JP2019052531A - Artificial lawn and manufacturing method - Google Patents

Abstract

To provide a method for manufacturing an artificial lawn.SOLUTION: It is provided with a step 100 for producing a polymer mixture, the polymer mixture being at least a three-phase system, the polymer mixture provided with a first polymer, a second polymer and a compatibilizer, the first polymer and the second polymer having no miscibility, and the first polymer forming within the second polymer a plurality of polymer beads surrounded by the compatibilizer; a step 102 for extruding the polymer mixture to be a monofilament; a step 104 for hardening the monofilament; a step 106 for reheating the monofilament; a step 108 for drawing the reheated monofilament to deform the plurality of polymer beads as a plurality of filamentous regions and forming the monofilament into artificial lawn fibers; and a step 110 for braiding the artificial lawn fibers in an artificial lawn carpet.SELECTED DRAWING: Figure 1

Description

  The present invention relates to the production of artificial lawns, also called synthetic lawns, and artificial lawns. The invention further relates to the production of fibers that mimic turf. In particular, the present invention relates to products and methods for producing artificial turf fibers based on polymer blends and to products and methods for producing artificial turf carpets made from these artificial turf fibers.

  Artificial turf or artificial turf is a surface composed of fibers used to replace turf. The structure of the artificial lawn is designed so that the artificial lawn has an appearance similar to lawn. Typically, artificial grass is used as a surface for sports such as soccer, American football, rugby, tennis, golf, stadiums, or playgrounds. In addition, artificial lawns are frequently used in landscape applications.

  The advantage of using an artificial lawn is that there is no need to care for all-you-can-eat turf or landscapes, such as regular mowing, digging, fertilizing and watering. Watering can be difficult, for example, due to regional restrictions on water use. In other climatic zones, turf regrowth and dense turf cover re-formation are slow compared to natural turf surface damage due to play and / or exercise on the ground. Artificial lawns do not require similar care and effort to maintain, but may require some maintenance such as removing dirt and debris or brushing regularly. . This may be done to help erect the fibers after being stepped down during play or exercise. Over a normal use period of 5-15 years, artificial turf sports fields can withstand high mechanical wear, can withstand UV, can withstand thermal cycling or aging, chemicals and various It would be beneficial if it could resist interaction with various environmental conditions. Thus, it would be beneficial if an artificial lawn has a longer service life, is durable, and maintains its play and surface properties and appearance over its period of use.

  US Patent Application 2010/0173102 A1 discloses an artificial turf characterized in that the cladding material has a different hydrophilicity than the hydrophilicity of the material used for the core.

  The present invention provides a method for producing an artificial lawn in an independent term. Embodiments are set forth in the dependent claims.

  In one aspect, the present invention provides a method of manufacturing an artificial lawn carpet. The method comprises the step of creating a polymer mixture. As used herein, a polymer mixture encompasses a mixture of different types of polymers, and in some cases, various additives may have been added to the polymer mixture. The term “polymer mixture” may also be replaced with the term “masterbatch” or “compound batch”. The polymer mixture is at least a three-phase system. As used herein, a three-phase system encompasses a mixture that separates into at least three different phases. The polymer mixture comprises a first polymer, a second polymer and a compatibilizer. These three elements form a plurality of phases in a three-phase system. If there are multiple additional polymers or compatibilizers added to the system, the three-phase system may be increased to four, five, or multiple phase systems. The first polymer and the second polymer are immiscible. The first polymer forms a plurality of polymer beads surrounded by a compatibilizing agent within the second polymer.

  The method further comprises extruding the polymer mixture into monofilaments. To perform this extrusion, the polymer mixture is heated, for example. The method further comprises quenching the monofilament. In this step, the monofilament is cooled. The method further comprises reheating the monofilament. The method further comprises stretching the reheated monofilament to transform the plurality of polymer beads into a plurality of filamentous regions and form the monofilament into artificial lawn fibers. In this step, the monofilament is drawn. This makes the monofilament longer and, in the process, the plurality of polymer beads are drawn and elongated. Depending on the amount to be stretched, the plurality of polymer beads become elongated.

  The method further comprises the step of incorporating the artificial lawn fiber into the artificial lawn substrate. In some examples, the artificial lawn substrate is a woven fabric or woven mat.

