Artificial turf with antimicrobial polyurethane undercoat

Abstract

The present invention relates to a method for producing an artificial turf (600) and an artificial turf obtained by this method, the method comprising the steps of incorporating artificial turf fibers into a carrier (104); adding a polyurethane reaction mixture onto the rear surface of the carrier (106); and curing the polyurethane reaction mixture to form a polyurethane substrate, characterized in that zinc pyrithione is added to the polyurethane reaction mixture to provide antimicrobial properties to the polyurethane substrate.

Description

[Technical field]

[0001] [explanation] The present invention relates generally to artificial turf, and more specifically to an artificial turf comprising a polyurethane antimicrobial substrate and a method for producing the artificial turf. [Background technology]

[0002] Artificial turf is becoming more popular because it is easier to maintain than natural turf and in many ways its surface properties are better than those of natural turf. Typically, artificial turf is manufactured by extruding a thermoplastic resin to produce artificial turf fibers that are inserted into a carrier via a process known as tufting. The polymer fibers on the surface of the artificial turf are in the form of loops, often referred to as pile. Often, a polymer resin is applied onto the rear surface of the carrier to improve the structural stability and pile tensile properties of the artificial turf. Artificial turf is used in many applications, including home floor coverings, playing field surfaces for sports such as soccer, football, rugby, tennis, golf, and the like, athletic fields, and landscaping applications.

[0003] A major problem with existing artificial turf is its tendency to microbial contamination, which may also reduce its service life. Several efforts to address this problem have been reported in the patent literature. For example, Korean Patent Publication No. KR101942846B1 discloses a method for manufacturing an artificial turf structure including a base layer, a foam layer, a turf pile layer, and an infill disposed between the turf piles. The turf piles are made of recyclable polyethylene materials. KR101942846B1 describes the use of an antimicrobial agent in the composition of the turf pile. According to KR101942846B1, the antimicrobial agent may be zinc supported on an inorganic carrier.

[0004] Korean Patent Publication No. KR101887103B1 describes a method for producing an artificial turf structure including a rear coating layer and a foam layer (also referred to as a grass cell layer) and grass piles formed on the rear coating layer. An infill material is added between the grass piles. The rear coating layer is said to be made of thermosetting polyurethane, thermoplastic polyurethane, ethyl vinyl acetate copolymer or hydroxylatex. The composition is said to include an antimicrobial agent without specifying whether this composition refers to a composition for the grass layer, the fibers, the rear coating or the infill added between the fibers on top of the grass fiber layer. The antimicrobial agent is said to be a zinc-based antimicrobial agent or an organic antimicrobial agent.

[0005] Korean Patent Publication No. KR101887105B1 describes an artificial turf structure including a primer layer formed at the construction site, a back coating layer formed on the primer layer, and a top layer having fibers formed on the back coating layer. The top layer is added onto the back coating layer while the back coating layer is still at a temperature of at least 50°C to ensure that the back coating layer, the top layer and the bottom of the fibers are integrated in situ to form a laminated structure. KR101887105B1 describes the use of an antimicrobial agent added to the back coating layer. The antimicrobial agent is said to be a zinc-based agent or an organic antimicrobial agent. In CN111607833A, zinc pyrithione is added as an antimicrobial agent in turf fibers made of polyethylene.

[0006] Despite the above, and more specifically, limited suggestions for the use of antimicrobial agents in artificial turf construction, no practical solutions exist, particularly for artificial turf constructions having a polyurethane thermoset substrate. Summary of the Invention

[0007] It is therefore an object of the present invention to provide an artificial turf with a thermoset polyurethane underlayment that has the tensile pile strength provided by the polyurethane underlayment and improved antimicrobial properties without sacrificing structural stability. It is also an object of the present invention to provide a method for producing the artificial turf.

[0008] According to the present invention, an artificial turf with a polyurethane antimicrobial substrate and a method for producing the artificial turf are provided that overcome the problems of the existing state of the art.

[0009] The invention provides an artificial lawn with a polyurethane antimicrobial substrate and also a method for producing the artificial lawn according to the independent claims. Embodiments are given in the dependent claims. The embodiments may be freely combined with one another if they are not mutually exclusive.

[0010] According to a first aspect of the present invention, a method for producing artificial turf comprises the steps of incorporating artificial turf fibers into a carrier and applying a viscous polyurethane reaction mixture onto a rear surface of the carrier to form a polyurethane base, the method being characterized in that an insecticide is added to the polyurethane reaction mixture.

[0011] Preferably, the insecticide is a metal coordination complex containing pyrithione, or a zinc-based antimicrobial agent. Examples of suitable metal coordination complexes containing pyrithione that can function as antimicrobial agents include zinc pyrithione, manganese pyrithione, copper pyrithione, and sodium pyrithione. Examples of suitable zinc-based antimicrobial agents other than zinc pyrithione include zinc oxide nanoparticles, and zinc-glucose-citrate complexes. Particularly preferred is zinc pyrithione (often commonly referred to as zinc pyrithione).

[0012] Zinc pyrithione is used as the antimicrobial agent in an amount of 0.05 to 1.5 wt% of the polyurethane reaction mixture, preferably 0.08 to 0.7 wt% of the polyurethane reaction mixture, more preferably zinc pyrithione is used as the antimicrobial agent in an amount of 0.1 to 0.5 wt% of the polyurethane reaction mixture.

[0013] Zinc pyrithione disperses well within the polyurethane reaction mixture. Zinc pyrithione has strong antimicrobial, fungistatic and antibacterial properties. However, unexpectedly, it has been found that zinc pyrithione also has the effect of slowing down the polymerization reaction rate of the polyurethane reaction mixture. This is rather a surprising effect that has been found to be beneficial in allowing the polyurethane reaction mixture to penetrate deeper into the carrier material of the artificial turf before it completely solidifies. It has also been found that the coverage of the polyurethane substrate becomes more uniform around the protruding fibers at the rear surface of the turf that is substantially free of any voids or air bubbles. Thus, the use of PZ not only provides the artificial turf with effective antimicrobial properties, but also has a synergistic effect in improving the penetration and coverage of the polyurethane substrate. On the other hand, an excessive amount of zinc pyrithione will slow down the reaction too much, resulting in the loss of the above-mentioned benefits. Therefore, the addition of zinc pyrithione to the polyurethane reaction mixture is necessary to control the polymerization reaction to prevent excessive retardation of the polyurethane reaction mixture.

[0014] Preferably, a chelating agent is added to the polyurethane reaction mixture to counteract the retarding effect of zinc pyrithione and allow better control of the reaction rate. Through extensive research, it has been found that the addition of certain chelating agents results in maintaining better control of the polymerization reaction of the polyurethane reaction mixture by mitigating the retarding effect of zinc pyrithione.

[0015] Preferably, the method further comprises adding a chelating agent to the polyurethane reaction mixture, which can bind or interact with the zinc metal ion of the zinc pyrithione and prevent the reaction retardation effect of the zinc pyrithione. The chelating agent is added in an effective amount to sufficiently adjust the polymerization reaction of the polyurethane reaction mixture to a desired level to ensure the formation of an improved, more uniform polyurethane substrate with effective antimicrobial properties. The specific amount of chelating agent depends on the amount of zinc pyrithione used and the desired time to complete the solidification of the polyurethane reaction mixture to a solid mass. The addition of the chelating agent is advantageous because it allows for better control of the solidification rate of the polyurethane reaction mixture. The improved control of the solidification reaction allows for a more uniform application of the polyurethane reaction mixture on the rear surface of the carrier in a uniform manner without voids or gaps, which allows for strong connections to be created between the polyurethane substrate and the carrier, and between the polyurethane substrate and the grass fibers. Voids and gaps can also be areas where microorganisms and bacteria can grow, so removing such voids and gaps further improves the antimicrobial properties of the artificial turf.

[0016] While the exact mechanism of interaction of zinc pyrithione and the chelating effect in the polymerization reaction is not well understood, the overall effect of using zinc pyrithione in combination with a chelating agent is that the coagulation reaction of the polyurethane reaction mixture proceeds at a similar rate as the polyurethane reaction without the inclusion of zinc pyrithione, resulting in the formation of a solid polyurethane base on the artificial turf carrier that is substantially free of voids or air bubbles.

[0017] Suitable chelating agents for polyurethane / zinc pyrithione mixtures that have been found to be effective in maintaining the setting reaction of the polyurethane reaction mixture are: Polymeric carboxylic acids, phosphonates (e.g., 2-phosphonobutane-1,2,4,-tricarboxylic acid (PBTC) or aminophosphonates); Alcoholamines (also called alkanolamines), such as isopropanolamine and aliphatic amine-initiated polyether polyols (with aliphatic amine-initiated polyether polyols being preferred); and Those salts Includes.

[0018] In particular, the salts of the abovementioned substance groups may be the sodium and potassium salts.

[0019] Examples of suitable chelating agents for polyurethane / zinc pyrithione mixtures that have been found to be effective in maintaining the coagulation reaction of the polyurethane reaction mixture include EDTA (ethylenediaminetetraacetic acid), nitrilotriacetic acid (NTA), aminotrismethylenephosphonic acid (ATMP), hydroxyethylidene diphosphonic acid (HEDP) and DETAPMP (diethylenetriaminepentamethylenephosphonic acid). Examples of preferred chelating agents include (1,2-diaminoethane)-initiated polyether polyols, (2-aminoethylethanolamine)-initiated polyols or (N,N-bis(3-aminopropyl)methylamine)-initiated polyols, (N-(2-aminoethyl)ethanolamine)-initiated polyether polyols, preferably the polyols are propoxylated or ethoxylated, or more preferably both the polyols are propoxylated and ethoxylated.

[0020] Examples of suitable commercially available chelating agents are VORANOL VORACTIV DNC 779.01 polyol (catalytically active high functionality polyether polyol), VORANOL 800 polyol (aliphatic amine-initiated polyol with a hydroxyl number of 800 mg KOH / g), N,N,N',N'-tetrakis(2-hydroxypropyl)ethylene-diamine (Quadrol) or LUPRANOl 1002 / 1 polyol (alkoxylate containing primary hydroxyl end groups).

