A reinforced weft layer for a turf base structure

Abstract

The utility model relates to the technical field of artificial turf, and particularly discloses an artificial turf base cloth structure with reinforced weft yarn layers, which comprises a base layer and a tufting layer, further comprises a reinforcing layer, the reinforcing layer is composed of a plurality of parallel and spaced weft yarn reinforcing units, the material of the weft yarn reinforcing unit is high modulus synthetic fiber material, the reinforcing layer is combined with the base layer through weaving and is located between the base layer and the tufting layer, so that the tufting fibers constituting the tufting layer successively pierce through the reinforcing layer and the base layer from top to bottom, the built-in high modulus weft yarn reinforcing layer strengthens the weakest horizontal mechanical properties of the artificial turf base cloth, improves the tensile resistance, creep resistance and tear resistance of the artificial turf base cloth, thereby ensuring that the artificial turf remains flat and stable in long-term use, eliminating the problems of wrinkles and joint cracking, and prolonging the service life. The structure is designed ingeniously, has good compatibility with the existing weaving and tufting processes, is easy to implement and controllable in cost.

Description

Technical Field

[0001] This utility model relates to the field of artificial turf technology, and specifically discloses an artificial turf base fabric structure with reinforced weft yarn layers. Background Technology

[0002] Artificial turf is widely used in sports fields, recreational green spaces, courtyards, and other occasions. It typically consists of a base fabric, grass fibers tufted onto the base fabric, and a coating or adhesive backing. As the load-bearing structure of the artificial turf, the mechanical properties of the base fabric, especially its dimensional stability, directly affect the turf's lifespan and performance.

[0003] Currently, most artificial turf base fabrics are woven from materials such as polypropylene. In practical use, especially in high-intensity sports fields, the base fabric not only bears the vertical load from the grass fibers but also frequently experiences horizontal shear and tensile forces from various directions. The weft direction (lateral direction) is often the relatively weak direction of the base fabric, making it prone to creep, tensile deformation, and even localized tearing due to repeated stress and changes in ambient temperature (thermal expansion and contraction). This weft deformation can cause problems such as undulations, wrinkles, and seam cracks in the entire turf surface, seriously affecting performance, sports safety, and aesthetics.

[0004] While some methods exist to improve strength by modifying the base fabric material or increasing the overall weight, these often result in significant cost increases and limited targeted improvements to weft performance. Therefore, there is an urgent need for a structural solution that can effectively and economically enhance the weft stability of the base fabric. Utility Model Content

[0005] This invention proposes an artificial turf base fabric structure with reinforced weft yarn layer. By incorporating a high-modulus weft yarn reinforcement layer, the weakest point of the artificial turf base fabric, transverse mechanical properties, are strengthened, and its tensile strength, creep resistance, and tear resistance are improved.

[0006] This invention is implemented as follows: an artificial turf base fabric structure with reinforced weft layer includes a base layer and a tufted layer, and also includes a reinforcing layer. The reinforcing layer is composed of multiple parallel and spaced weft reinforcing units. The material of the weft reinforcing units is a high-modulus synthetic fiber material. The reinforcing layer is woven together with the base layer and is located between the base layer and the tufted layer, so that the tufted fibers constituting the tufted layer pierce through the reinforcing layer and the base layer sequentially from top to bottom.

[0007] As a preferred embodiment of the artificial turf base fabric structure for reinforcing the weft layer of this utility model, the weft reinforcing unit is one of glass fiber filament, aramid fiber filament, or ultra-high modulus polyethylene fiber filament.

[0008] As a preferred embodiment of the artificial turf base fabric structure for reinforcing the weft yarn layer of this utility model, the weft yarn reinforcing units are arranged in a uniformly spaced manner, and the spacing between two adjacent weft yarn reinforcing units is 1 to 5 times the original weft yarn spacing of the base layer.

[0009] As a preferred embodiment of the artificial turf base fabric structure with reinforced weft yarn layer of this utility model, the reinforcing layer is integrated with the base layer by weaving. The weft yarn reinforcing unit, as an independent reinforcing weft yarn, is interwoven with the warp yarn and the base weft yarn of the base layer according to a preset pattern to form an integrated fabric.

[0010] As a preferred embodiment of the artificial turf base fabric structure with reinforced weft yarn layer according to this utility model, the elastic modulus of the weft yarn reinforcing unit is not less than 10 GPa.

