JPH08109610A - Artificial turf - Google Patents

Abstract

PURPOSE: To secure the elasticity while reducing the cost by a method wherein a base fabric is made up by overlaying an elastic sheet on the surface of a fiber base and by making the elastic sheet integral with the fiber base, and sod-like blades made of synthetic resin piled yarns formed in fluffiness are planted to the elastic sheet with backing applied. CONSTITUTION: Tubular films made, for instance, of polypropylene are cut into pieces after molding, and tape-like pieces made up therefrom are formed into flat yarns with drawing applied. Then, crimping is applied to split yarns obtained by splitting the flat yearns, and thereby synthetic resin piled yarns 2 are prepared. A nonwoven fabric made of polyester fibers is used as a fiber base 3, and an elastic sheet 4 made of polyethylene foam is overlaid on and joined to the fiber base 3 with urethane adhesives applied. The made-up material is used as a base fabric, and the piled yarns 2 are planted thereto so that sod- like blades project beyond the surface of the elastic sheet 4 with cutting applied to the yarns to form fluffiness. After acrylic backing agent is applied to the reverse side of the base fabric, a backing layer 5 is formed with hot-air drying applied, and thereby an artificial turf 1 is produced.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an artificial lawn used for athletics facilities, greening of parks and gardens, terraces and balconies of amusement parks and various buildings, and decorative purposes for exhibition.

[0002]

2. Description of the Related Art Artificial turf is manufactured by lining synthetic fiber pile yarn on a base cloth and lining it. As it is excellent in durability and beautiful, it can be replaced with natural turf or artificial turf. Since it is a lawn, it is used in a wide variety of applications, including those that can be used. When used in stadiums and parks, this artificial lawn is laid directly on a base such as flat soil, asphalt, concrete, etc. Lack,
In addition, the legs of athletes and pedestrians are likely to be overloaded.

Focusing on these problems, for example, a method for manufacturing an artificial turf which is integrated with a mat bottom by loading an artificial turf sheet in a foam molding die and filling the expanded particles with heat expansion molding. (Japanese Patent Publication No. 61-14932), rubber material, synthetic resin, inorganic filler, fibrous material kneaded into a bituminous material and molded into a backing material for artificial turf (Japanese Patent Publication No. 62-42947), elastic foamed plastic The artificial turf with an underpad provided in a substantially spherical distribution (JP-A-4-115003), 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 5-50541), an artificial turf gland in which an artificial turf mat is laid on a base layer made of soil cement mixed with elastic particles (JP-A-6-136717), and the like. 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]

In view of the above-mentioned problems, the present invention provides an artificial lawn which has an appropriate cushioning property and is composed of inexpensive members without requiring any special manufacturing equipment. It is what

[0005]

SUMMARY OF THE INVENTION According to the present invention, a pile of synthetic resin is formed on a base fabric in which an elastic sheet 4 is superposed on and bonded to an upper surface of a fiber substrate 3 so that turf leaves can be planted on the elastic sheet side. The artificial lawn is characterized by tufting the yarn 2 and applying a backing process.

As described above, the artificial lawn 1 of the present invention is composed of the fiber base material 3, the elastic sheet 4, the synthetic resin pile yarn 2, and the backing layer 5, as shown in FIG.

The fibrous base material 3 is generally used as a primary base cloth for tufted products, and is a synthetic resin stretched tape which has the advantage that it is easily torn in the length direction when the needle is inserted and is unlikely to break. Examples thereof include woven fabrics in which yarns are closely woven into warp and weft yarns, fibrous nonwoven fabrics with low needle penetration resistance, high strength, and no directionality.

The elastic sheet 4 is a relatively bulky sheet-like material having flexibility and cushioning property.
Synthetic resin foam such as polypropylene, polyethylene, ethylene-vinyl acetate copolymer, polystyrene, polyvinyl chloride, or various elastomers, and rubber or rubber foam such as natural rubber, styrene-butadiene rubber, urethane rubber or chloroprene rubber. Examples include bulky non-woven fabric to which a body and a web made of low-fineness filament are bonded.

The elastic sheet 4 also needs to be a porous sheet-like material having a relatively low density because it acts as a cushioning material having a compression recovery property.
It is desirable that the thickness is 200 kg / m ³ and the thickness is 5 to 20 mm. This is not suitable because it has a low density and has a low impact absorption capacity, and it does not achieve the intended purpose as a cushioning material and is inferior in wear resistance.When it is a high density, it is not suitable for tufting pile yarn. This is unsuitable because the needle has a large penetration resistance and is apt to be damaged, resulting in poor efficiency. Also, thickness 5
If the thickness is smaller than 20 mm, the elasticity is inferior, and if the thickness exceeds 20 mm, the feeling of treading is heterogeneous, and it is assumed that the cut length of the pile yarn is longer than necessary, which causes a problem.

The above-mentioned elastic sheet 4 is laid on the upper surface of the above-mentioned fiber base material 3 and bonded and integrated, and is used as a tufted base cloth for planting the pile of the artificial grass 1 of the present invention. As a method for laminating and adhering the fiber base material 3 and the elastic sheet 4 to each other, a known adhesive such as urethane-based, vinyl-based, acid-based or epoxy-based adhesive, heat seal, hot melt web or powder fusion is used. Joined by means. Further, a liquid or paste unfoamed resin composition to which a foaming agent is added or unvulcanized latex rubber material is directly coated on the fiber base material 3 and, after a tufting step described later, is heated and foamed. Alternatively, the elastic sheet 4 may be vulcanized.

