METHOD FOR MANUFACTURING ARTIFICIAL TURF

Abstract

Provided is a method for manufacturing an artificial turf, including: providing a base cloth; providing artificial turf yarns; tufting the artificial turf yarns on the base cloth, and applying an adhesive; and blowing air to the base cloth having the adhesive applied thereto to obtain the artificial turf. According to the manufactured artificial turf, when passing air through the air blowing device, water permeable holes are formed in the bonding layer applied on the base cloth. The water seepage rate of the artificial turf is increased by means of water seepage through the water permeable holes. Moreover, there is no need to pierce the adhesive applied surface of the base cloth during production, thereby avoiding damage to the structure of the artificial turf by piercing. This effectively prevents the artificial turf yarns from loosening and falling off and prolongs the service life of the artificial turf.

Claims

1. A method for manufacturing an artificial turf, comprising: providing a base cloth having a surface; providing artificial turf yarns; implanting the artificial turf yarns on the base cloth by tufting, and applying an adhesive to the surface of the base cloth; and blowing air to the base cloth having the adhesive applied thereto through an air blowing device to obtain the artificial turf after the adhesive is cured.

2. The method according to claim 1, wherein the base cloth comprises warp yarns and weft yarns, and the warp yarns and the weft yarns are cross-woven with each other.

3. The method according to claim 1, wherein the adhesive is applied via scraping or roller coating, and the air is blown out by the air blowing device at an air pressure of 1-4 MPa.

4. The method according to claim 2, wherein a cross section of the warp yarn is a flat structure, and the weft yarns comprise first yarns and second yarns, wherein a cross section of the first yarn is a circular structure, a cross section of the second yarn is a flat structure, and the first yarns and the second yarns are interlaced.

5. The method according to claim 2, wherein a cross section of the weft yarn is a flat structure, and the warp yarns comprise first yarns and second yarns, wherein a cross section of the first yarn is a circular structure, a cross section of the second yarn is a flat structure, and the first yarns and the second yarns are interlaced.

6. The method according to claim 2, wherein providing the base cloth comprises: selecting warp yarns and weft yarns; placing the warp yarns and the weft yarns on a weaving machine for weaving; and performing shaping and coiling operations to obtain the base cloth.

7. The method for manufacturing an artificial turf according to claim 1, wherein providing the artificial turf yarns comprises: placing granules in a wire drawing machine; adding a drawing liquid to the wire drawing machine; controlling a drawing temperature and a retraction ratio; performing wire drawing treatment on the granules through a wire drawing process; and performing shaping and winding operations to obtain the artificial turf yarns.

8. The method according to claim 7, wherein the granules are selected from one or more of polyethylene, polypropylene, polyvinyl chloride and polyamide.

9. The method according to claim 7, wherein the drawing temperature is 100 C.-150 C.

10. The method according to claim 7, wherein the retraction ratio is 0.90-0.98.

11. The method according to claim 1, further comprising: forming pinholes in the base cloth for accommodating the artificial turf yarns, wherein the implanting the artificial turf yarns comprises tufting the artificial turf yarns and inserting the artificial turf yarns into the pinholes.

12. The method according to claim 11, wherein the inserting the artificial turf yarns into the pinholes of the base cloth comprises passing first ends of artificial turf yarns, which are tufted in the base cloth, through respective ones of said pinholes thereby forming respective protrusions.

13. The method according to claim 12, the method further comprising: applying, prior to blowing air to the base cloth, a bonding layer to the surface of the base cloth, the surface being disposed opposite to a side of the base cloth having the artificial turf yarns tufted; and contacting the applied bonding layer with the protrusions formed by the artificial turf yarns.

14. The method according to claim 13, wherein the applying the bonding layer comprises applying the bonding layer to the surface of the base cloth with one or more portions of the bonding layer partially penetrating into said pinholes for fixing the artificial turf yarns.

15. The method according to claim 14, wherein after applying the bonding layer to the surface of the base cloth, the method comprises: blowing air through the air blowing device to the base cloth that is implanted with said artificial turf yarns inserted in said pinholes; and forming, via air passing through the pinholes, water permeable holes in the bonding layer, wherein the water permeable holes are in communication with the pinholes and configured to facilitate seepage of water through the artificial turf.

16. A method for manufacturing an artificial turf, the method comprising: implanting artificial turf yarns on a surface of a base cloth by tufting, and applying an adhesive to the surface of the base cloth; applying a bonding layer to the surface of the base cloth, the surface being opposite to a side of the base cloth having the artificial turf yarns tufted; and blowing air to the base cloth having the adhesive applied thereto through an air blowing device to obtain the artificial turf after the adhesive is cured.

