JP6729916B2 - Artificial grass - Google Patents

Description

The present invention relates to artificial grass, also referred to as synthetic grass, and the manufacture of artificial grass. The invention further relates to the production of turf-mimicking fibers. The invention particularly relates to products and methods for producing artificial grass fibers based on polymer blends, as well as methods and products for manufacturing artificial grass carpets made from these artificial grass fibers.

Artificial grass or turf is a surface composed of fibers used to replace turf. The structure of artificial grass is designed so that the artificial grass has a grass-like appearance. Typically, artificial grass is used as a surface for sports such as soccer, American football, rugby, tennis, golf, stadiums, or athletic fields. Moreover, artificial lawns are frequently used in landscape applications.

The advantage of using artificial grass is that you don't have to care for your free-running grass or landscape as you would with regular mowing, digging, fertilizing and watering. Watering can be difficult, for example due to regional restrictions on water use. In other climatic zones, regrowth of grass and remodeling of dense grass cover are slow compared to damage to the natural grass surface from play and/or movement on the ground. Artificial grass fields do not require similar care and effort to maintain, but may require some maintenance such as removing dirt and debris and having to be brushed regularly. .. This may be done to help raise the fibers after being stepped on during play or exercise. Over a period of normal use of 5 to 15 years, artificial grass sports fields can withstand a high degree of mechanical wear, can withstand UV, can withstand thermal cycling or aging, can use chemicals and various It would be beneficial if it could resist interactions with various environmental conditions. Therefore, it would be beneficial if an artificial lawn would have a longer service life, be durable and maintain its play and surface properties, as well as its appearance, over its period of use.

US Patent Application No. 2010/0173102A1 discloses an artificial turf characterized in that the material for the cladding has a hydrophilicity different from that of the material used for the core.

The present invention provides a method for producing an artificial lawn according to the independent claim. Embodiments are shown in the dependent claims.

In one aspect, the invention provides a method of making an artificial grass carpet. The method comprises the steps of making a polymer mixture. The polymer mixture as used herein covers a mixture of different types of polymers, and in some cases various additives may be added to the polymer mixture. The term "polymer mixture" may also be replaced by the terms "masterbatch" or "compound batch". The polymer mixture is at least a three phase system. As used herein, a three-phase system covers a mixture that separates into at least three different phases. The polymer mixture comprises a first polymer, a second polymer and a compatibilizer. These three elements form the multiple phases of a three-phase system. A three-phase system may be expanded into four, five or more phase systems, provided there are multiple additional polymers or compatibilizers added to the system. The first polymer and the second polymer are immiscible. The first polymer forms a plurality of polymer beads surrounded by a compatibilizer within the second polymer.

The method further comprises extruding the polymer mixture into monofilaments. To carry out this extrusion, the polymer mixture is heated, for example. The method further comprises quenching the monofilament. In this step, the monofilament is cooled. The method further comprises the step of reheating the monofilament. The method further comprises the steps of drawing the reheated monofilament to transform the plurality of polymer beads into a plurality of filamentous regions and forming the monofilament into artificial grass fibers. In this step, the monofilament is drawn. This results in longer monofilaments, and in the process, the polymeric beads are stretched and elongated. Depending on the amount stretched, the plurality of polymer beads become more elongated.

The method further comprises incorporating artificial grass fibers into the artificial grass substrate. In some examples, the artificial grass substrate is a woven or woven mat.

The incorporation of artificial grass fibers into an artificial grass substrate is, for example, forming artificial grass fibers into a tuft and putting them in the artificial grass substrate, and then bonding a plurality of tufted artificial grass fibers to the artificial grass substrate. Can be performed by. For example, artificial grass fibers are inserted into the substrate with a needle, such that the carpet is tufted. Once the artificial grass fiber loops have been formed, they may be cut during the same process. The method further comprises bonding a plurality of artificial grass fibers to the artificial grass substrate. In this step, the artificial grass fibers are bonded or attached to the artificial grass substrate. This may be done in various ways to hold the artificial grass fibers in place, such as by gluing or coating the surface of the artificial grass substrate. This is done, for example, by coating the surface or part of the artificial grass substrate with a material such as latex or polyurethane.

