Artificial turf and manufacturing method thereof

Abstract

The present invention discloses an artificial turf and a manufacturing method thereof, belonging to the technical field of artificial turf. The artificial turf comprises: a base fabric layer, a grass yarn layer tufted on the base fabric layer, and an adhesive layer laminated to the bottom of the base fabric layer. The grass yarn layer comprises a skin-friendly layer, a shock-absorbing layer, and a damping layer. The skin-friendly layer is composed of multiple straight yarns, which are used to reduce burn resistance and lower the surface temperature of the turf during exercise. The shock-absorbing layer is composed of multiple curved yarns, which are used to reduce shock and absorb impact during exercise. The damping layer is composed of multiple spring yarns with a spring structure, which are used to provide anti-slip performance and rotational resistance during exercise. The combination of these three layers significantly reduces the turf's tendency to fall over and meet ball sliding requirements, making it an artificial turf suitable for training and sports.

Description

Technical Field

[0001] The present invention relates to the technical field of artificial turf, and in particular to an artificial turf and a manufacturing method thereof. Background Art

[0002] Natural turf fields are the preferred venue for large-scale competitions and sports, but due to factors such as high maintenance costs and the inability to use them in northern winters, they cannot meet the growing demand for sports, and artificial turf has developed rapidly.

[0003] The grass fibers in traditional artificial turfs are composed of a double-layer structure of curved fibers and straight fibers. For example, the patent with publication number CN207376400U, titled "A Filling-Free Artificial Football Turf," discloses a base layer, multiple clusters of straight grass fibers, and multiple clusters of curved grass fibers. The double-layer structure of curved grass fibers and straight grass fibers is the only one in which the curved grass fibers can support and protect the straight grass fibers, allowing the straight grass fibers to quickly reset after being stepped on multiple times. However, the patent has problems such as insufficient anti-slip properties, insufficient rotational resistance, and unsatisfactory skin-friendliness. Summary of the Invention

[0004] In order to solve the problems of the prior art, the present invention provides an artificial turf and a method for manufacturing the same. The technical solution is as follows:

[0005] In one aspect, an artificial turf is provided, comprising: a base fabric layer, a grass yarn layer tufted on the base fabric layer, and a backing adhesive layer glued to the bottom of the base fabric layer;

[0006] The grass silk layer consists of a skin-friendly layer, a shock-absorbing layer and a damping layer;

[0007] The skin-friendly layer is composed of a plurality of straight threads and is used to reduce burn resistance during exercise and lower the surface temperature of the lawn;

[0008] The shock-absorbing layer is composed of a plurality of curved wires and is used for shock absorption and impact absorption during exercise;

[0009] The damping layer is composed of multiple spring wires and has a spring structure, which is used to solve the anti-slip performance and rotation resistance during the movement process.

[0010] Furthermore, the straight wire shape is at least one of S-shape, wavy shape, C-shape, diamond shape, and olive shape; the curved wire shape is at least one of flat wire, olive shape, and diamond shape; and the spring wire shape is at least one of C-shape, S-shape, wavy shape, and diamond shape.

[0011] Furthermore, during tufting, any two of the straight yarn, curved yarn and spring yarn are plied together and double-sided yarn feeding is used, or three types of grass yarn are plied together and single-sided yarn feeding is performed, or two of the grass yarns are plied together and the other type of grass yarn is tufted in alternate rows;

[0012] The tufting row spacing is 1 / 16 to 10 / 16 inches, and the number of needles is 100 to 400 needles per meter.

[0013] Furthermore, the number of the curved wires, the straight wires and the spring wires in each tuft of grass wire is 2 to 12.

[0014] The spring wire in each bunch of grass wire includes a left-handed structure and a right-handed structure.

[0015] Furthermore, the decitex number of the spring wire and the straight wire is smaller than the decitex number of the curved wire, and the decitex number of the straight wire is smaller than or equal to the decitex number of the spring wire;

[0016] The colors of the spring wire and the straight wire are lighter than the color of the curved wire, and the color of the straight wire is lighter than or equal to the color of the spring wire.

[0017] In another aspect, a method for manufacturing an artificial turf is provided, the method comprising:

[0018] S1: Mixing, extruding, drawing, expanding (or weaving), and heat-setting the raw materials of the curved yarn to obtain the curved yarn;

[0019] The spring wire raw materials are mixed, extruded, drawn, twisted (or braided), and heat-set to obtain the spring wire;

[0020] The straight yarn raw materials are mixed, extruded, drawn, and heat-set to obtain the straight yarn;

[0021] S2: Tufting the curved yarn, spring yarn and straight yarn onto the base fabric layer to form a skin-friendly layer, a shock-absorbing layer and a damping layer;

[0022] S3: Applying adhesive to the bottom of the base fabric layer to obtain the artificial turf.

[0023] Furthermore, the yarn raw material includes: 85-98 parts of polypropylene resin, 1-5 parts of masterbatch, 0.1-5 parts of processing aid and 0.3-5 parts of anti-aging agent.

[0024] The spring wire raw materials include: 80-90 parts of polyethylene resin, 1-10 parts of masterbatch, 0.5-5 parts of processing aid and 0.5-5 parts of anti-aging agent;

[0025] The straight yarn raw materials include: 60-90 parts of polyethylene resin, 5-20 parts of metallocene polyethylene, 1-10 parts of masterbatch, 0.5-5 parts of processing aid, 0.5-5 parts of anti-aging aid, 0.1-1 parts of hydrophilic additive and 1-5 parts of cooling masterbatch;

[0026] Among them, the processing aid is selected from at least one of fluorine additives, silicone additives, oleamide, erucamide and antistatic additives, the anti-aging additive is composed of antioxidants, ultraviolet absorbers and hindered amines, the metallocene polyethylene is selected from at least one of metallocene polyethylenes with a melt index of 0.2g / 10min, 0.5g / 10min, 1g / 10min and 2g / 10min, the hydrophilic additive is selected from at least one of anionic surfactants, nonionic surfactants, cationic surfactants and amphoteric surfactants, and the cooling masterbatch is selected from at least one of nano-titanium dioxide, nano-zinc oxide and nano-ceramic powder with reflective properties.

