Reinforced artificial turf, adhesive latex for artificial turf and method of production

Abstract

The invention discloses a kind of complex bottom artificial turf, adhesive latex for artificial turf and production method, complex bottom artificial turf includes grass silk, base cloth and bottom cloth, grass silk is woven on base cloth, the bottom end of grass silk protrudes from the bottom surface of base cloth, bottom cloth is below base cloth, and bottom cloth is fixed by being bonded between the base cloth and adhesive latex, the bottom end of grass silk is covered by bottom cloth;Adhesive latex viscosity is 15000-30000mpa.s, and by mass percentage, it includes the following raw materials: carboxyl styrene latex 10-30%, polyvinyl acetate emulsion 10-30%, calcium carbonate powder 40-80%, dispersing agent 0.2-0.8%, defoaming agent 0.2-1% and fungicide 0.2-0.8%.The invention solves the problem of poor performance and short service life of existing artificial turf.

Description

Technical Field

[0001] This invention belongs to the field of artificial turf technology, specifically relating to a multi-layered artificial turf, an adhesive latex for artificial turf, and a production method thereof. Background Technology

[0002] Artificial turf includes injection-molded artificial turf and woven artificial turf (woven lawn). Compared to injection-molded artificial turf, woven artificial turf has a higher degree of realism. Woven lawn uses synthetic fibers (i.e., grass fibers) that mimic grass blades embedded in a base fabric, with a coating applied to the back to fix and protect the roots of the grass fibers. In daily use, the bottom of the woven lawn, i.e., the coating, is in contact with the ground. Walking or running on the woven lawn causes friction between the coating and the ground, resulting in partial peeling off of the coating. Because the bottom ends of the grass fibers protrude from the bottom surface of the base fabric, even after the coating is applied, these protruding ends still experience greater friction. Therefore, after a period of use, the grass fibers may fall off, resulting in a shorter lifespan for woven lawns. Furthermore, to completely cover the bottom ends of the grass fibers, the entire bottom surface of the base fabric is usually completely covered by the coating, which makes the woven lawn relatively hard and has poor water permeability. Therefore, it is necessary to propose a new type of artificial turf to solve these problems. Summary of the Invention

[0003] To address the aforementioned technical problems, the present invention aims to provide a composite artificial turf, an adhesive latex for artificial turf, and a production method thereof, thereby resolving the issues of poor performance and short service life of existing artificial turf.

[0004] To achieve the above-mentioned objectives, the technical solution adopted by the present invention is as follows:

[0005] In a first aspect, the present invention provides a multi-layered artificial turf, comprising grass fibers, a base fabric, and a backing fabric. The grass fibers are woven onto the base fabric, and the bottom ends of the grass fibers protrude from the bottom surface of the base fabric. The backing fabric is located below the base fabric, and the backing fabric and the base fabric are fixed together by adhesive latex. The bottom ends of the grass fibers are covered by the backing fabric.

[0006] Preferably, the base fabric includes any one of levorotatory fabric, mesh fabric, PP fabric, or nonwoven fabric; the sub-fabric includes any one of levorotatory fabric, mesh fabric, PP fabric, or nonwoven fabric.

[0007] More preferably, the base fabric is provided with multiple water-permeable zones, and a water-permeable channel is formed between the substrate and the base fabric.

[0008] In a second aspect, the present invention provides an adhesive latex for artificial turf, having a viscosity of 15,000 to 30,000 mPa·s, and comprising, by mass percentage, the following raw materials: 10 to 30% carboxylated styrene-butadiene latex, 10 to 30% polyvinyl acetate emulsion, 40 to 80% calcium carbonate powder, 0.2 to 0.8% dispersant, 0.2 to 1% defoamer, and 0.2 to 0.8% bactericide.

[0009] Preferably, the carboxylated styrene-butadiene latex has a solid content of 46-51%, a viscosity of 100-300 mPa·s, and a particle size of 120-180 nm.

[0010] Preferably, the polyvinyl acetate emulsion has a VA value of 75-90%, a pH value of 4-6, a latex particle size of 0.3-0.6 μm, and a solid content of 35-60%.

[0011] Preferably, the dispersant comprises one or more of polynaphthalene sulfonate, sodium dodecylbenzene sulfonate, and potassium dodecylbenzene sulfonate.

[0012] Preferably, the particle size of the calcium carbonate powder is 300-800 mesh.

[0013] In a third aspect, the present invention also provides a method for producing multi-layered artificial turf, comprising the following steps:

[0014] S1. Weave grass fibers onto the front side of the base fabric;

[0015] S2. A pre-designed water-permeable area is formed on the bottom surface of the base fabric. Adhesive latex is applied along the edge of the water-permeable area to surround it, and then it is dried.

