Artificial turf and production method

Abstract

The invention provides for a method of manufacturing artificial turf ( 1000 ). The method comprising the steps of: creating ( 100 ) a polymer mixture ( 100, 400, 500 ), wherein the polymer mixture is at least a three-phase system, wherein the polymer mixture comprises a first polymer ( 402 ), a second polymer ( 404 ), and a compatibiiizer ( 406 ), wherein the first polymer and the second polymer are immiscible, wherein the first polymer forms polymer beads ( 408 ) surrounded by the compatibiiizer within the second polymer; extruding ( 102 ) the polymer mixture into a monofilament ( 606 ); quenching ( 104 ) the monofilament; reheating ( 106 ) the monofilament; stretching ( 108 ) the reheated monofilament to deform the polymer beads into threadlike regions ( 800 ) and to form the monofilament into an artificial turf fiber ( 1004 ); incorporating ( 110 ) the artificial turf fiber into an artificial turf carpet ( 1002 ).

1 . A method of manufacturing artificial turf ( 1000 ), the method comprising the steps of:
 creating ( 100 ) a polymer mixture ( 100 ,  400 ,  500 ), wherein the polymer mixture is at least a three-phase system, wherein the polymer mixture comprises a first polymer ( 402 ), a second polymer ( 404 ), and a compatibilizer ( 406 ), wherein the first polymer and the second polymer are immiscible, wherein the first polymer forms polymer beads ( 408 ) surrounded by the compatibilizer within the second polymer;   extruding ( 102 ) the polymer mixture into a monofilament ( 606 );   quenching ( 104 ) the monofilament;   reheating ( 106 ) the monofilament;   stretching ( 108 ) the reheated monofilament to deform the polymer beads into threadlike regions ( 800 ) and to form the monofilament into an artificial turf fiber ( 1004 );   incorporating ( 110 ) the artificial turf fiber into an artificial turf backing ( 1002 ).   
     
     
         2 . The method of  claim 1 , wherein the polymer bead comprises crystalline portions and amorphous portions, wherein stretching the polymer beads into threadlike regions causes an increase in the size of the crystalline portions relative to the amorphous portions. 
     
     
         3 . The method of  claim 1  or  2 , wherein the creating of the polymer mixture comprises the steps of:
 forming ( 200 ) a first mixture by mixing the first polymer with the compatibilizer; 
 heating ( 202 ) the first mixture; 
 extruding ( 204 ) the first mixture; 
 granulating ( 206 ) the extruded first mixture; 
 mixing ( 208 ) the granulated first mixture with the second polymer; and 
 heating ( 210 ) the granulated first mixture with the second polymer to form the polymer mixture. 
 
     
     
         4 . The method of  claim 1  or  2 , wherein the polymer mixture is at least a four phase system, wherein the polymer mixture comprises at least a third polymer ( 502 ), wherein the third polymer is immiscible with the second polymer, wherein the third polymer further forms the polymer beads surrounded by the compatibilizer within the second polymer. 
     
     
         5 . The method of  claim 4 , wherein the creating of the polymer mixture comprises the steps of:
 forming ( 300 ) a first mixture by mixing the first polymer and the third polymer with the compatibilizer;   heating ( 302 ) the first mixture;   extruding ( 304 ) the first mixture;   granulating ( 306 ) the extruded first mixture;   mixing ( 308 ) the first mixture with the second polymer; and   heating ( 310 ) the mixed first mixture with the second polymer to form the polymer mixture.   
     
     
         6 . The method of  claim 4  or  5 , wherein the third polymer is a polar polymer. 
     
     
         7 . The method of any one of the preceding claims, wherein the third polymer is any one of the following: polyamide, polyethylene terephthalate (PET), and polybutylene terephthalate (PBT). 
     
     
         8 . The method of any one of the preceding claims, wherein the polymer mixture comprises 1 to 30 percent by weight the first polymer and the third polymer combined. 
     
     
         9 . The method of any one of  claims 1  to  7 , wherein the polymer mixture comprises 1 to 20 percent by weight the first polymer and the third polymer combined. 
     
     
         10 . The method of any one of  claims 1  to  7 , wherein the polymer mixture comprises 5 to 10 percent by weight the first polymer and the third polymer combined. 
     