[0027] Furthermore, the yarn raw material includes: 75-85 parts of polypropylene resin, 1-5 parts of masterbatch, 5-15 parts of first modified resin, 1-5 parts of compatibilizer, 0.1-5 parts of processing aid and 0.3-5 parts of anti-aging agent.

[0028] The spring wire raw materials include: 70-85 parts of polyethylene resin, 5-10 parts of second modified resin, 1-10 parts of masterbatch, 0.5-5 parts of processing aid and 0.5-5 parts of anti-aging agent;

[0029] The straight yarn raw material includes: 60-90 parts of polyethylene resin, 5-20 parts of POE, 1-10 parts of masterbatch, 0.5-5 parts of processing aid, 0.5-5 parts of anti-aging additive, 0.1-0.5 parts of cooling masterbatch and 0.1-1 parts of hydrophilic additive;

[0030] Among them, the first modified resin is selected from at least one of PET, PBT and nylon, the second modified resin is selected from at least one of thermoplastic elastomer SEBS, polyethylene elastomer POE and metallocene polyethylene, the compatibilizer is selected from at least one of maleic anhydride grafted polymer, epoxy grafted polymer, block copolymer and random copolymer, the processing aid is selected from at least one of fluorine additives, silicone additives, oleamide, erucamide and antistatic additives, the anti-aging additive is composed of antioxidants, ultraviolet absorbers and hindered amines, the POE is selected from at least one of POE with a melt index of 0.5g / 10min, 1g / 10min, 5g / 10min and 7.5g / 10min, the hydrophilic additive is selected from at least one of anionic surfactants, nonionic surfactants, cationic surfactants and amphoteric surfactants, and the cooling masterbatch is selected from at least one of nano-titanium dioxide, nano-zinc oxide and nano-ceramic powder with reflective properties.

[0031] Furthermore, the curved yarn raw material includes: 75-90 parts of polypropylene resin, 1-10 parts of high resilience modifying material, 1-5 parts of compatibilizer, 1-5 parts of masterbatch, 0.1-5 parts of processing aid and 0.3-5 parts of anti-aging agent;

[0032] The spring wire raw materials include: 80-98 parts of polyethylene resin, 1-10 parts of masterbatch, 0.5-5 parts of processing aid and 0.5-5 parts of anti-aging agent;

[0033] The straight yarn raw material comprises: 60-90 parts of polyethylene resin, 5-20 parts of modified material, 1-10 parts of masterbatch, 0.5-5 parts of processing aid, 0.5-5 parts of anti-aging aid, 0.1-1 parts of hydrophilic additive and 1-5 parts of cooling masterbatch;

[0034] Among them, the compatibilizer is selected from at least one of maleic anhydride grafted polymers, epoxy grafted polymers, block copolymers and random copolymers, the processing aid is selected from at least one of fluorine additives, silicone additives, oleamide, erucamide and antistatic additives, the high resilience modified material is selected from at least one of PET, PBT and nylon, the anti-aging additive is composed of an antioxidant, an ultraviolet absorber and a hindered amine, the modified material is selected from at least one of metallocene polyethylene, POE and SEBS, the hydrophilic additive is selected from at least one of anionic surfactants, nonionic surfactants, cationic surfactants and amphoteric surfactants, and the cooling masterbatch is selected from at least one of nano-titanium dioxide, nano-zinc oxide and nano-ceramic powder with reflective properties.

[0035] Furthermore, in S1, the extrusion temperature is 180-260°C, the drawing temperature is 60-90°C, the puffing temperature is 100-250°C, the puffing pressure is 0.4-0.8 MPa, and the heat setting temperature is 100-180°C;

[0036] In the S2, the extrusion temperature is 180-260°C, the drawing temperature is 60-90°C, the twisting is divided into S twist and Z twist, S twist is right-handed, Z twist is left-handed, the twist is 10-70 twists, and the heat setting temperature is 100-180°C.

[0037] In S3, the extrusion temperature is 180-260°C, the drawing temperature is 60-90°C, and the heat setting temperature is 90-180°C;

[0038] In said S4, said tufting comprises: tufting the base fabric layer on a 1 / 16 inch to 10 / 16 inch tufting machine at a grass height of 15 to 60 mm and a needle count of 100 to 400 needles / m;

[0039] In S5, the backing of the base fabric layer is performed using any one of styrene-butadiene adhesive, styrene-acrylic adhesive, polyurethane adhesive and SPU adhesive, the temperature of the upper drying channel for the backing is 100-150° C., the temperature of the lower drying channel is 40-70° C., the humidity of the glue is less than 10%, and the pull-out force is greater than 45 N / tuft, and the artificial turf is rolled up to obtain the artificial turf.

[0040] The beneficial effects brought about by the technical solution provided by the embodiment of the present invention are as follows: the artificial turf in the present invention includes: a base fabric layer, a grass fiber layer tufted on the base fabric layer and a backing adhesive layer glued to the bottom of the base fabric layer; the grass fiber layer is composed of a skin-friendly layer, a shock-absorbing layer and a damping layer; the skin-friendly layer has a silky and soft surface and has a good cooling function, which is used to reduce the burn resistance and reduce the surface temperature of the lawn during exercise; the shock-absorbing layer has good resilience and is used for shock absorption and impact absorption during exercise to ensure the safety performance of exercise, while meeting the vertical rebound performance of the ball; the damping layer has a spring structure and has excellent resilience and anti-skid performance, which is used to solve the anti-skid performance and rotational resistance during exercise; the combination of the three layers greatly reduces the lawn's lodging and falling directionality, meets the ball's sliding performance, and is an artificial turf suitable for training and sports. BRIEF DESCRIPTION OF THE DRAWINGS

[0041] In order to more clearly illustrate the technical solutions in the embodiments of the present invention, the following briefly introduces the drawings required for use in the description of the embodiments. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without creative work.

[0042] Figure 1 This is a schematic structural diagram of an artificial lawn provided by the present invention;

[0043] Reference numerals: 1 - base fabric layer; 2 - adhesive layer; 3 - straight wire; 4 - curved wire; 5 - spring wire. DETAILED DESCRIPTION

[0044] To make the objectives, technical solutions and advantages of the present invention more clear, the embodiments of the present invention will be described in further detail below with reference to the accompanying drawings.

