WO2008072073A2

WO2008072073A2 - A synthetic turf mat, a synthetic turf structure including the mat, and a manufacturing method of the mat

Info

Publication number: WO2008072073A2
Application number: PCT/IB2007/003885
Authority: WO
Inventors: Maurizio Gilardi
Original assignee: Italgreen S.P.A.
Priority date: 2006-12-14
Filing date: 2007-12-13
Publication date: 2008-06-19
Also published as: WO2008072073A3; ITMI20062400A1

Abstract

A synthetic turf structure (1) for sports fields is formed by a synthetic turf mat (2), having a primary- sheet support (3) from which filaments (4) simulating a greensward extend, a bed (5), e.g. a packed earth bed, on which the mat (2) rests, and an infill (6) formed by a particle filling material (7) arranged between the filaments (4). The upper face (8) of the support (3) is coupled to an auxiliary draining mat (15), having draining and shock- absorbing properties. Specifically, the auxiliary mat (15) is made of different kinds of synthetic material, in layers or in fibers of different compactness and with variable thickness, and however so as to have a high draining capacity (i.e. to allow the flow of water therein) and, at the same time, specific shock-absorbing qualities.

Description

A SYNTHETIC TURF MAT, A SYNTHETIC TURF STRUCTURE INCLUDING THE MAT, AND A MANUFACTURING METHOD OF THE MAT

TECHNICAL FIELD The present invention relates to a synthetic turf mat, to a synthetic turf structure including such mat, and to a manufacturing method of the mat . STATE OF THE PRIOR ART

It is known that, in general terms, synthetic turfs, in particular for sports fields, consist of a synthetic turf mat formed by a sheet substrate, generally named primary support, from which filaments extend vertically, the filaments being of different kinds, having different composition, and being woven onto the substrate, and simulating a natural greensward; infill materials are arranged between the filaments to form one of more filling layers; the infill materials commonly used to make the filling layers are sand, relatively elastic polymeric materials, natural materials .

It is also known that the sheet substrate is coated with rubber materials, such as different kinds of rubber latex or polyurethane , after weaving the filaments. The coating has the main function of securing the filaments onto the substrate, thus avoiding the release and the detachment of the filaments themselves during use.

The substrate, after having been coated and having passed through an oven for the reticulation and/or polymerization of the coating material, is provided with through holes, e.g. by means of mechanical machining; the holes, of different diameter, have the function of allowing the rainwater, which percolates through the various filling layers, to run off and be dispersed in the bed.

The mat is laid on a bed appropriately prepared on site, normally formed by inert materials arranged on the soil (e.g. on a packed earth base); the preparation of the bed is essential to later allow a good operation and a long-lasting duration of the synthetic turf, both because the bed must allow the perfect drainage of the rainwater and because it is the supporting structure on which the synthetic turf rests and thus effects its mechanical features (specifically, its elasticity and its shock absorbance) .

The construction of the bed is often difficult and may lead, due to the difficulty and the cost of retrieving suitable material and/or due to the lack of expertise of the employed workers, thus compromising the success of the entire works.

Alternatively to the creation of a typical bed formed by inert materials, it is known to use draining mats formed by various superimposed layers, or mats formed by woven materials, so that the weaves therein leave voids which allow the flow of water; such mats are normally installed between the ground and the synthetic turf mat, so as to create a horizontal flowing zone of the rainwater, which is then collected in a peripheral channel. Such mats however present considerable drawbacks related to the manufacturing costs and to the lack of laying practicality because they have to be transported to the site in an autonomous step, prior to the installation of the synthetic turf mat, and then mounted according to precise methods. All this is added to the normal assembly costs of the synthetic turf mat, thus doubling the installation costs and making the use not very interesting, despite its technical operation efficiency.

It is similarly known that, despite relatively elastic materials (e.g. rubber granules, but also of natural material) being arranged between the filaments, the synthetic turf mats need to be mounted on an elastic support which improves the performance thereof in order to obtain given requirements in terms of shock absorbance; such support, usually in the form of prefabricated mat, is also formed by rubber or different kinds of plastic materials; as in the case of the draining mats, despite the fact that the result of the elastic support is technically effective, the high assembly and transportation costs greatly limit its use. OBJECT OF THE INVENTION It is thus an object of the present invention to provide a synthetic turf mat and a synthetic turf structure including such mat which are free from the drawbacks illustrated above. Specifically, it is an object of the present invention to provide a synthetic turf mat which allows to make synthetic turf which, with any type of filling (rubber, sand, natural original compounds, single layer or overlapping layers, etc.), has low manufacturing costs, high draining, excellent shock absorption, extreme installation ease and contained transportation costs .

