CN107009631A - 一种整体可回收人造草坪及其制备方法 - Google Patents

一种整体可回收人造草坪及其制备方法 Download PDF

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Publication number
CN107009631A
CN107009631A CN201710337490.8A CN201710337490A CN107009631A CN 107009631 A CN107009631 A CN 107009631A CN 201710337490 A CN201710337490 A CN 201710337490A CN 107009631 A CN107009631 A CN 107009631A
Authority
CN
China
Prior art keywords
base fabric
artificial grass
grass filaments
hot
chinampa
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
CN201710337490.8A
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English (en)
Inventor
钱浩
赵春贵
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
JIANGSU CO-CREATION GRASS Co Ltd
Original Assignee
JIANGSU CO-CREATION GRASS Co Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Family has litigation
First worldwide family litigation filed litigation Critical https://patents.darts-ip.com/?family=59450103&utm_source=google_patent&utm_medium=platform_link&utm_campaign=public_patent_search&patent=CN107009631(A) "Global patent litigation dataset” by Darts-ip is licensed under a Creative Commons Attribution 4.0 International License.
Application filed by JIANGSU CO-CREATION GRASS Co Ltd filed Critical JIANGSU CO-CREATION GRASS Co Ltd
Priority to CN201710337490.8A priority Critical patent/CN107009631A/zh
Publication of CN107009631A publication Critical patent/CN107009631A/zh
Priority to EP17909963.5A priority patent/EP3450628A4/en
Priority to JP2018553962A priority patent/JP2019525028A/ja
Priority to PCT/CN2017/115542 priority patent/WO2018209931A1/zh
Priority to AU2017414195A priority patent/AU2017414195B2/en
Priority to US16/152,803 priority patent/US20190032286A1/en
Priority to JP2020105705A priority patent/JP7089552B2/ja
Pending legal-status Critical Current

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Classifications

    • E—FIXED CONSTRUCTIONS
    • E01—CONSTRUCTION OF ROADS, RAILWAYS, OR BRIDGES
    • E01C—CONSTRUCTION OF, OR SURFACES FOR, ROADS, SPORTS GROUNDS, OR THE LIKE; MACHINES OR AUXILIARY TOOLS FOR CONSTRUCTION OR REPAIR
    • E01C13/00—Pavings or foundations specially adapted for playgrounds or sports grounds; Drainage, irrigation or heating of sports grounds
    • E01C13/08—Surfaces simulating grass ; Grass-grown sports grounds
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/40—Applying molten plastics, e.g. hot melt
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/48—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
    • B29C65/4805—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding characterised by the type of adhesives
    • B29C65/481—Non-reactive adhesives, e.g. physically hardening adhesives
    • B29C65/4815—Hot melt adhesives, e.g. thermoplastic adhesives
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/48—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
    • B29C65/486—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding characterised by their physical form being non-liquid, e.g. in the form of granules or powders
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    • B29C65/56—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using mechanical means or mechanical connections, e.g. form-fits
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    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
