Fully extruded coated artificial grass system with a laminated structure woven with double-needle pre-tufting

Abstract

The present invention relates to a full-extrusion coated artificial turf system having a laminated structure woven by double needle pre-tufting, comprising an artificial turf mat (100) in an artificial turf system, wherein the artificial turf mat (100) comprises: a triple embossed fabric (110) located on top; a foam sheet (120) provided below the triple embossed fabric (110); a glass scrim sheet (130) attached below the foam sheet (120) by full-extrusion coating; and a pile (140) woven into the triple embossed fabric (110) and the foam sheet (120) by double needle pre-tufting.

Description

Technology Field

[0001] The present invention relates to an artificial turf system. In particular, the present invention relates to an artificial turf system that can improve the straightness and durability of artificial turf piles by tufting with double needles, increase shock absorption by using an embossed layer fabric, improve pull-out resistance performance by using a full-surface extrusion coating combined with a glass fiber sheet, and reduce the occurrence of defects caused by shrinkage and expansion. Background Technology

[0002] Artificial turf is a synthetic fiber product made to mimic the shape and texture of natural grass. It is widely used in sports facilities such as soccer fields, baseball fields, futsal courts, tennis courts, and gateball courts, and is also utilized for various purposes including walking paths, landscaping, and interior construction.

[0003] Artificial turf is widely used because, unlike natural grass, it does not require fertilization or weeding, remains green throughout all four seasons, and can be installed on various surfaces such as soil and concrete.

[0004] Artificial turf must be able to absorb shock from users running or falling, the fibers must not be pulled out, and it must have a certain level of durability.

[0005] However, conventional artificial turf lacked shock absorption performance, which sometimes resulted in users falling and sustaining injuries. Additionally, the tensile strength, pull-out strength, wear resistance, and resilience of the artificial turf piles were insufficient, leading to cases where piles deteriorated or wore away, resulting in missing or insufficient sections after a certain period of use. Furthermore, repeated shrinkage and expansion caused by temperature and humidity changes sometimes resulted in cracking, lifting, or peeling at the joints.

[0006] Conventional artificial turf often featured a structure in which PE yarns were woven into a foamed sheet and then fixed with an SBR latex coating; however, recently, a structure has been developed in which PE or PET sheets are heat-fused using PE powder instead of SBR latex.

[0007] Conventional SBR latex coatings make it difficult to recycle artificial turf, and since SBR latex must be mixed with silica sand for drying, the pull-out strength is reduced when submerged, leading to severe pile pulling, and there was a problem with reduced long-term durability of the artificial turf due to prolonged rain during the summer.

[0008] Although PE and PET heat-fusion coated products partially compensated for the shortcomings of SBR latex, if the heat from the heat roller used was inconsistent or the PE powder was not adhered evenly, insufficient tensile strength and unevenness occurred, and delamination of the air bubbles appeared in some sections. Furthermore, severe shrinkage and expansion of the PE and PET sheets bonded to bond the PE yarn caused frequent separation of the artificial turf joints, resulting in defects in the artificial turf and even causing injuries to users.

[0009] Therefore, there was a need to develop an artificial turf system with minimal pile pullout and excellent shock absorption performance and durability. Prior art literature

[0010] Korean Registered Patent Publication No. 10-2851063 The problem to be solved

[0011] To improve upon the problems of the prior art described above, the present invention aims to provide an artificial turf system capable of improving shock absorption and durability, and a method for manufacturing the same.

[0012] The present invention aims to provide an eco-friendly and functional artificial turf system and a method for manufacturing the same, which has strong tensile strength and immersion tensile strength of artificial turf piles, minimal deformation due to shrinkage and expansion, and is free of heavy metals. means of solving the problem

[0013] In the present invention, an artificial turf system comprises an artificial turf mat (100), wherein the artificial turf mat (100) comprises a triple embossed fabric (110) positioned on top; a foam sheet (120) provided below the triple embossed fabric (110); a glass scrim sheet (130) provided below the foam sheet (120); and a pile (140) woven through pre-tufting on the triple embossed fabric (110) and the foam sheet (120), thereby providing a full-face extrusion coated artificial turf system having a laminated structure woven by double needle pre-tufting.

[0014] The pile (140) is woven through the laminated triple embossed fabric (110) and the foam sheet (120), and after extruding and applying a synthetic resin to the lower surface of the foam sheet (120), the glass scrim sheet (130) is attached to the lower surface of the foam sheet (120) by front extrusion coating, thereby forming a front extrusion coating layer (101) between the foam sheet (120) and the glass scrim sheet (130). The weaving of the pile (140) into the triple embossed fabric (110) and the foam sheet (120) is characterized by being carried out by a double needle structure (10).

[0015] The above double needle structure (10) comprises a needle bar (11); a leading needle (12) and a trailing needle (13) each provided in a row below the needle bar (11), wherein the leading needle (12) pre-perforates the triple embossed fabric (110) and the foam paper (120), and the trailing needle (13) weaves a pile (140) at the location pre-perforated by the leading needle (12).

[0016] The above triple embossed fabric (110) is woven into a grid so that a cross-section of a three-layer structure is repeatedly connected to form it.

[0017] The above glass scrim sheet (130) is structured such that a grid-shaped glass fiber reinforcement layer is laminated on a spunlaid type polyester nonwoven fabric heat-bonded with a dual-component continuous filament having polyester as the core and polyamide 6 (PA-6) as the skin.

[0018] A filler layer (200) may be provided on the above triple embossed fabric (110).

[0019] The above filler layer (200) includes at least one of a silica sand layer, an elastic chip layer, and a natural chip layer.

[0020] A pad layer (300) may be provided under the artificial turf mat (100) above.

[0021] The above pad layer (300) includes a shock-absorbing pad or a drainage plate.

[0022] An aggregate layer (400) or a concrete layer (500) may be provided under the artificial turf mat (100).