[0045] Example 1

[0046] See also Figure 1, an artificial turf, comprising a base fabric layer 1, a grass fiber layer tufted on the base fabric layer 1 and a backing adhesive layer 2 glued to the bottom of the base fabric layer 1, the backing adhesive layer 2 can use styrene-butadiene adhesive, styrene-acrylic adhesive, polyurethane adhesive, SPU backing adhesive, or recyclable hot-melt adhesive, the grass fiber layer is composed of a skin-friendly layer, a shock-absorbing layer and a damping layer; the skin-friendly layer is composed of a plurality of straight wires 3, the surface of the grass fiber is silky and soft, and has a good cooling function, which is used to reduce the burn resistance and reduce the surface temperature of the lawn during exercise; the shock-absorbing layer is composed of a plurality of curved wires 4 with good resilience, which is used for shock absorption and impact absorption during exercise to ensure the safety performance of exercise while meeting the vertical rebound performance of the ball; the damping layer is composed of a plurality of spring wires 5 with a spring structure, excellent resilience and anti-slip performance, which is used to solve the anti-slip performance and rotational resistance during exercise. The combination of the three layers greatly reduces the lodging and tilting of the lawn, meets the sliding performance of the ball, and is suitable for artificial turf for training.

[0047] The shock-absorbing layer is composed of multiple high-dtex, high-rebound curved yarns 4, which can be shaped into at least one of flat yarn, olive shape, and diamond shape, with a decitex of 3000-20000D; the damping layer is composed of medium- and low-dtex grass yarns with a spring structure, which are divided into left-handed and right-handed structures. They are generally used in combination to ensure that when the player changes the direction of movement, there is appropriate rotational resistance to prevent slipping and sprains during high-speed movement. The decitex is 3000-10000D, and the shape can be at least one of C-shape, S-shape, wavy shape, and diamond shape; the skin-friendly layer is composed of multiple straight yarns 3 with a silky and soft surface, good burn resistance, strong hydrophilicity, and cooling function, with a decitex of 3000-10000D, and the shape can be at least one of S-shape, wavy, C-shape, diamond shape, and olive shape.

[0048] During specific manufacturing, in terms of decitex, the curved wire 4 of the shock-absorbing layer has the largest decitex, and the spring wire 5 of the damping layer and the straight wire 3 of the skin-friendly layer have relatively smaller decitex, or the spring wire 5 of the damping layer and the straight wire 3 of the skin-friendly layer have the same decitex, in short, the overall effect of heavy bottom and light top is formed; in terms of color, the curved wire 4 of the shock-absorbing layer is the darkest, such as dark green, dark green, etc., the straight wire of the skin-friendly layer 3 is the lightest, and the spring wire 5 of the damping layer 2 is between the two, or the two colors are the same, such as light green, fruit green, olive green, etc., in short, the bottom is dark and the top is light, which gives a thick feeling; in terms of tufting, any two kinds of grass silks, straight wire 3, curved wire 4 and spring wire 5, are twisted together to make Use double-sided feeding, or combine three kinds of grass silk to perform single-sided feeding, or combine two of the grass silks and tuft the other one in alternate rows, or tuft the three kinds of grass silk in alternate rows, the tufting row spacing is 1 / 16 to 10 / 16 inches, the number of needles is 100 needles / meter to 400 needles / meter, and in each tuft of grass silk, when there are curved wires 4, the number of curved wires is 2 to 12, when there are straight wires 3, the number of straight wires 3 is 2 to 12, and when there are spring wires 5, the number of spring wires 5 is 2 to 12; when there are spring wires 5 in each tuft of grass silk, the spring wires 5 include left-handed structure and right-handed structure, and the number of left-handed structure and right-handed structure can be the same.

[0049] Example 2

[0050] A method for manufacturing artificial turf, comprising the following steps:

[0051] Step (101): 85 parts of polypropylene resin, 1 part of masterbatch, 0.1 part of fluorine additive, and 1 part of anti-aging additive are mixed evenly, added into a screw extruder for extrusion at an extrusion temperature of 180-260°C, then stretched at a stretching temperature of 60°C, then expanded at a puffing temperature of 100°C and a puffing pressure of 0.4MPa, then heat-set at a heat-setting temperature of 100°C, and finally rolled to obtain a curved yarn 4 with a high decitex number, high curvature, and high resilience shock-absorbing layer, wherein the anti-aging additive is composed of an antioxidant, an ultraviolet absorber, and a hindered amine in a ratio of 1:0.5:1; the antioxidant can be antioxidant 1010, the ultraviolet absorber can be UV326, and the hindered amine can be hindered amine 770.

[0052] Step (102): 80 parts of polyethylene resin, 1 part of masterbatch, 0.5 parts of silicone additive and 1.5 parts of anti-aging additive are mixed evenly, added into a screw extruder and extruded at an extrusion temperature of 180-260°C, then hot-stretched at a stretching temperature of 60°C, and then twisted, the twisting is divided into S twist and Z twist, S twist is right-handed direction, Z twist is left-handed direction, the twist is 10 twists, the greater the twist, the stronger the spring structure, and then heat-set at a heat-setting temperature of 100°C, unwinding and winding to obtain spring wire 5; wherein the anti-aging additive is composed of an antioxidant, an ultraviolet absorber and a hindered amine in a ratio of 1:0.5:1; the antioxidant can be antioxidant 1010, the ultraviolet absorber can be UV326, and the hindered amine can be hindered amine 770.

[0053] Step (103): 60 parts of polyethylene resin, 5 parts of metallocene polyethylene with a melt index of 0.2g / 10min, 1 part of masterbatch, 0.5 parts of oleic acid amide, 2.5 parts of anti-aging additives, 0.1 parts of anionic surfactants and 1 part of nano titanium dioxide absorbent are mixed evenly, added into a screw extruder for extrusion at an extrusion temperature of 180-260°C, then hot-stretched at a stretching temperature of 80°C, and then heat-set at a heat-setting temperature of 90°C, and yarn-wrapped and wound to obtain straight yarn 3; wherein the anti-aging additive is composed of an antioxidant, an ultraviolet absorber and a hindered amine in a ratio of 1:0.5:1; the antioxidant can be antioxidant 1010, the ultraviolet absorber can be UV326, and the hindered amine can be hindered amine 770.

