KR102580785B1 - Method for manufacturing an artificial turf mat having a self-impact absorbing function with a shock-absorbing pad layer integrally formed and the artificial turf mat - Google Patents

Abstract

The present invention relates to a method of manufacturing an artificial turf mat having a self-shock absorbing function by integrally forming a shock absorbing pad layer, and to an artificial turf mat thereof. In the present invention, a pile is provided on the foam paper to have a high weaving density per unit area of the foam paper. A first weaving step (S100) of forming a shock-absorbing pad layer using yarn; and a non-woven fabric attached to the top of the shock-absorbing pad layer formed in the first weaving step (S100) and fixed by heat fusion. Heat fusion step (S200); And, a second weaving step (S300) of forming an artificial turf layer using pile yarn on the nonwoven fabric of the nonwoven fabric heat fusion step (S200); And, The second weaving step (S300) ) Then, a heat-sealing or back-coating step (S400) of manufacturing an artificial turf mat by fusing the bottom surface of the foam paper by applying heat alone, attaching a non-woven fabric and heat-sealing it, or back-coating it; and a step of rolling and packaging the artificial turf mat (S500). A method of manufacturing an artificial turf mat having a magnetic shock absorption function by integrally forming a shock-absorbing pad layer, and the artificial turf manufactured thereby. The mat starts.

Description

Method for manufacturing an artificial turf mat having a self-impact absorbing function with a shock-absorbing pad layer integrally formed and the artificial turf mat}

The present invention relates to a method of manufacturing an artificial turf mat having a magnetic shock absorption function by integrally forming a shock absorbing pad layer, and to the artificial turf mat. More specifically, the present invention relates to a pile to have a high weaving density per unit area on the top of the foam paper. By weaving yarn to form a shock-absorbing layer on the lower layer of the artificial turf mat, it has a self-shock-absorbing function. At the same time, the formation of the shock-absorbing layer reduces the amount of silica sand and filler used and prevents the loss of silica sand and filler. The present invention relates to a method of manufacturing an artificial turf mat having a self-shock absorbing function and an artificial turf mat composed of a shock-absorbing pad layer with excellent water drainage while reducing weight.

Recently, as the number of cases of constructing school or public facility playgrounds as grass fields or artificial turf fields has increased, natural grass fields are created for user safety and landscaping effects by spraying grass seeds or transplanting grass.

However, in Korea, due to the long winter season, natural grass fields can only be used for 40 to 50 days a year, and if use is restricted to protect the grass, the efficiency of the field drops sharply. In addition, natural grass is difficult to maintain because it requires detailed care, such as watering and protecting it from damage.

Meanwhile, artificial turf fields cause less damage to the grass than natural grass fields, but require periodic maintenance and replacement because they are damaged when used for a long period of time. In addition, unlike natural grass stadiums, artificial turf stadiums are subject to loss of silica sand and filler materials laid on artificial turf due to rain, and harden when used for a long period of time, which reduces safety, such as shock absorption, and requires periodic replacement of silica sand and fillers. There is a problem.

Republic of Korea Patent Publication No. 10-2233661 Republic of Korea Patent Publication No. 10-2319114 Republic of Korea Patent Publication No. 10-2319113 Republic of Korea Patent Publication No. 10-2019094

The present invention was developed to solve the problems of the conventional artificial turf described above. It reduces the loss of silica sand and filler in artificial turf fields, and has an integrated shock-absorbing pad layer that maintains shock absorption without hardening even after long-term use. The problem to be solved is to provide a method of manufacturing an artificial turf mat and the artificial turf mat having a magnetic shock absorption function.

