KR102382126B1 - An artificial turf and its manufacturing method - Google Patents

Abstract

The present invention relates to an artificial turf structure, and in the artificial turf structure including a foam layer, a base layer, a pile part and a backing layer, includes a foam disposed between the foam layer and the base layer, wherein the foam can absorb the impact while supporting a portion of the pile part located between the foam layer and the base layer. According to the present invention, by forming the foam inside the artificial turf structure, the use of a filler material can be minimized.

Description

Artificial turf structure and its manufacturing method {An artificial turf and its manufacturing method}

The present invention relates to an artificial turf structure and a method for manufacturing the same.

Since artificial turf is cheaper to construct than natural turf, it is used in soccer fields, playgrounds, golf driving ranges, and baseball fields where sports events are held.

Artificial turf is manufactured by fixing a plurality of pile yarns serving as grass leaves to a base material. The manufactured artificial turf is installed on the ground to be constructed, and then a filler is installed for uprightness and shock absorption of the pile yarn. The filler is a material that fills between the plurality of pile yarns, and silica sand and rubber chips are generally used.

However, the filler material was lost due to rain, wind and player activity. As a result, the manager had to constantly replenish the filler material.

Republic of Korea Patent Publication No. 10-1254384

The problem to be solved by the present invention is to provide an artificial turf structure that minimizes the use of a filler by forming a foam capable of absorbing shock inside the artificial turf structure.

The artificial turf structure according to an embodiment of the present invention includes a foam disposed between the cell layer and the base layer in the artificial turf structure comprising a cell layer, a base layer, a pile part and a backing layer, wherein the foam includes It is possible to support a portion of the pile portion located between the foam layer and the base layer and absorb the impact.

The foam is any one selected from the group consisting of polyurethane, water-based flexible foam, flexible polyurethane, semi-rigid polyurethane, rigid polyurethane, and combinations thereof.

An artificial turf structure according to another embodiment of the present invention includes a bubble layer, a plurality of pile parts coupled to the bubble layer at a distance, a backing layer for preventing separation of the plurality of pile parts, and between the bubble layer and the backing layer Including a foam positioned between adjacent pile parts in each, the foam layer and the backing layer are combined with the foam, the foam is each formed with pores, the bubbles between the adjacent pile parts by the foam The layer portion (A) protrudes relative to the cell layer portion (B) to which the pile portion is coupled.

The artificial turf structure further includes a base layer disposed between the foam layer and the backing layer.

The method for manufacturing an artificial turf structure according to an embodiment of the present invention includes the steps of laminating a foam layer and a base layer, forming a mat by tufting a pile part on the foam layer, bonding a backing layer to the mat, and the mat Including the step of forming a foam by spraying the foam, the foam is introduced between the foam layer and the base layer and comes into contact with the foam layer while foaming.

In the step of forming the foam, a hole is formed around the pile part by the pile part, and the foam supports the pile part.

In the step of forming the foam, the mat sprayed with the foam is heated at 40 to 80° C. for 3 minutes to 10 minutes.

1 is a cross-sectional view showing an artificial turf structure according to an embodiment of the present invention.
Figure 2 is an enlarged view of Figure 1
Figure 3 is a perspective view showing the foam of Figure 1;
4 is a cross-sectional view showing an artificial turf structure according to another embodiment of the present invention.
Fig. 5 is an enlarged view of Fig. 4;
6 is a perspective view showing an artificial turf structure according to another embodiment of the present invention.
7 is a block diagram illustrating a method for manufacturing an artificial turf structure according to an embodiment of the present invention.

Hereinafter, embodiments of the present invention will be described in detail with reference to the accompanying drawings so that those of ordinary skill in the art can easily carry out the present invention. However, the present invention may be embodied in several different forms and is not limited to the embodiments described herein. Throughout the specification, like reference numerals are assigned to similar parts.

Then, an artificial turf structure according to an embodiment of the present invention will be described with reference to FIGS. 1 and 2 .

1 is a cross-sectional view showing an artificial turf structure according to an embodiment of the present invention, FIG. 2 is an enlarged view of FIG. 1, and FIG. 3 is a perspective view showing the foam of FIG.

