JP2000027111A - Manufacture of artificial lawn - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a manufacturing method for artificial lawn to be used for a field surface layer in which the artificial lawn can be efficiently produced by one manufacturing process using one unit of a tufting machine, the artificial lawn of which has a lawn leaf layer filling granular matter and a lawn leaf layer hardly accepting the granular matter used for the surface layer of end peripheral part of at least one of its side and/or equipment installation portion. SOLUTION: This is a manufacturing method for artificial lawn having a lawn leaf 111 layer filled with granular matter and a lawn leaf 112 layer at least one side portion to which the granular matter is hard to enter. At least one side portion of one unit of a planting machinery 12 is supplied with a lawn leaf 112 thread which makes larger its mean presumed surface area per unit volume of the lawn leaf layer compared to the lawn leaf 111 thread supplied to other portions, these lawn leaf 112 threads are planted at the same time to a lining basic cloth 113 having a predetermined width thereby forming the lawn leaf 112 layer and then the rear surface of the lining basic cloth is fixed by back hooking.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for producing an artificial turf having a turf leaf layer filled with particulate matter and a turf leaf layer on at least one side of the turf leaf where the particulate matter hardly enters.

[0002]

2. Description of the Related Art Artificial turf is generally manufactured by using synthetic resin yarn as turf yarn, laying a large number of these on a base cloth using a tufting machine, and then fixing the back inside with rubber latex or the like. Have been. The artificial lawn is laid on a base layer such as asphalt, and a granular material such as sand is filled in the grass, and the artificial lawn filled with the granular material is used for various sports grounds, walking paths, and gardens. It is used as a field for various applications.

[0003] In the case of this kind of artificial lawn, when exercising on the artificial lawn, watering or raining, the peripheral edge of the artificial lawn or the sprinkler, sprinkler, drainage ditch, competition pole for the artificial lawn is used. The granular filler flows into gaps and recesses in the peripheral portion of the equipment installation portion such as a buried pipe, and the lawn leaves in this portion are set, causing various troubles. For example, a lid is fitted in a concave portion of an instrument setting portion in an artificial lawn so that a foot is not hooked on the concave portion when not in use, and an artificial lawn is also laid on an upper surface of the lid. When such a lid is opened and closed, the granular filler flows into the gap between the instrument installation part and the lid, and the lid cannot be completely closed or the recess is clogged. Also, with the opening and closing of the lid, the turf leaves at the peripheral edge are cut into the gap and fall down, and the fallen turf leaf is caught in the gap of the lid, and the lid may not be completely closed.

In addition, at the peripheral edge of the artificial grass, the granular filler is scattered on the site outside the artificial grass to impair the aesthetic appearance, the discharged granular filler accumulates in a drain, or the granular The amount of the filler decreases, and the feeling of landing deteriorates. In order to prevent the outflow of the particulate filler and to prevent the setting of the lawn leaves in this part, the lawn leaves at the edge of the artificial lawn and / or the periphery of the equipment installation part are replaced with the lawn leaves in other parts. Japanese Patent Application Laid-Open No. 1-84304 and Japanese Utility Model Application Laid-Open No. 3-79308 disclose a granular-filled artificial lawn in which the number density of planting is larger than that of Japanese Patent Application Laid-Open No. 1-84304 and 3-79308.

[0005] However, increasing the number of turf leaves planted in this way has been improved, but requires much time and effort to manufacture artificial turf. This is because two artificial grasses having different plant leaf number density basically need to be manufactured by different manufacturing machines and / or different manufacturing processes.

[0006]

SUMMARY OF THE INVENTION The present invention has been made to solve the above-mentioned conventional problems, and has been made in order to solve the above-mentioned problems. And / or an artificial lawn used as a surface surface of a field which can efficiently manufacture an artificial lawn having a turf-leaf layer hardly entering particulate matter used in a surface layer of an instrument installation part in one production process with one tufting machine. The purpose of the present invention is to provide a production method.

[0007]

SUMMARY OF THE INVENTION The present invention is a method for producing an artificial turf having a turf leaf layer filled with particulate matter and a turf leaf layer on at least one side of the turf leaf which is hard to enter the particulate matter.
To one planting machine, at least one side is supplied with turf-leaf such that the average deemed surface area per unit volume of the turf-leaf layer is larger than the turf-leaf supplied to the other part. ,
This is a method for producing an artificial turf in which turf leaves are simultaneously planted on a backing base fabric having a predetermined width to form a turf leaf layer, and the back surface of the backing base fabric is backed and fixed.

In the present invention, the average deemed surface area S of turf yarn in a unit volume of a turf leaf layer is a value satisfying the following equation. S = L × N × H (1) In the formula (1), L is the average deemed cross-sectional circumference of the turf-leaf yarn, N
Is the number of turf yarns per unit area (planting number density), and H is the average turf yarn length per unit thickness of the turf leaf layer.