The method of manufacturing an artificial turf mat having a magnetic shock absorption function by integrating a shock absorption pad layer according to the present invention, which solves the above problems, includes polyethylene (PE) sheet, polypropylene (PP) sheet, and nylon (NYLON) sheet. A first weaving step (S100) of forming a shock absorbing pad layer using pile yarns to have a high weaving density per unit area of the foam paper on any one of the foam papers (S100); and, in the first weaving step (S100) A non-woven fabric heat-sealing step (S200) of attaching a non-woven fabric to the upper part of the formed shock-absorbing pad layer and fixing it by heat-sealing; and pile yarn having a total fineness of 12,000 denier to 14,000 denier to the non-woven fabric of the non-woven fabric heat-sealing step (S200). A second weaving step (S300) of forming an artificial turf layer using a second weaving step (S300); and, after the second weaving step (S300), the bottom surface of the foam paper is fused by applying heat only, or a non-woven fabric is attached to the bottom surface of the foam paper. A heat-sealing or back-coating step (S400) of manufacturing an artificial turf mat by heat-sealing or back-coating; and rolling and packaging the artificial turf mat (S500),
The pile yarn forming the shock absorption pad layer in the first weaving step (S100) is any one of polyethylene (PE) yarn, polypropylene (PP) yarn, and nylon (NYLON) yarn with a total yarn fineness of 3000 to 7000 denier. It is woven using , but the pile length is 10 to 20 mm, and the density is 40,000 to 60,000 (EA/㎡) per unit area of foam paper.
In the heat fusion or back coating step (S400), the synthetic resin sheet used for heat fusion is attached by heat fusion using a polyethylene (PE) or polypropylene (PP) sheet, or the back coating is SBR LATEX or It is characterized by forming a coating layer by back coating the entire surface using polyurethane (PU).

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Here, the nonwoven fabric in the nonwoven fabric heat fusion step (S200) is characterized in that it is polyethylene (PE) nonwoven fabric, polypropylene (PP) nonwoven fabric, or polyester (PET) nonwoven fabric.

Here, the pile yarn forming the artificial turf layer in the second weaving step (S300) is woven by selecting one of polyethylene (PE), polypropylene (PP) yarn, or nylon (NYLON) yarn with a total yarn fineness. The resulting pile length is characterized by being woven to have a length of 40 to 60 mm.

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In addition, in the present invention, it is manufactured according to the above-described manufacturing method,
One of polyethylene (PE) sheets, polypropylene (PP) sheets, and nylon (NYLON) sheets, and a pile yarn on the bubble paper 10. A shock-absorbing pad layer (20) formed by being woven to have a pile length of 10 mm to 20 mm, a non-woven fabric layer (30) attached by heat fusion to the upper surface of the shock-absorbing pad layer (20), and the non-woven fabric layer (30) It is composed of an artificial turf layer 40 in which pile yarns are woven to form artificial turf, and a bottom layer 50 formed of a non-woven fabric layer or coating layer heat-sealed and attached to the lower part of the foam paper,
The pile yarn forming the shock absorption pad layer 20 is woven using any one of polyethylene (PE) yarn, polypropylene (PP) yarn, and nylon (NYLON) yarn having a total yarn fineness of 3000 to 7000 denier,
The nonwoven layer forming the bottom layer 50 is heat-sealed using polyethylene (PE) or polypropylene (PP) sheets, or the coating layer forming the bottom layer 50 is SBR LATEX or polyurethane (PU). An artificial turf mat with a magnetic shock absorption function is provided by integrating a shock-absorbing pad layer formed by back-coating the entire surface.

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Here, the non-woven layer 30 is characterized by using polyethylene (PE) non-woven fabric, polypropylene (PP) non-woven fabric, or polyester (PET) non-woven fabric.

Here, the artificial turf layer 40 is woven with a total yarn fineness of polyethylene (PE), polypropylene (PP) yarn, or nylon (NYLON) yarn, and the pile length is 40 to 60 mm. Do it as

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The artificial turf mat manufactured according to the method of manufacturing an artificial turf mat having a self-shock absorbing function by integrally forming a shock-absorbing pad layer provided according to the present invention is manufactured using PE/PP/NYLON yarn, so that it can be used in artificial turf stadiums. Even after several years after construction, the silica sand and filler layer do not harden and the shock absorption pad functions well, so the system items (ball rolling resistance, rotational resistance, skin surface friction, water permeability) required for artificial turf stadiums are continuously maintained. It has the advantage of being maintained.

In addition, the artificial turf mat, which has a self-shock absorbing function by integrally forming a shock-absorbing pad layer according to the manufacturing method of the present invention, is heat-sealed by using a PE/PP sheet as foam paper and adding a PE/PP/PET non-woven fabric on top. It is completed. Therefore, it has excellent drainage even in bad weather such as torrential rain, prevents loss of silica sand and filler, maintains smooth performance during playground games, and is effective in preventing injuries. It is also excellent for preserving the artificial turf mat as well as replacing artificial turf. It can also be recycled, which also has the advantage of saving resources.

Figure 1 is a block diagram showing a method of manufacturing an artificial turf mat of the present invention.
Figure 2 is a schematic diagram of the manufacturing method of the artificial turf mat according to the present invention.
Figure 3 shows the structure of an artificial turf mat according to the present invention.
Figure 4 is a cross-sectional view of an artificial turf stadium constructed with an artificial turf mat according to the present invention.

