Process for producing synthetic-grass structures and corresponding synthetic-grass structure

• US 7,264,854 B2
• Filed: 06/11/2003
• Issued: 09/04/2007
• Est. Priority Date: 06/17/2002
• Status: Expired due to Fees

• Current Assignee: Mondo S.p.A.
• Original Assignee: Mondo S.p.A.
• Inventors: Stroppiana, Fernando
• Primary Examiner(s): Zimmerman; John J.
• Assistant Examiner(s): Austin; Aaron
• Application Number:
  US10/460,549
• Publication Number:
  US 20040037975A1
• Time in Patent Office: 1,546 Days
• Field of Search: 428/15, 428/17, 428/25, 428/26, 428/542.6, 273/DIG.13, 404/17, 404/71, 156/279
• US Class Current: 428/17
• 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 428/23957 Particular shape or structure of pile

Abstract

A synthetic-grass flooring may include a substrate with multiple filiform formations extending upwards from the substrate to simulate natural-grass cover or turf. End portions of the filiform formations may be curled to bestow upon the filiform formations a general tree-like conformation. The synthetic-grass flooring may be manufactured as a finished product in a factory. A particulate filling material or infill may be retained on the substrate by the curly ends of the filiform formations.

Claims

1. A process for making a synthetic-grass covering, comprising the operation of providing a substrate with a plurality of filiform formations that extend from the substrate to simulate natural-grass cover or sward, said filiform formations being provided with respective proximal ends and distal ends with respect to the substrate, the process comprising the operation of selectively curling only said distal ends by application of a heated flow to said distal ends, bestowing upon said filiform formations a general tree-like conformation.

2. The process according to claim 1, further comprising the operation of providing said application of heat by means of a flow of a heated aeriform substance.

3. The process according to claim 1, wherein said distal ends of said filiform formations undergo curling after the synthetic-grass covering has been laid.

4. The process according to claim 1, wherein said distal ends of said filiform formations undergo curling before the synthetic-grass covering has been laid.

5. The process according to claim 1, further comprising the operation of dispersing a particulate filling material or infill amongst said filiform formations so as to maintain the latter in substantially upright conditions.

6. The process according to claim 5, further comprising the operation of dispersing said particulate infill amongst said filiform formations before subjecting said distal ends of said filiform formations to curling.

7. The process according to claim 1, further comprising the operation of making said filiform formations starting from a polyolefin material.

8. The process according to claim 1, further comprising the operation of making said filiform formations starting from a bulk-pigmented material.

9. The process according to claim 1, wherein said treatment of curling said distal ends of said filiform formations is performed without causing the setting-up of points of connection between distal ends associated to different filiform formations.

10. The process according to claim 1, wherein said treatment of curling said distal ends of said filiform formations is performed causing at least marginal connection between distal ends associated to different filiform formations.

11. The process according to claim 5, further comprising the operation of rendering at least partially cohesive said particulate infill.

12. The process according to claim 11, wherein said particulate infill is rendered at least partially cohesive by the addition of a bonding agent.

13. The process according to claim 11, wherein said particulate infill is rendered at least partially cohesive by a treatment of compacting.

14. The process according to claim 5, wherein said operation of dispersing a particulate filling material or infill and said subsequent treatment of curling of the distal ends of said filiform formations are performed as successive steps of an industrial manufacturing process.

15. The process according to claim 14, further comprising the operation of winding said synthetic-grass covering comprising said particulate infill withheld on said substrate by said tree-shaped filiform formations in the form of a material wound in rolls.

16. A synthetic-grass flooring comprising a substrate with a plurality of filiform formations extending from the substrate for simulating natural turf or sward, said filiform formations being provided with respective basically rectilinear proximal ends and respective distal ends, wherein only said distal ends are substantially curled by application of a heated flow to said distal ends, so that said filiform formations have a general tree-like conformation.

17. The synthetic-grass flooring according to claim 16, wherein said filiform formations are made of thermoplastic material.

18. The synthetic-grass flooring according to claim 16, wherein said distal ends of said filiform formations are made of material rendered curly after laying of said synthetic-grass flooring.

19. The synthetic-grass flooring according to claim 16, wherein said distal ends of said filiform formations are made of material subjected to curling before laying of said synthetic-grass flooring.

20. The synthetic-grass flooring according to claim 16, further comprising a particulate infill dispersed amongst said filiform formations so as to maintain said filiform formations in a substantially upright condition.

21. The synthetic-grass flooring according to claim 20, wherein said particulate infill is a material dispersed amongst said filiform formations before said distal ends of said filiform formations are subjected to curling.

22. The synthetic-grass flooring according to claim 16, wherein said filiform formations are made of a polyolefin material.

23. The synthetic-grass flooring according to claim 16, wherein said filiform formations are made of a bulk-pigmented material.

24. The synthetic-grass flooring according to claim 16, wherein said distal ends of said filiform formations are subjected to curling without causing points of connection between distal ends associated to different filiform formations.

25. The synthetic-grass flooring according to claim 16, wherein said distal ends of said filiform formations are subjected to curling to cause at least marginal points of connection between distal ends associated to different filiform formations.

26. The synthetic-grass flooring according to claim 20, wherein said particulate infill is at least partially cohesive.

27. The synthetic-grass flooring according to claim 26, wherein said particulate infill contains an added bonding agent.

28. The synthetic-grass flooring according to claim 26, wherein said particulate infill is a material subjected to compacting.

29. The synthetic-grass flooring according to claim 20, in the form of the finished product of an industrial manufacturing process comprising said infill withheld on said substrate by said curly distal ends of said filiform formations.

30. The synthetic-grass flooring according to claim 29, in the form of a sheet or strip material wound in rolls pre-arranged for laying on a subfloor.

31. A process for making a synthetic-grass covering, comprising the operation of providing a substrate with a plurality of filiform formations that extend from the substrate to simulate natural-grass cover or sward, said filiform formations being provided with respective proximal ends and distal ends with respect to the substrate, the process comprising the operation of selectively curling only the distal end of at least one filiform formation by subjecting at least said distal end to a first temperature greater than a second temperature of at least a portion of said at least one filiform formation.