1 and 2 , the artificial turf structure 100 according to this embodiment includes a bubble layer 110 , a pile part 130 , a base layer 150 , a backing layer 120 , and a foam 140 . do.

The bubble layer 110 is made of any one selected from the group consisting of polyethylene (PE), polyolefin (PO), polyester (PS), cellulose (Cellulose; CL), nylon (Nylon), and combinations thereof. can be made The bubble layer 110 is formed in a net structure. However, the structure of the bubble layer 110 is not limited to a net.

The base layer 150 is laminated with the bubble layer 110 and the pile unit 130 is coupled thereto. The base layer 150 may be made of polyolefin (PO), polyester (PS), polyamide (PA), or the like. The artificial turf structure 100 exhibits dimensional stability by the base layer 150 . Accordingly, the artificial turf structure 100 does not contract or expand according to the temperature of the season. The base layer 150 is formed in the same net structure as the bubble layer 110 . However, the structure of the base layer 150 is not limited to a net.

The pile unit 130 is made of a plurality of pile yarns 131 and is disposed at intervals in one direction from the bubble layer 110 and the base layer 150 . The pile yarn 131 may be made of nylon (NYLON), polyethylene (PE), polypropylene (PP), polyethylene phthalate (PET), or the like.

The backing layer 120 is coupled to the pile unit 130 and may be made of a nonwoven fabric having a density of 5 to 40 g/m ³ . When the density is less than 5 g/m ³ , the pile unit 130 is not strongly fixed, and thus the uprightness may be deteriorated. The backing layer 120 is connected to a portion of the pile part 130 to fix the pile part 130 not to be separated from the bubble layer 110 .

Such a bubble layer 110, pile part 130, backing layer 120, and base layer 150 have the same configuration and effect as the bubble layer, pile part, and backing layer of known artificial turf structures, so they overlap. A description is omitted.

The foam 140 is positioned between the bubble layer 110 and the base layer 150 and is disposed between the adjacent pile units 130 . An upper portion of the foam 140 is coupled to the foam layer 110 , and a lower portion is coupled to the base layer 150 . Accordingly, the movement of the foam 140 does not occur between the adjacent pile units 130, so the shape stability is improved. However, the foam 140 may maintain a contact state without being combined with the bubble layer 110 and the base layer 150 .

On the other hand, the foam 140 is formed with a hole 160 in which the pile part 130 is located. Rainwater may be drained to the ground through the hole 160 . Accordingly, the artificial turf structure 100 has excellent drainage efficiency of rainwater while absorbing the impact by the foam 140 .

In addition, a separate drain hole forming process is performed in the artificial turf structure 100 by the net structure of the foam layer 110 and the base layer 150, the backing layer 120 of the nonwoven fabric, and the hole 160 formed in the foam 140. Since it does not occur, the manufacturing efficiency of the artificial turf structure 100 is improved. In addition, the foam 140 of the portion where the pile part 130 is not located is connected to each other.

The foam 140 protrudes to a thickness of 10-20 mm in the direction of the foam layer 110 with respect to the base layer 150 . Accordingly, the bubble layer 110 is spaced apart in a direction away from the base layer 150 .

Referring to FIG. 3 , the thickness (D) of the foam 140 is 20 to 40% of the height (E) of the pile part 130 . When the thickness (D) exceeds 40% of the height of the pile part 130, the height (E) of the pile part 130 is shortened and cannot function properly, and the thickness (D) is the pile part 130 height ( If it is less than 20% of E), the shock absorption function and the erection performance of the pile part 130 cannot be exhibited (see FIG. 2).

Such a foam 140 may be made of water-based flexible foam or polyurethane (Polyurethane; PU), and may have a hardness of Shore A 20 to 70. In the present invention, the water-based flexible foam is a type of polyurethane and has an open cell structure, and the density is 6 to 8 kg/m ³ . Because water-based flexible foam uses water as a foaming agent, it does not generate toxic gases such as chlorofluorocarbons (CFC) or pentane (C ₅ H ₁₂ ), unlike general polyurethane foams. Because of the low toxicity, the operator can safely manufacture the water-based flexible foam foam.

In the present specification, the foam having a density exceeding 1,000 kg/m 3 may be hard, 150 to 1,000 kg/m 3 may be semi-rigid, and less than 150 kg/m 3 may be soft. The foam 140 according to the present embodiment may be made of semi-rigid polyurethane. The strength of the foam is not limited to rigid, semi-rigid and flexible. The strength of the foam may vary depending on the design of the artificial turf structure.

