Artificial turf and process for manufacturing artificial turf

Abstract

An improved artificial turf resembles natural grass better. The artificial turf includes first tufts including first artificial turf fibers tufted into the primary backing at a first gauge and a first stitch-rate, the first artificial turf fibers extending to a first length from the first surface of the primary backing, and second tufts including second artificial turf fibers tufted into the primary backing at a second gauge and a second stitch-rate, the second artificial turf fibers extending to a second length from the first surface of the primary backing wherein the second gauge is different from the first gauge, thereby providing a non-uniform distribution of tufts in the artificial turf.

15 . An artificial turf comprising a primary backing having a first surface and a second surface, first tufts comprising first artificial turf fibers tufted into the primary backing along the longitudinal direction of the primary backing at a first gauge and a first stitch-rate, the first artificial turf fibers extending to a first length from the first surface of the primary backing, second tufts comprising second artificial turf fibers tufted into the primary backing along the longitudinal direction of the primary backing at a second gauge and a second stitch-rate, the second artificial turf fibers extending to a second length from the first surface of the primary backing wherein the second gauge is different from the first gauge, and wherein the ratio of the second gauge to the first gauge is not an integer and the ratio of the first gauge to the second gauge is not an integer. 
     
     
         16 . The artificial turf according to  claim 15  wherein the second stitch-rate is different from the first stitch-rate. 
     
     
         17 . The artificial turf according to  claim 15  wherein the second length is different from the first length. 
     
     
         18 . The artificial turf according to  claim 15  wherein the first tufts comprise third artificial turf fibers, the third artificial turf fibers extending to a third length from the first surface of the primary backing. 
     
     
         19 . The artificial turf according to  claim 15  wherein the second tufts comprise fourth artificial turf fibers, the fourth artificial turf fibers extending to a fourth length from the first surface of the primary backing. 
     
     
         20 . The artificial turf according to  claim 15  wherein the first artificial turf fibers are non-texturized fibers. 
     
     
         21 . The artificial turf according to  claim 15  wherein the second artificial turf fibers are non-texturized fibers. 
     
     
         22 . The artificial turf according to  claim 15  wherein the third artificial turf fibers are texturized fibers. 
     
     
         23 . The artificial turf according to  claim 15  wherein the fourth artificial turf fibers are texturized fibers. 
     
     
         24 . A process for manufacturing an artificial turf comprising the steps of providing a primary backing having a first surface and a second surface, tufting first artificial turf fibers into the primary backing along the longitudinal direction of the primary backing in a first tufting step at a first gauge and a first stitch-rate to extend from the first surface of the primary backing to a first length to form first tufts, tufting second artificial turf fibers into the primary backing along the longitudinal direction of the primary backing in a subsequent second tufting step at a second gauge and a second stitch-rate to extend from the first surface of the primary backing to second length to form second tufts wherein the second gauge in the second tufting step is different from the first gauge in the first tufting step, and wherein the ratio of the second gauge to the first gauge is not an integer and the ratio of the first gauge to the second gauge is not an integer. 
     
     
         25 . The process for manufacturing an artificial turf according to  claim 24  wherein the second stitch-rate is equal to the first stitch-rate and wherein the alignment of the second stitch-rate in the subsequent second tufting step is such that the rows comprising second tufts are located equidistantly between two rows comprising first tufts in the artificial turf. 
     
     
         26 . The process for manufacturing an artificial turf according to  claim 24  wherein the second stitch-rate is equal to the first stitch-rate and wherein the alignment of the stitch-rate in the subsequent second tufting step is such that the rows comprising second tufts are located non-equidistantly between two rows comprising first tufts in the artificial turf. 
     
     
         27 . The process for manufacturing an artificial turf according to  claim 24  wherein the second stitch-rate is different from the first stitch-rate. 
     
     
         28 . The process for manufacturing an artificial turf according to  claim 24  wherein the second length is different from the first length.