JP5256106B2 - Fire retardant artificial grass - Google Patents

Description

  The present invention relates to a flame retardant artificial lawn, and more particularly to an artificial lawn having flame retardancy due to the density of planting straight pile yarns and crimped pile yarns.

  In recent years, artificial lawns have been used in sports applications such as baseball fields, tennis courts, rugby fields, soccer fields, gateball fields, golf practice mats, poolside mats, public spaces such as parks, hospitals, schools, kindergartens, and homes. It is widely used in gardens, terraces and verandas. Among these various uses, when artificial lawn is used in fire prevention objects designated by the Fire Service Act or government ordinance such as high-rise buildings, underground malls, hotels, hospitals, kindergartens, welfare facilities, churches, exhibition halls, playgrounds, etc. Must have a flameproof performance exceeding the standard specified by a Cabinet Order.

In order to impart flame resistance to an artificial lawn, it is common to add flame retardant to the material constituting the pile yarn to impart flame resistance to the material itself, thereby expressing the flame resistance. Yes (Patent Document 1).
However, halogen-based substances, which are flame retardants, have a large environmental load, and it is necessary to suppress their use from the environmental aspect.
In addition, when a flame retardant is added to the constituent material of the pile yarn, the mechanical strength, weather resistance, and wear resistance of the pile yarn are reduced.
Furthermore, when a flame retardant is added to the constituent material of the pile yarn, considering recycling, it is necessary to separate the material from the material to which the flame retardant is not added, and the processing becomes complicated.
Furthermore, the material to which the flame retardant is added is inferior in processability, and the material cost is high, and the manufacturing cost of the artificial lawn is high as a whole.
Therefore, development of the flame-retardant artificial lawn using the material which does not use a flame retardant was calculated | required.

On the other hand, artificial turf is required to have functions such as cushioning, slip resistance, natural turf functions such as texture resulting from appearance, and sand filling properties during construction.
In order to ensure these functions, various proposals have been made (Patent Documents 2 and 3). However, none of these proposals have been studied including flameproofing.

JP 2000-303257 A JP-A-6-158609 JP-A-7-109661

  The present invention solves the above-mentioned problems and exhibits a flameproof property that can be used in places specified by the Fire Service Act or a government ordinance, and also has a function of natural turf such as cushioning, slip resistance, and texture resulting from the appearance. It is also a technical problem to provide an artificial lawn that satisfies the requirements for sand filling.

In order to achieve the above-mentioned object, the present invention provides a base fabric made of a thermoplastic resin cloth, in which straight pile yarns and crimped pile yarns are approximately the same length and are alternately planted to form a row. An artificial lawn, in which both the straight pile yarn and the crimped pile yarn are present above the base fabric, and only the straight pile yarn is present above the high density layer. possess a low density layer, the straight pile yarns and crimped pile yarn are each free of flame retardant, wherein a straight pile yarns flat yarn or split yarn is uniaxially stretched, the crimped pile yarn multi The straight pile yarn has a fineness of 6,000 to 10,000 dtex, and the crimped pile yarn has a fineness of 2,000 to 4,000. A dtex, the base fabric, the straight pile yarns and said total number of crimped pile yarn 4 to six / cm ^2, and the total weight of the straight pile yarns and said crimped pile yarn 1,000 It is planted so that it may become thru | or 1,400 g / m < ² > .

  According to the present invention, a high density layer of pile yarn formed by straight pile yarn and crimped pile yarn inhibits oxygen supply from the outside during combustion without containing a flame retardant in the constituent material of the pile yarn To suppress combustion and self-digest.

Moreover, since a flame retardant is not used, it is possible to recycle together with other loss materials without separating the loss materials generated during production.
Furthermore, the presence of a low-density pile layer makes it easy to ensure general sanding workability with a sand spreader or the like.
Furthermore, since no flame retardant is used, the used artificial lawn can be incinerated and landfilled in the same manner as before without concern about the generation of harmful gases such as halogens.

In addition, since the pile yarn does not contain a flame retardant, the mechanical strength, weather resistance and wear resistance of the pile yarn due to the use of the flame retardant are reduced, and the flame resistance is reduced due to the bleed out of the flame retardant. Does not occur.
Furthermore, since a flame retardant is not used, there is no deterioration in workability when forming pile yarns, the material cost can be suppressed, and the manufacturing cost of the artificial lawn as a whole can be reduced.
In addition, the cut processability can be improved by cutting the crimped pile yarn and the stray pile yarn with the dedicated knife so that the lengths of the crimped pile yarn and the stray pile yarn are substantially the same.
In addition, by containing a flame retardant in the pile yarn, more effective flame retardant performance can be obtained.