(1) In the present invention, the average deemed cross-sectional perimeter of grass leaf yarn is the average of the cross-section perimeters of the smallest of the rectangular parallelepipeds containing the contour figure of grass leaf yarn. For example, as shown in FIG. 3, it means the average of the cross-sectional perimeters of the smallest rectangle T among the rectangles including the contour figure of the grass leaf thread I in a straightened state. In the case where the turf-leaf yarn is formed by twisting a plurality of single yarns, the average deemed transverse cross-sectional perimeter L of the turf-leaf yarn is the total value of the twisted single yarns. As is clear from equation (1), increasing the average deemed cross section perimeter of the grass leaf yarn increases the surface area of the grass leaf yarn alone. The average length H of the turf yarn refers to an average length of the turf yarn in a unit thickness of the turf leaf layer in a state where the turf yarn is straightened, and is equal to or larger than the thickness of the turf leaf layer.

The turf-leaf forming the turf-leaf layer, which is hard to enter the granular material used in the peripheral portion of the end of the field and / or the peripheral portion of the equipment installation portion, is a turf-leaf layer which fills the other portion of the granular material. A turf-leaf having an average deemed surface area larger than that of the turf-leaf forming the turf-leaf, for example, a turf-leaf having a larger crimp is used. This means that the former turf is denser in a smaller thickness area than the latter.
Therefore, the effect of hindering the movement of the granular filler is great, and the outflow of the granular filler can be prevented, and the settling of the turf leaves is less likely to occur. The turf leaf layer used as the surface layer of the peripheral portion of the terminal of the field and / or the peripheral portion of the device installation portion is provided with a cushioning material between the laying base layer and the other portion of the turf leaf layer. By making the height level of the grass leaf surface substantially the same, it is possible to obtain a field in which the user can safely exercise and walk without any surface step. Furthermore, since the length of the extended grass leaf yarns is substantially the same, and the density of the number of planted grass leaf yarns is substantially the same, this makes it possible to combine two types of artificial grass. Can be efficiently manufactured simultaneously in one manufacturing process of the manufacturing machine.

[0011] Turf yarn containing a polyamide resin as a main component is easy to obtain a particularly large crimp rate and has a property that it is hard to set, so that the field terminal peripheral portion and / or equipment in the field of the present invention. It is most suitable as a turf leaf thread forming a turf leaf layer at the periphery of the ground contact part. Also, in the case of artificial grass, the lawn yarn mainly composed of polyamide resin has a potential for crimping during the planting of the lawn yarn, and a heating process for fixing the backing of the lawn yarn. Since the crimping becomes apparent in the above, the frictional resistance of the thread applied to the yarn guide tube and the sewing needle at the time of the planting process is relatively close to that of the non-crimped thread, and the two types of turf leaf layers according to the present invention are combined into one unit. It can be efficiently manufactured simultaneously in one manufacturing process of the manufacturing machine.

[0012] As a lawn leaf yarn having an average deemed surface area larger than a lawn leaf yarn forming a lawn leaf layer filled with particulate matter,
Even with the same capacity than the former, the average turf yarn length (H) per unit thickness of the turf leaf layer is large, such as the one with a large crimp;
Those having a large degree of flattening and a large average deemed cross-sectional circumference are used.

[0013]

The method for producing an artificial turf of the present invention is a method for producing an artificial turf having a turf leaf layer filled with a granular material and a turf leaf layer on at least one side of the turf layer where the granular material is difficult to enter. At least one side portion of the planting machine is supplied with turfleaf having a larger average deemed surface area than the turfleaf supplied to the other portion, and the turfleaf is provided on a backing backing cloth having a predetermined width. After the yarn is simultaneously planted to form a turf leaf layer, the back surface of the backing backing fabric is fixed with a backing, so that the turf leaf layer is filled with the granular material, and the turf is hard to enter the granular material on at least one side. An artificial turf having two types of turf leaf layers composed of leaf layers can be efficiently produced simultaneously in one production process of one production machine.

[0014]

Embodiments of the present invention will be described below with reference to the drawings. FIG. 1 is an explanatory diagram illustrating a manufacturing process of an example of a method for manufacturing an artificial lawn according to the present invention. In FIG. 1, reference numeral 115 denotes a non-crimped turf leaf yarn for forming a turf leaf layer filled with particulate matter laid on a surface layer of a normal portion of a field, and is generally a polypropylene resin having a denier of about 2000 to 20,000, A non-crimped yarn such as a split yarn or a modified cross-section monofilament made of a synthetic resin having good weather resistance such as a polyethylene resin or a polyamide resin is preferably used.

