MULTI-PURPOSE SPORTS SURFACE

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of priority under 35 U.S.C. § 119(e) to U.S. Patent Application Provisional Application Ser. No. 63/641,466, entitled “MULTI-PURPOSE SPORTS SURFACE”, filed May 2, 2024, which is hereby expressly incorporated by reference herein for all purposes.

TECHNICAL FIELD

The present disclosure relates generally to the field of sports surface constructions. More particularly, the present disclosure relates to a synthetic turf system used for sport courts.

BACKGROUND

In the rapidly growing sport of pickleball, courts are traditionally constructed using hard surface materials like asphalt or concrete. While these materials are economically viable and durable, they come with a host of significant drawbacks. Firstly, the risk of injuries is heightened on such hard surfaces, with common injuries including soft tissue damage and fractures, which are especially problematic among older players. The inherent rigidity of materials like asphalt and concrete fails to adequately absorb shocks, potentially exacerbating joint and muscle injuries.

Furthermore, these impermeable surfaces contribute to elevated surface temperatures, negatively impacting player comfort and exacerbating the urban heat island effect, thereby contributing to local climate warming. Environmental impacts extend beyond temperature issues, as the impermeability of these materials hinders water percolation, leading to inefficient water management and runoff problems that carry pollutants to local water bodies.

From an aesthetic standpoint, traditional hard courts offer little appeal, providing a functional yet uninviting playing environment. Additionally, the playability of the game is affected on hard surfaces due to inconsistent ball bounce and the abrasive nature of these courts, which can lead to quicker wear of balls and equipment.

On the other hand, the typical synthetic turf infill system consists of a shock pad under artificial turf, using rubber, sand or a combination of these materials as infill. The standard synthetic turf infill system effectively manages shock attenuation. However, the unbound particles of the standard infill will absorb the force and move. Furthermore, the standard synthetic turf infill system does not have enough elasticity, potential energy, for a ball (e.g., a tennis ball or pickleball) to bounce to the required height.

Given these challenges with traditional pickleball court surfaces, there exists a clear need for a court surface that not only reduces injury risk, lowers surface temperatures, and provides environmental benefits through improved water management but also enhances aesthetic appeal and ensures consistent playability. The present invention has many of the same characteristics of standard synthetic turf systems while adding the element of elasticity or springiness that facilitates required ball bounce and playing characteristics.

BRIEF SUMMARY

The present disclosure envisages a synthetic turf covering for use in sports courts. The synthetic turf covering includes a foundation having a topside and a bottom side; a plurality of grass-like pile filaments attached to and extending upward from the topside of the foundation; and a particulate infill disposed between the grass-like pile filaments, where the particulate infill includes both elastic and inelastic particles bound with a suitable organic or inorganic binder.

In one embodiment, a portion of the grass-like pile filaments are above the bound infill in order to give it a more natural look of grass as well as provide cushioning. In another embodiment, the bound resilient particles of the infill provide a softer surface as well as shock attenuation and springiness.

In one embodiment, the foundation includes materials selected from the group consisting of ground, gravel, sand, rubber, and combinations thereof.

In one embodiment, the foundation is angled to facilitate drainage. In still further aspects, the disclosed playing surface assemblies can be permeable to moisture.

In one embodiment, the binder initiates a curing process upon hydration. The binder creates a bound infill material. Specifically, binding the particles allows the infill to absorb force making it a safer playing surface while allowing a return of the energy to the ball for proper bounce. The bound aspect gives the surface a sort of “trampoline” effect. In contrast, the typical turf infill system consists of a shock pad under turf, rubber, sand or a combination of these materials. The standard system effectively manages shock attenuation. However, the unbound particles absorb the force and transfer the energy from particle to particle via friction and infill movement. For example, as a system standard turf install does not have enough elasticity, potential energy, for a sports ball (e.g., a pickleball) to bounce to the required height.

In one embodiment, the sport surface is a sports court. In another embodiment, the sport surface is a pickleball court that provides adequate ball bounce from the surface. In another embodiment, the sport surface is a pickleball court that provides adequate cushioning for shock absorption, without adversely affecting the ball bounce height.

In one embodiment, the infill is bound by a suitable organic or inorganic binder. A typical organic binder is selected from at least one member of the group consisting of a phenolic resole resin or phenolic novolac resin, urethanes (for example polyol resins, e.g., phenolic resin, dissolved in petroleum solvents which are cross-linkable with a polymeric isocyanate using an amine catalyst), alkaline modified resoles set by esters, melamine, and furans. Typical inorganic binders include silicates, e.g., sodium silicate, phosphates, e.g., polyphosphate glass, borates, or mixtures thereof, e.g., silicate and phosphate. Typical binders for the present invention also may be selected from polymer/cement combinations and MDF cement.

In some embodiments, the infill layer coating composition includes a binder component and a particle component. The binder component may include a cementitious binder that includes Portland cement, such as white cement or grey cement, alone or in combination with one or more supplementary cementitious materials (SCMs), such as fly ash, metakaolin, pumice, natural pozzolan, slag, or silica fume. Alternatively, or in addition to the cementitious binder, the binder component may comprise a polymer binder, such as an acrylic binder that includes an acrylic resin and/or polymer. Other polymer binders include, but are not limited to, polyvinyl alcohol (PVA), alkyd resins, polyurethane, and other materials typically used to bind particles.

Some embodiments also include geopolymer binders or cements, hydraulic cements, supplementary cementitious materials (SCMs), hydraulic concrete mixtures, and solid concrete powders including microspheroidal glassy particles as defined herein. According to some embodiments, a geopolymer cement is used, which may include a cementitious reagent as disclosed herein. The geopolymer cement may further include an ambient cure reagent, and a solid or liquid hardener. An example geopolymer cement mixture may include 40-70 wt. % cementitious reagent, 15-25 wt. % ambient cure reagent, and 5-45 wt. % solid aggregate. Some embodiments also relate to geopolymer binders or cements, hydraulic cements, supplementary cementitious materials (SCMs), hydraulic concrete mixtures, and solid concrete powders including microspheroidal glassy particles as defined herein.

In the present invention, the term “geopolymer binder” or “geopolymer cement” relates to a mixture that sets and hardens due to polycondensation. The overall hardening process is known as the “geopolymerization” process. These reactions often occur at low temperatures. The term “geopolymer” includes a material in the dry state, obtained following the hardening of a mixture containing finely ground materials (i.e. generally an alumino-silicate source) and a saline solution (i.e. an activation solution), said mixture being capable of setting and hardening over time. The hardening of the geopolymer is the result of the dissolution/polycondensation of the finely ground materials of the geopolymeric mixture in a saline solution such as a high-pH saline solution (i.e. the activation solution).

According to an implementation a method of producing geopolymer-bound infill may include providing a geopolymer binder. The geopolymer binder may include a geopolymer precursor, magnesium oxide as an alkali activator. The method may further include mixing the geopolymer binder with water. The geopolymer precursor may include a material containing amorphous silicates of one or more of calcium, aluminum, and magnesium. The geopolymer precursor may include one or more of: slag cements; fly ash; metakaolin; fumed silica; and rice husks. The geopolymer binder may include between about 10% to about 95% of the geopolymer precursor by weight of the geopolymer binder. The magnesium oxide may include magnesium oxide calcined to exhibit a caustic magnesia activity neutralization time of between about 9 seconds to about 30 seconds using a 1.0N acetic acid. The magnesium oxide may exhibit a magnesium oxide purity from between about 75% to about 99%. The geopolymer binder may include between about 1% to about 50% magnesium oxide by weight of the geopolymer binder. The geopolymer binder may further include a co-alkali activator. The co-alkali activator may include one or more of: sodium silicate; potassium silicate; sodium metasilicate having a formula Na₂SiO₃; .nH₂O, where n=one of 5, 6, 8, 9; sodium hydroxide; sodium aluminate; sodium carbonate; hydrated lime; quick lime; dolime; hydrated dolime; potassium oxide; lithium oxide; alumina; iron oxide; nickel oxide; copper oxide; sodium lactate; ordinary Portland cement; and calcium gluconate. The geopolymer binder may include an amount of co-alkali activator that is equal to or less than an amount of the magnesium oxide by weight.

