensions.

In some examples, all or most of the grains have fibrous extensions. In other examples, at least 40%, 50%, 60%, 70%, 80% or 90% of the grains have the fibrous extensions. A fibrous extension, as used herein, encompasses a region of the grain that is substantially narrower than another portion of the grain. The material of the grain can be ngido, but the fibrous extension is sufficiently narrow so that the fibrous extension can flex or bend.

The use of irregularly shaped grains such as artificial grass filling can have several benefits. A potential benefit is that non-elastomeric thermoplastics can be used. Normally, the artificial grass filling is composed of an elastomeric material or material that can easily be pushed to the side so that the surface of the artificial grass has real properties, such as the imitation of a real grass surface that has dirt or sand in it. its interior. Irregularly shaped grains have the benefit that air pockets can occur and the packing ratio of artificial turf fill is reduced. This allows hard non-elastomeric thermoplastics to be used and still have properties that realistically mimic a real grass surface.

In another embodiment, the at least one non-elastomeric thermoplastic type is viscoelastic at temperatures below 100 ° C.

In another embodiment, the at least one type of non-elastomeric thermoplastic comprises recycled artificial grass fibers. Recycled artificial grass fibers are equivalent to artificial grass fibers. Recycled artificial grass fibers are artificial grass fibers that have been removed from a previously installed artificial grass surface. The use of non-elastomeric thermoplastics from recycled artificial grass fibers can have the benefit that the reuse of thermoplastic reduces the amount of waste that is deposited in landfills. It may also have the advantage that the recycled artificial grass fibers may contain additives that are useful for artificial grass filling. For example, recycled artificial grass fibers may be green. That the artificial grass fill has green color can be beneficial to make the artificial grass surface look more realistic. It can also have the benefit that recycled artificial grass fibers contain other additives such as ultraviolet protection that increases the longevity of the artificial grass filling.

In another embodiment, the irregularly shaped grains have a curved and longitudinally extended volume expansion with length to diameter / cross section ratios within 1: 2 to 1:50.

In another embodiment, the irregularly shaped grains have a screen size of between 0.2 mm and 12 mm. In this embodiment, the irregularly shaped grains have been selected so that they pass through a first screen with an opening of 12 mm or less. The irregularly shaped grains have been further selected so that they are captured by a screen with openings of 0.2 mm or more. The opening of the first screen is still larger than the opening of the second screen.

In another embodiment, the irregularly shaped grains have a screen size less than 12 mm. In this embodiment, the irregularly shaped grains have been selected so that they pass through a screen with an opening of 12 mm or less.

In another embodiment, the irregularly shaped grains have a thickness of between 0.5 mm and 2 mm.

In another embodiment, the at least one type of non-elastomeric thermoplastic comprises any one of the following: at least one thermoplastic polymer, a polyolefin, waste plastic, fibrous waste plastic, preconsumption yarns, post-consumption yarns recovered from synthetic sports fields , artificial grass fiber, recovered plastic waste, recycled packaging material, polyethylene food packaging, polyethylene, polypropylene, a mixture of polyethylene and polypropylene, LLDPE, HDPE, LDPE, MDPE, PP, PE, a polyolefin and their combinations . This embodiment can be beneficial because the thermoplastic that is normally removed can be used to make a high quality artificial grass surface.

In another embodiment, the surface of the artificial grass further comprises a layer of sand between the backing and the artificial grass filling. The use of the sand layer between the backing and the artificial grass filling can also serve to improve the replication of the properties of the surface of the natural grass by the surface of the artificial grass. The use of the sand layer can also reduce the amount of artificial grass fill required to be used.

In another embodiment, the majority of the irregularly shaped grains have a curved profile. The curved profile can occur in a cross-sectional view of the irregularly shaped grain. Having a curved profile can be beneficial because it reduces the way irregularly shaped beans can be packaged side by side. That this form is less dense can be beneficial because the artificial grass filling has a more soft or elastic profile, although the agglomerate is made of a non-elastomeric thermoplastic.

In another embodiment, the fibrous extensions of the irregularly shaped grains are intertwined with any of the following: the artificial grass fibers, the fibrous extensions of other irregularly shaped grains, and combinations thereof. This embodiment can be beneficial because the interlacing of the fibrous extensions can serve to keep the irregularly shaped grains in the same position with respect to one another, and possibly also to help maintain their position with respect to the artificial grass fibers. This can, for example, achieve the benefit of reducing the splash effect when a ball hits an artificial grass surface. Splashing occurs when the impact of a ball or other object causes the artificial grass to fly over the surface of the outer layer of the artificial grass. It is similar to the splash of an object that hits a puddle of water.