And a plurality of pores 141 are formed in the foam 140 . The pores 141 of the foam 140 can absorb the user's impact by allowing the foam 140 to be variable.

Such a foam 140 may exhibit a shock absorbing function due to the existence of the aforementioned material and pores, and the foam 140 is not lost unlike the filler in the artificial turf structure 100 inside.

On the other hand, although the bubble layer 110 is shown in a flat form in FIG. 1 , depending on the degree of foaming of the foam 140 , the upper portion of the foam layer 110 and the foam layer 110 in contact with the foam body 140 is wavy. may be formed. In this case, the upper surface of the foam 140 has a plurality of waveforms having different heights with respect to the base layer 150 .

And in the above description and drawings, it is assumed that the base layer 150 is formed between the foam 140 and the backing layer 120 , but the base layer 150 may be omitted. In this case, the foam 140 may be positioned between the foam layer 110 and the backing layer 120 .

Next, another embodiment of the present invention will be described with reference to FIGS. 4 to 5 .

4 is a cross-sectional view showing an artificial turf structure according to another embodiment of the present invention, and FIG. 5 is an enlarged view of FIG.

Referring to FIG. 4 , the artificial turf structure 100a according to the present embodiment includes a bubble layer 110 , a pile part 130 , a backing layer 120 , and a foam 140 .

The bubble layer 110 may be formed in a net structure. In addition, the elongation of the bubble layer 110 may be 100% or more. Accordingly, the bubble layer 110 may be stretched by an external force. According to this embodiment, the foam layer portion B to which the pile portion is coupled is coupled to the backing layer (see FIG. 4 ).

The pile unit 130 is made of a plurality of pile yarns 131 and is arranged in a plurality of spaced apart from each other in the bubble layer 110 in one direction.

The backing layer 120 is connected to a portion of the pile part 130 to fix the pile part 130 not to be separated from the bubble layer 110 .

The bubble layer 110 , the pile unit 130 , and the backing layer 120 have the same configuration and effects as the bubble layer, pile unit and backing layer of a known artificial turf structure, so a duplicate description will be omitted.

The foam 140 is positioned between the foam layer 110 and the backing layer 120 and is disposed between the adjacent pile units 130 . An upper portion of the foam 140 is coupled to the foam layer 110 , and a lower portion is coupled to the backing layer 120 . Accordingly, the movement of the foam 140 does not occur between the adjacent pile units 130, so the shape stability is improved. However, the foam 140 may maintain a contact state without being combined with the foam layer 110 and the backing layer 120 .

Due to the foam 140 , the foam layer 110 may protrude in a direction away from the backing layer 120 , and the backing layer 120 may protrude in a direction away from the foam layer 110 . Accordingly, the interval between the adjacent pile units 130 may be narrowed. The length value of the portion (A) of the bubble layer 110 positioned between the adjacent pile units 130 may be greater than the value of the interval (C) between adjacent pile units facing each other. The interval (C) of the portion where the adjacent pile units 130 face each other may be 1 to 25 mm, and the length value of the portion (A) of the bubble layer 110 located between the neighboring pile units 130 is It can be 2-30mm.

Many of the features discussed in the embodiment shown in Figs. 1 to 3 can be applied to this embodiment.

Next, another embodiment of the present invention will be described with reference to FIG. 6 .

6 is a cross-sectional view showing an artificial turf structure according to another embodiment of the present invention.

Referring to FIG. 6 , the artificial turf structure 100b according to the present embodiment further includes a base layer 150 while retaining the features according to the embodiment of FIG. 4 . At this time, the pile part 130 penetrates through the bubble layer 110 and the base layer 150 and is coupled to the base layer 150 and the base layer 110 .

The base layer 150 is laminated with the bubble layer 110 and the pile unit 130 is coupled thereto. The base layer 150 is positioned between the bubble layer 110 and the backing layer 120 . The base layer 150 may be deformed into an irregular wavy shape as the foam 140 is formed.