[0054] Step (104): The curved yarn 4, the spring yarn 5 and the straight yarn 3 are tufted on the base fabric layer on a 1 / 16 inch tufting machine at a grass height of 15-60 mm and a needle count of 200 needles / m to form a skin-friendly layer, a shock-absorbing layer and a damping layer. The shock-absorbing layer is dark green, and the skin-friendly layer and the damping layer are fruit green.

[0055] Step (105): back gluing the base fabric layer with styrene-butadiene adhesive, with the upper drying oven temperature at 100° C., the lower drying oven temperature at 40° C., the gluing humidity at 9%, the pull-out force at 46 N / cluster, and rolling up to obtain artificial turf.

[0056] Example 3

[0057] A method for manufacturing artificial turf, comprising the following steps:

[0058] Step (201): 90 parts of polypropylene resin, 3 parts of masterbatch, 3 parts of erucamide, and 3 parts of anti-aging additive are mixed evenly, added into a screw extruder for extrusion at an extrusion temperature of 180-260°C, then stretched at a stretching temperature of 70°C, and then expanded (or braided) at a puffing temperature of 180°C and a puffing pressure of 0.6MPa. The yarn is then heat-set at a heat-setting temperature of 140°C and finally rolled to obtain a curved yarn 4 with a high decitex number, high curvature, and high resilience of the shock-absorbing layer; wherein the anti-aging additive is composed of an antioxidant, an ultraviolet absorber, and a hindered amine in a ratio of 1:0.5:1; the antioxidant can be antioxidant 1076, the ultraviolet absorber can be UV327, and the hindered amine can be hindered amine 944.

[0059] Step (202): 85 parts of polyethylene resin, 5 parts of masterbatch, 3 parts of antistatic additive and 3 parts of anti-aging additive are mixed evenly, added into a screw extruder for extrusion at an extrusion temperature of 180-260°C, then hot-stretched at a stretching temperature of 80°C, and then twisted (or braided), wherein the twisting is divided into S twist and Z twist, wherein the S twist is a right-handed direction and the Z twist is a left-handed direction, and the twist is 40 twists, and then heat-set at a heat-setting temperature of 150°C, unwound and wound to obtain spring wire 5; wherein the anti-aging additive is composed of an antioxidant, an ultraviolet absorber and a hindered amine in a ratio of 1:0.5:1; the antioxidant can be antioxidant 1076, the ultraviolet absorber can be UV327, and the hindered amine can be hindered amine 944.

[0060] Step (203): 75 parts of polyethylene resin, 10 parts of metallocene polyethylene with a melt index of 1 g / 10 min, 5 parts of masterbatch, 3 parts of silicone additives, 3 parts of anti-aging additives, 0.5 parts of non-ionic surfactants and 3 parts of nano zinc oxide are mixed evenly, added into a screw extruder for extrusion at an extrusion temperature of 180-260°C, then hot-stretched at a stretching temperature of 70°C, and then heat-set at a heat-setting temperature of 150°C, and wrapped and wound to obtain straight yarn 3; wherein the anti-aging additive is composed of an antioxidant, an ultraviolet absorber and a hindered amine in a ratio of 1:0.5:1; the antioxidant can be antioxidant 1076, the ultraviolet absorber can be UV327, and the hindered amine can be hindered amine 944.

[0061] Step (204): The curved yarn 4, the spring yarn 5 and the straight yarn 3 are tufted on the base fabric layer on a 6 / 16 inch tufting machine at a grass height of 15-60 mm and a needle count of 220 needles / m to form a skin-friendly layer, a shock-absorbing layer and a damping layer. The shock-absorbing layer is dark green, and the skin-friendly layer and the damping layer are fruit green.

[0062] Step (205): The backing of the base fabric layer is performed with styrene-acrylic adhesive, the upper drying oven temperature of the backing adhesive is 130° C., the lower drying oven temperature is 50° C., the laminating humidity is 8%, the pulling force is 50 N / cluster, and the artificial turf is rolled up.

[0063] Example 4

[0064] A method for manufacturing artificial turf, comprising the following steps:

[0065] Step (301): 98 parts of polypropylene resin, 5 parts of masterbatch, 5 parts of silicone additive, and 5 parts of anti-aging additive are mixed evenly, added into a screw extruder and extruded at an extrusion temperature of 180-260°C, then stretched at a stretching temperature of 90°C, and then expanded at a puffing temperature of 250°C, a puffing pressure of 0.8 MPa, and a heat setting temperature of 180°C. Finally, the mixture is wound to obtain a curved yarn 4 having a high decitex number, high curvature, and high resilience of the shock-absorbing layer.

[0066] Step (302): 90 parts of polyethylene resin, 10 parts of masterbatch, 5 parts of erucamide and 5 parts of anti-aging additive are mixed evenly, added into a screw extruder and extruded at an extrusion temperature of 180-260°C, then hot-stretched at a stretching temperature of 90°C, and then twisted, with S twist and Z twist, S twist being a right-handed direction and Z twist being a left-handed direction, with a twist of 70 twists, and then heat-set at a heat-setting temperature of 180°C, unwinding and winding to obtain a spring wire 5.

[0067] Step (303): 90 parts of polyethylene resin, 20 parts of metallocene polyethylene with a melt index of 2 g / 10 min, 10 parts of masterbatch, 5 parts of silicone additive, 5 parts of anti-aging additive, 1 part of cationic surfactant and 5 parts of nano-ceramic powder are mixed evenly, added to a screw extruder for extrusion at an extrusion temperature of 180-260°C, then hot-stretched at a stretching temperature of 90°C, and then heat-set at a heat-setting temperature of 180°C, and the yarn is wrapped and wound to obtain straight yarn 3.

[0068] Step (304): The curved yarn 4, the spring yarn 5 and the straight yarn 3 are tufted on the base fabric layer on a 10 / 16 inch tufting machine at a grass height of 15-60 mm and a needle count of 400 needles / m to form a skin-friendly layer, a shock-absorbing layer and a damping layer. The shock-absorbing layer is dark green, and the skin-friendly layer and the damping layer are olive green.

[0069] Step (305): The base fabric layer is back-glued with polyurethane adhesive, the upper drying oven temperature of the back-gluing is 150° C., the lower drying oven temperature is 70° C., the pulling force is 60 N / cluster, and the artificial turf is rolled up.

