Artificial turf and method of manufacturing

Abstract

A method of manufacturing an artificial turf provides for moving a carrier mesh through an air gap formed between a first electrode and a second electrode of a dielectric barrier discharge device, applying a dielectric barrier discharge to a backside of the carrier mesh for plasma-activating the backside, and applying a backing layer to the plasma-activated backside of the carrier mesh for providing the artificial turf.

1 - 23 . (canceled) 
     
     
         24 . A method of manufacturing an artificial turf, comprising:
 moving a carrier mesh through an air gap formed between a first electrode and a second electrode of a dielectric barrier discharge device, wherein the carrier mesh includes a backside, and wherein the carrier mesh includes fibers integrated such that a portion of the fibers are exposed on the backside;   applying a dielectric barrier discharge to the backside of the carrier mesh for plasma-activating the backside; and   applying a backing layer to the plasma-activated backside of the carrier mesh for providing the artificial turf.   
     
     
         25 . The method of  claim 24 , wherein the first and second electrodes are elongated in a first direction, and wherein the carrier mesh is moved in a second direction that is perpendicular to the first direction. 
     
     
         26 . The method of  claim 24 , wherein the carrier mesh includes a frontside, wherein the first electrode is adjacent to the backside, wherein the second electrode is adjacent to the frontside, and wherein the second electrode is at least partially encased in a dielectric, the dielectric extending at least in a direction towards the first electrode. 
     
     
         27 . The method of  claim 24 , wherein the second electrode is a metal cylinder which is at least partially encased in a dielectric. 
     
     
         28 . The method of  claim 24 , wherein the dielectric comprises a plastic material. 
     
     
         29 . The method of  claim 24 , wherein the dielectric has a thickness of at least 0.2 cm. 
     
     
         30 . The method of  claim 24 , wherein the dielectric is shaped as a hollow cylinder with circular or ellipsoid cross section, wherein the second electrode is elongated along a major axis of the dielectric, and wherein the dielectric is in contact with the frontside of the carrier mesh. 
     
     
         31 . The method of  claim 24 , wherein the second electrode is at least partially encased in the dielectric and is configured to be rotatable about its longitudinal axis. 
     
     
         32 . The method of  claim 31 , wherein rotating the second electrode with the dielectric moves the carrier mesh through the air gap formed between the first electrode and the second electrode. 
     
     
         33 . The method of  claim 24 , wherein the moving of the carrier mesh through the air gap comprises moving the carrier mesh through the air gap at at least one of a manually-adjustable and automatically-adjustable speed. 
     
     
         34 . The method of  claim 24 , wherein the applying the dielectric barrier discharge comprises applying the dielectric barrier discharge at an energy density of at least 0.1 J/cm 2 . 
     
     
         35 . The method of  claim 24 , further comprising manually or automatically adjusting a gap between the first electrode and second electrode. 
     
     
         36 . The method of  claim 35 , wherein the gap is adjusted such that a distance between the first electrode and the outer surface of the dielectric at least partially enchasing the second electrode is greater than 0 mm. 
     
     
         37 . The method of  claim 24 , wherein the first electrodes are positioned such that a distance between the first electrode and a surface of the backside of the carrier mesh and the fiber portions protruding therefrom is below 10 mm. 
     
     
         38 . The method of  claim 24 , wherein the applying of the dielectric barrier discharge further comprises controlling the dielectric barrier discharge device to continuously apply the dielectric barrier discharge for plasma-activating the backside. 
     
     
         39 . The method of  claim 24 , wherein the first electrode is a single wire or a set of two or more wires. 
     
     
         40 . The method of  claim 24 , wherein the first electrode is a conductive profile or a set of two or more of said profiles. 
     
     
         41 . The method of  claim 24 , wherein the first electrode is a set of two or more conductive wires or profiles galvanically decoupled from each other. 
     
     
         42 . The method of  claim 24 , wherein the method is part of a continuously executed, inline roll-to-roll production process comprising: unrolling a carrier mesh roll; tufting the fibers into the unrolled carrier mesh; performing the method according to  claim 24  for providing the artificial turf; and forming an artificial turf roll from the provided artificial turf. 
     
     
         43 . An artificial turf, comprising:
 a carrier mesh including a backside, wherein the carrier mesh includes fibers integrated such that a portion of the fibers are exposed on the backside; and   a backing layer positioned on the backside of the carrier mesh and connected to the backside via a plasma-discharge-assisted homogeneous distribution of binding forces between a backside surface of the carrier mesh and the backing layer.   
     
     
         44 . The artificial turf of  claim 43 , wherein the homogeneous distribution of binding forces between the backside of the carrier mesh and the backing layer is the result of a homogenous distribution of ions forming covalent bonds between the backside of the carrier mesh and the backing layer. 
     
     
         45 . The artificial turf of any one of  claim 43 , wherein a tuft binding force is determined by pre-processing the artificial turf according to DIN EN 13744 and then determining the tuft withdrawal force according to FIFA Test Method 26, whereby the tuft binding force is at least 40 N. 
     
     
         46 . A method of manufacturing an artificial turf, comprising:
 moving a carrier through an air gap formed between a first electrode and a second electrode of a dielectric barrier discharge device;   applying a dielectric barrier discharge to one side of the carrier for plasma-activating the side; and   using the plasma-activated carrier for manufacturing the artificial turf.