Seeking a New Polymer Formulation for Turf Carpet Fibers

First generation artificial turf was made of polyamide (nylon) and showed great resilience and toughness, but was very abrasive.

Existing turf carpet fibers are made from low density and linear low density polyethylene (LDPE & LLDPE) due to their soft touch and feel, as well as UV resistance, but are not as durable or resilient as the older polyamide fibers.

Formulation properties can be conveyed by the polymer blend or by other additives to the components.

Requirements

• Material formulation that can be produced consistently in large production volumes
• Cost of materials must be within the same order of magnitude
• Fibers can be extruded as films or as monofilament fibers, though shaped monofilaments are prefered
• Fibers should be wholly or largely infrared transparent or reflecting
• High toughness and resistance to splitting or breaking

Discarded solutions

• Nylon particulate within a polyethylene continuous medium
• Direct bico extrusion of only nylon within polyethylene sheath

Possible solution areas

• Novel polymers with increased softness and resilience
• High resilience and soft polymer blends
• Multiextrusion technologies
• Multilayer films sliced and/or molded into fiber shapes

Nice to Have

• High recyclability for post-industrial and Post-consumer materials
• Production in North America or Europe
• Recycled content and low carbon emissions