In one embodiment, the geopolymer binder composition is a precursor composition of a geopolymer. In other words, it comprises ingredients (e.g., aluminosilicate, alkaline silicate, water, alkaline base, metakaolin, etc.) which geopolymerize together (by polycondensation) to form a geopolymer, also known as geopolymer material, as defined in the invention.

In one embodiment, the geopolymer binder is an aluminosilicate geopolymer composition. In another embodiment, the geopolymer binder is a geopolymer composition comprising water, silicon (Si), aluminum (Al), oxygen (O), and at least one element selected from potassium (K), sodium (Na), lithium (Li), cesium (Cs), and calcium (Ca), and preferably selected from potassium (K) and sodium (Na). In another embodiment, the geopolymer binder composition may comprise at least an aluminosilicate, an alkali metal silicate, water, and optionally an alkaline base. In one embodiment, the aluminosilicate can be selected from metakaolins (i.e. calcined kaolins), fly ash, blast furnace slag, swelling clays such as bentonite, calcined clays, any type of compound comprising aluminum and silica fume, zeolites, and a mixture thereof.

In the invention, “metakaolin” means a calcined kaolin or a dehydroxylated aluminosilicate. It is preferably obtained by dehydration of kaolin or of a kaolinite. This dehydration is conventionally obtained by calcination.

In one embodiment, the geopolymer composition may comprise from 5% to 50% by weight approximately of aluminosilicate, and preferably from 10% to 35% by weight approximately of aluminosilicate, relative to the total weight of the geopolymer composition.

In one embodiment, the binder can be polymer based or cementitious materials, such as Portland cement, silica fume (microsilica), fly ash, lime, etc. In one embodiment, the binder is powdered or liquid solution polymer binders that are designed to bind soil and other particles such as DirtGlue® polymers produced by GES/Global Environmental Solutions.

The term “particle” as used herein refers to any shaped single element of the materials and volume specified. The mean size of the particles refers to the largest dimension of a given particle and the mean is the arithmetic mean. Preferably the mean size of the particles will lie between 0.5 mm and 5 mm and preferably no particles will have dimensions greater than 10 mm. Alternatively, the particles may be defined in terms of mesh size as defined by EN 933-1 In one embodiment at least 90% by weight of the particles are retained by a 0.5 mm sieve, while at least 90% of particles will pass through a 5 mm sieve. In one embodiment, the particulate infill comprises particles with a granule size ranging from about 0.2 mm to 6 mm. In another embodiment, the particulate infill comprises particles with a granule size ranging from about 0.5 mm to 5 mm. In another embodiment, the particulate infill comprises particles with a granule size ranging from 1 mm to 5 mm.

The particles may be of any shape, both defined and undefined, similar, different or random. The particle shape will depend on the process of manufacture and on the intended functional performance. In certain embodiments, one or a combination of any of spherical, cuboidal, cylindrical, lozenge or lenticular shapes may be chosen.

In one embodiment, the particulate infill is applied to a depth that is between 10% and 95% of the average height of the grass-like filaments.

The height of the infill may vary by design and also the pile height. A typical infill height is from about 10 mm to about 50 mm. The infill height is designed to provide adequate weight of the infill per square area of the infill to provide a stabilized playing surface.

In one embodiment, the particulate infill particles are applied at about ¼ lbs to about 9 lbs per square foot, depending on specific infill materials bulk density. For example, a particulate infill that includes cork particles will have a lower bulk density than an all sand infill.

As indicated above, the infill may comprise various relative amounts of binder, infill particle material and further optional components as determined by the required properties. In one embodiment, the infill comprises from 50 to 99 wt % of the particle material and from 1 to 50 wt. % binder, from 2 to 15 wt. % binder, more preferably from 5 wt % to 10 wt % binder.

In certain embodiments, the composition comprises a mixture of from 25 to 95 volume percent resilient particles and from 5 to 75 volume percent fine sand interspersed among the pile elements, wherein said resilient particles comprise cork granules or rubber particles, wherein said rubber is natural rubber or a synthetic rubber selected from the group consisting of styrene-butadiene rubber, butyl rubber, cis-polyisoprene rubber, neoprene rubber, nitrile rubber and urethane rubber.

In one embodiment, the particulate infill comprises materials selected from the group consisting of sand, rubber granules, cork granules, polymer beads, ceramic beads, zeolite powder, bio-based material, crushed coral, diatomaceous earth, vermiculate particles, soil, and combinations thereof.

A “bio-based material” as used herein is a material wholly or partly derived from materials of biological origin. In particular, bio-based materials can be materials which predominantly (>50 wt. %) comprise or consist of biodegradable and/or compostable materials, and, in some embodiments, materials only consisting of compostable materials. Examples include cork particles and fragments of fruit pits and nut shells.

In one embodiment, the particulate infill substantially comprises cork particles mixed with liquid or dry powdered binder, which cure upon hydration. In one embodiment, the particulate infill is substantially homogeneous.

The present disclosure also envisages a method for installing a synthetic turf covering on a sports court. The method includes the steps of providing a foundation with a topside and a bottom side; attaching a plurality of grass-like pile filaments to the topside of the foundation such that the filaments extend upward; dispersing a particulate infill among the grass-like pile filaments, the particulate infill comprising elastic and inelastic particles and a binder; and applying a liquid to the particulate infill to initiate curing of the binder.

In one embodiment, the particulate infill is applied to a depth that is between 10% and 95% of the average height of the grass-like filaments.

In one embodiment, the foundation comprises materials selected from the group consisting of ground, gravel, sand, rubber, and combinations thereof.

In one embodiment, the particulate infill further comprises materials selected from the group consisting of sand, rubber granules, cork granules, polymer beads, ceramic beads, zeolite powder, crushed coral, diatomaceous earth, vermiculate particles, soil, and combinations thereof. In another embodiment, the particulate infill further comprises materials selected from the group consisting of cork, hemp, bamboo, and coconut coir (fiber).

In one embodiment, the particulate infill is substantially homogeneous.

In one embodiment, the grass-like pile filaments are made from materials selected from the group consisting of polyethylene, nylon, and polypropylene.

In one embodiment, the backing layer comprises a woven or non-woven fabric coated with a rubber-type material.

In one embodiment, the playing surface assembly has a surface impact attenuation (gmax) ranging from 100 to 250. In another embodiment, the playing surface assembly has a surface impact attenuation (gmax) ranging from 150 to 250. In another embodiment, the playing surface assembly has a surface impact attenuation (gmax) at least 100. In another embodiment, the playing surface assembly has a surface impact attenuation (gmax) at most 200. In another embodiment, the playing surface assembly has a surface impact attenuation (gmax) ranging from 50-200.

In one embodiment, the Gmax value of the playing field for lower impact sports would be selected to be within a range of about 115-200, with a more preferred range being about 135-165. For higher impact sports, a preferred Gmax value of the playing field would be about 90-160, with a more preferred range being about 100-145. In another embodiment, the Gmax value of the playing field be selected to be within a range of about 50 to about 160. In another embodiment, the Gmax value of the playing field be selected to be within a range of about 80 to about 145. In another embodiment, the Gmax value of the playing field be selected to be within a range of about 115 to about 200. In another embodiment, the Gmax value of the playing field be selected to be within a range of about 135 to about 165.