Sectional drawing which showed schematic shape of embodiment of the flame-retardant artificial lawn 1 Sectional drawing which showed schematic shape before and after crimping treatment after planting pile yarn Schematic of woven fabric

  FIG. 1 is a sectional view showing a schematic shape of an embodiment of a flame-retardant artificial lawn 1 of the present invention.

  Referring to FIG. 1, a flame-retardant artificial lawn 1 according to the present invention comprises a base fabric 4 made of a thermoplastic resin cloth and straight pile yarns 2 and crimped pile yarns 3 alternately at predetermined intervals in the lateral direction. The back-up resin layer 6 is formed by applying SBR or the like on the lower surface of the base fabric for preventing the straight pile yarn and the crimped pile yarn from coming off.

  FIG. 2A is a cross-sectional view showing a schematic shape in which a loop portion of a pile yarn is cut after the pile yarn is implanted.

  Referring to FIG. 2 (A), in the flame-retardant artificial lawn 1 of the present invention, a straight pile yarn 2 and a crimped pile yarn 3 have substantially the same length on a base fabric 4 made of a thermoplastic resin cloth. Then, they are alternately planted at predetermined intervals so as to form a row, and the loop portions are cut so that the lengths of the straight pile yarn 2 and the crimped pile yarn 3 are substantially the same.

  FIG. 2 (B) is a cross-sectional view showing a schematic shape in a state where the tension state of the crimped pile yarn 3 is relaxed and the height is lowered.

  Referring to FIG. 2 (B), after the straight pile yarn 2 and the crimped pile yarn 3 are cut so that the length is substantially the same, the crimped pile yarn is crimped.

  Returning to FIG. 1, a high-density layer 7 of pile yarn is formed in the lower portion of the flame-retardant artificial lawn 1, in which both pile yarns of the crimped pile yarn 3 and the straight pile yarn 2 are present. Further, a low density layer 8 of pile yarn in which only the straight pile yarn 2 exists is formed above the high density layer 7.

  FIG. 3 is a diagram showing an outline of weaving of the base fabric 4.

  With reference to FIG. 3, the base fabric 4 is formed by making the linear fabric linear bodies 5a and 5b obtained by uniaxially stretching a thermoplastic resin into a cloth shape.

  In the present invention, the cloth-like body is a generic term for a flexible sheet-like body formed by a striated body, and a woven fabric mainly composed of a striated body formed by uniaxially stretching a thermoplastic resin, Used as knitted fabric or cross-bonded fabric (soft).

  As the filaments 5a, 5b for the base fabric, they can be used as tapes, yarns, split yarns, monofilaments, long fibers, spun yarns, etc., and these filaments are twisted as necessary.

  As the thermoplastic resin constituting the base fabric 4, a resin having a large stretching effect, generally a crystalline resin is used, and olefins such as high density polyethylene, low density polyethylene, medium density polyethylene, polypropylene, and ethylene / propylene copolymer are used. Polymers, polyesters such as polyethylene terephthalate and polybutylene terephthalate, modified polyesters, nylon 6 and nylon 66 are used. Of these, olefin polymers such as polyethylene, linear low-density polyethylene, and polypropylene are desirable from the viewpoint of processability and economy.

  Various additives can be added to the thermoplastic resin constituting the base fabric filaments 5a and 5b 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 Type, organic metal salt type, ester type lubricants; organic pigments; inorganic pigments; inorganic fillers, organic fillers; metal ion type inorganic and organic antibacterial agents, and the like.

  These additives are blended in any step for producing the material composition of the base fabric 4 by appropriately combining them. 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 fineness of the filaments 5a and 5b for the base fabric can be arbitrarily determined according to the purpose, but is generally 10 to 10,000 dtex, preferably 50 to 5,000 dtex, and the yarn width is 0.3 to 200 mm. A range of 0.5 to 100 mm is preferable.

  The base fabric filaments 5a and 5b thus obtained are plain weave or are woven by a method such as twill weave, oblique weave, silk weave, double weave, imitation weave, etc. 4.

  The shape of the straight pile yarn 2 can be used as tape, yarn, split yarn, monofilament, multifilament, long fiber, spun yarn, etc., preferably flat yarn or split yarn obtained by splitting flat yarn is used.

  The fineness of the straight pile yarn 2 can be arbitrarily determined according to the purpose, but is generally 100 to 20,000 dtex, preferably 6,000 to 10,000 dtex, and the yarn width is 1 to 100 mm, preferably 5 to 5 mm. A range of 50 mm is suitable.