  For example, artificial lawn fibers can be incorporated into artificial lawn grounds by, for example, forming artificial lawn fibers into tufts and placing them in artificial lawn grounds, and then joining multiple artificial lawn fibers formed in tufts into artificial lawn grounds. Can be executed by. For example, artificial lawn fibers are inserted into the ground with a needle and the carpet is formed into a tuft. Once the artificial lawn fiber loop is formed, it may be cut during the same process. The method further comprises the step of combining a plurality of artificial lawn fibers with the artificial lawn substrate. In this process, the artificial lawn fiber is bonded or attached to the artificial lawn substrate. This may be done in a variety of ways to hold the artificial lawn fibers in place, such as gluing or coating the surface of the artificial lawn substrate. This is done, for example, by coating the surface or part of the artificial lawn substrate with a material such as latex or polyurethane.

  Incorporation of artificial grass fibers into an artificial lawn substrate can be done, for example, by weaving artificial grass fibers into an artificial grass substrate (or fiber mat) instead during the manufacture of an artificial grass carpet. This artificial lawn manufacturing technique is known from US Patent Application No. 201212025474A1.

  The term “polymer bead” or “bead” may refer to a local region, such as a polymer droplet, that is immiscible in the second polymer. The plurality of polymer beads may in some cases be round, spherical or elliptical, and they may also be irregularly shaped. In some cases, the polymer beads typically have a diameter of about 0.1-3 micrometers, preferably 1-2 micrometers. In other examples, the plurality of polymer beads are larger. Their size is, for example, a maximum of 50 micrometers in diameter.

  In some examples, the drawn monofilament may be used directly as artificial lawn fiber. For example, the monofilament can be extruded as a tape or other shape.

  In other examples, the artificial lawn fibers may be bundles or groups of several stretched monofilament fibers that are generally cabled together, twisted, or bundled together. In some cases, the bundle is rewound with a so-called wrap yarn, which maintains the bundle of yarn together and prepares for the later tufting or weaving process.

  The size of the plurality of monofilaments is, for example, 50 to 600 micrometers in diameter. The weight of the yarn may typically reach 50 to 3000 dtex.

  Embodiments may have the advantage that the second polymer and any of the plurality of immiscible polymers may not delaminate from each other. The plurality of thread-like regions are embedded in the second polymer. Therefore, they cannot be peeled off. By using the first polymer and the second polymer, a plurality of characteristics of the artificial lawn fiber can be adjusted. For example, a softer plastic is used for the second polymer, giving the artificial grass a softer feel like a natural grass. A stiffer plastic may be used for the first polymer or other other immiscible polymers to give the artificial lawn greater elasticity and stability, giving it the ability to bounce after being stepped on or pushed down May be.

  A further advantage may be that in some cases a plurality of threadlike regions are concentrated in the central region of the monofilament during the extrusion process. This concentrates the stiffer material in the center of the monofilament and places a large amount of soft plastic on the outer or outer region of the monofilament. This further results in artificial lawn fibers with more turf-like properties.

  A further advantage may be that multiple artificial lawn fibers have improved long-term elasticity. As a result, after a plurality of artificial lawn fibers are used or trampled, their shapes recover more naturally and stand up, reducing the necessary maintenance of the artificial lawn and reducing the number of artificial lawn fibers. There may be less need for brushing.

  In another embodiment, the polymer bead comprises a plurality of crystalline portions and a plurality of amorphous portions. The polymer mixture is probably heated during the extrusion process, and the portions of the first polymer and further the second polymer have structures that are more amorphous or more crystalline in various regions. May be.

  By stretching the polymer beads into thread-like regions, the size of the plurality of crystalline portions may increase in the first polymer compared to the plurality of non-crystalline portions. This makes, for example, the first polymer stiffer than if it has an amorphous structure. This may result in an artificial lawn with higher rigidity and the ability to bounce back when depressed. Monofilament stretching may also cause a second polymer or a plurality of other additional polymers to make a larger portion of their structure more crystalline.

  In a specific example of this, the first polymer can be a polyamide and the second polymer can be polyethylene. Stretching the polyamide results in an increase in multiple crystalline regions that make the polyamide stiffer. This is also true for a plurality of other plastic polymers.

  In another embodiment, the step of creating the polymer mixture comprises forming the first mixture by mixing the first polymer with a compatibilizer. The step of creating the polymer mixture further includes the step of heating the first mixture. The step of creating the polymer mixture further comprises extruding the first mixture. Making the polymer mixture further comprises extruding the first mixture. The step of creating the polymer mixture further includes a step of granulating the extruded first mixture. The step of creating the polymer mixture further comprises the step of mixing the granulated first mixture with the second polymer. The step of creating the polymer mixture further comprises the step of heating the granulated first mixture with the second polymer to form a polymer mixture. This particular method of making the polymer mixture may be advantageous because it allows for very precise control over how the first polymer and compatibilizer are distributed within the second polymer. For example, the size or shape of the extruded first mixture determines the size of the plurality of polymer beads within the polymer mixture.

