KR101977176B1 - Manufacturing method of artificial turf mat with pile yarn of triple structure - Google Patents

Abstract

The present invention relates to a manufacturing method for an artificial turf mat having a pile yarn with a triple structure, comprising: (a) a step of acquiring the pile yarn with the triple structure from a spinning machine; (b) a step of performing a turfting weaving of the pile yarn with the triple structure on a piece of foaming paper; and (c) a step of heating a rear surface of the piece of foaming paper by heat of thermosetting or a front surface back coating process. Accordingly, according to the present invention, the artificial turf mat with the triple structure comprises: a first pile in a straight shape; and a second pile and a third pile in a crimped shape. The crimped extent is different between the second pile and the third pile to vertically support the first pile. The present invention is able to improve a vertical strength, to enhance a repulsive power and a rolling of a ball, to develop a user′s athletic performance, and to prevent an injury.

Description

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an artificial turf mat having pile yarn,

The present invention relates to a method of manufacturing artificial turf mat having a triple structure pile yarn, and more particularly, to a method of manufacturing artificial turf mat by forming a triple structure by taking advantage of the characteristics of a three- To improve the repulsive force of the ball and the ball cloud, thereby improving the performance of the user and preventing injuries.

Recently, there are many cases where the playgrounds of schools or public facilities are constructed as grass fields or artificial grass fields. The natural grass field that is created for user's safety and landscaping effect is made by spraying grass seeds or planting grass.

In Korea, where the winter season is long, the efficiency of the playground falls sharply, including the case where the use time of the natural turf grass is only about 40 to 50 days a year, In addition, natural grass requires careful management such as watering cycle, loss of consciousness due to damage, and so on.

 Therefore, the construction area of the artificial turf field, which is highly utilized compared to the natural grass field, is rapidly expanding. Artificial turf mat for artificial turf construction is technically very important to improve pulling power of artificial hair and drainage of mat. In general, artificial turf mat is made by using filament yarn in bubble paper, and the bottom surface of filament with knotted filament yarn is completely coated with SBR latex, polyurethane (PU) and polyvinyl chloride (PE) To increase the pulling force.

The artificial turf mat manufactured by the above-described method has a mono structure or a double (mono + crimp) structure. When the artificial turf mat is put on a playground, the pile yarn lie in one direction or in various directions There is a problem that the straightness of the ball is lowered, the control is changed according to the direction in which the ball is rolled, the cushion feeling is poor, and the risk of ankle injury is lowered compared to the natural grass ball.

In order to solve the above-mentioned problems, the artificial turf mat is constituted by a first file in a straight shape and a second file and a third file in a crimped shape, respectively, so that the respective yarns play different roles. The first file is smoothly changed in four directions even after a small impact during exercise and is then restored to its original state, the second file is formed between the first files so that the first file is restored to its original state, And the first file and the second file are supported, and the shock absorbing and supporting part is performed. Thus, the above-mentioned problem is solved, and without the installation of sandpaper or filler We have developed a method of manufacturing artificial turf mats with triple structure pile yarns that can be used to construct a playground.

Korean Registered Patent No. 10-1906426 (October 10, 2018) Korean Utility Model Registration No. 20-0413557 (2006.04.07.)

In order to solve the above-mentioned problems, an object of the present invention is to provide a method for fabricating a yarn, comprising the steps of: (a) obtaining three types of filament yarns in a yarn feeder; (b) tufting the three types of filament yarns on a bubble paper; and And heating the back surface of the base paper with heat of fusion or front back coating process. The present invention also provides a method of manufacturing an artificial turf mat having a triple structure pile yarn.

Another object of the present invention is to obtain the three types of pile yarns in the (a) radiator by using different yarn materials having different melting points to obtain different pile yarns. The three kinds of pile yarns produced by the above-mentioned spinning machine are characterized by comprising a first file having no bending and a large warp, a second file having an intermediate degree of warping and finer than the first file, and a third file having a degree of bending And a method for manufacturing an artificial turf mat having a triple structure filament yarn.

A still further object of the present invention is to provide a filament yarn for use in the present invention, wherein the filament yarn is melted and spun by the filament yarn to produce a yarn. The yarn thus produced is cooled in a cooler and heated again to regulate the thickness of the yarn to produce a straight hair. The yarn is then fed into a constant space to apply hot air and apply air pressure to produce half yarns / And a method for manufacturing an artificial turf mat having a filament yarn of a structure.

