JP2006132026A - Durable base fabric for artificial turf and artificial turf - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide an artificial turf which is lightweight, has excellent flexibility and water resistance, firmly holds pile yarns over a long period, is free from the slipping-out and permanent set of the pile yarns, can be used for a long period, has excellent durability, and can be produced in good productivity, and to provide a base fabric which can give an artificial turf having excellent durability. <P>SOLUTION: This tufting base fabric for tufting linear articles used for piles and obtained by monoaxially stretching a thermoplastic resin is characterized by weaving linear articles used for the base fabric and comprising connected yarns. The connected yarns are obtained by connecting many small diameter linear articles monoaxially stretched from a thermoplastic resin to each other through connection films having a thickness (a) of 0.05 to 0.7 and a width (b) of 0.05 to 1.0 based on the maximum width (c) of the thickness direction of the small linear article. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention provides an artificial lawn that is lightweight, excellent in flexibility and water resistance, and has excellent durability and can be used for a long time with little pile yarn slipping out, and such an artificial lawn. It is related with the tufting base fabric which can be used.

  In recent years, artificial grass made of thermoplastic resin has been widely used in soccer fields, baseball fields, tennis fields, and other stadiums. These artificial lawns made of thermoplastic resin are formed by tufting pile yarn stretched with polyethylene, polyester, polyamide, etc. on a base fabric woven from flat yarn etc. uniaxially stretched with a tape-shaped thermoplastic resin. ing.

  These artificial lawns made of thermoplastic resin do not corrode and are easy to manage, and are expected to become increasingly popular in the future.

  However, when an artificial lawn made of thermoplastic resin is used for a stadium such as a soccer field, intense movement is performed on the lawn, so the pile yarn forming the lawn is quickly pulled out, and the pile is It was out of shape and aging quickly, and it was necessary to replace the paper more quickly than expected, which required enormous costs each time.

  As a result of detailed investigations by the present inventors, in order to obtain a durable artificial lawn that can be used for a long period of time without pile yarn coming out even when intense exercise is performed on the pile, It was found that the durability of the base fabric used as the primary backing is important in addition to the durability of the yarn.

  In other words, in order to impart durability to an artificial lawn and make it usable for a long time, even when intense exercise is performed and a strong force is applied, the pile yarn is firmly held without breaking the structure. It has been found important to use a tough base fabric to obtain.

  Conventionally, a woven fabric is formed by using a flat yarn or a split yarn in which a number of longitudinal cuts are made in a flat yarn to form a base fabric, and an artificial lawn is manufactured using this fabric. When weaving a thick pile thread like artificial grass, there is a problem that the filaments are broken by the tufting needle and the strength is lowered. Even when a lined flat yarn having a rib-like rib is used, as long as a film-like yarn is used as a base material, breakage of the yarn and reduction in strength cannot be avoided. If this happens, the weaving of the woven fabric will loosen and it will not be possible to hold the pile yarn, and the pile yarn will come out, the pile yarn will fall, and so-called sag will occur. It has been found that not withstand use.

  In order to hold the pile yarn firmly without causing misalignment, it is conceivable to weave the base fabric using a thick filament, but if the filament is thickened, It has also been found that since the rigidity becomes high, the pile yarn is torn apart when tufted, and as a result, the strength is greatly reduced. As expected, a tough primary base fabric cannot be obtained.

  For this reason, as shown in FIG. 6, the present inventors use a connecting yarn 3 in which a plurality of filaments 5 and 5 of appropriate thickness are arranged in parallel and the adjacent filaments are connected as a base fabric. Proposed that (prior application description 1). As a result, the pile was prevented from being finely divided to a thickness of 5 or less in the striatum, the strength decrease due to tufting was reduced, and the productivity was greatly improved.

However, even in such a method, since the linear bodies are directly fused, it has been found that the pile yarn is likely to be stiff and the productivity of the weaving process is likely to be reduced.
Japanese Patent Laid-Open No. 7-158007

Prior application description 1

  Japanese Patent Application No. 2003-185683

  The present invention is lightweight, excellent in flexibility and water resistance, and holds the pile yarn firmly for a long period of time. It is an object to provide an artificial lawn that is excellent in water resistance and a base fabric from which such an artificial lawn can be obtained.

