Water permeable artificial turf and method of making same

Abstract

The invention comprises a method. The method comprises applying to a primary backing and loop backs of a tufted synthetic turf a plurality of solid polymer particles having a particle size less than or equal to 1,000 microns such that a layer of solid polymer particles is formed across the width and length of the primary backing, wherein the polymer particles are applied to the primary backing at a rate of approximately 10 to approximately 18 ounces of polymer per square yard and wherein the solid polymer particles are thermoplastic polymer particles or a mixture of thermoplastic polymer particles and thermosetting polymer particles. The method also comprises heating the polymer particles on the primary backing and loop backs to a temperature at or above the melting temperature of the polymer particles and allowing the heated polymer particles to cool below their melting temperature wherein the tufted synthetic turf has bundle lock of at least 6.8 pounds and the tufted synthetic turf has a water permeability of at least 10 inches of water per hour.

What is claimed is: 
     
         1 . A method comprising:
 (a) applying to a primary backing and loop backs of a tufted synthetic turf one of:
 (i) a quantity of an aqueous dispersion of thermoplastic polymer particles have an average particle size of approximately 1 micron to approximately 1,000 microns; 
 (ii) an aqueous dispersion of colloidal thermosetting polymer particles or colloidal thermoplastic polymer particles and second thermoplastic polymer particles dispersed in the aqueous dispersion, wherein the second thermoplastic polymer particles have an average particle size of approximately 200 micron to approximately 1,000 microns; or 
 (iii) a plurality of solid polyethylene polymer particles to a first primary surface of a tufted primary backing to form a coating thereon, wherein the solid polyethylene polymer particles have an average particle size of approximately 1 to approximately 1,000 microns and a melt index of approximately 50 to approximately 500 grams/10 minutes at 190° C. at a weight of 2.16 kg; and 
 wherein the polymer particles are applied to the primary backing at a rate of approximately 10 to approximately 18 ounces per square yard; 
   (b) heating the polymer particles on the primary backing and loop backs to a temperature at or above the melting temperature of the polymer particles; and   (c) allowing the heated polymer particles to cool below their melting temperature wherein the tufted synthetic turf has bundle lock of at least 6.8 pounds and the tufted synthetic turf has a water permeability of at least 10 inches of water per hour.   
     
     
         2 . The method of  claim 1 , wherein the thermoplastic polymer particles of step (a) have a particle size of approximately 1 micron to approximately 100 microns. 
     
     
         3 . The method of  claim 1 , wherein the thermoplastic polymer particles of step (a) have an average particle size of approximately 1 micron to approximately 80 microns. 
     
     
         4 . The method of  claim 1 , wherein the aqueous dispersion of step (a) comprises:
 approximately 50% to approximately 90% by weight water;   approximately 0.1% to approximately 10% by weight dispersion agent; and   approximately 20% to approximately 70% by weight thermoplastic polymer particles.   
     
     
         5 . The method of  claim 1 , wherein the thermoplastic polymer particles of step (a) comprise polypropylene, polyethylene, thermoplastic polyester, polystyrene, polyvinylchloride, thermoplastic polyurethanes, thermoplastic copolymers thereof and mixtures thereof. 
     
     
         6 . The method of  claim 1 , wherein the colloidal thermosetting polymer particles of step (b) are styrene butadiene (SBR), carboxylated styrene butadiene or vinyl acetate ethylene (VAE). 
     
     
         7 . The method of  claim 1 , wherein the colloidal thermoplastic polymer particles of step (b) are high density polyethylene (HDPE), low density polyethylene (LDPE), polypropylene, ethylene acrylic acid or copolymers thereof. 
     
     
         8 . The method of  claim 1 , wherein the second thermoplastic polymer particles of step (b) are high density polyethylene (HDPE), low density polyethylene (LDPE), linear low density polyethylene (LLDPE), polypropylene (PP), poly-vinyl chloride (PVC), ethylene-vinyl acetate (EVA), styrene ethylene butylene styrene (SEBS), poly(styrene-block-butadiene-block-styrene) (SBS), polyamide, acrylonitrile butadiene styrene (ABS), thermoplastic polyurethane (TPU), polylactic acid (PLA), ethyl methacrylate (EMA) or polyester. 
     
     
         9 . The product of  claim 1 , wherein the colloidal thermosetting polymer particles or colloidal thermoplastic polymer particles of step (b) comprise about 5% to about 95% by weight and the second thermoplastic polymer particles of step (b) comprise about 5% to about 95% by weight based on the total weight of dry polymer. 
     
     
         10 . The product of  claim 1 , wherein the second thermoplastic polymer particles of step (b) have an average particle size of approximately 400 micron to approximately 800 microns. 
     
     
         11 . The method of  claim 1 , wherein the polyethylene polymer particles of step (c) has a melt index of approximately 150 to approximately 250 g/10 minutes at 190° C. at 2.16 kg. 
     
     
         12 . The method of  claim 1 , wherein the polyethylene polymer particles of step (c) has a melt index of approximately 200 g/10 minutes at 190° C. at 2.16 kg. 
     
     
         13 . The method of  claim 1 , wherein the polyethylene polymer particles of step (c) has a melting point of approximately 150 to approximately 250° F. 
     
     
         14 . The method of  claim 1 , wherein the polyethylene polymer particles of step (c) has a melting point of approximately 200 to approximately 235° F. 
     
     
         15 . The method of  claim 1  further comprising applying a secondary backing material to the heated polymer particles on the primary backing and loop backs between steps (b) and (c). 
     
     
         16 . A synthetic turf made by the process of  claim 1 . 
     
     
         17 . A synthetic turf made by the process of  claim 15 . 
     
     
         18 . A method comprising:
 applying to a primary backing and loop backs of a tufted synthetic turf a plurality of solid polymer particles having a particle size of less than or equal to 1,000 microns such that a layer of solid polymer particles is formed across the width and length of the primary backing, wherein the polymer particles are applied to the primary backing at a rate of approximately 14 to approximately 18 ounces of polymer per square yard, and wherein the solid polymer particles are thermoplastic polymer particles or a mixture of thermoplastic polymer particles and thermosetting polymer particles;   heating the polymer particles on the primary backing and loop backs to a temperature at or above the melting temperature of the polymer particles; and   allowing the heated polymer particles to cool below their melting temperature wherein the tufted synthetic turf has bundle lock of at least 6.8 pounds and the tufted synthetic turf has a water permeability of at least 10 inches of water per hour.   
     
     
         19 . The method of  claim 18  further comprising applying a secondary backing material to the heated polymer particles on the primary backing and loop backs before the heated polymer particles are allowed to solidify. 
     
     
         20 . A synthetic turf made by the process of  claim 19 .