Hereinafter, the present invention will be described in more detail with reference to the accompanying drawings.

The present invention has a magnetic shock absorption function by forming a shock absorption pad layer on the lower layer of the artificial turf mat by weaving pile yarns to have a high weaving density per unit area on the top of the foam paper, and at the same time, forming the shock absorption layer makes silica sand (sand) ) and a method of manufacturing an artificial turf mat with a magnetic shock absorption function, which is composed of a shock-absorbing pad layer with excellent drainage while reducing the loss of silica sand and filler while reducing the amount of filler used, and the artificial turf mat The purpose is to provide,

As shown in Figures 1 and 2, the method of manufacturing an artificial turf mat having a self-shock absorbing function by integrally forming a shock-absorbing pad layer according to the present invention, which has achieved the above object, is a method of producing a high per unit area of foam paper on the foam paper. A first weaving step (S100) of forming a shock-absorbing pad layer 20 using pile yarns to have a weaving density; and a non-woven fabric on the top of the shock-absorbing pad layer formed in the first weaving step (S100) A non-woven fabric heat-sealing step (S200) of attaching and heat-sealing and fixing the pile to form the shock-absorbing pad layer 20; A second weaving step (S300) of forming a turf layer; and, after the second weaving step (S300), the bottom surface of the bubble paper is fused by applying heat only, or a PE or PP sheet is attached to the bottom surface of the bubble paper. A heat-sealing or back-coating step (S400) of manufacturing an artificial turf mat by heat-sealing or back-coating; and rolling and packaging the artificial turf mat (S500).

According to the present invention, the foam paper 10 formed in the first weaving step is preferably made of any one of polyethylene (PE) sheets, polypropylene (PP) sheets, and nylon (NYLON) sheets.

According to the present invention, the pile yarn forming the shock absorbing pad layer 20 in the first weaving step (S100) is preferably polyethylene (PE) yarn having a total yarn fineness of 3,000 to 7,000 denier, and polypropylene (PP). It is woven using either yarn or nylon yarn, and is characterized in that the pile length is 10 to 20 mm. At this time, the pile formed on the foam paper is preferably woven as tightly as possible to have a density of 40,000 to 60,000 (EA/㎡) per unit area of the foam paper in order to achieve the function of a shock absorbing layer.

At this time, when the total fineness of the pile yarn is less than 3,000 denier, there is a problem that shock absorbency cannot be maintained for a long time due to the weak restoring force of the pile yarn to maintain shock absorbency (the strength of the pile to recover), and those with a denier exceeding 7,000 denier are used. When used, the artificial turf pile is thick, making it impossible to produce within the density range required for weaving, and the pile yarn that is supposed to maintain shock absorbency cannot be restored and is bent, making it impossible to maintain shock absorbency. There may be a problem.

In addition, if the pile length is less than 10mm, shock absorbency is inadequate among the quality standards for artificial turf systems for schools and sports stadiums, which has the disadvantage of shortening the maintenance of the artificial turf quality system. If it exceeds 20mm, use time increases. Accordingly, the artificial turf pile may be bent, which may cause problems in maintaining the quality standards of the artificial turf system.

According to the present invention, the nonwoven fabric used in the nonwoven fabric heat fusion step (S200) is any one of polyethylene (PE) nonwoven fabric, polypropylene (PP) nonwoven fabric, or polyester (PET) nonwoven fabric. At this time, the non-woven fabric is preferably used as a product with a thickness of 3 to 7 mm. If the non-woven product with a thickness of less than 3 mm is used, the artificial turf layer in the first weaving step (S100) collapses due to the weight of the silica sand during artificial turf construction, causing the silica sand to descend to the artificial turf layer in the first weaving step (S100). It has the disadvantage of not being able to realize the performance of the shock absorbent pad, and when using products exceeding 7mm, the weight of the non-woven envelope (S200) increases after submersion as the amount of usage increases after artificial turf construction, resulting in the first weaving stage ( S100) has the disadvantage of not being able to act as a shock absorbing pad for artificial turf.

According to the present invention, the pile yarn forming the artificial turf layer 40 in the second weaving step (S300) is preferably one of polyethylene (PE) yarn, polypropylene (PP) yarn, or nylon (NYLON) yarn. Weave by selection, but preferably, the pile length is 40 to 60 mm. At this time, it is recommended that the total fineness of the pile yarn used has a denier of 12,000 or more. When using a denier of less than 12,000, it is used to improve the abrasion strength and stud wear quality of artificial turf mats and systems in schools and stadiums. There is a downside to not being able to maintain it. More preferably, the total fineness of the pile yarn is 12,000 denier to 14,000 denier.

