JP2003319864A - Tufted mat made of polyolefin and manufacturing method therefor - Google Patents

Abstract

(57) [Summary] [Problem] To provide a polyolefin tufting mat that is lightweight, has excellent water resistance and flexibility, and has good drainage properties. A pile fabric (4) is formed by tufting a polyolefin pile yarn (3) on a polyolefin primary fabric (2), and a heated and melted polyolefin film (6) is formed on the back surface of the pile fabric (4) by air pressure. A polyolefin tufting mat, wherein the polyolefin film 6 has a structure in which the entire surface is in close contact with the unevenness of the pile yarn 3 by joining.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a polyolefin tufting mat, and more particularly to a polyolefin tufting mat which is lightweight, has excellent water resistance and flexibility, and has good recyclability.

[0002]

2. Description of the Related Art In recent years, pile mats in which pile yarns have been planted have been widely used as artificial lawns and rugs. As shown in FIG. 7, the pile mat 20 is formed as an artificial lawn by fixing the pile yarn 22 by applying latex 24 to the back surface of the pile fabric 23 obtained by tufting the pile yarn 22 on the primary base fabric 21. There is.

However, in the pile mat 20, the pile yarn 22 is made of polypropylene, polyester, polyamide, etc., the primary base cloth 21 is made of polyester, polypropylene, etc., and the pile mat 20 is made of various materials. Moreover, since latex is used as an adhesive for fixing the pile yarn, various materials are mixed in the obtained pile mat 20, which makes recovery and recycling of the pile mat 20 difficult.

For the purpose of solving this problem, in order to facilitate the recovery and regeneration of the pile mat, a pile mat in which polypropylene is used for the primary backing cloth and the pile yarn and a polyethylene film is bonded to the back surface has been proposed ( JP 20
00-17605). However, since the pile yarns 22 tufted on the back surface of the pile cloth 20 have innumerable irregularities formed by the pile yarns 22, when polyethylene is formed into a film and is melted by heating and pressure-bonded by a roll or the like, Since the convex portion of the pile yarn 22 hinders the pressing of the entire surface and a non-adhesive portion remains around the convex portion, the appearance is visually impaired and the pile yarn fixing function cannot be sufficiently exerted. There is a risk that the pile yarn 22 will fall out.

Therefore, Japanese Patent Laid-Open No. 2000-17605 discloses
As the polyethylene to be lined, fine powder polyethylene is used, and it is spread on the back surface of the pile cloth and then heated and melted. However, it takes time and cost to make polyethylene into fine powder, and it takes time to heat and melt the spread polyethylene to bond it to the back surface of the pile cloth, increasing productivity. There is a problem that you can not.

Further, when the spread polyethylene powder is heated and melted, the surface of the polyethylene becomes flat, so that when it is laid on concrete or the like, the drainage of rainwater is poor.

[0007]

SUMMARY OF THE INVENTION The present invention is directed to an artificial lawn,
Provided is a polyolefin tufting mat suitable for use as a rug, which is lightweight, has excellent water resistance and flexibility, has good recyclability, and has good drainage.

[0008]

Means for Solving the Problems The present invention has been made as a result of intensive studies for solving the above problems. Specifically, a primary pile fabric made of polyolefin is tufted with pile yarn made of polyolefin. By forming a pile cloth and bonding a heat-melted polyolefin film to the back surface of the pile cloth using air pressure, the polyolefin film has a structure in which substantially the entire surface is closely adhered along the unevenness of the pile yarn. The present invention provides a polyolefin tufting mat characterized by the following.

In the present invention, the polyolefin film is a polyethylene, ethylene / α-olefin copolymer, polypropylene or a mixture thereof, which is polymerized by using a metallocene catalyst. The above polyolefin tufting mat made of an ethylene polymer or a propylene polymer, the above polyolefin tufting mat having a large number of drain holes formed at predetermined intervals in a polyolefin film,
And a tufting mat made of the above polyolefin, wherein the tufting mat is an artificial lawn.