[0023] An aggregate layer (400) or a concrete layer (500) may be provided below the pad layer (300).

[0024] The present invention provides a method for manufacturing an artificial turf mat having a laminated structure woven by double needle pre-tufting, comprising the steps of: a) preparing a triple embossed fabric (110), a backing sheet (120), and pile (140); b) weaving pile (140) onto the triple embossed fabric (110) and backing sheet (120); and c) attaching a glass scrim sheet (130) to the lower surface of the backing sheet (120).

[0025] The above step (c) is characterized by extruding and applying a synthetic resin to the lower surface of the bubble sheet (120), and then attaching the glass scrim sheet (130) to the lower surface of the bubble sheet (120) by full-surface extrusion coating.

[0026] Step b) above is carried out by a double needle structure (10) comprising a needle bar (11); a leading needle (12) and a trailing needle (13) each arranged in a row below the needle bar (11), wherein the leading needle (12) perforates the triple embossed fabric (110) and the foam paper (120), and the trailing needle (13) weaves a pile (140) at the location perforated by the leading needle (12).

[0027] The above triple embossed fabric (110) is woven into a grid so that a cross-section of a three-layer structure is repeatedly connected to form it.

[0028] The glass scrim sheet (130) is formed with a structure in which a grid-shaped glass fiber reinforcement layer is laminated on a spunlaid-type polyester nonwoven fabric heat-bonded with a dual-component continuous filament having polyester as the core and polyamide 6 (PA-6) as the skin, and in step c), the glass scrim sheet (130) is supplied from top to bottom by a turret-type automatic feeding device.

[0029] The present invention provides a front extrusion-coated artificial turf mat having a laminated structure woven by double needle pre-tufting, comprising: a triple embossed fabric (110) located at the top; a foam sheet (120) provided below the triple embossed fabric (110); a glass scrim sheet (130) provided below the foam sheet (120); and a pile (140) woven into the triple embossed fabric (110) and the foam sheet (120), wherein the pile (140) is woven through the laminated triple embossed fabric (110) and the foam sheet (120), and after extruding and applying a synthetic resin to the lower surface of the foam sheet (120), the glass scrim sheet (130) is attached to the lower surface of the foam sheet (120) by front extrusion coating.

[0030] The weaving of pile (140) on the above triple embossed fabric (110) and air-filled paper (120) is characterized by being carried out by a double needle structure (10).

[0031] The above double needle structure (10) comprises a needle bar (11); a leading needle (12) and a trailing needle (13) each provided in a row below the needle bar (11), wherein the leading needle (12) perforates the triple embossed fabric (110) and the foam paper (120), and the trailing needle (13) weaves a pile (140) at the location perforated by the leading needle (12).

[0032] The above triple embossed fabric (110) is woven into a grid so that a cross-section of a three-layer structure is repeatedly connected to form it.

[0033] The above glass scrim sheet (130) is structured such that a grid-shaped glass fiber reinforcement layer is laminated on a spunlaid type polyester nonwoven fabric heat-bonded with a dual-component continuous filament having polyester as the core and polyamide 6 (PA-6) as the skin.

[0034] The present invention provides a method for constructing an artificial turf system having a laminated structure woven by double-needle pre-tufting, comprising the steps of: a) preparing the artificial turf mat; b) leveling the original ground and then laying the artificial turf mat on top of the original ground; and c) connecting a plurality of laid artificial turf mats.

[0035] After step c) above, the method may further include a step of laying a filler on top of the artificial turf mat to form a filler layer (200).

[0036] The above filler layer (200) may include at least one of a silica sand layer, an elastic chip layer, and a natural chip layer.

[0037] Before step b) above, the method may further include a step of providing a pad layer (300) under the artificial turf mat.

[0038] The above pad layer (300) includes a shock-absorbing pad or a drainage plate.

[0039] Prior to step b) above, the method may further include a step of providing an aggregate layer (400) or a concrete layer (500) under the artificial turf mat.

[0040] Prior to step b) above, the method may further include the step of providing an aggregate layer (400) under the artificial turf mat and a pad layer (300) on top of the aggregate layer (400).

[0041] Prior to step b) above, the method may further include the step of providing a concrete layer (500) under the artificial turf mat and providing a pad layer (300) on top of the concrete layer (500). Effects of the invention

[0042] The present invention has the following effects.

[0043] First, by laminating a triple-embossed fabric on top of the artificial turf mat, the shock absorption of the artificial turf mat is improved, and the temperature of the sports field surface can be reduced during the summer due to its hygroscopic properties.

[0044] Second, by attaching a glass scrim sheet to the bottom of the foam sheet through full-surface extrusion coating, the problems of reduced tensile strength and uneven tensile strength, which are disadvantages of conventional latex coating and heat fusion coating, can be improved. Additionally, since it has properties that are resistant to shrinkage and expansion, the strength of the joint area can be increased, thereby reducing various problems caused by shrinkage and expansion.

[0045] Third, in order to facilitate the tufting of a thick triple-embossed fabric, a weaving method using double needles has been devised. The weaving method using double needles of the present invention improves weaving stability by having a leading needle pre-perforate the pile and then having a trailing needle insert the pile into the pre-perforated hole and weave, prevents the needle from overheating, and prevents excessive tensile force from being generated in the pile during weaving, thereby significantly improving the straightness and durability of the artificial turf pile.