[0016] S3. Apply adhesive latex to the area outside the water-permeable zone on the bottom surface of the base fabric, cover the bottom surface of the base fabric with the backing fabric, press the backing fabric and the base fabric together with the pressure roller, and obtain the composite artificial turf after drying.

[0017] Preferably, in steps S2 and S3, the drying temperature is 100–120°C.

[0018] Beneficial effects:

[0019] This invention uses a base fabric to cover the bottom of the substrate, which protects the ends of the grass fibers and prevents the bottom ends of the grass fibers from directly contacting and rubbing against the ground, effectively extending the service life of the artificial turf. The base fabric and the substrate are bonded together with an adhesive latex, which has advantages such as strong adhesion, good aging resistance, high temperature resistance, and excellent hydrolysis resistance, which helps to improve the performance of the artificial turf. Attached Figure Description

[0020] Figure 1 The diagram shown is a structural schematic of the present invention.

[0021] Reference numerals: 1-base fabric, 2-adhesive latex, 3-backing fabric, 4-water-permeable area. Detailed Implementation

[0022] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, specific implementation methods of the present invention will be described below. Obviously, the following description is merely some embodiments of the present invention; those skilled in the art can obtain other implementation methods based on these embodiments without creative effort.

[0023] like Figure 1 As shown, this invention provides a multi-layered artificial turf, comprising grass fibers, a base fabric 1, and a backing fabric 3. The grass fibers are woven onto the base fabric 1, with the bottom ends of the grass fibers protruding from the bottom surface of the base fabric 1. The backing fabric 3 is located below the base fabric 1, and the backing fabric 3 and the base fabric 1 are bonded together using adhesive latex 2. The bottom ends of the grass fibers are bonded and fixed by the adhesive latex 2 and covered by the backing fabric 3. In this invention, the bottom ends of the grass fibers are hidden between the backing fabric 3 and the base fabric 1, and do not directly contact the ground. The backing fabric 3 and the bottom ends of the grass fibers have a protective function. When the backing fabric 3 comes into contact with and rubs against the ground, the grass fibers and the base fabric 1 are not affected, thus extending the service life of the artificial turf.

[0024] Furthermore, since the bottom of the grass fibers is protected by the backing fabric 3, the latex between the backing fabric 3 and the base fabric 1 does not have to completely cover the bottom of the grass fibers. For example, when the base fabric 1 is coated with latex, a water seepage area is reserved, and no latex is coated on the water seepage area 4 of the base fabric 1. After the backing fabric 3 and the base fabric 1 are bonded and fixed, a water seepage channel is formed between the backing fabric 3 and the base fabric 1, which makes it easy to drain the water accumulated on the artificial turf.

[0025] It should be noted that, Figure 1 The image shows the location of the water-permeable area 4 within the adhesive latex layer 2. The corresponding locations on the base fabric 1 and the bottom fabric 3 are also water-permeable areas 4. Figure 1 To make it easier to show the location of the seepage zone 4, the size of the seepage zone is shown in a larger form. It is easy to understand that in this invention, the size of the seepage zone is small and avoids the area at the end of the grass fibers as much as possible. For example, the seepage zone is set along the gap between adjacent horizontal or vertical rows of grass fibers.

[0026] In this invention, both the base fabric 1 and the bottom fabric 3 are made of materials with good water permeability, including any one of nylon fabric (PP or polyester), mesh fabric (PP), PP fabric or non-woven fabric (PET).

[0027] In existing technologies, the base of conventional artificial turf requires a complete coating. Typically, this coating is formed using asphalt or hot melt adhesive. For example, hot melt adhesive powder is first sprinkled onto the base fabric 1 with woven grass fibers. Under high temperature conditions, the hot melt adhesive powder melts, and then the molten hot melt adhesive is completely applied to the base fabric 1 using rollers or similar devices. After cooling, the coating is formed. Alternatively, molten asphalt is coated onto the base fabric 1 with woven grass fibers, and the coating is formed after cooling. This type of coating has extremely poor water permeability, and the artificial turf is relatively stiff overall, resulting in a low degree of realism.

[0028] In this invention, the bottom and the base fabric 1 are made of soft materials, and since the latex does not come into direct contact with the ground, it is less affected by direct friction from the ground. The latex needs to have strong adhesion, good aging resistance, good high temperature resistance, and excellent hydrolysis resistance.