Further, according to the present invention, a pile fabric made of polyolefin is planted on a primary base fabric made of polyolefin to form a pile fabric, and the polyolefin film is heated and melted by radiant heat, and air pressure is utilized on the back surface of the pile fabric. By joining the polyolefin film along the irregularities of the pile yarn, the method of manufacturing a polyolefin tufting mat, characterized in that it adheres to substantially the entire back surface of the pile cloth, radiant heat absorbing fine powder A method for manufacturing the above-mentioned polyolefin tufting mat using a polyolefin film blended with, overlaying the polyolefin film on the back surface of the pile cloth,
By heating with a radiant heating device from the polyolefin film side, the manufacturing method of the above polyolefin tufting mat to heat and melt the polyolefin film to join, the polyolefin film on the back side of the pile cloth by blowing hot air from the upper surface of the polyolefin film. A method for producing the above-mentioned polyolefin tufting mat to be joined, and a method for producing the above-mentioned polyolefin tufting mat for joining the polyolefin film to the back of the pile cloth by sucking from the pile surface side of the pile cloth. is there.

[0011]

BEST MODE FOR CARRYING OUT THE INVENTION The pile mat 1 of the present invention is shown in FIG.
As shown in (A) and (B), a pile cloth 4 obtained by tufting a pile thread 3 made of polyolefin is formed on a primary base cloth 2 made of polyolefin, and a polyolefin melted by heating is formed on the back surface of the pile cloth 4. It is obtained by joining the films 6.

As the primary base cloth 2, a cloth-like body made of a filament 5 made of polyolefin is used. In the present invention, the cloth-like body is a generic term for a flexible sheet-like body made of a polyolefin filamentous body 5, and the filamentous body 5 is
It means a narrow uniaxially stretched product, and includes yarns, tapes, split yarns, monofilaments, short fibers, long fibers and the like.

As the polyolefin forming the filament 5, crystalline polyolefin having a large stretching effect is desirable, and high density polyethylene, linear low density polyethylene, polypropylene, ethylene / propylene copolymer and the like are used. Among them, high-density polyethylene and polypropylene are preferable in terms of workability and economy.

Various additives may be added to these polyolefins depending on the purpose. Specifically, phenol-based, organic phosphite-based, organic phosphorus-based antioxidants such as phosnite, and thioether-based antioxidants; hindered amine-based light stabilizers; benzophenone-based, benzotriazole-based, benzoate-based UV absorbers, etc. Nonionic, cationic, anionic antistatic agents; bisamide, wax, organometallic salt dispersants, alkaline earth metal carboxylate scavengers, amides, waxes -Based, organometallic salt-based, ester-based lubricants;
Metal deactivators such as hydrazine and amine acid; flame retardants such as bromine-containing organic, phosphoric acid, antimony trioxide, magnesium hydroxide and red phosphorus; organic pigments; inorganic pigments; inorganic fillers, organic fillers; Examples include inorganic and organic antibacterial agents such as metal ion type.

These additives are appropriately combined and compounded in any step of producing the material composition of the filamentous body 5. Blending of the additives, conventionally known twin-screw extruder, Banbury mixer, kneader, using a kneading device such as a mixing roll at a predetermined ratio, may be prepared by melt kneading, A so-called masterbatch having a high concentration may be prepared, and this may be diluted before use.

The stretching can be carried out by stretching with a hot roll, stretching with a hot plate, stretching with a hot air oven, or the like. The stretching ratio is usually about 3 to 10 times.

When a uniaxially stretched flat yarn is used as the filament 5, its thickness can be set arbitrarily according to the purpose without any limitation, but generally 75-.
2000 decitex, and the yarn width is in the range of 0.3 to 10 mm. The uniaxially stretched flat yarn thus obtained can be made into split yarns by making small cuts in the longitudinal direction. By using split yarn, the texture and feel can be improved.

As the filament 5, a stretched monofilament can be used. Further, short fibers can be used when forming a non-woven fabric. It is also possible to use twisted yarn obtained by spinning short fibers.