The incorporation of the artificial grass fibers into the artificial grass substrate can be done, for example, by alternatively weaving the artificial grass fibers into the artificial grass substrate (or fiber mat) during manufacture of the artificial grass carpet. The technology for producing this artificial lawn is known from US patent application No. 2012125474A1.

The term "polymer beads" or "beads" may refer to localized areas, such as droplets of polymer, that are immiscible with the second polymer. The plurality of polymer beads may be round, spherical, or oval in shape in some cases, and they may also be irregularly shaped. In some cases, polymeric beads typically have a size of about 0.1-3 micrometers in diameter, preferably 1-2 micrometers. In another example, the plurality of polymer beads is larger. Their size is, for example, up to 50 micrometers in diameter.

In some examples, drawn monofilaments may be used directly as artificial grass fibers. For example, the monofilament can be extruded as a tape or other shape.

In another example, the artificial grass fibers may be a bundle or group of several drawn monofilament fibers, generally cabled together, twisted, or bundled together. In some cases, the bundle is rewound with a so-called rewound yarn, which keeps the bundle of yarns together and prepares for the subsequent tufting or weaving process.

The size of the plurality of monofilaments is, for example, 50 to 600 micrometers in diameter. The weight of the yarn may typically reach 50-3000 dtex.

Embodiments may have the advantage that the second polymer and the plurality of some immiscible polymers may not exfoliate from each other. The plurality of thread-like regions are embedded within the second polymer. Therefore, it is impossible for them to peel off. The use of the first polymer and the second polymer allows tailoring of several properties of the artificial grass fibers. For example, a softer plastic is used for the second polymer to give the artificial grass a softer feel, like a more natural grass. Stiffer plastics may be used for the first polymer or a plurality of other immiscible polymers to give the artificial grass higher elasticity and stability, giving it the ability to bounce after being stepped or depressed. May be.

A further advantage may, in some cases, be that the multiple thread regions are concentrated in the central region of the monofilament during the extrusion process. This causes the stiffer material to be concentrated in the center of the monofilament and a large amount of softer plastic to be located on the outer surface or outer region of the monofilament. This further results in artificial grass fibers with more turf-like properties.

A further advantage may be that the artificial grass fibers have improved long-term elasticity. This allows them to more naturally recover and stand up after being used or trampled on by multiple artificial lawn fibers, reducing the required maintenance of the artificial lawn and at the same time The need for brushing may be less.

In another embodiment, the polymer beads comprise a plurality of crystalline moieties and a plurality of amorphous moieties. The polymer mixture is probably heated during the extrusion process and the first polymer and further portions of the second polymer have structures that are more amorphous or more crystalline in the various regions. You may.

Stretching the polymer beads into a thread-like region may result in an increase in the size of the crystalline portions in the first polymer relative to the amorphous portions. This makes the first polymer stiffer than if it has an amorphous structure, for example. This may result in an artificial lawn with greater rigidity and the ability to bounce when pushed down. Stretching the monofilaments may also, in some cases, cause the second polymer or other additional polymers to render a larger portion of their structure more crystalline.

In a specific example of this, the first polymer can be polyamide and the second polymer can be polyethylene. Stretching the polyamide results in an increase in multiple crystalline regions that makes the polyamide more rigid. This also applies to several other plastic polymers.

In another embodiment, the step of making the polymer mixture comprises mixing the first polymer with a compatibilizer to form the first mixture. The step of making the polymer mixture further comprises the step of heating the first mixture. Creating the polymer mixture further comprises extruding the first mixture. Creating the polymer mixture further comprises extruding the first mixture. The step of making the polymer mixture further comprises the step of granulating the extruded first mixture. The step of preparing the polymer mixture further comprises mixing the granulated first mixture with the second polymer. The step of forming the polymer mixture further comprises heating the granulated first mixture with the second polymer to form the polymer mixture. This particular method of making the polymer mixture may be advantageous as it allows for very precise control over how the first polymer and compatibilizer are distributed within the second polymer. For example, the size or shape of the extruded first mixture determines the size of the plurality of polymer beads within the polymer mixture.