     
         11 . The method of  claim 1 ,  2 , or  3 , wherein the polymer mixture comprises 1 to 30 percent by weight the first polymer. 
     
     
         12 . The method of  claim 1 ,  2 , or  3 , wherein the polymer mixture comprises 1 to 20 percent by weight the first polymer. 
     
     
         13 . The method of  claim 1 ,  2 , or  3 , wherein the polymer mixture comprises 5 to 10 percent by weight the first polymer. 
     
     
         14 . The method of any one of the preceding claims, wherein the first polymer is a polar polymer. 
     
     
         15 . The method of any one of the preceding claims, wherein the first polymer is any one of the following: polyamide, polyethylene terephthalate (PET), and polybutylene terephthalate (PBT). 
     
     
         16 . The method of any one of the preceding claims, wherein the second polymer is a non-polar polymer. 
     
     
         17 . The method of any one of the preceding claims, wherein the second polymer is any one of the following: polyethylene, polypropylene, and a mixture thereof. 
     
     
         18 . The method of any one of the preceding claims, wherein the compatibilizer is any one of the following: a maleic acid grafted on polyethylene or polyamide; a maleic anhydride grafted on free radical initiated graft copolymer of polyethylene, SEBS, EVA, EPD, or polyproplene with an unsaturated acid or its anhydride such as maleic acid, glycidyl methacrylate, ricinoloxazoline maleinate; a graft copolymer of SEBS with glycidyl methacrylate, a graft copolymer of EVA with mercaptoacetic acid and maleic anhydride; a graft copolymer of EPDM with maleic anhydride; a graft copolymer of polypropylene with maleic anhydride; a polyolefin-graft-polyamidepolyethylene or polyamide; and a polyacrylic acid type compatibilizer. 
     
     
         19 . The method of any one of the preceding claims, wherein the polymer mixture comprises 80 to 90 percent by weight the second polymer. 
     
     
         20 . The method of any one of the preceding claims, wherein the polymer mixture further comprises any one of the following: a wax, a dulling agent, a UV stabilizer, a flame retardant, an anti-oxidant, a pigment, and combinations thereof. 
     
     
         21 . The method of any one of the preceding claims, wherein creating the artificial turf fiber comprises forming the stretched monofilament into a yarn. 
     
     
         22 . The method of any one of the preceding claims, wherein creating the artificial turf fiber comprises weaving, spinning, twisting, rewinding, and/or bundling the stretched monofilament into the artificial turf fiber. 
     
     
         23 . The method of any one of the preceding claims, wherein incorporating the artificial turf fiber into the artificial turf backing comprises: tufting the artificial turf fiber into the artificial turf backing and binding the artificial turf fibers to the artificial turf backing. 
     
     
         24 . The method of any one of  claims 1  through  22 , wherein incorporating the artificial turf fiber into the artificial turf backing comprises weaving the artificial turf fiber into the artificial turf backing. 
     
     
         25 . A artificial turf manufactured according to the method of any one of the preceding claims. 
     
     
         26 . An artificial turf ( 1000 ) comprising an artificial turf textile backing ( 1002 ) and artificial turf fiber ( 1004 ) incorporated into the artificial turf backing, wherein the artificial turf fiber comprises at least one monofilament, wherein each of the at least one monofilament comprises:
 a first polymer ( 402 ) in the form of threadlike regions ( 800 );   a second polymer ( 404 ), wherein the threadlike regions are embedded in the second polymer, wherein the first polymer is immiscible in the second polymer;   a compatibilizer ( 406 ) surrounding each of the threadlike regions and separating the at least one first polymer from the second polymer.   
     
     
         27 . The artificial turf of  claim 26 , wherein the threadlike regions have a diameter less than 50 micrometers. 
     
     
         28 . The artificial turf of  claim 26 , wherein the threadlike regions have a diameter less than 10 micrometers. 
     
     
         29 . The artificial turf of  claim 26 , wherein the threadlike regions have a diameter of between 1 and 3 micrometers. 
     
     
         30 . The artificial turf of any one of  claims 27  to  30 , wherein the artificial turf fiber extends a predetermined length ( 1008 ) beyond the artificial turf backing, and wherein threadlike regions have a length less than one half of the predetermined length. 
     
     
         31 . The artificial turf of any one of  claims 27  to  31 , wherein the threadlike regions have a length less than 2 mm.