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    • B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
    • B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
    • B29C66/45—Joining of substantially the whole surface of the articles
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
    • B29C66/729—Textile or other fibrous material made from plastics
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
    • B29C66/729—Textile or other fibrous material made from plastics
    • B29C66/7294—Non woven mats, e.g. felt
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/90—Measuring or controlling the joining process
    • B29C66/91—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux
    • B29C66/919—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux characterised by specific temperature, heat or thermal flux values or ranges
    • B29C66/9192—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux characterised by specific temperature, heat or thermal flux values or ranges in explicit relation to another variable, e.g. temperature diagrams
    • B29C66/91921—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux characterised by specific temperature, heat or thermal flux values or ranges in explicit relation to another variable, e.g. temperature diagrams in explicit relation to another temperature, e.g. to the softening temperature or softening point, to the thermal degradation temperature or to the ambient temperature
    • B29C66/91931—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux characterised by specific temperature, heat or thermal flux values or ranges in explicit relation to another variable, e.g. temperature diagrams in explicit relation to another temperature, e.g. to the softening temperature or softening point, to the thermal degradation temperature or to the ambient temperature in explicit relation to the fusion temperature or melting point of the material of one of the parts to be joined
    • B29C66/91935—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux characterised by specific temperature, heat or thermal flux values or ranges in explicit relation to another variable, e.g. temperature diagrams in explicit relation to another temperature, e.g. to the softening temperature or softening point, to the thermal degradation temperature or to the ambient temperature in explicit relation to the fusion temperature or melting point of the material of one of the parts to be joined lower than said fusion temperature
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/919—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux characterised by specific temperature, heat or thermal flux values or ranges
    • B29C66/9192—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux characterised by specific temperature, heat or thermal flux values or ranges in explicit relation to another variable, e.g. temperature diagrams
    • B29C66/91921—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux characterised by specific temperature, heat or thermal flux values or ranges in explicit relation to another variable, e.g. temperature diagrams in explicit relation to another temperature, e.g. to the softening temperature or softening point, to the thermal degradation temperature or to the ambient temperature