The filament 5 such as the uniaxially stretched tape thus obtained is woven by a method such as a plain weave, a twill weave, a twill weave, a ridge weave, a double weave and a dummy weave as shown in FIG. Alternatively, FIG.
As shown in FIG. 1, a primary base cloth 2 is used which is a cross-bonded cloth (sof) in which a large number of filaments 5b are arranged in parallel and the filaments 5a are arranged so as to intersect with each other and the intersections are joined. Further, the primary base cloth 2 can be obtained by knitting in vertical knitting, weft knitting, Russell knitting, tricot knitting or the like.

When the soft cloth is used as the primary base cloth 2, a polyolefin layer 9 having a melting point lower than that of the base material layer 8 is laminated on the surface of the base material layer 8 made of crystalline polyolefin as shown in FIG. It is desirable to stack the low melting point polyolefin layers 9 so that the intersections can be joined by heat fusion.

The pile yarn 3 is formed of a uniaxially stretched polyolefin, and as the polyolefin forming the pile yarn 3, a crystalline polyolefin having a large stretching effect is used. High density polyethylene, linear low density polyethylene, polypropylene , Ethylene / propylene block copolymers and the like are used. Of these, polypropylene and ethylene / propylene block copolymers are preferable in terms of processability and economy.

In the present invention, the pile yarn 3 may be a monolayer of crystalline polyolefin, but a surface layer containing a pigment or an inorganic filler is laminated on the surface of a base layer made of crystalline polyolefin. For example, as shown in FIG. 4 (A), a single layer of a crystalline thermoplastic synthetic resin can be used, and as shown in FIG. 4 (B), a crystalline polyolefin can be used. The base layer 10 may have a structure in which the surface layer 11 in which a pigment or an inorganic filler is mixed is laminated on one surface, and further, as shown in FIG. Can be In addition, as shown in FIG.
The sheath core structure may be a side-by-side structure as shown in FIG. Above all, as shown in FIG. 4C, it is preferable that the surface layers 11 are laminated on both surfaces of the tape-shaped base layer 10.

The surface layer 11 imparts a texture to the pile yarn or colors the pile mat 1 in a desired color, and the base layer 10 contains a small amount of a pigment or an inorganic filler.
By laminating a surface layer 11 containing a large amount of a pigment or an inorganic filler, the functional layer can be differentiated.
Provides mechanical strength, and the surface layer 11 provides color and texture. As a result, the desired pile yarn 3 can be obtained without lowering the mechanical strength.

Various additives can be added to the polyolefin forming the pile yarn 3 depending on the purpose. Specifically, phenol-based, organic phosphite-based, organic phosphorus-based antioxidants such as phosnite, and thioether-based antioxidants; hindered amine-based light stabilizers; benzophenone-based, benzotriazole-based, benzoate-based UV absorbers, etc. Nonionic, cationic, anionic antistatic agents; bisamide, wax, organometallic salt dispersants, alkaline earth metal carboxylate scavengers, amides, waxes -Based, organometallic salt-based, ester-based lubricants; hydrazine-based, amine-acid-based metal deactivators; bromine-containing organic-based, phosphoric acid-based, antimony trioxide, magnesium hydroxide, red phosphorus, and other flame retardants;
Examples include organic pigments, inorganic pigments, inorganic fillers, organic fillers, metal ion-based inorganic and organic antibacterial agents, and the like.

These additives are appropriately combined and compounded in any step of producing the material composition of the base layer 10 and the surface layer 11. The additives are mixed in a predetermined ratio by using a kneading device such as a conventionally known twin screw extruder, Banbury mixer, kneader, and mixing roll,
This may be prepared by melt-kneading, or a high-concentration so-called masterbatch may be prepared and diluted before use.