The present invention thus relates to a synthetic turf mat and to a manufacturing method of such mat as defined in the appended claims 1 and 17, respectively; the invention further relates to a synthetic turf structure including such mat.

According to the invention, the draining and shock-absorbing mat element is incorporated directly into the synthetic turf structure, being specifically constituted by an auxiliary mat woven (or fixed in other manner) onto the same face of the primary support from which the filaments extend or, according to another embodiment, forming the primary support itself (and thus replacing the traditional primary support which does not have the required draining and shock-absorbing features) .

The draining and shock-absorbing mat element, in virtue of its composition and structure ensures both an effective drainage of the water, by defining a water flowing zone, and excellent shock absorbing features. Specifically, such element defines a water flowing zone in which the rainwater may flow towards peripheral channels appropriately made about the area occupied by the synthetic turf, and at the same time ensures, in virtue of the elasticity of the material it is made of, optimal shock-absorption.

These results are obtained without implying additional installation costs because the installation of the element occurs at the same time as that of the entire synthetic turf, in a single operative step.

The draining and shock-absorbing mat element being incorporated (woven) directly into the synthetic turf mat moreover allows, with respect to the traditional systems installed separately and underneath the synthetic turf mat, to further cut transportation costs.

Furthermore, the presence of the element within the synthetic turf mat structure reduces the volume which needs to be filled with the traditional infill materials, however ensuring optimal performance in terms of elasticity and shock-absorption, in virtue of the intrinsic features of the element; there follows a further cost saving in the manufacturing of the synthetic turf because smaller amounts of infill materials are required.

The high draining capacity of the element allows to avoid the presence of draining holes; however, in specific cases, the synthetic turf mat of the invention may also be provided with draining holes formed through the primary support onto which the auxiliary mat which forms the draining and shock-absorbing mat element is coupled; for example, a mat with draining holes may be used in presence of particularly good draining beds, so that the auxiliary mat, in addition to ensuring the flow of the water and thus facilitating its disposal in case of heavy rain, also has the function of filter, thus maintaining separate the filling material from the draining holes and thus maintaining the latter clear and efficient. Instead, in case of laying in presence of poor draining beds, a mat without draining holes may be employed, so that the polymeric reinforcement layer placed on the lower face of the primary support has , in addition to the normal reinforcement function, the object of fully waterproofing the auxiliary mat of the bed; in this manner, the vertical percolation of the water being prevented, the water will flow within the auxiliary mat and run off horizontally thus exploiting the slope of the construction surface towards the peripheral ducts; the integrity of the bed from possible water erosion and the preservation of the original construction features is thus ensured, in addition to perfect draining.

The manufacturing of the synthetic turf mat according to the invention is also simple and cost- effective. If the draining and shock-absorbing mat element forms the auxiliary mat which is coupled to the primary support, it is indeed inserted between the primary sheet support and the weaving mechanism which produces the filaments; it is possible to couple, prior to weaving, the normal sheet support with the auxiliary mat, and then proceed by weaving the filaments.

If instead the draining and shock-absorbing element forms the primary support, the step of coupling is not even required and the filaments are woven directly onto the draining and shock-absorbing mat element .

BRIEF DESCRIPTION OF THE DRAWINGS Further features and advantages of the present invention will be apparent in the description of the following non-limitative example, with reference to the accompanying drawings, in which:

- figure 1 is a diagrammatic view of a synthetic turf structure according to a first embodiment of the invention;

- figure 2 shows a detail on an enlarged scale of a draining and shock-absorbing mat element belonging to the structure in figure 1; - figure 3 is a diagrammatic view of a synthetic turf structure according to a second embodiment of the invention. PREFERRED EMBODIMENT OF THE INVENTION

Referring to figure 1, a synthetic turf structure 1 for sports fields comprises a synthetic turf mat 2, having a primary sheet support 3 from which filaments 4 simulating a greensward extend, a bed 5, e.g. a packed earth bed, on which mat 2 rests, and possibly an infill 6 formed by a particle filling material 7 arranged between filaments 4.

Support 3 consists of a sheet or strip of suitable plastic material, specifically a fabric, a non-woven fabric or a synthetic rubber felt, e.g. styrene- butadiene rubber (SBR) , or synthetic fiber, for example polypropylene or the like. Support 3 presents an upper face 8, from which filaments 4 extend, and a lower face 9, opposite to face 8 and resting on bed 5.