In another embodiment, at least a portion of the fibrous extensions is branched. The branching of the fibrous extensions can be beneficial because it can make the fibrous extensions more flexible. The branch can also produce hook-shaped structures that allow irregularly shaped grains to interconnect better between themselves or with artificial grass fibers.

In another embodiment, the artificial grass surface further comprises a top layer of filler. The irregularly shaped grains are located between the backing and the top filling layer.

In another embodiment, the top filler layer comprises granules in a regular manner. The granules on a regular basis can have, for example, a round, oval, rounded or beaded shape. The use of granules on a regular basis can be beneficial because they can have the effect of reducing friction between an object that slides on the surface of artificial grass and irregularly shaped grains.

For example, the grains on a regular basis can be made of an agglomerate that is similar or has a composition equivalent to irregularly shaped grains. In other examples, the granules on a regular basis may be made of an elastomeric compound such as crumb rubber or other materials conventionally used as an artificial grass filler. For example, the elastomeric granulates used for artificial turf filling may be located on the surface of the artificial grass filling formed by the irregularly shaped grains. This can reduce the amount of elastomeric granules that are used. By using a smaller amount of the elastomeric granulate, the splash effect can be reduced when a ball or other object hits the surface of the artificial turf.

In another embodiment, the granules on a regular basis comprise any one of the following: at least one thermoplastic polymer, one polyolefin, waste plastic, fibrous waste plastic, preconsumption yarns, post-consumption yarns recovered from synthetic sports fields, grass fiber artificial, recovered waste plastic, recycled packaging material, polyethylene food packaging, EPDM, LLDPE, HDPE, LDPE, MDPE, PP, PE, a polyolefin, an elastomeric compound, rubber, crumb rubber, and combinations thereof.

In another embodiment, the top filler comprises elongated granules. In some examples, the elongated granules may comprise an elastic or flexible material. The use of the elongated granulates in the top fill can have several advantages. First, the elongated shape can help the top filling remain above or cover the filling made with irregularly shaped grains. The elongated shape may, in some instances, result in less friction between a person or object that slides on artificial turf. The use of the elongated granules can also reduce the splash effect when a ball or other object hits the surface of the artificial turf.

In another embodiment, the elongated granulate is formed from any one of the following: an elastomeric compound, chips of a block of an elastomeric compound, rubber, crumb rubber, EPDM and combinations thereof.

In another embodiment, the elongated granulate are chips formed from a block of an elastomeric compound. The use of the chips of an elastomeric compound can make the surface of the artificial grass look more realistic. The use of chips of an elastomeric compound can also make the chips have a structure similar to the fiber that helps keep them in place and reduce the splash effect.

In another embodiment, the surface of the artificial grass further comprises a layer of sand between the backing and the artificial grass filling. The artificial turf surface further comprises a top filler layer, wherein the irregularly shaped grains are located between the backing and the top filler layer. The top filler comprises irregularly shaped granules. The irregularly shaped granulate comprises chips from a block of an elastomeric compound. This embodiment can be beneficial because the irregularly shaped granulate can cause the impacts to be absorbed and can also reduce the friction between an object sliding on the surface of the artificial grass and irregularly shaped grains.

In another aspect, the invention provides a method for manufacturing an artificial grass system. An artificial grass system as used herein encompasses the components that are supplied to make an artificial grass surface.

The method comprises providing an artificial grass mat with a pile. The artificial grass carpet comprises a backrest. The artificial grass carpet also comprises artificial grass fibers. The artificial grass fibers are knotted to the support. The artificial grass fibers form the surface of the pile. The artificial grass fibers are fixed to the backrest.

The method further comprises agglomerating at least one type of non-elastomeric plastic into an agglomerate to form irregularly shaped grains to provide a filler for the artificial turf carpet.

In embodiments that do not fall within the scope of the present invention, the agglomeration of at least one type of the elastomeric thermoplastic in the agglomerate and the formation of the irregularly shaped grains forming the agglomerate is carried out using an agglomerator. An agglomerator as used herein is a device that applies heat and pressure to agglomerate multiple thermoplastics into a single structure. The agglomerator can also cut or break the agglomeration in the irregularly shaped grains.