[0029] This invention proposes an adhesive latex 2 for artificial turf, with a viscosity of 15,000–30,000 mPa·s, comprising the following raw materials by mass percentage: 10–30% carboxylated styrene-butadiene latex, 10–30% polyvinyl acetate emulsion, 40–80% calcium carbonate powder, 0.2–0.8% dispersant, 0.2–1% defoamer, and 0.2–0.8% bactericide.

[0030] The dispersant includes one or more of polynaphthalenesulfonate, sodium dodecylbenzenesulfonate, and potassium dodecylbenzenesulfonate. The defoamer includes polysiloxane-polyether copolymer.

[0031] Pure carboxylated styrene-butadiene latex has insufficient adhesion to the base fabric 3 of this invention, and its overall hardness is relatively high. This invention improves the latex composition by mixing carboxylated styrene-butadiene latex with polyvinyl acetate emulsion to increase bonding strength, and by incorporating calcium carbonate powder to enhance latex performance. The latex of this invention is suitable for manufacturing multi-layer artificial turf, exhibiting excellent hydrolysis resistance. Even with a permeable zone 4 within the multi-layer artificial turf, the latex adhesion between the base fabric 1 and the base fabric 3 remains unaffected.

[0032] In this invention, the content of each component is limited. Excessive content of carboxylated styrene-butadiene latex will significantly reduce the adhesiveness and water resistance of adhesive latex 2, while excessive calcium carbonate powder will significantly reduce the adhesive strength of the latex.

[0033] In this invention, carboxylated styrene-butadiene latex is generated by polymerization of butadiene, styrene, carboxylic acid and additives, with a solid content of 46-51%, a viscosity of 100-300 mPa·s, and a particle size of 120-180 nm for butadiene-styrene latex particles.

[0034] In this invention, the polyvinyl acetate emulsion has a VA value of 75-90%, a pH value of 4-6, a latex particle size of 0.3-0.6 μm, and a solid content of 35-60%.

[0035] The dispersant includes one or more of the following: sodium polynaphthalene sulfonate, sodium dodecylbenzene sulfonate, and potassium dodecylbenzene sulfonate.

[0036] The particle size of calcium carbonate powder is 300-800 mesh. If the calcium carbonate particle size is too small, it will result in a high oil absorption value, affecting the filling amount and the degree of latex dispersion, causing a significant increase in the viscosity of the system and making it difficult to stir; if the calcium carbonate particle size is too large, it will affect the strength of the mixed latex and reduce the latex adhesion.

[0037] It should be noted that the latex of the present invention is applicable to the multi-layer artificial turf of the present invention and is designed based on the structure of multi-layer artificial turf. Since a water-permeable area 4 needs to be reserved between the base fabric 1 and the back fabric 3, if existing hot melt adhesives or molten asphalt are used to bond the base fabric 1 and the back fabric 3, the water-permeable area 4 will be completely covered during the coating process, failing to achieve the purpose of reserving the water-permeable area 4. The latex of the present invention can achieve bonding between the base fabric 1 and the back fabric 3 under relatively low temperature conditions. More preferably, the present invention also provides a method for producing multi-layer artificial turf, the specific steps of which are as follows:

[0038] S1. Weave grass fibers on the front side of base fabric 1;

[0039] S2. A pre-set water-permeable area 4 is formed on the bottom surface of the base fabric 1. Adhesive latex 2 is applied along the edge of the water-permeable area 4 to surround the water-permeable area 4, and then dried.

[0040] S3. Apply adhesive latex 2 to the area outside the water-permeable area 4 on the bottom surface of the base fabric 1, cover the bottom surface of the base fabric 1 with the base fabric 3, press the base fabric 3 and the base fabric 1 together with the pressure roller, and obtain the composite artificial turf after drying.

[0041] In step S2, the seepage area 4 is first surrounded by adhesive latex, which facilitates the bonding of the base fabric 3 and the base fabric 1 in the subsequent step S3. Since the seepage area 4 is pre-surrounded by adhesive latex, when the base fabric 3 and the base fabric 1 are pressed together in step S3, the already dried adhesive latex at the edge of the seepage area 4 acts as a barrier against liquid adhesive latex, preventing adhesive latex outside the seepage area 4 from being squeezed into it. Preferably, in steps S2 and S3, the drying temperature is 100–120°C.

[0042] The technical solution of the present invention will be described in detail below with specific embodiments.

[0043] Example 1

[0044] Adhesive latex 2 comprises the following components: 10% carboxylated styrene-butadiene latex, 30% polyvinyl acetate emulsion, 57.6% calcium carbonate powder, 0.6% dispersant, 1% defoamer, and 0.8% bactericide, wherein the particle size of the calcium carbonate powder is 300 mesh.