[0046] The effects of the present invention are not limited to those mentioned above, and other unmentioned effects will be clearly understood by a person skilled in the art from the description in the claims. Brief explanation of the drawing

[0047] FIG. 1 is a cross-sectional view of an embodiment of the artificial turf mat of the present invention having a filler layer. FIG. 2 is an embodiment of FIG. 1 in which a pad layer is additionally provided. FIG. 3 is an embodiment of FIG. 2 in which an aggregate layer is additionally provided. FIG. 4 is an embodiment of FIG. 2 in which a concrete layer is additionally provided. FIG. 5 is an embodiment of FIG. 1 in which an aggregate layer is additionally provided. FIG. 6 is an embodiment of FIG. 1 in which a concrete layer is additionally provided. Figure 7 is an example of an artificial turf mat of the present invention. FIG. 8 is an embodiment of FIG. 7 in which a pad layer is additionally provided. FIG. 9 is an embodiment of FIG. 8 in which an aggregate layer is additionally provided. FIG. 10 is an embodiment of FIG. 8 in which a concrete layer is additionally provided. FIG. 11 is an embodiment of FIG. 7 in which an aggregate layer is additionally provided. FIG. 12 is an embodiment of FIG. 7 in which a concrete layer is additionally provided. FIG. 13 is a perspective view of the double needle structure of the present invention. Figure 14 illustrates a process for manufacturing an artificial turf mat according to the present invention. Fig. 15 is an enlarged view of part A of Fig. 14. FIG. 16 is a plan view and a cross-sectional view of the triple embossed fabric of the present invention. A triple embossed fabric with a three-layer structure is illustrated. FIG. 17 is a plan view of the glass scrim sheet of the present invention. Specific details for implementing the invention

[0048] Embodiments of the present invention are described in detail below with reference to the attached drawings so that those skilled in the art can easily implement the invention. However, the present invention may be embodied in various different forms and is not limited to the embodiments described herein. Furthermore, in order to clearly explain the present invention in the drawings, parts unrelated to the explanation have been omitted, and similar parts throughout the specification are given similar reference numerals. Throughout the specification, when a part is described as "comprising" a certain component, this means that, unless specifically stated otherwise, it does not exclude other components but may include additional components. Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the attached drawings.

[0049] The present invention relates to an artificial turf system with excellent shock absorption performance and durability, and a method for manufacturing the same.

[0050] Specifically, the invention relates to an artificial turf mat based on dual-needle pre-tufting and having a triple embossed fabric layer and a full-surface extrusion coating structure, an artificial turf system in which such an artificial turf mat is laid, and a method for manufacturing the same.

[0051] The present invention relates to an artificial turf mat in which a triple-embossed fabric is laminated on top of a foam sheet, artificial turf pile is woven using a dual-needle pre-tufting method, synthetic resins such as PE, EVA, PP, and PA are coated on the lower part of the foam sheet using a melt extrusion method, and a glass scrim sheet is attached.

[0052] The triple-woven embossed fabric with an embossing structure used in the artificial turf mat of the present invention has excellent shock absorption performance, and the full-surface extrusion coating using a glass scrim sheet improves the disadvantages of existing latex or heat fusion methods to enhance tensile strength and immersion tensile strength, maintains uniform tensile strength throughout the artificial turf pile yarn, has excellent resistance to deformation due to shrinkage and expansion, can reduce the occurrence of defects, and has the advantage of being easy to recycle.

[0053] The artificial turf system of the present invention, which has excellent shock absorption performance and durability, may include an artificial turf mat (100), a filler layer (200), a pad layer (300), an aggregate layer (400), and a concrete layer (500). The filler layer (200), the pad layer (300), the aggregate layer (400), and the concrete layer (500) may be combined in various ways.

[0054] The artificial turf mat (100) may include a triple embossed fabric (110), a foam sheet (120), a front extrusion coating layer (101), a glass scrim sheet (130), and a pile (140).

[0055] The above triple embossed fabric (110) is located at the top of the mat layer.

[0056] The warp (length direction of the fabric) of the above triple embossed fabric (110) can be provided by sizing PET 100~300d / 48~96f DTY (Draw Textured Yarn) yarn (d / f: denier / filament).

[0057] The weft yarn (in the width direction of the fabric) of the above triple embossed fabric (110) can be provided by sizing PET 100~300d / 48~96f DTY (Draw Textured Yarn) yarn.

[0058] The warp density of the triple embossed fabric (110) can be 104 to 128 / inch, the weft density can be 153 to 187 / inch, and the weight of the triple embossed fabric (110) can be 324 to 396 grams / yard.

[0059] A triple-embossed fabric woven through a water jet weaving machine is laminated onto a foam sheet, and an artificial turf pile (140) is woven.

[0060] Using triple-embossed fabric allows it to act as a thin pad alongside the synthetic resin full-face extrusion coating on the underside of the artificial turf, thereby cushioning impact and improving the shock absorption of the artificial turf. Additionally, due to its hygroscopic properties, it can reduce the temperature rise of the artificial turf ground during the summer. Furthermore, by being organically combined with the full-face extrusion coating structure, it enhances pile tensile strength, thereby improving the long-term durability of the artificial turf.

[0061] Although conventional artificial turf woven on 5mm or 10mm pads had no issues with shock absorption performance, it was difficult to wind more than 30 to 40m during production, and due to the characteristics of artificial turf fields requiring a length of 60 to 70m, joints had to be joined during construction. As a result, defects (such as separation and lifting) caused by multiple joints inevitably occurred, leading to problems that caused injuries to users, degraded the condition of the field, and reduced long-term durability.

[0062] In order to solve these problems, the present invention laminates a triple-embossed fabric having a three-layer structure that is thinner than conventional materials but has excellent shock absorption performance, thereby improving the shock absorption of the artificial turf mat and enabling it to be wound up to 60 to 70 meters or more during processing, which minimizes joints in the artificial turf sports field, facilitates construction, and reduces the occurrence of defects.

[0063] The triple embossed fabric (110) of the present invention has a structure in which a cross-section of a three-layer structure is repeatedly connected as shown in FIG. 16, and is woven in a grid on a flat basis.

[0064] In addition, since the PET yarn used in the triple-embossed fabric of the present invention is recycled yarn, it can exhibit the advantages of being environmentally friendly and recycling resources.