The use of an agglomerator can be beneficial because it can provide an economical means for the manufacture of irregularly shaped grains.

In such embodiments that do not fall within the scope of the present invention, the agglomerator may be a friction agglomerator. The friction agglomerator can have one or more movable portions that use friction to generate the necessary heat to form the agglomerate.

In other embodiments of this type, the agglomerator may be a disk agglomerator. The disk agglomerator may have one or more rotating discs that receive the heated non-elastomeric thermoplastic and agglomerate it in the agglomerate and form the irregularly shaped grains at the same time.

According to the invention, the formation of irregularly shaped grains from the agglomerate is carried out using an extruder. The use of an extruder is beneficial because the properties of irregularly shaped grains can be precisely controlled. An extruder as used herein encompasses a device that heats at least one type of non-elastomeric thermoplastic and then forces them through a hole to extrude them. There may also be a device that cuts the extruded agglomerate in the irregularly shaped grains. The extruded material of the extruder can be referred to as an extrudate. However, the extrudate is the agglomerate.

In preferred embodiments, the extruder comprises any of the following: an underwater pelletization system, a water ring pelletization system, a strand pelletizing system and a hot-cutting pelletizing system.

In another embodiment, the extruder optionally comprises a pelletizing or granulating system to additionally form the shape of the irregularly shaped grains.

The use of an extruder is also beneficial because it allows precise control of the length, the curvature of the grain and the relative size distribution.

According to the present invention, the extruder comprises an extrusion die. The extrusion die has multiple orifices to extrude the agglomerate. The at least one hole has a first portion and a portion in opposition. In an embodiment that is not within the scope of the present invention, the first portion is rough. The opposing portion is smooth to form irregularly shaped grains that have a curved profile. The first portion, which is rough, causes a break or deceleration effect when the agglomerate is extruded. This causes the resulting irregularly shaped grain to have a curved profile. This can be beneficial as it can cause irregularly shaped beans to be packaged less thickly. This can cause them to have a more elastic behavior, although they are made of a non-elastomeric thermoplastic.

In another embodiment that does not fall within the scope of the present invention, the extruder comprises multiple orifices. The multiple orifices have at least two different sizes. This embodiment can be beneficial because the distribution of irregularly shaped grain size and its relative frequency can be precisely controlled.

According to the invention, the multiple orifices can have an irregular shape or profile.

The use of irregular shape or profile has the benefit of producing irregularly shaped agglomerate grains.

In a preferred embodiment, the extruder comprises a cutting system for cutting irregularly shaped grains.

In another embodiment, the extruder cutting system is configured to produce irregularly shaped grains of varying lengths. This can be achieved, for example, by controlling the frequency with which the cutting system cuts the extrudate (the agglomerate) that is being extruded. By varying the times between cuts of the agglomerate or by choosing a time distribution, the distribution of the relative size of the irregularly shaped grains can be controlled.

In another embodiment, the method further comprises mixing at least one additive in the agglomerate before forming the irregularly shaped grains. This can be beneficial by adding various properties to irregularly shaped grains, such as flame retardants, ultraviolet light protection or coloring dyes to change the appearance of artificial grass fill.

In another embodiment, the at least one additive comprises any one of the following: a dye or dye, an ultraviolet stabilizer, a flame retardant, a filler, an expanding agent, an anti-adherent agent, a lubricant, a compatibilizer, a agent of union, and their combinations.

In another embodiment, the method further comprises recycling the artificial lawn used to provide at least one of at least one type of non-elastomeric thermoplastic. This can be beneficial because it can reduce the environmental impact of the installation of a new artificial grass surface. It may also have the benefit that the thermoplastic recovered from the artificial turf used may contain additives such as dyes or ultraviolet stabilizers or flame retardants that are already present. This can reduce the cost of manufacturing a new artificial grass surface.

In another aspect, the invention provides a method for manufacturing an artificial grass surface. The method comprises a method for manufacturing an artificial grass system according to one embodiment. The method also comprises the installation of the artificial grass carpet. The method further comprises distributing the irregularly shaped grains within the pile and between the artificial grass fibers to form the artificial turf.

In another embodiment, the method for manufacturing the artificial grass surface comprises distributing a sand layer inside the pile before distributing the irregularly shaped grains.