In one embodiment, the playing surface assembly has drainage, according to ASTM BS 7044 Method 4 (Determination of infiltration rate-buffered ponding-type infiltrometer) of greater than 10, 15, 20 inches of water per hour (in/hr) or more, preferably, greater than 25 in/hr. In another embodiment, the playing surface assembly has drainage of 10-60 in/hr. In another embodiment, the playing surface assembly has drainage of at least 5, 10, 15, 20 or more in/hr.

In one embodiment, the backing layer is flexible enough to conform to the topography of the underlying foundation.

BRIEF DESCRIPTION OF THE DRAWINGS

The description of the illustrative embodiments can be read in conjunction with the accompanying figures. It will be appreciated that for simplicity and clarity of illustration, elements illustrated in the figures have not necessarily been drawn to scale. For example, the dimensions of some of the elements are exaggerated relative to other elements. Embodiments incorporating teachings of the present disclosure are shown and described with respect to the figures presented herein, in which:

FIG. 1 illustrates a schematic view of a synthetic turf covering on a sports court, in accordance with an embodiment of the present subject matter.

FIG. 2 illustrates a block diagram depicting a method 200 for installing a synthetic turf covering on a sports court, in accordance with an embodiment of the present disclosure.

DETAILED DESCRIPTION

In the following detailed description of exemplary embodiments of the disclosure, specific exemplary embodiments in which the disclosure may be practiced are described in sufficient detail to enable those skilled in the art to practice the disclosed embodiments. For example, specific details such as specific method orders, structures, elements, and connections have been presented herein. However, it is to be understood that the specific details presented need not be utilized to practice embodiments of the present disclosure. It is also to be understood that other embodiments may be utilized and that logical, architectural, programmatic, mechanical, electrical and other changes may be made without departing from general scope of the disclosure. The following detailed description is, therefore, not to be taken in a limiting sense, and the scope of the present disclosure is defined by the appended claims and equivalents thereof.

References within the specification to “one embodiment,” “an embodiment,” “embodiments”, or “one or more embodiments” are intended to indicate that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present disclosure. The appearance of such phrases in various places within the specification are not necessarily all referring to the same embodiment, nor are separate or alternative embodiments mutually exclusive of other embodiments. Further, various features are described which may be exhibited by some embodiments and not by others. Similarly, various requirements are described which may be requirements for some embodiments but not other embodiments.

Ranges can be expressed herein as from “about” one particular value, and/or to “about” another particular value. When such a range is expressed, another aspect includes from the one particular value and/or to the other particular value. Similarly, when values are expressed as approximations, by use of the antecedent “about,” it will be understood that the particular value forms another aspect. It will be further understood that the endpoints of each of the ranges are significant both in relation to the other endpoint, and independently of the other endpoint. Optionally, in some aspects, when values are approximated by use of the antecedent “about,” it is contemplated that values within up to 15%, up to 10%, up to 5%, or up to 1% (above or below) of the particularly stated value can be included within the scope of those aspects. Similarly, in some optional aspects, when values are approximated by use of the term “substantially” or “substantially equal,” it is contemplated that values within up to 15%, up to 10%, up to 5%, or up to 1% (above or below) of the particular value can be included within the scope of those aspects. As used herein, the terms “optional” or “optionally” mean that the subsequently described event or circumstance may or may not occur, and that the description includes instances where said event or circumstance occurs and instances where it does not.

FIG. 1 illustrates an exemplary embodiment of a synthetic turf covering or sport surfacing 10, in accordance with an embodiment of the present disclosure. In an embodiment, the synthetic turf covering 10 comprises multiple layers and components, where each layer and component contribute to the overall performance and utility of the covering.

In accordance with an embodiment of the present disclosure the synthetic turf covering 10 is provided on a foundation layer 15. The foundation layer 15 is a structural base and is composed of various materials that may include, but are not limited to, bare ground, paving, gravel, sand, rubber, or a combination thereof with stones or similar aggregates. In accordance with one or more embodiments, the aforementioned materials are selected to ensure appropriate support and drainage for the synthetic turf covering. In alternative embodiments, foundation layer 15 might comprise engineered composites designed to optimize load distribution and water management. Options could include recycled materials, geotextiles, and advanced polymers that complement or replace the traditional materials to provide enhanced performance characteristics.

As used herein, the “performance characteristics” of the playing surface assembly can include, for example and without limitation, g-max, head injury criterion (HIC), Advanced Artificial Athlete (AAA) (e.g., vertical deformation, force reduction, and energy restitution), shear vane, rotational traction, and combinations thereof. Other exemplary performance characteristics of the playing surface assembly include moisture content (measured as volumetric water content), friction (measured in accordance with the procedure of ASTM F1015-03), and ball bounce and pace, which can be determined using conventional video analysis in accordance with conventional methods. Optionally, a playability assessment tool can measure certain performance properties of playing surfaces as disclosed herein. The playability assessment tool can determine a quantifiable playability score for fields (e.g., sports fields, surfaces or turf). The playability of a field, or sports surface, relates to the way in which objects and players interact with the surface. Various factors, including the surface hardness, stability, strength, moisture, composition, and other factors can affect the overall playability of a surface.

In some embodiments, the foundation layer 15 may be configured with a slight gradient to direct water toward strategically positioned drainpipes (not shown in FIG. 1), thereby enhancing the drainage and expedited drying of the synthetic turf covering 10 after rain or the melting of snow. In an embodiment, the gradient is not a steep incline but is enough to influence the flow of water towards drainpipes, which, although not depicted, are precisely placed to facilitate this function. The implementation of the gradient improves the drainage system's efficiency, thereby promoting a faster drying surface of synthetic turf covering 10 following wet weather conditions such as rain or when snow melts.

In accordance with one embodiment, a backing layer 20 is provided upon the foundation layer 15. The backing layer 20 has a bottom side 22 and a top side 24. In one embodiment, the backing layer 20 may comprise any suitable woven or non-woven fabric known in the art, with grass-like filaments 30 affixed thereto. In accordance with exemplary embodiments, the backing layers may employ woven warp strands and cross or weft strands, forming a woven sheet which can optionally be coated with a rubber-type material on the topside 24, the bottom side 22, or both. The preferred materials for backing layer 20 include stable, weather-resistant substances such as polypropylene, nylon, or a comparable synthetic material.

The synthetic grass-like filaments (fibers) are generally composed of polyethylene, polypropylene or nylon. The fibers are for example single fibers or multiple fibers but also a mixture of multiple fibers and single fibers may be used. The thickness of the fibers may vary. However also a mix of thick and thin fibers is possible. The general criteria for making the backing sheet and the fibers are known in the art, and hence do not require a detailed description.

The term “backing” as used herein includes both primary backing materials and secondary backing materials. The term “backing” refers to any conventional backing material that can be applied to a tufted product, such as a woven, a non-woven, a knitted, a needle punched fabric, as well as a stitch bonded primary backing material. As one skilled in the art will appreciate, materials such as polypropylene, polyesters, hemp, composites, blend, nylons, or cottons can be used to form the backing material.

In certain embodiments, the primary backing layer is a woven textile such as PET (polyethylene terephthalate) or PP (polypropylene) woven textiles or geotextile fabrics. Pet woven geotextile fabric is woven geo fabric made from high tenacity, low elongation material of multifilament polyester yarns to form a stable structure. The woven textiles are generally from about 2 to about 8 ounces per square yard.