    • B29C66/91941—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux characterised by specific temperature, heat or thermal flux values or ranges in explicit relation to another variable, e.g. temperature diagrams in explicit relation to another temperature, e.g. to the softening temperature or softening point, to the thermal degradation temperature or to the ambient temperature in explicit relation to Tg, i.e. the glass transition temperature, of the material of one of the parts to be joined
    • B29C66/91943—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux characterised by specific temperature, heat or thermal flux values or ranges in explicit relation to another variable, e.g. temperature diagrams in explicit relation to another temperature, e.g. to the softening temperature or softening point, to the thermal degradation temperature or to the ambient temperature in explicit relation to Tg, i.e. the glass transition temperature, of the material of one of the parts to be joined higher than said glass transition temperature
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Abstract

本发明公开了一种整体可回收人造草坪，该人造草坪解决了原有人造草坪簇绒困难的问题，簇绒效率高，人造草坪强度高，同时整体可回收。本发明的整体可回收人造草坪，包括有人造草丝和底布，所述的底布含有机织布，人造草丝簇绒在含有机织布的底布上，再使人造草丝根部熔融或局部熔融，冷却定型后人造草丝与底布形成一个整体，其中所述的人造草丝材质的熔点低于底布材质的熔点。

Description

一种整体可回收人造草坪及其制备方法
技术领域
本发明涉及一种人造草坪及其制备方法，更具体的说是涉及一种整体可回收人造草坪及其制备方法。
背景技术
人造草坪由人造草丝、底布、背胶三部分组成，其性能主要由人造草丝体现，良好的耐磨、缓冲性能，优良的耐候性及清新、绿色的外观使其不论是在运动草还是休闲草方面都深受用户好评。人造草丝的材质主要有PE、PP和PA，其中PE因其优良柔软性、耐老化性能优越和价格低廉而成为人造草丝主要原材料，底布主要起到固定人造草丝和提供人造草坪整体力学性能的作用，先将人造草丝簇绒到底布上，在底面涂上一层背胶将人造草丝固定，使得人造草丝和底布成为一个整体，其中背胶主要有丁苯胶和PU胶两种。
上述结构的人造草坪即目前应用最广泛的常规人造草坪，由于丁苯胶或者PU胶的存在，使得其在达到使用年限后无法回收利用，只能作填埋或焚烧处理，这样一方面对环境造成污染，另一方面也造成巨大的原料浪费，在当面资源枯竭和倡导可循环利用的背景下，随着人造草坪使用量的快速增长，其回收及再利用问题已经成为急需解决的问题，各人造草坪制造商都在努力寻求解决方法，其中可回收人造草坪的研发已经成为解决这一问题的主要突破口。
可回收人造草坪，核心问题是解决背胶的回收，用热塑性材料替代传统的丁苯或者PU背胶是解决这一问题的途径之一，公开号为CN102808368A的专利提供了一种可回收人造草坪及其制备方法，将EVA热熔胶加热到160-180℃，熔融状态下将其均匀的涂覆在簇有人造草丝的PP基布上，通过EVA热熔胶对人造草丝加以固定，同时也实现了人造草坪的整体回收；公开号为CN104060518A的专利提供了另一种可回收人造草坪及其制备方法，其制备方法是先将人造草丝簇在PP基布上制备半成品，然后通过流延涂布工艺将TPR、TPE及TPU等热塑性弹性体涂在基布的背侧形成厚度为0.3-5mm的背胶层，制备可回收人造草坪。上述两种方法即用热塑性的材料代替PU或者丁苯胶乳，利用其将人造草丝和底布固定在一起，虽然都满足了人造草坪的可回收技术要求，但存在以下明显缺点：
(1)每簇草上有多根人造草丝，熔融状态下的热熔胶粘度大，难以渗透到人造草丝簇内部，造成人造草丝拔脱力低，在人造草坪的使用过程中，人造草丝很容易整根从底部上掉落出来。
(2)由于是满涂于底部上，而热塑性材料是不透水的，因而人造草坪系统需要打排水孔方可实现排水功能，打排水孔破坏了人造草坪的整体结构，降低人造草坪的力学性能。
公开号为CN104727202A的专利提供了一种可回收人造草坪，其制备方法是将人造草丝簇绒在含有无纺布的底布上制成半成品，然后在半成品底下再覆一层无纺布，通过底层无纺布对人造草丝根部加热，两层无纺布间有热熔粉，受热熔融的人造草丝根部和热熔粉粘在一起固定在两层无纺布之间，从而实现人造草坪的整体回收，同时无纺布具有很好的渗水功能，再加上热熔粉不是满涂，相互间有间隙，该方法制得的人造草坪不打排水孔也有非常好的排水性能。然而该方法制备的可回收人造草坪，其在结构及性能上依然存在很大的问题，主要表现在如下两方面：
(1)固定人造草丝的底布由无纺布构成，因其结构松散，在实际应用中，簇绒非常困难，生产效率极低，并且生产出的人造草坪其外观质量不好。
(2)无纺布的松散结构导致人造草坪强度差，难于满足运动场地的要求。
综上所述，目前可回收人造草坪的开发，无论在结构还是性能上，均存在着较大缺陷，不利于量产和新产品的推广，因此需要研制一种新型的整体可回收人造草坪及制备方法以解决现有技术中存在的问题，从而满足市场日益发展的需要。
发明内容
本发明解决上述存在的问题，提供了一种整体可回收人造草坪，该人造草坪解决了原有人造草坪簇绒困难的问题，簇绒效率高，人造草坪强度高，同时整体可回收。
本发明还提供该整体可回收人造草坪的制备方法，其制备方法简单，节省人力，节约成本，操作简便，利于工业化应用。
本发明是通过以下技术方案实现的：
本发明的整体可回收人造草坪，包括有人造草丝和底布，所述的底布含有机织布，人造草丝簇绒在含有机织布的底布上，再使人造草丝根部熔融或局部熔融，冷却定型后人造草丝与底布形成一个整体，其中所述的人造草丝材质的熔点低于底布材质的熔点。当然机织布本身也可以就是底布。
本发明的整体可回收人造草坪，其进一步的技术方案是所述的人造草丝根部为簇绒后位于底布底面下方的人造草丝。
本发明的整体可回收人造草坪，其进一步的技术方案还可以是所述的使人造草丝根部熔融或局部熔融是通过热复合的方式进行。
本发明的整体可回收人造草坪，其进一步的技术方案还可以是所述的机织布为单层机织布或复合机织布。