  The present invention has been made as a result of intensive studies to solve the above-mentioned problems. Specifically, in a base fabric for tufting a pile filament obtained by uniaxially stretching a thermoplastic resin, A large number of small diameter filaments made of a plastic resin and uniaxially stretched have a thickness a of 0.05 to 0.7 and a width b of 0.05 with respect to the maximum width c in the thickness direction of the small diameter filaments. A tufting base fabric is provided, which is formed by weaving a filament for a base fabric composed of connecting yarns bonded to each other through a connecting membrane at a ratio of ˜1.0.

  Further, in the present invention, five or more small-diameter linear filaments are arranged in parallel, and the maximum width in the thickness direction is 0.1 to 1.0 mm, and the maximum lateral width is 1.0 to 10 mm. After the tufting base fabric and at least the small-diameter linear body are formed and woven by the base layer and the joining layer covering the base layer made of a thermoplastic resin having a melting point lower than that of the base layer, The above-mentioned tufting base fabric is provided in which the base fabric filaments are thermally bonded.

  Furthermore, the present invention provides a durable artificial lawn obtained by tufting a pile filament obtained by uniaxially stretching a thermoplastic resin to the tufting base fabric according to any one of the above. A laminate sheet obtained by laminating a film made of an olefin polymer having a low melting point on the above-mentioned durable artificial lawn, wherein the striated body for a base fabric and the striated body for a pile are made of an olefin polymer. The above-mentioned durable artificial lawn obtained by tufting the pile filaments and then heat-treating the pile filaments, and the film made of the olefin polymer having a low melting point after tufting the pile filaments on the base fabric The above-mentioned durable artificial lawn formed by heat bonding is provided.

  The present invention is lightweight, excellent in flexibility and water resistance, and holds the pile yarn firmly for a long period of time, and does not come out of the pile yarn, has no settling, has excellent durability, and has excellent productivity. In addition, it is possible to obtain a base fabric from which an artificial lawn and an artificial lawn having excellent durability and other pile fabrics can be obtained.

  As shown in FIG. 1, the tufting base fabric 1 of the present invention is formed by weaving a base fabric linear body 3 obtained by uniaxially stretching a thermoplastic resin. As shown in FIG. 2, the pile filaments 4 made of a thermoplastic resin are tufted to form a pile fabric such as an artificial lawn 2.

  In the present invention, as shown in FIGS. 3A to 3C, a large number of small-diameter linear bodies 5 having a small diameter are juxtaposed as the base fabric linear bodies 3, and the side portions thereof are connected via a connecting film 6. It is characterized in that a connecting thread joined to the adjacent small-diameter linear body 5 is used.

  As shown in FIG. 3 (A), the base fabric filament 3 can be a single-layer connecting yarn, and depending on the purpose, the base layer 10 can be formed as shown in FIG. 3 (B). It can also be formed by connecting this as a composite filament covered with the bonding layer 11. Furthermore, as shown in FIG. 3C, the base layer 10 can be formed by connecting the base layer 10 and laminating the bonding layer 11 on one or both sides thereof.

  As the thermoplastic resin constituting the monolayer of the base fabric filament 3 or the composite filament base 10, a resin having a large stretching effect, generally a crystalline resin is used. Polyethylene such as density polyethylene, linear low density polyethylene, polypropylene, ethylene / propylene copolymer, polyester such as polyethylene terephthalate and polybutylene terephthalate, modified polyester, polyamide of nylon 6, nylon 66, and the like are used. Among them, olefin polymers such as polyethylene, linear low density polyethylene, and polypropylene are desirable from the viewpoint of processability and economy. Particularly, polyethylene polymerized using a metallocene catalyst from the viewpoint of adhesion and transparency, linear low density polyethylene, Polypropylene is preferred.