In another aspect, the invention provides the use of an agglomerate as a filler for artificial turf. The agglomerate comprises irregularly shaped grains formed by at least one type of non-elastomeric thermoplastic. At least a portion of the grains may have fibrous extensions.

It will be apparent that one or more of the aforementioned embodiments of the invention can be combined as long as the combined embodiments are not mutually exclusive.

Brief description of the drawings

The following embodiments of the invention are explained in more detail, by way of example only, with reference to the drawings in which:

Figure 1 illustrates an example of an artificial grass surface;

Figure 2 illustrates a further example of an artificial grass surface;

Figure 3 illustrates an example of irregularly shaped grains;

Figure 4 illustrates an example of an agglomerator;

Figure 5 illustrates an example of an extruder;

Figure 6 illustrates an example of an extrusion die;

Figure 7 illustrates an example of an artificial grass system;

Figure 8 illustrates a further example of an artificial grass surface;

Figure 9 illustrates a further example of an extrusion die; Y

Figure 10 illustrates a further example of an artificial grass surface.

Detailed description

Elements similarly numbered in these Figures are equivalent elements or perform the same function. Elements that have been previously treated are not necessarily treated in later Figures if the function is equivalent.

Figure 1 shows an example of an artificial grass surface 100. The artificial grass surface 100 is formed by an artificial grass carpet 102 having a stack 104. The artificial grass carpet 102 comprises a back 106. Inside the backrest there is artificial grass fibers 108 which are knotted 110 to the back 106. The pile 104 has been formed from the artificial grass fibers 108. The artificial grass fibers 108 can be formed, for example, from a thermoplastic or plastic yarn. artificial grass The backing 106 may be disposed on a base layer 112. The base layer may have different shapes in different examples. In an example, the base layer is simply the ground. The artificial grass carpet 102 can simply extend on the ground. In other examples, the base layer 112 may contain different components to provide drainage and shock absorption of the athletes or other users of the artificial grass surface 100. Within the stack 104 and between the artificial grass fibers 108 an artificial grass filling 114. In this case, the filling 114 comprises irregularly shaped grains 116. The irregularly shaped grains have been formed from an agglomerate comprising at least one type of non-elastomeric thermoplastic material. Non-elastomeric thermoplastics can also be thermoplastic polymers. The use of the irregularly shaped grains causes droughts 118 among several of the irregularly shaped grains 116. These fords provide and give elasticity to the irregularly shaped grains 116 that are made of what is normally considered a rigid thermoplastic. This makes it possible to use a material that is not normally suitable for making the artificial grass filling work properly. Artificial turf filler 114 can help the artificial grass fibers 108 remain stiff and in the correct position. In addition, they can provide impact absorption or other physical properties that help the artificial grass surface 100 to more closely approximate the properties of a real grass surface.

Figure 2 shows a further example of an artificial grass surface 200. The artificial grass surface 200 is similar to the artificial grass surface 100 shown in Figure 1. However, in this example there is an additional layer of sand between the backing and padding 114. The example shown in Figure 2 can be closer to the real grass properties and more accurately. The use of filler 114 with irregularly shaped grains 116 can provide a more realistic and elastic surface than when only sand 202 is used.

Figure 3 shows a photograph of several grains 116 of irregular shape. The irregularly shaped grains comprise at least one non-elastomeric number. The photograph shows that at least some of the irregularly shaped grains comprise fibrous extensions 302. Not all the fibrous structure of the extensions is visible in the photograph. Some of the grains also show fibrous extensions 302 with a branched structure 304. Some of the fibrous extensions 302 also have a structure similar to a hook 306. The branched structure 304 or the hook-like structure 306 can assist the grains in shape. Irregular to interconnect between each other and / or with thermoplastic artificial grass fibers.

The irregularly shaped grains of Figure 3 were tested as artificial turf fill. Although made of nipple thermoplastics, they proved to have shock absorbing properties. The recycled SBR rubber filling was compared to the irregularly shaped grain filling of two different sizes. The first size of irregularly shaped grain fill has a characteristic dimension of less than 2.5 mm. The second size has a characteristic dimension greater than 2.5 mm. A screen with a 2.5 mm screen was used to separate the two. In the experiment, the reduction of the strength of a soccer ball hitting the surface was measured during three consecutive strokes in the same place on each stroke. The results are summarized in the table below:

Filling agglomerated agglomerated SBR

For reference <2.5 mm> 2.5 mm

Force reduction 1st hit 32.8% 40.3% 36.6%

Force reduction 2nd hit 19.3% 9.8% 25.7%

Force reduction 3rd hit 15.8% 6.1% 19.8%

In the above table it can be seen that the agglomerate filling made of the irregularly shaped grains has a shock absorption which is comparable to that of the SBR filling made of recycled black crumb rubber. In fact, the larger grains (more than 2.5 mm) surprisingly showed an impact absorption that was greater than that of the SBR filler material for the three impacts.

