JP2851241B2 - Method of manufacturing artificial grass - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for producing athletic facilities, parks and gardens, and a method for producing artificial turf used as a terrace or veranda of a playground or various buildings, or as a decoration for display. It is.

[0002]

2. Description of the Related Art Artificial turf is manufactured by embedding a synthetic resin pile yarn in a base cloth and subjecting it to backing. It is durable and beautiful and can be replaced with natural turf. It is used in a wide variety of applications, including applications that can be used because it is a lawn. When this artificial lawn is used in stadiums, parks, etc., it is laid directly on a base such as flat soil, asphalt, concrete, etc., but as a mat-like material it is relatively thin and has cushioning and walking feeling. Chipping,
In addition, a burden is likely to be applied to the legs of the athlete or the pedestrian.

[0003] Focusing on these problems, for example, a method for manufacturing an artificial turf integrated with a mat bottom by loading an artificial turf sheet in a foaming mold, filling the foamed particles, and performing heat expansion molding. (Japanese Patent Publication No. 61-14932), rubber material, synthetic resin, inorganic filler, fiber material, kneaded with bituminous material and molded for artificial turf (Japanese Patent Publication No. 62-42947), elastic foam plastic Turf with an under pad provided in a substantially spherical distribution (Japanese Patent Laid-Open No. 4-15003), and an artificial turf in which a turf-like surface material is bonded to a base material in which elastic chips are bonded in a plate shape (Japanese Patent Laid-Open No. No. 5,505,541), and an artificial turf ground in which an artificial turf mat is laid on a base layer made of soil cement mixed with elastic particles (Japanese Patent Application Laid-Open No. 6-136717). These are not commonly used because they require special manufacturing equipment, require complicated processing means as members, are expensive or difficult to obtain, and require extensive infrastructure maintenance. is the current situation.

[0004]

SUMMARY OF THE INVENTION In view of the above-mentioned problems, the present invention provides a method of manufacturing an artificial turf having an appropriate cushioning property and made of inexpensive members without requiring special manufacturing equipment. It is intended to provide.

[0005]

According to the present invention, there is provided a synthetic resin in which a lawn leaf is planted on the elastic sheet side on a base cloth in which an elastic sheet 4 is previously laminated on a fiber base material 3 and joined and integrated. The pile yarn 2 is tufted and then backed.
A method for producing artificial turf, characterized in that to.

The artificial turf 1 obtained by the production method of the present invention as shown in FIG. 1 is also shown in FIG. 1, but the fiber base material 3, the elastic sheet 4, the synthetic resin pile yarn 2, the backing layer 5 is constituted.

The fibrous base material 3 is generally used as a primary base fabric of a tufted product, and is a synthetic resin stretched tape which has an advantage of being easily torn in the length direction when a needle is inserted and hard to be broken. Examples of the woven fabric include a woven fabric in which yarn is densely woven into warp yarns, and a fibrous non-woven fabric having low resistance to penetration of a needle, high strength, and no direction.

The elastic sheet 4 is a relatively bulky sheet having flexibility and cushioning properties.
Synthetic resin foams such as polypropylene, polyethylene, ethylene-vinyl acetate copolymer, polystyrene, polyvinyl chloride, and various elastomers; rubbery bodies such as natural rubber, styrene butadiene rubber, urethane rubber, and chloroprene rubber; and rubber foams Bulky nonwoven fabric obtained by bonding a web made of a body or a low fineness filament.

The elastic sheet 4 needs to be a relatively low-density porous sheet because it acts as a cushioning material having a compressive recovery property.
Those having a thickness of 200 kg / m ³ and a thickness of 5 to 20 mm are desirable. This is unsuitable in that the low-density material has a low impact absorption capacity and cannot achieve its intended purpose as a cushioning material, and is inferior in wear resistance. This is unsuitable in that the penetration resistance of the needle is large and the needle is liable to be damaged, resulting in poor efficiency. In addition, thickness 5
If the thickness is less than mm, the elasticity is inferior, and if the thickness exceeds 20 mm, the feeling of treading is different, and it is assumed that a problem arises because the pile yarn requires a longer cut length than necessary.