 It is a further object of the present invention to provide a method of making a composite artificial turf mat, wherein the first file has a straight shape and is made the thickest and longest to be the highest in artificial turf mat to dominate the vertical strength, The third file is cut to the same length at the time of weaving, but the original restoration degree is larger than the first file and smaller than the third file to form a middle height in the artificial turf mat, and the third file has a degree of crimp And a pile yarn of a triple structure formed at the lowest height in artificial turf mat when the extreme force is removed after the weaving.

It is still another object of the present invention to provide a method for tufting and weaving three kinds of pile yarns on a bubble sheet, wherein the three types of pile yarns are made to be woven simultaneously, Which is formed by cutting a pile yarn of a triple structure into a same length.

It is a further object of the present invention to provide a method of manufacturing a synthetic grass mat according to the present invention, wherein the step (c) of heating the back surface of the base paper by heat of the heat fusion or the entire back coating process comprises: (EN) An artificial turf mat having a triple structure pile yarn configured to heat in a process of thermally fusing a knot or applying the entire surface of the base paper with SBR latex, polyurethane (PU), polyvinyl chloride (PE) And a method of manufacturing the same.

It is a further object of the present invention to provide a method and apparatus for forming a crimp in an intermediate length of a crimped filament, 3 file has a shortest and severe degree of crimp so that the first file is maintained in a vertical state.

In order to achieve the above object, the method for manufacturing artificial grass mat according to the present invention having a triple structure pile yarn comprises the steps of (a) obtaining three kinds of pile yarns from a radiator, (b) And (c) heating the backside of the bubble deflector with heat of a hot melt or front back coating process.

Another aspect of the method of manufacturing an artificial turf mat having a triple structure pile yarn according to the present invention is that the step (a) of obtaining the three types of pile yarns in the emitter includes the steps of: To obtain a filament yarn. The three kinds of pile yarns produced by the above-mentioned spinning machine are characterized by comprising a first file having no bending and a large warp, a second file having an intermediate degree of warping and finer than the first file, and a third file having a degree of bending .

Another feature of the method of manufacturing an artificial turf mat having a triple structure pile yarn according to the present invention is that the pile yarn used in the present invention dissolves and emits the raw material for each material in the radiator to produce yarn. The yarn thus produced is cooled in a cooler, heated again to regulate the thickness to produce a hair straightener, and then yarn twisted in a certain space is added to generate hot air and air pressure to produce semi-straight hair / curly hair.

 Another feature of the method of manufacturing an artificial turf mat having a triple structure pile yarn according to the present invention is that the first pile has a straight shape and is the thickest and longest longest to be formed in the artificial turf mat to dominate the vertical strength, The second file has a greater degree of bending than the first file but less than the third file and is cut to the same length at the time of weaving, but the degree of original reconstruction is larger than that of the first file and smaller than that of the third file, And the third file has a very high degree of crimp. When the external force is lost after the weaving, it is bent most and formed as the lowest height in the artificial turf mat.

Another aspect of the method of manufacturing an artificial turf mat having a triple structure pile yarn according to the present invention is that the step (b) of tufting and weaving the three kinds of pile yarns into the bubble paper comprises: And the tufted three-kind filament yarns are all cut to have the same length.

Another characteristic of the artificial turf mat producing method having a triple structure pile yarn according to the present invention is that the step (c) of heating the back surface of the prepreg with the heat of the thermal fusion welding or the front back coating process comprises: Heating is performed in a process of thermally fusing the knot on the bottom surface of the substrate using a heat fusion press as in the manufacturing method or entirely coating the bottom surface of the substrate with SBR latex, polyurethane (PU), polyvinyl chloride (PE) .

Another feature of the method for manufacturing artificial turf mat having a triple structure pile yarn according to the present invention is that, when heat is applied to the base fabric, the crimp expanded in the cutting process among the three types of pile yarn is restored to its original shape, The second file is configured to form a crimp with a medium length and the third file forms the shortest and severe crimp to maintain the first file in a vertical position.

As described above, according to the present invention, there is provided a method of manufacturing an artificial turf mat having a triple structure pile yarn, which comprises melting a raw material (bead) of a raw material in a radiator to produce a yarn by spinning, The yarn twisted in a certain space is added to the yarn, and hot air is applied and air pressure is applied to obtain three types of filament yarns. Therefore, it is possible to manufacture artificial grass mats having high density by manufacturing pile yarn having different characteristics, thereby providing a playground most similar to a natural grass field.