[0065] The above triple embossed fabric (110) can be produced as a fabric having a three-layer structure by inputting a weaving card into a weaving machine and following the process.

[0066] It can be produced through a sizing process that beams DTY yarn, a process of connecting warp threads to heddles and bodies according to the weave (warp threading process), a process of weaving by blowing weft threads with water on a weaving machine (weaving process), and a process of checking and inspecting defects and specifications of the woven fabric (inspection process).

[0067] The above-mentioned foam sheet (120) is laminated below the triple-embossed fabric (110) and woven together with the triple-embossed fabric (110) by a pile (140).

[0068] The above bubble sheet (120) can be made of 100% polypropylene (PP) or olefin-based synthetic resin by weight.

[0069] You can select the weight of the foam sheet depending on the intended use of the sports field, ranging from 100 to 180 g / m² 2 A substance of this type may be used, preferably 130~150g / m² 2 You can use the one.

[0070] The above glass scrim sheet (130) is a sheet made of glass fiber in a grid (net) shape, and is lightweight, has excellent tensile strength, heat resistance, and shrinkage resistance, is resistant to impact, and has low elongation.

[0071] In the present invention, the glass scrim sheet (130), which has excellent strength and durability, is attached to the underside of the foam sheet using a full-surface extrusion coating method, thereby preventing deformation of the entire artificial turf mat and suppressing shrinkage and expansion of the artificial turf mat due to temperature and humidity changes, thereby preventing the joint portions of the mat from separating or the artificial turf mat from lifting, and improving the structural stability and tensile strength of the entire artificial turf mat.

[0072] The glass scrim sheet (130) is provided below the bubble sheet (120), and unlike the conventional heat fusion method, it is attached below the bubble sheet (120) by a synthetic resin full-surface extrusion coating method.

[0073] The above glass scrim sheet (130) is composed of a structure in which a grid-shaped glass fiber reinforcement layer is laminated on a spunlaid type polyester nonwoven fabric heat-bonded with a dual-component continuous filament having polyester as the core and polyamide 6 (PA-6) as the skin.

[0074] The weight of the glass cream sheet (130) is 78 to 148 g / m² 2 A substance of this type may be used, preferably 90 to 110 g / m² 2 You can use the one.

[0075] The thickness of the glass scrim sheet (130) may be 0.60 to 0.80 mm, and the width of the glass scrim sheet (130) may be 3.9 to 4.1 m.

[0076] The tensile strength of the glass scrim sheet (130) is 235 to 515 N / (5 cm length) in the warp (length) direction and 180 to 430 N / (5 cm length) in the weft (width) direction.

[0077] The maximum stress of the glass fibers included in the glass scrim sheet (130) is 260 to 370 N / (5 cm length) in the inclined (length) direction.

[0078] The above file (140) is woven into a laminated triple-embossed fabric (110) and a foam sheet (120).

[0079] The above file (140) uses polyethylene resin as the main material, and can be manufactured by blending octene (side body length-C8), hexene (side body length-C6), and butene (side body length-C4) based LLDPE (linear low-density polyethylene) and HDPE (high-density polyethylene) in a weight ratio of 7:3, 8:2, or 9:1, or can be manufactured with 100% LLDPE only.

[0080] A small amount of LDPE (low-density polyethylene) can also be mixed and used.

[0081] Based on 100 parts by weight of the above blended polyethylene, 3 to 7 parts by weight of a color masterbatch (including color pigments, UV agents, and antioxidants) and 3 to 7 parts by weight of an FR masterbatch (flame retardant) are mixed, and after extrusion, stretching, and drying, the PET DTY (Draw Textured Yarn) yarn is wrapped (a step of wrapping the pile for weaving) or twisted before winding. At this time, various additives may be applied to the yarn as masterbatches for special effects or functionality.

[0082] As explained above, piles can primarily be manufactured using PE (polyethylene) resin as the main material, but they are not necessarily limited to this; various synthetic resins such as PA and PP may also be used depending on the type and application of the sports field.

[0083] When weaving the pile described above on a tufting machine, straight pile or crimped pile can be woven individually, straight pile and crimped pile can be woven in a 1x1 form (one row straight and one row crimped on the loom), straight pile and crimped pile can be woven in a twisted form, and various other structures can be woven.

[0084] Pile weaving by the dual-needle pre-tufting method of the present invention is performed by a dual-needle structure (10).

[0085] The above double needle structure (10) includes a needle bar (11), a leading needle (12) and a trailing needle (13) each arranged in a row below the needle bar (11).

[0086] The above double needle structure (10) is a device devised by boring two types of needles, rather than one type of needle, into a needle bar (11) so that they can pass through the triple embossed fabric (110) and the foam sheet (120) in order to weave the thick triple embossed fabric used in the present invention.

[0087] In order to solve the problem where the needle has difficulty passing through (piercing) the triple-embossed fabric (110) and the base paper (120) during tufting due to the density of the triple-embossed fabric, and the pile is deformed or stretched due to heat and stress during the passing process, thereby worsening the straightness and reducing the durability of the artificial turf pile, the present invention devises a double needle structure (10) so that the leading needle (12) can easily weave through pre-tufting (a process of pre-punching the triple-embossed fabric (110) and the base paper (120) through the leading needle to facilitate weaving), thereby improving the straightness and durability of the artificial turf pile along with the shock absorption performance effect of the triple-embossed fabric (110).

[0088] The trailing needle (13) (the needle that actually weaves) has a diameter of Ø3.5 to 5.5 mm, and the leading needle (12) for facilitating weaving has a diameter of Ø3 to 5 mm.

[0089] The power of the tufting machine uses a motor of at least 15kW or more and can be driven by an inverter of 20kW or more.

[0090] Power supply should be 380V / 50~70Hz, but 60Hz is suitable due to domestic power conditions.