[0070] Example 5

[0071] A method for manufacturing artificial turf, comprising the following steps:

[0072] Step (401): 75 parts of polypropylene resin, 1 part of masterbatch, 5 parts of PET, 1 part of maleic anhydride grafted polymer, 0.1 part of fluorine additive, and 1 part of anti-aging additive are mixed uniformly, added to a screw extruder and extruded at an extrusion temperature of 180-260°C, then stretched at a stretching temperature of 60°C, then expanded at a puffing temperature of 100°C, an puffing pressure of 0.4 MPa, and a heat setting temperature of 100°C, and finally wound to obtain a high-decitex, high-curvature, and high-resilience shock-absorbing layer curved yarn 4. The compatibilizer increases the compatibility of the modified material and the polypropylene resin.

[0073] Step (402): 75 parts of polyethylene resin, 5 parts of thermoplastic elastomer SEBS, 1 part of masterbatch, 0.5 parts of silicone additive and 1 part of anti-aging additive are mixed evenly, added to a screw extruder and extruded at an extrusion temperature of 180-260°C, then hot-stretched at a stretching temperature of 60°C, and then twisted, with S twist and Z twist, S twist being a right-hand direction and Z twist being a left-hand direction, with a twist of 10 twists, and then heat-set at a heat-setting temperature of 100°C, unwinding, and winding to obtain spring wire 5. The modified resin further improves the long-lasting anti-slip performance of the damping layer grass wire.

[0074] Step (403): 60 parts of polyethylene resin, 5 parts of POE with a melt index of 0.5 g / 10 min, 1 part of masterbatch, 0.5 parts of oleic acid amide, 1 part of anti-aging additive, 0.1 parts of amphoteric surfactant and 0.1 parts of nano-titanium dioxide absorbent are mixed evenly, added to a screw extruder for extrusion at an extrusion temperature of 180-260°C, then hot-stretched at a stretching temperature of 60°C, and then heat-set at a heat-setting temperature of 90°C, and the yarn is wrapped and wound to obtain straight yarn 3.

[0075] Step (404): The curved yarn 4, the spring yarn 5 and the straight yarn 3 are tufted on the base fabric layer on a 1 / 16 inch tufting machine at a grass height of 15-60 mm and a needle count of 100 needles / m to form a skin-friendly layer, a shock-absorbing layer and a damping layer. The shock-absorbing layer is dark green, and the skin-friendly layer and the damping layer are olive green.

[0076] Step (405): back gluing the base fabric layer with styrene-butadiene adhesive, with the upper drying oven temperature at 100° C., the lower drying oven temperature at 40° C., the gluing humidity at 9%, the pull-out force at 46 N / cluster, and rolling to obtain artificial turf.

[0077] Example 6

[0078] A method for manufacturing artificial turf, comprising the following steps:

[0079] Step (501): 80 parts of polypropylene resin, 3 parts of masterbatch, 10 parts of PBT, 3 parts of epoxy graft polymer, 2 parts of silicone additive, and 3 parts of anti-aging additive are mixed evenly, added into a screw extruder and extruded at an extrusion temperature of 180-260°C, then stretched at a stretching temperature of 70°C, and then expanded at a puffing temperature of 180°C, a puffing pressure of 0.6 MPa, and a heat setting temperature of 140°C. Finally, the yarn 4 having a high decitex number, high curvature, and high resilience of the shock-absorbing layer is obtained by winding.

[0080] Step (502): 80 parts of polyethylene resin, 8 parts of polyethylene elastomer POE, 5 parts of masterbatch, 3 parts of oleic acid amide and 3 parts of anti-aging additive are mixed evenly, added into a screw extruder and extruded at an extrusion temperature of 180-260°C, then hot-stretched at a stretching temperature of 80°C, and then twisted, with S twist and Z twist, S twist being a right-handed direction and Z twist being a left-handed direction, with a twist of 40 twists, and then heat-set at a heat-setting temperature of 150°C, unwinding and winding to obtain spring wire 5.

[0081] Step (503): 70 parts of polyethylene resin, 10 parts of POE with a melt index of 1 g / 10 min, 5 parts of masterbatch, 3 parts of erucamide, 3 parts of anti-aging additive, 0.3 parts of cationic surfactant and 0.6 parts of nano-titanium dioxide are mixed uniformly, added to a screw extruder and extruded at an extrusion temperature of 180-260°C, then hot-stretched at a stretching temperature of 70°C, and then heat-set at a heat-setting temperature of 150°C, and the yarn is wrapped and wound to obtain straight yarn 3.

[0082] Step (504): The curved yarn 4, spring yarn 5 and straight yarn 3 are tufted on the base fabric layer on a 6 / 16 inch tufting machine at a grass height of 15-60 mm and a needle count of 200 needles / m to form a skin-friendly layer, a shock-absorbing layer and a damping layer. The shock-absorbing layer is dark green, and the skin-friendly layer and the damping layer are light green.

[0083] Step (505): back-glue the bottom fabric layer with SPU glue, the upper drying oven temperature of the back glue is 130°C, the lower drying oven temperature is 50°C, the glue humidity is 8%, the pull-out force is 50N / cluster, and the artificial turf is rolled up.

[0084] Example 7

[0085] A method for manufacturing artificial turf, comprising the following steps:

[0086] Step (601): 85 parts of polypropylene resin, 5 parts of masterbatch, 15 parts of nylon, 5 parts of block copolymer, 5 parts of silicone additive, and 5 parts of anti-aging additive are mixed evenly, added to a screw extruder and extruded at an extrusion temperature of 180-260°C, then stretched at a stretching temperature of 90°C, and then expanded at a puffing temperature of 250°C, a puffing pressure of 0.8 MPa, and a heat setting temperature of 180°C. Finally, the mixture is wound to obtain a curved yarn 4 having a high decitex number, high curvature, and high resilience of the shock-absorbing layer.

[0087] Step (602): 85 parts of polyethylene resin, 10 parts of metallocene polyethylene, 10 parts of masterbatch, 5 parts of oleic acid amide and 5 parts of anti-aging additive are mixed evenly, added into a screw extruder and extruded at an extrusion temperature of 180-260°C, then hot-stretched at a stretching temperature of 90°C, and then twisted, with S twist and Z twist, the S twist being right-handed and the Z twist being left-handed, with a twist of 70 twists, and then heat-set at a heat-setting temperature of 180°C, unwinding and winding to obtain a spring wire 5.

