Process for applying film backing to synthetic turf and product

1. A method of making synthetic turf comprising:

applying an ethylene vinyl acetate copolymer adhesive to a first primary surface of a tufted primary backing to form a coating thereon and wherein the primary backing is tufted with a plurality of synthetic filaments to form a face pile extending outwardly from a second primary surface of the synthetic turf opposite the first primary surface; and

heating the ethylene vinyl acetate copolymer adhesive to a temperature above its melting point so that the ethylene-vinyl acetate copolymer adhesive melts and at least partially flows into the primary backing;

heating a linear low-density polyethylene film to a temperature below the softening point of the film;

pressing the heated linear low-density polyethylene film into contact with the polymer coated first primary surface of the tufted primary backing; and

allowing the ethylene vinyl acetate copolymer adhesive and the linear low-density polyethylene film to cool, whereby the linear low-density polyethylene film is adhered to the tufted primary backing.

2. The method of claim 1 , wherein the linear low-density polyethylene film is heated to a temperature of about 125 to about 175° F.

3. The method of claim 1 , wherein the primary backing comprises a woven polypropylene.

4. The method of claim 1 , wherein the primary backing comprises a woven polypropylene fabric and a polyethylene terephthalate nonwoven fabric attached to one side of the woven polypropylene fabric.

5. The method of claim 4 , wherein the polyethylene terephthalate nonwoven fabric is attached to the woven polypropylene fabric by needling.

6. The method of claim 1 , wherein the linear low-density polyethylene film has a thickness of about 40 mils.

7. The method of claim 1 , wherein the ethylene vinyl acetate copolymer adhesive is applied at a rate of approximately 5 to approximately 20 ounces per square yard of primary backing.

8. The method of claim 1 , wherein the ethylene vinyl acetate copolymer adhesive is applied at a rate of approximately 8 to approximately 16 ounces per square yard of primary backing.

9. The method of claim 1 , wherein the ethylene vinyl acetate copolymer adhesive is applied at a rate of approximately 8 ounces per square yard of primary backing.

10. The method of claim 1 , wherein the ethylene vinyl acetate copolymer adhesive is applied in the form of solid ethylene-vinyl acetate polymer particles having an average particle size of approximately 1 to approximately 1,000 microns.

11. The method of claim 10 , wherein the solid ethylene-vinyl acetate polymer particles have a melt index of approximately 5 to approximately 500 grams/10 minutes at 190° C. at a weight of 2.16 kg.

12. The method of claim 1 , wherein the ethylene vinyl acetate copolymer adhesive comprises approximately 18% by weight vinyl acetate.

13. A method of making synthetic turf comprising:

applying an ethylene-vinyl acetate copolymer adhesive to a first primary surface of a tufted primary backing to form a coating thereon and wherein the primary backing is tufted with a plurality of synthetic filaments to form a face pile extending outwardly from a second primary surface of the synthetic turf opposite the first primary surface, wherein the primary backing comprises a woven polypropylene; and

heating the ethylene-vinyl acetate copolymer adhesive to a temperature above its melting point so that the ethylene-vinyl acetate copolymer adhesive melts and at least partially flows into the primary backing;

heating a linear low-density polyethylene film to a temperature of about 125 to about 175° F.;

pressing the heated linear low-density polyethylene film into contact with the polymer coated first primary surface of the tufted primary backing; and

allowing the ethylene-vinyl acetate copolymer adhesive and the linear low-density polyethylene film to cool, whereby the linear low-density polyethylene film is adhered to the tufted primary backing.

14. The method of claim 13 , wherein the primary backing comprises a woven polypropylene fabric and a polyethylene terephthalate nonwoven fabric attached to one side of the woven polypropylene fabric.

15. The method of claim 14 , wherein the polyethylene terephthalate nonwoven fabric is attached to the woven polypropylene fabric by needling.

16. The method of claim 15 , wherein the linear low-density polyethylene film has a thickness of about 40 mils.

17. The method of claim 16 , wherein the ethylene vinyl acetate copolymer adhesive is applied at approximately 5 to approximately 20 ounces per square yard of primary backing.

18. The method of claim 16 , wherein the ethylene vinyl acetate copolymer adhesive is applied at a rate of approximately 8 to approximately 16 ounces per square yard of primary backing.

19. The method of claim 16 , wherein the ethylene vinyl acetate copolymer adhesive is applied at a rate of approximately 8 ounces per square yard of primary backing.

20. The method of claim 17 , wherein the ethylene vinyl acetate copolymer adhesive is applied in the form of solid ethylene-vinyl acetate polymer particles have an average particle size of approximately 1 to approximately 1,000 microns.

21. The method of claim 20 , wherein the solid ethylene-vinyl acetate polymer particles have a melt index of approximately 5 to approximately 500 grams/10 minutes at 190° C. at a weight of 2.16 kg.

22. The method of claim 21 , wherein the ethylene vinyl acetate copolymer adhesive comprises approximately 18% by weight vinyl acetate.