[0021] The chelating agent is added in an amount sufficient to chelate the chemically available zinc pyrithione to affect polymerization of the polyurethane formulation, the amount varying in proportion to the molecular weight of the amine-initiated polyol. Generally, a lower level of low molecular weight chelating polyol is required than that of high molecular weight chelating polyol. On a molar basis, the chelating amine-initiated polyol should be added in an amount of 10% to 100% of the total moles of zinc pyrithione in the formulation, preferably 20% to 90%, more preferably 30% to 80%, and most preferably 40% to 70% of the moles of zinc pyrithione in the polyurethane reaction mixture. The chelating agent is added in an amount of 0.01 wt% to 10 wt% of the polyurethane reaction mixture, for example 0.01 to 0.3 wt%, preferably 0.1 to 1 wt% of the polyurethane reaction mixture, with the ratio of insecticide to chelating agent by weight being 0.05 to 2. According to a preferred embodiment, the chelating agent is added in a molar ratio such that the molar ratio of pesticide to chelating agent is from 0.5 to 2. This may be beneficial as this molar ratio may ensure that there is a sufficient molar amount of chelating agent present to compensate for the effect of the pesticide on the reaction rate.

[0022] The turf fibers include polymeric fibers made of any suitable polymer, but preferably the turf fibers include hydrophobic polyethylene fibers selected from the group consisting of polyethylene homopolymer fibers, polyethylene alloy fibers, polyethylene copolymer fibers and polyethylene impact copolymer fibers.

[0023] The step of incorporating the grass fibers into the carrier includes positioning the fibers so that a first portion of the fibers is located at the rear surface of the carrier (hereinafter also referred to as the rear portion of the fibers), a second portion of the fibers protrudes to the front surface of the carrier (hereinafter also referred to as the front portion of the fibers), and a third portion of the fibers is within the carrier (hereinafter also referred to as the central portion of the fibers or the carrier portion of the fibers).

[0024] In some embodiments, the polyurethane reaction mixture comprises at least one polyol, at least one isocyanate, a curing agent, and zinc pyrithione. Preferably, the polyurethane reaction mixture comprises at least one polyol, at least one isocyanate, a curing agent, zinc pyrithione, and a chelating agent. Preferably, the zinc pyrithione, and also the chelating agent (if used), are mixed in a separate container from the polyol and isocyanate, and then added and mixed into the reaction mixture immediately before application of the polyurethane reaction mixture on the rear surface of the artificial turf carrier.

[0025] In some embodiments, the polyurethane is the reaction product of a first and a second polyol with an isocyanate, where the first polyol is a polyether polyol and / or a polyester polyol having at least two hydroxyl groups per molecule, the second polyol is a polybutadiene diol, and the isocyanate comprises an isocyanate monomer, an isocyanate polymer, or an isocyanate prepolymer, or a mixture thereof, where the isocyanate monomer, isocyanate polymer, and isocyanate prepolymer have two or more isocyanate groups per molecule.

[0026] These and other features and advantages of the present invention will be better understood by those skilled in the art from the following drawings and detailed description of specific embodiments of the invention. [Brief description of the drawings]

[0027] [Figure 1A] 1 illustrates a flow chart of a method for producing an artificial turf with an antimicrobial polyurethane substrate according to some embodiments of the present invention.

[0028] [Figure 1B] 2 shows a flow chart of a method for producing an artificial turf with an antimicrobial polyurethane substrate according to another embodiment of the present invention.

[0029] [Diagram 2] FIG. 1 illustrates a simplified block diagram of a process for forming a polyurethane reaction mixture for an artificial turf substrate according to some embodiments of the present invention.

[0030] [Diagram 3] 1 illustrates a "knife over roll" polyurethane priming according to some embodiments of the present invention.

[0031] [Figure 4] 1 illustrates the extrusion of a polymer mixture into a monofilament according to some embodiments of the present invention.

[0032] [Figure 5a] 1 illustrates tufting of an artificial grass fiber and first and second portions of the fiber according to some embodiments of the present invention. [Figure 5b] 1 illustrates tufting of an artificial grass fiber and first and second portions of the fiber according to some embodiments of the present invention.

[0033] [Figure 6a] 1 illustrates a section of monofilament and fiber embedded in a polyurethane substrate according to some embodiments of the present invention. [Figure 6b] 1 illustrates a section of monofilament and fiber embedded in a polyurethane substrate according to some embodiments of the present invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0034] Various embodiments of the invention will now be described in more detail with reference to the accompanying drawings, in which:

[0035] The present invention provides a method for producing an artificial turf, comprising the steps of incorporating artificial turf fibers into a carrier and applying a viscous polyurethane reaction mixture onto the rear surface of the carrier to form a polyurethane substrate, characterized in that an effective amount of an insecticide is added into the polyurethane reaction mixture. The insecticide has antimicrobial, antibacterial and antifungal properties. The insecticide is added and dispersed via mixing within the polyurethane reaction mixture before the polyurethane reaction mixture is applied onto the rear surface of the carrier. Once the polyurethane reaction mixture is placed on the rear surface of the carrier, curing of the polyurethane reaction mixture is carried out to form a solid polyurethane substrate with a portion of the grass fibers protruding from the rear surface of the carrier firmly embedded within the solid mass of the polyurethane substrate. The polyurethane substrate improves the structural strength of the artificial turf and the fiber tensile properties of the grass fibers. In addition, because the insecticide is added, the artificial turf has antimicrobial properties.

[0036] Preferably, the polyurethane reaction mixture enters the interior of the carrier structure before completely solidifying, thereby providing the carrier with antimicrobial properties. Depending on the viscosity of the polyurethane reaction mixture of the carrier structure and the coagulation rate of the polyurethane reaction mixture, the polyurethane reaction mixture may enter deeper into the carrier, thereby increasing the antimicrobial, antibacterial and antifungal properties of the artificial turf. In some other embodiments, the polyurethane reaction mixture enters the carrier before completely solidifying and also forms a thin coating on the front surface of the carrier, thereby completely covering both the rear and front surfaces of the carrier and filling any voids inside the carrier. Preferably, the method further includes the step of adding a chelating agent to the polyurethane reaction mixture. The chelating agent is added in an effective amount to sufficiently maintain the polymerization reaction of the polyurethane reaction mixture.

[0037] While the exact mechanism and chelating effect of zinc pyrithione in the polymerization reaction are not well understood, the overall effect of using zinc pyrithione in combination with a chelating agent is that the coagulation reaction of the polyurethane reaction mixture is sufficiently sustained, resulting in the formation of a solid polyurethane substrate on the artificial turf carrier that is substantially free of voids or air bubbles.

[0038] The rate at which the coagulation reaction of the polyurethane reaction mixture occurs is dependent on the amount of zinc pyrithione and the amount of chelating agent which acts to reduce the deleterious effects of zinc pyrithione on the polymerization rate. Thus, the amount of chelating agent used can be adjusted based on the amount of zinc pyrithione used and the desired time for completion of the coagulation reaction.

[0039] The chelating agent is used in an amount sufficient to achieve the desired crosslinking rate of the polyurethane reaction mixture, which amount can vary according to the zinc pyrithione content and temperature.

[0040] The addition of the chelating agent is advantageous because it allows for better control of the setting rate of the polyurethane reaction mixture, allowing the polyurethane reaction mixture to be applied more uniformly in a uniform manner on the rear surface of the carrier without voids or gaps, resulting in strong connections between the polyurethane substrate and the carrier, and between the polyurethane substrate and the grass fibers. The elimination of voids and gaps further improves the antimicrobial properties of the artificial turf, as they can be infested with microorganisms. The use of a chelating agent to counteract the delayed reaction effect of zinc pyrithione allows the amount of zinc pyrithione in the substrate to be optimized based on the desired antimicrobial properties. Also, the addition of another control variable to control the crosslinking reaction allows for better overall control of the setting reaction of the polyurethane reaction mixture. Unexpectedly, it has been found that controlling the crosslinking reaction (also called the setting reaction) by adjusting the amount of chelating agent results in a more uniform distribution of crosslink density, resulting in a more uniform polyurethane substrate. Too much of these alcohols as chelating agents, especially above 10% by weight, can act as non-specific catalysts, or "blowing agents," which is undesirable since the substrate should be void-free.

[0041] Zinc pyrithione is used as the antimicrobial agent in an amount of from 0.05 to 1.5 wt% of the polyurethane reaction mixture, preferably from 0.08 to 0.7 wt% of the polyurethane reaction mixture, more preferably from 0.1 to 0.5 wt% of the polyurethane reaction mixture.

[0042] In some preferred embodiments, a method for producing artificial turf includes preparing a polyurethane reaction mixture including zinc pyrithione in an amount from 0.08 wt % to 0.7 wt % of the polyurethane reaction mixture, incorporating artificial turf fibers into a carrier, applying the polyurethane reaction mixture onto a rear surface of the carrier, and curing the polyurethane reaction mixture on the rear surface of the carrier to form a polyurethane substrate for securing the artificial turf fibers to the polyurethane substrate.

[0043] In some embodiments, the zinc pyrithione concentration is between 0.05 wt% and 0.2 wt% of the polyurethane reaction mixture. In one embodiment, zinc pyrithione is used as an antimicrobial agent in an amount of 0.1 wt% of the polyurethane reaction mixture. Zinc pyrithione has been found to be particularly effective against bacteria such as Escherichia coli and Staphylococcus aureus when added to the polyurethane reaction mixture in an amount of 0.1 wt% to 0.5 wt% of the polyurethane reaction mixture. The amount of zinc pyrithione in the reaction mixture is calculated based on the total weight of the polyurethane reaction mixture, including any fillers.

[0044] The zinc pyrithione is added to the polyurethane reaction mixture prior to curing of the polyurethane reaction mixture.

[0045] Zinc pyrithione is a very effective antimicrobial agent that exhibits fungistatic and antibacterial properties. Zinc pyrithione also disperses well in the polyurethane reaction mixture, thus ensuring a well-dispersed distribution of zinc pyrithione inside the polyurethane substrate. However, zinc pyrithione also has the effect of retarding the polymerization reaction of the polyurethane reaction mixture. Adding zinc pyrithione in an amount greater than 1.5 wt% makes the polyurethane reaction mixture cure too slowly, resulting in insufficient hardening of the polyurethane reaction mixture on the rear surface of the carrier for a good processing technique. If the amount of zinc pyrithione in the polyurethane reaction mixture is less than 0.05 wt%, the effect of zinc pyrithione is reduced to an insufficient amount.

