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Title:
A PROCESS FOR PRODUCING TEXTILE- OR PLASTIC SURFACES COVERED BY FIBRES, AND PROCESS FOR ITS APPLICATION
Document Type and Number:
WIPO Patent Application WO/2010/125410
Kind Code:
A1
Abstract:
The invention relates to the production of textile- or plastic surfaces covered by fibres by die-casting, first of all from a textile- or plastic material serving as a grounding, or without it. The surfaces covered by die-cast fibres can find various employments by setting them next to each other. It is characterized as follows a) knots made from synthetic material are die-cast through holes located in a cloth first of all textile cloth serving as a grounding, or b) knots die-cast from synthetic material are sewed or otherwise fastened to a cloth first of all textile cloth serving as a grounding, or c) panels containing both plastic surface grounding and knots are developed by die-casting, or d) knots made from synthetic material or die-cast panels covered fibres are sewed or otherwise fastened to a plastic ground plate element serving as a grounding. ˙

Inventors:
NEMETH MIKLOS (HU)
SZILVASSY MIHALY (HU)
Application Number:
PCT/HU2009/000038
Publication Date:
November 04, 2010
Filing Date:
April 27, 2009
Export Citation:
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Assignee:
NEMETH MIKLOS (HU)
SZILVASSY MIHALY (HU)
International Classes:
B29C45/14; B29C45/26; E01C13/08
Domestic Patent References:
WO1996033638A11996-10-31
Foreign References:
US20030163884A12003-09-04
JPH07137172A1995-05-30
US20050006819A12005-01-13
GB1237746A1971-06-30
JPH08158310A1996-06-18
Attorney, Agent or Firm:
PINTZ, György (Pf. 590, Budapest, HU)
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Claims:
CLAIMS

1. A process for production of textile or plastic surfaces covered by fibres by fixing artificial fibres or knots made from thermoplastic synthetic material on a suitable grounding with suitable frequency characterized in that the artificial fibres or artificial knots with 20 - 100 mm length are produced by die-casting technology and are fixed mainly on a textile- or plastic material serving as a grounding or one die-cast grounding piece.

2. A process according to Claim 1 characterized in that as a thermoplastic synthetic material certain polyolefin mainly polyethylene, polypropylene or their certain copolymer are applied.

3. A process according to Claim 1 or 2 characterized in that a die-casting apparatus is placed on the lower side of the carpet ground plate, and at least one tool opening suitable for the shape of the planned knot is carried to another side of the carpet ground plate, and across these openings thermoplastic synthetic material is die-cast at pressure 2.108 Pa - 3.1010 Pa and at temperature 170°C - 3000C, and after cooling down knots are formed on the upper side, while a coating is formed on the lower side of the carpet ground plate with 0,1 mm - 2 mm thickness.

4. A process according to Claim 1 or 2 characterized in that across tool opening(s) of a die-casting apparatus suitable for the shape of the planned knot a thermoplastic synthetic material is die-cast at pressure 2.10s Pa - 3.1010 Pa and at temperature 1700C - 3000C; in this manner knots are formed, which are get to a mainly textile ground plate serving as a grounding and are sewed with 500 - 1500 knot/m2 frequency, furthermore the lower side of the carpet ground plate is provided with plastic- rubber- or another weather-resistant coating with 0,1 mm - 2 mm thickness.

5. A process according to Claim 1 or 2 characterized in that such die-casting apparatus and tool is used which die-cast simultaneously the ground plate and the planned knots within a panel without a carpet serving as a grounding at pressure 2.10 Pa - 3.10 Pa and at temperature 1700C - 300°C.

6. A process according to Claim 1 or 2 characterized in that across the opening of the die-casting apparatus suitable to the shape of a planned knot or panel thermoplastic synthetic material are die-cast at pressure 2.10s Pa - 3.1010 Pa and at temperature 170°C - 300°C; in this manner knots or panels covered by fibres are formed and fixed to plastic ground plate elements.

7. A process according to Claim 6 characterized in that the panels covered by knots or fibres are fixed to the plastic ground plate elements by sticking, sewing, nailing or threading into holes.

8. A process according to any of Claims 1 - 7 characterized in that the fibres or knots of the formed textile- or plastic surfaces covered by fibres optionally are texturized by mechanical treatment or heat treatment.