  After being woven, the joining layer 11 joins the base cloth filaments 3, or joins the base cloth filaments 3 and the pile filaments 4, and constitutes the base layer 10. A thermoplastic resin having a lower melting point than that of the thermoplastic resin and excellent heat fusion property is used. Specifically, high pressure method low density polyethylene, linear low density polyethylene, high density polyethylene, polypropylene, olefin polymers such as ethylene / propylene copolymer, ethylene / vinyl acetate copolymer, polyethylene terephthalate, polybutylene terephthalate Such as polyester such as polyester, modified polyester, nylon 6 and nylon 66, etc., and a thermoplastic resin having a melting point lower than that of the base layer 10 in relation to the thermoplastic resin of the base layer 10, preferably 10 ° C. or more, more preferably A thermoplastic resin having a low melting point of 15 ° C. or higher is selected.

  Of these, olefin polymers such as high-pressure low-density polyethylene, linear low-density polyethylene, high-density polyethylene, polypropylene, ethylene / propylene copolymer, and ethylene / vinyl acetate copolymer are desirable due to processability and economy. From the viewpoint of enhancing strength, an ethylene / α-olefin copolymer such as an ethylene polymer, a propylene polymer, an ethylene / propylene copolymer, or an ethylene / butene copolymer polymerized using a metallocene catalyst is preferable. .

  When the pile thread is tufted when tufting needles are pierced when tufting the pile thread, the filament 3 for the base fabric of the present invention is made of a connecting thread composed of a plurality of small diameter filaments 5. Since the pile filaments 3 are both composed of the small-diameter filaments 5, they have a predetermined strength and are not cut. Therefore, it is possible to obtain the artificial turf base fabric 1 that can hold the pile firmly without lowering the strength. Also in the weaving process, the contact with the yarn feed mechanism becomes a line contact with the small-diameter linear member 5, so that the frictional resistance with the yarn feed mechanism is reduced, the yarn feed is smooth, and strength reduction is prevented. And increase productivity.

  An inorganic filler can be added to the thermoplastic resin constituting the base layer 10 and the bonding layer 11 according to the purpose. As the kind of inorganic filler, known inorganic fillers can be used as thermoplastic resin additives. For example, talc, clay, mica, calcium carbonate, barium sulfate, wollastonite, zeolite, aluminum hydroxide Magnesium hydroxide, calcium silicate, etc. can be used. The compounding amount of the inorganic filler is 1 to 40% by weight, preferably 3 to 30% by weight.

  In addition, various additives can be added to the thermoplastic resin depending on the purpose. Specifically, the phosphorus-based, organic phosphite-based, phosnite-based organic phosphorus-based, thioether-based antioxidants, etc. ; Light stabilizers such as hindered amines; UV absorbers such as benzophenones, benzotriazoles, and benzoates; Antistatic agents such as nonionics, cationics, and anions; Bisamides, waxes, organometallic salts, etc. Dispersants; Chlorine scavengers such as alkaline earth metal salt carboxylates; Lubricants such as amides, waxes, organometallic salts and esters; Metal deactivators such as hydrazines and amine acids; Bromine-containing Flame retardants such as organic, phosphoric acid, antimony trioxide, magnesium hydroxide and red phosphorus; organic pigments; inorganic pigments; inorganic and organic antibacterial agents such as metal ions And the like.

  These additives are appropriately combined and blended in any of the steps for producing the material composition of the base fabric filament 3. The blending of the additive may be prepared by mixing at a predetermined ratio using a kneading device such as a conventional known twin screw extruder, Banbury mixer, kneader, mixing roll, and melt-kneading the mixture. A so-called master batch having a high concentration may be prepared and used after being diluted.

  The stretching can be performed by stretching with a hot roll, stretching with a hot plate, stretching with a hot air furnace, or the like. The draw ratio is usually about 3 to 10 times.

  The thickness a of the coupling film 6 is 0.05 to 0.7, preferably 0.1 to 0.6, and more preferably 0.1 to 0.0, of the maximum width c in the thickness direction of the small-diameter filament 5. The ratio is 5. The width b of the connecting film 6 is 0.05 to 1.0, preferably 0.1 to 0.9, more preferably 0.1 to 0 of the maximum width c in the thickness direction of the small-diameter filament 5. .7. By interposing the thin connecting film 6 between the small-diameter linear bodies 5, the base fabric linear bodies 3 become supple and followability to the feeding mechanism during weaving is improved, and productivity of the weaving process is improved. be able to. When the thickness a of the coupling film 6 is less than 0.05 of the maximum width c in the thickness direction of the small-diameter filaments 5, it easily breaks during the weaving process, resulting in a decrease in strength, and exceeding 0.7. In some cases, the base fabric filament 3 becomes rigid. When the width b of the coupling film 6 is less than 0.05, the base fabric filament 3 becomes rigid. When the width b exceeds 1.0, when the filament 5 is split, the coupling film 6 becomes fin-like and the filament. 5, the fin-like body is torn into thin pieces by a tufting needle of the pile, and becomes easy to cut into a whisker shape, and whisker-like dust is easily generated during use.

