Protective binding layer

Abstract

The embodiments of the present invention are directed to a synthetic turf system that includes a hardened layer adjacent or immediately adjacent to a backing layer and also includes artificial turf fibers that extend from the backing layer and the hardened layer. The hardened layer may have been hardened by applying a hardening agent to a layer comprising felt or felt-like material. The layer comprising felt or felt-like material has characteristics that improves wicking and consistency of the hardening agent as compared to the backing layer. The hardening agent may also reach or apply to a backing sheet of the backing layer. Other embodiments and variations of embodiments are also contemplated.

What is claimed is: 
     
         1 . A synthetic turf system comprising:
 a backing layer comprising a flexible backing sheet and a felt layer formed from a felt-type material, wherein the backing layer contains a hardening agent that is hardened to protect the backing layer from damage; and   a plurality of grass-like artificial filaments attached to the backing layer, wherein the artificial filaments extend upward from the backing layer.   
     
     
         2 . The synthetic turf system of  claim 1  comprises the felt layer being a layer that is hardened with a multi-component epoxy. 
     
     
         3 . The synthetic turf system of  claim 1  wherein the felt layer is adjacent to the backing layer, and further wherein the backing layer contains a multi-part epoxy that has hardened at least a portion of the felt layer to protect the backing layer from damage; and further wherein the synthetic turf system further comprises an infill layer lying above the backing layer comprising an infill material wherein the plurality of grass-like artificial filaments attached to the backing layer extend upward from the backing layer over the infill layer. 
     
     
         4 . The synthetic turf system according to  claim 3 , wherein the felt layer is sandwiched between the infill layer and the backing sheet. 
     
     
         5 . The synthetics turf system according to  claim 4 , wherein the felt layer is on the backing sheet without completely covering the backing sheet. 
     
     
         6 . The systematic turf system according to  claim 4 , wherein the multi-part epoxy is hardened to a depth including a portion of the felt layer. 
     
     
         7 . The system turf system according to  claim 4 , wherein the multi-part epoxy is hardened to a depth including the entire felt layer but without any portion of the backing sheet. 
     
     
         8 . The system turf system according to  claim 4 , wherein the multi-part epoxy is hardened to a depth including the entire felt layer and a portion of the backing sheet. 
     
     
         9 . The system turf system according to  claim 4 , wherein the multi-part epoxy is hardened to a depth including the entire felt layer and the entire backing sheet. 
     
     
         10 . The system turf system according to  claim 3 , wherein backing sheet is sandwiched between the infill layer and the felt layer. 
     
     
         11 . The systematic turf system according to  claim 10 , wherein the multi-part epoxy is hardened to a depth including a portion of the backing sheet. 
     
     
         12 . The system turf system according to  claim 10 , wherein the multi-part epoxy is hardened to a depth including the entire backing sheet but without any portion of the felt layer. 
     
     
         13 . The system turf system according to  claim 10 , wherein the multi-part epoxy is hardened to a depth including the entire backing sheet and a portion of the felt layer. 
     
     
         14 . The system turf system according to  claim 10 , wherein the multi-part epoxy is hardened to a depth including the entire backing sheet and the entire felt layer. 
     
     
         15 . A method for manufacturing a synthetic turf system comprising:
 forming a backing layer by attaching a felt layer and a backing sheet together;   tufting a plurality of grass-like artificial filaments through the backing layer;   flipping over the backing layer with the filaments such that the felt layer faces the direction in which a multi-part epoxy is applied;   applying the multi-part epoxy to the backing layer with filaments;   hardening the multi-part epoxy in the backing layer;   flipping over the backing layer with hardened multi-part epoxy; and   dispersing an infill layer on the backing layer with hardened multi-part epoxy.   
     
     
         16 . A synthetic turf surface comprising:
 a flexible backing layer comprising a middle felt layer, wherein the middle felt layer is inserted between at least two layers of the backing layer, and further wherein the flexible backing layer contains a two-component epoxy that is hardened to protect the backing layer from damage;   an infill layer lying above the backing layer comprising infill material; and   a plurality of grass-like artificial filaments attached to the backing layer, wherein the artificial filaments extend upward from the backing layer over the infill.   
     
     
         17 . The synthetic turf surface of  claim 16  comprises the felt layer being a layer that is hardened with the two-component epoxy.