On the other hand, reference numeral 116 denotes a crimped turf leaf yarn for forming a turf leaf layer which is hardly filled with particulate matter and is laid on the surface layer of the peripheral portion of the terminal of the field and / or the peripheral portion of the device installation portion, and is made of polyamide. Monofilament high crimped yarns containing a base resin as a main component are preferably used. These turf yarns are typically wound on cone paper tubes that are beveled for easy extraction. Normally, non-crimped grass leaf 115
And about 465 crimped turf leaf yarns 116 are set in total. As the tufting machine (planting machine) 12, a sewing machine that sets about 465 sewing needles 121 in a horizontal row at a pitch of 16 per 5 inches and produces an artificial turf having a width of about 3.66 m is preferably used. Is done.

The non-crimped turf needle 115 and the crimped turf needle 116 are each passed through a roller or a yarn guide tube to form a tufting machine 12.
, And planted at regular intervals on the backing base cloth 113 and cut into a fixed length to form crimp-free turf leaves 111 and crimp-turf leaves 112. At that time, the non-crimped turf leaf yarn 115 is supplied to most of the width of the tufting machine 12,
A crimped turf leaf thread 116 is supplied to one side thereof to plant each turf leaf. The planting density of the non-crimped turf needle 115 and the crimped turf needle 116 is 16 per 5 inches which is the pitch of the sewing needle 121 in the horizontal direction, and 2 to 10 per 1 inch in the vertical direction. More preferably, the number is set to 3 to 6. In addition, the length when the non-crimped turf needle 115 and the crimped turf needle 116 are stretched is generally about 10 to 40 mm. Non-crimped turf needle 115 and crimped turf needle 1
The base fabric 14 on which the base material 16 is planted is coated with a synthetic rubber latex or the like by a coating roll 15 or the like on the back surface thereof. The backing is fixed to 113 to obtain the target artificial grass 11.

As shown in FIG. 2, the artificial turf 11 thus obtained has an area of the non-crimped artificial turf 17 in which only the non-crimped turf leaf 111 is planted and only the crimped turf leaf 112 is planted. The region of the crimped artificial grass 18 is formed with a constant width. The thickness of the turf leaf layer is usually about 10 to 40 mm for the non-crimped artificial lawn 17 and about 30 to 40 mm for the crimped artificial lawn 18.
About 80% is preferable. FIG. 1 shows a preferred example of the manufacturing method of the present invention, and the present invention is not limited to this.

For example, the turf yarn forming the turf layer that fills the particulate matter laid in the normal part of the field need not be crimp-free. If the turf yarn forming the turf leaf layer, which is hardly filled with the filler, laid on the periphery of the terminal of the field and / or the periphery of the device installation section, the average deemed surface area is larger than the former, for example, the crimping is large. I just need. In FIG. 1, the production by tufting has been described, but the invention can also be applied to a production method using other known planting machines such as Russell. The production width of artificial turf, the horizontal pitch of sewing needles, or the pitch of turf leaves can also be arbitrarily selected. In FIG.
Although an example is shown in which synthetic rubber latex or the like is used as a material for backing and fixing turf leaves to a backing base fabric, various materials such as a molten resin and a solvent-based adhesive can be applied. The main component of the crimped turf leaf yarn is not limited to the polyamide resin.

[0019]

EXAMPLES Examples of the present invention and comparative examples are shown below. Example 1 In the manufacturing process described with reference to FIG. 1, an artificial turf having two turf-leaf layer regions having different turf-leaves within a product width was manufactured by tufting. As the turf yarn for the non-crimped turf leaf 111, a monofilament having a profile of 7200 deniers was prepared by twisting 16 monofilaments having an irregular cross section mainly composed of polypropylene. In order to provide this for tufting, it is wound around a cone paper tube divided into small portions, and
Five corns were prepared. As the turf yarn for the crimped turf leaf 112, a material obtained by subjecting a raw yarn of the turf leaf for the turf leaf 111 to a steam set crimping process (a crimp rate of 40%) was prepared. This was divided in the same manner as above to prepare 30 cones.

