Synthetic fiber and method of manufacture

Abstract

The present invention relates to a method for producing a synthetic fiber for use in an artificial grass sports field, including the steps of supplying a layer of synthetic material; and obtaining the synthetic fiber from the layer of synthetic material, wherein the layer of synthetic material comprises at least two layers of different synthetic materials, using a co-extrusion process. The invention also relates to such a synthetic fiber and to an artificial lawn suitable for sports fields, including a substrate to which synthetic fibers according to the invention have been attached.

1 . A method for producing a synthetic fiber for use in an artificial grass sports field, comprising the steps of:
 i) supplying a layer of synthetic material; and   ii) providing the synthetic fiber from the layer of synthetic material, wherein the layer of synthetic material comprises at least two layers of different synthetic materials, using a co-extrusion process.   
     
     
         2 - 21 . (canceled) 
     
     
         22 . The method according to  claim 1 , wherein after step i), the layer of synthetic material is stretched. 
     
     
         23 . The method according to  claim 1 , wherein after step ii), the layer of synthetic material is stretched. 
     
     
         24 . The method according to  claim 1 , wherein the fiber comprises at least one monofilament. 
     
     
         25 . The method according to  claim 24 , wherein the fiber comprises several twined monofilaments. 
     
     
         26 . The method according to  claim 1 , wherein the fiber is in the form of a band. 
     
     
         27 . The method according to  claim 26 , wherein the band is a fibrillated band fiber. 
     
     
         28 . The method according to  claim 1 , wherein the layer of synthetic material comprises a core layer of a first synthetic material, which core layer is surrounded on both sides by one or more outer layers, each consisting of a different synthetic material. 
     
     
         29 . The method according to  claim 28 , wherein the layers have different thicknesses. 
     
     
         30 . The method according to  claim 28 , wherein the first synthetic material comprises a mixture of a polymer and a plastomer. 
     
     
         31 . The method according to  claim 30 , wherein the ratio of the plastomer in the core layer is about 30 to about 80 weight percent. 
     
     
         32 . The method according to  claim 31 , wherein the ratio of the plastomer in the core layer is about 35 to about 50 weight percent. 
     
     
         33 . The method according to  claim 28 , wherein at least one of the other synthetic materials comprises a hydrophilic additive. 
     
     
         34 . The method according to  claim 33 , wherein the hydrophilic additive is an ethylene vinyl alcohol co-polymer. 
     
     
         35 . The method according to  claim 33 , wherein the hydrophilic additive is a polyhydroxyethyl methacrylate. 
     
     
         36 . The method according to  claim 28 , wherein at least one of the other synthetic materials comprises an antistatic additive. 
     
     
         37 . The method according to  claim 36 , wherein the antistatic additive is a polymer, in particular a polyamide or a polyether block amide. 
     
     
         38 . A synthetic fiber produced according to the method of  claim 1   
     
     
         39 . An artificial lawn suitable for sports fields including synthetic fibers produced according to the method of  claim 1 . 
     
     
         40 . The artificial lawn according to  claim 39 , wherein the lawn includes a substrate to which the synthetic fibers are attached. 
     
     
         41 . The artificial lawn according to  claim 39 , including a granular material between the synthetic fibers. 
     
     
         42 . A method of producing a synthetic fiber for use in an artificial grass surface comprising:
 i) providing a layer of synthetic material comprising at least two layers of different synthetic materials having different function-specific properties; and   ii) forming the synthetic fiber therefrom using a co-extrusion process.   
     
     
         43 . The method according to  claim 42 , wherein after step 1), the layer of synthetic material is stretched. 
     
     
         44 . The method according to  claim 42 , wherein after step ii), the synthetic fiber is stretched.