In certain embodiments, the secondary backing layer is a latex polyurethane textile or geotextile fabric. The secondary backing layer generally from about 12 to about 24 ounces per square yard. In yet other aspects, the nonwoven backing layer can comprise any fibers known in the art. In certain aspects, the fibers are polymeric fibers. In yet other aspects, the fibers are natural fibers. In still other aspects, the fibers are biodegradable fibers. In yet certain aspects, the fibers are degradable fibers. In still further aspects, the fibers can comprise polyester fibers, polyolefin fibers, polyamide fibers, polyurethane fibers, acrylic fibers, or any other fibers known in the art. In some aspects, the nonwoven backing material is comprised of the fibers comprising at least one of nylon, polyester, polyethylene, and polypropylene, cotton, Kenaf, jute, or any combination thereof.

In certain embodiments, the nonwoven backing layer can have a thickness between about 1/16 inch to about 2.5 inches, including exemplary values of about ⅛ inch, about ¼ inch, about ½ inch, about ¾ inch, about 1 inch, about 1.2 inch, about 1.5 inch, about 1.7 inch, about 2 inch, about 2.2 inch, and about 2.4 inch. It is understood that the nonwoven backing layer can have any thickness value between any foregoing values.

In still further aspects, the nonwoven backing layer can have a thickness from about 1/16 inch to about 2.5 inches and a density from about 3 lbs/ft³ to about 30 lbs/ft³.

In still further aspects, the nonwoven backing layer can be further capped with a mesh, scrim, or felt. The mesh, scrim, or felt can be optionally added to either the face side and/or the back side of the nonwoven backing layer. In still further aspects, the artificial turf can further comprise a secondary backing. In such aspects, the secondary backing can be attached to the nonwoven backing layer to either the face side and/or the back side of the nonwoven backing layer. In yet other aspects, the secondary backing can be attached by any methods known in the art, including, for example, through the coating, lamination, extrusion, and the like.

In certain aspects, the secondary backing can comprise various layers and coatings. Such exemplary backings can comprise extruded polymer sheets, laminated films, calendered hot melts and glues, latex, crosslinked polyurethanes, woven layer(s), meshes and scrims, or any combination thereof. In still further aspects, the secondary backing can comprise a film that can be laminated to the back side of the nonwoven backing layer to thermobond the turf fibers to themselves.

As disclosed herein, the playing surface assemblies comprise a plurality of reinforcement or artificial turf fibers or yarns. In certain aspects, a plurality of grass-like filaments 30 are gravitationally laid on the face side of the nonwoven backing layer, and subsequently, needlepunched through the fibers. In such aspects, wherein the plurality of grass-like filaments 30 are added to the nonwoven backing layer, the denier of the fibers present in the nonwoven backing layer can be from about 2 denier to about less than 20,000 denier including exemplary values of about 10 denier, about 50 denier, about 100 denier, about 200 denier, about 500 denier, about 800 denier, about 1,000 denier, about 1,500 denier, about 2,000 denier, about 2,500 denier, about 3,000 denier, about 3,500 denier, about 4,000 denier, about 4,500 denier, about 5,000 denier, about 5,500 denier, about 6,000 denier, about 6,500 denier, about 7,000 denier, about 7,500 denier, about 8,000 denier, about 8,500 denier, about 9,000 denier, about 9,500 denier, about 10,000 denier, about 10,500 denier, about 11,000 denier, about 11,500 denier, about 12,000 denier, about 12,500 denier, about 13,000 denier, about 13,500 denier, about 14,000 denier, about 14,500 denier, about 15,000 denier, about 15,500 denier, about 16,000 denier, about 16,500 denier, about 17,000 denier, about 17,500 denier, about 18,000 denier, about 18,500 denier, about 19,000 denier, about 19,500 denier, and less than 20,000 denier. In still further aspects, the fibers can have any denier value between any two foregoing denier values. It is understood that in some exemplary aspects, a fiber can be characterized as a multifilament bundle. In still other exemplary aspects, the fiber can be characterized as a single filament.

It is understood that the plurality of grass-like filaments 30 can comprise any fibers known in the art and conventionally utilized in the artificial turfs. In yet other aspects, the plurality of fibers comprise tufted fibers. In still further aspects, the plurality of fibers comprise staple fibers. In still further aspects, the plurality of fibers are comprised of slit film fibers, monofilaments, or texturized fibers.

In yet other aspects, the plurality of grass-like filaments 30 present in the disclosed playing surface assemblies can have any length predetermined by one of ordinary skill in the art and based on the specific application. In still further aspects, the plurality of grass-like filaments 30 can have a length from about 0.25 inches to about 6 inches, including exemplary values of about 0.5 inches, about 0.75 inches, about 1 inch, about 1.25 inches, about 1.5 inches, about 1.75 inches, about 2 inches, about 2.25 inches, about 2.5 inches, about 2.75 inches, about 3 inches, about 3.25 inches, about 3.5 inches, about 3.75 inches, about 4 inches, about 4.25 inches, about 4.5 inches, about 4.75 inches, about 5 inches, about 5.25 inches, about 5.5 inches, and about 5.75 inches. It is understood that the plurality of grass-like filaments 30 can have any length value between any two foregoing values.

In still further aspects, the plurality of grass-like filaments 30 present in the disclosed playing surface assemblies can have any denier predetermined by one of ordinary skill in the art and based on the specific application. In some aspects, the plurality of fibers can have a denier value from about 3 denier to about 20,000 denier, including exemplary values of about 5 denier, about 10 denier, about 20 denier, about 30 denier, about 40 denier, about 50 denier, about 60 denier, about 70 denier, about 80 denier, about 90 denier, about 100 denier, about 200 denier, about 300 denier, about 400 denier, about 500 denier, about 600 denier, about 700 denier, about 800 denier, about 900 denier, about 1,000 denier, about 1,500 denier, about 2,000 denier, about 2,500 denier, about 3,000 denier, about 3,500 denier, about 4,000 denier, about 4,500 denier, about 5,000 denier, about 5,500 denier, about 6,000 denier, about 6,500 denier, about 7,000 denier, about 7,500 denier, about 8,000 denier, about 8,500 denier, about 9,000 denier, about 9,500 denier, about 10,000 denier, about 10,500 denier, about 11,000 denier, about 11,500 denier, about 12,000 denier, about 12,500 denier, about 13,000 denier, about 13,500 denier, about 14,000 denier, about 14,500denier, about 15,000 denier, about 15,500 denier, about 16,000 denier, about 16,500 denier, about 17,000 denier, about 17,500 denier, about 18,000 denier, about 18,500 denier, about 19,000 denier, about 19,500 denier, and less than 20,000 denier. In still further aspects, the fibers can have any denier value between any two foregoing denier values. For example and without limitation, in aspects where the slit film fibers are present, the fiber denier is from about 100 denier to about 15,000 denier. In yet other exemplary aspects, where the monofilament fibers are present, the fiber denier is from about 3 denier to about 3,000 denier. In certain exemplary aspects, the small denier fibers from about 3 denier to about 500 denier can act as binding fibers, to add cushion, or to provide support along the base of the slit film fibers to assist them in standing rather than laying over onto the nonwoven backing layer.

The plurality of grass-like filaments 30 can comprise any material that is conventionally used in the artificial manufacturing, singly or in a combination with other such materials. For example, and without limitation, the plurality of fibers can be synthetic, such as, for example, a material comprising one or more of a conventional nylon, polyester, polypropylene (PP), polyethylene (PE), polyurethane (PU), polyvinyl chloride (PVC), polyethylene terephthalate (PET), polypropylene terephthalate (PPT), polybutylene terephthalate (PBT), polytrimethylene terephthalate (PTT), or any combination thereof. In still further aspects, the plurality of grass-like filaments 30 can comprise polymeric fibers comprising at least one of nylon, polyester, polyethylene, and polypropylene. In some exemplary aspects, the plurality of fibers can comprise one or more of the biodegradable materials, including, for example, and without limitation, polylactic acid (PLA). In still further aspects, the plurality of grass-like filaments 30 can comprise a combination of any of the materials mentioned above. In still further aspects, a portion of the back side fibers of the playing surface assemblies described herein can be bonded to themselves via an adhesive coating. In such aspects, the adhesive coating can be any adhesive coating known in the art.