A level cut and tufting machine 12 having a tuftable width of 3.7 m, in which the pitch of the sewing needles is 16 between 5 inches, is attached to the above-mentioned turf yarn and curl for the non-crimped turf leaf 111. A total number of turf-leaf yarns for the shredded turf-leaf 112 are set by dividing the area, and the plain woven fabric 11 made of polypropylene yarn is used.
Grass leaves were planted on 3 at a cut length of 26 mm and a vertical sewing pitch of 5.4 per inch. Then, SBR latex was added to the back of the finished woven fabric.
It was applied in an amount of 1 kg per m ^{2 and} passed through an oven dryer set at about 125 ° C. for 13 minutes to be heated and solidified. As a result, the width of the planting area of the non-crimped turf leaf 111 is 344 cm, the width of the planting area of the crimped turf leaf 112 is 24 cm,
1. The thickness of the turf leaf layer and the length when the crimped turf leaf 112 is stretched are about 25 mm, and the thickness of the turf leaf layer of the crimped turf leaf 112 is about 16 m
m artificial turf having two types of turf leaf layers in different use areas could be obtained in one tufting step. At this time, the average deemed surface area (S) for forming the non-crimped lawn leaf 111 was 7.63 cm ² by the following calculation. S = (0.178cm) × (16 present) × (2.679 present ^{/ cm 2) × (1cm)} ≒ (7.63cm 2) Average regarded surface area to form a crimp ShibaYo 112 (S) is,
According to the following calculation, it was 11, 92 cm ² . S = (0.178 cm) × (16 lines) × (2.679 lines / cm ² ) × (25/16 cm) ≒ (11.92c
m ² )

Example 2 The lawn yarn of the crimped lawn leaf 112 in Example 1 was made of nylon 6, 6 and a modified monofilament having a cross section of 24 was used.
An artificial turf was manufactured in the same manner as in Example 1 except that the twentieth twisted denier was changed to a steam set crimping process (crimp ratio: 45%). The thickness of the turf layer of the obtained crimped turf leaf 112 was 14 mm. Also in this case, the production was performed smoothly with one machine and one process in the same amount of time and labor as in the production of ordinary artificial grass using only one kind of yarn.

[0022] The grass height for non-crimp ShibaYo 111 in Comparative Example 1 Example 1 465
Prepare a cone and use only this thread, first Example 1
An artificial turf having the same specifications as that of the non-crimped artificial turf was manufactured with a width of 3.68 m. Next, by changing the setting of the tufting machine 12, the vertical sewing pitch of the turf leaves is increased by 40%, and the other tufting specifications are not changed. It was manufactured with a width of 68 m. The obtained non-crimped high-density artificial turf has a horizontal sewing pitch of about 8 turf leaves.
mm (16 pieces per 5 inches), the vertical stitching pitch was about 3.4 mm (7.5 pieces per inch), and the vertical and horizontal balance was lost, giving the appearance of streaking in the vertical direction.

Comparative Example 2 First, as in Comparative Example 1, a non-crimped artificial turf having a planting pitch of about 8 mm in the lateral direction of turf leaves was produced with a width of 3.68 mm. Next, after removing all the raw yarns for turf leaves from the tufting machine 5, and further removing all sewing needles, loopers, cutters, etc., a new high-density sewing machine is used so that the pitch of the sewing needles becomes 32 per 5 inches. A set of 930 sewing needles, loopers, cutters, etc. is attached, and 12 monofilament monofilaments mainly composed of nylon 6 and 6 are twisted into 4500 denier to obtain a steam set type crimping process (crimping). A 930 cone of yarn having a 25% ratio was set. It took two days for these conversion and thread changing work. After tufting and backing,
Approximately 4 mm of horizontal thread planting pitch, approximately 3 mm of vertical thread planting pitch, 17 mm length when turf leaves are stretched,
A high-density crimped artificial lawn having a lawn leaf layer thickness of 14 mm was prepared. At that time, about 30 g of yarn was consumed on average per cone in cueing the yarn and setting the conditions.

[0024]

Since the present invention has been made as described above, the turf leaf layer to be filled with the granular material and the granular material used for the terminal peripheral portion of at least one side portion thereof and / or the surface layer of the appliance installation portion are provided. The hard-to-enter turf is used as a field surface layer in which artificial turf having layers can be efficiently manufactured by one tufting machine in one manufacturing process.

[Brief description of the drawings]

FIG. 1 is an explanatory diagram illustrating a manufacturing process of an example of a method for manufacturing an artificial lawn according to the present invention.

FIG. 2 is a perspective view showing an example of an artificial turf produced by the method for producing an artificial turf of the present invention.

FIG. 3 is a cross-sectional view for explaining an average deemed transverse cross-section perimeter of turf yarn in the present invention.

[Explanation of symbols]

 11 Artificial lawn 12 Tufting machine (planting machine) 111 Non-crimped turf leaf 112 Crimped turf leaf 113 Base cloth

Claims (1)

[Claims] 1. A method for producing an artificial turf having a turf leaf layer filled with a granular material and a turf leaf layer on at least one side of the turf leaf, wherein the granular material is difficult to enter. On one side, turf leaves are supplied such that the average deemed surface area per unit volume of the turf layer is larger than the turf fibers supplied to the other portions, and the backing fabric having a predetermined width is supplied to the backing fabric. A method for producing an artificial turf, characterized in that the turf yarns are simultaneously planted to form a turf leaf layer, and the back surface of the backing fabric is fixed with a backing.