17. The method according to claim 16, wherein prior to implanting the artificial turf yarns on the surface of the base cloth, the method comprises manufacturing the artificial turf yarns by: performing a wire drawing treatment on granules at a drawing temperature of 100 C. to 150 C. and a retraction ratio of 0.90 to 0.98; and performing shaping and winding operations to obtain the artificial turf yarns from the granules.

18. The method according to claim 16, wherein prior to implanting the artificial turf yarns on the surface of the base cloth, the method comprises: forming the base cloth from warp yarns and weft yarns that are cross-woven and interlaced with each other, wherein: a cross section of the warp yarn is a flat structure, and the weft yarns comprise interlaced first yarns and second yarns, wherein a cross section of the first yarn is a circular structure, and a cross section of the second yarn is a flat structure; or a cross section of the weft yarn is a flat structure, and the warp yarns comprise interlaced first yarns and second yarns, wherein a cross section of the first yarn is a circular structure, and a cross section of the second yarn is a flat structure.

19. The method according to claim 16, wherein prior to implanting the artificial turf yarns on the surface of the base cloth, the method comprises: forming pinholes in the base cloth for accommodating the artificial turf yarns, wherein the implanting the artificial turf yarns on the surface of the base cloth comprises tufting the artificial turf yarns and inserting the artificial turf yarns respectively into the pinholes, wherein the inserting the artificial turf yarns into the pinholes comprises passing first ends of the artificial turf yarns tufted in the base cloth through respective ones of said pinholes to form respective protrusions with the first ends contacting the bonding layer.

20. The method according to claim 19, wherein the applying the bonding layer comprises applying the bonding layer to the surface of the base cloth with one or more portions of the bonding layer partially penetrating into said pinholes for fixing the artificial turf yarns, and after applying the bonding layer to the surface of the base cloth, the method comprises: blowing air through the air blowing device to the base cloth that is implanted with the artificial turf yarns inserted in said pinholes; and forming, via air passing through the pinholes, water permeable holes in the bonding layer, wherein the water permeable holes are in communication with the respective pinholes and are configured to facilitate seepage of water through the artificial turf.

Description

DESCRIPTION OF THE DRAWINGS

[0023] The present invention will be further described below in conjunction with the accompanying drawings and embodiments.

[0024] FIG. 1 is a schematic structural view of an artificial turf of the present invention;

[0025] FIG. 2 is a cross-sectional view of the artificial turf of the present invention shown in FIG. 1;

[0026] FIG. 3 is a top view of a base cloth in the artificial turf of the present invention shown in FIG. 1; and

[0027] FIG. 4 is a cross-sectional view of the base cloth shown in FIG. 3.

[0028] In the figures: 100. artificial turf, 1. base cloth, 11. warp yarn, 12. weft yarn, 121. first yarn, 122. second yarn, 13. pinhole, 14. water permeable hole, 2. artificial turf yarn, 3. bonding layer.

DETAILED DESCRIPTION

[0029] The present invention will be described in detail with reference to the accompanying drawings. The figures are simplified schematic views which only illustrate the basic structure of the present invention in a schematic manner, and therefore only show the components related to the present invention.

[0030] As shown in FIG. 1, the present invention provides an artificial turf 100 for laying on the ground to beautify the environment. The artificial turf 100 includes a base cloth 1, artificial turf yarns 2 tufted on the base cloth 1, and a bonding layer 3 applied on the surface of the base cloth 1 for fixing the artificial turf yarns 2. The artificial turf yarns 2 are tufted on the base cloth 1 by a tufting machine. The bonding layer 3 is applied on the base cloth 1 opposite to a side where the artificial turf yarns 2 are implanted. One end of the artificial turf yarn 2 passes through the base cloth 1 and is in contact with the bonding layer 3.

[0031] As shown in FIG. 1, FIG. 3 and FIG. 4, the base cloth 1 includes a plurality of warp yarns 11 and a plurality of weft yarns 12 that are cross-woven with each other, and the warp yarns 11 and the weft yarns 12 are woven by a weaving machine and then interlaced with each other to form the base cloth 1. In this embodiment, the cross section of the warp yarn 11 is a flat structure, the plurality of warp yarns 11 are arranged parallel to each other, the spacing between every two warp yarns 11 is equal, the weft yarns 12 include first yarns 121 with a circular cross section and second yarns 122 with a flat cross section, the first yarns 121 and the second yarns 122 are interlaced in parallel, and the spacing between the first yarn 121 and the second yarn 122 is equal. In another embodiment, the cross section of the weft yarn 11 is a flat structure, the plurality of weft yarns 11 are arranged parallel to each other, the spacing between every two weft yarns 11 is equal, the warp yarns 12 include first yarns 121 with a circular cross section and second yarns 122 with a flat cross section, the first yarns 121 and the second yarns 122 are interlaced in parallel, and the spacing between the first yarn 121 and the second yarn 122 is equal.