In one embodiment, the grass-like filaments 30 are vertically oriented relative to the horizontal backing material, meaning that the polymer fibers extend substantially upward and away from the backing layer. The vertical polymer fibers can have any suitable length. In one embodiment, the fibers have a length sufficient to provide a pile height of about ½″ (12 mm) to about 1″ (26 mm), or about ½″ (12 mm) to about ⅝″ (16 mm).

In alternative embodiments, backing layer 20 may comprise advanced textiles that incorporate smart materials capable of responding to environmental stimuli, such as changes in temperature or moisture. These smart materials may provide additional benefits, such as enhancing player comfort or further improving the durability of the synthetic turf covering. In one embodiment, the backing layer 20 is designed to be supple and capable of conforming to the contours of foundation layer 15. Furthermore, the backing layer 20 may be configured to absorb impacts, thereby providing additional safety features for users.

In one embodiment, the grass-like filaments 30 project upward from backing layer 20, which may be individual or grouped filaments securely attached to the backing layer 20 (as shown in FIG. 1). In one embodiment, the grass-like filaments 30 can be split at their ends to create the appearance of natural grass. In accordance with the present disclosure, the grass-like filaments 30 are made from materials including, but not limited to, polyethylene, nylon, polypropylene, or similar synthetics, selected for their durability and resemblance to natural grass.

In alternative embodiments, the grass-like filaments 30 could also incorporate bi-component or composite fibers, which utilize a combination of materials to optimize performance characteristics like resilience, colorfastness, and UV resistance. Such fibers may further improve the playing experience and extend the service life of the synthetic turf covering.

The disclosed playing surface assemblies can optionally comprise a primary backing disposed between the plurality of fibers and the nonwoven backing layer. In aspects where the primary backing is present, the primary backing comprises a polyolefin, a polyester, a polyamide, or a combination thereof. In such aspects, the primary backing can be woven and non-woven. In certain aspects, the primary backing can comprise non-woven webs, or spunbonded materials. In some aspects, the primary backing can comprise a combination of woven and non-woven materials. In some aspects, the primary backing comprises a polyolefin polymer. In other aspects, the polyolefin polymer comprises polypropylene.

Following the installation of backing layer 20 with grass-like filaments 30 upon foundation layer 15, a particulate infill 40 is added to the synthetic turf covering 10.

The particulate infill 40 layer, comprising the above-discussed granules, is placed above the backing layer 20. The infill layer may have granules provided in the range of 0.5-10 1b/ft², depending on the infill material. For example, cork particles are lighter and hence, are lower in weight per square foot. In another embodiment, the infill layer has granules provided in the range of preferably 1-9 lb/ft². In another embodiment, the infill layer has granules provided at less than about 9 lb/ft², less than about 8 lb/ft², less than about 7 lb/ft², less than about 6 lb/ft², l or less than about 5 1b/ft².

In accordance with an embodiment of the present disclosure, the depth to which the particulate infill 40 is applied may vary, preferably from about 10% to about 95% of the average height of the grass-like filaments 30. In accordance with a preferred embodiment, the depth to which the particulate infill 40 is applied ranges from about 25% to about 75% of the average height of the grass-like filaments 30.

In accordance with an embodiment of the present disclosure, the depth to which the particulate infill 40 is applied according to the length of the turf blade filament and the portion of the turf blade filament that is left above the infill surface when in place. In one embodiment, the particulate infill 40 is applied such that the tips of the grass-like filaments 30 are on average about 1/64″ to ¾″ above the surface of the infill matrix. In one embodiment, the particulate infill 40 is applied such that the tips of the grass-like filaments 30 are on average about 1/16″ to ½″ above the surface of the infill matrix. In another embodiment, the particulate infill 40 is applied such that the tips of the grass-like filaments 30 are on average about ⅛″ to ⅜″ above the surface of the infill matrix (the particulate infill 40 after activation or curing of the binder). In another embodiment, the particulate infill 40 is applied such that the tips of the grass-like filaments 30 are on average about ⅛″ to ⅜″ above the surface of the infill matrix (the particulate infill 40 after activation or curing of the binder). In another embodiment, the particulate infill 40 is applied such that the tips of the grass-like filaments 30 are on average at least 1/64, 1/32, 1/16, ⅛, ¼, ⅜, ½, ⅝, or ¾ inches or more above the surface of the infill matrix. In another embodiment, the particulate infill 40 is applied such that the tips of the grass-like filaments 30 are on average at most 1/64, 1/32, 1/16, ⅛, ¼, ⅜, ½, ⅝, or ¾ inches or more above the surface of the infill matrix.

In one embodiment, the particulate infill 40 is applied from about 10% to about 90% of the average height of the grass-like filaments 30. In alternate embodiments, the particulate infill 40 is applied to at least about 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, 98, or 100% of the average height of the grass-like filaments 30. In other embodiments, the particulate infill 40 is applied to at most about 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, 98, or 100% of the average height of the grass-like filaments 30.

In accordance with an embodiment of the present disclosure, the depth to which the particulate infill 40 is applied is from about 0.25-3.5 inches in depth. In another embodiment, the depth to which the particulate infill 40 is applied is from about 0.5 to about 2.5 inches in depth. In another embodiment, the depth to which the particulate infill 40 is applied is from about 0.75 to about 2 inches in depth. In another embodiment, the depth to which the particulate infill 40 is applied is from about 0.75 to about 1.5 inches in depth. In one embodiment, the depth to which the particulate infill 40 is applied is at least 0.1, 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, 1, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, 2, 2.1, 2.2, 2.3, 2.4, 2.5 inches or more. In one embodiment, the depth to which the particulate infill 40 is applied is at most 0.1, 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, 1, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, 2, 2.1, 2.2, 2.3, 2.4, 2.5 inches or less.

In alternative embodiments, the composition and granule size of the particulate infill 40 may differ to cater to specific performance requirements or environmental conditions. Such variations might include different types of cushioning agents, thermal conductive materials, or water-retentive substances to enhance the functionality of the synthetic turf covering 10.

In an exemplary synthetic turf construction, the face grass-like filaments 30 can make up from about 10 wt % to about 80 wt % of the overall synthetic turf, including exemplary values of about 20 wt %, about 30 wt %, about 40 wt %, about 50 wt %, about 60 wt %, and about 70 wt %. The primary backing material can make up from about 1 wt % to about 25 wt % of a synthetic turf, including exemplary values of about 5 wt %, about 10 wt %, about 15 wt %, and about 20 wt %. The adhesive backing material can make up from about 15 wt % to about 80 wt % of a synthetic turf, including exemplary values of about 20 wt %, about 30 wt %, about 40 wt %, about 50 wt %, about 60 wt %, and about 70 wt %.

In exemplary embodiments set forth by the present disclosure, the composition of particulate infill 40 is a blend of both elastic and inelastic particles. More precisely, particulate infill 40 may comprise materials such as sand, rubber granules, ceramic beads, and soil, cork individually or in any conceivable combination. These components are amalgamated with one or more types of dry powdered binders specifically engineered to activate a curing process upon contact with moisture. Once particulate infill 40, inclusive of the binder, is adequately hydrated, the curing sequence is initiated.

