Nylon Artificial Grass

Abstract

An artificial grass product has 100% nylon face fabric which forms blades of grass when tufted. This grass shows a melt temperature exceeding 400 degrees Fahrenheit, at least about 100 degrees hotter than prior art materials. The thatch can be made of similar materials for at least some embodiments. When coupled with multiple yarns extending from common penetrations, quite durable and attractive products can be provided. Furthermore, resiliency in excess of 10% over prior art polyethylene or polypropylene grass products can be experienced with at least some embodiments.

Description

CLAIM OF PRIORITY[0001]The present invention is a divisional of U.S. Non-Provisional application Ser. No. 15 / 655,973, filed on Jul. 21, 2017 which claims the benefit of U.S. Provisional Application No. 62 / 368,555 filed Jul. 29, 2016, both of which are incorporated herein by reference in their entirety.FIELD OF THE INVENTION[0002]The present invention relates to a 100% nylon artificial or synthetic grass product.BACKGROUND OF THE INVENTION[0003]Polypropylene and polyester have been utilized for face fabric yarns (i.e. grass blades) for years. Although there are advantages of either of these plastic fibers yarns, there are also disadvantages.[0004]Both of these yarns have a melt temperature of around 270 degrees Fahrenheit. Resiliency is also somewhat of an issue with polypropylene and polyethylene face fibers in that if they are deformed for a significant period of time, they may tend to retain their deformed shape. Accordingly there is a need for a product with higher melt temperatu...

AI Technical Summary

Benefits of technology

[0011]Another object of many embodiments of the present invention is to provide an improved synthetic grass product having at least two yarn ends provided on a cone to be tufted through backing as face fabric tufts so as to provide at least one of increased durability, resiliency and increased aesthetic appeal by essentially having multiple yarns and / or colors directed through the same opening provided by a needle as the artificial grass is tufted through the backing as the face fabric tufts. The same is possible as well for thatch fiber tufts.

[0012]Still other embodiments are desirable to have at least three ends or more provided on a single cone to then be directed to a single needle for use in tufting up to three colors or more while also providing additional durability and / or resilience through either or both of the thatch and the face fiber yarns.

[0013]Presently preferred embodiments provide two or three color (or more) options for either or both of face fabrics and thatch yarns. By tufting multiple ends through a single needed for artificial grass, improved resiliency and durability such as resistance to wear can be experienced in addition to different coloration possibilities.

[0014]By utilizing all nylon, the melting point for the artificial grass can be elevated to up above 420 degrees Fahrenheit for nylon as opposed to below 300 degrees Fahrenheit or polyethylene and polypropylene. Such a large increase may allow some manufacturers to provide a melt proof warranty for many if not all installations. Accordingly a whole new set of artificial grass products with improved characteristics can be provided to the marketplace.

[0015]Improved artificial grass products over those presently provided in the marketplace are believed to be possible with the applicant's current technology.

Problems solved by technology

Although there are advantages of either of these plastic fibers yarns, there are also disadvantages.

Resiliency is also somewhat of an issue with polypropylene and polyethylene face fibers in that if they are deformed for a significant period of time, they may tend to retain their deformed shape.

Additionally no manufacturer is known by the applicant to provide multi-color nylon face fabric.

Furthermore, no manufacturer is known by the applicant to utilize nylon face fiber in combination with nylon thatch to provide a 100% nylon artificial grass product in the marketplace.

As one can readily see, even if someone were to provide a product utilizing nylon as a portion of the total product, the melt temperature of the face fiber yarns which are normally polyethylene and polypropylene would still be a limiting factor for those products.

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