[0032] As shown in FIG. 1 and FIG. 2, pinholes 13 for accommodating the artificial turf yarns 2 are formed in the base cloth 1. The artificial turf yarns 2 are tufted and inserted in the pinholes 13 by a tufting machine. One end of the artificial turf yarn 2 tufted in the base cloth 1 passes through the pinhole 13 to form a protrusion and is in contact with the bonding layer 3. The bonding layer 3 applied on the base cloth 1 partially penetrates into the pinhole 13 to fix the artificial turf yarns 2. After the bonding layer 3 is applied, air is blown to the base cloth 1 implanted with the artificial turf yarns 2 by means of the pinholes 13 through the air blowing device. Part of the adhesive in the pinholes 13 flows to the outside of the pinholes 13 under the drive of the airflow. Water permeable holes 14 for water seepage, which are in communication with the pinholes 13, are formed in the bonding layer 3 through the gas flowing out of the pinholes 13. The water seepage rate of the artificial turf 100 is increased by means of water seepage through the water permeable holes 14.

[0033] The material of the base cloth 1 and the artificial turf yarns 2 includes any one or more of polyethylene, polypropylene, polyvinyl chloride and polyamide.

[0034] The present invention further provides a method for manufacturing the artificial turf 100, including the following steps: [0035] (1) Warp yarns 11 and weft yarns 12 are selected, the warp yarns 11 and the weft yarns 12 are placed on a weaving machine for weaving, and shaping and coiling operations are performed to obtain a base cloth 1. [0036] (2) Granules are placed in a wire drawing machine, a drawing liquid is added to the wire drawing machine, a drawing temperature is controlled to be 100-150 C., a retraction ratio is controlled to be 0.90-0.98, wire drawing treatment is performed on the mixed granules through a wire drawing process, and winding, shaping and coiling operations are performed to obtain artificial turf yarns 2. [0037] (3) The artificial turf yarns 2 manufactured in step (2) are tufted by a tufting machine and implanted on the base cloth 1 manufactured in step (1), a plurality of pinholes 13 are penetrated in the surface of the base cloth 1 by the tufting machine, an adhesive is applied on the surface of the base cloth 1 by means of scraping or roller coating, air is blown to the base cloth 1 having the adhesive applied through an air blowing device at the air pressure of 1-4 MPa, the airflow causes part of the adhesive in the pinholes 13 to flow to the outside of the pinholes 13 to form water permeable holes 14, a bonding layer 3 is formed after the adhesive is cured, and coiling and packaging operations are performed to obtain an artificial turf.

[0038] The granule is any one or more of polyethylene, polypropylene, polyvinyl chloride and polyamide.

Embodiment 1

[0039] A method for manufacturing an artificial turf in this embodiment includes the following steps: [0040] (1) Warp yarns and weft yarns are selected, the warp yarns and the weft yarns are placed on a weaving machine for weaving, and shaping and coiling operations are performed to obtain a base cloth. [0041] (2) Polyethylene granules are placed in a wire drawing machine, a drawing liquid is added to the wire drawing machine, a drawing temperature is controlled to be 100 C., a retraction ratio is controlled to be 0.90, wire drawing treatment is performed on the mixed granules through a wire drawing process, and winding, shaping and coiling operations are performed to obtain artificial turf yarns. [0042] (3) The artificial turf yarns manufactured in step (2) are tufted by a tufting machine and implanted on the base cloth manufactured in step (1), an adhesive is applied on the surface of the base cloth, air is blown to the base cloth having the adhesive applied through an air blowing device at the air pressure of 1 MPa, and coiling and packaging operations are performed after the adhesive is cured to obtain an artificial turf.

Embodiment 2

[0043] (1) Warp yarns and weft yarns are selected, the warp yarns and the weft yarns are placed on a weaving machine for weaving, and shaping and coiling operations are performed to obtain a base cloth. [0044] (2) Polypropylene granules are placed in a wire drawing machine, a drawing liquid is added to the wire drawing machine, a drawing temperature is controlled to be 110 C., a retraction ratio is controlled to be 0.92, wire drawing treatment is performed on the mixed granules through a wire drawing process, and winding, shaping and coiling operations are performed to obtain artificial turf yarns. [0045] (3) The artificial turf yarns manufactured in step (2) are tufted by a tufting machine and implanted on the base cloth manufactured in step (1), an adhesive is applied on the surface of the base cloth, air is blown to the base cloth having the adhesive applied through an air blowing device at the air pressure of 2 MPa, and coiling and packaging operations are performed after the adhesive is cured to obtain an artificial turf.