9. A process for the application of surfaces manufactured according to Claims 1 - 8 characterized in that the surface elements or panels are ranked next to each other in order to form panel-fields suitable to establish a sports field or a land unit, and the elements are fixed to each other.

10. A process according to Claim 9 characterized in that the panels constituting the surface elements are fixed to each other on a suitable supporting grounding by sticking and/or toothed fitting.

Description:
A process for producing textile- or plastic surfaces covered by fibres, and process for its application

The invention relates to the production of textile- or plastic surfaces covered by fibres by die-casting based on a textile- or plastic material, or without it. The textile- or plastic surfaces covered by die-cast fibres may have various applications. The process according to the present invention can be applied first of all to the formation of artificial lawn. To this very day with the spread of the organized sport activities, mainly ball games, the playing surface of the outdoor sports fields, has been the natural lawn. Its historical reason is that the majority of these kinds of sports has been developed permanently in England rich in rain and grass where the lawn production had not only centuries-old traditions but also excellent natural circumstances, because of the climatic conditions. Let us think first of all about football, tennis, golf, field hockey and many others, the playing field of which was given almost by itself in England; however, in the vast majority of another countries, these playing fields can be established and maintained only with serious difficulties and expenses, or they cannot be realized at all. Therefore, with the rising of the popularity and expansion of the sport, various kinds of sport game surfaces have become acceptable to substitute the natural lawn, e.g. sandy-, cinder- and earthy playing fields for football, clay- and later concrete- and bitumen playing fields for tennis. It is not necessary to specially emphasize the frequency of the injuries on this type of grounds.

Standards about the ground of the natural lawn football field practically do not exist; the ground of the playing fields are determined by the local practice and climactic circumstances, thus their usefulness is the consequence of the weather. There has been a demand to establish and apply sports field surfaces that can be used under whatever weather conditions, and reach or exceed the properties of the natural lawn as far as the appearance and playing properties are concerned. The solution to this question has been given by the development of plastics. During the more than 100 years development of the formation and processing of plastics in sixties of the last century the situation got to that point that the plastics invaded the sport equipment manufacture and sports ground construction, too. This became possible first of all when the by-products of the petroleum industry supplied almost endless amount of basic material to the greater production of plastics, too. Regarding sports fields at first the cinder-tracks of the athletic grounds were replaced by plastic grounds (Bob Beamon's fantastic long-jumping world record of 890 cm was born on this type of ground in 1968), but cast- or spread-in-carpet plastic, firstly rubber covering with polyurethane sticking were applied instead of sports grounds with traditional cinder-, bitumen-, chad and similar bases. Of course, these solutions are not those, which constitute the object of the present invention but we illustrate the invasion of the plastics to the sports field construction by the help of the above. The open-air sports fields covered by natural lawn and/or made from natural materials, firmly kept their autocracy until quite recently, although the demand have been formulated long ago to the establishment of such sports grounds, first of all football-, field hockey-, tennis-, maybe golf grounds which have standard quality, are independent from the extreme effects of the weather and can be applied at all times. In the beginning they thought about training fields but also about construction of constant race grounds. The first football field covered by artificial lawn was built in West-Berlin on year 1975, but only as a training field. The international associations of the different sports permitted the fields covered artificial lawn for playing official matches only in the last decades, e.g. in field hockey since year 1996, in football since year 2000. It is not necessary to explain why it could mean an advantage for both spectators and players if the players would play on fields of same quality from Bahrain to Japan, from Argentina to Norway, since in this case the matches would been organized under same conditions. Of course, all this does not mean that the fields covered by natural lawn should be forbidden at any time. In order to clarify the concepts we emphasize that although the process according to the present invention is applied mainly for sports field construction and land planning and also for other purposes, hereinafter we shall deal only sports field construction. Those surfaces on which the play is going are called "artificial lawn" while the fibres themselves and the knots made from these fibres which play the role of the grass in this artificial lawn both in appearance and suitability for playing, are called to "artificial grass". The process according to the present invention obviously can be applied for any other purposes where preparation of textile- or plastic surfaces covered by fibres are necessary. At the construction of sports fields the artificial lawn has to be placed on some kind of ready-made base, because it could not play the intended role being alone or laying down without suitable ground. In order to form artificial lawn surfaces suitable for playing the gaps between the fibres of the artificial grass are filled with certain filling material in most of the sports. The filling material can be selected from quartz sand, rubber granulates and similars.

