KR102617188B1 - Manufacturing method of twisted artificial turf pile yarn and pile yarn manufactured accordingly - Google Patents

Abstract

The present invention includes the following steps: obtaining a pile yarn containing a polyolefin resin; obtaining a stretched pile yarn by stretching the pile yarn; winding the stretched pile yarn to obtain a first wound twisted pile yarn; It relates to a method of manufacturing twisted artificial turf pile yarn, including the step of rewinding the wound pile yarn to obtain a secondary wound pile yarn, and the step of post-processing the secondary wound pile yarn to obtain a post-processed pile yarn.

Description

Manufacturing method of twisted artificial turf pile yarn and pile yarn manufactured accordingly}

The present invention relates to a method for manufacturing twisted artificial turf pile yarn and the pile yarn manufactured thereby.

Artificial turf is a substitute for artificial turf made of synthetic fibers and shaped like grass. Since it was first produced in the United States in 1956, it has been mainly used in sports fields such as baseball, soccer, and golf. Furthermore, it can be used in places such as indoor gardens where grass cannot grow or outdoor areas facing the north side of high-rise buildings where sunlight hours are extremely limited.

Existing artificial turf has been mainly installed in places where natural grass cannot be installed, for example, in areas where natural grass is difficult to grow, such as dome stadiums where natural lighting is blocked.

However, in recent years, although the initial construction cost is high, it can be used semi-permanently compared to natural grass, and in particular, not only is it convenient for maintenance, but thanks to the ever-developing technology, natural grass has a texture and quality as good as natural grass. Regardless of constructability, the preference for artificial turf is rapidly increasing in various places.

Although this type of artificial turf requires a higher initial construction cost than natural grass, it is highly preferred because it can be used semi-permanently, is convenient for maintenance, and has an even surface suitable for exercise. In addition, artificial turf has the advantage of being able to maintain its unique color at all times, not being limited by environmental conditions, and being easy to manage after construction.

Meanwhile, artificial turf is mostly manufactured using the tufting method. The tufting method is a method that takes into account productivity and workability, but due to the nature of the process, the yarn is formed in a specific direction to form directionality, which causes the problem of reduced shock absorption. there is.

In order to improve these shortcomings, the artificial turf industry is developing non-directional artificial turf products by applying heat to the back coating layer during the manufacture of artificial turf to deform the artificial turf pile. However, the deformation of the pile cannot be completely controlled, so rather than shock absorption. There are problems with this degradation.

Republic of Korea Patent No. 10-2374724 (announced on March 14, 2022)

The problem to be solved by the present invention is to provide a method for manufacturing twisted artificial turf pile yarns in which the artificial turf piles do not have directionality even when the tufting method is applied when manufacturing artificial turf.

In one aspect, the present invention includes the steps of obtaining a pile yarn containing a polyolefin resin, drawing the pile yarn to obtain a stretched pile yarn, and winding the stretched pile yarn to obtain a primary wound twisted pile yarn. It provides a method of manufacturing artificial turf pile yarn, comprising the steps of rewinding the primary wound pile yarn to obtain a secondary wound pile yarn, and post-processing the secondary wound pile yarn to obtain a post-processed pile yarn. .

In the manufacturing method according to the present invention, the step of obtaining pile yarn may include melt spinning a polyolefin resin and cooling the melt spun pile yarn.

In the production method according to the present invention, the polyolefin resin is one selected from the group consisting of Linear Low Density Polyethylene, Low Density Polyethylene, Middle Density Polyethylene, and High Density Polyethylene. There may be more than one species.

In the step of obtaining pile yarn in the manufacturing method according to the present invention, one or more types selected from the group consisting of pigments, anti-aging agents, antioxidants, and flame retardants may be further added.

The step of obtaining a stretched pile yarn in the manufacturing method according to the present invention includes obtaining a hot-stretched pile yarn by stretching at a temperature of 70 to 110°C, and obtaining a cold-stretched pile yarn by stretching at a temperature of 10 to 50°C. It may include obtaining steps.