In addition, the artificial turf mat having a triple structure pile yarn manufactured according to the present invention is characterized in that three types of pile yarn are simultaneously woven on a base paper, and the pile yarn is cut to the same length, Or with a front coating. Therefore, as the crimped portions of the second and third files expanded in the cutting process are restored to their original positions, the filament yarn naturally forms a triple structure, thereby improving the vertical strength of the first filament.

In addition, when a filler is not installed on a conventional dual structure artificial turf mat, there is a case where the cushion feeling of the grass falls within a short period of time and the function is not performed. However, in the artificial turf The mat has a high density of pile yarn formed in three stages, so that the vertical strength of the pile yarn can be maintained without installing the filling material during the construction of the athletic field regardless of indoor or outdoor conditions.

1 is a step-by-step process diagram of a method for manufacturing an artificial turf mat having a pile yarn of a triple structure according to the present invention.
FIG. 2 is a view schematically showing a phenomenon in which a pile yarn is crimped in a weaving step and a heating step of an artificial turf mat manufactured according to the present invention.

While the invention is susceptible to various modifications and alternative forms, specific embodiments thereof are shown by way of example in the drawings and are herein described in detail.

It is to be understood, however, that the invention is not to be limited to the specific embodiments, but includes all modifications, equivalents, and alternatives falling within the spirit and scope of the invention.

The terms or words used in the present invention are used only to describe specific embodiments and are not intended to limit the present invention. It should be construed in the meaning and concept consistent with the technical idea of the present invention based on the principle that the concept of the term can be appropriately defined in order to explain the invention in the best way.

Conventional artificial grass mats have a mono structure or a double (mono + crimp) structure. When the artificial turf mat is put on a playground, the straightness of the ball is lowered due to the fact that the pile yarn lie in one direction or several directions, The control changes according to the direction of rolling the ball, and the cushion feeling is poor, which causes the drop in preference compared to the natural grass field.

The artificial turf mat 10 manufactured according to the manufacturing method of the present invention is a filament yarn 11 of a triple structure (first, second, and third files), which includes a first file 11.1 in a straight- The first file 11.1 is a portion in which the sneaker reaches the earliest portion. The first file 11.1 is normally in an upright state or in a small impact during exercise. The first file 11.1 is formed of a second and a third file 11.2, 11.3 in the form of a crimp, The second file 11.2 is formed between the first files 11.1 and serves as a support for restoring the first file 11.1 to its original state. In addition, the first file 11.1 changes in all directions while the second file 11.2 changes in all directions to absorb the impact when the impact is applied. When the impact is removed, It serves to recover the files. The third file 11.3 is formed between the first file 11.1 and the second file 11.2 and has a large amount of crimp to maximize the density of the lower layer of artificial turf and the first file 11.1 and the second file 11.2, It is a role to support. In addition, the third file 11.3 changes its shape vertically and downward like the second file 11.2 to serve as a shock absorbing and supporting member, thereby improving the repulsive force of the ball and the ball cloud by increasing the vertical strength, To provide an artificial turf mat manufacturing method for preventing injury.

Specific features and advantages of the present invention will become more apparent from the following description taken in conjunction with the accompanying drawings.

FIG. 1 is a process diagram showing the steps of a method for manufacturing an artificial turf mat having a triple structure filament yarn according to the present invention. FIG. 2 is a view showing a process of fabricating a synthetic turf mat according to the present invention. ) Is a schematic illustration of the phenomenon.

1, a method of manufacturing an artificial turf mat having a triple structure pile yarn 11 according to the present invention comprises the steps of: (a) obtaining three kinds of pile yarns 11 from a radiator (S100); (b) tufting and weaving the three kinds of pile yarns 11 on the base fabric (S200), and (c) heating the back surface of the base paper by heat of the heat fusion or front back coating process (S300) .

The step (S100) of obtaining the three kinds of pile yarns in the (a) emitter of the method for producing an artificial turf mat having the triple structure pile yarn according to the present invention may be performed by using different yarn materials having different melting points Of the file yarn. The three types of file yarns produced by the emitter (not shown) are a first file 11.1 of a bend-free, thick-wired model, a second file 11.1 of a bend- 11.2), and a third file (11.3) which is very severe in bending.