We first present a groundwork solution, which is especially accepted at the establishment of sports field, and then we present a solution for filling the artificial lawn with filling material(s). These solutions are not objects of our invention but it is advisable to be informed where and how the artificial lawn according to the present invention can be applied best of all. We are thinking always about football fields but this groundwork- and grass-filling technology can be applied in case of the sports fields of other sports, too, with practical and rational modifications. Regarding the ground, in the solution considered currently as best an elastic coating comes to a base from puddle stone, chad, concrete, bitumen and the like, the material of this coating is primarily rubber grist stuck with polyurethane and an adhesive. This base performs an elastic up and down movement under the weight of the player thus this playing field becomes similar to a soil of a natural field of excellent quality. The field base with artificial lawn sloping slightly laterally carries away the rainwater from the field by the help of a catchwater (drain) system or a wasteway. The artificial lawn then comes to this base and provides the playing surface together with the suitable filling material. The quartz sand filling material gives the weighting (loading) of the artificial lawn, and guarantees elastic playing surface with great strength gripping together with rubber granulates, thus reducing the chance of the injuries with abrasions, too. The presently accepted solution is the filling of the sand and the rubber after each other or an artificial lawn filling made from rubber granulate mixed with sand. Because of its significant weight the sand filling serves as a fastener or a weighting material for the artificial lawn. The grain size of 0,3 mm - 0,5 mm prevents the formation of dust; because of its great density it is positioned at the bottom of double-layer filling. The rubber granulate or similar elastic preparation of 0,5 mm - 2,5 mm grain size guarantees among others the elasticity of the field and the clinging of the sports shoes, too. There exists already a solution for preparation of artificial lawn that is based on a usual textile industrial technology, the carpet making. According to the generally accepted solution the artificial lawn is an undertexture cloth (fabric), mainly textile fabric, on which fibres are looped by a technology well known in the carpet making. It is possible to loop fibrillated (cut from folia), extruded, extruded-textured (handled mechanically and by heat) yarns (fibres) within the undertexture fabric. There can be manifold suitable materials for the yarns, they are, however, mainly polyethylene, polypropylene and their different copolymers. In case of fibrillated fibres cut from folia, the thickness of the fibre is the same as the thickness of folia and its width varies according to the wish of the manufacturer and the customer. The fibrillated fibre can be plate- or twisted shaped. The length of the fibres can vary, e.g. in case of field hockey and tennis 10-20 mm, for football 35-70 mm. The looping of the fibres can occur in a straight line, in a zigzag line, in wavy line, and so on. Fibres of different length and with varying quality and thickness are applied in the same carpet, respectively. To the reverse of the carpet a plastic, rubber or other material coating layer resisting to the weather is applied in order to prevent the tensibility of fibres. However, the fibres of artificial grass are always parallel, their characteristic is that in consequence of the same looping direction they lean in the same direction, their strength is established only with the support of the filling material. During the utilization of the sports field the artificial grass fibre lies down sinking down and compacting, therefore this fibre becomes shattered, and breaks. Thus the artificial grass fibre is not able to resist the mechanical effects. In connection with the sports fields supplied with artificial lawn several hundred patent were born which relate to ground, drainage of water, sticking, material of carpet, density and formation of artificial grass fibres (naps), water permeability of the base carpet, and many others. Within the traditional carpet looping technology we can emphasize such partial solutions which make possible that the artificial lawn reminds as well as possible of the natural lawn, and should be suitable as well as possible for the given purpose. EP 02559940 European patent document makes known such solution in which the plastic fibre is subjected to curling or waving in order to obtain the isotropic properties of the lawn. In this manner it is possible to reach a significant decrease of the coefficient of friction. A circular also known as "knitdeknit" looping process serves this aim, and the waving can be fixed by heat treatment. JP 9235702 Japanese patent document presents a solution in which the artificial lawn is constituted from thicker and thinner fibres; in this way a very beautiful, "leafy" lawn can be formed, which also retains better the filling material (counterweight). According to JP 2005200997 Japanese patent document the artificial lawn is prepared from twisted fibres that can be produced by twisting bunches of fibre; twisted and fastened fibres are woven into the fabric in order to form an artificial lawn with excellent durability similar to the natural lawn.