本发明的整体可回收人造草坪，其进一步的技术方案还可以是所述的底布在簇绒人造草丝前，通过撒粉工序在底布底面上撒有热熔胶粉；更进一步的技术方案是所述的底布还含有网格布；再进一步的技术方案是所述的网格布材质的熔点高于人造草丝材质的熔点，网格布使用前要先经过热处理。所述的网格布或者无纺布的热处理方法优选如下：通过烘箱热辐射或者热辊直接加热的方式对网格布或者无纺布加热，加热温度控制在材料的玻璃化温度和熔点之间，冷却定型后完成网格布或无纺布的热处理。材质优选为聚对苯二甲酸乙二醇酯，加热温度优选范围是170-200℃。
本发明的整体可回收人造草坪，其再进一步的技术方案还可以是所述的网格布克重为50-200g/m2，所述的网格布材质优选为聚对苯二甲酸乙二醇酯。
本发明的整体可回收人造草坪，其进一步的技术方案是还可以在所述的簇绒上人造草丝的底布底面上热复合上另外一层底布。更进一步的技术方案是所述的热复合在簇绒有人造草丝的底布底面上的底布材质的熔点高于人造草丝材质的熔点，且底布在热复合前，通过撒粉工序在其一面上撒有热熔胶粉。更进一步的技术方案还可以是所述的热复合在簇绒有人造草丝的底布底面上的底布为无纺布或者无纺布和网格布的复合布。再进一步的技术方案是所述的无纺布或者无纺布和网格布的复合布在使用前要先经过热处理。更进一步的技术方案是所述的网格布或者无纺布的热处理方法是：通过烘箱热辐射或者热辊直接加热的方式对网格布或者无纺布加热，加热温度控制在材料的玻璃化温度和熔点之间，冷却定型后完成网格布或无纺布的热处理。更进一步的技术方案还可以是所述的无纺布和网格布的复合布的热处理方法有两种，一是通过烘箱热辐射或者热辊直接加热的方式分别对无纺布和网格布进行热处理，加热温度控制在材料的玻璃化温度和熔点之间，然后通过撒粉工序将二者热粘合在一起形成复合布；二是将无纺布和网格布先通过缝编工艺缝在一起，然后再通过烘箱热辐射或者热辊直接加热的方式对复合布加热，加热温度控制在材料的玻璃化温度和熔点之间，冷却定型后完成热处理。再进一步的技术方案是所述的无纺布克重优选为50-150g/m2，网格布克重优选为80-150g/m2，所述的无纺布或网格布材质优选为聚对苯二甲酸乙二醇酯。所述的无纺布或网格布材质为聚对苯二甲酸乙二醇酯时，其热处理时加热温度范围优选是170-200℃。
本发明的整体可回收人造草坪，其进一步的技术方案还可以是所述的热熔胶粉材质的熔点低于底布材质的熔点；优选与人造草丝材质的熔点接近或相同的热熔胶粉，所述的熔点接近是指相差在±10℃。更进一步的技术方案是所述的热熔胶粉为PE、EVA、TPU中的一种或其组合，热熔胶粉的撒粉量为60-150g/m2。
本发明上述的整体可回收人造草坪的制备方法，其包括以下步骤：
(1)按照规格将人造草丝簇绒在机织布底布上制成半成品；
(2)经过热复合工序，对半成品底部进行加热，使人造草丝根部熔融或局部熔融，冷却定型后人造草丝与底布形成一个整体，得到整体可回收人造草坪。
本发明的整体可回收人造草坪的制备方法，其进一步的技术方案是包括以下步骤：
(1)通过撒粉工序在机织布底布的一面上撒上热熔胶粉；
(2)按照规格将人造草丝簇绒在机织布底布上制成半成品；
(3)经过热复合工序，对半成品底部进行加热，使人造草丝根部熔融或局部熔融并与热熔胶粉熔融，冷却定型后人造草丝与底布形成一个整体，得到整体可回收人造草坪。
本发明的整体可回收人造草坪的制备方法，其再进一步的技术方案是包括以下步骤：
(1)通过撒粉工序将机织布和网格布一起撒粉制成底布，或者先对机织布撒粉然后再与网格布结合在一起制成底布；
(2)按照规格将人造草丝簇绒在底布上制成半成品；
(3)经过热复合工序，对半成品底部进行加热，使人造草丝根部熔融或局部熔融并与热熔胶粉熔融，冷却定型后人造草丝与底布形成一个整体，得到整体可回收人造草坪。
本发明的整体可回收人造草坪的制备方法，其更进一步的技术方案是包括以下步骤：
(1)通过撒粉工序在无纺布或者无纺布和网格布的复合布的一面撒上一层热熔胶粉，制成底层的底布；
(2)通过撒粉工序将机织布和网格布一起撒粉制成底布，或者先对机织布撒粉然后再与网格布结合在一起制成簇绒所用的底布；
(3)按照规格将人造草丝簇绒在底布上制成半成品，并将撒过粉的另一底布覆于半成品底面，该底布的带热熔胶粉面与草根接触；
(4)经过热复合工序，对底层底布不带热熔胶粉面加热，使人造草丝根部熔融或局部熔融并与熔融后的热熔胶粉粘在一起，冷却定型后人造草丝与两层底布形成一个整体，得到整体可回收人造草坪。
本发明的整体可回收人造草坪的制备方法，其进一步的技术方案还可以是所述的网格布、无纺布或者无纺布和网格布的复合布在使用前需要经过热处理，其中所述的网格布或者无纺布的热处理方法是：通过烘箱热辐射或者热辊直接加热的方式对网格布或者无纺布加热，加热温度控制在材料的玻璃化温度和熔点之间，冷却定型后完成网格布或无纺布的热处理；所述的无纺布和网格布的复合布的热处理方法有两种，一是通过烘箱热辐射或者热辊直接加热的方式分别对无纺布和网格布进行热处理，加热温度控制在材料的玻璃化温度和熔点之间，然后通过撒粉工序将二者热粘合在一起形成复合布；二是将无纺布和网格布先通过缝编工艺缝在一起，然后再通过烘箱热辐射或者热辊直接加热的方式对复合布加热，加热温度控制在材料的玻璃化温度和熔点之间，冷却定型后完成热处理。更进一步的技术方案是所述的无纺布或网格布材质优选为聚对苯二甲酸乙二醇酯，热处理时加热温度范围是170-200℃。
本发明的整体可回收人造草坪的制备方法，其进一步的技术方案是所述的撒粉工序是利用烘箱热辐射或者热辊直接加热的方式对热熔胶粉加热，使其熔融产生黏性粘在机织布或无纺布表面，或者将机织布与网格布、无纺布与网格布粘在一起，冷却定型后形成整体。
本发明的整体可回收人造草坪的制备方法，其进一步的技术方案还可以是所述的热复合工序是利用烘箱热辐射或者热辊直接加热的方式对人造草丝根部或不带热熔胶粉面的底布加热，使人造草丝根部和热熔胶粉熔融产生黏性，相互结合在一起，再经过冷却定型，把人造草丝牢牢的固定在底布上。
与现有技术相比本发明有以下有益效果：
1、利用底布和人造草丝材质的熔点差，使得人造草丝根部熔融或局部熔融的同时，底布不受影响，一方面实现了人造草丝在底布上的固定，另一方面保证了人造草坪的整体性。
本发明的整体可回收人造草坪，其制备方法是采用热复合方式，通过烘箱热辐射或者热辊直接加热的方法对簇绒人造草丝的底布底面加热，由于每簇上有数根人造草丝，当人造草丝根部熔融或者局部熔融后，相互间产生黏性结合在一起并粘在底布上，冷却定型后形成整体从而得到整体可回收人造草坪，该制备方法决定了人造草丝材质的熔点要低于底布材质的，且两者熔点的差值越大越容易实现，人造草丝的材质主要有PP和PE，且PE占大部分，故而有PET和PP两类常用的机织布可供选择，而目前市场PP机织布的普及率远高于PET，因此，克服PE和PP熔点差值小带来的热复合难度大和保持人造草坪的整体性成为本发明的关键技术之一。
2、机织布力学强高，固定人造草丝能力强，解决现有技术存在的簇绒困难和人造草坪外观不好两大难题。
机织布制造过程先后经历拉丝、热处理、整经、机织等工序，拉丝和热处理两道工序使得机织布有较高的力学强度和热稳定性，再经过整经和机织，形成经纬线紧密交织的网状结构，保证了其固定人造草丝的能力，彻底解决现有技术存在的簇绒难问题，同时其紧密结构又不影响布的渗水性能，且热熔胶粉在其表面呈点状分布，从而使其具有良好的排水性能，机织布常用的材质为PP和PET两种，其中PP机织布优先的克重范围是90-200g/m2，PET机织布优选的克重范围是150-350g/m2。
复合机织布在单层机织布的基础上制作而成，主要有两种制备方法，一是在单层机织布表面针刺一层PET短纤或长纤，另一种方法是用缝编机在单层机织布表面缝上一层PET纤维。PET具有较高的熔点，尤其是和PP机织布复合使用时，隔热效果好，对PP布起到保护作用，从而可以在较高的加工温度下进行生产，提升产能，同时PET纤维的毛面更有利于热熔胶粉的附着，复合PET层的常用克重为50-150g/m2。