The step of obtaining stretched pile yarn in the manufacturing method according to the present invention can be performed at a stretching ratio of 1 to 4.

In the manufacturing method according to the present invention, the step of obtaining the first wound pile yarn can be performed at a speed of 1,000 to 5,000 rpm.

In the manufacturing method according to the present invention, the primary wound pile yarn in the step of obtaining the primary wound pile yarn may have a twisted form.

In the manufacturing method according to the present invention, the step of obtaining the secondary wound pile yarn can be performed at a speed of 500 to 2,000 rpm.

In the manufacturing method according to the present invention, the number of secondary wound pile yarns in the step of obtaining the secondary wound pile yarns may be 20 to 80 in a twisted form as measured by the following measurement method.

[Method of measuring the number of twisted shapes]

Randomly select 10 1m long artificial turf pile yarns, count the total number of twisted shapes, and then divide by 10 to measure the average number.

In the manufacturing method according to the present invention, the step of obtaining post-processed pile yarn may be heat treated at a temperature of 50 to 100°C.

In another aspect, the present invention provides a twisted artificial turf pile yarn manufactured by a pile yarn manufacturing method.

According to the present invention, it is possible to manufacture twisted artificial turf pile yarns of different shapes for each section using a single spinner without replacing the spinneret and branch pipe, which is better than the conventional method of manufacturing pile yarns of various shapes by replacing spinnerets. Efficiency can be increased and pile yarn with a natural grass appearance can be provided.

In addition, it is possible to provide a twisted artificial turf pile yarn that has improved shock absorption compared to monofilament pile yarn, has excellent elastic recovery, improves uprightness and durability, and can prevent loss of filler material.

Figure 1 is a flowchart showing the manufacturing method of the twisted artificial turf pile yarn of the present invention.
Figure 2 is an image showing a twisted artificial turf pile yarn (left) manufactured according to the present invention.
Figure 3 shows a pile yarn manufacturing system.
Figure 4 is an image showing the bobbin and circular pipe used when winding artificial turf pile yarn.
Figure 5 exemplarily shows the winding step of pile yarn.
Figure 6 is an image showing one twisted form that is the basis for coefficients (red dotted line portion, i.e., reference form).

Hereinafter, embodiments of the present invention will be described in detail with reference to the attached drawings so that those skilled in the art can easily implement the present invention. However, the present invention may be implemented in many different embodiments and is not limited to the embodiments described herein. Throughout the specification, similar parts are given the same reference numerals.

In addition, when similar expressions such as the terms “about,” “approximately,” or at least are used in relation to a numerical value in the present invention, ±10%, ±7% based on the numerical value. It is intended that theoretical, experimental, statistical, or rule of thumb errors of %, ±5%, ±3%, ±2%, or ±1% are permitted.

In one aspect, the present invention includes a step of obtaining a pile yarn containing a polyolefin resin (S100), a step of obtaining a stretched pile yarn by stretching the pile yarn (S200), and winding the stretched pile yarn to produce a first wound twisted yarn. A step of obtaining a pile yarn of the form (S300), a step of rewinding the primary wound pile yarn to obtain a secondary wound pile yarn (S400), and a step of post-processing the secondary wound pile yarn to obtain a post-processed pile yarn. A method for manufacturing a twisted artificial turf pile yarn comprising (S500) is provided.

Hereinafter, it will be described in detail with reference to the drawings.

Steps to obtain pile yarn containing polyolefin resin

First, the step of obtaining a pile yarn containing a polyolefin resin shown in FIG. 1 (S200) includes melt spinning the polyolefin resin and cooling the melt spun pile yarn.

In this step, melt spinning the polyolefin resin may be performed at a temperature of 210 to 270°C, preferably 230 to 240°C. Additionally, melt spinning at this stage can be performed by applying conventional techniques in the field of artificial turf manufacturing.