In contrary to our solution all these solutions are based on the carpet-looping process, and they want only to perfect the artificial lawn within this technology. Summarizing shortly, the basic idea of our invention is that by strengthening the most important properties of the artificial lawn (reduced maintenance, usefulness under whatever weather conditions, wear resistance, natural effect and appearance) we reproduce the aesthetical and spatial form of the natural lawn with an absolutely new method, and the formation and spatial visualization of a fibre form similar until delusion to the natural grass. Accordingly we plan the appearance and static properties of the individual fibres and knots of grass, thus increasing the quality of the sport activity on them and the better enjoyment for the spectators.

In the solution according to the present invention the novelty is that an artificial lawn is formed by the application of a different kind of technology; this artificial lawn exceeds the so far known solutions as far as the attractiveness, wear resistance, stability of the quality of the playing surface built from it and suitability are concerned, thus this technology provides more opportunity to the spread and standardization of sports fields furnished with artificial lawn. Thus our invention provides a new process for the production of artificial lawn from a cloth based on a textile cloth, or without it. The most general realization is possible according to Claims 1 and 9. The individual modes can be realized according to the texts formulated in the dependent claims. The process can be characterized as follows: a) knots made from synthetic material are die-cast through holes located in a mainly textile cloth serving as a grounding, or b) knots die-cast from synthetic material are sewed or otherwise fastened to a cloth mainly textile cloth serving as a grounding, or c) panels containing both plastic surface grounding and knots are developed by die- casting, or d) knots die-cast from synthetic material or die-cast panels covered fibres are sewed or otherwise fastened to a plastic ground plate element serving as a grounding.

The technology for achieving the given aim is the die-casting (also known as injection moulding) at all the four cases. It is possible to plan unique knots ("bunch of grass") by the suitable planning of the casting-die, forming their shape, density, aesthetical visualization, fibre length, static quality etc., correspondingly to the aim of the application. Applying this technology all the above-mentioned disadvantages of the carpet-looping technology disappear. The casting-die tool can be planned to a given aim, and it is possible to take into consideration the shape and the fibre length that the artificial grass fibre and the artificial grass knot intend to achieve, as well as the nature of the thermoplastic material. The characteristics of the traditional artificial grass are the following: number of artificial grass knots within 1 m 2 , length of fibres, thickness of fibres, and weight of the material of fibres within 1 m 2 . In our process the number of artificial grass fibres within 1 m 2 , length of fibres, and weight of fibres within 1 m 2 serve to the characterization of the artificial lawn. The number of the fibres within 1 m 2 is 2400-180000 pieces, and the length of the fibres is between 12 mm and 100 mm. The weight of the fibres depends on the sport for which the artificial lawn is prepared; this value can vary between 300 g and 4500 g. This number can be influenced partly by the form of the aimed die-casting tools or bunches of tools, and partly by the movements of the die-casting heads and the carpet serving as grounding, or in case of sewing of the plastic knots or panels, by the number of the sewing within 1 m 2 . The reason of the change in the number of knots or panels within 1 m 2 can be the suitability to a given play but also can be financial, too. Namely, the less frequent knot number means less cost and for certain sports fields the artificial lawn with less frequent knot number is also suitable. According to Method 1, the arrangement for the manufacturing technology of the artificial lawns consists of a roll train serving for the conveyance of a textile cloth reverse rolled up similarly to the traditional carpet-looping production process and of a - die-casting machine and tool or wreath of tools. In the case of the application of wreath of tools a die-casting machine have to be used with suitable size (die-casting pressure). The maximum dimension of the wreath of tools thus the size of the artificial lawn pieces, which can be die-cast simultaneously, is limited by the greatest possible die- casting pressure. In the solution according to the present invention the material of the artificial grass knot gets directly in die-casting manner into the reverse of the textile cloth from the die-casting tool at a temperature 170 0 C - 300 0 C and at pressure 2.10 s Pa - 3.10 10 Pa (-22000 atm - 300000 atm), where the die-casting tool is positioned on the one side of the textile grounding, and the discharge opening(s) of the die-casting tool(s) are positioned on the other side. By positioned moving of the textile cloth that constitutes the back panel and of the die-casting machine the knots or panels of the artificial grass can be adjusted to the desired frequency and distribution. By cooling down the material the die-cast material on the "grass knot" side of the textile cloth solidifies forming knots, while a continuous "film" layer of 0,1 mm - 2 mm thickness is developed from the material of the artificial grass on the side of the die-casting-die. The role of this coating is the same as in the carpet-looping process, i.e. the fibres should be fixed against drawing-off as well as the shape constancy of the carpet and the resistance against the weather should be guaranteed; to this, however, it is not necessary any separate technological step. The strips of the carpet are fixed to each other by sticking on a traditional glass cloth strip or by a sewing technology. The carpet is fixed by quartz sand used for filling the base of the sports field.

