High-permeability base fabric, artificial turf comprising same and preparation method

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Solution Overview

Problem

Existing artificial turfs face issues with water permeability, leading to weed growth and quartz sand leakage, which affect durability and maintenance, and require costly and labor-intensive hole punching.

Innovation Solution

A high-permeability base fabric is woven with specific yarn thicknesses and densities, eliminating the need for hole punching, and a foamed adhesive layer enhances water permeability without compromising durability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the ferroelectrics punching method is used to ensure water permeability, then water permeability is improved, but the base fabric requires subsequent maintenance due to weed growth and quartz sand leakage

Engineering Contradiction:

Improvewater permeabilityVSAvoidmaintenance requirement

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The base fabric is designed with pre-formed through-holes during the weaving process, eliminating the need for subsequent punching operations. This preliminary structuring ensures water permeability is built-in from the start, avoiding later maintenance issues with punched holes

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The invention changes the structural parameters of the base fabric by incorporating through-holes as an integral part of the woven structure, with specific hole densities (5-15 holes per square meter) and yarn thicknesses (0.08-0.5mm) that optimize both water permeability and durability without requiring post-manufacturing modifications

Inventive Principle:

Principle #35Parameter changes

2Reliability

If holes are punched in the base fabric to improve water permeability, then water drainage is enhanced, but quartz sand leaks through the holes causing wear to the back adhesive layer

Engineering Contradiction:

Improvewater drainageVSAvoidquartz sand leakage

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

Inventive Principle:

Principle #35Parameter changes

3Reliability

If the yarn thickness is reduced below 0.08 mm to improve water permeability, then water flow is enhanced, but the yarn cannot be properly woven and holes are formed

Engineering Contradiction:

Improvewater permeabilityVSAvoidweaving quality

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The patent identifies and applies optimal parameter ranges for yarn thickness (0.08-0.5mm) that balance water permeability requirements with manufacturability. This parameter optimization ensures the yarn is thin enough to allow water flow but thick enough to maintain structural integrity during weaving

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention incorporates through-holes as an integral part of the woven structure, with specific hole densities (5-15 holes per square meter) that provide sufficient water permeability without over-thinning the yarn or compromising the weaving process

Inventive Principle:

Principle #16Partial or excessive action

4Ease of manufacture

If the yarn thickness is increased above 0.5 mm to improve weaving stability, then manufacturing is simplified, but water permeability is reduced

Engineering Contradiction:

Improveweaving stabilityVSAvoidwater permeability

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

Inventive Principle:

Principle #16Partial or excessive action

Data Source

PatentUS20250376807A1High-permeability base fabric, artificial turf comprising same and preparation method

Publication Date: 2025.12.11 COCREATION GRASS CO LTD

AI summary

A high-permeability base fabric and a high-permeability durable artificial turf including the same are disclosed. The high-permeability base fabric is formed by interweaving warp yarns and weft yarns. The warp yarns and/or the weft yarns contain yarns A, and the thickness of the yarns A is 0.08-0.5 mm, or include yarn B with thickness of 0.03-0.06 mm. The high-permeability base fabric is obtained by weaving in regular or irregular arrangement. The high-permeability base fabric applied to the artificial turf has excellent water permeability and can meet the use requirements. The artificial turf designed by the invention does not need to be punched by an electric iron, which can effectively prevent the growth of natural weeds, simultaneously avoid the problems of abrasion of a back glue layer and the like caused by leakage of quartz sand during paving, has a simple preparation method, can save labour and cost, and is beneficial to market popularization and industrial production.