In general, artificial turf yarns use polyethylene (PE), polypropylene (PP) and nylon (PA) materials in synthetic fibers. Each of the materials has a melting point (heat resistance point), durability, friction strength, touch and cost, and is selectively used where appropriate. Polyethylene (PE) is smoother than other polyolefin or polyester synthetic resins, giving a feeling of natural grass, having excellent restoring force, and less frictional heat generation, thereby preventing injuries caused by heat of the user. Polypropylene (PP) is excellent in repulsive force, but there is a risk of laceration.

In the present invention, the first file 11.1 having the largest physical contact with the user uses polyethylene (PE) material having the least relative risk of letharge and excellent resilience, and the second file 11.2 has a high repulsive force Polypropylene (PP) was used for the third pile 11.3 and polyethylene (PE) was used for the third pile 11.3. The selection of the above-mentioned material files (first, second, and third files) can be made differently depending on the construction conditions and places.

In the manufacturing process of the pile yarn according to the present invention, the raw material (bead) for each material is melted and radiated in the radiator to produce yarn. The yarn thus produced is cooled in a cooler (not shown), heated again to adjust the thickness of the yarn (→ straightener production), put the yarn spun into a certain space again, apply hot air and apply air pressure Hair / turf production).

At this time, the shape of the yarn is determined by the degree of the air pressure when the yarn is radiated from the radiator, and the wave form (crimp) becomes worse as the air pressure is higher.

Table 1 shows the specifications of pile yarns applied to the artificial turf mat producing method having the triple structure pile yarn according to the present invention.

The pile yarn specimen applied to the present invention File yarn Material File length (mm) Yarn thickness (decitex) File Shape Remarks First file PE 35 to 60 8,000 ~ 15,000 Straight hair Second file PP 20 to 40 3,000 ~ 8,000 Crimp Third file PE 10-25 3,000 ~ 8,000 Crimp

 As shown in Table 1, the first file has a straight shape, and the thickest and longest longest weave is formed in the artificial turf mat to determine the vertical strength. The second file 11.2 is crimped but the degree of bending is larger than that of the first file 11.1 and less than that of the third file 11.3 and cut to the same length at the time of weaving, 1 < / RTI > file (11.1) and smaller than the third file (11.3) to form a moderate height in artificial turf mats. The third file (11.3) has a very high degree of crimp, and is most bent when the external force is lost after weaving to form the lowest height in artificial turf mat. The finished product made of the three kinds of yarns described above forms a synthetic grass mat 10 constituting a three-tiered pile yarn layer having a very high density. The cut length of such filament yarns (first, second and third files) is preferably 35 to 60 mm, and most preferably 35 to 45 mm.

Referring to FIG. 2, step (S200) of tufting and weaving the three kinds of pile yarns into the bubble of the (b) bubble of the method of producing an artificial turf mat having a triple structure pile yarn according to the present invention, The three kinds of pile yarns 11 are formed to be woven simultaneously, and the tilted three-pile yarns are all cut to have the same length.

At this time, the second file 11.2 and the third file 11.3 emitted from the radiator are cut in a crimped state.

1 and 2, in the method (c) of the method for producing artificial turf mat having the triple structure pile yarn according to the present invention, the back surface of the base paper 12 (S300) may be performed by thermally fusing a knot on the bottom surface of the base paper (a heat fusion method) by using a heat fusion press (not shown) as in the conventional artificial turf mat manufacturing method, (Front-back coating method) in which the entire surface is coated with latex, polyurethane (PU), polyvinyl chloride (PE) or the like.

When heat is applied to the bulge 12 as described above, the crimped portion expanded in the cutting process out of the three types of filament yarns is restored to its original shape, and the second file 11.2 is restored to a medium height (20 to 40 mm) And the third pile 11.3 forms a very severe crimp with the lowest height (10-25 mm) so that the first pile 11.1 remains vertical.

The method for manufacturing artificial turf mat having a triple structure pile yarn according to the present invention is manufactured in the following order.

end. Yarn acquisition

- Produce yarn for each material by putting raw material (bead) of PE and PP material into radiator.

- Cool the produced yarn in the cooler.

- Heat the yarn again to regulate the yarn (twist) to acquire the straight hair (first file).

- Put the twisted straight hair back into a certain space and apply hot air and air pressure to obtain a semi-facial hair (second file) and a loose (third file) thinner than the first file.

(At this time, the higher the air pressure, the more pile yarn is obtained.)

I. Weaving on bubble paper

- The obtained three kinds of file yarns (first, second and third files) are tufted and sewn on the paper 12 at the same time.