The polyolefin resin used in the step of melt spinning the polyolefin resin may be polyethylene-based, and specifically, it may be one or more types selected from the group consisting of linear low-density polyethylene, low-density polyethylene, medium-density polyethylene, and high-density ethylene, and more specifically, linear low-density polyethylene. It may be polyethylene.

In the step of melt spinning the polyolefin resin, functional additives can be further mixed to provide functionality to the pile yarn. As such functional additives, one or more types selected from the group consisting of pigments, anti-aging agents, antioxidants, and flame retardants can be used. .

The functional additives used in the present invention may each contain 1 to 10 parts by weight based on 100 parts by weight of the polyolefin resin. If the content of each functional additive is less than 1 part by weight, the activity of the functional additive cannot be exerted and the desired The function cannot be achieved, and if it exceeds 10 parts by weight, the characteristics of artificial turf, such as durability and upright stability, may be deteriorated.

The step of cooling the melt-spun pile yarn may use a cooling water tank, but is not particularly limited as long as it can provide an appropriate cooling effect for the pile yarn.

The step of cooling the melt-spun pile yarn may be performed at a temperature of 30°C or lower, preferably 10 to 30°C.

Step of stretching pile yarn to obtain stretched pile yarn

Thereafter, as shown in FIG. 1, a step (S200) of stretching the pile yarn to obtain the stretched pile yarn is performed.

The step of obtaining the drawn pile yarn can be performed at a draw ratio of 1 to 4.

In addition, the step of obtaining the stretched pile yarn may include the step of obtaining a hot-stretched pile yarn by stretching at a temperature of 70 to 110 ℃, and the step of obtaining a cold-stretched pile yarn by stretching at a temperature of 10 to 50 ℃. You can.

At this stage, hot drawing and cold drawing can be carried out by immersing the yarn in a water bath, a water bath heating method, to create a difference in heating temperature.

Referring to Figure 3, after the previous step of cooling the melt-spun pile yarn, the pile yarn is supplied to a water bath at 70 to 110°C through rollers to be hot stretched, and then supplied to a water bath at 10 to 50°C. It is cold drawn.

In this step, if the hot stretching temperature exceeds 110℃ and the cold stretching temperature exceeds 50℃, the rate of increase in crystallinity is low, and it is not easy to deform the twisted artificial turf pile yarn during post-processing, so the twist shape per meter of the set pile yarn is not easy. The number cannot be adjusted, and as a result, the effect of the twisted pile yarn is reduced, and there is a problem of not maintaining the twisted shape. If the hot stretching temperature is lower than 70℃ and the cold stretching temperature is lower than 10℃, During post-processing, the pile yarn shrinks excessively, the number of twisted forms per meter of pile yarn increases, the production rate of the pile yarn decreases, and the increased friction may cause injury to the user.

The fineness of the stretched pile yarn may be 7,000 to 17,000 denier, specifically 10,000 to 14,000 denier. If the fineness of the stretched pile yarn is less than 7,000 denier or exceeds 17,000 denier, the winding and post-processing processes described later may not be easy.

Step of winding the stretched pile yarn to obtain the first wound pile yarn

Thereafter, a step (S300) of first winding the stretched pile yarn is performed as shown in FIG. 1.

This step is to transform the shape of the pile yarn, and a twisted shape can be given to the pile yarn by increasing the winding speed.

The pile yarn drawn in this step can be wound on a bobbin mounted on the spindle (Figure 4)

In this step, the bobbin refers to a cylindrical tube into which the stretched pile yarn is temporarily wound, and can be applied to wind the pile yarn when spinning it in large quantities.

In this step, the pile yarn is first wound on the bobbin rotating by the spindle. At this time, the pile yarn is wound while rotating around the bobbin in the form of a balloon.

At this stage, the stretched pile yarn passes through various parts such as traveler and guide hole and is wound around the bobbin. At this time, a difference occurs between the number of revolutions of the pile yarn and the number of revolutions of the spindle, and the difference in rotational force causes the pile yarn to A twisted form is given.