And the foam 140 is positioned between the foam layer 110 and the base layer 150 , and between the base layer 150 and the backing layer 120 . However, the foam 140 may be positioned only between the bubble layer 110 and the base layer 150 . In addition, the foam 140 may be positioned only between the base layer 150 and the backing layer 120 .

Many of the features discussed in the embodiment shown in Figs. 1 to 5 can be applied to this embodiment.

Next, a method of manufacturing the artificial turf structure 100 according to an embodiment of the present invention will be described with reference to FIG. 7 .

7 is a block diagram illustrating a method for manufacturing an artificial turf structure according to an embodiment of the present invention.

Referring to FIG. 7 , the method for manufacturing an artificial turf structure according to an embodiment of the present invention includes the steps of laminating a base layer (S10), forming a mat (S20), and bonding a backing layer to the mat (S30). ) and forming a foam (S40).

The operator laminates the bubble layer 110 on the base layer 150 (S10).

One pile yarn is connected to a tufting mechanism such as a needle, and the needle is penetrated in one direction and the opposite direction several times to form a pile yarn 131 having a continuous shape in the bubble layer 110 and the base layer 150 . combine Thereafter, the pile yarns 131 of the continuous shape are cut and the plurality of pile parts 130 are fixed to the bubble layer 110 and the base material layer 150 (S20).

A backing layer 120 made of a nonwoven fabric having a density of 5 to 40 g/m ³ is bonded to the pile unit 130 bonded to the bubble layer 110 and the base layer 150 . The backing layer 120 is coupled to the pile unit 130 in a heat-sealing manner. At this time, the backing layer 120 may be combined with a portion of the base layer 150 (S30).

The operator sprays the liquid foam on the backing layer 120 . At this time, when the density of the backing layer 120 is less than 5 g/m ³ , the pile unit 130 is not strongly fixed and the uprightness may be reduced, and when it exceeds 40 g/m ³ , the foam passes through the backing layer 120 . If not, the foam may not flow between the base layer 150 and the bubble layer 110 .

And in the state in which the foam is sprayed, it is heated at 40 to 80° C. for 3 to 10 minutes. By heating the foam, the formation of the foam 140 is accelerated, thereby improving the foaming efficiency. If the temperature is less than 40 ℃, the foam 140 may not be formed uniformly and the foam may not be cured. When the mat is heated at a temperature exceeding 80° C., the shape of the artificial turf structure 100 may be deformed and damaged. When the mat is heated for less than 3 minutes, the foam 140 is not easily formed, and when the mat is heated for more than 10 minutes, the artificial turf structure 100 may be deformed and damaged.

The foam is formed into the foam 140 while foaming between the base layer 150 and the bubble layer 110 (S40).

The step of laminating the bubble layer 110 on the base layer 150 may be omitted while including the embodiment of FIG. 7 according to another embodiment of the present invention. In this case, the pile part 130 is combined with the base layer 150 and the foam 140 is positioned between the base layer 150 and the backing layer 120 to support the pile part 130 and the impact applied from the outside. can absorb.

For other configurations, the configuration of the embodiment of FIG. 7 may be applied as it is.

Hereinafter, the shock absorbing effect of the present invention will be described in more detail through examples and experimental examples of the present invention.

Example 1

A pile of 55 mm in height made of polyethylene was tufted to the base layer and the base layer.

After heat-sealing a backing layer composed of a nonwoven fabric having a density of 25 g/mm ³ on one side of the base layer, the foam was sprayed.

Next, by heating the intermediate body of the artificial turf structure at 60° C. for 5 minutes to foam the foam composed of water-based flexible foam, the artificial turf structure in which the foam is formed with a hardness of Shore A 50 and a thickness of 16 mm (29% of the pile height) prepared.

Example 2

An artificial turf structure having a foam hardness of Shore A 20 was prepared in the same manner as in Example 1.

Example 3

An artificial turf structure in which a foam having a hardness of Shore A 70 was formed was prepared in the same manner as in Example 1.

Example 4

It was prepared in the same manner as in Example 1, but an artificial turf structure in which a foam having a thickness of 11 mm (20% of the pile height) was formed.

Example 5

An artificial turf structure was prepared in the same manner as in Example 1, but in which a foam having a thickness of 22 mm (40% of the height of the pile part) was formed.