[0046] Preferably, a suitable chelating agent is added to the polyurethane reaction mixture to maintain the polymerization reaction of the polyurethane reaction mixture and prevent the retarding effect of zinc pyrithione.Preferably, the method includes adding an effective amount of a chelating agent to the polyurethane reaction mixture to fully maintain the polymerization reaction of the polyurethane reaction mixture, thereby allowing the polyurethane reaction mixture containing zinc pyrithione to completely cover the rear of the grass fiber and to solidify uniformly in a uniform manner without voids or gaps on the rear surface of the carrier.The formation of voids and gaps should be avoided because voids and gaps weaken the connection between the polyurethane substrate and the carrier, and between the polyurethane substrate and the grass fiber.Depending on the structure and porosity of the carrier, the polyurethane reaction mixture containing antimicrobial and chelating agent can also penetrate deep into the carrier, thereby increasing the antimicrobial, antibacterial and antifungal properties of the artificial grass while maintaining a sufficient polymerization rate to achieve sufficient hardening.

[0047] Preferably, the desired molar ratios of zinc pyrithione and the chelating agent are premixed together in separate containers before being added to the polyurethane reaction mixture.

[0048] The preparation of the grass fiber includes forming a polymer mixture, extruding the polymer mixture into monofilaments, quenching the monofilaments, reheating the monofilaments, and stretching the reheated monofilaments to form the artificial grass fiber from the monofilaments. The formed polymer mixture further includes a nucleating agent for crystallizing the polymer within and on the surface of the monofilaments. The artificial grass fiber is a bundle of monofilaments.

[0049] For example, it may be desirable to produce artificial turf fibers that have a desired set of properties with respect to fiber smoothness, tensile strength, resistance to shear forces, and / or resistance to bonding.

[0050] In some embodiments, the artificial grass fibers are hydrophobic polyolefin fibers that are inserted into the carrier via a tufting process or by weaving the artificial grass fibers into the carrier.

[0051] In some embodiments, the polyurethane is the reaction product of a first and a second polyol with an isocyanate, where the first polyol is a polyether polyol and / or a polyester polyol having at least two hydroxyl groups per molecule, the second polyol is a polybutadiene diol, and the isocyanate comprises an isocyanate monomer, an isocyanate polymer, or an isocyanate prepolymer, or a mixture thereof, where the isocyanate monomer, isocyanate polymer, and isocyanate prepolymer have two or more isocyanate groups per molecule.

[0052] The polybutadiene diol is used in an amount of 0.5-10% by weight of the first polyol and isocyanate combination, more preferably in an amount of 1.0-9.0% by weight of said combination, and most preferably in an amount of 4.0-8.0% by weight of said combination. The polybutadiene diol has a number average molecular weight in the range of 1000 to 6000 g / mol, more preferably in the range of 1.500 to 4.500 g / mol.

[0053] The polyurethane reaction mixture further comprises a surfactant in an amount of from 0.01 to 1.2% by weight of the combination of the first and second polyols and isocyanates, more preferably in an amount of 0.8-1.0% by weight of said combination, and most preferably in an amount of 0.05-0.15% by weight of said combination, and the fluid polyurethane mass has a density greater than 1000 g / l, preferably has a density in the range of 1100 g / l to 1500 g / l, and more preferably has a density in the range of 1200 g / l to 1400 g / l.

[0054] Curing of the fluid polyurethane mass may be carried out by heating the polyurethane reaction mixture on the rear surface of the carrier to a temperature of from 70 to 140°C.

[0055] Once the polyurethane substrate is formed, the artificial turf can be rolled and stored in roll form.

[0056] Artificial turf made with a polyurethane antimicrobial substrate is advantageous because it can prevent microbial buildup of fungi and bacteria and can have a longer life span.

[0057] In addition, in some embodiments, using polybutadiene diol to make a polyurethane substrate is particularly advantageous because it further strengthens the connection of the substrate containing grass fibers, and is particularly suitable for more firmly and securely fixing hydrophobic polyolefin fibers such as polyethylene fibers. Since polyurethane is a hydrophilic material, the van der Waals forces between the fibers and the polyurethane substrate may be weak, and the fibers may be pulled from the polyurethane substrate when a tufting pull-off force is applied. By adding polybutadiene diol (PBD) to the reaction mixture used to make polyurethane in a polyaddition reaction, the polyurethane becomes more hydrophobic and increases the adhesion of the polyurethane to the fibers via van der Waals forces. In the polyaddition reaction, PBD acts as a hydrophobic polyol that increases the hydrophobicity of the polyurethane. The resulting polyurethane is more hydrophobic than standard polyurethane, and therefore adheres more strongly to polyethylene surfaces or fibers. This new polyurethane variant is used in the production of artificial turf that can strongly fix individual monofilaments, fibers made of multiple monofilaments, or tapes made of hydrophobic materials (e.g., PE) in the substrate.

[0058] In a further beneficial aspect, the creation of a polyurethane substrate according to an embodiment of the present invention may be advantageous since such a substrate is better protected against the effects of water. The applicant has observed that water, for example rain falling on the artificial turf of a sports arena, may act as a softener with respect to the polyurethane substrate. When the polyurethane comes into contact with water, the water softens the polyurethane and causes it to expand. This expansion may cause the destruction of the mechanical fixation of the fibers in both polyester-based and polyether-based polyurethanes. Contact with water may also cause the polyester-based polyurethane to be chemically destroyed by saponification, which may also result in the destruction of the mechanical fixation of the fibers in the polyurethane substrate. Thus, in a further aspect, an embodiment of the present invention relates to a method for providing a hydrolytically stable form of polyurethane that does not undergo either significant swelling or saponification when exposed to water and water-based liquids.

[0059] Thus, according to some embodiments, polybutadiene diol is added to a polyol or to a reaction mixture containing a polyol and an isocyanate to increase the hydrophobicity of the polyurethane and / or to create a hydrolytically stable form of the polyurethane, i.e., one that does not swell or saponify when exposed to water, and / or to provide strong mechanical fixation of hydrophobic polyolefin fibers at least partially embedded in the polyurethane substrate.

[0060] In a further beneficial embodiment, the chemical bond between PBD and polyisocyanate is created, which prevents any peeling effect that may occur when hydrophilic and hydrophobic materials are combined in one mix.The reaction that creates this chemical bond is a polyaddition reaction, whereby the first polyol and PBD react with isocyanate, respectively, to form polyurethane.In yet another beneficial effect, the prevention of the swelling of polyurethane substrate caused by the use of PBD can prevent the loss of added antimicrobial agent, which results in the prolongation of the antimicrobial properties of artificial turf.

[0061] According to an embodiment, the isocyanate is a diisocyanate. According to an embodiment, the at least two hydroxyl groups per molecule of the first polyol are two terminal hydroxyl groups. According to an embodiment, the polybutadiene diol has an amount of 0.5-10% by weight of the combination of the first polyol (i.e. polyester polyol or polyether polyol) and the isocyanate. According to some of the above embodiments, the polybutadiene diol has an amount of 1.0-9% by weight of the combination, preferably 4.0-8.0% by weight of the combination. This feature can be beneficial, since it has been observed that this PBD concentration strongly fixes the polyolefin fibers embedded therein, thereby producing a polyurethane substrate that generates a so-called "stick-slip effect", especially when using very hydrophobic monofilaments, such as PE monofilaments. The stick-slip effect describes a specific form of relative movement of two surfaces (e.g., a PE-fiber surface and a polyurethane surface surrounding said fibers) whereby the movement of the surfaces alternates between sticking to each other and sliding against each other, resulting in a corresponding change in frictional force. Typically, the static friction coefficient (heuristic number) between the two surfaces is greater than the kinetic friction coefficient. If the applied force is large enough to overcome the static friction, the reduction of this friction to kinetic friction can rapidly increase the speed of the movement. Typically, the stick-slip effect is considered an undesirable effect, for example, with respect to the relative movement of human skin and PE (polyethylene) fibers, since in this context the risk of injury and skin burns can increase. However, the applicant has surprisingly observed that the stick-slip effect occurs in the context of PE polyurethane. The movement of the surfaces is a desirable and useful effect, since it increases the resistance of the fibers to tufting forces. Even if the pulling force is high enough to pull the fiber a certain distance from the substrate, the stick-slip effect will cause the fiber to stop again, so that the static rather than kinetic coefficient of friction comes into effect.

[0062] Thus, according to a further advantageous aspect of the present invention, an antimicrobial polyurethane artificial turf substrate is provided which mechanically fixes hydrophobic polyolefin fibers or monofilaments, particularly PE-based fibers and monofilaments, particularly well by exhibiting a stick-slip effect. In particular, when PBD is added to the reaction mixture within the most preferred concentration range of 2.0-4.0% by weight of the first polyol and isocyanate combination, e.g. 3% by weight of said combination, the artificial turf fibers are sometimes so firmly fixed to the polyurethane substrate that the fibers are often destroyed and torn off rather than pulled from the substrate.

[0063] Both the polyether polyol and the polyester polyol can be comprised of a single type of polyol or a mixture of different types of polyols. Depending on the embodiment, the PBD and the first polyol can be added separately to the reaction mixture or can be contained in a single mixture that is mixed with the isocyanate.

[0064] According to an embodiment, the first polyol does not contain either PBD or hydrogenated PBD. In other words, the first polyol consists of one or more non-PBD polyols. According to an embodiment, the first polyol is preferably a polyether polyol. According to an embodiment, the first polyol is preferably selected from the group comprising polycarbonate polyols, polycaprolactone polyols, propylene oxide-based polyols, polypropylene polyols, polysulfide polyols, polyether glycols such as polytetramethylene ether glycol (PTMEG) or a mixture of one or more of the above polyols. A "propylene oxide-based polyol" may be produced from a monomer mixture consisting of or including propylene oxide monomers. In a further embodiment, the first polyol is a mixture of one or more of the above-mentioned polyether polyols with diglycols or triglycols having a hydroxyl value ranging from 400 to 2000 mg KOH / g. Preferably, the diglycol or triglycol is a short-chain diglycol or a short-chain triglycol.For example, the diglycol or triglycol can be one or more of diethylene glycol, dipropylene glycol, methylene glycol, propylene glycol, butylene glycol.Adding diglycol or triglycol can be advantageous because it can increase the crosslink density in polyurethane.