[0091] Since the leading needle (12) is intended to punch a thick triple-embossed fabric as a preceding process, the length of the leading needle (12) may be shorter than the length of the trailing needle (13).

[0092] Weaving using the dual-needle pre-tufting method can be carried out through the following processes.

[0093] 1. A pile (140) for weaving artificial turf is received (pile receiving process).

[0094] 2. After mounting the received artificial turf pile (140) onto the pile supply device (creel bar), the pile (140) is connected (pile mounting process).

[0095] 3. The bubble sheet (120) and the triple embossed fabric (110) laminated thereon are each supplied through a double device (bubble sheet mounting process).

[0096] 4. The pile (140) supplied through the pile supply device is mounted on the trailing needle (13) to complete the setting for weaving (weaving machine pile setting process).

[0097] 5. Set the stitch count (stitch density) per 10cm for each product (loom machine setting process).

[0098] 6. Weaving is performed using the dual-needle pre-tufting method (weaving process).

[0099] 7. The triple-embossed fabric (110) and the lining (120) on which the pile (140) is woven are inspected through an inspection table (inspection process).

[0100] 8. The inspected fabric is loaded into the loading section (20) (loading process).

[0101] Afterwards, a process is carried out to attach a glass scrim sheet (130) to the bottom of the fabric woven by the above processes 1 to 8 (a state in which pile (140) is woven into the triple embossed fabric (110) and the foam sheet (120)) using a full extrusion coating method.

[0102] The synthetic resin full-surface extrusion coating that laminates the glass scrim sheet (130) can be carried out by the following process.

[0103] a. The woven artificial turf fabric (a state in which pile (140) is woven into a triple-embossed fabric (110) and a foam sheet (120)) is connected to a front extrusion coating machine (woven fabric mounting process).

[0104] b. Supply the mounted fabric to the processing machine (fabric supply process).

[0105] c. Extruded synthetic resin is applied to the back side (back coating side) of the woven fabric to form a front extrusion coating layer (101) (synthetic resin front extrusion coating process).

[0106] The extruded synthetic resin can be used as PE (selectable from LLDPE, LDPE, and HDPE) alone, or as a mixture of PE (selectable from LLDPE, LDPE, and HDPE) and EVA (can be mixed in weight ratios of 8:2, 7:3, 6:4, 5:5, 4:6, 3:7, and 2:8).

[0107] In addition, synthetic resins such as PP and PA can be used alone or in a mixture of two or more.

[0108] It is preferable to set the melting setting temperature of the extruder (51) to 220~280 ℃, the temperature of the T-die (52) to 240~280 ℃, and the extrusion rotation speed to 75~100 rpm.

[0109] In setting the melting temperature of the extruder (51), the temperature can be set sequentially on a total of 50 sections of heater plates in the extruder (#1~#50: 50 degrees~300 degrees). It is preferable to set the temperature of the T-die (52) to 240~330 ℃ and the extrusion rotation speed to 20~60 rpm.

[0110] If the temperature of the extruder (51) and the T-die (52) is lower than the above numerical range, the viscosity of the synthetic resin increases, resulting in insufficient fluidity, and the synthetic resin does not spread widely and evenly on the surface of the foam sheet, and the synthetic resin does not penetrate into the fine pores of the foam sheet and the glass scrim sheet (130), resulting in reduced bonding strength and, consequently, insufficient adhesion, which may cause a peeling phenomenon in which the foam sheet and the glass scrim sheet (130) separate.

[0111] In addition, there is a problem where the extrusion-coated surface becomes rough or uneven due to the inconsistent flow of the synthetic resin, and the thickness of the extrusion-coated layer may not be uniform due to inconsistent extrusion volume, and there is a risk of damage to the extruder due to overloading the extruder.

[0112] If the temperature of the extruder (51) and the T-die (52) is higher than the above numerical range, thermal decomposition and carbonization may occur in the synthetic resin, causing the molecular chains of the resin to break and weakening the physical properties, discoloration may occur, the viscosity of the synthetic resin may become lower than necessary, the neck-in phenomenon in which the synthetic resin film passing through the T-die shrinks inward at both ends may be exacerbated, and the problem may occur where the ends of the synthetic resin film do not come out in a straight line and shake, resulting in uneven coating.

[0113] Conventional heat fusion coating methods are limited to full-surface application and mainly involve bonding PE or PET sheets, which often results in shrinkage, expansion, and wave phenomena of the fabric. However, the present invention applies a high-strength glass scrim sheet and integrates it using a full-surface extrusion coating method, thereby ensuring structural shape stability, improved tensile strength, uniformity of tensile strength, and resistance to shrinkage and expansion deformation.

[0114] In addition, unlike conventional latex or heat fusion coating methods, the full-surface extrusion coating method of the present invention is eco-friendly as it does not use fossil fuels such as LPG or kerosene; furthermore, it improves productivity by shortening the drying section and drying time, and contributes to industrial safety and the reduction of social costs by decreasing the risk of workers' exposure to hazardous substances.

[0115] L. A woven fabric with synthetic resin extrusion coating on the back-coated surface is bonded to a glass scrim sheet (130) and laminated (glass scrim sheet lamination process).

[0116] A glass scrim sheet (130) is supplied to laminate the glass scrim sheet by a full-face extrusion coating method.

[0117] A sheet supply device (40) for supplying a glass scrim sheet (130) is provided. In the present invention, the sheet supply device (40) is provided as a turret-type automatic supply device and supplies the glass scrim sheet (130) in the direction of gravity from top to bottom.

[0118] In the present invention, by providing a turret-type automatic feeding device, the glass scrim sheet (130) can be supplied continuously without interruption, thereby improving production efficiency.

[0119] Glass scrim sheet (130) has higher rigidity and is stiffer than ordinary fabric, so wrinkles or tilting to one side (bias) may occur during the supply process. In the present invention, considering the characteristics of the glass scrim sheet with high rigidity, a turban-type upper supply system is adopted.