  The crimped pile yarn 3 may be a tape, yarn, split yarn, or monofilament, but is preferably an elliptical, hollow, continuous, irregular, or other cross-sectional monofilament.

  The crimped pile yarn 3 is crimped by heat treatment. Generally, crimping is performed in advance before planting. After planting, a difference in height appears between the straight pile yarn 2 and the crimped pile yarn 3.

  As a crimping method, a method known per se can be widely adopted. For example, a heat and heat fixing method in which a strong twist is wound around a bobbin, and this is heat-treated in an autoclave and then deflammed. By rotating the spindle with a spindle at the top and bottom, it is twisted in the opposite direction, and after the heat treatment, it is pulled out, the modified method in which the drawn wire is heat-set, and the hot cylinder is pushed in. For example, an indentation method of crimping can be employed.

  The fineness of the crimped pile yarn 3 can be arbitrarily determined according to the purpose. In general, the crimped pile yarn 3 in which a plurality of filaments are bundled is applied to the base fabric 4, preferably 10 to 10,000 dtex. Plant in the range of 50-5,000 dtex.

  The planting is performed by alternately arranging straight pile yarns 2 and crimped pile yarns 3 on a tufting machine.

The straight pile yarn 2 and the crimped pile yarn 3 are so-called cut piles obtained by planting in a loop shape continuously to the base fabric 4 and cutting the loop portion.
The straight pile yarn 2 and the crimped pile yarn 3 preferably have a pile length (a state in which the pile yarn is stretched) from the surface of the base fabric 4 to the pile tip of 15 to 30 mm.

  The backing material as a material for preventing the straight pile yarn and the crimped pile yarn from coming off may be SBR latex rubber, acrylic resin, or the like, and the resin layer 6 is formed using them.

  EXAMPLES Hereinafter, although an Example demonstrates this invention further more concretely, this invention is not limited by a following example.

  A straight pile yarn was obtained by splitting a uniaxially drawn polypropylene flat yarn having a fineness of 7000 dtex and a yarn width of 9.5 mm. Also, six monofilaments of nylon 6 having a flat cross section with a single yarn fineness of 500 dtex are aligned, twisted to facilitate planting, and a crimped pile yarn consisting of a monofilament aggregate with a fineness of 3,000 dtex It was. The planting interval (number of gauges) is 6.4 pieces / 吋 and the vertical planting interval (number of stitches) is 4.8 so that the straight pile yarns and crimped pile yarns are alternately arranged in the horizontal direction. This was planted with a book / 吋, and rubber latex was applied to the entire back surface. The straight pile yarn and the crimped pile yarn were cut so that the length from the base cloth surface to the tip was 20 mm in a state where the crimp was extended to make an artificial lawn of this example.

An artificial lawn was made in the same manner as in Example 1 except that the number of stitches in Example 1 was 5.0 / ５．０.

An artificial lawn was made in the same manner as in Example 1 except that the number of stitches in Example 1 was set to 5.2 / claw.

An artificial lawn was made in the same manner as in Example 1 except that the number of stitches in Example 1 was 5.8 stitches / knot.

Comparative Example 1

  A straight pile yarn was obtained by splitting a uniaxially drawn polypropylene flat yarn having a fineness of 7000 dtex and a yarn width of 9.5 mm. In addition, six nylon 6 monofilaments having a flat cross section with a single yarn fineness of 500 dtex were aligned and twisted to facilitate planting to obtain a crimped pile yarn composed of a monofilament aggregate with a fineness of 3,000 dtex. . The planting interval (number of gauges) is 6.4 pieces / 吋, and the vertical planting interval (number of stitches) is 4.5 so that the straight pile yarns and crimped pile yarns are alternately arranged in the horizontal direction. This was planted with a book / 吋, and rubber latex was applied to the entire back surface. The straight pile yarn and the crimped pile yarn were cut so that the length from the base cloth surface to the tip was 20 mm in a state where the crimp was extended to make an artificial lawn of this example.

Comparative Example 2

The artificial lawn was made in the same manner as in Comparative Example 1 except that the number of stitches in Comparative Example 1 was 6.0 / 吋.

Comparative Example 3

  A straight pile yarn was obtained by splitting a uniaxially drawn polypropylene flat yarn having a fineness of 7,000 dtex and a yarn width of 9.5 mm. The straight pile yarn was planted at a planting interval (number of gauges) of 3.2 / 吋 and a vertical planting interval (stitch number) of 5.8 / 吋, and rubber latex was applied to the entire back surface. The upper part was cut so that the length of the straight pile yarn was 20 mm, and the artificial lawn of the comparative example 3 was made.