[0065] In a further embodiment, the first polyol comprises or consists of a mixture of polyether polyols and polyester polyols, which may be, for example, vegetable oil-based polyols, such as castor oil-based polyols, e.g., DESMOPHEN 1150, or soybean oil-based polyols, or may be obtained from a reesterification process.

[0066] According to an embodiment, the first polyol has a number average molecular weight of 500 to 6000 g / mol, more preferably 1.500 to 4.000 g / mol. The number average molecular weight Mn is the total weight of all polymer molecules in a sample divided by the total number of polymer molecules in the sample.

[0067] According to an embodiment, the polyether polyol is a bifunctional polyether polyol having a hydroxyl value of about 50-60 mg KOH / g. According to another example, a bifunctional polyether polyol having a hydroxyl value of about 26-30 mg KOH / g can be used, for example a polyol based on propylene oxide having a number average molecular weight of about 4000 g / mol. However, it is also possible to use polyether polyols having a lower or even higher molecular weight.

[0068] According to an embodiment, the polybutadiene diol has a number average molecular weight in the range of 1000-6000 g / mol, more preferably 1.500-4.500 g / mol. According to a preferred embodiment, the polybutadiene diol is a hydrogenated polybutadiene diol. The use of hydrogenated PBD can provide improved chemical stability of the polyurethane produced. In particular, the saturation of hydrogenated PBD can prevent the polyurethane substrate from losing mechanical properties such as flexibility, elongation and strength. Compared to the non-hydrogenated version, hydrogenated PBD improves the miscibility of PU-PBD mixtures.

[0069] For example, a hydrogenated polybutadiene diol having a number average molecular weight of about 2000 g / mol, in which the double bonds are fully hydrogenated (>97%) while retaining the hydroxyl units, can be used as the PBD added to the reaction mixture. According to another example, a polybutadiene diol having a number average molecular weight of about 3000 g / mol can be used as the PBD added to the reaction mixture.

[0070] According to an embodiment, the method further comprises adding a wetting agent to the mixture comprising the first and / or second polyol and / or isocyanate. Adding a wetting agent to the reaction mixture to create the polyurethane reaction mixture can be advantageous because the wetting agent reduces the surface tension and helps the polyurethane reaction mixture to wet the carrier (which may be, for example, a hydrophobic polyolefin-based woven fabric) and / or to wet the monofilaments and fibers at least partially embedded in the polyurethane substrate. Wetting the monofilaments is a particularly demanding task for fixing tufted bundles of PE monofilaments to the polyurethane-coated substrate, since the monofilament tufted bundles are often arranged very close to each other, which prevents any polyurethane liquid or polyurethane foam from penetrating into the spaces within the tufted monofilament bundles.

[0071] The use of a wetting agent can be advantageous since it has been observed that PBD increases the viscosity of a liquid polyurethane reaction mixture compared to a polyurethane made from the same reaction mixture but lacking the PBD. It has been observed that increasing polyurethane viscosity reduces wetting of the carrier fabric and / or wetting of the fibers. Compensating for this effect by using a wetting agent allows for increased hydrophobicity without negatively affecting fiber wetting.

[0072] In a further beneficial embodiment, the wetting agent allows for a higher amount of PBD to be used, thereby compensating for the increased viscosity by producing more hydrophobic polyurethane as the wetting agent.

[0073] According to an embodiment, the wetting agent is a surfactant having an amount of 0.01 to 1.2% by weight of the combination of the first and second polyols and isocyanates, more preferably an amount of 0.8-1.0% by weight of the combination, and most preferably an amount of 0.05-0.15% by weight of the combination. The surfactant concentration is typically not high enough for strong foam generation and to control the density and volume of the polyurethane foam applied on the rear surface of the artificial turf base carrier. However, since the surfactant according to an embodiment of the present invention is added as a wetting agent, not to create a foam, the concentration range mentioned above is preferred.

[0074] As used herein, the "rear face" of the carrier is the side opposite the side from which the larger portion of the fibers emerge.

[0075] As used herein, a "surfactant" is a compound that reduces the surface tension (or interfacial tension) between two liquids or between a liquid and a solid. The surfactant may be, for example, an amphiphilic substance, particularly an organic amphiphilic substance that contains both hydrophobic and hydrophilic groups. Thus, the surfactant contains both a water-insoluble (or oil-soluble) component and a water-soluble component. The surfactant diffuses within the liquid polyurethane reaction mixture and adsorbs at the interface between the polyurethane reaction mixture and the hydrophobic monofilament and / or the underlying hydrophobic carrier. The surfactant may be, for example, a hydrocarbon surfactant, such as Triton X-100, or more preferably, a fluorosurfactant, or a mixture of a hydrocarbon surfactant and a fluorosurfactant. A fluorosurfactant has a hydrophobic tail in the form of a linear fluorocarbon, and a polar portion. Fluorosurfactants are particularly stable in harsh thermal and / or chemical environments.

[0076] In a preferred embodiment, a silicon-based surfactant is used, particularly preferred as a surfactant are polyalkylene oxide-dimethylsiloxane copolymers.

[0077] According to an embodiment, the method comprises adding oil to the mixture comprising polyol and / or the mixture comprising isocyanate. The oil is added in an amount of 0.5 to 4% by weight, more preferably 0.7 to 1.2% by weight of the combination of polyol and isocyanate. Preferably, the oil is a mineral oil, more preferably a pale oil, or a mixture of pale oils. Oil is any neutral, non-polar chemical that is a viscous liquid at ambient temperature and is both hydrophobic and oleophilic. Oil has a high carbon and hydrogen content and is usually flammable and surface active. As used herein, "pale oil" or "white oil" is a highly refined mineral oil that is only lightly colored or colorless and is chemically inert. For example, a petroleum lubricating or processing oil refined to a pale yellow color (measured by transmitted light) is a "pale oil". Preferably, the pale oil used in the embodiments of the present invention is also pure, stable, odorless and non-toxic. The term "white oil" is a misnomer in that white oil is not white, but is crystal clear. Pale oil can be produced from a variety of materials, depending on the process used. For example, naphthenic oil and some mineral oils can be used as pale oil.

[0078] For example, a light colored, non-staining naphthenic oil refined from specially selected wax-free crude oils through the use of rigorous hydrogenation, such as NYNAS' PALE OIL 40-NYTEX 5130, may be used.

[0079] As used herein, the term "tufting" refers to a method of incorporating fibers into an existing carrier. Short U-shaped loops of fibers are introduced through the carrier from one side with the ends facing the outside of the carrier in the other direction. Usually, the tufting yarns form a regular array of "dots" on the other side. On the side of the carrier where the U-shaped loops are located, the tufting fibers can be tied off for safety, but need not be. The ends of the tufting yarns can then be optionally frayed or otherwise treated, thus later creating a dense layer of fibers protruding from the carrier.

[0080] As used herein, the term "weave" refers to the method of incorporating artificial grass fibers (which may be monofilaments or bundles of multiple monofilaments) into an existing carrier, whereby the artificial grass fibers and fibers that make up the carrier are interwoven. The interwoven fibers and mesh form a woven or cloth-like structure. When artificial grass fibers are incorporated by weaving, the fibers interweave a series of mesh fibers at least three times. Thus, when fibers are incorporated by weaving rather than tufting, a higher portion of the artificial grass fibers are interwoven into the carrier material. This can increase the resistance of the artificial grass to wear and tear.

[0081] The addition of pale oil may further reduce the viscosity of the liquid polyurethane reaction mixture, thereby increasing the wetting of the carrier and / or artificial turf monomers and fibers, and increasing the strength of mechanical fixation.

[0082] According to an embodiment, the method further comprises the step of adding a catalyst to the polyol or isocyanate or to a reaction mixture comprising same.

[0083] According to an embodiment, the fluid polyurethane mass has a density of more than 1000 g / l, preferably in the range of 1100 g / l to 1500 g / l, more preferably in the range of 1200 g / l to 1400 g / l. The first polyol and / or catalyst may be selected such that the density of the resulting polyurethane reaction mixture falls within at least one of a number of specified density ranges. It has been observed that the above density ranges provide a polyurethane artificial turf substrate that is elastic and robust against various tensile, compressive and shear forces, and can be easily laid without swelling.

[0084] According to some embodiments, the liquid polyurethane reaction mixture is a non-foam polyurethane, i.e., a (substantially) non-porous polyurethane. Foams and fluids in this high density range are often very viscous and often do not adequately wet the fibers, especially the monofilaments in monofilament bundles. However, by using more hydrophobic polyurethane forms, optionally further comprising a wetting agent, the polyurethane reaction mixtures with the above-mentioned high densities can also be used to secure PE filaments by van der Waals forces. Thus, embodiments of the present invention may allow for the secure anchoring of hydrophobic fibers even to high density polyurethane substrates.

[0085] According to an embodiment, incorporating the artificial grass fibers into the carrier comprises tufting the artificial grass fibers into the carrier. According to an alternative embodiment, incorporating the artificial grass fibers into the carrier comprises weaving the artificial grass fibers into the carrier.

[0086] According to an embodiment, the artificial grass fibers are bundles of monofilaments. In this context, the use of more hydrophobic polyurethanes, optionally in combination with wetting agents, is particularly advantageous, since standard polyurethane foams and fluids are usually unable to wet the monofilaments located inside the monofilament bundles. Furthermore, wetting the monofilaments inside the bundles significantly improves the mechanical fixation.

[0087] According to an embodiment, the artificial grass fibers are hydrophobic polyolefin fibers, such as polyethylene (PE) fibers, polypropylene (PP) fibers, polybutylene fibers, or fibers made of a polymer mixture containing a hydrophobic polyolefin as the main component.

[0088] Depending on the embodiment, the curing process may be performed passively, for example, by incubating a liquid polyurethane reaction mixture coated and dispersed on the rear surface of the carrier at room temperature, or by heating the polyurethane substrate to a temperature significantly above room temperature for a given period of time.

[0089] According to some embodiments, curing of the fluid polyurethane mass comprises heating the polyurethane mass applied and dispersed on the rear surface of the carrier to a temperature of 70-140° C. For example, the heating is applied for a period of 1-5 minutes, preferably 2-3 minutes.

[0090] A "curing process", also called a "hardening" process, is carried out so that the polyurethane reaction mixture hardens and develops its strength. Curing (or hardening) involves reacting an NCO-terminated diisocyanate with a hydroxyl-terminated polyol. The cured polyurethane reaction mixture on the substrate tightly surrounds those portions of the fiber that are embedded in the fluid polyurethane mass.