The pile yarn used to form the artificial turf layer 40 can be selected from polyethylene (PE) yarn, polypropylene (PP) yarn, or nylon (NYLON) yarn to form a monotype artificial turf pile. Alternatively, a double-structured artificial turf pile may be formed by selecting and using a plurality of yarns with different properties among the above yarns.

According to the present invention, the sheet used in the heat sealing or back coating step (S400) is preferably attached using polyethylene (PE) sheet or polypropylene (PP).

According to the present invention, in the heat sealing or back coating step, it is preferable to form a coating layer by back coating the entire surface of the lower part of the bubble paper using SBR LATEX or polyurethane (PU).

In the present invention, according to the manufacturing method disclosed above, it is possible to provide an artificial turf mat having a magnetic shock absorption function by integrally forming a shock absorption pad layer.

More specifically, as shown in Figure 3, the artificial turf mat includes a foam paper 10 using any one of polyethylene (PE) sheet, polypropylene (PP) sheet, and nylon (NYLON) sheet, and the foam paper Pile yarn is woven on (10) to create a shock-absorbing pad layer (20) with a pile length of 10 to 20 mm and a maximum pile density per unit area of foam paper, and a shock-absorbing pad layer (20) attached by heat fusion to the upper surface of the shock-absorbing pad layer (20). A bottom layer formed of a non-woven fabric layer (30), an artificial turf layer (40) in which pile yarns are woven on the non-woven fabric layer (30) to form artificial turf, and a non-woven fabric layer or coating layer that is heat-sealed and attached to the lower part of the foam paper. There is a characteristic of its technical composition in that it is composed of (50).

At this time, the pile yarn forming the shock absorption pad layer 20 is preferably any one of polyethylene (PE) yarn, polypropylene (PP) yarn, and nylon (NYLON) yarn having a total yarn fineness of 3,000 to 7,000 denier. So, he is dismissed from the service,

The non-woven layer 30 is made of polyethylene (PE) non-woven fabric, polypropylene (PP) non-woven fabric, or polyester (PET) non-woven fabric.

In addition, preferably, the artificial turf layer 40 is woven using one or more of polyethylene (PE) yarn, polypropylene (PP) yarn, or nylon (NYLON) yarn, and has a pile length of 40 to 60 mm. It's in the thing. At this time, the yarn used to form the artificial turf layer is preferably one having a total yarn fineness of 12,000 denier or more. More preferably, it is best to use yarn having a total fineness of 12,000 denier to 14,000 denier.

In addition, preferably, the pile yarn used to form the artificial turf layer 40 is selected from polyethylene (PE) yarn, polypropylene (PP) yarn, or nylon (NYLON) yarn and is monotyped as an artificial turf pile. Alternatively, a double-structured artificial turf pile can be formed by selecting and using a plurality of yarns with different properties among the above yarns.

In addition, when applying the heat fusion method as a component of the bottom layer 50, it is better to form it using a sheet, preferably using a polyethylene (PE) or polypropylene (PP) sheet. Preferably, when forming a coating layer using the above back coating method, it is better to back coat the entire lower surface of the foam paper using SBR LATEX or polyurethane (PU).

An example of an artificial turf field constructed to form an artificial turf field using the artificial turf mat provided according to the present invention will be described with reference to FIG. 4, wherein the artificial turf mat provided according to the present invention is laid on the floor. , the top surface of the non-woven fabric layer 30 fused to the top surface of the shock absorbing pad layer 20 is filled with silica sand to form a silica sand layer, and the top of the silica sand layer is filled with a filler material to form a filler layer to protect against adverse events such as torrential rain. It has excellent drainage properties even in rainy weather and can provide an excellent artificial turf stadium by preventing loss of silica sand and filler materials. In addition, it is possible to provide an artificial turf mat that has the advantage of saving resources by increasing the maintainability of the artificial turf mat and enabling recycling even when replacing artificial turf.