3、底布表面撒上一层热熔胶粉，一方面提升底布的热收缩性能，另一方面增强底布对人造草丝的固定强度。
撒粉工序的操作是：首先将热熔胶粉均匀的分散在底布表面，热熔胶粉在布表面呈点状分布，然后通过烘箱热辐射或热辊直接加热的方式对热熔胶粉加热至熔融，热熔胶粉产生黏性粘在底布上，冷却定型后和底布形成整体(如图1所示)，且底布在撒粉过程中相当于经历一次热定型，从而也提高了底布的耐热性能。
撒粉后的底布簇绒上人造草丝制成半成品后，通过烘箱热辐射或热辊直接加热的方式对半成品底面加热，人造草丝根部熔融，同时底布表面的热熔胶粉也熔融，与人造草丝根部结合在一起，进一步增强了底布对人造草丝的固定能力，另一方面，由于热熔胶粉在底布表面呈点状分布，不影响底布的透水性能，从而也保证了人造草坪的整体渗水性能。
4、簇绒底布结构中添加预先经过热处理的网格布，一方面保证了人造草坪的整体力学强度，另一方面解决人造草坪使用过程中可能出现的热收缩问题。
网格布的生产流程与机织布基本一致，也要经过拉丝、热定型、整经和机织等工序，主要区别在于其经线、纬线间有间隙，从而形成网状结构，网孔大小为1×1mm～5×5mm，由于网格布上的每一根经线或纬线都是由一定数量的PET丝组成，这些PET丝经过拉丝和热定型后，具有一定的力学强度，从而使得整体网格布的具有很高的强度，与单层或复合机织布一起使用时，能明显提高人造草坪强度。另一方面，网格布在织造过程中丝线在受到牵引、拉伸、扭曲等机械作用时，其分子结构会发生变化，这种形变由于发生在PET的玻璃化温度(Tg＝81℃)以下，因此保留下来的形变属强迫高弹形变，即使在外力除去后也不能回复，形变保留在纤维上，而当再次受热时(温度高于Tg)，产生分子运动，其结果是趋于能量最低状态，宏观表现就是网格布的热变形，因此在使用前要对PET网格布进行热定型，温度应控制在其Tg和Tm之间，实际生产中热定型的方式有两种，一种是烘箱热辐射的方式，加热温度控制在150-220℃，线速度在10-15m/min，另一种是热辊直接加热的方式，辊表面温度控制在180-200℃，线速度在3-7m/min。
另一方面，网格布作为底布的一部分，主要起增加力学强度的作用，其与机织布的组合方式比较灵活，可以随机织布一起经撒粉后通过热熔胶粉的热粘合作用结合在一起，也可以待机织布表面的热熔胶粉熔融后再将网格布覆在其上，施加一定压力使二者结合在一起，还可以在人造草丝的簇绒过程中将二者结合在一起，以上三种方式中，前两种网格布和机织布间结合的较紧密，但撒粉工序相对较繁琐，第三种网格布和机织布间仅通过人造草丝结合在一起，外观上不如前二者，但机织布的撒粉工序操作相对简便，但无论何种方式，均不会对人造草丝的固定强度及人造草坪的整体强度产生影响，可视具体情况进行选择。
5、再热复合一层底层底布，保护人造草坪底部，降低对铺装场地地基的要求。
底布材质的熔点要高于人造草丝材质的，常用的如PET类，考虑到底布的导热效率，一般选择结构较为松散的无纺布，同时底布上还可以含有网格布，以进一步增强人造草坪的整体力学强度。
常规人造草坪底面为一层胶乳层(丁苯或者PU胶乳)，由于丁苯类胶乳的耐水性较差，长时间浸泡在水中可能会出现“掉胶”现象，从而使部分人造草丝的根部露出，在实际使用过程中就有可能出现人造草丝根部与地基间的摩擦现象，为减小人造草丝根部的磨损，一般运动场地在铺装时对地基都有严格的要求，表面要平整且光滑，以免因磨损严重而影响使用寿命，通过在人造草坪底层增加一层底布，有效避免了人造草丝根部与地基间的摩擦，从而降低对场地地基的要求，节省人力财力，降低铺装成本。
附图说明
图1撒粉后的底布结构示意图
图2是本发明的整体可回收人造草坪的半成品结构示意图
图3是本发明的整体可回收人造草坪的成品结构示意图
图4是底布撒粉后的整体可回收人造草坪的半成品结构示意图
图5是底布撒粉后的整体可回收人造草坪的成品结构示意图
图6是底布撒粉且加网格的整体可回收人造草坪的半成品结构示意图
图7是底布撒粉且加网格的整体可回收人造草坪的成品结构示意图
图8是含有底层底布的整体可回收人造草坪结构示意图
具体实施方式
通过以下实施例说明本发明，但本发明并不限定于这些实施例，并对以下实施例作如下说明：
1、人造草丝的制备方法
(1)将5000S树脂50份，7042树脂40份，色母粒8份，加工助剂(包括紫外光稳定剂、抗氧剂、抗静电剂、开口剂、分散剂)2份，混合均匀；
(2)挤出成型温度控制在190℃～230℃，牵伸比设定为5-6，烘箱温度控制在95～100℃，经单螺杆挤出机挤出、拉丝，制备人造草丝。
2、网格布、无纺布或无纺布和网格布的复合布的热处理有以下几种方式：
(1)烘箱加热，温度170-175℃，线速度约13m/min；
(2)烘箱加热，温度180-185℃，线速度约15m/min；
(3)热辊加热，温度185-190℃，线速度约4.5m/min；
(4)热辊加热，温度195-200℃，线速度约7.0m/min。
3、对比样(CN104727202A)的制备方法
(1)按100g/m2的撒粉量将PE热熔胶粉均匀的分散于100g/m2PET无纺布和80g/m2PET网格布复合的基布A上，烘箱加热，温度控制在170-180℃，热熔胶粉熔融产生黏性将网格布与无纺布粘在一起得到基布A。
(2)按100g/m2的撒粉量将PE热熔胶粉均匀的分散于80g/m2PET无纺布和120g/m2PET网格布复合的基布B上，烘箱加热，温度控制在170-180℃，热熔胶粉熔融产生黏性将网格布与无纺布粘在一起得到基布B。
(3)按相应的针距和行距将人造草丝簇在基布A上(网格面在下)得到半成品草坪，以网格面相贴的方式将尺寸相同的基布B与半成品草坪一起通过加热辊，传输速度为3m/min，温度控制在180-190℃，冷却定型后得到公开号为CN104727202A的可回收人造草坪。
4、人造草坪强度检测，按照BS EN12228:2002规定的方法测试底背的拉断力，人造草丝拔出力按FIFA要求的ISO4919-1978标准进行检测。
实施例1
(1)按80g/m2的撒粉量将PE热熔胶粉均匀的撒在200g/m2的PP单层机织布上，烘箱加热，温度控制在130-140℃，热熔胶粉熔融产生黏性粘在机织布上，冷却、定型，制成底布。
(2)将人造草丝簇绒在底布上制成半成品人造草坪(带热熔胶粉面为底面)，然后通过热辊对半成品底面加热，加热温度控制在150-160℃，人造草丝根部和热熔胶粉熔融，粘在一起，冷却、定型，得到整体可回收人造草坪。
(3)测试人造草丝拔出力及人造草坪底背拉断力，结果见附表1。
实施例2
(1)按120g/m2的撒粉量将PE热熔胶粉均匀的撒在150g/m2的PP单层机织布上，烘箱加热，温度控制在130-140℃，热熔胶粉熔融产生黏性粘在机织布上，冷却、定型，制成底布。
(2)将人造草丝簇绒在底布上制成半成品人造草坪(带热熔胶粉面为底面)，然后通过热辊对半成品底面加热，加热温度控制在150-160℃，人造草丝根部和热熔胶粉熔融，粘在一起，冷却、定型，制备整体可回收人造草坪。
(3)测试人造草丝拔出力及人造草坪底背拉断力，结果见附表1。
实施例3
(1)按160g/m2的撒粉量将PE热熔胶粉均匀的撒在135g/m2的PP单层机织布上，烘箱加热，温度控制在130-140℃，热熔胶粉熔融产生黏性粘在机织布上，冷却、定型，制成底布。
(2)将人造草丝簇绒在底布上制成半成品人造草坪(带热熔胶粉面为底面)，然后通过热辊对半成品底面加热，加热温度控制在150-160℃，人造草丝根部和热熔胶粉熔融，粘在一起，冷却、定型，制备整体可回收人造草坪。