[0091] Like numbered elements in these figures are either equivalent elements or perform the same function. An element previously described is not necessarily discussed in a subsequent figure if the function is equivalent.

[0092] FIG. 1A shows a flow chart of a method for producing a polyurethane artificial grass underlay 602, for example, as shown in FIG. 6b. Referring now to FIG. 1A, a method for producing an artificial grass is provided, comprising the steps of preparing a polyurethane reaction mixture (PU-RM) containing an effective amount of 0.05wt% to 1.5wt% pyrithione zinc (PZ) (step 102), incorporating artificial grass fibers into a carrier (step 104), adding the polyurethane reaction mixture onto the rear surface of the carrier (step 106), and curing the polyurethane reaction mixture onto the rear surface of the carrier to form a polyurethane underlay (step 108). The polyurethane underlay secures the artificial grass fibers and also provides support and structural strength to the carrier. The method is characterized in that the polyurethane reaction mixture contains an effective amount of pyrithione zinc, which is added to the polyurethane reaction mixture before curing the polyurethane reaction mixture.

[0093] Preferably, zinc pyrithione is added in an amount of 0.08 to 0.7 wt% of the polyurethane reaction mixture, more preferably 0.1 to 0.5 wt%, and most preferably 0.3 to 0.5 wt%. Zinc pyrithione has fungistatic, antimicrobial and antibacterial properties and disperses well in the polyurethane reaction mixture. However, zinc pyrithione also has the effect of retarding the polymerization reaction of the polyurethane reaction mixture. Adding zinc pyrithione in an amount of more than 1.5 wt% makes the polyurethane reaction mixture cure too slowly, making it impractical to apply the polyurethane reaction mixture on the rear surface of the carrier. If the amount of zinc pyrithione in the polyurethane reaction mixture is less than 0.05 wt%, the effect of zinc pyrithione is reduced to an insufficient amount.

[0094] In one embodiment, a silicon-based surfactant is used. In a particularly preferred embodiment, the silicon-based surfactant is a polyalkylene-oxydimethylsiloxane copolymer.

[0095] In some embodiments, in step 102, creating a liquid polyurethane reaction mixture includes reacting a first and a second polyol with an isocyanate. The first polyol is a polyether polyol or a polyester polyol, or a mixture thereof, and the second polyol is a polybutadiene diol. The zinc pyrithione is preferably added with the PBD in a vessel separate from the vessel containing the first polyol and the isocyanate. The polyether and / or polyester polyol have two hydroxyl groups per molecule.

[0096] In one preferred embodiment, creating the liquid polyurethane mixture includes creating a first mixture by first mixing together all of the polyol, filler, curing agent, PBD, zinc pyrithione pre-dispersed in a chelating agent, optional agents including any optional wetting agents, etc. All of these materials may be added together from separate containers. Formation of the liquid polyurethane reaction mixture is then carried out by mixing an isocyanate into the first mixture.

[0097] Polyether polyols are made by reacting an epoxide such as ethylene oxide or propylene oxide with a multifunctional initiator in the presence of a catalyst, often a strong base such as potassium hydroxide or a double metal cyanide catalyst such as zinc reduced to t-butanol complex. Common polyether polyols are polyethylene glycol, polypropylene glycol and poly(tetramethylene ether) glycol.

[0098] Polyester polyols are formed by condensation or step-growth polymerization of polyols and dicarboxylic acids (or their derivatives), for example, the reaction of phthalic acid with diethylene glycol. Alternatively, in the case of caprolactone, the hydroxyl groups and the carboxylic acid (or their derivatives) may be present in the same molecule. Polyether polyols and / or polyester polyols may be purchased off-the-shelf from a variety of suppliers.

[0099] Isocyanates include isocyanate monomers, isocyanate polymers or isocyanate prepolymers, or mixtures of isocyanate monomers, isocyanate polymers and isocyanate prepolymers. Isocyanate monomers, polymers and prepolymers have two or more isocyanate groups per molecule.

[0100] For example, the isocyanate can be methylene diphenyl diisocyanate ("MDI"). MDI is an aromatic diisocyanate. It exists in three isomers: 2,2'-MDI, 2,4'-MDI, and 4,4'-MDI. An embodiment of the present invention can be based on any of the above isomers, preferably the 4,4' isomer is used as the isocyanate. MDI reacts with polyols (i.e., with PBD and polyether or polyester polyols) in the production of a polyurethane reaction mixture.

[0101] In step 104, one or more grass fibers are incorporated into a carrier, such as a woven fabric or other material that contains holes. For example, this incorporation may include weaving, spinning, twisting, unwinding, and / or bundling monofilaments, such as stretched monofilaments, into an artificial grass fiber and then incorporating the fiber into a carrier. This technique for producing artificial grass is known, for example, from U.S. Patent Application No. 20120125474A1.

[0102] In step 106, the polyurethane reaction mixture produced in step 102 is applied onto the rear surface of the carrier (see, e.g., FIG. 3), causing the fibers, including the monofilaments in the bundled fibers, and the carrier material to be wetted with the liquid polyurethane mixture.

[0103] In step 108, the liquid polyurethane reaction mixture solidifies into a solid polyurethane artificial turf substrate that strongly secures the hydrophobic fibers without the need to create chemical bonds between the polyurethane substrate and the fiber material. For example, the polyurethane reaction mixture on the rear surface of the carrier can be cured at room temperature or in an oven.

[0104] FIG. 1B shows a flow chart of a preferred method of manufacturing a polyurethane artificial turf underlay 602, including the use of a chelating agent to prevent zinc pyrithione from slowing down the polymerization reaction of the polyurethane reaction mixture. As shown in FIG. 1B, in order to maintain the polymerization reaction of the polyurethane reaction mixture and prevent the reaction retardation effect of zinc pyrithione, a suitable chelating agent is added to the polyurethane reaction mixture in step 102'. Preferably, the method includes adding a chelating agent to the polyurethane reaction mixture in an effective amount to sufficiently maintain the polymerization reaction of the polyurethane reaction mixture, thereby allowing the polyurethane reaction mixture containing the insecticide to completely cover the rear of the grass fibers and to solidify uniformly in a uniform manner on the rear surface of the carrier without voids or gaps, thereby creating strong connections between the polyurethane underlay and the carrier, and between the polyurethane underlay and the grass fibers. Depending on the porosity of the carrier, the polyurethane reaction mixture containing the insecticide and the chelating agent can also penetrate deep into the inside of the carrier, thereby increasing the antimicrobial, antibacterial and antifungal properties of the artificial turf.

[0105] Preferably, the zinc pyrithione is pre-dispersed within the chelating agent to minimize the possibility of the zinc pyrithione chemically affecting the curing agent, as there would be an increased possibility of the zinc pyrithione interacting with the catalyst if all of these materials were added together at the same time.

[0106] In some embodiments, in step 102', creating the liquid polyurethane reaction mixture includes reacting first and second polyols with an isocyanate as described for step 102 of Figure 1A. In the embodiment of Figure 1B, steps 104, 106 and 108 are as described above with reference to Figure 1A.

[0107] FIG. 2 shows a number of tanks and mixers containing extracts for making a polyurethane reaction mixture according to an example. A first mixing unit 201 (also referred to as a first tank or a first container) is used to make a first mixture 202 containing a polyether polyol or a polyester polyol. For example, the first mixture 202 contains a polyether polyol (e.g., a polyether polyol having a number average molecular weight of about 4000 g / mol), for example, a polyol based on polymerized propylene oxide. The polyether polyol can be obtained, for example, in the form of a ready-made polyol.

[0108] Optionally, the first mixture 202 includes a filler material. The addition of a filler may reduce cost and / or help achieve a particular look or weight. The filler may be selected from the group consisting of surface limestone, precipitated calcium carbonate, china clay, coal fly ash, silicates, and other inert materials including non-reactive liquids. Also, aluminum hydroxide (Al(OH)3) or ammonium polyphosphate (NH4PO3] may be used. n Fillers having flame retardant and / or expansion efficiency such as (OH)2) or mixtures of the above mentioned fillers may be used.

[0109] The first mixture 202 may also include a catalyst for promoting the polyaddition reaction to produce polyurethane. The catalyst may be, for example, an amine compound and a metal-organic complex. Traditional amine catalysts have been tertiary amines, such as triethylenediamine (TEDA, 1,4,-diazabicyclo[2.2.2]octane or DABCO), dimethylcyclohexylamine (DMCHA) and dimethylethanolamine (DMEA). Metal-organic complexes used as polyurethane catalysts may be based, for example, on mercury (e.g., mercury carboxylates), lead, tin (e.g., alkyltin carboxylates and oxides), bismuth and zinc (e.g., bismuth and zinc carboxylates). The first mixture is then stored in a first tank 201, for example, a day tank, i.e., a tank sized to provide a day's usage.

[0110] Preferably, a mixture of organotin and amine catalysts is used. Suitable amines include, for example, cyclohexyldimethylamine, 2-dimethylaminoethanol, 4-ethylmorpholine, N,N,4-trimethylpiperazine-1-ethylamine, 1,4-dimethylpiperazine, 3-aminopropyldimethylamine, 2,2'-iminodiethanol, 1-methylimidazole, 1,2-dimethylimidazole, 2-[[2-(dimethylamino)ethyl]methylamino]ethanol, N-[3-(dimethylamino)propyl]-N,N',N'-trimethylpropane-1,3-diamine, formic acid, compounds including 2,2'-oxybis[N,N-dimethylamine] (2:1), 1,1'-[[3-(dimethylamino)propyl]imino]bispropan-2-ol, +2-[(2-[2-(dimethylamino)ethoxy]ethyl)methylamino]ethanol, benzyldiamine, 1,2'-dimethylimidazole, 1,2'-dimethylimidazole, 2-[[2-(dimethylamino)ethoxy]ethyl)methylamino]ethanol, benzyldiamine, 1,1'-[[3-(dimethylamino)propyl]imino]bispropan-2-ol, 1,2'-dimethylimidazole, 2-[[2-(dimethylamino)ethoxy]ethyl)methylamino]ethanol, benzyldiamine, 1,2'-dimethylimidazole ... Methylamines include 4-methylmorpholine, N,N,N,N'-tetramethylhexamethylenediamine, 2-[2-(dimethylamino)ethoxy]ethanol, 1,4-diazabicyclooctane, bis(2-dimethylaminoethyl)(methyl)amine, N,N,N',N'-tetramethyl-2,2'-oxybis(ethylamine), 2,2'-dimorpholinyl diethyl ether, 1,8-diazabicyclo[5.4.0]undec-7-ene, N'-[3-(dimethylamino)propyl]-N,N-dimethylpropane-1,3-diamine, N,N,N',N',N'',N''-hexamethyl-1,3,5-triazine-1,3,5(2H,4H,6H)-tripropanamine and N,N-bis[3-(dimethylamino)propyl]-N',N'-dimethylpropane-1,3-diamine.

