Shock Pad for Synthetic Turf and Methods for Making Same

Abstract

Disclosed are methods for making shock absorbing pads utilizing reclaimed artificial turf and reclaimed carpet materials. It is demonstrated that the artificial turf systems comprising inventive pads exhibit improved Head Impact Criteria (HIC) and cradle-to-cradle score.

What is claimed is: 
     
         1 . A method of making a shock absorbing pad, comprising:
 a) forming a composite blend of at least one reclaimed artificial turf material and a binder material wherein the at least one reclaimed artificial turf material comprises face fibers, primary backing fibers, adhesive backing, or any combination thereof;   b) forming the composite blend into a composite web; and   c) treating the composite web to set the binder material under conditions effective to provide a composite nonwoven pad.   
     
     
         2 . The method of  claim 1 , wherein the step of treating comprises step of heating, pressuring, calendering, or a combination thereof. 
     
     
         3 . The method of  claim 1 , wherein the reclaimed artificial turf material comprises face fibers, primary backing fibers, and adhesive backing. 
     
     
         4 . The method of  claim 1 , wherein the formed composite blend comprises artificial turf infill material, at least one performed additive, at least one reclaimed carpet material, or a combination thereof. 
     
     
         5 . The method of  claim 1 , wherein the reclaimed artificial turf material comprises a thermoset polymer, a thermoplastic polymer, or a combination thereof. 
     
     
         6 . The method of  claim 1 , wherein the binder is a low melt fiber. 
     
     
         7 . The method of  claim 1 , wherein the binder is a bi-component fiber. 
     
     
         8 . The method of  claim 1 , wherein the reclaimed artificial turf material comprises a polyolefin, polyamide, polystyrene, polyurethane, polyester, polyvinyl chloride, polyacrylic, or any combination thereof. 
     
     
         9 . The method of  claim 1 , wherein the composite nonwoven pad of step c) has a face surface and an opposed back surface and after step c) a reinforcing scrim is adhered to at least one of a face surface or back surface of the composite nonwoven pad. 
     
     
         10 . The method of  claim 1 , wherein the composite nonwoven pad has a density from about 2 lbs/ft 3  to about 30 lbs/ft 3 . 
     
     
         11 . The method of  claim 1 , wherein the composite nonwoven pad has a thickness that is from about 0.1 in to about 5 in. 
     
     
         12 . The method of  claim 1 , wherein when the composite nonwoven pad present as a component in an artificial turf system, the artificial turf system exhibits a Gmax value less than about 165 g's as measured according to ASTM F-355. 
     
     
         13 . The method of  claim 1 , wherein when the composite nonwoven pad present as a component in an artificial turf system, the artificial turf system exhibits a Head Impact Criteria of less than about 1,000 as measured according to EN 1177 test. 
     
     
         14 . The method of  claim 1 , wherein the composite nonwoven pad exhibits a compression set from about 1% to about 30% as measured according to ASTM D-3676 or ASTM D3574. 
     
     
         15 . The method of  claim 1 , further comprising forming a plurality of channels in the composite nonwoven pad, wherein the plurality of channels extends from the face surface to the opposed back surface, and wherein the each of the plurality of channels has a diameter in the range of from about 1 mm to about 15 mm. 
     
     
         16 . The method of  claim 15 , wherein the plurality of channels are configured to provide a predetermined rate of horizontal drainage of moisture through the nonwoven pad from the face surface through the back surface, wherein the predetermined rate of horizontal drainage is from about 10 in/h to about 7,000 in/h. 
     
     
         17 . The method of  claim 16 , wherein the plurality of channels are configured to provide a predetermined rate of vertical drainage of moisture through the nonwoven pad from the face surface through the back surface, wherein the predetermined rate of the vertical drainage is greater than 100 in/h. 
     
     
         18 . The method of  claim 1 , further comprising adhering a moisture barrier film to the back surface. 
     
     
         19 . The method of  claim 1 , wherein the composite nonwoven pad exhibits a rate of lateral drainage between about 10 in/h to about 7,000 in/h. 
     
     
         20 . The method of  claim 1 , wherein the composite nonwoven pad comprises opposed first and second side edges and wherein the method further comprises profiling the plurality of side edges to define an edge locking structure.