According to the Method 2 the die-cast artificial grass knots are prepared one by one or line by line at pressure 2.10 s Pa - 3.10 10 Pa (-22000 atm - 300000 atm) and at temperature 170 0 C - 300 0 C. The knots being finished separately will be sewed or otherwise fixed on the "artificial grass" side of the textile cloth after cooling down and hardening with suitably selected frequency. On the side of the cloth not covered by artificial grass it is possible optionally to apply a plastic-, rubber- or other weatherproof layer with 0,1 mm - 2 mm thickness on behalf of the shape constancy and resistance against weather, whilst it serves simultaneously the protection of sewing. The strips of the carpet are fixed to each other by sticking on a traditional glass cloth strip or by a sewing technology. The carpet is fixed by quartz sand used for filling the base of the sports field. The artificial lawn carpet formed according to Method 1 and 2 is coiled up and will be transported in coil from the scene of the manufacture to the scene of the application. According to Method 3 prefabricated carpet is not applied but primary panels of the artificial lawn are prepared. The die-casting tool forms such frame in which plastic skeleton substituting the prefabricating carpet and artificial grass knots inside can be found in proper frequency. The dimension and capacity of the die-casting apparatus and tool determine the dimensions of the panels, which are therefore smaller than the dimensions of the prefabricated carpets. The primary panels, the dimensions of which are not greater than 0,5 m x 0,5 m can be connected into each other and the artificial lawn can be formed on the surface having the desired size by the production of suitable number of elements (panels). The panels can get from the scene of the manufacture to the scene of the application on pallets where the panel units formed according to the dimensions of the pallet can be fixed to each other placing them side by side e.g. with gullet tooth coupling or another coupling equivalent to it. According to Method 4, the die-cast artificial grass knots or die-cast plastic panels are built onto the ground plates made from thermoplastic synthetic material (or expressing in another way, the die-cast artificial grass knots or die-cast artificial grass panels are planted). The ground plate lawn elements and panels are prepared in this manner. The grounding plate can be built from elements of different size depending on the dimension of the sports field to be covered. The dimension of the ground plate lawn elements, panels - without any intention to limitations - can expand from 25 cm x 25 cm maybe to 200 cm x 200 cm, too, preferably e.g. 100cm x 100 cm, but the square shape is not obligatory at all; if another shape brings about technological advantages, then whatever well fitting shape can be realized, e.g. rectangles with dimensions 12,2 cm x 24,4 cm, etc. The thickness of the grounding plate element varies between 2,5 mm and 50 mm, preferably it is 25 mm. The suitable dimensions and thickness of the ground plate elements and ground plate lawn elements, are determined by the accessibility of the manufacturing technology, the suitable transportability and adjustability of the elements, as well as the aim of the application. The ground plate lawn elements can be joined to each other with a formation of puzzle or with gullet tooth coupling or another equivalent method, and a surface of whatever size can be formed by joining a number of ground plate lawn elements of suitable size. By the help of different prefabricated ground plate lawn elements it is possible to complete the full ground plate lawn assortment of the sports fields, e.g. forming ground plate lawn elements of different colours to the lines, edges, borders, etc. of the field. The ground plate lawn elements suitably can be formed in a central manufacturing place and they can be transported to the sports fields e.g. on pallets. At the formation of the sports field, at the fitting of ground plate lawn elements it may be necessary to form special-shaped lawn pieces; this can be solved by the local application of a smaller equipment, or in case of smaller items, by hand-operated manufacturing to build a die- cast artificial lawn knot or artificial lawn panel to a ground plate piece of a given special shape. At the construction of the field on a carefully formed, flat, preferably water- permeable or water run-off base which can be - without any intention of limitation - bitumen, concrete, compacted crushed stone or gravel base, the ground plate lawn elements placed next to each other are joined by some kind of joining method. The lines and other painted signs of the sports field on the predefined ground plate lawn elements can be formed by changing the colour of the implanted artificial lawn knot or artificial lawn panel. In case of less exigent constructions the field lines are painted on the spot by traditional tools.