[0111] A second mixture 204, i.e., an isocyanate monomer / polymer / prepolymer mixture, e.g., MDI, is stored in a second tank 203, which is preferably also a day tank. A further container 205, typically smaller in size than the first and second tanks, contains a third mixture of substances 206, which also includes pyrithione zinc ("PZ"), and preferably a chelating agent.

[0112] In a variation of the embodiment shown in FIG. 2, the PZ and chelating agent are mixed separately in a fourth vessel (not shown) and added to the reaction mixture, while the PBD is added separately via third vessel 205 along with other additives, pale oil, etc.

[0113] 2, PBD is also added to the third material mixture 206, although it should be understood that in other embodiments PBD is not added. According to some embodiments, the PZ and chelating agent are mixed together in a separate tank (not shown) and then added to the reaction mixture.

[0114] Optionally, additional materials may be added, such as a wetting agent, pale oil, and / or one or more additional additives. The one or more additional additives may be, for example, fire retardants, pigments, extenders, crosslinkers, blowing agents, and the like. The vessel 203 may be part of or connected to a blender 208. The blender 208 receives the first mixture 202 from the first vessel 201, the second mixture 204 from the second vessel 203, and the PBD, zinc pyrithione, chelating agent, and one or more optional materials (wetting agent, pale oil, and / or additional additives) from the third vessel 205. The blender 208 mixes the first, second, and third mixtures received from their respective tanks in amounts suitable to produce a polyurethane reaction mixture 210 having material concentrations within the ranges specified herein for embodiments of the present invention. For example, the first, second and third mixtures are mixed such that the number of OH groups in the molecules of the first polyol in the first mixture in combination with the number of OH groups in the PBD molecules in the third mixture roughly corresponds to the number of NCO groups in the isocyanate molecules (monomer and prepolymer) (e.g., within a ratio range of "0.9:1" to "1:0.9"). The third mixture 206 is added to the reaction mixture 210 by blender 208 in an amount such that the PBD in the reaction mixture has a concentration range of 0.05 to 5% by weight of the first polyol and isocyanate combination.

[0115] PU reaction mixture examples 1 to 4 are given in Table 1 below.

[0116] [Table 1] [Table 1]

[0117] The reaction mixtures were tested for antimicrobial properties and reaction kinetics. All PU reaction mixtures and the resulting PU substrates were observed to provide PU substrates with effective antimicrobial properties.

[0118] It was also observed that the reaction rate decreased with increasing amounts of PZ in Examples 1 and 2. However, in Examples 3 and 4, the decrease in reaction rate was mitigated by the addition of a chelating agent.

[0119] No PBD was used in Examples 1 to 3. Example 4, in which PBD was also added, showed improved effectiveness of the antimicrobial agent, likely due to the increased hydrophobicity of the PU substrate imparted by the addition of PBD.

[0120] According to an embodiment, the first and second mixtures 202 and 204 are supplied as a "two pack system" or "two component system", with the polyol portion acting as the first mixture 202 in the first tank 201 and the polyisocyanate portion acting as the second mixture 204 in the second tank 203. The first and second mixtures may be purchased as ready-made two-component polyurethane generating systems, while the third mixture 206 in the container 205 may be customized for the specific needs of the customer, for example, by adding specific pigments to achieve a desired color effect, or by adding specific amounts of PBD and / or oils and wetting agents to achieve a desired viscosity given a desired polyurethane density. As illustrated in this example, zinc pyrithione and chelating agents are added to the third mixture in the container 206, which may be customized.

[0121] The blender 208 may be a low pressure gear pump that produces the desired mix ratio of the first, second and third mixtures. The ratio and material distribution is effected by computer aided equipment. Despite the viscosity of the polyurethane reaction mixture 210, it penetrates deep into the tufts of the artificial turf and wets the woven carrier and monofilaments contained in the tufts.

[0122] The polyurethane reaction mixture 210 produced by the blender 208 is output to a container 212, which may have the form of a hose. The chamber 212 has an opening 214 that leads to a coater (e.g., a "knife over roll" substrate assembly, such as depicted in FIG. 3). Typically, the reaction mixture output by the blender 208 reaches the opening 214, which is part of the substrate assembly, within 30 seconds. At this point, the polyaddition reaction that results in the production of the liquid polyurethane reaction mixture used to substrate the carrier fabric of a piece of artificial turf is already mostly complete, although some reaction may still continue during substrate processing.

[0123] According to an embodiment, the first polyol (optionally, PBD) and isocyanate together constitute at least 25% (according to other embodiments), at least 40%, or even more than 95% of the total reaction mixture used to produce the liquid polyurethane reaction mixture used as an artificial turf base after curing. This means that the total of antimicrobial agents, chelating agents, fillers, wetting agents, pale oil, and any additional additives (such as extenders, crosslinkers, surfactants, flame retardants, blowing agents, and pigments) typically constitutes less than 75% by weight or less than 60% by weight, or in further embodiments less than 5% by weight, of the reaction mixture used to produce the polyurethane. In a specific example, the reaction mixture has a weight percentage of about 21.5% isocyanate, 0.5% PBD, 21.5% first polyol, 2.1% catalyst, 0.5% zinc pyrithione, 2.5% additives such as oil, dyes or flame retardants, and 51.45% filler materials.

[0124] In another embodiment, the reaction mixture has weight percentages of about 20% isocyanate, 0.1% PBD, 20% first polyol, 2.1% catalyst, 0.5% zinc pyrithione, 4.0% (1,2-diaminoethane) initiated polyol as a chelating agent, 2.0% additives such as oils, dyes or flame retardants, and 51.4% filler material.

[0125] In yet another embodiment, the reaction mixture has weight percentages of about 19.0% isocyanate, 0.3% PBD, 19.0% first polyol, 2.0% catalyst, 0.7% zinc pyrithione, 7% (2-aminoethylethanolamine) initiated polyol as a chelating agent, 2.0% additives such as oils, dyes or flame retardants, and 50.0% filler material. In some exemplary embodiments, the reaction mixture does not include any filler material.

[0126] According to a preferred embodiment, the liquid polyurethane reaction mixture is a non-foam polyurethane, i.e. a (substantially) non-porous polyurethane.

[0127] Polyols or polyhydroxylated compounds are known to absorb water and are generally the source for introducing water into the formulation. When moisture is introduced into either the polyhydroxylated compound or some other component, it can react with the isocyanate to produce urea linkages and carbon dioxide. The urea linkages are highly desirable; however, the carbon dioxide causes air bubbles to appear in the product. In many cases, the presence of air bubbles in the product weakens the structure of the polyurethane substrate. Therefore, according to an embodiment of the present invention, the reaction conditions and extracts are selected to produce a non-foamed liquid polyurethane reaction mixture 210. The production of a "non-foamed" liquid polyurethane reaction mixture is described, for example, in "Polyurethanes: Science, Technology, Markets, and Trends", Mark F. Sonnenschein, ISBN:978-1-118-73791-0.

[0128] FIG. 3 shows a "knife-over-roll" polyurethane substrate process and corresponding substrate assembly. A liquid viscous reaction mixture 210, also referred to as liquid polyurethane reaction mixture, is applied onto a carrier 308 as it leaves an opening 214 in a container 212. A plurality of artificial grass fibers 501 protrude from the front of the carrier. The liquid polyurethane reaction mixture 210 is applied onto the rear surface of the carrier. The polyurethane reaction mixture is continuously applied while the roll 306 moves the carrier 308 in the direction indicated by the arrow. A "knife" 304, shown in cross section, is located a defined distance above the carrier 308 to ensure that the viscous polyurethane reaction mixture 210 passing through the space between the knife 304 and the carrier 308 has a defined height.

[0129] According to a preferred embodiment, the liquid polyurethane reaction mixture is a non-foaming polyurethane, i.e. a (substantially) non-porous polyurethane. The high viscosity of the polyurethane reaction mixture according to an embodiment of the invention and the configuration and dimensions of the opening 214 and the speed at which the polyurethane reaction mixture flows through this opening are selected so that a defined amount of the polyurethane reaction mixture pools and accumulates on the front face of the knife 304. This ensures that the thickness of the polyurethane underlay of the generated artificial turf is consistent.

[0130] The polyurethane reaction mixture 210 is evenly applied onto the rear surface of the carrier 308 and then cured (viscosity increased) by maintaining the coated artificial turf at room temperature for about 10 minutes. Typically, the polyurethane base is solid 30 minutes after application to the carrier.

[0131] Preferably, to accelerate solidification, the artificial turf is exposed to an elevated temperature of about 100° C. once the polyurethane reaction mixture is placed on the rear surface of the artificial turf. Typically, after 90 seconds at the elevated temperature, 90 to 95% of the polyurethane reaction mixture is "hardened" (in a solid state). This heating can be performed, for example, in an oven. For example, the substrate assembly can automatically transport the coated artificial turf to the oven.

[0132] 4 shows a liquid polymer mixture 400 for producing a monofilament 412 in an extrusion process. The polymer is a polyolefin, e.g., a polyethylene mixture. The polymer mixture 400 includes additives 404, 406, e.g., UV stabilizers, pigments, or flame retardants. A screw, piston, or other device is used to force the polymer mixture 400 through holes 410 in a plate 408. This causes the polymer mixture 400 to be extruded into a monofilament 412.

[0133] In some embodiments, the polymer blend may include polymer beads of a stronger polymer, such as polyamide. Due to flow dynamics during the extrusion process, the beads tend to concentrate at the center of the monofilament 412. This may lead to a concentration of strong thread-like PA regions in the core region of the monofilament, while the surface of the monofilament is almost entirely composed of hydrophobic PE. Thus, a fiber with improved elasticity is provided that protects against injury and skin burns, but has a very hydrophobic surface, and therefore a soft PE surface that can be easily separated from the polar polyurethane substrate.