  In any case, the cross-sectional shape of each small-diameter linear body 5 is not particularly limited and can be arbitrarily determined, but is generally circular, elliptical, or oval.

  Although the thickness of the base fabric filament 3 and the small diameter filament 5 can be arbitrarily determined according to the purpose, generally, the average diameter of the small filament 5 is 0.05 to 2 mm, preferably 0. 0.1 to 1.0 mm, and the width of the base fabric filament 3 is 0.3 to 20 mm, preferably 1.0 to 10 mm.

  As shown in FIG. 1, the thus obtained base fabric filament 3 is a plain weave, or by weaving by a method such as twill weave, oblique weave, woven weave, double weave, imitation weave, The tufting base fabric 1 is used.

  The pile linear body 4 to be tufted on the tufting base fabric 1 is made of a thermoplastic resin, and a thermoplastic resin having a high stretching effect is used as the thermoplastic resin. High density polyethylene, medium density polyethylene, wire Olefin polymers such as low-density polyethylene, polypropylene, ethylene / propylene copolymer, polyesters such as polyethylene terephthalate and polybutylene terephthalate, modified polyesters, nylon 6, nylon 66 polyamide, and the like are used. Of these, olefin polymers such as polyethylene and polypropylene are desirable from the viewpoint of processability and economy, and polyethylene, linear low density polyethylene and polypropylene polymerized using a metallocene catalyst are particularly preferred from the viewpoint of adhesion and transparency.

  In the present invention, the pile filament 4 may be a single layer of a crystalline olefin polymer, but on the surface of the base layer made of the crystalline olefin polymer, an adhesive resin, Alternatively, a surface layer made of a resin containing a pigment or an inorganic filler can be laminated, for example, as shown in FIG. 4A, a single layer of a crystalline thermoplastic synthetic resin can be used, As shown in FIG. 4 (B), a structure in which a surface layer 13 in which a pigment or an inorganic filler is blended on one surface of a base layer 12 made of a crystalline olefin polymer can be formed. As shown to C), it can be set as the sandwich structure by which the surface layer 13 was laminated | stacked on both surfaces of the base layer 12. FIG. Further, a seascore structure as shown in FIG. 4D and a side-by-side structure as shown in FIG. Among these, as shown in FIG. 4C, it is desirable to laminate the surface layer 13 on both surfaces of the tape-like base layer 12. The surface layer 13 can give bondability and a texture to the pile yarn filament 3.

  For the surface layer 13, a thermoplastic resin having a lower melting point than that of the thermoplastic resin constituting the base layer 12 and excellent heat fusion properties is used. Specifically, high pressure method low density polyethylene, linear low density polyethylene, high density polyethylene, polypropylene, olefin polymers such as ethylene / propylene copolymer, ethylene / vinyl acetate copolymer, polyethylene terephthalate, polybutylene terephthalate Such as polyester such as polyester, modified polyester, nylon 6 and nylon 66, etc., and a thermoplastic resin having a melting point lower than that of the base layer 12 in relation to the thermoplastic resin of the base layer 12, preferably 10 ° C. or more, more preferably A thermoplastic resin having a low melting point of 15 ° C. or higher is selected.

  Among these, olefin polymers such as high pressure method low density polyethylene, linear low density polyethylene, high density polyethylene, polypropylene, ethylene / propylene copolymer, and ethylene / vinyl acetate copolymer are desirable from the viewpoint of processability and economy. Ethylene / α-olefin copolymers such as ethylene polymer, propylene polymer, ethylene / propylene copolymer, or ethylene / butene copolymer polymerized using a metallocene catalyst from the viewpoint of increasing the bonding strength with the cloth. Polymers are preferred.