The ground plate lawn elements can be manufactured at a central place of production planting the die-cast artificial grass knots or artificial grass panels in a prefabricated ground plate made from thermoplastic synthetic material. The artificial grass knots can be separately prepared artificial grass knots according to Method 2, too. The mentioned artificial grass elements can be smaller artificial lawn elements prepared according to Method 3. The plantation can be realized by sticking, sewing or nailing up the artificial grass knot or artificial grass panel, or, depending on the technology, by placing or fixing to the holes formed in the ground plate element, where the latter solution is suitable for press-stud fixation or gullet tooth fixation. According to a preferable manner the insertion can occur by the application of an engus also known as inlet opening (it is a fashioned solidifying material in the channel that ensures the flow of material formed on the die-casting tool) as a joining element, or by the formation and application of another joining part suitable for this purpose at die-casting- of the artificial grass knot or panel. The fixation can be realized by the application of gullet tooth, press-stud or spring- pinned solution or by any method suitable for this purpose. Whatever manufacturing technology is applied, the material of the manufacture is certain thermoplastic synthetic material, mainly some sort of polyolefin as polyethylene, polypropylene or their different copolymers, but it is possible to apply thermoplastic polyesters or other thermoplastic synthetic materials, too. If artificial lawn prepared by whatever process is applied, the following advantages are demonstrable in contradiction with the earlier artificial lawns:

1. the field has a natural impression and supplies pleasant sight;

2. the surface of the field is absolutely flat;

3. the field can be used throughout the year; 4. the soil of the field is elastic, it behaves as a well-groomed natural grass; the fibres stand upwards;

5. excellent ball-bouncing and rolling properties, quick play;

6. strength-absorbing property is about 70%;

7. point- and territorial elasticity; 8. there is no fear of contact with the surface, the injuries caused by abrasion decrease significantly, the playing surface is secure;

9. the tackles, mainly the sliding tackles and turnings are as on the natural grass;

10. the field maintains its excellent properties, its playing characteristics do not change. Whatever process is applied, the artificial grass knots obtained can be subjected to a texturization process, too. The texturization process consists of mechanical- and heat- treating procedures as a result of which the fibres are curled and elastically regain this form after whatever application and under different weather conditions. Hereinafter we present the production- and application possibilities of the artificial lawn related to our process, without any intention to limit our scope of protection. Example 1