When a laminated body is used as the pile yarn 3, as a means for forming a laminated film as a molding material, a film to be the base layer 10 and a film to be the surface layer 11 are previously formed, and a dry laminating method or a thermal laminating method is used. To form a multilayer using the method, a method of coating the surface of the film to be the base layer 10 with a thermoplastic synthetic resin to be the surface layer 11, and the surface layer 1 to be formed on the film to be the base layer 10 in advance.
1 may be used by appropriately selecting from known means such as a method of extrusion laminating 1 or extrusion molding as a laminated film by a multi-layer co-extrusion method. From the viewpoint of the transparency and the light transmittance, a method of obtaining the laminate of the base layer 10 and the surface layer 11 in one step by the multi-layer coextrusion method is desirable. Seescore structure,
Alternatively, the side-by-side structure is generally produced by a coextrusion method. When the linear body 5 is a laminated body, it can be formed by the same method.

The pile yarn 3 thus obtained is tufted onto the primary base fabric 2 to form the pile fabric 4. The pile yarn 3 can be tufted by the same method as a conventionally known method for manufacturing a tufting carpet.

Next, a polyolefin film 6 is bonded to the back surface of the pile cloth 4 obtained by tufting the pile threads 3 on the primary base cloth 2.

As the polyolefin film 6, an ethylene-based polymer such as a high-density polyethylene, a linear low-density polyethylene, polypropylene, an ethylene / propylene block copolymer, or a propylene-based polymer is used.

Among them, MFR is 10 or more, preferably M
An ethylene polymer or a propylene polymer having an FR of 15 or more, and more preferably an MFR of 20 or more is desirable. If the MFR is less than 10, it becomes difficult to bond by air pressure, and it becomes necessary to raise the bonding temperature, which may cause the pile yarn 3 to shrink. In particular, polyethylene that has been polymerized using a metallocene catalyst from the viewpoint of flexibility and slip resistance,
An ethylene / α-olefin copolymer, polypropylene or a mixture thereof is desirable, and particularly has a melting point of 50 to 120.
Ethylene polymers at ° C are preferred.

The thickness of the polyolefin film 6 is arbitrary and can be selected according to the purpose, but is generally 20 μm or more, preferably 50 μm or more and 2 mm or less.

The polyolefin film 6 may be joined by any method as long as it is pressed by using air pressure. However, as shown in FIG. 5, the pile cloth 4 is attached so that the back surface is the top surface. Is heated and the polyolefin film 6 is superposed thereon, and the polyolefin film 6 is melted by heating the polyolefin film 6 using a radiant heat heating type heating device 15 such as a heater, and then hot air such as an air knife is used. By pressing the polyolefin film 6 with the blowing device 16, the polyolefin film 6 is pushed to the pile cloth 4
Can be joined to. The joining of the polyolefin film 6 and the pile cloth 4 is performed in a temperature range in which the pile yarn 3 does not shrink.

Polyolefin film 6 using air pressure
The polyolefin film 6 by joining
Will be shaped along the irregularities on the back surface of the pile cloth 4 and will be exactly attached to the entire back surface of the pile cloth 4. Further, a continuous concave portion 13 is formed between the convex portions 12 formed by the pile yarn 3, and the concave portion 13 can function as a drainage channel for draining rainwater and the like when the pile mat 1 is laid. If necessary, a large number of drainage holes may be provided in the polyolefin film 6 at predetermined intervals to drain the upper surface when the pile mat 1 is laid.

In the present invention, when the polyolefin film 6 is joined with the fine powder of the radiant heat absorbing substance, when the polyolefin film 6 is joined, the heating efficiency by the radiant heat can be improved. Carbon black and graphite are preferable as the radiant heat absorbing substance.

Various other methods can be used for joining the polyolefin film 6, for example, as shown in FIG.
From the pile cloth 4 can be directly extrusion-molded onto the back surface of the pile cloth 4 and can be superposed on each other. Further, as a pressing method by pneumatic pressure, suction can be performed from the pile yarn 3 side using a suction device 18 such as a vacuum chamber. .

The pile mat of the present invention is used for baseball, soccer,
It can be used as a lawn for multipurpose grounds such as rugby, tennis courts, golf driving ranges, walking paths,
It can be used as a rug for cars, airplanes, halls, etc.