  Various additives can be added to the thermoplastic resin constituting the filament yarn linear body 4 depending on the purpose. Specifically, antioxidants such as phenols, organic phosphites and phosnite, organic phosphorus and thioethers; hindered amines and other light stabilizers; benzophenone, benzotriazole and benzoate UV absorbers Nonionic, cationic and anionic antistatic agents; bisamide, wax and organometallic salt dispersants; alkaline earth metal carboxylates and other chlorine supplements; amides and waxes -Based, organometallic salt-based, ester-based lubricants; hydrazine-based, amine-acid-based metal deactivators; bromine-containing organic-based, phosphoric acid-based, antimony trioxide, magnesium hydroxide, red phosphorus and other flame retardants; organic Pigments; inorganic pigments; inorganic fillers, organic fillers; inorganic and organic antibacterial agents such as metal ions.

  These additives are appropriately combined and blended in any process for producing the material composition of the base layer 12 and the surface layer 13. The blending of the additive may be prepared by mixing at a predetermined ratio using a kneading apparatus such as a conventional known twin screw extruder, Banbury, mixer, kneader, or mixing roll, and melt-kneading the mixture. Alternatively, a so-called master batch having a high concentration may be prepared and used after being diluted.

  When a laminated body is used as the pile linear body 4, as a means for forming a laminated film as a molding material, a film to be a base layer 12 and a film to be a surface layer 13 are formed in advance, and a dry laminating method or a heat laminating method is used. A method of multilayering using a method, a method of coating the surface of the film to be the base layer 12 with a thermoplastic synthetic resin to be the surface layer 13, a method of extrusion laminating the surface layer 13 to a film to be the base layer 12 formed in advance, or The multilayer coextrusion method may be appropriately selected from known means such as extrusion molding as a laminated film by the multilayer coextrusion method. However, from the viewpoint of ease of molding, cost, and adhesion between each layer of the product, the multilayer coextrusion method Thus, a method of obtaining a laminated body of the base layer 12 and the surface layer 13 in one step is desirable. The seascore structure or side-by-side structure is generally based on a coextrusion method.

  The obtained pile linear body 4 is tufted to the tufting base cloth 1 to form an artificial lawn 2 or the like. Tubing of the pile filaments 4 can be performed by a method similar to a conventionally known method for producing tufting carpets.

  In the present invention, in order to strengthen the connection between the tufting base fabric 1 and the pile wire 4, as shown in FIG. The united film 7 can be laminated.

  In the present invention, whether the melting point is high or low is determined by comparison with the thermoplastic resin constituting the base fabric filament 3, and when the base fabric filament 3 is a laminate, it is compared with the thermoplastic resin constituting the base layer. Is done.

  As the olefin polymer film 7, ethylene polymer such as high density polyethylene, linear low density polyethylene, polypropylene, ethylene / propylene block copolymer, or propylene polymer is used. Among them, olefin polymers such as polyethylene, linear low density polyethylene, and polypropylene are desirable from the viewpoint of processability and economy, and polyethylene polymerized using a metallocene catalyst, linear low density polyethylene, and polypropylene are particularly preferable from the viewpoint of adhesion. .

  The thickness of the olefin polymer film 7 is arbitrary and can be selected according to the purpose, but is generally 20 μm or more, preferably about 50 μm or more and 2 mm or less.

  In addition, as shown in FIG. 2, an olefin polymer film 8 having a low melting point can be laminated on the back surface of the artificial lawn 2 or the like on which the pile filaments 4 are tufted. As the olefin polymer forming the olefin polymer film 8, the same polymer as the olefin polymer film 7 can be used.

  When joining the olefin polymer film 8 to the back surface of the artificial lawn 2, it is desirable to use a method of pressing using the air pressure. As shown in FIG. The olefin polymer film 8 is supplied to the joining device, and the olefin polymer film 8 is stacked thereon, and the olefin polymer film 8 is heated by using a radiant heat heating type heating device 16 such as a heater. Can then be joined to the artificial lawn 2 by pressing the olefin polymer film 8 using a hot air blowing device 17 such as an air knife.