Figure 4 shows an example of an agglomerator 400. The agglomerator has a hopper 402 for receiving thermoplastic waste 404. A feeder 406 then feeds the thermoplastic waste 404 into a agglomerator 408 comprising a rotating disk and a stationary portion. The agglomerator 408 can heat and compress the residual thermoplastic 404. The rotating disk 408 can have veins or surfaces in the form of gears that compress and cut the residual thermoplastic 404 into irregularly shaped grains 116.

Figure 5 shows an example of an extruder 500. The extruder again has a hopper for receiving thermoplastic waste 404. The residual thermoplastic is then fed by a feeder 406 which heats and forces the residual thermoplastic material through a through hole. of an extrusion die 504. A cutting system 506 then cuts the agglomerate which is extruded from the hole 502 in the irregular shaped grains 116. The speed at which the cutting system 508 cuts the agglomerate controls the length of the Irregularly shaped grains 116. The speed of cutting system 506 may be varied to produce an irregularly shaped distribution of grain lengths 116.

Figure 6 shows an example of an extrusion die 504 with a hole 502. The orifice 502 has a first portion 600 and an opposing portion 602. The first portion 600 is rough and the opposing portion 602 is smooth. This modification causes the material extruded through hole 502 to have a curvature due to it.

Figure 7 shows a flow diagram illustrating a method for manufacturing an artificial grass system. First, in step 700, an artificial grass carpet 102 is provided as shown in Figures 1 or 2. Next, in step 702, the irregularly shaped grains 116 are manufactured using the machine as illustrated in Figure 4 or 5. At least one type of non-elastomeric thermoplastic is provided as an agglomerate or is formed with another material such as a second elastomeric thermoplastic or a dye in powder form. The agglomerate is then forced into the irregularly shaped grains 116. In some examples that are not within the scope of the present invention, the agglomeration process is used to form the irregularly shaped grains. According to the invention, an extruder is used to form the agglomerate in the irregularly shaped grains.

Figure 8 shows a further example of an artificial grass surface 800. The artificial grass surface 800 is similar to the artificial grass surface 200 shown in Figure 2. However, in this example there is additionally an upper filler layer ( 801) which comprises regular granules 802. The upper filling layer (801) is disposed on the irregularly shaped grains 114. The use of the granules on a regular basis 802 has the advantage of reducing the friction when something slips on the surface of artificial grass surface 800. Regularly shaped granules 802 may be made of several different materials. In one example, the granules on a regular basis are made of an agglomerate comprising at least one type of non-elastomeric thermoplastic. In another example, the granules on a regular basis are made of an elastomer.

Figure 9 illustrates another example of an extrusion die (504) similar to that shown in Figure 6. The matrix of extrusion has a series of holes 502 'to extrude irregularly shaped granules. The holes have a variety of different sizes. The relative sizes of the holes can be used to generate a distribution of grains with different sizes. The shape or profile of the holes is modified to help provide the beans with an irregular shape.

Figure 10 shows a further example of an artificial grass surface 1000. The artificial grass surface 1000 is similar to the artificial grass surface 800 shown in Figure 8. However, in this example, the upper fill layer comprises granules. elongate 1002 and / or irregularly shaped granulate 1002 in the upper part of irregularly shaped grains 114. The use of elongated granules 1002 and / or irregularly shaped granulate 1002 may have the advantage of reducing friction when something slips over the surface of the artificial grass surface 1002. The elongated granules 1002 and / or the irregularly shaped granulate 1002 may be made of several different materials. In one example, the elongated granules 1002 and / or the irregularly shaped granulate 1002 can be manufactured, for example, from an elastomeric compound or other flexible material.

The following examples are several possible practical examples of artificial grass surfaces that use irregularly shaped grains as artificial turf fill. The artificial grass filling made of irregularly shaped grains is known as "polymer agglomerate". All weights refer to the amount of material distributed on the surface of an artificial grass carpet. The polymer agglomerate is placed on the sand layer. The term "layer e" refers to a substructure made of a layer that absorbs shocks of granulated rubber, mats or other material under the artificial grass carpet.