Example 1 gives example to the process of Method 1. A roll train conveys a coil made from prefabricated double-layer carpet reverse of 4 m, consisting of 100% polypropylene cloth and geotextile coating. The mass of the carpet is 1000 g/m 2 . One part of the die-casting tools are positioned on the lower, i.e. backside, the other part of the tools with the discharge openings for die-casting are positioned on the upper, "grass" side, getting across the carpet. The die-casting is carried out at pressure 8.10 9 Pa with polypropylene at temperature 195°C. The movement of the carpet and die-casting apparatus can adjust the frequency and distribution of the artificial grass knots in the artificial lawn. The shape of the artificial grass knots can be adjusted by proper planning of the tool. After cooling down artificial grass knots of 30 mm as greatest fibre length are formed with a frequency of 800 pieces/m 2 (which corresponds to 40000 fϊbre/m 2 ) on the artificial grass side while on the lower side of the carpet a 1 mm layer is formed from polypropylene. The finished artificial lawn can be transported in coils to the scene of the application. Example 2 Example 2 gives an example to the procedure of Method 2. In the die-casting tool having more seating polyethylene knots with 88 fibre/knot are prepared with 70 mm greatest length from at pressure 1,5.10 10 Pa and at temperature 180°C; these knots are sewed in frequency 900 knot/m 2 (79200 fibre/m 2 ) to the artificial grass side of the carpet serving as a reverse grounding which is unwound from a coil of carpet. The basic material of reverse grounding carpet coil is the same as in Example 1. On the reverse side a 0,8 mm latex layer is formed to protect the shape of the sewing and the reverse of carpet. The finished artificial lawn can be transported in coils to the scene of the application. Example 3 Example 3 gives an example to Method 3. By the help of a die-casting apparatus and a die-casting tool belonging to it such panel is die-cast from polyethylene-polypropylene copolymer, which includes both the ground plate (i.e. a separate ground plate cloth is not wanted) and the properly shaped artificial grass knots arranged with suitable frequency; the longest fibre in the knots has 50 mm length. The frequency of the knots is 2500 piece/m 2 , 55 fibre/knot. The dimension of each panel is 0,5 m x 0,5 m, the panels can be coupled to each other by toothing, thus the artificial lawn can be formed on any surface.. More panels can be assembled to the size of a pallet and they can be transported placing over each other on a pallet to the scene of the assembly. The artificial lawn surface of the field is fixed to the base by weighting (loading) with quartz sand of 0,3 mm - 0,8 mm grain size (20 kg/m 2 - 30 kg/m 2 ). The elastic playing surface is given by a recycled rubber granulate filling of 1 mm - 2 mm grain size spreading in 6 kg/m 2 - 8 kg/m 2 thickness. Example 4

Example 4 gives an example of Method 4. A ground plate is prepared as follows. A polypropylene ground plate element with 100 cm x 100 cm dimensions and with 15 mm thickness is used, and 1000 pieces of holes are pecked into it. 1000 pieces of artificial grass knots with 55 mm fibre length are prepared by die-casting from polypropylene, according to the technological parameters given at Example 2, where a knot contains 50 fibres. The tools for die-casting are formed so that the engus (inlet opening) of the die- cast artificial grass knot should fix the die-cast artificial grass with its extension and shape on the opposite (not the lawn) side of the ground plate element. The elements formed in this way are placed to the in previously formed holes. Example 5

Example 5 gives further example to the process of Method 4. The process is performed according to Example 4, but the die-cast plastic knot (of course with inlet opening of another formation) is fixed by sewing on the lawn side of the ground plate element. Example 6

Example 6 gives an additional example to Method 4. A composite plastic ground plate element with dimensions of 100 cm x 100 cm and with thickness of 10 mm is used on which 25 pieces of previously prepared artificial grass panel are stuck. Each of the previously prepared artificial grass panel has dimensions of 20 cm x 20 cm and is made according to Method 3. The ground plate element prepared in this way can be applied in the construction of sports fields. Example 7

Example 7 demonstrates the production of a sports field supplied with artificial lawn made from elements according to Methods 1 and 2 In order to gain the desired water- permeable, flat, broken stone base compacted to Try 95% value a layer with 30 mm thickness from 1 to 10 mixture of rubber granulate with 2-7 mm grain size and polyurethane adhesive is put down with a spreading machine (finisher). After absorbing the atmospheric humidity or watering the carpet coils with 400 cm width prepared according to Example 1 or 2 are laid down next to each other and their edges are stuck to a textile glass with 40 cm width with a polyurethane adhesive. The artificial lawn gives a homogenous surface on the field. The place of the lines and the sleeves of the built-in sports equipments are cut out from the artificial lawn, and the playing field are marked by sticking lines with suitable colour. The built-in sleeves are given a plastic covering supplied with artificial lawn in order to avoid the clogging of the sleeves. After complete hardening of the fittings and sticking, the artificial lawn made in this manner is filled in the whole area of the sports field with absolutely dry, dust-free quartz sand with 0,3 mm - 0,8 mm grain size in an amount of 20 kg/m 2 - 25 kg/m 2 . To this surface recycled rubber granulates with a desired - mainly black - colour and with of 0,5 mm - 2 mm grain size are placed in a thickness of 8 mm - 10 mm. Example 8 Example 8 demonstrates the construction of a sports field supplied with artificial lawn made from elements produced according to Method 3. The procedure is the same as the one in Example 7 but in advance assembled artificial grass panels according to Example 3 are applied, where the length of the artificial grass fibres is 40 mm. The panels are mounted to a uniform dimension in the manufacturing plant and are stored and transported on pallets. The panels are fixed to each other with suitable toothing. Previously produced line panels perform the lining of the sports field. The artificial lawn surface of the field is fixed to the base by weighting (loading) with quartz sand of 0,3 mm - 0,8 mm grain size (25 kg/m 2 - 30 kg/m 2 ). The elastic playing surface is given by filling in the artificial lawn with a recycled rubber granulate of 1 mm - 2 mm grain size spreading in 8 kg/m 2 - 10 kg/m 2 thickness. Example 9