[0120] In particular, by supplying the glass scrim sheet (130) in a vertical transport path in the direction of gravity by the self-weight of the glass scrim sheet (130), wrinkles or deflection phenomena that may occur due to artificial tension are blocked, the rigidity of the sheet is offset by gravity so that the sheet can be kept taut, and the alignment of the multilayer laminated structure can be precisely ensured by minimizing material deformation caused by heat and tension through shortening the transport path.

[0121] ㅁ. Drill drainage holes in the artificial turf mat for drainage (drilling process).

[0122] b. The artificial turf mat (100) that has been laminated and perforated is dried and inspected to stabilize the artificial turf mat (100) (drying and inspection process).

[0123] S. The artificial turf mat (100) is wound and packaged. A label sticker may be attached to the packaged surface (winding and packaging process).

[0124] Below, an artificial turf system using an artificial turf mat (100) manufactured by the above process is described.

[0125] The artificial turf system of the present invention, which has excellent shock absorption performance and durability, may include an artificial turf mat (100), a filler layer (200), a pad layer (300), an aggregate layer (400), and a concrete layer (500). The filler layer (200), the pad layer (300), the aggregate layer (400), and the concrete layer (500) may be combined in various ways.

[0126] The above filler layer (200) can be provided between the piles (140) on the upper part of the triple embossed fabric (110).

[0127] The above filler layer (200) may be a silica sand layer in which silica sand is used as a filler, an elastic chip layer in which elastic chips are used as a filler, or a natural chip layer in which natural chips are used as a filler.

[0128] The above filler layer (200) may have only one of the silica sand layer, elastic chip layer, and natural chip layer, or may have two or more.

[0129] When two or more of the silica sand layer, elastic chip layer, and natural chip layer are provided, each material may be laminated as a separate layer, or the two materials may be mixed and used.

[0130] No. 4 to No. 7 silica sand can be used.

[0131] Elastic chips can be made of rubber, such as synthetic rubber, natural rubber, or recycled rubber.

[0132] Natural chips are made by processing various natural plants into chips, and can include cork chips, wood chips, coconut chips, etc.

[0133] The pad layer (300) can be provided under the artificial turf mat (100).

[0134] The above pad layer (300) may be provided by a shock-absorbing pad or by a drainage plate. Depending on the case, a drainage function may be provided by forming a drainage hole or a drainage groove in the shock-absorbing pad, or a shock-absorbing function may be provided in the drainage plate.

[0135] The aggregate layer (400) may include at least one of gravel, crushed stone, and stone powder.

[0136] The above concrete layer (500) may be provided by pouring concrete, and the concrete may include permeable concrete.

[0137] The artificial turf system of the present invention, which has excellent shock absorption performance and durability, can be implemented in embodiments having various structures.

[0138] In the first embodiment, only an artificial turf mat (100) may be laid on top of the original ground (1).

[0139] In a second embodiment, an artificial turf mat (100) is laid on the upper surface of the original ground (1), and a filler layer (200) may be provided on the upper surface of the triple embossed fabric (110).

[0140] In a third embodiment, a pad layer (300) is provided on the upper part of the original ground (1), and an artificial turf mat (100) can be laid on the upper part of the pad layer (300).

[0141] In a fourth embodiment, a pad layer (300) is provided on the upper part of the original ground (1), an artificial turf mat (100) is laid on the upper part of the pad layer (300), and a filler layer (200) may be provided on the upper part of the triple embossed fabric (110).

[0142] In the fifth embodiment, an aggregate layer (400) is provided on the upper part of the original ground (1), and an artificial turf mat (100) can be laid on the upper part of the aggregate layer (400).

[0143] In the sixth embodiment, an aggregate layer (400) is provided on the upper part of the original ground (1), an artificial turf mat (100) is laid on the upper part of the aggregate layer (400), and a filler layer (200) may be provided on the upper part of the triple embossed fabric (110).

[0144] In the seventh embodiment, a concrete layer (500) is provided on the upper part of the original ground (1), and an artificial turf mat (100) can be laid on the upper part of the concrete layer (500).

[0145] In the eighth embodiment, a concrete layer (500) is provided on the upper part of the original ground (1), an artificial turf mat (100) is laid on the upper part of the concrete layer (500), and a filler layer (200) may be provided on the upper part of the triple embossed fabric (110).

[0146] In the ninth embodiment, an aggregate layer (400) is provided on the upper part of the original ground (1), a pad layer (300) is provided on the upper part of the aggregate layer (400), and an artificial turf mat (100) can be laid on the upper part of the pad layer (300).

[0147] In the 10th embodiment, an aggregate layer (400) is provided on the upper part of the original ground (1), a pad layer (300) is provided on the upper part of the aggregate layer (400), an artificial turf mat (100) is laid on the upper part of the pad layer (300), and a filler layer (200) may be provided on the upper part of the triple embossed fabric (110).

[0148] In the 11th embodiment, a concrete layer (500) is provided on the upper part of the original ground (1), a pad layer (300) is provided on the upper part of the concrete layer (500), and an artificial turf mat (100) can be laid on the upper part of the pad layer (300).

[0149] In the 12th embodiment, a concrete layer (500) is provided on the upper part of the original ground (1), a pad layer (300) is provided on the upper part of the concrete layer (500), an artificial turf mat (100) is laid on the upper part of the pad layer (300), and a filler layer (200) may be provided on the upper part of the triple embossed fabric (110).

[0150] The artificial turf system of the present invention, which has excellent shock absorption performance and durability, can be implemented by combining the artificial turf mat (100), filler layer (200), pad layer (300), aggregate layer (400), and concrete layer (500) in various ways in addition to the embodiments listed above.

[0151] The following describes a construction method for the artificial turf system of the present invention, which has excellent shock absorption performance and durability.