Specifically, referring to Figure 5, in the winding step, the pile yarn is wound in a large rotation around the bobbin while following the path of the balloon control ring, and in this process, a difference occurs between the pile yarn supply speed and the rotation speed of the bobbin (spindle). do. At this time, twisted pile yarn can be manufactured due to friction between the balloon control ring, yarn guide, and pile yarn.

In addition, in the present invention, the cause of giving the twisted shape to the pile yarn is the friction and tension applied to the pile yarn, and it has the effect of preventing the pile yarn from being cut when wound along the path of the balloon control ring.

Additionally, the number of twisted forms of the pile yarn can be adjusted by adjusting the primary winding speed.

In this step, the number of twisted forms formed in the pile yarn increases when the difference in rotational force is large. For example, the spindle rotation speed of the winding machine is increased, the production speed of the pile yarn ejected/stretched during spinning is reduced, or the pile yarn is passed through. For example, the number of twist shapes can be adjusted by adjusting the difference in rotational force between the bobbin and the pile yarn by changing the friction force of the guide hole, etc.

The step of winding the stretched pile yarn to obtain the first wound pile yarn can be performed at a speed of 1,000 to 5,000 rpm, and specifically, can be performed at a speed of 1,500 to 3,500 rpm.

In this step, if the winding speed (primary) is less than 1,000 rpm, twisted pile yarn cannot be manufactured and productivity is reduced, and if the winding speed exceeds 5,000 rpm, the load on the twisting machine due to the weight of the bobbin As it gets worse and the tension applied to the pile yarn increases, thread breakage problems may occur.

Step of rewinding the primary wound pile yarn to obtain the secondary wound pile yarn

Thereafter, as shown in FIG. 1, a step (S400) of rewinding the primary wound pile yarn to obtain a secondary wound pile yarn is performed.

This step is a step in which the pile yarn first wound on the bobbin is secondarily wound on a circular tube for post-processing and reorganization process when manufacturing the artificial turf structure.

Specifically, the step of obtaining the secondary wound pile yarn is the step of transferring the pile yarn of the bobbin given a twist shape to a circular tube and winding it. In this step, when the bobbin and the circular tube are rotated at the same speed, the pile yarn according to the rotational force Deformation of the yarn does not occur, and a pushing phenomenon may occur due to friction. At this time, the number of twisted shapes decreases in the central part of the pile yarn where friction and tension are strong, and the upper and lower ends where friction is relatively weak may increase by the number of reduced twisted forms in the central part.

The step of obtaining the secondary wound pile yarn can be performed at a speed of 500 to 2,000 rpm. If the secondary winding speed is less than 500 rpm, the production speed decreases and the tension given to the yarn is small, so it is not uniformly distributed in the circular tube. There is a problem that workability during weaving is reduced because it is not wound, and if the speed exceeds 2,000 rpm, excessive shearing occurs and the twisted shape is not uniformly applied to the pile yarn.

In the step of obtaining the secondary wound pile yarn, the number of twisted pile yarns measured by the following measurement method may be 20 to 80.

[Method of measuring number of twisted forms]

Ten 1m long artificial turf pile yarns were randomly selected, the total number of twisted shapes was determined, and the average number was measured by dividing by 10.

If the number of twists formed in the pile yarn is less than 20 per 1m of pile yarn, the effect of shock absorption and preventing loss of filler material is minimal, and if it exceeds 80, the friction force of the pile yarn increases, which may cause injury to the user. , when manufacturing artificial turf, workability such as tufting may be reduced, and there are problems with poor aesthetics.

Step of post-processing the secondary wound pile yarn to obtain post-processed pile yarn

Finally, as shown in FIG. 1, a step (S500) of post-processing the secondary wound pile yarn to obtain post-processed pile yarn is performed.