[0045] Grass fibers are woven on the front side of the base fabric 1; a water-permeable area 4 is pre-set on the bottom surface of the base fabric 1, and adhesive latex 2 is applied along the edge of the water-permeable area 4 to surround the water-permeable area 4, and then dried at 100°C; adhesive latex 2 is applied to the area outside the water-permeable area 4 on the bottom surface of the base fabric 1, and the base fabric 3 is covered on the bottom surface of the base fabric 1. The base fabric 3 and the base fabric 1 are pressed together by a pressure roller, and after drying at 100°C, a composite artificial turf is obtained.

[0046] Example 2

[0047] Adhesive latex 2 comprises the following components: 18% carboxylated styrene-butadiene latex, 30% polyvinyl acetate emulsion, 49.9% calcium carbonate powder, 0.5% dispersant, 0.8% defoamer, and 0.8% bactericide, wherein the particle size of the calcium carbonate powder is 500 mesh.

[0048] Grass fibers are woven on the front side of the base fabric 1; a water-permeable area 4 is pre-set on the bottom surface of the base fabric 1, and adhesive latex 2 is applied along the edge of the water-permeable area 4 to surround the water-permeable area 4, and then dried at 110°C; adhesive latex 2 is applied to the area outside the water-permeable area 4 on the bottom surface of the base fabric 1, and the base fabric 3 is covered on the bottom surface of the base fabric 1. The base fabric 3 and the base fabric 1 are pressed together by a pressure roller, and after drying at 110°C, a multi-layered artificial turf is obtained.

[0049] Example 3

[0050] Adhesive latex 2 comprises the following components: 28.1% carboxylated styrene-butadiene latex, 30% polyvinyl acetate emulsion, 40% calcium carbonate powder, 0.5% dispersant, 0.8% defoamer, and 0.6% bactericide, wherein the particle size of the calcium carbonate powder is 800 mesh.

[0051] Grass fibers are woven on the front side of the base fabric 1; a water-permeable area 4 is pre-set on the bottom surface of the base fabric 1, and adhesive latex 2 is applied along the edge of the water-permeable area 4 to surround the water-permeable area 4, and then dried at 120°C; adhesive latex 2 is applied to the area outside the water-permeable area 4 on the bottom surface of the base fabric 1, and the base fabric 3 is covered on the bottom surface of the base fabric 1. The base fabric 3 and the base fabric 1 are pressed together by a pressure roller, and after drying at 120°C, a multi-layered artificial turf is obtained.

[0052] Comparative Example 1

[0053] Compared with Example 1, in this comparative example, only carboxylated styrene-butadiene latex was used as the adhesive latex.

[0054] Grass fibers are woven on the front side of the base fabric 1; a water-permeable area 4 is pre-set on the bottom surface of the base fabric 1, and adhesive latex 2 is applied along the edge of the water-permeable area 4 to surround the water-permeable area 4, and then dried at 100°C; adhesive latex 2 is applied to the area outside the water-permeable area 4 on the bottom surface of the base fabric 1, and the base fabric 3 is covered on the bottom surface of the base fabric 1. The base fabric 3 and the base fabric 1 are pressed together by a pressure roller, and after drying at 100°C, a composite artificial turf is obtained.

[0055] In this comparative example, the adhesive properties and water resistance of the adhesive latex 2 decreased. During use, there was obvious separation between the base fabric 1 and the bottom fabric 3 in the area near the water seepage zone 4, and there was also partial separation between the base fabric 1 and the bottom fabric 3 in other areas.

[0056] Comparative Example 2

[0057] Compared with Example 1, in this comparative example, the adhesive latex contains an excess of carboxylated styrene-butadiene latex.

[0058] Adhesive latex 2 comprises the following components: 50% carboxylated styrene-butadiene latex, 0% polyvinyl acetate emulsion, 47.4% calcium carbonate powder, 0.8% dispersant, 0.8% defoamer, and 1% bactericide, wherein the particle size of the calcium carbonate powder is 300 mesh.

[0059] Grass fibers are woven on the front side of the base fabric 1; a water-permeable area 4 is pre-set on the bottom surface of the base fabric 1, and adhesive latex 2 is applied along the edge of the water-permeable area 4 to surround the water-permeable area 4, and then dried at 100°C; adhesive latex 2 is applied to the area outside the water-permeable area 4 on the bottom surface of the base fabric 1, and the base fabric 3 is covered on the bottom surface of the base fabric 1. The base fabric 3 and the base fabric 1 are pressed together by a pressure roller, and after drying at 100°C, a composite artificial turf is obtained.

[0060] In this comparative example, the adhesive properties and water resistance of the adhesive latex 2 decreased. During use, the base fabric 1 and the bottom fabric 3 separated in the area near the water seepage zone 4, and the base fabric 1 and the bottom fabric 3 also separated in other areas.