(3)测试人造草丝拔出力及人造草坪底背拉断力，结果见附表1。
实施例4
(1)将人造草丝簇绒在300g/m2的PET单层机织布上制成半成品人造草坪。
(2)通过烘箱对半成品底面加热，加热温度控制在160-170℃，人造草丝根部熔融产生黏性粘在底布上，冷却、定型，制备整体可回收人造草坪。
(3)测试人造草丝拔出力及人造草坪底背拉断力，结果见附表1。
实施例5
(1)按120g/m2的撒粉量将EVA热熔胶粉均匀的撒在250g/m2的PET单层机织布上，烘箱加热，温度控制在120-130℃，热熔胶粉熔融产生黏性粘在机织布上，冷却、定型，制成底布。
(2)将人造草丝簇绒在底布上制成半成品人造草坪(带热熔胶粉面为底面)，然后通过烘箱对半成品底面加热，加热温度控制在160-170℃，人造草丝根部和热熔胶粉熔融，粘在一起，冷却、定型，制备整体可回收人造草坪。
(3)测试人造草丝拔出力及人造草坪底背拉断力，结果见附表1。
实施例6
(1)按120g/m2的撒粉量将TPU热熔胶粉均匀的撒在200g/m2的PET单层机织布上，烘箱加热，温度控制在130-140℃，热熔胶粉熔融产生黏性粘在机织布上，冷却、定型，制成底布。
(2)将人造草丝簇绒在底布上制成半成品人造草坪(带热熔胶粉面为底面)，然后通过烘箱对半成品底面加热，加热温度控制在160-170℃，人造草丝根部和热熔胶粉熔融，粘在一起，冷却、定型，制备整体可回收人造草坪。
(3)测试人造草丝拔出力及人造草坪底背拉断力，结果见附表1。
实施例7
(1)按120g/m2的撒粉量将PE和EVA混合热熔胶粉均匀的撒在150g/m2的PET单层机织布上，烘箱加热，温度控制在130-140℃，热熔胶粉熔融产生黏性粘在机织布上，冷却、定型，制成底布。
(2)将人造草丝簇绒在底布上制成半成品人造草坪(带热熔胶粉面为底面)，然后通过烘箱对半成品底面加热，加热温度控制在160-170℃，人造草丝根部和热熔胶粉熔融，粘在一起，冷却、定型，制备整体可回收人造草坪。
(3)测试人造草丝拔出力及人造草坪底背拉断力，结果见附表1。
实施例8
(1)按120g/m2的撒粉量将EVA热熔胶粉均匀的撒在PP复合机织布(120g/m2PP单层机织布+80g/m2PET长纤)上，烘箱加热，温度控制在120-130℃，热熔胶粉熔融产生黏性粘在PP复合机织布上，冷却、定型，制成底布。
(2)将人造草丝簇绒在底布上制成半成品人造草坪(带热熔胶粉面为底面)，然后通过烘箱对半成品底面加热，加热温度控制在160-170℃，人造草丝根部和热熔胶粉熔融，粘在一起，冷却、定型，制备整体可回收人造草坪。
(3)测试人造草丝拔出力及人造草坪底背拉断力，结果见附表1。
实施例9
(1)按120g/m2的撒粉量将EVA热熔胶粉均匀的撒在PET复合机织布(180g/m2PET单层机织布+60g/m2PET短纤)上，烘箱加热，温度控制在120-130℃，热熔胶粉熔融产生黏性粘在PET复合机织布上，冷却、定型，制成底布。
(2)将人造草丝簇绒在底布上制成半成品人造草坪(带热熔胶粉面为底面)，然后通过烘箱对半成品底面加热，加热温度控制在160-170℃，人造草丝根部和热熔胶粉熔融，粘在一起，冷却、定型，制备整体可回收人造草坪。
(3)测试人造草丝拔出力及人造草坪底背拉断力，结果见附表1。
实施例10
(1)将宽幅相同的100g/m2的pp单层机织布和120g/m2的PET网格布贴在一起，然后按120g/m2的撒粉量将PE热熔胶粉均匀的撒在网格布面上，通过热辊对网格布面加热，温度控制在135-145℃，热熔胶粉熔融产生黏性将PP单层机织布和PET网格布粘在一起，冷却、定型，制成底布。
(2)将人造草丝簇绒在底布上制成半成品人造草坪(带热熔胶粉面为底面)，然后通过烘箱对半成品底面加热，加热温度控制在160-170℃，人造草丝根部和热熔胶粉熔融，粘在一起，冷却、定型，制备整体可回收人造草坪。
(3)测试人造草丝拔出力及人造草坪底背拉断力，结果见附表1。
实施例11
(1)将宽幅相同的300g/m2的PET单层机织布和60g/m2的PET网格布贴在一起，然后按120g/m2的撒粉量将PE热熔胶粉均匀的撒在网格布面上，通过热辊对网格布面加热，温度控制在135-145℃，热熔胶粉熔融产生黏性将PET单层机织布和PET网格布粘在一起，冷却、定型，制成底布。
(2)将人造草丝簇绒在底布上制成半成品人造草坪(带热熔胶粉面为底面)，然后通过烘箱对半成品底面加热，加热温度控制在160-170℃，人造草丝根部和热熔胶粉熔融，粘在一起，冷却、定型，制备整体可回收人造草坪。
(3)测试人造草丝拔出力及人造草坪底背拉断力，结果见附表1。
实施例12
(1)按120g/m2的撒粉量将PE热熔胶粉均匀的撒在250g/m2的PET单层机织布上，然后经过烘箱加热使热熔胶粉熔融，温度控制在135-145℃，PET单层机织布出烘箱后立即将相同宽幅的100g/m2的PET网格布覆在其上，再在压辊压力作用下使网格布粘在尚未固化的热熔胶粉上与PET单层机织布结合在一起，冷却、定型，制成底布。
(2)将人造草丝簇绒在底布上制成半成品人造草坪(带热熔胶粉面为底面)，然后通过烘箱对半成品底面加热，加热温度控制在160-170℃，人造草丝根部和热熔胶粉熔融，粘在一起，冷却、定型，制备整体可回收人造草坪。
(3)测试人造草丝拔出力及人造草坪底背拉断力，结果见附表1。
实施例13
(1)按120g/m2的撒粉量将PE热熔胶粉均匀的撒在200g/m2的PET单层机织布上，然后经过烘箱加热使热熔胶粉熔融，温度控制在135-145℃，冷却、定型后待用。
(2)取相同宽幅的150g/m2的PET网格布，与上述机织布一起在簇绒机上簇绒人造草丝，制成半成品人造草坪(网格布面为底面)，然后通过烘箱对半成品底面加热，加热温度控制在160-170℃，人造草丝根部和热熔胶粉熔融，将网格布和底布粘在一起，冷却、定型，制备整体可回收人造草坪。
(3)测试人造草丝拔出力及人造草坪底背拉断力，结果见附表1。
实施例14
(1)将宽幅相同PP复合机织布(120g/m2PP单层机织布+120g/m2涤纶长纤)和80g/m2的PET网格布贴在一起，然后按120g/m2的撒粉量将PE热熔胶粉均匀的撒在网格布面上，通过热辊对网格布面加热，温度控制在135-145℃，热熔胶粉熔融产生黏性将PP复合机织布和PET网格布粘在一起，冷却、定型，制成底布。
(2)将人造草丝簇绒在底布上制成半成品人造草坪(带热熔胶粉面为底面)，然后通过烘箱对半成品底面加热，加热温度控制在160-170℃，人造草丝根部和热熔胶粉熔融，粘在一起，冷却、定型，制备整体可回收人造草坪。
(3)测试人造草丝拔出力及人造草坪底背拉断力，结果见附表1。
实施例15
(1)将宽幅相同的PET复合机织布(200g/m2的PET单层机织布+120g/m2的涤纶短纤)和50g/m2的PET网格布贴在一起，然后按120g/m2的撒粉量将PE热熔胶粉均匀的撒在网格布面上，通过热辊对网格布面加热，温度控制在135-145℃，热熔胶粉熔融产生黏性将PET复合机织布和PET网格布粘在一起，冷却、定型，制成底布。
(2)将人造草丝簇绒在底布上制成半成品人造草坪(带热熔胶粉面为底面)，然后通过烘箱对半成品底面加热，加热温度控制在160-170℃，人造草丝根部和热熔胶粉熔融，粘在一起，冷却、定型，制备整体可回收人造草坪。
(3)测试人造草丝拔出力及人造草坪底背拉断力，结果见附表1。
实施例16
(1)按90g/m2的撒粉量将EVA热熔胶粉均匀的撒在60g/m2的PET无纺布上，烘箱加热，温度控制在140-150℃，热熔胶粉熔融产生黏性粘在PET无纺布上，冷却定型后待用。