  In the above-mentioned method for producing the polymer mixture, for example, a so-called single screw extrusion method is used. As an alternative to this, the polymer mixture may also be made at once by bringing all of the constituent components together. For example, the first polymer, the second polymer and the compatibilizer can all be added together at the same time. Multiple other syntheses, such as multiple additional polymers or multiple other additives, can also be brought together at the same time. Next, the amount of mixing the polymer mixture can be increased, for example, by using a twin screw feed for extrusion. In this case, the desired distribution of the plurality of polymer beads can be achieved by using an appropriate mixing rate or amount.

  In another embodiment, the polymer mixture is at least a four phase system. The polymer mixture comprises at least a third polymer. The third polymer is immiscible with the second polymer. The third polymer further forms a plurality of polymer beads surrounded by a compatibilizing agent within the second polymer.

  In another embodiment, creating the polymer mixture comprises forming the first mixture by mixing the first polymer and the third polymer with a compatibilizer. The step of creating the polymer mixture further comprises the step of heating the first mixture. The step of creating the polymer mixture first comprises the step of extruding the first mixture. The step of creating the polymer mixture further comprises the step of granulating the extruded first mixture. The step of creating the polymer mixture further comprises the step of mixing the first mixture with the second polymer. Making the polymer mixture further comprises heating the first mixture with the second polymer to form a polymer mixture. This method may use two different polymers to create a polymer mixture and provide an accurate means of controlling the size and distribution of multiple polymer beads. As an alternative, the first polymer can be used to make the granulation with the same or different compatibilizer, apart from making the third polymer with the compatibilizer. The plurality of granulations can then be mixed with a second polymer to make a polymer mixture.

  As an alternative to this, the polymer mixture can be made by adding the first polymer, the second polymer, the third polymer and the compatibilizer all together at the same time and then mixing them more vigorously. For example, twin screw feed can be used for the extruder. In another embodiment, the third polymer is a polar polymer. In another embodiment, the third polymer is a polyamide.

  In another embodiment, the third polymer is polyethylene terephthalate, which is generally abbreviated as PET.

  In another embodiment, the third polymer is polybutylene terephthalate, which is commonly abbreviated as PBT.

  In another embodiment, the polymer mixture comprises 1 wt% to 30 wt% of the first polymer and the third polymer combined. In this example, the weight balance may be constituted by a plurality of components such as a second polymer, a compatibilizing agent, and a plurality of other additional additives placed in the polymer mixture.

  In another embodiment, the polymer mixture comprises 1% to 20% by weight of the first polymer and the third polymer together. Again, in this example, the weight balance of the polymer mixture may be constituted by the second polymer, the compatibilizer, and a plurality of other additive additives.

  In another embodiment, the polymer mixture comprises 5% to 10% by weight of the first polymer and the third polymer together. Again, in this example, the weight balance of the polymer mixture may be constituted by the second polymer, the compatibilizer, and a plurality of other additive additives.

  In another embodiment, the polymer mixture comprises 1 wt% to 30 wt% of the first polymer. In this example, the weight balance is constituted by, for example, the second polymer, the compatibilizer, and a plurality of other additional additives.

  In another embodiment, the polymer mixture comprises 1 wt% to 20 wt% of the first polymer. In this example, the weight balance may be constituted by the second polymer, the compatibilizer, and a plurality of other additional additives mixed into the polymer mixture.

  In another embodiment, the polymer mixture comprises 5% to 10% by weight of the first polymer. This example may have a weight balance constituted by the second polymer, the compatibilizer, and a plurality of other additional additives mixed into the polymer mixture. In another embodiment, the first polymer is a polar polymer. In another embodiment, the first polymer is a polyamide.

  In another embodiment, the first polymer is polyethylene terephthalate, commonly known by the abbreviation PET.

  In another embodiment, the first polymer is polybutylene terephthalate, also known by the general abbreviation PBT. In another embodiment, the second polymer is a nonpolar polymer. In another embodiment, the second polymer is polyethylene. In another embodiment, the second polymer is polypropylene.

  In another embodiment, the second polymer is a mixture of the aforementioned polymers that may be used for the second polymer.

  In another embodiment, the compatibilizer is maleic acid grafted onto polyethylene or polyamide; polyethylene using unsaturated acids or anhydrides such as maleic acid, glycidyl methacrylate, ricinoloxazoline maleinate, Maleic anhydride grafted to SEBS, EVA, EPD or polypropylene free radical initiated graft copolymer; graft copolymer of SEBS using glycidyl methacrylate; graft copolymer of EVA using mercaptoacetic acid and maleic anhydride; EPDM graft copolymer with maleic anhydride; Polypropylene graft copolymer with maleic anhydride; Polyolefin grafted polyamide polyethylene or polyamide; and Poly Acrylic acid compatibilizer agent is any one of.