Comparative Example 4

  An artificial lawn was made in the same manner as in Comparative Example 3 except that the number of stitches in Comparative Example 3 was 7.1 stitches / knot.

Comparative Example 5

  An artificial lawn was made in the same manner as in Comparative Example 3 except that the gauge number of Comparative Example 3 was 6.4 / 吋 and the number of stitches was 3.8 / 吋.

Comparative Example 6

  The artificial lawn was made in the same manner as in Comparative Example 5 except that the number of stitches in Comparative Example 5 was 4.2 / 吋.

Comparative Example 7

  The artificial lawn was made in the same manner as in Comparative Example 5 except that the number of stitches in Comparative Example 5 was 4.5 / 吋.

Comparative Example 8

The artificial lawn was made in the same manner as in Comparative Example 5 except that the number of stitches in Comparative Example 5 was 5.0 / 吋.

[Test 1: Flameproof test]
The flameproof test was done about Examples 1-4 and Test Examples 1-8.
(1) Test method It was performed based on the flameproof test method specified in JISL4405 8.6.
(2) Test results From the results in Table 1, Examples 1 to 4 satisfied the flameproof performance. From the results shown in Table 2, Comparative Examples 2, 7, and 8 also satisfied the flameproof performance. From this result, it was confirmed that flameproof performance was exhibited by planting pile yarns at high density.

[Test 2: Appearance]
An appearance evaluation test was performed on Examples 1 to 4 and Test Examples 1 to 8.
(1) Test method The appearance was evaluated by comparison with Comparative Example 3 which is a commercial product by visual observation.
(2) Test results Tables 1 and 2 show the test results. In all of Examples 1 to 4, the same appearance as that of Comparative Example 3 was obtained. On the other hand, in Comparative Examples 1, 2, 4, and 5, the same appearance as Comparative Example 3 was obtained, but in Comparative Examples 6 to 8, the artificial lawn surface at the tip of the pile yarn became flat, and the natural texture was lost. .

[Test 3: Boundability]
A bounce test was performed on Examples 1 to 4 and Test Examples 1 to 8.
(1) Test method The test was conducted based on the tennis ball repulsion test method established by the Japan Physical Education Facility Association.
(2) Test results Tables 1 and 2 show the test results. All of the examples and comparative examples were above the standard values determined by the Japan Physical Education Facility Association, and no significant difference was observed depending on the planting density.

[Test 4: slipperiness]
Examples 1 to 4 and Test Examples 1 to 8 were subjected to a slip test.
(1) Test method The slip property was tested by a test method established by the company.
(2) Test results Tables 1 and 2 show the test results. In any of the Examples and Comparative Examples, no significant difference was observed depending on the planting density.

[Test 5: Sandability]
The sandability test was conducted on Examples 1 to 4 and Test Examples 1 to 8.
(1) Test method The sand penetration property was tested by a test method determined by the company. Sand filling ability was evaluated with a sand filling amount of 25 kg / m ² .
(2) Test results Tables 1 and 2 show the test results. In the examples, there is no significant difference due to the planting density. In the comparative example, if the planting density was increased as in Test Example 6 and Test Example 7, the sandability was reduced.

[Comprehensive evaluation of the test]
Examples 1 to 4 satisfied other properties in addition to the flameproofness. On the other hand, none of the comparative examples satisfied all the performance.

1 Fire Retardant Artificial Law 2 Straight Pile Yarn 3 Crimped Pile Yarn 4 Base Cloth 5 Base Lines 6 Backup Resin Layer 7 Pile Yarn High Density Layer 8 Pile Yarn Low Density Layer

Claims (1)

An artificial lawn in which straight pile yarns and crimped pile yarns are substantially the same length on a base fabric made of a thermoplastic resin cloth, and are alternately planted in rows, the straight pile yarns in the upper part of the high-density layer and the dense layer of the pile yarns both straight pile yarns and said crimped pile yarn exists only exists possess a lower density layer,
Each of the straight pile yarn and the crimped pile yarn does not contain a flame retardant,
The straight pile yarn is a uniaxially drawn flat yarn or split yarn, and the crimped pile yarn is a multifilament or monofilament,
The fineness of the straight pile yarn is 6,000 to 10,000 dtex, and the fineness of the crimped pile yarn is 2,000 to 4,000 dtex,
The total number of the straight pile yarn and the crimped pile yarn is 4 to 6 / cm ^{2 on} the base fabric , and the total weight of the straight pile yarn and the crimped pile yarn is 1,000 to 1,400 g. A flame-retardant artificial lawn that has been planted to be / m ² .

Images