[0011] As a preferred embodiment of the artificial turf base fabric structure with reinforced weft yarn layer of this utility model, the back side of the base layer is further coated with an adhesive layer, and the coating material of the adhesive layer penetrates into the fabric gaps of the base layer and covers the surface of the weft yarn reinforcing unit located on the back side.

[0012] The beneficial effects of this utility model are: By incorporating a built-in high-modulus weft reinforcement layer, the weakest point of the artificial turf base fabric—the transverse mechanical properties—is strengthened, enhancing its tensile, creep, and tear resistance. This ensures the turf remains flat and stable over the long term, eliminating wrinkles and seam cracking, and extending its service life. The ingenious structural design is highly compatible with existing weaving and tufting processes, making implementation simple and cost-effective. Attached Figure Description

[0013] To more clearly illustrate the specific embodiments of this utility model or the technical solutions in the prior art, the drawings used in the description of the specific embodiments or the prior art will be briefly introduced below. In all the drawings, similar elements or parts are generally identified by similar reference numerals. In the drawings, the elements or parts are not necessarily drawn to scale.

[0014] Figure 1 This is a cross-sectional view of the present invention. Figure 2 This is a schematic diagram of the weft yarn reinforcement unit structure of this utility model.

[0015] The markings in the diagram are: 1. Base layer; 2. Reinforcing layer; 3. Tufted layer; 4. Backing adhesive layer; 5. Weft yarn reinforcement unit. Detailed Implementation

[0016] The present invention will be further described below with reference to the accompanying drawings and specific embodiments to aid in understanding its content. Unless otherwise specified, the methods used in this invention are conventional methods; the raw materials and apparatus used, unless otherwise specified, are conventional commercially available products.

[0017] Please see Figure 1-2 An artificial turf base fabric structure with reinforced weft layers includes a base layer 1 and a tufted layer 3, and also includes a reinforcing layer 2. The reinforcing layer 2 is composed of multiple parallel and spaced weft reinforcing units 5. The weft reinforcing units 5 are made of high-modulus synthetic fiber material. The reinforcing layer 2 is woven together with the base layer 1 and is located between the base layer 1 and the tufted layer 3, so that the tufted fibers constituting the tufted layer 3 pierce through the reinforcing layer 2 and the base layer 1 from top to bottom.

[0018] In this embodiment: Above the base layer 1 and below the tufted layer 3, a reinforcing layer 2 is integrated, consisting of parallel arrangement of multiple high-modulus synthetic fiber weft reinforcing units 5. This layer is then woven together with the base layer 1. When the tufted fibers pierce through the reinforcing layer 2 and the base layer 1 from top to bottom, these spaced weft reinforcing units 5 act as a rigid skeleton, firmly woven into the base fabric structure. This directly and specifically bears and disperses the tensile and shear stress borne by the base fabric in the weft direction (transverse direction), constraining the elastic deformation and creep tendency of the base fabric in the weft direction. This structurally improves the overall transverse dimensional stability and tear resistance of the artificial turf, effectively preventing problems such as surface undulation and seam cracking.

[0019] As a technical optimization of this utility model, the weft reinforcing unit 5 is one of glass fiber filament, aramid fiber filament or ultra-high modulus polyethylene fiber filament.

[0020] In this embodiment, specific high-modulus fibers such as glass fiber, aramid, or ultra-high modulus polyethylene are selected as the materials for the weft reinforcing unit 5. These materials themselves have extremely high tensile modulus and strength, and can provide the base fabric with extremely significant weft tensile and deformation resistance with a finer diameter or less dosage, resulting in high reinforcement efficiency.

[0021] As a technical optimization of this utility model, the weft yarn reinforcing units 5 are arranged in a uniformly spaced manner, and the spacing between two adjacent weft yarn reinforcing units 5 is 1 to 5 times the original weft yarn spacing of the base layer 1.

[0022] In this embodiment, the amount of material used can be optimized while ensuring that the base layer 1 is supported by an effective and uniform latitudinal reinforcing grid.

[0023] As a technical optimization of this utility model, the reinforcing layer 2 is integrated with the base layer 1 by weaving. The weft yarn reinforcing unit 5, as an independent reinforcing weft yarn, is interwoven with the warp yarn of the base layer 1 and the base weft yarn of the base layer 1 according to a preset pattern to form an integrated fabric.

[0024] In this embodiment, the reinforcing layer 2 and the base layer 1 are combined into an integrated fabric with a unified physical structure at the source of production, with a strong and reliable bonding force, avoiding the risk of interlayer separation that may occur in later composite processes, and the production process is consistent.