[0037]

Since the pile mat of the present invention has such a structure, it is lightweight and has excellent durability. Further, since it is made of only polyolefin, it can be easily recovered and recycled. Furthermore, since the polyolefin film lined with pile cloth is shaped along the irregularities on the back surface of the pile cloth, continuous concave portions are formed between the convex portions, and the concave portions form drainage channels. Even when it is laid, it will be drained quickly.

[Brief description of drawings]

FIG. 1 shows an example of a pile mat of the present invention (A) is a front sectional view, (B) is a side sectional view.

FIG. 2A is a plan view and FIG. 2B is a longitudinal sectional view showing an example of a primary base cloth.

FIG. 3 is a vertical sectional view showing another example of the primary base cloth.

FIG. 4 is a longitudinal sectional view showing an example of pile yarn.

FIG. 5 is a side view showing an example of a method for manufacturing a pile mat.

FIG. 6 is a side view showing another example of a method for manufacturing a pile mat.

FIG. 7 is a vertical sectional view showing a conventional pile mat.

[Explanation of symbols]

1: Pile mat 2: Primary base cloth 3: pile yarn 4: Pile cloth 5: Striatum 6: Polyolefin film 8: Base material layer 9: Polyolefin layer 10: Base layer 11: Surface layer 12: convex part 13: recess 15: Heating device 16: Hot air blowing device 17: T die 18: Suction device

   ─────────────────────────────────────────────────── ─── Continued front page    F term (reference) 2D051 AB04 AE04 AG15 AH02 HA01                       HA02 HA05 HA06                 3B120 AA23 BA03 BA11 BA28 BA36                       CA08 DB01 EB15 EB16                 4F055 AA28 BA14 DA20 EA07 EA22                       EA28 FA05 FA29 GA34 GA40

Claims (10)

[Claims] 1. A primary cloth made of polyolefin is tufted with pile threads made of polyolefin to form a pile cloth, and a heat-melted polyolefin film is bonded to the back surface of the pile cloth by using air pressure. ,
A polyolefin tufting mat, characterized in that the polyolefin film has a structure in which substantially the entire surface is adhered along the irregularities formed by the pile yarn. 2. The polyolefin footing mat according to claim 1, wherein the polyolefin film is polyethylene, an ethylene / α-olefin copolymer, polypropylene or a mixture thereof, which is polymerized using a metallocene catalyst. 3. The polyolefin tufting mat according to claim 1 or 2, wherein the polyolefin film is made of an ethylene polymer having an MFR of 10 or more or a propylene polymer. 4. The polyolefin tufting mat according to claim 1, wherein a large number of drainage holes are formed in the polyolefin film at predetermined intervals. 5. The polyolefin tufting mat according to claim 1, wherein the tufting mat is artificial grass. 6. A polyolefin primary pile cloth is vegetated with polyolefin pile yarn to form a pile cloth, and the polyolefin film is heated and melted by radiant heat and bonded to the back surface of the pile cloth using air pressure. A polyolefin tufting mat manufacturing method, characterized in that the polyolefin film is caused to follow the irregularities of the pile thread and adhere to substantially the entire back surface of the pile cloth. 7. The method for producing a polyolefin tufting mat according to claim 6, wherein a polyolefin film containing a radiant heat absorbing fine powder is used. 8. The polyolefin tufting according to claim 6 or 7, wherein a polyolefin film is superposed on the back surface of the pile cloth, and the polyolefin film is heated by a radiant heating device to heat and melt the polyolefin film for joining. Method of manufacturing mat. 9. The method for producing a polyolefin tufting mat according to claim 6, wherein the polyolefin film is joined to the back surface of the pile cloth by blowing hot air from the upper surface of the polyolefin film. 10. The method for producing a polyolefin tufting mat according to claim 6, wherein the polyolefin film is bonded to the back surface of the pile cloth by suctioning from the pile surface side of the pile cloth.