  In another embodiment, the polymer mixture comprises 80% to 90% by weight of the second polymer. In this example, the weight balance is the second polymer, the compatibilizer, and multiple other chemicals or additions added to the polymer mixture if present in the first polymer, optionally in the polymer mixture. It may be constituted by an agent.

  In another embodiment, the polymer mixture further comprises any one of waxes, blunting agents, UV stabilizers, flame retardants, antioxidants, pigments and combinations thereof. These listed additional ingredients are added to the polymer mixture to make the artificial lawn fiber a flame retardant, have a green color so that the artificial lawn more closely resembles the lawn, greater under sunshine A plurality of other desired characteristics such as stability may be provided.

  In another embodiment, creating the artificial lawn fiber comprises weaving the monofilament into the artificial lawn fiber. That is, in some examples, artificial lawn fibers are not a single monofilament, but a combination of many fibers. In another embodiment, the artificial lawn fiber is a woven yarn.

  In another embodiment, the method further comprises the step of binding the drawn monofilaments together to create artificial lawn fibers.

  In another embodiment, the method further comprises the step of weaving, binding, or spinning a plurality of monofilaments together to create an artificial lawn fiber. A plurality, for example 4-8 monofilaments, can be formed or finished into a woven yarn.

  In another aspect, the present invention provides artificial turf manufacture according to any one of the foregoing methods.

  In another aspect, the present invention provides an artificial lawn comprising an artificial lawn base and artificial lawn fibers formed in a tuft in the artificial lawn base. The artificial lawn substrate is, for example, a woven fabric or other flat structure that can have a plurality of fibers formed in a tuft shape therein. The artificial lawn fiber comprises at least one monofilament. Each of the at least one monofilament comprises a first polymer in the form of a plurality of threadlike regions. Each of the at least one monofilament comprises a second polymer, and the plurality of thread-like regions are embedded in the second polymer. Each of the at least one monofilament includes a compatibilizer that surrounds each of the plurality of thread-like regions and separates at least one first polymer from the second polymer. This artificial lawn may have the advantage of being extremely durable because a plurality of filamentous regions are embedded in the second polymer via a compatibilizing agent. They are therefore not capable of peeling. Having a second polymer surrounding the first polymer may provide a hard artificial lawn that is soft and has a feel similar to real lawn. The artificial grass described herein is different in nature from coextruded artificial grass. In coextrusion, a core, typically 50-60 micrometers in diameter, may be surrounded by an outer cover or coating material having a diameter of about 200-300 micrometers. In this artificial lawn, there are many filamentous regions of the first polymer. The plurality of threadlike regions may not continue along the entire length of the monofilament. The artificial lawn may also have properties or characteristics provided by any of the method steps described above. In another embodiment, the plurality of filamentous regions have a diameter of less than 20 micrometers. In another embodiment, the plurality of filamentous regions have a diameter of less than 10 micrometers. In another embodiment, the plurality of filamentous regions have a diameter of 1 micrometer to 3 micrometers.

  In another embodiment, the artificial lawn fiber extends a predetermined length beyond the artificial lawn substrate. The plurality of filamentous regions have a length that is less than half of the predetermined length. In another embodiment, the plurality of thread-like regions have a length of less than 2 mm.

  It will be appreciated that one or more of the foregoing embodiments of the invention may be combined as long as the combined embodiments are not mutually exclusive.

In the following, embodiments of the present invention will be described in more detail with reference to the drawings, which are merely examples.
FIG. 1 shows a flowchart illustrating an example of a method for manufacturing an artificial lawn. FIG. 2 shows a flowchart illustrating one method of making a polymer mixture. FIG. 3 shows a flowchart illustrating a further example of how to make a polymer blend. FIG. 4 shows a diagram illustrating a cross section of the polymer mixture. FIG. 5 shows a further example of a polymer mixture. FIG. 6 illustrates an extrusion that turns the polymer mixture into monofilaments. FIG. 7 shows a cross section of a small piece of monofilament. FIG. 8 illustrates the effect of drawing the monofilament. FIG. 9 shows an electron micrograph of a cross section of a stretched monofilament. FIG. 10 shows a cross-sectional example of an example of an artificial lawn.

  Elements with the same reference in these figures are either equivalent elements or perform the same function. The multiple elements discussed above are not necessarily discussed in later figures if their functions are equivalent.