(2)将人造草丝簇绒在135g/m2的PP单层机织布底布上制成半成品人造草坪，然后将制备的PET无纺布贴在半成品的底面(PET无纺布带热熔胶粉面与人造草丝根部相接)，通过热辊对PET无纺布不带热熔胶粉面加热，加热温度控制在180-190℃，人造草丝根部和热熔胶粉熔融，PET无纺布与人造草丝根部及底布粘在一起，冷却、定型，制备整体可回收人造草坪。
(3)测试人造草丝拔出力及人造草坪底背拉断力，结果见附表1。
实施例17
(1)按90g/m2的撒粉量将EVA热熔胶粉均匀的撒在220g/m2的PET单层机织布上，烘箱加热，温度控制在140-150℃，热熔胶粉熔融产生黏性粘在PET单层机织布上，冷却、定型，制成底布。
(2)按90g/m2的撒粉量将EVA热熔胶粉均匀的撒在120g/m2的PET无纺布上，烘箱加热，温度控制在140-150℃，热熔胶粉熔融产生黏性粘在PET无纺布上，冷却定型后待用。
(3)将人造草丝簇绒在底布上制成半成品人造草坪(带热熔胶粉面为底面)，然后将制备的PET无纺布贴在半成品的底面(PET无纺布带热熔胶粉面与人造草丝根部相接)，通过热辊对PET无纺布不带热熔胶粉面加热，加热温度控制在180-190℃，人造草丝根部和热熔胶粉熔融，PET无纺布与人造草丝根部及底布粘在一起，冷却、定型，制备整体可回收人造草坪。
(4)测试人造草丝拔出力及人造草坪底背拉断力，结果见附表1。
实施例18
(1)按150g/m2的撒粉量将TPU热熔胶粉均匀的撒在PP复合机织布(120g/m2的PP单层机织布+150g/m2的涤纶长纤)上，烘箱加热，温度控制在140-150℃，热熔胶粉熔融产生黏性粘在机织布上，冷却、定型，制成底布。
(2)按150g/m2的撒粉量将TPU热熔胶粉均匀的撒在150g/m2的PET无纺布上，烘箱加热，温度控制在140-150℃，热熔胶粉熔融产生黏性粘在PET无纺布上，冷却定型后待用。
(3)将人造草丝簇绒在底布上制成半成品人造草坪(带热熔胶粉面为底面)，然后将制备的PET无纺布贴在半成品的底面(PET无纺布带热熔胶粉面与人造草丝根部相接)，通过热辊对PET无纺布不带热熔胶粉面加热，加热温度控制在180-190℃，人造草丝根部和热熔胶粉熔融，PET无纺布与人造草丝根部及底布粘在一起，冷却、定型，制备整体可回收人造草坪。
(4)测试人造草丝拔出力及人造草坪底背拉断力，结果见附表1。
实施例19
(1)按130g/m2的撒粉量将TPU热熔胶粉均匀的撒在PET复合机织布(180g/m2的PET单层机织布+100g/m2的涤纶短纤)上，烘箱加热，温度控制在140-150℃，热熔胶粉熔融产生黏性粘在机织布上，冷却、定型，制成底布。
(2)按130g/m2的撒粉量将TPU热熔胶粉均匀的撒在PET复合无纺布(150g/m2的PET无纺布+80g/m2的PET网格布)上，烘箱加热，温度控制在140-150℃，热熔胶粉熔融产生黏性粘在PET复合无纺布上，冷却定型后待用。
(3)将人造草丝簇绒在底布上制成半成品人造草坪(带热熔胶粉面为底面)，然后将制备的PET复合无纺布贴在半成品的底面(PET复合无纺布带热熔胶粉面与人造草丝根部相接)，通过热辊对PET复合无纺布不带热熔胶粉面加热，加热温度控制在180-190℃，人造草丝根部和热熔胶粉熔融，PET复合无纺布与人造草丝根部及底布粘在一起，冷却、定型，制备整体可回收人造草坪。
(4)测试人造草丝拔出力及人造草坪底背拉断力，结果见附表1。
实施例20
(1)将宽幅相同的120g/m2的PP单层机织布和70g/m2的PET网格布贴在一起，然后按110g/m2的撒粉量将PE热熔胶粉均匀的撒在带网格的一面上，通过热辊对网格布面加热，温度控制在135-145℃，热熔胶粉熔融产生黏性将PP单层机织布和PET网格布粘在一起，冷却、定型，制成底布。
(2)按110g/m2的撒粉量将PE热熔胶粉均匀的撒在PET复合无纺布(120g/m2的PET无纺布+100g/m2的PET网格布)上，烘箱加热，温度控制在140-150℃，热熔胶粉熔融产生黏性粘在PET复合无纺布上，冷却定型后待用。
(3)将人造草丝簇绒在底布上制成半成品人造草坪(带热熔胶粉面为底面)，然后将制备的PET复合无纺布贴在半成品的底面(PET复合无纺布带热熔胶粉面与人造草丝根部相接)，通过热辊对PET复合无纺布不带热熔胶粉面加热，加热温度控制在180-190℃，人造草丝根部和热熔胶粉熔融，PET复合无纺布与人造草丝根部及底布粘在一起，冷却、定型，制备整体可回收人造草坪。
(4)测试人造草丝拔出力及人造草坪底背拉断力，结果见附表1。
实施例21
(1)将宽幅相同PP复合机织布(110g/m2的PP单层机织布+110g/m2的涤纶长纤)和90g/m2的PET网格布贴在一起，然后按110g/m2的撒粉量将PE热熔胶粉均匀的撒在带网格的一面上，通过热辊对网格布面加热，温度控制在135-145℃，热熔胶粉熔融产生黏性将PP复合机织布和PET网格布粘在一起，冷却、定型，制成底布。
(2)按110g/m2的撒粉量将PE热熔胶粉均匀的撒在PET复合无纺布(100g/m2的PET无纺布+130g/m2的PET网格布)上，烘箱加热，温度控制在140-150℃，热熔胶粉熔融产生黏性粘在PET复合无纺布上，冷却定型后待用。
(3)将人造草丝簇绒在底布上制成半成品人造草坪(带热熔胶粉面为底面)，然后将制备的PET复合无纺布贴在半成品的底面(PET复合无纺布带热熔胶粉面与人造草丝根部相接)，通过热辊对PET复合无纺布不带热熔胶粉面加热，加热温度控制在180-190℃，人造草丝根部和热熔胶粉熔融，PET复合无纺布与人造草丝根部及底布粘在一起，冷却、定型，制备整体可回收人造草坪。
(4)测试人造草丝拔出力及人造草坪底背拉断力，结果见附表1。
实施例22
(1)将宽幅相同PET复合机织布(180g/m2的PET单层机织布+110g/m2的涤纶短纤)和70g/m2的PET网格布贴在一起，然后按110g/m2的撒粉量将PE热熔胶粉均匀的撒在带网格的一面上，通过热辊对网格布面加热，温度控制在135-145℃，热熔胶粉熔融产生黏性将PP复合机织布和PET网格布粘在一起，冷却、定型，制成底布。
(2)按110g/m2的撒粉量将PE热熔胶粉均匀的撒在PET复合无纺布(80g/m2的PET无纺布+150g/m2的PET网格布)上，烘箱加热，温度控制在140-150℃，热熔胶粉熔融产生黏性粘在PET复合无纺布上，冷却定型后待用。
(3)将人造草丝簇绒在底布上制成半成品人造草坪(带热熔胶粉面为底面)，然后将制备的PET复合无纺布贴在半成品的底面(PET复合无纺布带热熔胶粉面与人造草丝根部相接)，通过烘箱对半成品底面加热，加热温度控制在170-180℃，人造草丝根部和热熔胶粉熔融，PET复合无纺布与人造草丝根部及底布粘在一起，冷却、定型，制备整体可回收人造草坪。
(4)测试人造草丝拔出力及人造草坪底背拉断力，结果见附表1。
实施例23
(1)将宽幅相同的300g/m2的PET单层机织布和70g/m2的PET网格布贴在一起，然后按110g/m2的撒粉量将PE热熔胶粉均匀的撒在带网格的一面上，通过热辊对网格布面加热，温度控制在135-145℃，热熔胶粉熔融产生黏性将PET单层机织布和PET网格布粘在一起，冷却、定型，制成底布。
(2)按110g/m2的撒粉量将PE热熔胶粉均匀的撒在PET复合无纺布(80g/m2的PET无纺布+150g/m2的PET网格布)上，烘箱加热，温度控制在140-150℃，热熔胶粉熔融产生黏性粘在PET复合无纺布上，冷却定型后待用。
(3)将人造草丝簇绒在底布上制成半成品人造草坪(带热熔胶粉面为底面)，然后将制备的PET复合无纺布贴在半成品的底面(PET复合无纺布带热熔胶粉面与人造草丝根部相接)，通过烘箱对半成品底面加热，加热温度控制在170-180℃，人造草丝根部和热熔胶粉熔融，PET复合无纺布与人造草丝根部及底布粘在一起，冷却、定型，制备整体可回收人造草坪。