  By joining the olefin polymer film 8 using air pressure, the olefin polymer film 8 is shaped along the irregularities on the back surface of the artificial lawn 2 and is closely attached to the entire back surface of the artificial lawn 2; The pile yarn can be firmly fixed. Moreover, the continuous recessed part 15 is formed between the convex parts 14 formed by the linear body 4 for piles, and when the artificial lawn 2 is laid, the recessed part 15 can function as a drainage channel which drains rainwater etc. it can. If necessary, it is possible to drain the upper surface when the artificial lawn 2 is laid by providing a large number of drain holes at predetermined intervals in the olefin polymer films 7 and 8.

  The tufting base fabric 1 of the present invention uses a collective yarn to which the small-diameter filaments 5 are connected. Therefore, when the tufting needle is inserted, the small-diameter filaments 5 are split and the pile yarn 4 is easily separated. Therefore, there is no breakage or strength reduction of the striate body, and the small-diameter striate body 5 has a predetermined diameter. Therefore, even when split, each split fibril maintains a predetermined strength. In addition, the thin and weak fibers are generated by the splitting, and no cutting occurs.

  Therefore, the artificial lawn 2 formed by using the durable artificial turf base cloth 1 of the present invention has a strong pile yarn holding force and is firmly held, and the pile yarn can be pulled out even when intense exercise is performed. There is no fear.

  The artificial lawn 2 formed using the tufting base fabric 1 of the present invention can be used as a lawn for a baseball field, a soccer field, a rugby field, or a multipurpose ground, a tennis court, a golf driving field, or walking. It can be used as a rug for roads, cars, airplanes, halls and the like. The artificial lawn 2 of the present invention can be laid and used as it is, and can also be used by filling sand 9 or the like between piles as shown in FIG.

(A) which shows an example of the base fabric for tufting of this invention is a top view, (B) is a longitudinal cross-sectional view (A) which shows the example of this invention artificial lawn is a front longitudinal cross-sectional view, (B) is a side longitudinal cross-sectional view Longitudinal sectional view showing an example of a striate for base fabric Longitudinal sectional view showing an example of pile filaments Longitudinal sectional view showing an example of artificial grass production Longitudinal sectional view showing an example of a conventional filament for a base fabric

Explanation of symbols

1. 1. Tufting base fabric Artificial grass Striate for base fabric 4. Pile striatum 5. Small diameter striated body 7.8. Olefin polymer film 10.12. Base layer 11. Bonding layer 13. Surface layer 16. Heating device 17. Hot air blowing device

Claims (7)

  In a base fabric for tufting a pile linear body obtained by uniaxially stretching a thermoplastic resin, a large number of small diameter linear bodies made of a thermoplastic resin and uniaxially stretched are arranged in the thickness direction of the small diameter linear body. A striated body for a base fabric comprising connecting yarns bonded to each other via connecting membranes having a thickness a of 0.05 to 0.7 and a width b of 0.05 to 1.0 with respect to the maximum width c. Tufting base fabric characterized by being woven.   5. The linear fabric striated body comprises five or more small-diameter striated bodies arranged in parallel, the maximum width in the thickness direction is 0.1 to 1.0 mm, and the maximum width in the lateral direction is 1.0 to 10 mm. The tufting base fabric described.   At least a small-diameter filament is formed by a base layer and a joining layer made of a thermoplastic resin having a melting point lower than that of the base layer and covering the base layer. The tufting base fabric according to claim 1 or 2.   A durable artificial lawn obtained by tufting a pile filament obtained by uniaxially stretching a thermoplastic resin on the tufting base fabric according to any one of claims 1 to 3.   The durable artificial lawn according to claim 4, wherein the base fabric filament and the pile filament are made of an olefin polymer.   6. The durability according to claim 4 or 5, wherein a film made of an olefin polymer having a low melting point is laminated on a base fabric, and the resulting laminate sheet is subjected to heat treatment after tufting the filaments for piles. Artificial lawn.   The durable artificial lawn according to any one of claims 4 to 6, which is obtained by thermally bonding a film made of an olefin polymer having a low melting point after tufting a pile linear body on a base fabric.

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