Comparative Example 1

An artificial turf structure having a foam hardness of Shore A 0 was prepared in the same manner as in Example 1.

Comparative Example 2

An artificial turf structure having a foam hardness of Shore A 100 was prepared in the same manner as in Example 1.

Comparative Example 3

An artificial turf structure in which a foam having a thickness of 5 mm (9.1% of the height of the pile part) was formed was prepared in the same manner as in Example 1.

Comparative Example 4

An artificial turf structure in which a foam having a thickness of 30 mm (55% of the height of the pile part) was formed was prepared in the same manner as in Example 1.

Comparative Example 5

An artificial turf structure without foam was prepared in the same manner as in Example 1.

Experimental Example 1

The shock absorption rates of the artificial turf structures of Examples 1 to 5 and Comparative Examples 1 to 5 were measured, and the results are shown in Table 1 below.

measurement method

The shock absorption of the artificial turf structure was measured in accordance with KS F 3888-1.

Shock absorption (%) Example 1 33 Example 2 27 Example 3 29 Example 4 29 Example 5 36 Comparative Example 1 11 Comparative Example 2 15 Comparative Example 3 17 Comparative Example 4 36 Comparative Example 5 5

As for the shock absorption rate, the higher the value, the better the shock absorption rate, 50 or more corresponds to A-1 or A-2, 20 or more and less than 50 corresponds to B-1 or B-2, 10 or more and less than 20 It corresponds to B-3. As can be seen in Table 1, the shock absorbency of Comparative Examples 1 to 3 and 5 corresponded to the B-3 grade, but it can be confirmed that the shock absorbency of Examples 1 to 5 is the quality corresponding to B-1. In the case of Comparative Example 4, the shock absorbency was 36%, but the height of the pile part protruding to the outside of the artificial turf structure was low, so that it could not perform the role of the artificial turf. The artificial turf structures of Examples 1 to 5 may further include a filler to improve the shock absorption function, and thus may exhibit A-1 grade performance.

Therefore, the artificial turf structure according to the embodiment of the present invention exhibits superior shock absorption performance compared to the artificial turf structure not including the foam and the artificial turf structure including the foam outside the limited range.

Although preferred embodiments of the present invention have been described in detail above, the scope of the present invention is not limited thereto, and various modifications and improvements by those skilled in the art using the basic concept of the present invention as defined in the following claims are also provided. is within the scope of the

100: artificial turf structure 100a: artificial turf structure
100b: artificial turf structure 110: bubble layer
120: backing layer 130: pile portion
131: pile yarn 140: foam
141: pores 150: base layer
160: Hall
A: Part of the bubble layer between adjacent pile parts
B: the part of the bubble layer to which the pile part is combined
C: Interval between adjacent pile parts facing each other
D: top and bottom thickness of foam E: height of pile part

Claims (7)

In the artificial turf structure consisting of a bubble layer, a base layer, a pile part and a backing layer,
It is arranged between the bubble layer and the base layer and is coupled to the bubble layer and the base layer and includes a plurality of foams capable of absorbing an impact,
The bubble layer and the base layer are laminated, and the pile part is coupled to the base layer and penetrates the bubble layer, and the pile part is positioned between the plurality of foams and supported by the plurality of foams, and the plurality of Each of the foams is any one selected from the group consisting of polyurethane, water-based flexible foam, flexible polyurethane, semi-rigid polyurethane, rigid polyurethane, and combinations thereof, and
artificial turf structure. delete delete delete Laminating a bubble layer and a base layer,
Forming a mat by tufting the pile portion on the base layer;
bonding a backing layer to the mat; and
Forming a foam by spraying the foam on the mat
includes,
The foam is introduced between the foam layer and the base layer and is expanded between the foam layer and the base layer while foaming, and is arranged in combination with the foam layer and the base layer, and the file part is arranged in the foam. The foams supported and arranged by each are made of any one selected from the group consisting of polyurethane, water-based flexible foam, flexible polyurethane, semi-rigid polyurethane, rigid polyurethane, and combinations thereof, and pores are formed therein.
A method for manufacturing an artificial turf structure. delete 6. The method of claim 5,
An artificial turf structure manufacturing method of heating the mat sprayed with the foam at 40 to 80° C. for 3 to 10 minutes in the step of forming the foam.

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