Agglomerate of polymers: 5 kg / m2

Sand: 15 kg / m2

layer e: 25 mm

Example 2 (artificial grass carpet with a stack of 40 mm in height):

Agglomerate of polymers: 7.5 kg / m2

Sand: 12.5 kg / m2

layer e: 25 mm

Example 3 (artificial grass carpet with a pile of 40 mm height):

Agglomerate of polymers: 5 kg / m2

Sand: 15 kg / m2

layer e: 30 mm

Example 4 (artificial grass carpet with a pile of 40 mm height):

Agglomerate of polymers: 5 kg / m2

Size distribution: 0 - 2.5 mm (ordered by sieve size)

Sand: 15 kg / m2

layer e: 25 mm

Example 5 (artificial grass carpet with a stack of 40 mm or 60 mm height):

Agglomerate of polymers: 5 kg / m2

Size distribution: 2.5 -12.5 mm (ordered by sieve size)

Sand: 15 kg / m2

layer e: 25 mm

In the above 5 examples, the numerical values can be varied up to 10%, 20% or 30% to produce alternative examples.

In Examples 1 to 3, the size distribution of the polymer agglomerate is given. It will be apparent that any sieve size between 1 and 12.5 mm can be used to classify the agglomerate of these two examples.

In examples 4 and 5: the grains passing through the 2.5 mm sieve are used in example 4. The grains that are trapped by the 2.5 mm sieve but pass through a sieve of 12.5 mm are used in example 5.

List of reference numbers

100 artificial grass surface

102 artificial grass carpet

104 battery

106 backup

108 artificial grass fibers

110 knotted

112 base layer

114 stuffing

116 irregularly shaped beans

118 ford

200 artificial grass surface

202 sand

302 fibrous extensions

304 branched structure

306 structure similar to a hook

400 agglomerator

402 hopper

404 waste thermoplastic

408 agglomerating disc

500 extruder

502 hole

502 'hole

504 extrusion matrix

506 cutting system

600 first portion

602 portion in opposition

700 provides an artificial grass carpet with a pile,

702 forms an agglomerate comprising at least one type of non-elastomeric thermoplastic in irregularly shaped grains to provide a filler for the artificial turf carpet

800 artificial grass surface

801 top layer of filling

802 granules on a regular basis

1000 artificial grass surface

1002 elongated granules or irregularly shaped granules

Claims (23)