[0088] Step (603): 90 parts of polyethylene resin, 20 parts of POE with a melt index of 7.5 g / 10 min, 10 parts of masterbatch, 5 parts of fluorine additive, 5 parts of anti-aging additive, 1 part of non-ionic surfactant and 0.5 parts of nano-ceramic powder are mixed uniformly, added to a screw extruder for extrusion at an extrusion temperature of 180-260°C, then hot-stretched at a stretching temperature of 90°C, and then heat-set at a heat-setting temperature of 190°C, and the yarn is wrapped and wound to obtain straight yarn 3.

[0089] Step (604): The curved yarn 4, the spring yarn 5 and the straight yarn 3 are tufted on the base fabric layer on a 10 / 16 inch tufting machine at a grass height of 15-60 mm and a needle count of 400 needles / m to form a skin-friendly layer, a shock-absorbing layer and a damping layer. The shock-absorbing layer is dark green, and the skin-friendly layer and the damping layer are light green.

[0090] Step (605): The base fabric layer is back-glued with polyurethane adhesive, the upper drying oven temperature of the back-gluing is 150° C., the lower drying oven temperature is 70° C., the pulling force is 60 N / cluster, and the artificial turf is rolled up.

[0091] Example 8

[0092] A method for manufacturing artificial turf, comprising the following steps:

[0093] Step (701): 75 parts of polypropylene resin, 1 part of masterbatch, 1 part of PET, 1 part of random copolymer, 0.1 part of silicone additive, and 1.3 parts of anti-aging additive are mixed evenly, added into a screw extruder and extruded at an extrusion temperature of 180-260°C, then stretched at a stretching temperature of 60°C, and then expanded at a puffing temperature of 100°C, a puffing pressure of 0.4 MPa, and a heat setting temperature of 100°C. Finally, the yarn 4 having a high decitex number, high curvature, and high resilience of the shock-absorbing layer is obtained by winding.

[0094] Step (702): 80 parts of polyethylene resin, 1 part of masterbatch, 0.5 parts of oleic acid amide and 1.3 parts of anti-aging additive are mixed evenly, added into a screw extruder and extruded at an extrusion temperature of 180-260°C, then hot-stretched at a stretching temperature of 60°C, and then twisted. The twisting is divided into S twist and Z twist, the S twist is a right-handed direction, the Z twist is a left-handed direction, and the twist is 30 twists. Then, heat-set at a heat-setting temperature of 100°C, unwinding and winding to obtain spring wire 5.

[0095] Step (703): 60 parts of polyethylene resin, 5 parts of SEBS, 1 part of masterbatch, 0.5 parts of fluorine additive, 1.3 parts of anti-aging additive 0, 0.1 part of non-ionic surfactant and 1 part of nano-ceramic powder are mixed evenly, added into a screw extruder for extrusion at an extrusion temperature of 180-260°C, then hot-stretched at a stretching temperature of 60°C, and then heat-set at a heat-setting temperature of 90°C, and the yarn is wrapped and wound to obtain straight yarn 3.

[0096] Step (704): The curved yarn 4, spring yarn 5 and straight yarn 3 are tufted on the base fabric layer on a 1 / 16 inch tufting machine with a grass height of 15-60 mm and a needle count of 230 needles / m to form a skin-friendly layer, a shock-absorbing layer and a damping layer. The shock-absorbing layer is dark green, and the skin-friendly layer and the damping layer are apricot green.

[0097] Step (705): back-glue the bottom fabric layer with styrene-butadiene adhesive, with the upper drying oven temperature at 100°C, the lower drying oven temperature at 40°C, the laminating humidity at 9%, the pull-out force at 48N / cluster, and rolling to obtain artificial turf.

[0098] Embodiment 9

[0099] A method for manufacturing artificial turf, comprising the following steps:

[0100] Step (801): 80 parts of polypropylene resin, 5 parts of masterbatch, 5 parts of PBT, 5 parts of epoxy graft polymer, 3 parts of oleic acid amide, and 3 parts of anti-aging additive are mixed evenly, added to a screw extruder and extruded at an extrusion temperature of 180-260°C, then stretched at a stretching temperature of 70°C, and then expanded at a puffing temperature of 180°C, a puffing pressure of 0.6 MPa, and a heat setting temperature of 140°C. Finally, the yarn 4 having a high decitex number, high curvature, and high resilience of the shock-absorbing layer is obtained by winding.

[0101] Step (802): 85 parts of polyethylene resin, 5 parts of masterbatch, 3 parts of erucamide and 3 parts of anti-aging additive are mixed evenly, added into a screw extruder and extruded at an extrusion temperature of 180-260°C, then hot-stretched at a stretching temperature of 80°C, and then twisted, with S twist and Z twist, S twist being a right-handed direction and Z twist being a left-handed direction, with a twist of 40 twists, and then heat-set at a heat-setting temperature of 150°C, unwinding and winding to obtain spring wire 5.

[0102] Step (803): 80 parts of polyethylene resin, 10 parts of POE, 5 parts of masterbatch, 3 parts of fluorine additive, 3 parts of anti-aging additive, 0.5 parts of amphoteric surfactant and 1 part of nano zinc oxide are mixed evenly, added into a screw extruder for extrusion at an extrusion temperature of 180-260°C, then hot-stretched at a stretching temperature of 70°C, and then heat-set at a heat-setting temperature of 150°C, and the yarn is wrapped and wound to obtain straight yarn 3.

[0103] Step (804): The curved yarn 4, spring yarn 5 and straight yarn 3 are tufted on the base fabric layer on a 6 / 16 inch tufting machine with a grass height of 15-60 mm and a needle count of 200 needles / m to form a skin-friendly layer, a shock-absorbing layer and a damping layer. The shock-absorbing layer is dark green, and the skin-friendly layer and the damping layer are apricot green.

[0104] Step (805): The base fabric layer is back-glued with polyurethane adhesive, the upper drying oven temperature of the back-gluing is 130° C., the lower drying oven temperature is 50° C., the pulling force is 70 N / cluster, and the artificial turf is rolled up.