The pile yarn made of synthetic resin is used for the laminated base cloth.
The artificial lawn pile yarn is added to the synthetic synthetic resin such as polyvinylidene chloride, nylon 6, polyester, polypropylene, and high density polyethylene with ultraviolet absorbers, antistatic agents, colorants, etc. if necessary. A uniaxially stretched tape yarn or filament obtained from a resin composition in which an agent is appropriately blended, and if necessary, split yarn, twisting, crimping, and other raw yarns having a total fineness of 1,000 to 10,000 dr are used. .

The pile thread 2 made of synthetic resin is planted as a cut pile with 4 to 8 stitches on the above-mentioned base cloth by a tufted machine of 1/10 to 3/8 gauge. Here, the pile length is set so as to exist on the elastic sheet surface for a length of 5 to 20 mm. If the leaf length is shorter than 5 mm, the appearance of the artificial lawn is not good, and if the leaf length is longer than 20 mm, the leaf tends to fall over and the lawn leaf is inferior in compression recovery, which is not preferable.

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

[0014]

The artificial lawn of the present invention can be provided with appropriate cushioning property due to the presence of the elastic sheet attached to the fiber base material. Further, by printing or painting the elastic sheet with a color or a design, it is possible to confirm on the surface of the artificial lawn through the grass so that the display function can be easily provided. Furthermore, when a granular material such as sand is sprayed as a filler 6 into the grass of the artificial lawn to form a sand-containing artificial lawn, the filler 6 near the bottom due to the compression recovery of the elastic sheet 4 at the time of use. It is possible to suppress uneven distribution and curing so that the buffering property and the lubricity are less likely to change with time.

[0015]

【Example】

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.
After extruding in an amorphous state with a cold, to form a tubular film by cooling, it is chopped into a tape shape, which is drawn by a hot plate contact drawing method at a drawing temperature of 140 ° C, an annealing temperature of 145 ° C, and a draw ratio of 5.2 times. The flat yarn was uniaxially stretched.
Split this flat yarn with a high-speed rotary blade to obtain a fineness of 3,80
I got 0dr split yarn. This split yarn is twisted twice / inch and then crimped at 10 threads / inch by a compression shaping crimper to produce a synthetic resin pile yarn 2 shown in FIG.
And

Polyester fiber non-woven fabric having a basis weight of 120 g / m ² is used as a fiber base material 3, urethane adhesive is applied to the surface of the fiber base material at 35 g / m ² , and polyethylene having a density of 30 kg / m ³ and a thickness of 15 mm is used. A 5 / 32-gauge tufting machine is used to make a 5 / 32-gauge tufting machine that uses the foamed elastic sheet 4 that is overlaid and joined.
By stitching, tufting was performed as a cut pile with a pile length of 27 mm so that approximately 12 mm of turf was projected on the surface of the elastic sheet that constitutes the base fabric.

Next, the backing layer 5 was formed by applying an acrylic backing agent on the back surface of the base cloth at 580 g / m ² and then drying with hot air to obtain an artificial lawn 1 as Example 1.

Example 2 As the elastic sheet 4, a nonwoven fabric having a density of 65 kg / m ³ and a thickness of 10 mm formed by impregnating a polyamide fiber web into a phenol resin was used. It was formed as Example 2. The artificial grass thus obtained had grass leaves protruding by about 10 mm from the surface of the elastic sheet.

Example 3 As the elastic sheet 4, a urethane rubber sheet having a density of 80 kg / m ³ and a thickness of 7.2 mm was used. The artificial grass thus obtained had grass leaves protruding about 8 mm from the surface of the elastic sheet.

Example 4 p- was used as a foaming agent in styrene-butadiene rubber latex.
A state in which toluenesulfonyl hydrazide is added, the surface of the fiber base material 3 is coated with a roll coater, and then dried with warm air at 65 ° C. to form a base cloth, and pile threads are planted on the latex-coated surface of the base cloth. Tufting and 500g / m styrene-butadiene backing agent on the back
² Application and drying with hot air at 135 ° C to fix pile yarns to the base fabric and foam styrene butadiene rubber latex to give an elastic sheet with a density of 100kg / m ³ and a thickness of 5.2mm 4
An artificial lawn that forms the Here, the same fiber base material and pile yarn made of synthetic resin as those used in Example 1 were used, and in the obtained artificial lawn, the turf leaf was projected on the elastic sheet surface by about 5 mm.

COMPARATIVE EXAMPLE An artificial lawn having no elastic sheet in the constitution of the artificial lawn of each of the examples and obtained in the same manner as in the other examples was used as a comparative example.

Evaluation When the artificial lawns of Examples and Comparative Examples were laid on a concrete base and used as a walking path, natural silica sand was sprayed as a filler 6 in the grass lawn, smoothed by brushing, and piled on the surface layer. The thread can be confirmed by about 2 to 3 mm.

In this way, when the state of the artificial lawn 1 after 8 months of laying was confirmed, in the example, the appearance was almost free of uneven distribution and outflow of natural silica sand, the cushioning property was maintained, and the tread feeling was also the same. In the comparative example, it was confirmed that the natural silica sand sank near the bottom and was concentrated, and there were many places where the turf leaves fell on the surface, and both the external appearance and the cushioning property were inferior to those of the example.

[0024]

As described above, the artificial lawn of the present invention has an appropriate cushioning property, so that a comfortable walking feeling and a load on the legs of a competitor or a pedestrian can be obtained. ing. In addition, it can be made with inexpensive members without requiring special manufacturing equipment.

[Brief description of drawings]

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

[Explanation of symbols]

 1 Artificial grass 2 Synthetic resin pile yarn 3 Fiber base material 4 Elastic sheet 5 Backing layer 6 Filler

Claims (1)

[Claims] 1. A backing made by tufting synthetic resin pile yarns 2 so that turf is planted on the elastic sheet side on a base fabric in which an elastic sheet 4 is superposed and joined integrally on the upper surface of a fiber base material 3. An artificial lawn characterized by being processed.