Novel Artificial Turf and Methods of Making Same

Abstract

Described are artificial turfs having a nonwoven backing layer and a plurality of turf fibers extending through the nonwoven backing layer such that a face side portion of the turf fibers extends from the face side of the nonwoven backing layer and a back side portion of the turf fibers extends from the back side of the nonwoven backing layer, wherein at least a portion of the back side portion of turf fibers are bonded to themselves. Also described herein are the methods of making the same.

What is claimed is: 
     
         1 . An artificial turf, comprising:
 a nonwoven backing layer having a face side and a back side, and   a plurality of turf fibers extending through the nonwoven backing layer such that a face side portion of the turf fibers extends from the face side of the nonwoven backing layer and a back side portion of the turf fibers extends from the back side of the nonwoven backing layer,   wherein at least a portion of the back side portion of turf fibers are bonded to themselves.   
     
     
         2 . The artificial turf of  claim 1 , wherein the nonwoven backing layer comprises a fiber batt. 
     
     
         3 . The artificial turf of  claim 2 , wherein the fiber batt comprises fibers that are mechanically bonded. 
     
     
         4 . The artificial turf of  claim 2 , wherein the fiber batt comprises fibers that are thermally bonded. 
     
     
         5 . The artificial turf of  claim 1 , wherein the nonwoven backing layer is needlepunched. 
     
     
         6 . The artificial turf of  claim 1 , wherein the nonwoven backing layer is comprised of fibers comprising at least one of nylon, polyester, polyethylene, and polypropylene, cotton, Kenaf, jute, or any combination thereof. 
     
     
         7 . The artificial turf of  claim 1 , wherein the nonwoven backing layer is comprised of fibers having a length from about 1 to 8 inches and a denier ranging between about 2 DPF to less than about 20,000 DPF. 
     
     
         8 . The artificial turf of  claim 1 , wherein the nonwoven backing comprises at least one additive material distributed therein, and wherein the at least one additive material comprises at least one of rubber crumbs, wood chips, sand, grass seeds, foam chips, and an inorganic filler. 
     
     
         9 . The artificial turf of  claim 1 , wherein the nonwoven backing layer is a cushion backing layer having a thickness between about 1/16 inch to about 2.5 inches. 
     
     
         10 . The artificial turf of  claim 1 , wherein the plurality of turf fibers are gravitationally laid and needlepunched. 
     
     
         11 . The artificial turf of  claim 1 , wherein the plurality of turf fibers are tufted fibers. 
     
     
         12 . The artificial turf of  claim 1 , wherein the plurality of turf fibers are comprised of staple fibers. 
     
     
         13 . The artificial turf of  claim 1 , wherein the plurality of turf fibers are comprised of slit film fibers, monofilaments, or texturized fibers. 
     
     
         14 . The artificial turf of  claim 1 , wherein the plurality of turf fibers have a length from 0.25 inches to about 6 inches. 
     
     
         15 . The artificial turf of  claim 14 , wherein the plurality of turf fibers have a denier from about 100 DPF to about 20,000 DPF. 
     
     
         16 . The artificial turf of  claim 1 , wherein the portion of the back side turf fibers bonded to themselves by an adhesive coating. 
     
     
         17 . The artificial turf of  claim 1 , wherein the portion of the back side turf fibers bonded to themselves by mechanical bonding. 
     
     
         18 . The artificial turf of  claim 1 , wherein the portion of the back side turf fibers bonded to themselves by thermobonding. 
     
     
         19 . The artificial turf of  claim 1 , wherein a portion of the back side portion of turf fibers is bonded to the back side of the nonwoven backing layer. 
     
     
         20 . A method for manufacturing an artificial turf, comprising:
 inserting a plurality of turf fibers into a nonwoven backing layer having a face side and a back side such that the plurality of turf fibers extend through the nonwoven backing layer and a face side portion of the turf fibers extends from the face side of the nonwoven backing layer, and a back side portion of the turf fibers extends from the back side of the backing layer; and   bonding at least a portion of the back side portion of turf fibers to themselves.