US 11,987,939 B2
Artificial turf and production method
Stephan Sick, Willich-Neersen (DE)
Assigned to Polytex Sportbeläge Produktions—GmbH, Grefrath (DE)
Filed by Polytex Sportbelage Produktions-GmbH, Grefrath (DE)
Filed on Dec. 1, 2021, as Appl. No. 17/539,551.
Application 17/539,551 is a continuation in part of application No. 15/129,456, abandoned, previously published as PCT/EP2014/056149, filed on Mar. 27, 2014.
Prior Publication US 2022/0161477 A1, May 26, 2022
Int. Cl. E01C 13/08 (2006.01); B29C 48/00 (2019.01); B29C 48/05 (2019.01); B29C 48/21 (2019.01); B29C 48/88 (2019.01); D01D 5/088 (2006.01); D01D 5/098 (2006.01); D01F 1/10 (2006.01); D01F 8/06 (2006.01); D01F 8/12 (2006.01); D02G 3/02 (2006.01); D05C 15/04 (2006.01); D05C 17/02 (2006.01); D06N 7/00 (2006.01); D06N 7/02 (2006.01); B29K 23/00 (2006.01); B29K 105/26 (2006.01)
CPC E01C 13/08 (2013.01) [B29C 48/0018 (2019.02); B29C 48/022 (2019.02); B29C 48/05 (2019.02); B29C 48/21 (2019.02); B29C 48/911 (2019.02); B29C 48/919 (2019.02); D01D 5/0885 (2013.01); D01D 5/098 (2013.01); D01F 1/10 (2013.01); D01F 8/06 (2013.01); D01F 8/12 (2013.01); D02G 3/02 (2013.01); D05C 15/04 (2013.01); D05C 17/02 (2013.01); D06N 7/0065 (2013.01); E01C 13/083 (2013.01); B29K 2023/0625 (2013.01); B29K 2105/26 (2013.01); D06N 2201/0254 (2013.01); D06N 2201/10 (2013.01); D10B 2505/202 (2013.01)] 11 Claims
OG exemplary drawing
 
1. A method of manufacturing artificial turf, the method comprising:
creating a polymer mixture, wherein the polymer mixture is at least a three-phase system, wherein the polymer mixture comprises a first polymer, a second polymer, and a compatibilizer, wherein the first polymer comprises polyamide and the second polymer comprises polyethylene, wherein the first polymer is included in an amount of 0.25 percent to 2.5 percent by weight, wherein the second polymer consists of:
55 percent to 70 percent by weight of a first linear low-density polyethylene (LLDPE), the first LLDPE having a melt flow rate from about 0.9 g/10 min to about 1.1 g/10 min as measured in accordance with DIN EN ISO 1133 190° C./2.16 kg,
10 percent to 20 percent by weight of a second LLDPE, the second LLDPE having a melt flow rate from about 2.2 g/10 min to about 2.4 g/10 min as measured in accordance with DIN EN ISO 1133 190° C./2.16 kg, and
8 percent to 14 percent by weight of a high-density polyethylene (HDPE), the HDPE having a melt flow rate from about 3.9 g/10 min to about 4.1 g/10 min as measured in accordance with DIN EN ISO 1133 190° C./2.16 kg,
wherein the compatibilizer is included in an amount of 0.75 percent to 7.5 percent by weight, wherein the polymer mixture further comprises 4 percent to 11 percent by weight of a polymer protection mixture comprising at least one of a hindered amine light stabilizer, an anti-oxidant, an oxygen scavenger, a third LLDPE, fillers and pigments, and 0.15 percent to 0.75 percent by weight of a processing aid additive, wherein the processing aid additive comprises a fluoropolymer based processing additive or a siloxane, wherein the first polymer and the second polymer are immiscible, and wherein the first polymer forms polymer beads surrounded by the compatibilizer within the second polymer;
extruding the polymer mixture into a monofilament;
quenching the monofilament;
reheating the monofilament;
stretching the reheated monofilament to deform the polymer beads into fibrous regions and to form the monofilament into an artificial turf fiber, the fibrous regions including the first polymer, the fibrous regions being at least partially surrounded by the compatibilizer and separated from the second polymer by the compatibilizer, and the fibrous regions being centrally located such that the fibrous regions do not delaminate after formation; and
incorporating the artificial turf fiber into an artificial turf backing,
wherein the extruding comprises extruding the polymer mixture into the monofilament including a round bulge and two protrusions extending from the round bulge, wherein the fibrous regions are centrally located throughout the round bulge and the two protrusions.