The above-mentioned elastic sheet 4 which is superposed on the upper surface of the above-mentioned fiber base material 3 and joined and integrated is used as a tufted base fabric for planting the pile of the artificial turf 1 of the present invention. Examples of a method of laminating and bonding the fiber base material 3 and the elastic sheet 4 include known adhesives such as urethane-based, vinyl-based, acid-based, and epoxy-based adhesives, heat seal, hot melt web, and powder fusion. Joined by means. Further, a liquid or paste-like unfoamed resin composition or an unvulcanized latex-like rubber material to which a foaming agent has been added is directly coated on the fiber base material 3, and after undergoing a tufting step described below, the foamed material is heated and foamed. Alternatively, the elastic sheet 4 can be vulcanized.

A pile yarn 2 made of synthetic resin is provided on the laminated base fabric.
The synthetic grass is made of a pile yarn, and thermoplastic synthetic resins such as polyvinylidene chloride, nylon 6, polyester, polypropylene, and high-density polyethylene are added as necessary, with an ultraviolet absorber, an antistatic agent, a coloring agent, etc. Uniaxially stretched tape yarns and filaments obtained from a resin composition appropriately blended with an agent, splitting, twisting, crimping, etc. are performed as needed.A raw yarn having a total fineness of 1,000 to 10,000 dr is used. .

The pile yarn 2 made of synthetic resin is planted as a cut pile with 4 to 8 stitches on the above-mentioned base fabric by a 1/10 to 3/8 gauge tufted machine. Here, the pile length is set so as to be 5 to 20 mm long on the surface of the elastic sheet. This is because short leaves having a length of less than 5 mm have poor appearance as an artificial lawn, and long leaves having a length exceeding 20 mm tend to lie down and the lawn leaves have poor compressive recovery properties, which is not preferable.

A backing layer 5 is formed on the back surface of the base fabric for the purpose of fixing the synthetic resin pile yarn 2 planted on the base fabric. This is, for example, a method of applying a predetermined amount of a backing agent such as an SBR type, an NBR type, an acrylic type, or an epoxy type, followed by drying with hot air, or an artificial method by coating a thermoplastic synthetic resin film by an extrusion lamination method. It forms the lawn 1.

[0014]

The artificial turf obtained by the production method of the present invention can have an appropriate cushioning property due to the presence of the elastic sheet bonded to the fiber base material. In addition, by giving a color or design to the elastic sheet by printing or painting, it is possible to check the surface of the artificial turf through the grass, so that the display function can be easily provided. further,
When a granular material such as sand is scattered as a filler 6 in the grass of the artificial turf to form an artificial turf containing sand, uneven distribution of the filler 6 near the bottom due to the compressive recovery of the elastic sheet 4 during use.
Curing can be suppressed to reduce the change with time in the buffering property and lubricity.

[0015]

EXAMPLES Example 1 Polypropylene (MFR = 0.8) was selected as a synthetic resin, and a melting temperature of 260 ° C. was obtained from a circular die by an inflation method.
Extruded in an amorphous state, cooled and formed into a tubular film, cut into tapes, and stretched at a stretching temperature of 140 ° C, an annealing temperature of 145 ° C, and a stretching ratio of 5.2 times using a hot plate contact stretching method. It was a uniaxially stretched flat yarn.
The flat yarn is split with a high-speed rotating blade to a fineness of 3,80.
You got a split yarn of 0dr. This split yarn is twisted twice / inch and then subjected to a crimping process of 10 ridges / inch with a compression shaping crimping machine to obtain a synthetic resin pile yarn 2 shown in FIG.
And

A polyester fiber non-woven fabric having a basis weight of 120 g / m ² is used as a fiber substrate 3, and a 35 g / m ² urethane-based adhesive is applied to the surface of the fiber substrate to form a 15 mm thick polyethylene having a density of 30 kg / m ^3. Using a base cloth, which is overlapped with and bonded to the elastic sheet 4 of the foamed material, the 5/32 gauge tufting machine is used.
The stitches were tufted as cut piles having a pile length of 27 mm such that grass leaves of about 12 mm protruded from the surface of the elastic sheet constituting the base fabric.