Embodiment 3

[0046] (1) Warp yarns and weft yarns are selected, the warp yarns and the weft yarns are placed on a weaving machine for weaving, and shaping and coiling operations are performed to obtain a base cloth. [0047] (2) Polyvinyl chloride granules are placed in a wire drawing machine, a drawing liquid is added to the wire drawing machine, a drawing temperature is controlled to be 120 C., a retraction ratio is controlled to be 0.94, wire drawing treatment is performed on the mixed granules through a wire drawing process, and winding, shaping and coiling operations are performed to obtain artificial turf yarns. [0048] (3) The artificial turf yarns manufactured in step (2) are tufted by a tufting machine and implanted on the base cloth manufactured in step (1), an adhesive is applied on the surface of the base cloth, air is blown to the base cloth having the adhesive applied through an air blowing device at the air pressure of 3 MPa, and coiling and packaging operations are performed after the adhesive is cured to obtain an artificial turf.

Embodiment 4

[0049] (1) Warp yarns and weft yarns are selected, the warp yarns and the weft yarns are placed on a weaving machine for weaving, and shaping and coiling operations are performed to obtain a base cloth. [0050] (2) Polyamide granules are placed in a wire drawing machine, a drawing liquid is added to the wire drawing machine, a drawing temperature is controlled to be 140 C., a retraction ratio is controlled to be 0.98, wire drawing treatment is performed on the mixed granules through a wire drawing process, and winding, shaping and coiling operations are performed to obtain artificial turf yarns. [0051] (3) The artificial turf yarns manufactured in step (2) are tufted by a tufting machine and implanted on the base cloth manufactured in step (1), an adhesive is applied on the surface of the base cloth, air is blown to the base cloth having the adhesive applied through an air blowing device at the air pressure of 4 MPa, and coiling and packaging operations are performed after the adhesive is cured to obtain an artificial turf.

Comparative Example

Commercially Available Artificial Turf.

Experimental Example

[0052] The water seepage rates of the artificial turf samples manufactured in Embodiments 1-4 and the commercially available artificial turf sample in Comparative Example are measured by a method for testing water permeability in GB/T20394-2006 Artificial Turf for Sports. 500 mm500 mm of a portion of the artificial turf samples manufactured in Embodiments 1-4 and a portion of the commercially available artificial turf sample in Comparative Example are taken. The artificial turf yarns facing upwards are placed in an experimental container, and the samples are flattened. 50 L of water is poured into the experimental container, and the time S when the water completely flows out is calculated (accurate to seconds). The water seepage rates of the samples are calculated by Formula =(50/S)/0.2560. Specific results are shown in Table 1:

TABLE-US-00001 TABLE 1 Measuring table of water seepage rates of artificial turf samples in Embodiments 1-4 and Comparative Example Item Water seepage rate (L/(min .Math. m.sup.2)) Standard 60 Embodiment 1 246 Embodiment 2 238 Embodiment 3 242 Embodiment 4 247 Comparative Example 62

[0053] As can be seen from Table 1, the water seepage rate of the artificial turf samples in Embodiments 1-4 manufactured by the present invention is much greater than that of the commercially available artificial turf sample. This is because the cross section of the warp yarns 11 of the artificial turf 100 manufactured by the manufacturing method of the present invention has a flat structure, and the cross section of the first yarns in the weft yarns 12 has a circular structure. After the warp yarns 11 and the weft yarns 12 are woven by the weaving machine and interlaced with each other to form the base cloth 1, when the base cloth 1 having the adhesive applied passes through the air blowing device, the airflow blown out by the air blowing device blows out part of the adhesive in the pinholes 13 on the base cloth 1. The water permeable holes 14 which are in communication with the pinholes 13 are formed in the bonding layer 3 through the airflow blown out by the pinholes 13. The water seepage rate of the artificial turf 100 is increased by means of water seepage through the water permeable holes 14. By using the artificial turf 100 manufactured by the present invention, there is no need to pierce the adhesive applied surface of the base cloth 1 by a piercing device, thereby avoiding damage to the structure of the artificial turf 100 by piercing, effectively preventing the artificial turf yarns 2 from loosening and falling off, and prolonging the service life of the artificial turf 100.

[0054] With the above-mentioned ideal embodiments of the present invention as inspiration, through the above-mentioned description content, the related staff can make various changes and modifications without departing from the scope of the present invention. The technical scope of the present invention is not limited to the content in the specification, and the technical scope thereof needs to be determined according to the scope of the claims.