[0152] a. An artificial turf mat (100) is produced and prepared by the manufacturing method described above.

[0153] b. After compacting or leveling the original ground (1) on which the artificial turf is to be laid, an artificial turf mat (100) is laid on top of the original ground (1).

[0154] c. Connect multiple laid artificial turf mats (100).

[0155] d. A filler is laid on top of the artificial turf mat (100) to form a filler layer (200).

[0156] The above filler layer (200) may have only one of the silica sand layer, elastic chip layer, and natural chip layer, or may have two or more.

[0157] When two or more of the silica sand layer, elastic chip layer, and natural chip layer are provided, each material may be laminated as a separate layer, or the two materials may be mixed and used.

[0158] No. 4 to No. 7 silica sand can be used.

[0159] Elastic chips can be made of rubber, such as synthetic rubber, natural rubber, or recycled rubber.

[0160] Natural chips are made by processing natural plants into chips, and can include cork chips, wood chips, coconut chips, etc.

[0161] If a pad layer (300) is to be provided in the artificial turf system, the pad layer (300) can be provided first before laying the artificial turf mat (100) in b.

[0162] The above pad layer (300) may be provided by a shock-absorbing pad or by a drainage plate. In some cases, a drainage hole or a drainage groove may be formed in the shock-absorbing pad to provide a drainage function.

[0163] In addition, if an aggregate layer (400) or a concrete layer (500) is to be provided in the artificial turf system, the aggregate layer (400) or the concrete layer (500) may be provided on the upper surface of the original ground (1) before laying the artificial turf mat (100) or before providing the pad layer (300).

[0164] The aggregate layer (400) may include at least one of gravel, crushed stone, and stone powder.

[0165] The above concrete layer (500) may be provided by pouring concrete, and the concrete may include permeable concrete.

[0166] The present invention has been described with reference to the embodiments illustrated in the drawings, but this is merely illustrative, and those skilled in the art will understand that various modifications and equivalent alternative embodiments are possible therefrom.

[0167] Therefore, the true scope of technical protection of the present invention should be determined by the technical concept of the appended claims. Explanation of the symbols

[0168] 100. Artificial turf mat 110. Triple-embossed fabric 120. Air bubble wrap 101. Full extrusion coating layer 130. Glass Scrim Sheet 140. File 200. Filler layer 300. Pad layer 400. Aggregate layer 500. Concrete layer 10. Double needle structure 11. Needle Bar 12. Leading needle 13. Lagging needle 20. Loading section 30. Air bubble supply unit 40. Sheet supply device 50. Extrusion section 51. Extruder 52. T-die 60. Perforation 70. Winding section 1. Original ground