Next, the backing layer 5 was formed by applying 580 g / m ^{2 of} an acrylic backing agent to the back surface of the base fabric, followed by drying with hot air to obtain an artificial lawn 1.

Example 2 As the elastic sheet 4, an artificial turf was used in the same manner as in Example 1 except that a nonwoven fabric having a density of 65 kg / m ³ and a thickness of 10 mm formed by impregnating a polyamide fiber web with a phenol resin was used. It was formed as Example 2. The resulting artificial turf had grass leaves protruding about 10 mm from the surface of the elastic sheet.

Example 3 An artificial lawn was formed in the same manner as in Example 1 except that a urethane rubber sheet having a density of 80 kg / m ³ and a thickness of 7.2 mm was used as the elastic sheet 4. The resulting artificial lawn had grass leaves protruding about 8 mm from the surface of the elastic sheet.

Example 4 p-styrene as a foaming agent for styrene-butadiene rubber latex
Toluenesulfonyl hydrazide is added, the surface of the fiber base material 3 is coated with a roll coater, and then dried with hot air at 65 ° C. to form a base fabric, and pile yarns are planted on the latex-coated surface of the base fabric. 500 g / m of styrene butadiene backing agent on the back
^2. Apply and dry with hot air at 135 ° C. to fix the pile yarn to the base fabric and foam styrene-butadiene rubber latex to obtain an elastic sheet 4 having a density of 100 kg / m ³ and a thickness of 5.2 mm.
Example 4 was obtained by obtaining an artificial lawn forming Here, the same fiber base and synthetic resin pile yarn as those used in Example 1 were used, and the obtained artificial turf had grass leaves protruding about 5 mm from the surface of the elastic sheet.

COMPARATIVE EXAMPLES In the construction of the artificial turf of each of the examples, no elastic sheet was present, and in all other cases, artificial turf obtained in the same manner was used as a comparative example.

Evaluation In laying the artificial turf of the example and the comparative example on a concrete base and using it as a walking path, natural silica sand was sprayed as a filler 6 in the grass, smoothed by brushing, and piled on the surface layer. The yarn was confirmed to be about 2-3 mm.

The state of the artificial grass 1 eight months after the installation was confirmed, and it was found that, in the example, there was almost no uneven distribution or outflow of natural silica sand in appearance, the cushioning property was maintained, and the feeling of treading was the same. In Comparative Examples, it was recognized that natural silica sand sank near the bottom and concentrated, and many turf leaves on the surface fell down, and both the appearance and the cushioning property were inferior to those of Examples.

[0024]

As described above, the artificial turf obtained by the production method of the present invention has an appropriate cushioning property. There is no burden. Further, it can be made of inexpensive members without requiring special manufacturing equipment.

[Brief description of the drawings]

FIG. 1 is a cross-sectional view showing a state where a filler is sprayed on an artificial lawn obtained by a production method of the present invention.

[Explanation of symbols]

 Reference Signs List 1 artificial grass 2 synthetic resin pile yarn 3 fiber base material 4 elastic sheet 5 backing layer 6 filler

──────────────────────────────────────────────────続 き Continued on front page (58) Field surveyed (Int.Cl. ⁶ , DB name) E01C 13/08

Claims (1)

(57) [Claims] To 1. A base fabric joined integrally previously overlaid elastic sheet 4 on the upper surface of the fiber substrate 3, and tufting the synthetic resin pile yarn 2 as ShibaYo is implanted in the elastic sheet side , then the method of manufacturing artificial turf, characterized in that to facilities the backing process.