Artificial turf and production method

Abstract

The method includes creating a polymer mixture, wherein the polymer mixture includes a stabilizing polymer, a bulk polymer, a flame retardant polymer combination, and a compatibilizer. The stabilizing polymer polymer and the bulk polymer are immiscible. The stabilizing polymer includes fibers surrounded by the compatibilizer within the bulk polymer. The stabilizing polymer is aramid. The flame retardant polymer combination is a mixture of triazin and melamine. The method further includes extruding the polymer mixture into a monofilament. The method further includes quenching the monofilament. The method further includes reheating the monofilament. The method further includes stretching the reheated monofilament to align the fibers relative to each other and to form the monofilament into an artificial turf fiber. The method further includes incorporating the artificial turf fiber into an artificial turf backing.

1 - 20 . (canceled) 
     
     
         21 . An artificial turf obtained by a process comprising:
 creating a polymer mixture, wherein the polymer mixture comprises a stabilizing polymer, a bulk polymer, a flame retardant polymer combination, and a compatibilizer, wherein the stabilizing polymer and the bulk polymer are immiscible, wherein the stabilizing polymer comprises fibers surrounded by the compatibilizer within the bulk polymer, wherein the stabilizing polymer is aramid, wherein the flame retardant polymer combination is a mixture of triazine and melamine;   extruding the polymer mixture into a monofilament;   quenching the monofilament;   reheating the monofilament;   stretching the reheated monofilament to align the fibers relative to each other and to form the monofilament into an artificial turf fiber; and   incorporating the artificial turf fiber into an artificial turf backing.   
     
     
         22 . The artificial turf of  claim 21 , wherein the polymer mixture comprises any one of the following: less than or equal to 8% stabilizing polymer by weight, less than or equal to 10% stabilizing polymer by weight, less than or equal to 12% stabilizing polymer by weight, and less than or equal to 15% stabilizing polymer by weight. 
     
     
         23 . The artificial turf of  claim 21 , wherein the polymer mixture comprises any one of the following: less than or equal to 20% flame retardant polymer combination by weight, less than or equal to 22% flame retardant polymer combination by weight, less than or equal to 25% flame retardant polymer combination by weight, less than or equal to 27% flame retardant polymer combination by weight, and less than or equal to 29% flame retardant polymer combination by weight. 
     
     
         24 . The artificial turf of  claim 21 , wherein the ratio of triazine to melamine by weight in the flame retardant polymer combination is any one of the following: 1.8, 1.9, 2.0, 2.1, and 2.2. 
     
     
         25 . The artificial turf of  claim 21 , wherein the bulk polymer comprises any one of the following: a polyolefin polymer, a thermoplastic polyolefin polymer, a polyethylene polymer, a polypropylene polymer, a polyamide polymer, a polyethylene polymer blend, and mixtures thereof. 
     
     
         26 . The artificial turf of  claim 21 , wherein the bulk polymer comprises a first polymer, a second polymer, and the compatibilizer, wherein the first polymer and the second polymer are immiscible, wherein the first polymer forms polymer beads surrounded by the compatibilizer within the second polymer. 
     
     
         27 . The artificial turf of  claim 26 , wherein stretching the reheated monofilament deforms the polymer beads into threadlike regions. 
     
     
         28 . The artificial turf of  claim 26 , wherein the creating the polymer mixture comprises:
 forming a first mixture by mixing the first polymer with the compatibilizer;   heating the first mixture;   extruding the first mixture;   granulating the extruded first mixture;   mixing the granulated first mixture with the second polymer; and   heating the granulated first mixture with the second polymer to form the polymer mixture.   
     
     
         29 . The artificial turf of  claim 26 , wherein the bulk polymer comprises any one of the following: 1 to 30 percent by weight the first polymer, 1 to 20 percent by weight the first polymer, and 5 to 10 percent by weight the first polymer. 
     
     
         30 . The artificial turf of  claim 26 , wherein the first polymer is any one of the following: a polar polymer, a polyethylene terephthalate (PET) polymer, a polybutylene terephthalate (PBT) polymer, a polyolefin polymer, a thermoplastic polyolefin polymer, a polyethylene polymer, a polypropylene polymer, a polyamide polymer, a polyethylene polymer blend, and mixtures thereof. 
     
     
         31 . The artificial turf of  claim 26 , wherein the second polymer is any one of the following: a non-polar polymer, polyethylene, polypropylene, and a mixture thereof. 
     
     
         32 . The artificial turf of  claim 21 , wherein the compatibilizer is any one of the following: a maleic acid grafted on polyethylene or polyamide; a maleic anhydride grafted on free radical initiated graft copolymer of polyethylene, SEES, EVA, EPD, or polypropylene with an unsaturated acid or its anhydride such as maleic acid, glycidyl methacrylate, ricinoloxazoline maleinate; a graft copolymer of SEBS with glycidyl methacrylate, a graft copolymer of EVA with mercaptoacetic acid and maleic anhydride; a graft copolymer of EPDM with maleic anhydride; a graft copolymer of polypropylene with maleic anhydride; a polyolefin graft-polyamidepolyethylene or polyamide; and a polyacrylic acid type compatibilizer. 
     
     
         33 . The artificial turf of  claim 21 , wherein the bulk polymer comprises 80 to 90 percent by weight the second polymer. 
     
     
         34 . The artificial turf of  claim 21 , wherein the polymer mixture further comprises any one of the following: a wax, a dulling agent, a UV stabilizer, a flame retardant, an anti-oxidant, a pigment, and combinations thereof. 
     
     
         35 . The artificial turf of  claim 21 , wherein the aramid is para-aramid. 
     
     
         36 . The artificial turf of  claim 35 , wherein the para-aramid has a fiber length less than any one of the following: 135 μm, 125 μm, and 115 μm. 
     
     
         37 . The artificial turf of  claim 35 , wherein the para-aramid has an average fiber length of any one of the following: between 65 μm and 35 μm, and 55 μm. 
     
     
         38 . The artificial turf of  claim 35 , wherein the para-aramid has a density between any one of the following: 1.44 g/cm3 and 1.45 g/cm3, and 1.43 g/cm3 and 1.46 g/cm3. 
     
     
         39 . The artificial turf of  claim 35 , wherein the para-aramid has a decomposition temperature of any one of the following: above 720 degrees, above 725 degrees, and 723 degrees Kelvin.