Filaments 4 are formed by appropriate yarns, e.g. polyethylene, polyamide, polypropylene fibers, etc. Filaments 4 are anchored to support 3, e.g. quilted or woven onto support 3 , by means of corresponding attachment ends 11 penetrating through support 3 and protruding from face 9, and ending with corresponding free ends 12.

Upper face 8 of support 3 is integrally coupled to a draining and shock-absorbing mat element 100, consisting of an auxiliary mat 15 applied onto face 8 of support 3, having draining and shock-absorbing properties .

Specifically, element 100 has a composition and/or structure such as to allow the flow of water therein and, at the same time, is essentially elastic and however provided with shock-absorbing properties. In particular, element 100 is soft and delimited by two opposite essentially parallel delimitation surfaces and is compressible in a direction essentially orthogonal to the delimitation surfaces. Element 100 is formed by different kinds of synthetic material, in layers or in fibers having different compactness and with variable thickness, and however so as to have a high draining capacity (i.e. to allow the flow of water therein) and, at the same time, specific shock-absorbing qualities. For example, element 100 is formed by synthetic polymeric fibers, e.g. polyester fibers, polyethylene, polypropylene, polyamide and the like, organized so as to allow the flow of water within element 100. For example, element 100 is made of synthetic flocked polymeric fibers and has the structure and consistency of felt or wadding.

According to a preferred embodiment, element 100 is made of flocked polyester fibers (e.g. PET or the like) which have been, for example, subjected to operations of carding, web laying, needlefelting, possible resin- coating and drying in oven.

By way of example, element 100 has a basic weight preferably (but not necessary) comprised between approximately 100 and approximately 500 g/m² and a thickness comprised between approximately 0.5 and approximately 5 mm, preferably between approximately 0.5 and approximately 3 mm. Advantageously, as shown in detail in figure 2, element 100 comprises a pair of flat, facing, essentially parallel walls 101, water permeable and joined by a fibrous, non-compact, transverse structure 102 which allows the circulation of water within and make element 100 essentially elastic.

Auxiliary mat 15 constituted by element 100 is woven or otherwise fixed onto face 8 of support 3. Preferably, auxiliary mat 15 is woven onto support 3 by means of filaments 4. Filaments 4 are anchored to support 3 by means of attachment ends 11 and extend from support 3 through auxiliary mat 15.

Mat 2 further comprises a reinforcement coating 16 made of polymeric material; coating 16 is arranged on lower face 9 of support 3 and is essentially waterproof; coating 16 incorporates ends 11 of filaments 4 which extend over face 9, firmly ensuring the anchoring of filaments 4 onto support 3.

Mat 2 is optionally provided with draining holes 17 formed through support 3 and coating 16 and essentially- orthogonal to faces 8 , 9. Given the draining capacity of element 100 (i.e. auxiliary mat 15), holes 17 do not need to extend also through auxiliary mat 15; auxiliary mat 15 may however be provided with draining holes. Mat 2 is advantageously made by means of the following method.

Primary sheet support 3 and auxiliary mat 15 forming element 100 are separately arranged; auxiliary mat 15 is then arranged on face 8 of support 3 ; support 3 and auxiliary mat 15 thus coupled (but not yet fixed) onto each other are thus inserted together in a traditional weaving machine which applies filaments 4 to support 3, in known manner. Although it is possible to integrally join support 3 to auxiliary mat 15 before weaving filaments 4, the weaving of filaments 4 suffices to ensure the union of auxiliary mat 15 to support 3. Before being inserted in the weaving machine, auxiliary mat 15 and support 3 are only coupled, but not integrally fixed, onto each other; filaments 4 are indeed woven onto support 3 and auxiliary mat 15 is woven onto support 3 by means of filaments 4.

Subsequently, polymeric material reinforcement coating 16 is applied onto lower face 9, e.g. by coating with an appropriate polymeric composition (e.g. a synthetic rubber latex) .

Possibly, mat 2 is also provided with draining holes 17; holes 17 may be made by a mechanical perforator after applying reinforcement coating 16, so that holes 17 are formed thorough support 3 and coating 16 (and optionally through auxiliary mat 15) .

In the embodiment shown in figure 3 , wherein the details similar or equivalent to those previously described are indicated by the same numerals, primary support 3 consists of a draining and shock-absorbing mat element 100 having the above described structure and composition, and filaments 4 extend directly from element 100. Filaments 4 are anchored directly onto element 100, e.g. by quilting or weaving, by means of corresponding attachment ends 11 penetrating through element 100 and are fixed onto element 100, e.g. by heat sealing or by application of coating 16.