[0061] The composite artificial turf of Example 1 and Comparative Example 1 were tested. The test items included grass fiber pull-out force, hot water pull-out rate and water seepage rate. The test results are shown in Table 1 below.

[0062] Table 1 shows the test results for Example 1 and Comparative Example 1.

[0063] project standard Example 1 Comparative Example 1 Grass fiber pulling force / N GB20394-2019 57.65 44.89 Hot water test pull-out force / N EN13744 43.41 28.74 Permeability - mm / h EN12612-2013 10352 8764

[0064] According to the results of Examples 1-3 and Comparative Examples 1-2, the adhesive latex 2 plays an important role in the bonding of the base fabric 1 and the bottom fabric 3. Since the present invention sets a water-permeable zone 4 between the base fabric 1 and the bottom fabric 3, when the adhesive latex 2 is not strong enough, separation will occur in the area near the water-permeable zone 4, and the performance of the composite artificial turf will be significantly affected.

[0065] According to the test results, the adhesive latex 2 of Example 1 is suitable for the composite artificial turf of the present invention. The composite artificial turf manufactured by the present invention has a high water permeability and good bonding performance. Under water permeability, the grass fibers and the base fabric 1 maintain a high bonding strength, and the base fabric 1 and the bottom fabric 3 also maintain a high bonding strength.

[0066] The embodiments provided by the present invention have been described in detail above. Specific examples have been used to illustrate the principles and implementation methods of the present invention, and the descriptions of the embodiments above are only for the purpose of helping to understand the core ideas of the present invention. It should be noted that those skilled in the art can make several improvements and modifications to the present invention without departing from the principles of the present invention, and these improvements and modifications also fall within the protection scope of the claims of the present invention.

Claims

1. A multi-layered artificial turf, characterized in that, It includes grass fibers, a base fabric (1) and a bottom fabric (3). The grass fibers are woven on the base fabric (1) and the bottom end of the grass fibers protrudes from the bottom surface of the base fabric (1). The bottom fabric (3) is located below the base fabric (1). The bottom fabric (3) and the base fabric (1) are fixed together by adhesive latex (2). The bottom end of the grass fibers is covered by the bottom fabric (3). The base fabric (3) includes any one of levorotatory fabric, mesh fabric, PP fabric or non-woven fabric; the base fabric (1) includes any one of levorotatory fabric, mesh fabric, PP fabric or non-woven fabric. The base fabric (1) is provided with multiple water-permeable zones (4), and a water-permeable channel is formed between the base fabric and the bottom fabric (3); The production process of composite artificial turf involves the following steps: S1. Weave grass fibers on the front side of the base fabric (1); S2. A pre-set water-permeable area (4) is made on the bottom surface of the base fabric (1). Adhesive latex (2) is applied along the edge of the water-permeable area (4) to surround the water-permeable area (4), and then dried. S3. Apply adhesive latex (2) to the area outside the water-permeable area (4) on the bottom surface of the base fabric (1), cover the bottom surface of the base fabric (1) with the base fabric (3), press the base fabric (3) and the base fabric (1) together with the pressure roller, and obtain the composite artificial turf after drying.

2. The multi-layered artificial turf according to claim 1, characterized in that, In steps S2 and S3, the drying temperature is 100–120°C.

3. The multi-layered artificial turf according to claim 1 or 2, characterized in that, The adhesive latex (2) has a viscosity of 15,000 to 30,000 mPa·s and, by mass percentage, comprises the following raw materials: The composition includes 10-30% carboxylated styrene-butadiene latex, 10-30% polyvinyl acetate emulsion, 40-80% calcium carbonate powder, 0.2-0.8% dispersant, 0.2-1% defoamer, and 0.2-0.8% bactericide.

4. The multi-layered artificial turf according to claim 3, characterized in that, The carboxylated styrene-butadiene latex has a solid content of 46-51%, a viscosity of 100-300 mPa·s, and a particle size of 120-180 nm.

5. The multi-layered artificial turf according to claim 3, characterized in that, The polyvinyl acetate emulsion has a VA value of 75-90%, a pH value of 4-6, a latex particle size of 0.3-0.6 μm, and a solid content of 35-60%.

6. The multi-layered artificial turf according to claim 3, characterized in that, The dispersant includes one or more of polynaphthalene sulfonate, sodium dodecylbenzene sulfonate, and potassium dodecylbenzene sulfonate.

7. The multi-layered artificial turf according to claim 3, characterized in that, The calcium carbonate powder has a particle size of 300-800 mesh.

Images