  FIG. 1 shows a flowchart illustrating an example of a method for manufacturing an artificial lawn. First, in step 100, a polymer mixture is created. The polymer mixture is at least a three-phase system. The polymer mixture comprises a first polymer. The polymer mixture further comprises a second polymer and a compatibilizer. The first polymer and the second polymer are immiscible. In other examples, there may be a plurality of additional polymers, such as a third polymer, a fourth polymer, or even a fifth polymer that are also immiscible with the second polymer. It may also be a plurality of additional compatibilizers used either in combination with the first polymer or in combination with additional third, fourth or fifth polymers. The first polymer forms a plurality of polymer beads surrounded by a compatibilizing agent. The plurality of polymer beads may also be formed by a plurality of additional polymers that are not miscible within the second polymer.

  The plurality of polymer beads are surrounded by a compatibilizing agent and are within or mixed into the second polymer. In the next step 102, the polymer mixture is extruded into monofilaments. Next, in step 104, the monofilament is quenched or cooled rapidly. Next, in step 106, the monofilament is reheated. In step 108, the reheated monofilament is stretched to transform the plurality of polymer beads into a plurality of filamentous regions and form the monofilament into artificial lawn fibers. A number of additional steps are also performed on the monofilament to form artificial lawn fibers. For example, monofilaments can be spun or woven into yarns with the desired properties. Next, in step 110, the artificial lawn fiber is incorporated into an artificial lawn substrate. Step 110 may be, for example, but not limited to, forming or weaving artificial lawn fibers into a tufted shape in an artificial lawn substrate. Next, in step 112, a plurality of artificial lawn fibers are bonded to the artificial lawn substrate. For example, a plurality of artificial lawn fibers are glued or held in place by a coating or other material. Step 112 is an optional step. For example, if multiple artificial lawn fibers are woven into an artificial lawn substrate, step 112 may not need to be performed.

  FIG. 2 shows a flowchart illustrating one method of making a polymer mixture. In this example, the polymer mixture is a three-phase system and comprises a first polymer, a second polymer and a compatibilizing agent. The polymer mixture may be colored, provide fire resistance or UV resistance, or may comprise a plurality of others, such as, for example, a plurality of additives, to improve a plurality of flow characteristics of the polymer mixture. First, at step 200, a first mixture is formed by mixing a first polymer with a compatibilizer.

  A plurality of additional additives may also be added during this step. Next, in step 202, the first mixture is heated. Next, in step 204, the first mixture is extruded. Next, in step 206, the extruded first mixture is then granulated or cut into small pieces. Next, in step 208, the granulated first mixture is mixed with the second polymer. At this time, a plurality of additional additives may also be added to the polymer mixture. Finally, in step 210, the granulated first mixture is heated with the second polymer to form a polymer mixture. The heating step and the mixing step may occur simultaneously.

  FIG. 3 shows a flowchart illustrating a further example of how to make a polymer blend 400. In this example, the polymer mixture further comprises at least a third polymer. The third polymer is immiscible with the second polymer, and the polymer mixture is at least a four-phase system. The third polymer further uses the second polymer to form a plurality of polymer beads surrounded by the compatibilizing agent. First, at step 300, a first mixture is formed by mixing a first polymer and a third polymer with a compatibilizer. At this time, a plurality of additional additives may be added to the first mixture. Next, in step 302, the first mixture is heated. The heating step and the mixing step of the first mixture may be performed simultaneously. Next, in step 304, the first mixture is extruded. Next, in step 306, the extruded first mixture is granulated or cut into small pieces. Next, in step 308, the first mixture is mixed with the second polymer. At this time, a plurality of additional additives may be added to the polymer mixture. Next, finally, in step 310, the heated first mixture and second polymer are heated to form a polymer mixture. The heating step and the mixing step may be performed simultaneously.

  FIG. 4 shows a diagram illustrating a cross section of polymer blend 400. The polymer mixture 400 comprises a first polymer 402, a second polymer 404 and a compatibilizer 406. The first polymer 402 and the second polymer 404 are immiscible. The first polymer 402 is not as abundant as the second polymer 404. The first polymer 402 is shown as being surrounded by the compatibilizer 406 and dispersed within the second polymer 404. The first polymer 402 surrounded by the compatibilizer 406 forms a number of polymer beads 408. The plurality of polymer beads 408 may be spherical or elliptical in shape, and they may also be irregularly shaped depending on how well the polymer mixture is mixed and depending on temperature. The polymer mixture 400 is an example of a three-phase system. The three phases are a plurality of regions of the first polymer 402. The second phase region is the compatibilizing agent 406 and the third phase region is the second polymer 404. A compatibilizer 406 separates the first polymer 402 from the second polymer 404.