[0134] Thus, the monofilament is produced by feeding the polymer mixture 400 to a fiber producing extrusion line. The molten mixture passes through an extrusion tool, i.e., a spinneret plate or wide slot nozzle, forming the melt stream into a filament or tape shape, quenched or cooled in a water spinning bath, dried and drawn by passing through multiple heated godets and / or heated ovens rotating at different rotational speeds. The monofilament or fiber can later be annealed on-the-fly in a second stage passing through additional heated ovens and / or a set of heated godets.

[0135] According to an embodiment, producing an artificial turf fiber (which may include one or more monofilaments 412) includes forming a drawn monofilament into a yarn. A plurality of monofilaments, for example, 4-8 monofilaments, may be formed or finished into a yarn.

[0136] According to an embodiment, the extrusion is carried out at a pressure of 40-140 bar, more preferably 60-100 bar. The polymer mixture may be made by adding polymer granules to a solid polymer composition that is mixed and heated until all the polymer is melted. For example, the polymer mixture may be heated to reach a temperature of 190-260°C, more preferably 210-250°C, during extrusion.

[0137] According to an embodiment, the drawing comprises drawing the reheated monofilament according to a stretch factor in the range of 1.1-8, more preferably in the range of 3-7.

[0138] According to an embodiment, the quenching is carried out in a quenching solution having a temperature of 10-60°C, more preferably 25°C-45°C.

[0139] According to an embodiment, incorporating the artificial grass fibers into the carrier includes tufting or weaving the artificial grass fibers into the carrier.

[0140] According to an embodiment, the quenching solution, for example a water bath, has a temperature (immediately after the extrusion nozzle or hole) of 10-60°C, more preferably 25°C-45°C, even more preferably 32°C-40°C.

[0141] According to an embodiment, the extrusion is carried out at a pressure of 80 bar, the polymer mixture during extrusion has a temperature of 230°C, the stretch factor is 5 and the quenching solution, for example a water bath, has a temperature of 35°C.

[0142] 5a and 5b, the step of incorporating the grass fibres 501 into the carrier 308 comprises positioning the fibres 501 such that a first portion of the fibres 302 protrudes to the front surface of the carrier (hereinafter also referred to as the front part of the fibres), a second portion of the fibres 506 is located at the rear surface of the carrier (hereinafter also referred to as the rear part of the fibres), and a third portion of the fibres 504 is located inside the carrier (hereinafter also referred to as the central part of the fibres).

[0143] According to the second aspect of the present invention, an artificial lawn with an antimicrobial polyurethane underlay is provided. With reference to Figures 6a and 6b, some embodiments of an artificial lawn are provided, which include a carrier 308 and an artificial lawn fiber 501 embedded in the carrier 308 such that a first portion 506 of the artificial lawn fiber 501 protrudes to the rear surface of the carrier, a second portion 302 of the artificial lawn fiber 501 protrudes to the front surface of the carrier, and a third portion 504 of the artificial lawn fiber 501 is inside the carrier 308. A polyurethane underlay 210 is formed on the rear surface of the carrier to cover the first portion of the artificial lawn fiber.

[0144] 5a shows tufting of artificial grass fibers and how multiple artificial grass fibers can be arranged by tufting within a carrier 308 (e.g., a woven surface). The carrier 308 can be a woven fabric made of a hydrophobic polymer, such as PE. Tufting is a type of woven fabric in which an artificial grass fiber 501 (which can be a monofilament 412 or a bundle of multiple monofilaments) is inserted onto the carrier 308.

[0145] As used herein, a "monofilament" is a filament produced by extruding a liquid polymer mixture through a single aperture, or a slice of polymer tape produced according to slit film technology.

[0146] After the insertion step is performed, the short U-shaped loops of the fibers are facing outward from the surface of the carrier, as depicted in FIG. 5a. Then, one or more blades cut 502 the loops. As a result of the cutting step, the loops and two artificial grass fiber ends per monofilament face outward from the carrier, and a grass-like artificial grass surface is generated, as depicted in FIG. 5b. This exposes the first portion 506 of the monofilament (corresponding to the first portion of the artificial grass fiber) inserted into the carrier 308 to the bottom side (rear surface) of the carrier, and the second portion 302 of the monofilament to the top side of the carrier. Some portions 504 of the monofilament / fiber are located within the carrier. Fibers or fiber bundles may protrude outward from the rear surface of the carrier in the loops 503. The artificial grass generated in the tufting process can be sent to the substrate assembly depicted in FIG. 3 for applying the polyurethane reaction mixture 210 onto the rear surface of the carrier.

[0147] 6a and 6b show a portion of monofilaments and fibers embedded in a polyurethane substrate. Reference number 600 refers to the total height of one artificial turf coated with a polyurethane reaction mixture 210 produced according to an embodiment of the present invention. The hydrophobized polyurethane reaction mixture may optionally contain pale oil, a liquid or fluid state, and a surfactant flowed around the fibers, including the monofilaments located inside the fiber consisting of a plurality of monofilaments, to wet the fibers. The polyurethane reaction mixture (referred to as a solidified polyurethane reaction mixture or polyurethane substrate) 210' depicted in Fig. 6a and 6b has already solidified and strongly fixes the hydrophobic polymer monofilaments in the polyurethane substrate.

[0148] 6a and 6b correspond to different embodiments of the present invention.

[0149] FIG. 6a shows one artificial lawn made from a highly viscous polyurethane reaction mixture and / or with a nearby mesh carrier 308 that prevents the polyurethane reaction mixture from penetrating the carrier. In this embodiment, the second portion 302 of the fiber 501 protrudes from the carrier 308 to the front of the artificial lawn and is not embedded in the polyurethane membrane because the liquid polyurethane reaction mixture 210 could not reach the front of the carrier during priming. Also, in this embodiment, the fiber portion 504 within the carrier was not wetted by the polyurethane reaction mixture. However, the rear surface portion 506 of the fiber is embedded in the liquid polyurethane reaction mixture 210 during priming. Although the length of these rear surfaces is relatively small, the high hydrophobicity of the fiber and improved wetting by the polyurethane reaction mixture 210 ensures that the fiber is firmly fixed in the substrate by van der Waals forces and that the slip-stick effect further protects the fiber against tuft pull-out forces. FIG. 6b shows an artificial lawn made of a viscous polyurethane reaction mixture (compared to the embodiment of FIG. 6a) and / or with a wide mesh-like carrier 308. The carrier can be a woven mesh or another type of material with holes that allow the polyurethane reaction mixture 210 to enter the carrier and reach the front of the artificial lawn. Thus, the front part 302 of the fiber in FIG. 6b includes an outer part 604 that is not embedded in the polyurethane film 210 and an inner part 602 that is embedded in the polyurethane film 210'.2 that penetrates the carrier. In addition, parts 504 and 506 are wetted by and embedded in the liquid polyurethane reaction mixture 210. Thus, the carrier, each part of the fiber inserted in the carrier, and a further part 602 of the fiber at the front of the carrier can become embedded in the polyurethane substrate in addition to the part 506 on the rear side of the carrier. This embodiment of FIG. 6b is advantageous in that an antimicrobial polyurethane primer is applied to both the rear and front surfaces of the carrier, thereby providing antimicrobial protection to the entire artificial turf structure except for the outer portions 604 of the fibers.

[0150] The liquid polyurethane reaction mixture 210 applied in the substrate treatment to the rear surface of the carrier surrounds at least some of the monofilaments of the deposited artificial turf fibers, thereby mechanically fixing them in place. The liquid polyurethane mixture 210 then solidifies at room temperature or in an oven into a polyurethane artificial turf substrate 210'. This solid film acts as the artificial turf substrate. In some instances, an additional substrate layer may be added to the bottom of the artificial turf substrate.