The step of obtaining the post-processed pile yarn (S500) is a step of fixing the twist shape formed on the pile yarn, and can be performed by a dry method using a hot air dryer or a wet method using a steamer.

At this time, the post-processing temperature may be 50 to 100 ℃. If the post-processing temperature is less than 50 ℃, the effect of fixing the twist shape is minimal, and if it exceeds 100 ℃, there is a problem that excessive deformation may occur in the pile yarn. .

In another aspect, the present invention provides a twisted artificial turf pile yarn manufactured by a pile yarn manufacturing method.

In another aspect, the present invention provides an artificial turf structure to which twisted artificial turf pile yarns are applied.

The artificial turf structure to which the twisted artificial turf pile yarn of the present invention is applied can not only have improved shock absorption, but also prevent loss of filler.

Hereinafter, to aid understanding of the present invention, it will be described in detail through examples. However, the embodiments according to the present invention may be modified into various other forms, and the scope of the present invention should not be construed as being limited to the following embodiments. Embodiments of the present invention are provided to more completely explain the present invention to those skilled in the art.

Example 1

Using the pile yarn production system shown in Figure 3, 1,000 g of linear low-density polyethylene and 50 g of green masterbatch were mixed, melted and spun at a temperature of 235°C. Thereafter, the spun pile yarn was cooled by putting it in a cooling water bath at 25°C, then hot-stretched at a temperature of 80°C and cold-stretched at a temperature of 20°C, and then first wound on a bobbin at a speed of 3,500 rpm.

The first wound pile yarn was wound secondarily on a circular tube at a speed of 1,000 rpm and then heat treated at 80°C to produce twisted artificial turf pile yarn.

At this time, the masterbatch was manufactured in the form of a chip by mixing linear low-density polyolefin, pigment, anti-aging agent, antioxidant and flame retardant, etc., and the secondary winding was wound in the opposite direction to the primary winding direction, so that the number of twisted forms was 1 m of pile yarn. It was adjusted to 50 per person.

Examples 2 to 5

Twisted pile yarn was manufactured in the same manner as in Example 1, but according to the conditions in Table 1 below.

division 1st winding speed
(rpm) Secondary winding speed
(rpm) Post-processing temperature
(℃) Number of twists per meter Example 2 1,000 1,000 80 25 Example 3 5,000 1,000 80 80 Example 4 3,500 1,000 50 50 Example 5 3,500 1,000 100 50

Comparative Examples 1 to 4

Artificial turf pile yarn was manufactured in the same manner as in Example 1, but according to the conditions in Table 2 below.

division 1st winding speed
(rpm) Secondary winding speed
(rpm) Post-processing temperature
(℃) Number of twists per meter Comparative Example 1 100 1,000 80 0 Comparative Example 2 8,000 1,000 80 100 Comparative Example 3 3,500 1,000 30 50 Comparative Example 4 3,500 1,000 120 50

Experimental Example 1: Evaluation of shock absorption rate and filler loss rate

Artificial turf structures were manufactured using artificial turf pile yarns manufactured according to Examples 1 to 5 and Comparative Examples 1 to 4, and shock absorption and filler loss rate were evaluated.

[Assessment Methods]

Shock absorption measurement (evaluation by FIFA Quality program for football turf)

The amount of impact applied to the object was measured by allowing a 20kg object to freely fall 55mm, and then the reduction in impact compared to when it was dropped on the concrete floor was measured and expressed as a percentage.

Measuring the loss rate of filler material (Splash Test)

Using a ball launcher, a ball is launched onto the filled artificial turf at a speed of 45 degrees and 50 km/h, and then the extent of the filler being splashed by the ball is filmed using a high-speed camera. In the photograph taken, the amount of filler in the air is the most. The ratio was expressed numerically.

division Shock absorption rate (%) Filler loss rate (%) Example 1 10.2 13 Example 2 9.3 28 Example 3 15.5 11 Example 4 12.1 14 Example 5 14.0 10 Comparative Example 1 1.3 39 Comparative Example 2 7.5 11 Comparative Example 3 1.5 45 Comparative Example 4 7.1 22

Referring to Table 3, comparing Examples 1 to 5 and Comparative Examples 1 to 4, it can be seen that Examples 1 to 5 all have better shock absorption than Comparative Examples 1 to 4, especially Example 3. You can see that this is the best.