In exemplary embodiments set forth by the present disclosure, the surface comprises an infill layer of a particulate infill 40 dispersed throughout and between the vertical polymer fibers and over the backing material. The infill material is a particulate material, and can be any infill material that can be in-filled between the vertical polymer fibers, provided that the infill layer gives surface playability characteristics suitable for bocce play. Suitable materials include as natural and synthetic sand (e.g., silica, quartz, glass, or polymer sand). In some embodiments the infill material comprises about 0% to about 50% or more (e.g., about 65% or more, about 75% or more, 85% or more, or 90% or more) sand. In some embodiments, the sand is a sub-angular sand, particularly a sub-angular quartz or silica sand.

In other exemplary embodiments, the surface comprises an infill layer of a particulate infill 40 dispersed throughout and between the vertical polymer fibers and over the backing material wherein the infill comprises from about 90 to about 95% cork particles having an average size range of 40/80 mesh to 3/8 mesh and from about 5 to about 10% polymer binder. In other exemplary embodiments, the polymer binder is a geopolymer binder.

In other exemplary embodiments, the surface comprises an infill layer of a particulate infill 40 dispersed throughout and between the vertical polymer fibers and over the backing material wherein the infill comprises from about 50 to about 60% cork particles having an average size range of about 40/80 mesh to about 3/8 mesh, from about 20 to about 40% sand particles having an average size range of about 10/20 mesh to about 40/80 mesh, and from about 10 to about 20% cementeous binder. In other embodiments,

In other exemplary embodiments, the surface comprises an infill layer of a particulate infill 40 dispersed throughout and between the vertical polymer fibers and over the backing material wherein the infill comprises from about 60 to about 80% cork particles having an average size range of about 40/80 mesh to about 3/8 mesh, from about 15 to about 25% sand particles having an average size range of about 10/20 mesh to about 40/80 mesh, and from about 5 to about 15% polymer binder. In other exemplary embodiments, the polymer binder is a geopolymer binder.

In another exemplary embodiment, the infill layer coating composition includes a binder component and a particle component. In some embodiments, the binder component includes a cementitious binder, such as white Portland cement. Although some embodiments may include ordinary (grey) Portland cement, the cementitious binder component is may include other compounds. A supplementary cementitious material may optionally be included, examples of which include fly ash, ground granulated blast furnace slag (GGBFS), metakaolin, silica fume, pumice, ground glass, and natural pozzolan. The cementitious binder component may make up about 1% to 45%, or about 5% to 40% (e.g., about 25% to 35%) of the weight of the infill composition (excluding water).

Examples of other cementitious binders include calcium aluminate cement (CAC), magnesium oxychloride cement, CSA cement (calcium sulphate aluminate cement), phosphate cement, silicate cement, geopolymer cement, and alkali-activated slags and pozzolans. Alternatively, or in addition to the cementitious binder, the binder component may comprise a polymer binder, such as an acrylic binder that includes an acrylic resin and/or polymer. Other polymer binders include, but are not limited to, polyvinyl alcohol (PVA), alkyd resins, polyurethane, and other materials typically used to bind particles.

Examples of other cementitious binders include polymer modified concrete, polymer modified cement plaster, polymer modified geopolymer or polymer modified mortar. Polymer modified concrete, cement plaster, geopolymer or mortar is known in the art and comprises a conventional concrete, plaster, geopolymer or mortar mix to which a polymer is added in a polymer-to-cement ratio of 0.1% to 50% by weight, preferably 0.1% to 25% by weight, more preferably approximately 1% to 25% by weight, most preferably approximately 5% to approximately 20% by weight. Polymer modified concrete can be made using the polymer amounts shown above in any of the concrete formulations shown below. Polymers suitable for addition to concrete, plaster or mortar mixes come in many different types: thermoplastic polymers, thermosetting polymers, elastomeric polymers, latex polymers and redispersible polymer powders. A preferred thermoplastic polymer is an acrylic polymer. Latex polymers can be classified as thermoplastic polymers or elastomeric polymers. Latex thermoplastic polymers include, but are not limited to, poly(styrene-butyl acrylate); vinyl acetate-type copolymers; e.g., poly(ethyl-vinyl acetate) (EVA); polyacrylic ester (PAE); polyvinyl acetate (PVAC); and polyvinylidene chloride (PVDC). Latex elastomeric polymers include, but are not limited to, styrene-butadiene rubber (SBR); nitrile butadiene rubber (NBR); natural rubber (NR); polychloroprene rubber (CR) or Neoprene; polyvinyl alcohol; and methyl cellulose. Redispersible polymer powders can also be classified as thermoplastic polymers or elastomeric polymers. Redispersible thermoplastic polymer powders include, but are not limited to, polyacrylic ester (PAE); e.g., poly (methyl methacrylate-butyl acrylate); poly(styrene-acrylic ester) (SAE); poly (vinyl acetate-vinyl versatate) (VA/VeoVa); and poly(ethylene-vinyl acetate) (EVA). Redispersible elastomeric polymer powders include, but are not limited to, styrene-butadiene rubber (SBR). Preferred polymers for modifying the concrete, plaster or mortar mixes of the present invention are polycarboxylates. Geopolymers are generally formed by reaction of an aluminosilicate powder with an alkaline silicate solution at roughly ambient conditions. Metakaolin is a commonly used starting material for synthesis of geopolymers, and is generated by thermal activation of kaolinite clay. Geopolymers can also be made from sources of pozzolanic materials, such as lava, fly ash from coal, slag, rice husk ash and combinations thereof.

In other exemplary embodiments, the infill layer binder may include a cementitious binder that includes Portland cement, such as white cement or grey cement, alone or in combination with one or more supplementary cementitious materials (SCMs), such as fly ash, metakaolin, pumice, natural pozzolan, slag, or silica fume. Alternatively, or in addition to the cementitious binder, the binder component may comprise a polymer binder, such as an acrylic binder that includes an acrylic resin and/or polymer. Other polymer binders include, but are not limited to, polyvinyl alcohol (PVA), alkyd resins, polyurethane, and other materials typically used to bind particles.

In another exemplary embodiment, the infill layer binder is a metakaolin-based geopolymer.

The term “sand” refers to any granular material formed by the disintegration of rocks to form particles smaller than gravel but coarser than silt. The sand employed in the manufactured surface composition may be of any common type or grade, such as silica sand, with the choice determined by availability and cost. In a specific embodiment, the sand may be dried or pre-heated to dry it before the mixing step. The average particle size (in diameter) of the sand may vary widely. In one embodiment, the sand will pass substantially through a number 7 U.S. mesh screen while being retained substantially on a number 200 U.S. mesh screen. In one or more embodiments, the sand is ASTM C33 all-purpose sand that ranges in size from about 4.75 mm to about a #200 sieve.

The infill material can have a size suitable for infilling between the polymer fibers. In some embodiments, the particles of the infill material can have a particle size distribution such that about 65% or more of the particles (e.g., about 70% or more, about 75% or more, about 80% or more, or even about 85% or more), by weight, pass through a sieve size of about #50 (about 0.3 mm). Optionally, about 85% or more of the particles (e.g., about 90% or more, about 95% or more, or about 97% or more), by weight, pass through a sieve size of about #40 (about 0.4 mm). Alternatively, or in addition, the infill particulate can have a particle size distribution such that about 35% or more (e.g., about 40% or more, about 45% or more, about 50% or more, about 55% or more, about 60% or more, or even about 65% or more) of the particles, by weight, are retained at a sieve size of about #70 (about 0.2 mm) or smaller. Optionally, about 70% or more (e.g., about 75% or more, about 80% or more, about 85% or more, about 90% or more, or about 95% or more of the particles), by weight, are retained at a sieve size of about #100 (about 0.15 mm) or smaller. Alternatively, or in addition, the infill material has a particle size distribution such that about 50% or more (e.g., about 55% or more, about 65% or more, about 70% or more, about 75% or more, about 80% or more, or about 85% or more) of the infill material passes through a sieve size of about #40 or greater (about 0.4 mm or more) and is retained in a sieve size of about #100 or smaller (about 0.1 mm). Thus, for instance, the infill material can have a particle size distribution by which about 50 wt. % or more of the particles have a sieve size of #70-#100, and about 90 wt. % or more of the particles have a sieve size of #50-#140.