[0105] Example 10

[0106] A method for manufacturing artificial turf, comprising the following steps:

[0107] Step (901): 90 parts of polypropylene resin, 5 parts of masterbatch, 10 parts of nylon, 5 parts of maleic anhydride grafted polymer, 5 parts of oleic acid amide, and 5 parts of anti-aging additive are mixed evenly, added into a screw extruder for extrusion at an extrusion temperature of 180-260°C, then stretched at a stretching temperature of 90°C, and then expanded at a puffing temperature of 250°C, a puffing pressure of 0.8 MPa, and a heat setting temperature of 180°C. Finally, the yarn 4 having a high decitex number, high curvature, and high resilience of the shock-absorbing layer is obtained by winding.

[0108] Step (902): 98 parts of polyethylene resin, 10 parts of masterbatch, 5 parts of erucamide and 5 parts of anti-aging additive are mixed evenly, added into a screw extruder and extruded at an extrusion temperature of 180-260°C, then hot-stretched at a stretching temperature of 90°C, and then twisted, with S twist and Z twist, S twist being a right-handed direction and Z twist being a left-handed direction, with a twist of 70 twists, and then heat-set at a heat-setting temperature of 180°C, unwinding and winding to obtain spring wire 5.

[0109] Step (903): 90 parts of polyethylene resin, 20 parts of metallocene polyethylene, 10 parts of masterbatch, 5 parts of fluorine additive, 5 parts of anti-aging additive, 1 part of amphoteric surfactant and 5 parts of nano-titanium dioxide are mixed uniformly, added to a screw extruder and extruded at an extrusion temperature of 180-260°C, then hot-stretched at a stretching temperature of 90°C, and then heat-set at a heat-setting temperature of 190°C, and the yarn is wrapped and wound to obtain straight yarn 3.

[0110] Step (904): The curved yarn 4, the spring yarn 5 and the straight yarn 3 are tufted on the base fabric layer on a 10 / 16 inch tufting machine at a grass height of 15-60 mm and a needle count of 400 needles / m to form a skin-friendly layer, a shock-absorbing layer and a damping layer. The shock-absorbing layer is dark green, and the skin-friendly layer and the damping layer are olive green.

[0111] Step (905): The base fabric layer is back-glued with polyurethane glue, the upper drying oven temperature of the back-gluing is 150° C., the lower drying oven temperature is 70° C., the pulling force is 82 N / cluster, and the artificial turf is rolled up.

[0112] It is worth noting that the artificial turf in the present invention includes: a base fabric layer, a grass fiber layer tufted on the base fabric layer and a backing adhesive layer glued to the bottom of the base fabric layer. The grass fiber layer is composed of a skin-friendly layer, a shock-absorbing layer and a damping layer. The surface of the skin-friendly layer is silky and soft, and has a good cooling function, which is used to reduce the burn resistance and reduce the surface temperature of the lawn during exercise. The shock-absorbing layer has good resilience and is used for shock absorption and impact absorption during exercise to ensure the safety performance of exercise, while meeting the vertical rebound performance of the ball. The damping layer has a spring structure, has excellent resilience and anti-slip performance, and is used to solve the anti-slip performance and rotational resistance during exercise. The combination of the three layers greatly reduces the lawn's lodging and falling direction, meets the ball's sliding performance, and is an artificial turf suitable for training and sports.

[0113] The serial numbers of the above embodiments of the present invention are for description only and do not represent the advantages or disadvantages of the embodiments.

[0114] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc. made within the spirit and principles of the present invention should be included in the scope of protection of the present invention.

Claims

1. An artificial turf, characterized in that: The artificial turf comprises: a base fabric layer (1), a grass fiber layer tufted on the base fabric layer (1), and a backing adhesive layer (2) glued to the bottom of the base fabric layer (1); The grass silk layer consists of a skin-friendly layer, a shock-absorbing layer and a damping layer; The skin-friendly layer is composed of a plurality of straight threads (3) and is used to reduce burn resistance during exercise and lower the surface temperature of the lawn; The shock-absorbing layer is composed of a plurality of curved wires (4) and is used for shock absorption and impact absorption during exercise; The damping layer is composed of a plurality of spring wires (5) and has a spring structure. The spring wires (5) include a left-handed structure and a right-handed structure, and are used to solve the anti-slip performance and rotation resistance during the movement process. The decitex numbers of the spring wire (5) and the straight wire (3) are smaller than the decitex number of the curved wire (4), and the decitex number of the straight wire (3) is smaller than or equal to the decitex number of the spring wire (5); The colors of the spring wire (5) and the straight wire (3) are lighter than the color of the curved wire (4), and the color of the straight wire (3) is lighter than or equal to the color of the spring wire (5).

2. The artificial turf according to claim 1, characterized in that: The straight wire (3) is shaped in at least one of an S-shape, a wavy shape, a C-shape, a diamond shape, and an olive shape; the curved wire (4) is shaped in at least one of a flat wire, an olive shape, and a diamond shape; and the spring wire (5) is shaped in at least one of a C-shape, an S-shape, a wavy shape, and a diamond shape.

3. The artificial turf according to claim 1, characterized in that: During tufting, any two of the straight yarns (3), the curved yarns (4) and the spring yarns (5) are plied together and fed on both sides, or three of the grass yarns are plied together and fed on one side, or two of the grass yarns are plied together and another grass yarn is tufted in alternate rows; The tufting row spacing is 1 / 16~10 / 16 inches, and the number of needles is 100 needles / meter~400 needles / meter.

4. The artificial turf according to claim 3, characterized in that: The number of the curved wires (4), the straight wires (3) and the spring wires (5) in each bunch of grass wires is 2 to 12.

5. A method for manufacturing the artificial turf according to any one of claims 1 to 4, characterized in that: The method comprises: S1: mixing, extruding, drawing, expanding, and heat-setting the raw materials of the yarn to obtain the yarn (4); The spring wire raw materials are mixed, extruded, drawn, twisted, and heat-set to obtain the spring wire (5); The straight yarn raw materials are mixed, extruded, drawn, and heat-set to obtain the straight yarn (3); S2: Tufting the curved yarn (4), spring yarn (5) and straight yarn (3) onto the base fabric layer (1) to form a skin-friendly layer, a shock-absorbing layer and a damping layer; S3: Applying adhesive to the bottom of the base fabric layer (1) to obtain the artificial turf.