[0151] While the present invention has been described with reference to specific embodiments, it should be understood that those skilled in the art, after reading this disclosure, may conceive of many other variations of the present invention without departing from the scope of the present invention as defined in the following claims. (Other possible items) (Item 1) Career (308); an artificial turf fiber (501) assembled into the carrier such that a first portion (506) of the artificial turf fiber protrudes to the rear side of the carrier, a second portion (302) of the artificial turf fiber protrudes to the front side of the carrier, and a third portion (504) of the artificial turf fiber is inside the carrier; and A polyurethane substrate (210') formed on the rear surface of the carrier. Equipped with The polyurethane substrate (210') has an insecticide. Artificial turf. (Item 2) The insecticide is a zinc-based antimicrobial or a metal coordination complex containing pyrithione. The artificial turf described in item 1. (Item 3) The artificial turf according to item 1, wherein the insecticide is zinc pyrithione added in an amount of from 0.05 wt% to 1.5 wt% of the polyurethane substrate (210'), preferably from 0.08 wt% to 0.7 wt% of the polyurethane substrate (210'). (Item 4) the polyurethane substrate (210') further comprises a chelating agent in an amount of from 0.01 wt % to 10.0 wt % of the polyurethane substrate (210') to prevent the zinc pyrithione from slowing down the polymerization reaction of the polyurethane reaction mixture (210); The ratio of the mass of the insecticide to the mass of the chelating agent is from 0.05 to 2.0; The artificial turf according to any one of items 1 to 3. (Item 5) The chelating agent is Polymeric carboxylic acids, Phosphonates, such as 2-phosphonobutane-1,2,4-tricarboxylic acid (PBTC) or aminophosphonates Alcohol amines, especially aliphatic amine-initiated polyether polyols; and Those salts selected from the group consisting of The artificial turf according to any one of items 1 to 4. (Item 6) 6. The artificial grass according to any one of the preceding claims, wherein the chelating agent is selected from the group consisting of (1,2-diaminoethane)-initiated polyols, (2-aminoethylethanolamine)-initiated polyols or (N,N-bis(3-aminopropyl)methylamine)-initiated polyols, preferably these polyols are propoxylated or ethoxylated, or more preferably both of the polyols are propoxylated and ethoxylated. (Item 7) 7. The artificial turf according to any one of the preceding claims, wherein the artificial turf fibres (501) comprise hydrophobic polyethylene fibres selected from the group consisting of polyethylene homopolymer fibres, polyethylene alloy fibres, polyethylene copolymer fibres and polyethylene impact copolymer fibres. (Item 8) The polyurethane substrate is obtained by curing a polyurethane reaction mixture (210) comprising a reaction product of a first polyol and a second polyol with an isocyanate, the first polyol is a polyether polyol and / or a polyester polyol having at least two hydroxyl groups per molecule; the second polyol is a polybutadiene diol; The isocyanate comprises a monomeric isocyanate, a polymeric isocyanate, or a prepolymeric isocyanate, or a mixture thereof; the isocyanate monomers, the isocyanate polymers and the isocyanate prepolymers have two or more isocyanate groups per molecule; 8. The artificial turf according to any one of items 1 to 7. (Item 9) A method for producing an artificial lawn (600), comprising: Providing a viscous polyurethane reaction mixture (102); incorporating the artificial grass fibers into a carrier (104); applying (106) the viscous polyurethane reaction mixture onto the rear surface of the carrier to form a polyurethane base (210'); and curing the viscous polyurethane reaction mixture to form a polyurethane base on the rear surface of the carrier (108); Equipped with The viscous polyurethane reaction mixture (210) contains an insecticide. method. (Item 10) 10. The method of claim 9, wherein the viscous polyurethane reaction mixture (210) further comprises a chelating agent added in an amount of from 0.1 wt % to 10 wt % of the viscous polyurethane reaction mixture to maintain a polymerization reaction of the viscous polyurethane reaction mixture, and the ratio of the mass of the insecticide to the chelating agent is from 0.05 to 2. (Item 11) 11. The method according to claim 9 or 10, wherein the step of incorporating the artificial turf fibers into the carrier (104) positions the artificial turf fibers (501) such that a first portion (506) of the artificial turf fibers (501) is located on the rear surface of the carrier (308), a second portion (302) of the artificial turf fibers (501) protrudes to the front surface of the carrier (308), and a third portion of the artificial turf fibers is in the center of the carrier (308). (Item 12) The step of preparing a viscous polyurethane reaction mixture (102) comprises mixing first and second polyols, an isocyanate, the insecticide and the chelating agent; the first polyol is a polyether polyol and / or polyester polyol having at least two hydroxyl groups per molecule and the second polyol is a polybutadiene diol; the isocyanate comprises an isocyanate monomer, an isocyanate polymer, or an isocyanate prepolymer, or a mixture thereof, the isocyanate monomer, the isocyanate polymer, and the isocyanate prepolymer having two or more isocyanate groups per molecule; 12. The method according to item 10 or 11. (Item 13) the insecticide is a zinc-based antimicrobial or metal coordination complex containing pyrithione, preferably zinc pyrithione added in an amount of from 0.05 wt % to 1.5 wt % of the viscous polyurethane reaction mixture (210), preferably from 0.08 wt % to 0.7 wt % of the viscous polyurethane reaction mixture (210); 13. The method according to any one of items 9 to 12. (Item 14) 14. The method according to any one of items 10 to 13, wherein the chelating agent is selected from the group consisting of (1,2-diaminoethane)-initiated polyols, (2-aminoethylethanolamine)-initiated polyols or (N,N-bis(3-aminopropyl)methylamine)-initiated polyols, preferably these polyols are propoxylated or ethoxylated, or more preferably both of the polyols are propoxylated and ethoxylated. (Item 15) The artificial turf fiber (501) comprises hydrophobic polyethylene fibers selected from the group consisting of polyethylene homopolymer fibers, polyethylene alloy fibers, polyethylene copolymer fibers, and polyethylene impact copolymer fibers; polybutadiene diol is added in an amount of 0.5 to 10% by weight of the combination of the first polyol and the isocyanate, more preferably in an amount of 1.0 to 9.0% by weight of the combination, and most preferably in an amount of 4.0 to 8.0% by weight of the combination; The polybutadiene diol has a number average molecular weight in the range of from 1000 to 6000 g / mol, more preferably in the range of from 1.500 to 4.500 g / mol. 15. The method according to any one of items 9 to 14. (Item 16) 16. An artificial turf obtained by the method according to any one of items 9 to 15. [Explanation of symbols]

[0152] 102~102'104~106~108 Method steps 201 First Tank 202 First Mixture 203 Second Tank 204 Second Mixture 205 Third Container 206 Third Mixture 208 Brenda 210 Polyurethane reaction mixture 210' Polyurethane base 212 Chamber 214 Aperture 302 Second Part 304 Knife 306 Rolls 308 Career 400 Polymer Mixture 404 Additives 406 Additives 408 Plate 410 holes 412 Monofilament 501 Artificial grass fiber 502 Disconnect 503 Loop 504 Third Part 506 First Part 600 Artificial Grass 602 Inner part 604 Outer part PU Polyurethane PZ Pyrithione Zinc

Claims

1. Career: artificial turf fibers, the artificial turf fibers being assembled into the carrier such that a first portion of the artificial turf fibers protrudes to a rear surface of the carrier, a second portion of the artificial turf fibers protrudes to a front surface of the carrier, and a third portion of the artificial turf fibers is inside the carrier; and A polyurethane substrate formed on the rear surface of the carrier. Equipped with The polyurethane substrate has an insecticide. Artificial turf.

2. The insecticide is a zinc-based antimicrobial or a metal coordination complex containing pyrithione. The artificial turf according to claim 1.

3. 2. The artificial turf according to claim 1, wherein the insecticide is zinc pyrithione added in an amount of from 0.05 wt % to 1.5 wt % of the polyurethane substrate, preferably from 0.08 wt % to 0.7 wt % of the polyurethane substrate.

4. the polyurethane primer further comprising a chelating agent in an amount of from 0.01 wt % to 10.0 wt % of the polyurethane primer to prevent the zinc pyrithione from slowing down the polymerization reaction of the polyurethane reaction mixture; The ratio of the mass of the insecticide to the mass of the chelating agent is from 0.05 to 2.0; The artificial turf according to claim 3.

5. The chelating agent is Polymeric carboxylic acids, Phosphonates, such as 2-phosphonobutane-1,2,4-tricarboxylic acid (PBTC) or aminophosphonates Alcohol amines, especially aliphatic amine-initiated polyether polyols; and Those salts selected from the group consisting of The artificial turf according to claim 4.

6. 5. The artificial turf of claim 4, wherein the chelating agent is selected from the group consisting of (1,2-diaminoethane)-initiated polyols, (2-aminoethylethanolamine)-initiated polyols or (N,N-bis(3-aminopropyl)methylamine)-initiated polyols, preferably these polyols are propoxylated or ethoxylated, or more preferably both of the polyols are propoxylated and ethoxylated.

7. 10. The artificial turf of claim 1, wherein the artificial turf fibers comprise hydrophobic polyethylene fibers selected from the group consisting of polyethylene homopolymer fibers, polyethylene alloy fibers, polyethylene copolymer fibers, and polyethylene impact copolymer fibers.

8. the polyurethane substrate is obtained by curing a polyurethane reaction mixture comprising a reaction product of a first polyol and a second polyol with an isocyanate; the first polyol is a polyether polyol and / or a polyester polyol having at least two hydroxyl groups per molecule; the second polyol is a polybutadiene diol; The isocyanate comprises a monomeric isocyanate, a polymeric isocyanate, or a prepolymeric isocyanate, or a mixture thereof; the isocyanate monomers, the isocyanate polymers and the isocyanate prepolymers have two or more isocyanate groups per molecule; An artificial lawn according to any one of claims 1 to 7.

9. A method for producing an artificial lawn, comprising: providing a viscous polyurethane reaction mixture; incorporating the artificial grass fibers into a carrier; applying the viscous polyurethane reaction mixture onto a rear surface of the carrier to form a polyurethane base; and curing the viscous polyurethane reaction mixture to form a polyurethane base on the rear surface of the carrier. Equipped with The viscous polyurethane reaction mixture contains an insecticide. method.

10. 10. The method of claim 9, wherein the viscous polyurethane reaction mixture further comprises a chelating agent added in an amount of from 0.1 wt % to 10 wt % of the viscous polyurethane reaction mixture to maintain a polymerization reaction of the viscous polyurethane reaction mixture, and the ratio of the mass of the insecticide to the chelating agent is from 0.05 to 2.

11. 10. The method of claim 9, wherein the step of incorporating the artificial turf fibers into the carrier positions the artificial turf fibers such that a first portion of the artificial turf fibers is located on the rear surface of the carrier, a second portion of the artificial turf fibers protrudes to the front surface of the carrier, and a third portion of the artificial turf fibers is in the center of the carrier.

12. said step of preparing said viscous polyurethane reaction mixture comprises the steps of combining first and second polyols, an isocyanate, said insecticide and said chelating agent; the first polyol is a polyether polyol and / or a polyester polyol having at least two hydroxyl groups per molecule, and the second polyol is a polybutadiene diol; the isocyanate comprises an isocyanate monomer, an isocyanate polymer, or an isocyanate prepolymer, or a mixture thereof, the isocyanate monomer, the isocyanate polymer, and the isocyanate prepolymer having two or more isocyanate groups per molecule; The method of claim 10.

13. the insecticide is a zinc-based antimicrobial or metal coordination complex containing pyrithione, preferably zinc pyrithione added in an amount of from 0.05 wt % to 1.5 wt % of the viscous polyurethane reaction mixture, preferably from 0.08 wt % to 0.7 wt % of the viscous polyurethane reaction mixture; 10. The method of claim 9.

14. 11. The method of claim 10, wherein the chelating agent is selected from the group consisting of (1,2-diaminoethane)-initiated polyols, (2-aminoethylethanolamine)-initiated polyols, or (N,N-bis(3-aminopropyl)methylamine)-initiated polyols, preferably the polyols are propoxylated or ethoxylated, or more preferably both the polyols are propoxylated and ethoxylated.

15. The artificial turf fibers include hydrophobic polyethylene fibers selected from the group consisting of polyethylene homopolymer fibers, polyethylene alloy fibers, polyethylene copolymer fibers, and polyethylene impact copolymer fibers; polybutadiene diol is added in an amount of 0.5 to 10% by weight of the combination of said first polyol and said isocyanate, more preferably in an amount of 1.0 to 9.0% by weight of said combination, and most preferably in an amount of 4.0 to 8.0% by weight of said combination; The polybutadiene diol has a number average molecular weight in the range of from 1000 to 6000 g / mol, more preferably in the range of from 1.500 to 4.500 g / mol. The method of claim 12.

16. Artificial turf obtained by the method according to any one of claims 9 to 15.

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