  FIG. 5 shows a further example of a polymer mixture 500. The example shown in FIG. 5 is the same as the example shown in FIG. However, the polymer mixture 500 further comprises a third polymer 502. Some of the polymer beads 408 here consist of a third polymer 502. The polymer mixture 500 shown in FIG. 5 is a four-phase system. The four phases are composed of a first polymer 402, a second polymer 404, a third polymer 502, and a compatibilizer 406. The first polymer 402 and the third polymer 502 are not miscible with the second polymer 404. The compatibilizer 406 separates the first polymer 402 from the second polymer 404 and separates the third polymer 502 from the second polymer 404.

  In this example, the same compatibilizer 406 is used for both the first polymer 402 and the third polymer 502. In several other examples, different compatibilizers 406 can be used for the first polymer 402 and the third polymer 502.

  FIG. 6 illustrates the extrusion of the polymer mixture into monofilaments. An amount of polymer mixture 600 is shown. There are a number of polymer beads 408 within the polymer mixture 600. The plurality of polymer beads 408 may be made of one or more polymers that are not miscible with the second polymer 404 and are separated from the second polymer 404 by a compatibilizer. A screw, piston or other device is used to push the polymer mixture 600 into the holes 604 of the plate 602. As a result, the polymer mixture 600 is extruded into a monofilament 606. Monofilament 606 is shown as including a plurality of polymer beads 408 as well. The second polymer 404 and the plurality of polymer beads 408 are extruded together. In some examples, the second polymer 404 is not as viscous as the plurality of polymer beads 408 and the plurality of polymer beads 408 will tend to concentrate in the center of the monofilament 606. This results in a concentration of a plurality of threadlike regions in the core region of monofilament 606, which may result in a plurality of desired properties for the final artificial lawn fiber.

  FIG. 7 shows a cross section of a small piece of monofilament 606. The monofilament is again shown as comprising a second polymer 404 in which a plurality of polymer beads 408 are mixed. The plurality of polymer beads 408 are separated from the second polymer 404 by a compatibilizer 406 (not shown). To form a plurality of thread-like structures, a portion of monofilament 606 is heated and then stretched along the length of monofilament 606. This is illustrated by the arrow 700 indicating the direction of stretching.

  FIG. 8 illustrates the effect of stretching the monofilament 606. In FIG. 8, an example of a cross-section of stretched monofilament 606 is shown. The plurality of polymer beads 408 in FIG. 7 are stretched to form a plurality of thread-like structures 800. The amount of deformation of the plurality of polymer beads 408 depends on how much the monofilament 606 'is stretched.

  Examples may relate to the production of artificial lawns, also called synthetic lawns. In particular, the present invention relates to the production of multiple fibers that mimic turf. The plurality of fibers are composed of a compatibilizing agent and first and second polymers that are not miscible and have different material properties such as rigidity, density, and polarity.

  In the first step, the first polymer is mixed with a compatibilizing agent. Color pigments, UV and heat stabilizers, processing aids, and other materials known as such from the art can be added to the mixture. Thereby, a granular material composed of a two-phase system in which the first polymer is surrounded by the compatibilizing agent may be obtained.

  In the second step, a three-phase system is formed by adding a second polymer to the mixture, whereby in this example the amount of the second polymer is about 80-90 weight percent of the three-phase system; The amount of the first polymer is 5% by mass to 10% by mass of the three-phase system, and the amount of the compatibilizer is 5% by mass to 10% by mass of the three-phase system. By using an extrusion technique, a mixture of droplets or beads of the first polymer surrounded by a compatibilizing agent dispersed in the polymer matrix of the second polymer is obtained. In practical practice, a so-called masterbatch is formed that contains the granulation of the first polymer and the compatibilizer. A masterbatch may also be referred to herein as a “polymer mixture”. The granulation mixture is dissolved and a mixture of the first polymer and the compatibilizer is formed by extrusion. The resulting multiple strands are crushed into granules. The resulting granulation and granulation of the second polymer is then used for the second extrusion to produce a thick fiber that is then drawn to become the final fiber.

  The melting temperature used during multiple extrusions depends on the type of polymer and the compatibilizer used. However, the melting temperature is typically between 230 ° C and 280 ° C.

  Monofilaments, which can also be referred to as monofilaments or fibrillated tapes, are produced by sending the mixture to an extrusion line for fiber production. The molten mixture passes through an extrusion device, i.e. a spinneret plate or a wide slot nozzle, shaping the molten stream into a single fiber or tape shape, quenched or cooled in a water spinning bath, and rotated at different rotational speeds. It is dried and stretched by passing through a plurality of heated godets and / or a heating oven.