- Cutting the tufted woven three-pile yarn to the same length.

(At this time, the second file and the third file are cut in a crimped state.)

All. Heated bottom surface

- Heat the knot on the bottom of the paper.

- Alternatively, coat the bottom of the paper with SBR latex, polyurethane (PU) and polyvinyl chloride (PE).

(In this case, the step of forming the drain hole is further added to the entire surface coating method.)

- The heat causes the crimp expanded in the cutting process to return to its original shape.

The second file and the third file are formed with a high density, so that the first file maintains a vertical state.

The artificial turf mat having the triple structure pile yarn of the present invention manufactured according to the above-described method is applied in the following manner.

end. Preparation phase

  - Keep the floor condition to be leveled.

  - Check the fit of artificial turf installation by checking whether there is bending of foundation, a certain gradient and drainage force.

  - The sand / crushed stone is installed uniformly and flatly.

  - Prepare an artificial grass mat wrapped in a roll.

I. Artificial turf mat installation steps

  - Arrange the artificial turf mat roll at the placement position.

  - The start line to install the artificial turf mat is set in advance and installed with a constant force.

  - Fixing between artificial turf mat and mat is done and line marking is done.

All. Fill-in stage

  - Keep the flatness of the entire playground and the amount of filling material between the piles (3 kg or more per 1 m 2) constant, and finally the cotton is selected.

As described above, the filler may be applied to the field, but the artificial turf mat having the triple structure filament yarn of the present invention can be applied without silica sand or filler.

The method of manufacturing an artificial turf mat having a triple structure pile yarn according to the present invention has the following advantages.

First, in the method of manufacturing artificial turf mat having a triple structure pile yarn according to the present invention, raw materials (beads) of a material are melted and produced by spinning to produce yarn, and heat is again applied to adjust thickness A yarn twisted in a space is added to the yarn, and hot air is applied and air pressure is applied to obtain three kinds of filament yarns.

Therefore, it is possible to manufacture artificial grass mats having high density by manufacturing pile yarn having different characteristics, thereby providing a playground most similar to a natural grass field.

In addition, the artificial turf mat having a triple structure pile yarn manufactured according to the present invention is characterized in that three types of pile yarn are simultaneously woven on a base paper, and the pile yarn is cut to the same length, Or with a front coating.

Therefore, as the crimped portions of the second and third files expanded in the cutting process are restored to their original positions, the filament yarn naturally forms a triple structure, thereby improving the vertical strength of the first filament.

In addition, when a filler is not installed on a conventional dual structure artificial turf mat, there is a case where the cushion feeling of the grass falls within a short period of time and the function is not performed. However, in the artificial turf The mat has a high density of pile yarn formed in three stages, so that the vertical strength of the pile yarn can be maintained without installing the filling material during the construction of the athletic field regardless of indoor or outdoor conditions.

10: Artificial grass mats
11: File yarn
11.1: First file
11.2: Second file
11.3: Third file
12: Supporting paper
13: heat fusion / back coated side

Claims (5)

1. A method for producing an artificial turf mat having a triple structure pile yarn (11)
(a) obtaining three kinds of pile yarns 11 from a radiator (S100);
(b) tufting the three kinds of pile yarns 11 on the base paper 12 (S200);
(c) heating (S300) the backside of the bulge to heat of fusion bonding or front back coating,
The three kinds of file yarns 11 are configured to obtain the file yarns 11 having different thicknesses by using yarn materials having different melting points from each other, A second file 11.2 made of a semi-straight shape with a slight warping by applying hot air and pressure to the straightened hair, and a second file 11. And a third file 11.3 in which the bending is very severe,
In the step (b) (S200), the tufted three-pile yarn 11 is woven at the same time and cut to have the same length,
The step (c) S300 may be performed by thermally fusing the knot on the bottom surface of the base paper using a heat fusion press or by using a SBR latex, polyurethane (PU), polyvinyl chloride (PE) Applying and heating,
The second file 11.2 and the third file 11.3 of the three kinds of file yarns 11 in step (c) (S300) are arranged in the order of Crimp (Crimp) ) Shape to its original shape,
The first file, the second file, and the third file are cut to 35 to 45 mm, and the crimped stretched crimped in the cutting process is restored to the original shape after cutting, and the second file 11.2 is crimped to a height of 20 to 40 mm , And the third file (11.3) is configured to form a crimp at a height of 10 to 25 mm.















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