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 Process of laying synthetic grass

Details
Inventors: Prevost, Jean;
Assignee: Fieldturf Holdings, Inc. (Montreal, CA)
Primary Examiner: Thomas; Alexander
Assistant Examiner:
Attorney, Agent or Firm: Birch, Stewart, Kolasch & Birch, LLP.

The invention relates to a synthetic grass turf assembly for installation on a supporting soil substrate to provide a game playing surface that combines the feel of natural turf with the wear resistance of synthetic turf. The turf assembly includes a pile fabric with a flexible sheet backing and rows of upstanding synthetic ribbons representing grass blades, extending upwardly from an upper surface of the backing. A unique infill layer of multiple distinct graded courses of particulate material is disposed interstitially between the upstanding ribbons upon the upper surface of the backing and of a depth less than the length of the ribbons. A base course is first placed upon the top surface of the backing and consists exclusively of hard sand granules. A middle course of intermixed hard sand and resilient rubber granules with relative weight ratio of 3 to 1 is then placed upon the base course. A top course exclusively of resilient rubber granules is then placed upon the middle course. The relatively thin top course that is in contact with users, has a high resilience where contact occurs and low abrasion due to exclusive use of rubber. The base sand course provides weight to hold the turf in place and to quickly drain the surface. The middle layer of mixed sand and rubber granules acts as a buffer to keep the base sand and top rubber courses separate avoiding migration of abrasive sand towards the top surface level. An upper portion of the synthetic ribbons extends upwardly from the top surface of the top course 0.25 to 1.00 inches to give the appearance of grass blades. Preferably the upper portion of the synthetic ribbons is fibrillated, split or frayed on site by passing over the installed surface with a stiff wire brush. The fibrillated surface has a slight resilience and visually appears like a natural grass turf. The criss-crossed fibrillated fibers contain the top course rubber granules while allowing dislodged rubber granules to fall back into place and permitting water to drain through to the sand containing courses.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS With reference to FIG.
1, the invention relates to a synthetic grass turf assembly consisting of a pile fabric with an infill layer of particulate matter which is installed on a supporting soil substrate to provide a game playing surface.
The pile fabric includes a flexible sheet backing 1 that in the embodiment shown is a two-ply open weave fabric.
Extending upwardly from an upper surface of the backing 1 is a large number of upstanding synthetic ribbons 2.
As indicated in FIG.
1, the ribbons 2 are tufted through the backing 1 spaced apart in rows by a distance W and of a length L.
The length is selected depending upon the depth of infill and the desired resilience of the completed synthetic grass turf assembly.
Disposed interstitially between the upstanding ribbons 2 upon the upper surface of the backing 1 is an infill layer 3 of particulate matter.
The particulate matter may be selected from any number of commonly available hard granules such as sand, small rocks or other graded particulate matter and resilient granules such as crumb rubber.
The infill layer 3 is made up of a base course 4, a middle course 5 and a top course 6.
The base course 4 is substantially exclusively of hard sand granules disposed immediately upon the top surface of the backing 1.
The middle course 5 is of intermixed hard sand granules and resilient rubber granules.
The mix is selected on the basis of a weight ratio greater than 2 to 1 of hard and resilient granules respectively.
The top course 6 is substantially exclusively of resilient rubber granules.
An upper portion 7 of the synthetic ribbons 2 extends upwardly from a top surface 8 of the top course 6.
The resulting artificial turf surface can be adapted for several indoor and outdoor uses, such as: athletic playing fields; horse racing, and recreational areas.
In order to deposit multiple distinct layers, it is necessary to pass over the same area several times with a substantially pure sand spreading operation then proceeding over the same area again with a mixed sand and rubber material



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