  The monofilament or tape is then annealed online in a second step through an additional heating oven and / or a heated set of godets.

  By this procedure, a plurality of beads or droplets of a first polymer surrounded by a compatibilizing agent are stretched in the longitudinal direction to form a plurality of fibrillar linear structures, however, these are the second polymer Remain completely embedded in the polymer matrix.

  FIG. 9 shows a photomicrograph of a cross section of a stretched monofilament produced using the example method described above. Horizontal white stripes in the drawn monofilament 606 are a plurality of thread-like structures 800. Some of these threadlike structures are labeled 800. The plurality of thread-like structures 800 can be shown as forming a plurality of filamentous structures of the first polymer within the second polymer.

  The resulting fiber may have a softness that combines several advantages: durability and long-term elasticity. In the case of multiple different stiffness and bending properties of multiple polymers, the fiber may exhibit better elasticity than the stiff first polymer (which means that the fiber will bounce once it is stepped on). The multiple filamentary fiber structures incorporated into the polymer matrix can provide polymer reinforcement of the fibers.

  Limit determination due to the composite formed by the first and second polymers is prevented by embedding a plurality of short fibers of the second polymer in a matrix provided by the first polymer. In addition, complicated co-extrusion requiring several extrusion heads to feed a single composite spinneret tool is not required.

  The first polymer can be a polar material such as polyamide, while the second polymer can be a nonpolar polymer such as polyethylene. Several alternatives to the first polymer are polyethylene terephthalate (PET) or polybutylene terephthalate (PBT) for the second polymer polypropylene. Finally, materials consisting of three polymers are possible (eg PET, PA and PP). PP creates the matrix and creates a plurality of fiber linear structures in which the other is independent of one another. The compatibilizer can be maleic anhydride grafted to polyethylene or polyamide.

FIG. 10 shows an example of a cross section of an example of an artificial lawn 1000. The artificial lawn 1000 includes an artificial lawn base 1002. The artificial lawn fiber 1004 is formed in a tuft shape in the artificial lawn base 1002. A coating 1006 is shown at the base of the artificial lawn substrate 1002. The coating may serve to bond or secure the artificial grass fiber 1004 to the artificial grass substrate 1002. The coating 1006 may be optional. For example, the plurality of artificial grass fibers 1004 are woven into the artificial grass substrate 1002 instead. Various types of glues, coatings or adhesives can be used for the coating 1006. The plurality of artificial lawn fibers 1004 are shown as extending a distance 1008 above the artificial lawn substrate 1002. The distance 1008 is essentially the pile height of the plurality of artificial lawn fibers 1004. The length of the plurality of thread-like regions in the plurality of artificial lawn fibers 1004 is half or less of the distance 1008.
LIST OF REFERENCE MARKS 100 Create a polymer mixture 102 Extrude the polymer mixture into monofilaments 104 Quench the monofilaments 106 Reheat the monofilaments 108 Elongate the reheated monofilaments and make multiple polymer beads into multiple filamentous regions And forming monofilaments into the artificial lawn fiber 110 Incorporating the artificial lawn fiber into the artificial lawn carpet 112 Optionally combining multiple artificial lawn fibers into the artificial lawn carpet 200 Forming the first mixture by mixing with a solubilizer 202 Heating the first mixture 204 Extruding the first mixture 206 Granulating the extruded first mixture 208 Granulating the first mixture with the second polymer Mix 21 0 The granulated first mixture is heated with the second polymer to form a polymer mixture

300 Forming the first mixture by mixing the first polymer and the third polymer with the compatibilizer 302 Heating the first mixture 304 Extruding the first mixture 306 Granulating the extruded first mixture 308 First Mixing the mixture with the second polymer 310 Heating the mixed first mixture with the second polymer to form a polymer mixture 400 Polymer mixture 402 First polymer 404 Second polymer 406 Compatibilizer 408 Polymer beads 500 Polymer mixture 502 Third polymer 600 Polymer mixture 602 Plate 604 Hole 606 Monofilament 606 'Stretched monofilament 700 Stretch direction 800 Multiple filamentary structures 1000 Artificial lawn 1002 Artificial lawn carpet 1004 Artificial lawn fiber (pile)
1006 Coating 1008 Pile height

Claims (26)