Meanwhile, in the case of the loss rate of the filler, it can be seen that the more twists given to the pile yarn, the lower the loss rate, and the less it is, the higher the loss rate of the propellant. However, when the twisted shape is formed over a certain range, there is a problem in that the shock absorption rate decreases rapidly over time when applied to an artificial turf structure.

In other words, when a twisted form is given to a specific number of pile yarns, the shock absorption rate is excellent, the loss rate of filler is low, and the replacement cycle can be prevented from being shortened due to a rapid decrease in the shock absorption rate.

1: pile yarn manufacturing system 10: spinning machine
20: cooling water tank 30: stretching roller
40: Winding machine S100: Step of obtaining pile yarn
S200: Step of obtaining stretched pile yarn S300: Step of obtaining primary wound pile yarn
S400: Step of obtaining secondary wound pile yarn S500: Step of obtaining post-processed pile yarn

Claims (11)

Obtaining pile yarn containing polyolefin resin,
Step of stretching the pile yarn to obtain stretched pile yarn,
A step of winding the stretched pile yarn to obtain a primary wound twisted pile yarn,
A step of rewinding the primary wound pile yarn to obtain a secondary wound pile yarn, and
It includes the step of post-processing the secondary wound pile yarn to obtain a post-processed pile yarn,
The steps for obtaining stretched pile yarn are:
Obtaining a hot-stretched pile yarn by stretching at a temperature of 70 to 110°C;
A method of manufacturing artificial turf pile yarn, comprising the step of obtaining cold-stretched pile yarn by stretching at a temperature of 10 to 50°C. According to paragraph 1,
polyolefin resin
Characterized by at least one selected from the group consisting of Linear Low Density Polyethylene, Low Density Polyethylene, Middle Density Polyethylene, and High Density Polyethylene,
Manufacturing method of artificial turf pile yarn. According to paragraph 1,
At the stage of obtaining a file company
Characterized by further adding at least one selected from the group consisting of pigments, anti-aging agents, antioxidants, and flame retardants,
Manufacturing method of artificial turf pile yarn. delete According to paragraph 1,
The steps for obtaining stretched pile yarn are:
Characterized by performing at a draw ratio of 1 to 4,
Manufacturing method of artificial turf pile yarn. According to paragraph 1,
The step of obtaining the first wound pile yarn is,
Characterized by performing at a winding speed of 1,000 to 5,000 rpm,
Manufacturing method of artificial turf pile yarn. According to paragraph 1,
In the step of obtaining the primary wound pile yarn, the primary wound pile yarn is characterized in that it has a twisted form,
Manufacturing method of artificial turf pile yarn. According to paragraph 1,
The step of obtaining the secondary wound pile yarn is,
Characterized in that it is performed at a winding speed of 500 to 2,000 rpm.
Manufacturing method of artificial turf pile yarn. According to paragraph 1,
In the step of obtaining the secondary wound pile yarn,
The secondary wound pile yarn is characterized in that the number of twisted forms measured by the following measurement method is 20 to 80,
Manufacturing method of artificial turf pile yarn
[Method of measuring the number of twisted shapes]
Randomly select 10 1m long artificial turf pile yarns, count the total number of twisted shapes, and then divide by 10 to measure the average number. According to paragraph 1,
The steps to obtain post-processed pile yarn are:
Characterized by heat treatment at a temperature of 50 to 100 ° C.
Manufacturing method of artificial turf pile yarn. Artificial turf pile yarn manufactured according to the method of any one of claims 1 to 3 and 5 to 10.