10: Bubble paper
20: Shock absorption pad layer
30: Non-woven layer
40: Artificial turf layer
50: bottom layer

Claims (14)

The first step is to form a shock absorbing pad layer using pile yarn to have a high weaving density per unit area of foam paper on any one of polyethylene (PE) sheets, polypropylene (PP) sheets, and nylon (NYLON) sheets. A weaving step (S100); A non-woven fabric heat-sealing step (S200) of attaching a non-woven fabric to the top of the shock-absorbing pad layer formed in the first weaving step (S100) and fixing it by heat-sealing; And, The non-woven fabric heat-sealing step A second weaving step (S300) of forming an artificial turf layer using pile yarns having a total fineness of 12,000 denier to 14,000 denier on the nonwoven fabric of (S200); and, the bottom of the base paper after the second weaving step (S300) A heat-sealing or back-coating step (S400) of manufacturing an artificial turf mat by fusing the bottom surface of the foam paper with only heat, or attaching a non-woven fabric and heat-sealing it, or back-coating it; and rolling and packaging the artificial turf mat (S500),
The pile yarn forming the shock absorption pad layer in the first weaving step (S100) is any one of polyethylene (PE) yarn, polypropylene (PP) yarn, and nylon (NYLON) yarn with a total yarn fineness of 3000 to 7000 denier. It is woven using , but the pile length is 10 to 20 mm, and the density is 40,000 to 60,000 (EA/㎡) per unit area of foam paper.
In the heat fusion or back coating step (S400), the synthetic resin sheet used for heat fusion is attached by heat fusion using a polyethylene (PE) or polypropylene (PP) sheet, or the back coating is SBR LATEX or A method of manufacturing an artificial turf mat that has a magnetic shock absorption function and is composed of an integrated shock-absorbing pad layer, characterized by forming a coating layer by back-coating the entire surface using polyurethane (PU). delete delete According to claim 1,
The non-woven fabric in the non-woven fabric heat fusion step (S200) is characterized as being polyethylene (PE) non-woven fabric, polypropylene (PP) non-woven fabric, or polyester (PET) non-woven fabric, and the non-woven fabric has an integrated shock-absorbing pad layer with a thickness of 3 to 7 mm. A method of manufacturing an artificial turf mat that has a magnetic shock absorption function. According to claim 1,
The pile yarn forming the artificial turf layer in the second weaving step (S300) is woven using one or more of polyethylene (PE) yarn, polypropylene (PP) yarn, or nylon (NYLON) yarn. A method of manufacturing an artificial turf mat that has a magnetic shock absorption function and is composed of an integrated shock-absorbing pad layer, characterized in that it is woven to have a length of 40 to 60 mm.
delete delete It is manufactured according to the manufacturing method described in claim 1, and includes a foam paper (10) made of polyethylene (PE) sheet, polypropylene (PP) sheet, or nylon (NYLON) sheet, and a top of the foam paper (10). A shock-absorbing pad layer (20) is formed by weaving pile yarns on bubble paper (10) to have a pile length of 10 mm to 20 mm, and is attached by heat fusion to the upper surface of the shock-absorbing pad layer (20). A non-woven fabric layer (30) and pile yarns having a total fineness of 12,000 denier to 14,000 denier are woven on the non-woven fabric layer (30) to form artificial turf, and the artificial turf layer (40) is heat-sealed to the lower part of the foam paper. It consists of a bottom layer 50 formed of an attached non-woven fabric layer or coating layer,
The pile yarn forming the shock absorption pad layer 20 is woven using any one of polyethylene (PE) yarn, polypropylene (PP) yarn, and nylon (NYLON) yarn having a total yarn fineness of 3000 to 7000 denier, The pile length is 10 to 20 mm, and the density is 40,000 to 60,000 (EA/㎡) per unit area of foam paper.
The nonwoven layer forming the bottom layer 50 is heat-sealed using polyethylene (PE) or polypropylene (PP) sheets, or the coating layer forming the bottom layer 50 is SBR LATEX or polyurethane (PU). An artificial turf mat that has a magnetic shock absorption function and is composed of an integrated shock-absorbing pad layer, which is formed by back-coating the entire surface using an artificial turf mat. delete delete According to claim 8,
The non-woven layer 30 is composed of an integrated shock-absorbing pad layer characterized by using any one of polyethylene (PE) non-woven fabric, polypropylene (PP) non-woven fabric, or polyester (PET) non-woven fabric satisfying a thickness of 3 to 7 mm. An artificial turf mat with magnetic shock absorption function. According to claim 8,
The artificial turf layer 40 is woven using one or more of polyethylene (PE) yarn, polypropylene (PP) yarn, or nylon (NYLON) yarn, and has a pile length of 40 to 60 mm. An artificial turf mat that is composed of an integrated shock-absorbing pad layer and has a magnetic shock-absorbing function. delete delete