1. An artificial grass surface (100, 200, 800, 1000) comprising: an artificial grass mat (102) with a pile (104), wherein the artificial grass mat comprises a back (106); wherein the artificial grass carpet further comprises artificial grass fibers (108), wherein the artificial grass fibers are knotted (110) to the backing, where the artificial grass fibers form the pile, wherein the fibers of artificial grass They are fixed to the backrest; Y artificial grass filling (114) distributed within the pile, characterized in that the surface of the artificial grass has been manufactured according to the method of any one of claims 16 to 22, thus comprising the filling of artificial grass, irregularly shaped grains (116), wherein the irregularly shaped grains comprise an agglomerate, wherein the agglomerate comprises at least one type of non-elastomeric thermoplastic, wherein at least a portion of the grains has fibrous extensions (302). 2. The artificial grass surface of claim 1, wherein the at least one of the non-elastomeric thermoplastic material types comprises recycled artificial grass fibers. 3. The artificial grass surface of claim 1 or 2, wherein the irregularly shaped grains have a longitudinally stretched volume expansion curved with length to diameter / cross section ratios of 1: 2 to 1:50. 4. The artificial grass surface of claim 1, 2 or 3, wherein the irregularly shaped grains have a screen size between 0.2 mm and 12 mm. 5. The artificial grass surface of any one of the preceding claims, wherein the irregularly shaped grains have a thickness between 0.05 mm and 2 mm. 6. The artificial grass surface of any one of the preceding claims, wherein the at least one non-elastomeric thermoplastic type comprises any one of the following: at least one thermoplastic polymer, a polyolefin, waste plastic, fibrous waste plastic , pre-consumer threads, post-consumer threads recovered from synthetic sports fields, artificial grass fiber, recovered plastic waste, recycled packaging material, polyethylene food packaging, polyethylene food packaging, polyethylene, polypropylene, a polyethylene blend and polypropylene, LLDPE, HDPE, LDPE, MDPE, PP, PE, a polyolefin, and their combinations. 7. The artificial grass surface of any one of the preceding claims, wherein the fibrous extensions of the irregularly shaped grains are interconnected with any of the following: the artificial grass fibers, the fibrous extensions of other irregularly shaped grains and your combinations 8. The artificial grass surface of any one of the preceding claims, wherein at least a portion of the fibrous extensions is branched (304) and / or has a hook shape (306). 9. The artificial grass surface of any one of the preceding claims, wherein the surface of the artificial turf further comprises a layer of sand (202) between the backing and the artificial grass fill. 10. The artificial grass surface of any one of the preceding claims, wherein the artificial turf surface (800, 1000) further comprises an upper filler layer (801), wherein the irregularly shaped grains are between the backing and the top filling layer. 11. The artificial grass surface of claim 10, wherein the top fill layer comprises granules of a regular shape (802). 12. The artificial grass surface of claim 11, wherein the granules of a regular form comprise any one of the following: at least one thermoplastic polymer, a polyolefin, waste plastic, fibrous waste plastic, pre-consumer yarns, Post-consumption recovered from synthetic sports fields, artificial grass fiber, recovered waste plastic, recycled packaging material, polyethylene food packaging, polyethylene, polypropylene, a mixture of polyethylene and polypropylene, LLDPE, HDPE, LDPE, MDPE, PP, PE , a polyolefin, an elastomeric compound, rubber, rubber crumb, EPDM, and combinations thereof. 13. The artificial grass surface of claim 10, 11 or 12, wherein the top filler comprises elongated granules (1002). The artificial grass surface of claim 13, wherein the granules have been formed from any of the following: an elastomeric composite, chips of at least one block of an elastomeric compound, rubber, crumb rubber, EPDM and your combinations 15. The artificial grass surface of any one of claims 1 to 8, wherein the artificial grass surface (1000) further comprises a layer of sand (202) between the backing and the grain filling layer of form. Irregular (116), wherein the artificial grass surface further comprises a top layer of filling (801), wherein the irregularly shaped grain filling layer (116) is between the backing and the top filling layer, wherein The top filler comprises an irregularly shaped granulate (1002), comprising chips of at least one block of an elastomeric compound. 16. A method for manufacturing an artificial grass system, wherein the method comprises: providing (700) an artificial grass mat (102) with a stack (104), wherein the artificial grass mat comprises a backing (106); wherein the artificial grass carpet further comprises artificial grass fibers (108), wherein the fibers of artificial grass are knotted (110) to the backing, wherein the fibers of artificial grass form the surface of the pile, wherein the fibers of artificial grass are fixed to the backrest; Y forming (702) an agglomerate comprising at least one type of non-elastomeric plastic to form irregularly shaped grains to provide a filler for the artificial turf carpet; characterized in that: the formation of irregularly shaped grains is carried out using an extruder (500); wherein the extruder comprises an extrusion die (504); and the extrusion die comprises multiple orifices, the multiple orifices have an irregular shape (502 '), so that at least one portion of the irregularly shaped beads has fibrous extensions (302). 17. The method of claim 16, wherein the extruder comprises any one of the following: an underwater pelletizing system, an irrigation pelletizing system, a strand pelletizing system, and a pelletizing system for cutting hot. 18. The method of claim 16 or 17, wherein the extruder comprises a cutting system (506) for cutting irregularly shaped grains, wherein the cutting system is configured to produce irregularly shaped grains of varying lengths. The method of any one of claims 16 to 18, wherein the method further comprises mixing at least one additive in the agglomerate before forming the irregularly shaped grains. The method of claim 19, wherein the at least one additive comprises any one of the following: a dye, a dye, an ultraviolet stabilizer, a flame retardant, a binding agent, a foaming agent, an anti-adhesion agent, a lubricant, a filler, a compatibilizer, and their combinations. The method of any one of claims 16 to 20, wherein the method further comprises recycling the artificial grass used to provide the at least one type of non-elastomeric thermoplastic. 22. A method for manufacturing an artificial grass surface, wherein the method comprises the method of any one of claims 16 to 21, wherein the method further comprises: install the artificial grass carpet; Y distribute the irregularly shaped beans inside the pile to form an artificial grass surface. 23. Use of an artificial grass surface (100, 200, 800, 1000) according to any one of claims 1 to 15.