This example demonstrates the construction of a sports field from ground plate elements formed according to Method 4. After stacking out the field firstly the so- called "mirror" will be formed. The field and also the mirror are absolutely horizontal and flat. The flatness of the mirror cannot diverge with more than ± 3 cm from the nominal value of the thickness of the build-up. The surface of the mirror is compacted to aTrγ 85% value. The four sides of the field are surrounded by "A" concrete brim placed in concrete beam of 100 cm x 25 cm x 5 cm. To the compacted mirror a drain (catchwater) system is formed placing its parts perpendicularly to the sidelines of the field being in 8-10 cm distance from each other. A filter layer is formed in 15 cm compacted thickness from frost-resistant breakstone with mostly 20 - 35 mm grain size in which the breakstone with less than d<0,02 mm grain size represents at last 5%, where the diversion from the nominal thickness can be 20 mm as a maximum. The surface unevenness can be 20 mm as a maximum, measuring with a 4 metres measuring rod. The extent of the compaction is Try 90%.

To the filter layera frost-resistant, loose supporting layer ranking to the category 0 - 20 mm is carried up in 10 cm compacted thickness. The proportion of the material with d<0,02 mm grain size can be 5% as a maximum. The value of the water absorption is >0,02 cm/s. The extent of the compaction is Try 90%. The deviation from the nominal thickness can be ± 10 mm as a maximum and its surface unevenness can be 10 mm as a maximum, measuring with a 4 metres measuring rod. Then the fine supporting layer will be carried up. This layer supports the loading and guarantees the even bearing of the artificial grass carpet or rather the ground plate lawn elements. This layer is made from frost-resistant material layer ranking to the category 0 - 8 mm with 3 cm compacted thickness. The material with 0,1 mm grain size as a maximum can represent at last 25%; the value of the water absorption is >0,02 cm/s. The extent of the compaction is Try 95%, the surface unevenness can be 4 mm as a maximum, measuring with a 4 metres levelling rod. By this procedure the under-structure becomes complete. The planted ground plate lawn elements made according to Method 4 with 12 mm thickness are laid to this under-structure, in these elements artificial grass knots were planted with 900 knot/m 2 frequency. The ground plate elements are put on the whole surface of the field from lawn elements (panels) with 100 cm x 100 cm dimensions transported to the scene on pallets. The field lines are formed with elements with different colours according to previously prepared, numbered system. In order to protect the fibres of the artificial grass and the weighting (loading) of the surface, the laid field is filled with quartz sand of 0,3 mm - 0,8 mm grain size in 15 mm thickness, hi order to guarantee the elasticity of the sports field the gaps between the grass fibres are filled with green "EPDM" rubber in 10 kg/m 2 quantity. Example 10

Example 10 demonstrates another process for the construction of a sports field from ground plate lawn elements (panels) made according to Method 4. The procedure is the same as in Example 9, but to the under-structure formed in that example a 20 mm thick elastic base is spread, and the ground plate lawn element will be carried to this additional layer. Example 11

The procedure for construction of the field base is the same as in Example 9, but the elastic base with 15 mm thickness is prepared during the assembly to the ground plate onto the artificial grass side. The artificial grass panels with dimensions of 25 cm x 25 cm are fixed to the ground plate across the elastic layer by nailing. In this manner well transportable pallet units can be obtained.