In some embodiments set forth by the present disclosure, the infill layer does not completely cover the vertical polymer fibers. Thus, the infill layer has a depth measured from the backing material that is less than the length of the polymer fibers. For instance, the infill layer can have a depth of about 10% or more (e.g., about 20% or more, about 30% or more, about 50% or more, or even about 75% or more) the length of the polymer fibers, provided the depth is less than the full length of the polymer fibers. In some embodiments, the infill layer has a depth that is about 95% or less (about 90% or less, about 80% or less, about 75% or less, about 60% or less, or about 50% or less) of the length of the polymer fibers.

Additionally, it should be understood that while certain materials and combinations thereof have been mentioned for the particulate infill 40, these are merely illustrative. The scope of the invention encompasses the use of any suitable materials for particulate infill that may present themselves as industry advancements emerge, provided they maintain the necessary properties for successful application within the synthetic turf system. Furthermore, the invention permits variations in the blend and granule sizes of the particulate infill to accommodate specialized applications, user preferences, and compliance with specific safety or performance standards.

In certain embodiments, after installing the particulate infill 40, the application of a liquid initiates the hydration and subsequent curing of the binder within the synthetic turf system. This liquid, which may be water or another suitable hydrating solution, permeates the particulate infill 40 and activates the binder, thus beginning the process that solidifies the infill structure.

The durability and lifespan of the particulate infill 40 are influenced by a range of factors. Adjacent soil conditions, which may vary based on geographical location and soil composition, play a critical role in determining the infill's structural integrity over time. The volume of foot traffic, indicative of the turf's usage, also significantly impacts the wear and tear of the particulate infill 40. Additionally, weather conditions, such as rainfall, temperature extremes, and exposure to UV radiation, are key determinants of the particulate infill's longevity.

It is also worth noting that the liquid applied to the synthetic turf system for hydration purposes can be tailored to suit specific environmental or performance needs. For instance, additives that promote faster curing, enhance binding strength, or provide resistance to microbial growth can be included in the liquid formulation.

FIG. 2 illustrates a block diagram depicting a method 200 for installing a synthetic turf covering on a sports court, in accordance with an embodiment of the present disclosure. To install a synthetic turf covering on a sports court, the method 200 begins at step 202 by preparing a foundation that has a topside and a bottom side. The foundation supports the entire structure of the surface 10, in accordance with an embodiment of the present disclosure. According to some exemplary embodiments of the present disclosure, suitable materials for the foundation include ground, gravel, sand, rubber, or a combination of these, which are selected based on the ability to provide stable support and adequate drainage.

Following the foundation's preparation, the method 200 at step 204 includes attaching a plurality of grass-like pile filaments to the topside of the foundation such that the filaments extend upward. These filaments extend upward from the foundation, mimicking the natural growth direction of grass. The materials used for the filaments include polyethylene, nylon, or polypropylene because of their durability, resilience, and grass-like appearance.

Once the filaments are securely in place, the method 200 continues to step 206, which includes dispersing a particulate infill among the grass-like pile filaments, the particulate infill comprising elastic and inelastic particles and a binder. The infill includes both elastic and inelastic particles, combined with the binder to facilitate the formation of a coherent, cushioned layer. The particulate infill might include materials such as sand, rubber granules, ceramic beads, and soil, either singly or in various combinations. The granule size of these particles typically ranges from 0.1 mm to 8 mm. In one embodiment, the particulate infill comprises particles with a granule size ranging from about 0.2 mm to 6 mm. In another embodiment, the particulate infill comprises particles with a granule size ranging from about 0.5 mm to 5 mm.

In accordance with one embodiment, the infill is substantially homogeneous to prevent layering or segregation of materials, which could affect the field's performance characteristics.

The depth at which this particulate infill is applied varies between 10% and 95% of the average height of the grass-like filaments. This range allows for customization according to the specific needs of the sports being played on the surface.

At step 208, the method 200 includes applying a liquid to the particulate infill to initiate curing of the binder. The liquid facilitates the hydration of the binder, which subsequently hardens and stabilizes the infill material, securing it within the matrix of filaments.

Furthermore, the backing layer onto which the filaments are attached includes either a woven or non-woven fabric, potentially coated with a rubber-type material to enhance its durability and moisture resistance. The backing layer is flexible enough to conform to the underlying topography of the foundation, thereby allowing for a uniform application over uneven ground surfaces.

In one embodiment, at least a portion of the synthetic turf covering or sport surfacing 10 can have a gmax, measuring surface impact attenuation, that is between 120 and 250. (The gmax can be measured according to the procedure of ASTM F355A.) In further embodiments, the gmax of at least a portion of the synthetic turf covering or sport surfacing 10 can be at least 180(optionally, ranging from 180-250), at least 190 (optionally, ranging from 190-250), or at least 200(optionally, ranging from 200-250). In some embodiments, the gmax of at least a portion of the playing surface can be between 165 and 250, or between at least 190 and 250. In further embodiments, the gmax of at least a portion of the synthetic turf covering or sport surfacing 10 can be between 90 and 115. As should be understood, an infield or warning track having a gmax that is too low or close to the gmax of the grass portion can cause a less realistic feel, causing balls to bounce at incorrect trajectories (e.g., too low or high) or providing a warning track that is insufficiently different from the grass for a player to feel the change. Optionally, at least a portion of the playing surface can have a head injury criterion (HIC), measuring surface impact attenuation, between 800 and 1500. (The HIC can be measured according to the procedure of ASTM F355A.) In further embodiments, the HIC of at least a portion of the playing surface is less than 1000. In further embodiments, the HIC of at least a portion of the playing surface can be between 400 and 900. Optionally, at least a portion of the playing surface can have a force reduction (FR), measuring surface impact attenuation, between 54% and 62%. (The FR can be measured according to the procedure of ASTM F3189-17AAA.) In further embodiments, the FR of at least a portion of the playing surface can be between 10% and 50%. According to various aspects, at least a portion of the playing surface can have a vertical deformation, measuring the firmness of the surface, between 5 mm and 10 mm. (The vertical deformation can be measured according to the procedure of ASTM F3189-17AAA.) In further embodiments, the vertical deformation of at least a portion of the sport surfacing 10 can be between 2 mm and 5 mm, or between 2 mm and 10 mm. Optionally, at least a portion of the playing surface can have an energy restitution, measuring surface rebound effect, between 15% and 35%. (The energy restitution can be measured according to the procedure of ASTM F3189-17AAA.) In further embodiments, the energy restitution of at least a portion of the playing surface can be between 10% and 15%, between 15% and 50%, or between 10% and 50%. Optionally, at least a portion of the playing surface can have a shear vane, measuring the surfacing stability, between 8 N-m and 15 N-m. (The shear vane can be measured according to the procedure of ASTM D8121/D8121M.) In further embodiments, the shear vane of at least a portion of the playing surface can be between 4 N-m and 9 N-m, between 4 N-m and 8 N-m, between 8 N-m and 15 N-m. Optionally, at least a portion of the playing surface can have a rotational traction, which can characterize the torque required to release cleats from the playing surface, between about 35 N-m and 45 N-m. (The rotational traction can be measured according to the procedure of ASTM F2333.) In further embodiments, the rotational traction of at least a portion of the playing surface can be between 35 N-m and 100 N-m or between 50 and 100 N-m. In still further embodiments, the rotational traction of at least a portion of the synthetic turf covering or sport surfacing 10 can be at least 60 N-m (optionally, between 60 N-m and 100 N-m), at least 70 N-m (optionally, between 70 N-m and 100 N-m), or at least 80 N-m (optionally, between 80 N-m and 100 N-m).

