Nylon Artificial Grass

Abstract

An artificial grass product has 100% nylon face fabric which forms blades of grass when tufted. This grass shows a melt temperature exceeding 400 degrees Fahrenheit, at least about 100 degrees hotter than prior art materials. The thatch can be made of similar materials for at least some embodiments. When coupled with multiple yarns extending from common penetrations, quite durable and attractive products can be provided. Furthermore, resiliency in excess of 10% over prior art polyethylene or polypropylene grass products can be experienced with at least some embodiments.

Having thus set forth the nature of the invention, what is claimed herein is: 
     
         1 . A method for manufacturing an artificial grass product comprising:
 tufting at least two nylon face fiber strands through a first penetration in a backing comprising a plurality of first penetrations to form grass blades, wherein the at least two nylon face fiber strands are all wound in an untwisted orientation together around a single cone and directed through a needle before being tufted through the first penetration in the backing; and   tufting at least two nylon thatch fiber strands through a second penetration in the backing additionally comprising a plurality of second penetrations to form thatch,   wherein the at least two nylon face fiber strands are of different colors and the at least two nylon thatch fiber strands are of different colors, and   wherein the second penetration is adjacent the first penetration.   
     
     
         2 . The method of  claim 1 , wherein the face fiber strands and the thatch fiber strands are 100% nylon. 
     
     
         3 . The method of  claim 1 , wherein the colors of the nylon face fiber strands and the nylon thatch fiber strands are different each from the other. 
     
     
         4 . The method of  claim 1 , comprising tufting three nylon face fiber strands. 
     
     
         5 . The method of  claim 4 , wherein the three nylon face fiber strands are each a different color. 
     
     
         6 . The method of  claim 1 , comprising tufting three nylon thatch fiber strands. 
     
     
         7 . The method of  claim 6 , wherein the three nylon thatch fiber strands are each a different color. 
     
     
         8 . A method for manufacturing an artificial grass product comprising:
 winding at least two nylon face fiber strands, in an untwisted orientation, together around a single cone;   directing the at least two nylon fiber strands through a needle;   providing a backing comprising a plurality of penetrations;   tufting the at least two nylon face fiber strands through a first penetration in the backing to form grass blades,   tufting at least two nylon thatch fiber strands through a second penetration in the backing to form thatch,   wherein the at least two nylon face fiber strands are of different colors and the at least two nylon thatch fiber strands are of different colors, and   wherein the second penetration is adjacent the first penetration.   
     
     
         9 . The method of  claim 8 , wherein the face fiber strands and the thatch fiber strands are 100% nylon. 
     
     
         10 . The method of  claim 8 , wherein the colors of the nylon face fiber strands and the nylon thatch fiber strands are different each from the other. 
     
     
         11 . The method of  claim 8 , comprising tufting three nylon face fiber strands. 
     
     
         12 . The method of  claim 11 , wherein the three nylon face fiber strands are each a different color. 
     
     
         13 . The method of  claim 8 , comprising tufting three nylon thatch fiber strands. 
     
     
         14 . The method of  claim 13 , wherein the three nylon thatch fiber strands are each a different color.