High-Permeability Base Fabric, Artificial Turf Comprising Same and Preparation Method

The invention relates to the technical field of artificial turfs, in particular to a high-permeability base fabric, a preparation method of the high-permeability base fabric, an artificial turf containing the high-permeability base fabric and a preparation method of the artificial turf.

The first artificial turf in the world was born in Houston space dome stadium, USA, in April 1966, and since then, the artificial turf has been officially taken to the world stage. With the continuous development of artificial turf manufacturing technologies, the artificial turf is closer to natural turf in appearance and hand feeling, and is simpler than the natural turf in terms of paving and maintenance, low in maintenance cost and barely influenced by environment, weather and regions. With the continuous expansion of the application scene of the artificial turf, the artificial turf is accepted by more and more people and have been widely applied on football grounds, courtyards, roofs, office buildings and the like. The artificial turf is generally composed of three parts, which includes synthetic turf yarns in the shape of grass leaf, base fabric for implanting synthetic turf yarns and back adhesive layer for fixing. During use, the water permeability performance of the artificial turf besides the appearance and the mechanical properties of the bottom and the back of the artificial turf shall be considered.

Existing artificial turf product adopts the ferroelectrics punching method to ensure the water permeability rate of the product after the gum procedure in order to solve the water permeability problem. However, natural weeds can grow out from holes punched by the ferroelectrics in the long-term use, which causes troubles for the subsequent maintenance. Furthermore, for some artificial turf paving, sand may fill, and the sand may leak to the the below of the turf and in contact with the back adhesive layer through the hole. During long-term use, the presence of quartz sand intensifies the wear of the backing layer on the lawn. Thus resulting to poorly cover, and may finally led to the shedding of the turf yarns.

Therefore, there is a need to develop an artificial turf having excellent water permeability without punching holes, and to improve durability of the back and sole to meet the market demand.

A high-permeability base fabric and a high-permeability durable artificial turf including the same have been disclosed. The base fabric has excellent water permeability and can meet the use requirement. Meanwhile, the artificial turf designed by the invention does not need to be punched by an electric iron, so that the growth of natural weeds can be avoided, and the problems of gum layer abrasion and the like caused by quartz sand leakage during paving are avoided. The preparation method is simple, labour saving and cost efficient, and is beneficial to market popularization and industrial production.

In order to achieve the above objects, one of the objects of the present invention is to provide a high-permeability base fabric.

The high-permeability base fabric is formed by interweaving warp yarns and weft yarns. The warp yarns and/or the weft yarns include yarns A, and the thickness of the yarns A is 0.08-0.5 mm.

The beneficial effects of adopting the above technical scheme at least include: when the thickness of the yarn is less than 0.08 mm, the yarn cannot be spread at the crossing position of the warp and weft due to the fact that the yarn is too thin in the weaving process, holes are formed to meet the water permeability performance. When the thickness of the yarn is more than 0.5 mm, stable production cannot be guaranteed when the yarn is cut and drawn, and the yarn cannot be woven due to the fact that the yarn is too thick in the follow-up process.

Further, the thickness of the yarn a is preferably 0.1 to 0.3 mm.

Preferably, the warp and/or weft yarns comprise yarns B, and the thickness of the yarns B is 0.03-0.06 mm.

Preferably, the warp yarn is yarn B and the weft yarn is yarn A.

Preferably, the warp yarn is yarn B, the weft yarn is yarns A and B, and the weft yarn is alternately arranged and woven in an ABAB mode or other regular or irregular modes.

Preferably, the weft yarn is yarn B and the warp yarn is yarn A.

Preferably, the weft yarn is yarn B, the warp yarn is yarns A and B, and the warp yarn is alternately arranged and woven in an ABAB mode or other regular or irregular modes.

Furthermore, the warp yarns have one thickness, the weft yarns have three thicknesses, and the weft yarns are arranged, combined and woven in a regular or irregular mode.

The weft yarns have one thickness, the warp yarns have three thicknesses, and the warp yarns are arranged, combined and woven in a regular or irregular mode.

The warp yarns have two thicknesses, the weft yarns have three thicknesses, and the warp yarns and the weft yarns are arranged, combined and woven in a regular or irregular mode;

The weft yarns have two thicknesses, the warp yarns have three thicknesses, and the warp yarns and the weft yarns are arranged, combined and woven in a regular or irregular mode; by analogy, as long as suitable yarns with different thicknesses can be selected to be arranged, combined and woven in a regular or irregular mode, the weaving mode of forming effective holes among the yarns to improve the water permeability is within the scope of the invention.

Preferably, the warp and weft yarns are both yarn A.

Preferably, the width of the warp yarn is 0.5-3 mm.

The width of the weft yarn is 0.5-4 mm.

The weaving density of the warp yarns is 400-2400 yarns/m.

The weaving density of the weft yarns is 300-2400 yarns/m.