Artificial grass,
An artificial lawn ground,
Artificial grass fibers incorporated into the artificial grass substrate;
With
The artificial lawn fiber is a woven yarn formed from monofilament,
The monofilament comprises a polymer mixture, the polymer mixture is at least a three-phase system, the polymer mixture comprises a first polymer, a second polymer and a compatibilizing agent, wherein the first polymer and the second polymer are An artificial lawn that is immiscible and wherein the first polymer forms a plurality of thread-like regions surrounded by the compatibilizer in the second polymer.   The artificial lawn according to claim 1, wherein the plurality of filamentous regions includes a plurality of crystal parts and a plurality of non-crystal parts.   The polymer mixture is at least a four-phase system, the polymer mixture comprises at least a third polymer, the third polymer is immiscible with the second polymer, and the third polymer is further The artificial lawn according to claim 1 or 2, wherein the plurality of filamentous regions surrounded by the compatibilizing agent are formed in two polymers.   The artificial lawn according to claim 3, wherein the third polymer is a polar polymer.   The artificial lawn according to claim 3 or 4, wherein the third polymer is any one of polyamide, polyethylene terephthalate (PET), and polybutylene terephthalate (PBT).   The artificial lawn according to any one of claims 3 to 5, wherein the polymer mixture comprises 1 wt% to 30 wt% of the first polymer and the third polymer.   The artificial lawn according to any one of claims 3 to 5, wherein the polymer mixture comprises 1 wt% to 20 wt% of the first polymer and the third polymer together.   The artificial lawn according to any one of claims 3 to 5, wherein the polymer mixture comprises 5 to 10% by weight of the first polymer and the third polymer together.   The artificial lawn according to claim 1 or 2, wherein the polymer mixture comprises 1 wt% to 30 wt% of the first polymer.   The artificial lawn according to claim 1 or 2, wherein the polymer mixture comprises 1 wt% to 20 wt% of the first polymer.   The artificial lawn according to claim 1 or 2, wherein the polymer mixture comprises 5% to 10% by weight of the first polymer.   The artificial lawn according to any one of claims 1 to 11, wherein the first polymer is a polar polymer.   The artificial lawn according to any one of claims 1 to 12, wherein the first polymer is any one of polyamide, polyethylene terephthalate (PET), and polybutylene terephthalate (PBT).   The artificial lawn according to any one of claims 1 to 13, wherein the second polymer is a nonpolar polymer.   The artificial lawn according to any one of claims 1 to 14, wherein the second polymer is any one of polyethylene, polypropylene, and a mixture thereof.   The compatibilizer is free of polyethylene, SEBS, EVA, EPD or polypropylene using an unsaturated acid such as maleic acid grafted to polyethylene or polyamide; an unsaturated acid such as maleic acid, glycidyl methacrylate, ricinol oxazoline maleate or the like. Maleic anhydride grafted to radical-initiated graft copolymer; graft copolymer of SEBS using glycidyl methacrylate; graft copolymer of EVA using mercaptoacetic acid and maleic anhydride; graft copolymer of EPDM using maleic anhydride; maleic anhydride Polypropylene graft copolymer using acid; polyolefin graft polyamide polyethylene or polyamide; and polyacrylic acid type compatibilizer, Artificial lawn according to any one of Motomeko 1 to 15.   The artificial lawn according to any one of claims 1 to 16, wherein the polymer mixture comprises 80% to 90% by weight of the second polymer.   The artificial polymer according to any one of claims 1 to 17, wherein the polymer mixture further comprises any one of waxes, blunting agents, UV stabilizers, flame retardants, antioxidants, pigments and combinations thereof. lawn.   19. The artificial lawn fiber comprises at least one of monofilaments woven, spun, twisted, rewound or bound into the artificial lawn fiber. The artificial lawn as described in any one of.   The artificial lawn according to any one of claims 1 to 19, wherein the artificial lawn fibers are tufted into the artificial lawn base and a plurality of the artificial lawn fibers are bonded to the artificial lawn base.   The artificial lawn according to any one of claims 1 to 19, wherein the artificial lawn fiber is woven into the artificial lawn substrate.   The artificial lawn according to any one of claims 1 to 21, wherein the plurality of filamentous regions have a diameter of less than 50 micrometers.   The artificial lawn according to any one of claims 1 to 21, wherein the plurality of filamentous regions have a diameter of less than 10 micrometers.   The artificial lawn according to any one of claims 1 to 21, wherein the plurality of filamentous regions have a diameter of 1 micrometer to 3 micrometers.   25. The artificial grass fiber according to any one of claims 22 to 24, wherein the artificial lawn fiber extends a predetermined length beyond the artificial lawn base, and the plurality of filamentous regions have a length less than half of the predetermined length. The artificial lawn according to one item.   The artificial lawn according to any one of claims 22 to 24, wherein the plurality of filamentous regions have a length of less than 2 mm.

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