Claims

Claim 1 In an artificial turf system, the artificial turf system comprises an artificial turf mat (100), wherein the artificial turf mat (100) comprises: a triple embossed fabric (110) located on top; a foam sheet (120) provided below the triple embossed fabric (110); and a glass scrim sheet (130) provided below the foam sheet (120). The invention includes a pile (140) woven through pre-tufting on the triple embossed fabric (110) and the foam sheet (120), wherein the pile (140) is woven through the laminated triple embossed fabric (110) and the foam sheet (120), and after extruding and applying a synthetic resin to the lower surface of the foam sheet (120), the glass scrim sheet (130) is attached to the lower surface of the foam sheet (120) by front extrusion coating, thereby forming a front extrusion coating layer (101) between the foam sheet (120) and the glass scrim sheet (130), and the weaving of the pile (140) on the triple embossed fabric (110) and the foam sheet (120) is carried out by a double needle structure (10), and the double needle structure (10) comprises a needle bar (11); A full-surface extrusion coated artificial turf system having a laminated structure woven by double needle pre-tufting, characterized by including a leading needle (12) and a trailing needle (13) each provided in a row at the lower part of the needle bar (11), wherein the leading needle (12) pre-perforates the triple embossed fabric (110) and the foam sheet (120), and the trailing needle (13) weaves pile (140) at the location pre-perforated by the leading needle (12). Claim 2 delete Claim 3 delete Claim 4 delete Claim 5 In claim 1, the triple embossed fabric (110) is a full-face extrusion coated artificial turf system having a laminated structure woven by double needle pre-tufting, in which a cross-section of a three-layer structure is repeatedly connected to form a grid. Claim 6 In claim 5, the glass scrim sheet (130) is a full-face extrusion coated artificial turf system having a laminated structure woven by double needle pre-tufting, wherein the structure is formed by a lattice glass fiber reinforcement layer laminated on a spunlaid type polyester nonwoven fabric heat-bonded with a dual-component continuous filament having polyester as the core and polyamide 6 (PA-6) as the skin. Claim 7 In claim 6, a full-face extrusion coated artificial turf system having a laminated structure woven by double needle pre-tufting, wherein a filler layer (200) is provided on the triple embossed fabric (110). Claim 8 In claim 7, the filler layer (200) is a full-face extrusion coated artificial turf system having a laminated structure woven by double needle pre-tufting, comprising at least one of a silica sand layer, an elastic chip layer, and a natural chip layer. Claim 9 A full-face extrusion coated artificial turf system having a laminated structure woven by double needle pre-tufting, wherein a pad layer (300) is provided under the artificial turf mat (100) in any one of claims 1, 5 to 8. Claim 10 In claim 9, the pad layer (300) is a full-face extrusion coated artificial turf system having a laminated structure woven by double needle pre-tufting, including a shock-absorbing pad or a drainage plate. Claim 11 A full-face extrusion coated artificial turf system having a laminated structure woven by double needle pre-tufting, wherein, in any one of claims 1, 5 to 8, an aggregate layer (400) or a concrete layer (500) is provided beneath the artificial turf mat (100). Claim 12 In claim 9, a full-face extrusion coated artificial turf system having a laminated structure woven by double needle pre-tufting, wherein an aggregate layer (400) or a concrete layer (500) is provided below the pad layer (300). Claim 13 A method for manufacturing an artificial turf mat comprises: a) a step of preparing a triple-embossed fabric (110), a backing sheet (120), and pile (140); b) a step of weaving pile (140) onto the triple-embossed fabric (110) and backing sheet (120); and c) a step of attaching a glass scrim sheet (130) to the lower surface of the backing sheet (120), wherein in step c), synthetic resin is extruded and applied to the lower surface of the backing sheet (120), and then the glass scrim sheet (130) is attached to the lower surface of the backing sheet (120) by full extrusion coating, and in step b), a needle bar (11); A method for manufacturing a full-face extrusion coated artificial turf mat having a laminated structure woven by double needle pre-tufting, characterized by being carried out by a double needle structure (10) including a leading needle (12) and a trailing needle (13) each provided in a row at the lower part of the needle bar (11), wherein the leading needle (12) perforates the triple embossing fabric (110) and the foam sheet (120), and the trailing needle (13) weaves a pile (140) at the location perforated by the leading needle (12). Claim 14 delete Claim 15 delete Claim 16 In claim 13, the above triple embossed fabric (110) is woven in a grid pattern such that a cross-section of a three-layer structure is repeatedly connected to form a laminated structure, and the method for manufacturing a full-face extrusion coated artificial turf mat is a method of manufacturing a laminated structure woven by double needle pre-tufting. Claim 17 In claim 16, the glass scrim sheet (130) is formed with a structure in which a grid-shaped glass fiber reinforcement layer is laminated on a spunlaid-type polyester nonwoven fabric heat-bonded with a dual-component continuous filament having polyester as the core and polyamide 6 (PA-6) as the skin, and in step c), the glass scrim sheet (130) is supplied from top to bottom by a turret-type automatic feeding device, characterized in that it is a method for manufacturing a full-face extrusion-coated artificial turf mat having a laminated structure woven by double-needle pre-tufting. Claim 18 A triple embossed fabric (110) located at the top; a foam sheet (120) provided below the triple embossed fabric (110); and a glass scrim sheet (130) provided below the foam sheet (120); The invention includes a pile (140) woven into the triple embossed fabric (110) and the foam sheet (120), wherein the pile (140) is woven through the laminated triple embossed fabric (110) and the foam sheet (120), and after extruding and applying a synthetic resin to the lower surface of the foam sheet (120), the glass scrim sheet (130) is attached to the lower surface of the foam sheet (120) by front extrusion coating, and the weaving of the pile (140) into the triple embossed fabric (110) and the foam sheet (120) is carried out by a double needle structure (10), and the double needle structure (10) comprises a needle bar (11); A full-face extrusion coated artificial turf mat having a laminated structure woven by double needle pre-tufting, characterized by including a leading needle (12) and a trailing needle (13) each provided in a row at the lower part of the needle bar (11), wherein the leading needle (12) perforates the triple embossing fabric (110) and the foam sheet (120), and the trailing needle (13) weaves pile (140) at the location perforated by the leading needle (12). Claim 19 delete Claim 20 delete Claim 21 In claim 18, the triple embossed fabric (110) is a full-face extrusion coated artificial turf mat having a laminated structure woven by double needle pre-tufting, in which a cross-section of a three-layer structure is repeatedly connected to form a grid. Claim 22 In claim 21, the glass scrim sheet (130) is a full-face extrusion coated artificial turf mat having a laminated structure woven by double needle pre-tufting, wherein the structure is formed by a lattice glass fiber reinforcement layer laminated on a spunlaid type polyester nonwoven fabric heat-bonded with a dual-component continuous filament having polyester as the core and polyamide 6 (PA-6) as the skin. Claim 23 A method for constructing an artificial turf system comprising: a) a step of preparing an artificial turf mat according to any one of claims 18, 21, and 22; b) a step of leveling the original ground and then laying the artificial turf mat according to any one of claims 18, 21, and 22 on the upper surface of the original ground; and c) a step of connecting a plurality of laid artificial turf mats, comprising a method for constructing a full-face extrusion-coated artificial turf system having a laminated structure woven by double-needle pre-tufting. Claim 24 A method for constructing a full-face extrusion coated artificial turf system having a laminated structure woven by double needle pre-tufting, wherein, in paragraph 23, after step c), a filler is laid on the upper surface of the artificial turf mat to form a filler layer (200). Claim 25 In claim 24, the method of constructing a full-face extrusion coated artificial turf system having a laminated structure woven by double needle pre-tufting, wherein the filler layer (200) comprises at least one of a silica sand layer, an elastic chip layer, and a natural chip layer. Claim 26 A method for constructing a full-face extrusion coated artificial turf system having a laminated structure woven by double needle pre-tufting, comprising, in addition to the step of providing a pad layer (300) under the artificial turf mat before step b) above in claim 25. Claim 27 In claim 26, the above pad layer (300) has a laminated structure woven by double needle pre-tufting including a shock-absorbing pad or a drainage plate, a method for constructing a full-face extrusion coated artificial turf system. Claim 28 A method for constructing a full-face extrusion coated artificial turf system having a laminated structure woven by double needle pre-tufting, comprising, in addition to the step of providing an aggregate layer (400) or a concrete layer (500) under the artificial turf mat before step b) above in claim 25. Claim 29 A method for constructing a full-face extrusion coated artificial turf system having a laminated structure woven by double needle pre-tufting, comprising, in addition to the step of providing an aggregate layer (400) under the artificial turf mat and a pad layer (300) on top of the aggregate layer (400) before step b) above. Claim 30 A method for constructing a full-face extrusion coated artificial turf system having a laminated structure woven by double needle pre-tufting, comprising, in addition to the step of providing a concrete layer (500) under the artificial turf mat and a pad layer (300) on top of the concrete layer (500) before step b) above.

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