6. The method for manufacturing artificial turf according to claim 5, characterized in that: The raw materials for the curved yarn include: 85-98 parts of polypropylene resin, 1-5 parts of masterbatch, 0.1-5 parts of processing aids and 0.3-5 parts of anti-aging aids. The spring wire raw materials include: 80-90 parts of polyethylene resin, 1-10 parts of masterbatch, 0.5-5 parts of processing aid and 0.5-5 parts of anti-aging agent; The straight yarn raw materials include: 60-90 parts of polyethylene resin, 5-20 parts of metallocene polyethylene, 1-10 parts of masterbatch, 0.5-5 parts of processing aid, 0.5-5 parts of anti-aging aid, 0.1-1 parts of hydrophilic additive and 1-5 parts of cooling masterbatch; Among them, the processing aid is selected from at least one of fluorine additives, silicone additives, oleamide, erucamide and antistatic additives, the anti-aging additive is composed of antioxidants, ultraviolet absorbers and hindered amines, the metallocene polyethylene is selected from at least one of metallocene polyethylenes with a melt index of 0.2g / 10min, 0.5g / 10min, 1g / 10min and 2g / 10min, the hydrophilic additive is selected from at least one of anionic surfactants, nonionic surfactants, cationic surfactants and amphoteric surfactants, and the cooling masterbatch is selected from at least one of nano-titanium dioxide, nano-zinc oxide and nano-ceramic powder with reflective properties.

7. The method for manufacturing artificial turf according to claim 5, characterized in that: The yarn raw materials include: 75-85 parts of polypropylene resin, 1-5 parts of masterbatch, 5-15 parts of first modified resin, 1-5 parts of compatibilizer, 0.1-5 parts of processing aid and 0.3-5 parts of anti-aging agent. The spring wire raw materials include: 70-85 parts of polyethylene resin, 5-10 parts of second modified resin, 1-10 parts of masterbatch, 0.5-5 parts of processing aid and 0.5-5 parts of anti-aging agent; The straight yarn raw material includes: 60-90 parts of polyethylene resin, 5-20 parts of POE, 1-10 parts of masterbatch, 0.5-5 parts of processing aid, 0.5-5 parts of anti-aging additive, 0.1-0.5 parts of cooling masterbatch and 0.1-1 parts of hydrophilic additive; Among them, the first modified resin is selected from at least one of PET, PBT and nylon, the second modified resin is selected from at least one of thermoplastic elastomer SEBS, polyethylene elastomer POE and metallocene polyethylene, the compatibilizer is selected from at least one of maleic anhydride grafted polymer, epoxy grafted polymer, block copolymer and random copolymer, the processing aid is selected from at least one of fluorine additives, silicone additives, oleamide, erucamide and antistatic additives, the anti-aging additive is composed of antioxidants, ultraviolet absorbers and hindered amines, the POE is selected from at least one of POE with a melt index of 0.5g / 10min, 1g / 10min, 5g / 10min and 7.5g / 10min, the hydrophilic additive is selected from at least one of anionic surfactants, nonionic surfactants, cationic surfactants and amphoteric surfactants, and the cooling masterbatch is selected from at least one of nano-titanium dioxide, nano-zinc oxide and nano-ceramic powder with reflective properties.

8. The method for manufacturing artificial turf according to claim 5, characterized in that: The raw materials for the curved yarn include: 75-90 parts of polypropylene resin, 1-10 parts of high resilience modifying material, 1-5 parts of compatibilizer, 1-5 parts of masterbatch, 0.1-5 parts of processing aid and 0.3-5 parts of anti-aging agent; The spring wire raw materials include: 80-98 parts of polyethylene resin, 1-10 parts of masterbatch, 0.5-5 parts of processing aid and 0.5-5 parts of anti-aging agent; The straight yarn raw material comprises: 60-90 parts of polyethylene resin, 5-20 parts of modified material, 1-10 parts of masterbatch, 0.5-5 parts of processing aid, 0.5-5 parts of anti-aging aid, 0.1-1 parts of hydrophilic additive and 1-5 parts of cooling masterbatch; Among them, the compatibilizer is selected from at least one of maleic anhydride grafted polymers, epoxy grafted polymers, block copolymers and random copolymers, the processing aid is selected from at least one of fluorine additives, silicone additives, oleamide, erucamide and antistatic additives, the high resilience modified material is selected from at least one of PET, PBT and nylon, the anti-aging additive is composed of an antioxidant, an ultraviolet absorber and a hindered amine, the modified material is selected from at least one of metallocene polyethylene, POE and SEBS, the hydrophilic additive is selected from at least one of anionic surfactants, nonionic surfactants, cationic surfactants and amphoteric surfactants, and the cooling masterbatch is selected from at least one of nano-titanium dioxide, nano-zinc oxide and nano-ceramic powder with reflective properties.

9. The method for manufacturing artificial turf according to claim 5, characterized in that: In S1, the extrusion temperature of the mixed curved yarn raw materials is 180-260°C, the drawing temperature is 60-90°C, the expanding temperature is 100-250°C, the expanding pressure is 0.4-0.8 MPa, and the heat setting temperature is 100-180°C; the extrusion temperature of the mixed spring yarn raw materials is 180-260°C, the drawing temperature is 60-90°C, the twisting is divided into S twist and Z twist, S twist is right-handed, Z twist is left-handed, the twist is 10-70 twists, and the heat setting temperature is 100-180°C; the extrusion temperature of the mixed straight yarn raw materials is 180-260°C, the drawing temperature is 60-90°C, and the heat setting temperature is 90-180°C; In said S2, said tufting comprises: tufting the base fabric layer on a 1 / 16 inch to 10 / 16 inch tufting machine at a grass height of 15 to 60 mm and a needle count of 100 to 400 needles per meter; In S3, the backing of the base fabric layer is performed using any one of styrene-butadiene adhesive, styrene-acrylic adhesive, polyurethane adhesive and SPU adhesive, the temperature of the upper drying channel for the backing is 100-150° C., the temperature of the lower drying channel is 40-70° C., the humidity of the glue is less than 10%, and the pull-out force is greater than 45 N / tuft, and the artificial turf is rolled up to obtain the artificial turf.

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