The beneficial effects of adopting the above technical scheme at least include: when the width of the warp yarn or the weft yarn is less than 0.5 mm, the base fabric with stable size cannot be obtained by weaving. When the width of the warp yarn is more than 3 mm or the width of the weft yarn is more than 4 mm, the base fabric cannot be flat due to the folding phenomenon during weaving because the yarn is too wide. When the weaving density of the warp yarns is less than 400 yarns/m and the weaving density of the weft yarns is less than 300 yarns/m, the produced base fabric has poor dimensional stability and cannot meet the use requirement. When the weaving density of the warp yarn is greater than 2400 yarns/m and the weaving density of the weft yarn is greater than 2400 yarns/m, the warp yarn can be woven only by matching with thinner yarns, and the problem of dimensional stability also exists.

Further, the width of the warp yarn is 1-2 mm.

The width of the weft yarn is 1-3 mm.

The weaving density of the warp yarns is 600-1200 yarns/m.

The weaving density of the weft yarns is 400-1200 yarns/m.

Preferably, the yarn is one or more of black, green, white, blue, violet, orange, yellow and brown in colour.

The invention also provides a preparation method of the high-permeability base fabric, which includes the following steps.

(1) One or more of polyethylene resin, polypropylene resin, polyamide resin and polyethylene glycol terephthalate resin with color master batch and processing aid are uniformly mixed, and the mixture is extruded by a screw extruder, cut and drawed into yarns with required width and thickness, shaped and rolled for later use.

(2) Placing the warp and weft yarns on a knitting machine according to a pre-set knitting density and arrangement mode to obtain the required high-permeability base fabric.

The invention also provides a high-permeability durable artificial turf, which includes a base fabric, turf yarns and gum. The base fabric is a high-permeability base fabric. The turf yarns are tufted on the base fabric, and the back adhesive is coated on the back of the base fabric.

Preferably, the base fabric is a layer of the high-permeability base fabric.

The base cloth is the combination of one layer of the high-permeability base cloth and one layer of the mesh cloth.

The base fabric is formed by matching and combining the high-permeability base fabric and any non-woven fabric.

Preferably, the back glue includes raw glue, filler and foaming agent.

The raw glue is selected from one or more of styrene-butadiene glue, styrene-acrylic glue, ethylene-vinyl acetate glue, acrylic glue, epoxy glue and polyurethane glue.

The mass ratio of the raw glue to the filler is 8:2-2:8.

The foaming agent accounts for 0.3-0.7% of the total mass of the raw glue and the filler.

The density of the glue after foaming in the back gluing process is controlled to be 0.8-0.2 times of the density of the glue before foaming.

The beneficial effects of adopting the above technical scheme at least include: the purpose of adding the foaming agent in the glue is to enable the glue to be foamed more easily, the foam is more stable and finer, holes which are communicated sufficiently are formed in the glue layer after solidification, and the water permeability performance of the glue layer is improved.

When the ratio of the raw glue to the filler is more than 8, the water permeability performance of the whole lawn is affected due to too dense glue film after later-stage curing because of too much raw glue. When the addition amount of the foaming agent is less than 0.3%, the foaming performance of the glue is poor, and the ideal foaming density cannot be achieved. When the foaming density ratio is more than 0.8, no enough holes are formed in the adhesive layer, so that the water permeability performance is influenced. When the ratio of the raw glue to the filler is less than 2, the addition amount of the foaming agent is more than 0.7%, the foaming density ratio is less than 0.2, and the glue film layer has more holes after later-stage curing, the good water permeability effect of the whole lawn can be ensured, but the mechanical property of the back glue layer of the lawn can be influenced due to excessive filler and low density.

Further, the mass ratio of the raw glue to the filler is 7.

The foaming agent accounts for 0.4-0.6% of the total mass of the raw glue and the filler.

The density of the glue after foaming in the back gluing process is controlled to be 0.3-0.7 times of the density of the glue before foaming.

Preferably, the foaming agent is selected from one or more of sodium dodecyl sulfate, sodium dodecyl benzene sulfonate, sodium dodecyl diphenyl ether disulfonate, sodium alpha-alkenyl sulfonate and sodium abietate.

The filler is selected from one or more of calcium carbonate, barium sulfate, mica powder, aluminum hydroxide, talcum powder and silicon dioxide.

Furthermore, the glue for the back glue can also include color paste and thickening agent in the formula. The color paste is selected from one or more of black color paste, red color paste, green color paste, orange color paste, blue color paste and purple color paste, the thickening agent is selected from one or more of polyacrylic acid, cellulose and polyurethane thickening agents, the color paste is added to color the back glue layer so as to meet the requirements of different customers on colors, and the thickening agent is added to adjust the viscosity of the glue so that the problem of glue bleeding is not easy to occur in the production of the back glue.

The fourth purpose of the invention is to provide a preparation method of a high-water-permeability durable artificial turf, which includes the following steps.