Synthetic turf system made with antistatic yarns and method of making

• US 10,323,361 B1
• Filed: 06/27/2012
• Issued: 06/18/2019
• Est. Priority Date: 06/12/2011
• Status: Active Grant

• Current Assignee: One Nine Management Group, LLC
• Original Assignee: One Nine Management Group, LLC
• Inventors: Karmie, Dale, Karmie, Brian, Allen, Ty, Lee, Davis
• Primary Examiner(s): Juska, Cheryl
• Application Number:
  US13/534,992
• Time in Patent Office: 2,547 Days
• Field of Search: 428 17, 428 97, 428 87
• CPC Class Codes: D02G 3/445 Yarns or threads for use in floor fabrics floor fabrics A47G27/00; floor coverings on textile basis D06N7/0005
• CPC Class Codes: D05C 17/026 characterised by the tufted pile surface
• CPC Class Codes: D06N 2201/0254 Polyolefin fibres
• CPC Class Codes: D06N 2201/0263 Polyamide fibres
• CPC Class Codes: D06N 2201/10 Conjugate fibres, e.g. core-sheath, side-by-side
• CPC Class Codes: D06N 2203/068 Polyurethanes
• CPC Class Codes: D06N 2209/041 Conductive
• CPC Class Codes: D06N 2209/046 Anti-static
• CPC Class Codes: D06N 7/0065 characterised by the pile
• CPC Class Codes: D10B 2401/16 antistatic; conductive
• CPC Class Codes: D10B 2505/202 Artificial grass
• CPC Class Codes: E01C 13/08 Surfaces simulating grass ; Grass-grown sports grounds grass-like surfaces for skiing E01C13/12
• CPC Class Codes: Y10T 428/23921 With particles
• CPC Class Codes: Y10T 428/23936 Differential pile length or surface
• CPC Class Codes: Y10T 428/23957 Particular shape or structure of pile
• CPC Class Codes: Y10T 428/23993 Composition of pile or adhesive

Abstract

A synthetic turf system and method includes turf tufted from monofilament fibers of a thermoplastic polymer where about 1 in about 32 tuft rows comprise at least one antistatic filament per tuft. Each antistatic filament has a first nonconductive polymeric component coextensive with a second non-conductive component. One or more of the antistatic filaments substantially reduces static electrical discharge within the turf. The thermoplastic polymer for each fiber may comprise at least one of nylon, polyethylene, polypropylene, and polyester. Each tuft of the tufted turf may be twisted and each tuft may be slit to form multiple ends. The turf system may comprise stitched turf. Each antistatic filament may comprise a carbon core surrounded by a non-conductive sheath, wherein a ratio of the antistatic filament per number of tuft rows may comprise at least one of 1:2, 1:4, 1:8, and 1:16.

Claims

1. A synthetic turf system comprising:

turf tufted from monofilament fibers of a thermoplastic polymer wherein the turf is tufted according to a ratio of one row of tufts comprising an antistatic filament per a number of tuft rows, each antistatic filament having a first nonconductive polymeric component coextensive with a component of a second conductive material comprising carbon, each antistatic filament comprising a core and a sheath surrounding the core, the sheath comprising the first nonconductive polymeric component and the core comprising the second conductive material, each antistatic filament having a denier between about 50.0 to about 200.0, one or more of the antistatic filaments substantially eliminates static electrical discharge within the turf when static electrical charge is generated within the synthetic turf;

wherein the thermoplastic polymer comprises at least one of nylon, polyethylene, polypropylene, and polyester;

wherein one or more monofilament fibers of the tufts are fibrillated or slit tape monofilament fibers;

wherein the ratio of the one row of tufts comprising an antistatic filament per number of tuft rows comprises at least one of 1;

2, 1;

4, 1;

8, 1;

16, and 1;

32;

wherein the monofilament fibers of the thermoplastic polymer form synthetic grass blades; and

an infill material positioned within the synthetic grass blades.

2. The system of claim 1, wherein the infill material comprises at least one of granulated cork;

rubber particles including natural rubber or synthetic rubber;

beads of synthetic polymers comprising at least one of vinyl chloride, vinyl ethers, vinyl acetate, acrylates, methacrylates, polyvinylidene chloride, urethanes, polyamids and polyesters;

synthetic polymer foam particles;

vinyl foams including polyvinyl chloride foams, polyvinyl ether foams, foamed polystyrene, foamed polyurethanes and foamed polyesters;

foamed natural rubber;

Ethylene Propylene Diene Monomer (EPDM);

ground tire rubber; and

Thermoplastic Elastomers (TPE).

3. The system of claim 1, wherein the turf is used for at least one of commercial and residential landscapes.

4. The system of claim 3, wherein the turf is used for a playground.

5. The system of claim 1, wherein the turf is used for an athletic field.

6. A synthetic turf system comprising:

turf tufted from monofilament fibers of a thermoplastic polymer where about 1 row of tufts comprising an antistatic filament in about 32 tuft rows comprise at least one antistatic filament per tuft, each antistatic filament having a nonconductive polymeric component coextensive with a component of carbon dispersed in a polymeric matrix, each antistatic filament comprising a core and a sheath surrounding the core, the sheath comprising the first nonconductive polymeric component and the core comprising the carbon, each antistatic filament having a denier between about 50.0 to about 200.0, one or more of the antistatic filaments substantially eliminates static electrical discharge within the turf when static charge is produced within the turf;

wherein the thermoplastic polymer comprises at least one of nylon, polyethylene, polypropylene, and polyester; and

wherein monofilament fibers of each tuft are fibrillated or slit tape monofilament fibers;

wherein the monofilament fibers of the thermoplastic polymer form synthetic grass blades; and

an infill material positioned within the synthetic grass blades.

7. The system of claim 6, wherein the turf is used for at least one of commercial and residential landscapes.

8. The system of claim 7, wherein the turf is used for a playground.

9. The system of claim 7, wherein the turf is used for an athletic field.