(4)测试人造草丝拔出力及人造草坪底背拉断力，结果见附表1。
附表1：整体可回收人造草坪和对比样的人造草丝拔出力及人造草坪的底背拉断力检测结果。
附表2：本发明的整体可回收人造草坪和对比样(公开号CN104727202A的现有技术人造草坪)的人造草丝簇绒比较：
由检测结果知，本发明制备的整体可回收人造草坪，在簇绒效率和人造草坪强度上具有明显优势。

Claims (26)

1.一种整体可回收人造草坪，包括有人造草丝和底布，其特征在于所述的底布含有机织布，人造草丝簇绒在含有机织布的底布上，再使人造草丝根部熔融或局部熔融，冷却定型后人造草丝与底布形成一个整体，其中所述的人造草丝材质的熔点低于底布材质的熔点。
2.根据权利要求1所述的整体可回收人造草坪，其特征在于所述的人造草丝根部为簇绒后位于底布底面下方的人造草丝。
3.根据权利要求1所述的整体可回收人造草坪，其特征在于所述的使人造草丝根部熔融或局部熔融是通过热复合的方式进行。
4.根据权利要求1所述的整体可回收人造草坪，其特征在于所述的机织布为单层机织布或复合机织布。
5.根据权利要求1所述的整体可回收人造草坪，其特征在于所述的底布在簇绒人造草丝前，通过撒粉工序在底布底面上撒有热熔胶粉。
6.根据权利要求5所述的整体可回收人造草坪，其特征在于所述的底布含有网格布。
7.根据权利要求6所述的整体可回收人造草坪，其特征在于所述的网格布材质的熔点高于人造草丝材质的熔点，网格布使用前要先经过热处理。
8.根据权利要求7所述的整体可回收人造草坪，其特征在于所述的网格布克重为50-200g/m2，所述的网格布材质为聚对苯二甲酸乙二醇酯。
9.根据权利要求1所述的整体可回收人造草坪，其特征在于所述的簇绒上人造草丝的底布底面上热复合有另外一层底布。
10.根据权利要求9所述的整体可回收人造草坪，其特征在于所述的热复合在簇绒上人造草丝的底布底面上的底布材质的熔点高于人造草丝材质的熔点，且底布在热复合前，通过撒粉工序在其一面上撒有热熔胶粉。
11.根据权利要求9所述的整体可回收人造草坪，其特征在于所述的热复合在簇绒上人造草丝的底布底面上的底布材质为无纺布或者无纺布和网格布的复合布。
12.根据权利要求11所述的整体可回收人造草坪，其特征在于所述的无纺布或者无纺布和网格布的复合布在使用前要先经过热处理。
13.根据权利要求7或12所述的整体可回收人造草坪，其特征在于所述的网格布或者无纺布的热处理方法是：通过烘箱热辐射或者热辊直接加热的方式对网格布或者无纺布加热，加热温度控制在材料的玻璃化温度和熔点之间，冷却定型后完成网格布或无纺布的热处理。
14.根据权利要求12所述的整体可回收人造草坪，其特征在于所述的无纺布和网格布的复合布的热处理方法有两种，一是通过烘箱热辐射或者热辊直接加热的方式分别对无纺布和网格布进行热处理，加热温度控制在材料的玻璃化温度和熔点之间，然后通过撒粉工序将二者热粘合在一起形成复合布；二是将无纺布和网格布先通过缝编工艺缝在一起，然后再通过烘箱热辐射或者热辊直接加热的方式对复合布加热，加热温度控制在材料的玻璃化温度和熔点之间，冷却定型后完成热处理。
15.根据权利要求11或14所述的整体可回收人造草坪，其特征在于所述的无纺布克重为50-150g/m2，网格布克重为80-150g/m2，所述的无纺布或网格布材质为聚对苯二甲酸乙二醇酯。
16.根据权利要求15所述的整体可回收人造草坪，其特征在于所述的无纺布或网格布材质为聚对苯二甲酸乙二醇酯时，其热处理时加热温度范围是170-200℃。
17.根据权利要求5或10所述的整体可回收人造草坪，其特征在于所述的热熔胶粉材质的熔点低于底布材质的熔点。
18.根据权利要求17所述的整体可回收人造草坪，其特征在于所述的热熔胶粉为PE、EVA、TPU中的一种或其组合，热熔胶粉的撒粉量为60-150g/m2。
19.一种如权利要求1-18任一所述的整体可回收人造草坪的制备方法，其特征在于包括以下步骤：
(1)按照规格将人造草丝簇绒在机织布底布上制成半成品；
(2)经过热复合工序，对半成品底部进行加热，使人造草丝根部熔融或局部熔融，冷却定型后人造草丝与底布形成一个整体，得到整体可回收人造草坪。
20.根据权利要求19所述的整体可回收人造草坪的制备方法，其特征在于包括以下步骤：
(1)通过撒粉工序在机织布底布的一面上撒上热熔胶粉；
(2)按照规格将人造草丝簇绒在机织布底布上制成半成品；
(3)经过热复合工序，对半成品底部进行加热，使人造草丝根部熔融或局部熔融并与热熔胶粉熔融，冷却定型后人造草丝与底布形成一个整体，得到整体可回收人造草坪。
21.根据权利要求20所述的整体可回收人造草坪的制备方法，其特征在于包括以下步骤：
(1)通过撒粉工序将机织布和网格布一起撒粉制成底布，或者先对机织布撒粉然后再与网格布结合在一起制成底布；
(2)按照规格将人造草丝簇绒在底布上制成半成品；
(3)经过热复合工序，对半成品底部进行加热，使人造草丝根部熔融或局部熔融并与热熔胶粉熔融，冷却定型后人造草丝与底布形成一个整体，得到整体可回收人造草坪。
22.根据权利要求21所述的整体可回收人造草坪的制备方法，其特征在于包括以下步骤：
(1)通过撒粉工序在无纺布或者无纺布和网格布的复合布的一面撒上一层热熔胶粉，制成底层的底布；
(2)通过撒粉工序将机织布和网格布一起撒粉制成底布，或者先对机织布撒粉然后再与网格布结合在一起制成簇绒所用的底布；
(3)按照规格将人造草丝簇绒在底布上制成半成品，并将撒过粉的另一底布覆于半成品底面，该底布的带热熔胶粉面与草根接触；
(4)经过热复合工序，对底层底布不带热熔胶粉面加热，使人造草丝根部熔融或局部熔融并与熔融后的热熔胶粉粘在一起，冷却定型后人造草丝与两层底布形成一个整体，得到整体可回收人造草坪。
23.根据权利要求22所述的整体可回收人造草坪的制备方法，其特征在于所述的网格布、无纺布或者无纺布和网格布的复合布在使用前需要经过热处理，其中所述的网格布或者无纺布的热处理方法是：通过烘箱热辐射或者热辊直接加热的方式对网格布或者无纺布加热，加热温度控制在材料的玻璃化温度和熔点之间，冷却定型后完成网格布或无纺布的热处理；所述的无纺布和网格布的复合布的热处理方法有两种，一是通过烘箱热辐射或者热辊直接加热的方式分别对无纺布和网格布进行热处理，加热温度控制在材料的玻璃化温度和熔点之间，然后通过撒粉工序将二者热粘合在一起形成复合布；二是将无纺布和网格布先通过缝编工艺缝在一起，然后再通过烘箱热辐射或者热辊直接加热的方式对复合布加热，加热温度控制在材料的玻璃化温度和熔点之间，冷却定型后完成热处理。
24.根据权利要求23所述的整体可回收人造草坪的制备方法，其特征在于所述的无纺布或网格布材质为聚对苯二甲酸乙二醇酯，热处理时加热温度范围是170-200℃。
25.根据权利要求20、21或22所述的整体可回收人造草坪的制备方法，其特征在于所述的撒粉工序是利用烘箱热辐射或者热辊直接加热的方式对热熔胶粉加热，使其熔融产生黏性粘在机织布或无纺布表面，或者将机织布与网格布、无纺布与网格布粘在一起，冷却定型后形成整体。
26.根据权利要求19、20、21或22所述的整体可回收人造草坪的制备方法，其特征在于所述的热复合工序是利用烘箱热辐射或者热辊直接加热的方式对人造草丝根部或不带热熔胶粉面的底布加热，使人造草丝根部和热熔胶粉熔融产生黏性，相互结合在一起，再经过冷却定型，把人造草丝牢牢的固定在底布上。
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CN111719380A (zh) * 2020-06-19 2020-09-29 江苏共创人造草坪股份有限公司 一种高排水性新型人造草坪系统
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