[0025] As a technical optimization of this utility model, the elastic modulus of the weft yarn reinforcing unit 5 is not less than 10 GPa.

[0026] In this embodiment, the incorporated reinforcement unit is ensured to have sufficient basic rigidity to resist deformation of the base fabric.

[0027] As a technical optimization of this utility model, the back of the base layer 1 is also coated with an adhesive layer 4. The coating material of the adhesive layer 4 penetrates into the fabric gap of the base layer 1 and covers the surface of the weft yarn reinforcing unit 5 located on the back side.

[0028] In this embodiment: an adhesive layer 4 is provided on the back of the base layer 1, and the adhesive penetrates into the fabric and covers the back of the weft reinforcing unit 5. The adhesive layer 4 can not only fix the roots of the grass fibers, but also further anchor the weft reinforcing unit 5 in the base fabric structure to prevent it from shifting during use. At the same time, the coating of the fibers by the adhesive can also play a certain protective role and improve durability.

[0029] The working principle and usage process of this utility model are as follows: First, during the weaving of the base layer 1, the high-modulus filaments serving as weft reinforcement units 5 are woven together with the warp yarns and conventional base weft yarns of the base layer 1 according to a set interval pattern (e.g., every few base weft yarns) to form an integrated composite base fabric. Subsequently, in the tufting process, tufting needles carrying grass fibers (i.e., the fibers constituting the tufted layer 3) pierce downwards from the front of the composite base fabric, forcefully penetrating the reinforcing layer 2 area composed of weft reinforcement units 5 and the base layer 1 below it, thereby embedding and mechanically locking the grass fibers into the base fabric, while the reinforcing yarns 5 are also inserted and fixed between the grass fibers. Finally, a liquid adhesive layer 4 is coated on the back of the composite base fabric. The adhesive penetrates into the fabric gaps around the base layer 1 and the reinforcing yarns 5, and after curing, firmly bonds the grass fiber roots, reinforcing yarns 5, and base layer 1 into a whole.

[0030] In the description of this utility model, it should be understood that the terms "left", "right", "up", "down", "top", "bottom", "front", "back", "inner", "outer", "back", "middle", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this utility model and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this utility model.

[0031] However, the above description is only a specific embodiment of this utility model and should not be construed as limiting the scope of implementation of this utility model. Therefore, any substitution of equivalent components or equivalent changes and modifications made in accordance with the scope of protection of this utility model should still fall within the scope of the claims of this utility model.

Claims

1. A reinforced weft layer artificial turf base fabric structure, comprising a base layer (1) and a tufted layer (3), characterized in that: It also includes a reinforcing layer (2), which is composed of multiple parallel and spaced weft reinforcing units (5). The material of the weft reinforcing units (5) is a high-modulus synthetic fiber material. The reinforcing layer (2) is woven together with the base layer (1) and is located between the base layer (1) and the tufted layer (3), so that the tufted fibers constituting the tufted layer (3) pierce through the reinforcing layer (2) and the base layer (1) from top to bottom.

2. The artificial turf base fabric structure with reinforced weft yarn layer according to claim 1, characterized in that: The weft reinforcing unit (5) is one of glass fiber filament, aramid fiber filament or ultra-high modulus polyethylene fiber filament.

3. The artificial turf base fabric structure with reinforced weft yarn layer according to claim 1, characterized in that: The weft yarn reinforcing units (5) are arranged at uniform intervals, and the distance between two adjacent weft yarn reinforcing units (5) is 1 to 5 times the original weft yarn spacing of the base layer (1).

4. The artificial turf base fabric structure with reinforced weft yarn layer according to claim 1, characterized in that: The reinforcing layer (2) is integrated with the base layer (1) by weaving. The weft reinforcing unit (5) is an independent reinforcing weft yarn, which is interwoven with the warp yarn of the base layer (1) and the base weft yarn of the base layer (1) according to a preset rule to form an integrated fabric.

5. The artificial turf base fabric structure with reinforced weft yarn layer according to claim 1, characterized in that: The elastic modulus of the weft yarn reinforcing unit (5) is not less than 10 GPa.

6. The artificial turf base fabric structure with reinforced weft yarn layer according to claim 1, characterized in that: The back of the base layer (1) is also coated with an adhesive layer (4), the coating material of which penetrates into the fabric gaps of the base layer (1) and covers the surface of the weft reinforcing unit (5) located on the back side.

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