In another embodiment, a system described herein can exhibit the Head Injury Criterion (HIC) test values of equal to or less than about 1,000, less than about 900, less than about 800, less than about 700, or less than about 600. As one of ordinary skill in the art would readily appreciate, the “Head Injury Criterion” Test, or HIC Test, is the internationally recognized measure for the likelihood of head injury. As cited in Ratte, D. J. ((1990) “Development of Human Factors Criteria For Playground Equipment Safety.” Silver Spring, Md.: COMSIS Corporation), the Head Injury Criteria (HIC) is an alternate interpretation of the 1970 Wayne State Tolerance Curve (WSTC) (King and Ball, 1989). As Ratter states, the portion of the impact pulse covered by the HIC was intended to taking into account the rate of load application, which is thought to be critical in determining soft tissue injury (Committee on Trauma Research, 1985; Goldsmith and Ommaya, 1984.) Per Ratte, an HIC value of 1,000 is taken as the concussion tolerance threshold and is currently used by the US Department of Transportation as the standard for evaluating head injury and testing safety systems (e.g. restraint systems) in the context of vehicular collisions.

The term “polymer” includes, but is not limited to, homopolymers, copolymers, for example, block, graft, random, and alternating copolymers, terpolymers, etc., and blends and modifications thereof. Furthermore, unless otherwise specifically limited, the term “polymer” shall include all possible configurational isomers of the material. These configurations include, but are not limited to isotactic, syndiotactic, and atactic symmetries.

Any suitable polymer can be used to carry out the present innovation. It is possible that the polymers of the present innovation may also comprise two, three, four or more different polymers. In some embodiments, of the present innovation only one polymer is used. In some preferred embodiments a combination of two or more polymers is used. Combinations of polymers can be in varying ratios, to provide coatings with differing properties. Those of skill in the art of polymer chemistry will be familiar with the different properties of polymeric compounds. Examples of polymers that may be used in the present innovation include, but are not limited to polycarboxylic acids, cellulosic polymers, proteins, polypeptides, polyvinylpyrrolidone, maleic anhydride polymers, polyamides, polyvinyl alcohols, polyethylene oxides, glycosaminoglycans, polysaccharides, polyesters, polyurethanes, polystyrenes, copolymers, silicones, polyorthoesters, polyanhydrides, copolymers of vinyl monomers, polycarbonates, polyethylenes, polypropylenes, polylactic acids, polyglycolic acids, polycaprolactones, polyhydroxybutyrate valerates, polyacrylamides, polyethers, polyurethane dispersions, polyacrylates, acrylic latex dispersions, polyacrylic acid, mixtures and copolymers thereof. The polymers of the present innovation may be natural or synthetic in origin, including gelatin, chitosan, dextrin, cyclodextrin, poly(urethanes), Poly(siloxanes) or silicones, Poly(acrylates) such as poly(methyl methacrylate), poly(butyl methacrylate), and Poly(2-hydroxy ethyl methacrylate), Poly(vinyl alcohol) Poly(olefins) such as poly(ethylene), poly(isoprene), halogenated polymers such as Poly(tetrafluoroethylene)—and derivatives and copolymers such as those commonly sold as Teflon products, Poly(vinylidine fluoride), Poly(vinyl acetate), Poly(vinyl pyrrolidone), Poly(acrylic acid), Polyacrylamide, Poly(ethylene-co-vinyl acetate), Poly(ethylene glycol), Poly(propylene glycol), Poly(methacrylic acid); etc.

“Binder,” “binding agent” or “coupling agent” refers to a material having binding, adhesive or attachment properties with or without chemical, thermal, pressure or other treatment. The term “binder” includes materials that are capable of attaching themselves to a substrate or are capable of attaching other substances to a substrate. The binder component used in the coating compositions of the present disclosure can include any polymeric material customarily used as a binder in coating compositions.

In one embodiment, the binder is a composition such as water, acrylics, polyurethanes, polymerizable compounds, lignin sulfonate (solid), polymeric binders, silicone polymer, e.g., polyorganosiloxane, and combinations thereof. In another embodiment, the organic polymerizable binders include, but are not limited to, carboxymethylcellulose (CMC) and its derivatives and its metal salts, guar gum, agar, cellulose, xanthan gum, starch, lignin, polyvinyl alcohol, polyacrylic acid, styrene butadiene resins (SBR), and polystyrene acrylic acid resins.

In one embodiment, the binders are selected from the group consisting of acrylic acid grafted starch, alginates, alkoxysilanes, for example, tetraethoxy silane (TEOS), block copolymers, carboxy methyl cellulose, carboxymethyl starch, carboxymethylcellulose, carrageenan gum, casein, cellulose acetate phthalate, cellulose based polymers, cellulose derivatives such as dextrans and starches, gelatin, guar gum cellulose, hydrolyzed acrylonitrile grafted starch, hydroxymethyl cellulose, lignin, locust bean gum, maleic anhydride copolymers, methyl cellulose, monomeric silanes, natural gums, pectins, poly (2-hydroxyethylacrylate), poly (ethylene oxide), poly (sodium acrylate-co-acrylic acid), poly(2-hydroxyethyl-methacrylate), poly(acrylamides), poly(acrylates), poly(ethers), poly(methacrylic acid), poly(N-vinyl pyrrolidone), poly(vinyl alcohol), poly(vinyl sulfonates), poly(vinylsulfonic acid), polyesters, polyethylene oxide, polymeric binders, polymers formed from acid-group containing monomers, polyorganosiloxane, polystyrene acrylic acid resins, polyurethanes, polyvinylalcohol, polyvinylmethyl ether, polyvinylpyrrolidone, silicates, silicone polymer, starch, starch-based polymers, silanes, organosiloxanes, styrene butadiene resins, xanthan gum and mixtures thereof.

The term “coupling agent” refers to a binder that is used as an adhesion promoter enhancing adhesion between a surface of an inorganic material, such as silica, and an organic material through chemical coupling there between during formulation of the composition.

In one embodiment, performance-enhancing additive(s) are added to the infill material. In one embodiment, the performance-enhancing additive(s) are antimicrobials. In one embodiment, the antimicrobial actives are boron containing compounds such as borax pentahydrate, borax decahydrate, boric acid, polyborate, tetraboric acid, sodium metaborate, anhydrous, boron components of polymers, and mixtures thereof. In one embodiment, the odor absorbing/inhibiting active inhibits the formation of odors. An illustrative material is a water-soluble metal salt such as silver, copper, zinc, iron, and aluminum salts and mixtures thereof.

In some aspects, additional additives may optionally be employed with the particulate infill compositions, including odor-binding substances, such as cyclodextrins, zeolites, inorganic or organic salts, and similar materials; anti-caking additives, flow modification agents, surfactants, viscosity modifiers, and the like. In addition, additives may be employed that perform several roles during modifications. In another embodiment, a color altering agent such as a dye, pigmented polymer, metallic paint, bleach, lightener, etc. may be added to vary the color of absorbent particles, such as to darken or lighten the color of all or parts of the infill composition so it is more appealing. Additional additives include anti-oxidants, fillers such as inorganic fillers, UV stabilizers, UV absorbers or combinations of these additives.

It should be understood that the aforementioned description pertains to preferred embodiments of the invention and that modifications and variations to the synthetic turf covering 10, as described, may be apparent to those skilled in the art without departing from the inventive concepts herein. The invention, therefore, is not restricted to the precise embodiments described, but is intended to encompass all such modifications and variations provided they come within the scope of the appended claims and their equivalents.