Claims

C L A I M S

1. A synthetic turf mat (2), comprising a primary sheet support (3) and filaments (4) which extend from an upper face (8) of the primary support (3) to simulate a greensward; the mat being characterized in that the primary support (3) either consists of or is integrally coupled by means of said upper face (8) with a draining and shock-absorbing element mat (100) , having draining and shock-absorbing composition and/or structure.

2. A mat according to claim 1, characterized in that the element (100) has a composition and/or a structure such as to allow the flow of water within the element (100) .

3. A mat according to claim 1 or 2, characterized in that the element (100) has a composition and/or a structure such as to be essentially elastic.

4. A mat according to one of the preceding claims, characterized in that the element (100) is soft, being delimited by two opposite, essentially parallel delimitation surfaces and being compressible in a direction essentially orthogonal to the delimitation surfaces .

5. A mat according to one of the preceding claims, characterized in that the element (100) comprises a pair of flat, facing, essentially parallel walls (101) , joined by a fibrous transverse structure (102) which allows the circulation of water therein.

6. A mat according to one of the preceding claims, characterized in that the element (100) has structure and consistency of felt or wadding.

7. A mat according to one of the preceding claims, characterized in that the element (100) is formed by synthetic polymeric fibers, e.g. polyester, polyethylene, polypropylene, polyamide fibers and the like.

8. A mat according to one of the preceding claims, characterized in that the element (100) is formed by synthetic flocked, polymeric fibers.

9. A mat according to one of the preceding claims, characterized in that the element (100) is formed by synthetic flocked polyester fibers.

10. A mat according to one of the claims from 1 to 9, characterized in that the element (100) consists of an auxiliary mat (15) , applied onto the upper face of the primary support (3) and woven or otherwise fixed to the primary support (3) .

11. A mat according to claim 10, characterized in that the auxiliary mat (15) is woven onto the primary support (3) by means of the filaments (4) .

12. A mat according to claim 10 or 11, characterized in that the filaments (4) are anchored to the primary support (3) and extend from the primary support (3) through the auxiliary mat (15) .

13. A mat according to one of the claims from 1 to 9, characterized in that the element (100) is the primary support (3) and the filaments (4) are woven direct onto the element (15) .

14. A mat according to one of the preceding claims, characterized in that the primary support (3) is provided with through draining holes (17) .

15. A mat according to one of the preceding claims, characterized in that a lower face (9) of the primary support (3), opposite to the upper face (8) is provided with a polymeric material reinforcement coating (16) .

16. A mat according to the preceding claim, characterized in that the reinforcement coating (16) is essentially waterproof.

17. A manufacturing method of a synthetic turf mat (2) , comprising the steps of arranging a primary sheet support (3) and applying filaments (4) onto the primary support extending from an upper face (8) of the primary support to simulate a greensward; the method being characterized by comprising a step of providing the primary support (3) with a draining and shock-absorbing mat element (100) having draining and shock-absorbing composition and/or structure.

18. A method according to claim 17, characterized in that the primary support (3) consists of the draining and shock-absorbing mat element (100) .

19. A method according to claims 17, characterized in that the element (100) consists of an auxiliary mat

(15) , applied onto the upper face of the primary support (3) and woven or otherwise fixed to the primary support (3) .

20. A method according to claim 19, characterized in that the auxiliary mat (15) is coupled onto the primary support (3) before the application of the filaments (4) .

21. A method according to claim 19 or 20, characterized in that the filaments (4) are woven onto the primary support (3) and the auxiliary mat (15) is woven onto the primary support (3) by means of the filaments (4) .

22. A method according to one of claims from 19 to 11, characterized in that the auxiliary mat (15) is firstly coupled to the primary support (3) , and then the auxiliary mat (15) is integrally joined to the primary support (3) by means of a step of weaving the filaments (4) onto the primary support (3) , the filaments (4) being .anchored to the primary support (3) and extending from the primary support (3) through the auxiliary mat (15) .

23. A method according to one of claims from 17 to

22, characterized by comprising a step of forming through draining holes (17) through the primary support

(3) .

24. A method according to one of claims from 17 to

23, characterized by comprising a step of applying an essentially waterproof polymeric material coating (16) onto a lower face (9) of the primary support (3) , opposite to the upper face (8) .

25. A synthetic turf structure (1), specifically for sports fields, comprising a synthetic turf mat (2) having a primary support (3) from which filaments (4) simulating a greensward extend; the structure (1) being characterized in that the synthetic turf mat (2) is a mat according to one of the claims from 1 to 16.

26. A structure according to the preceding claims, characterized by comprising a filling (6) formed by a particle infill material (7) arranged between the

filaments (4) .