The above-mentioned method of preparing the polymer mixture uses, for example, the so-called single screw extrusion method. As an alternative to this, the polymer mixture may also be made at one time by bringing together all of its constituent components. For example, the first polymer, the second polymer and the compatibilizer can all be added together at the same time. Multiple other synthetic components such as additional polymers or other additives can also be combined at the same time. The amount of polymer mixture mixed can then be increased, for example, by using a twin screw feed for extrusion. In this case, the desired distribution of polymeric beads can be achieved by using appropriate mixing speeds or amounts.

In another embodiment, the polymer mixture is at least a four phase system. The polymer mixture comprises at least a third polymer. The third polymer is immiscible with the second polymer. The third polymer further forms a plurality of polymer beads surrounded by a compatibilizer within the second polymer.

In another embodiment, the step of forming the polymer mixture comprises mixing the first polymer and the third polymer with a compatibilizer to form the first mixture. The step of making the polymer mixture further comprises the step of heating the first mixture. The step of forming the polymer mixture first comprises extruding the first mixture. The step of creating the polymer mixture further comprises the step of granulating the extruded first mixture. The step of making the polymer mixture further comprises the step of mixing the first mixture with the second polymer. The step of forming the polymer mixture further comprises heating the first mixture with the second polymer to form the polymer mixture. This method may use two different polymers to make a polymer mixture and provide an accurate means of controlling the size and distribution of multiple polymer beads. Alternatively, the first polymer can be used to make the granulation with the same or different compatibilizer, apart from making the third polymer with the compatibilizer. The plurality of granulations can then be mixed with a second polymer to make a polymer mixture.

As an alternative to this, the polymer mixture can be made by adding the first polymer, the second polymer, the third polymer and the compatibilizer all together at the same time and then mixing them more vigorously. For example, a twin screw feed can be used for the extruder. In another embodiment, the third polymer is a polar polymer. In another embodiment, the third polymer is a polyamide.

In another embodiment, the third polymer is polyethylene terephthalate, which is also commonly abbreviated as PET.

In another embodiment, the third polymer is polybutylene terephthalate, which is also commonly abbreviated as PBT.

In another embodiment, the polymer mixture comprises 1% to 30% by weight of the first polymer and the third polymer together. In this example, the weight balance may be constituted by a plurality of components such as the second polymer, a compatibilizer, and a plurality of other additional additives incorporated into the polymer mixture.

In another embodiment, the polymer mixture comprises 1% to 20% by weight of the first polymer and the third polymer together. Again, in this example, the weight balance of the polymer mixture may be constituted by the second polymer, the compatibilizer, and a plurality of other additional additives.

In another embodiment, the polymer mixture comprises 5% to 10% by weight of the first polymer and the third polymer together. Again, in this example, the weight balance of the polymer mixture may be constituted by the second polymer, the compatibilizer, and a plurality of other additional additives.

In another embodiment, the polymer mixture comprises 1% to 30% by weight of the first polymer. In this example, the weight balance is constituted by, for example, the second polymer, the compatibilizer, and a plurality of other additional additives.

In another embodiment, the polymer mixture comprises 1% to 20% by weight of the first polymer. In this example, the weight balance may consist of the second polymer, the compatibilizer, and a number of other additional additives mixed into the polymer mixture.

In another embodiment, the polymer mixture comprises 5% to 10% by weight of the first polymer. This example may have a weight balance made up of the second polymer, the compatibilizer, and a number of other additional additives mixed into the polymer mixture. In another embodiment, the first polymer is a polar polymer. In another embodiment, the first polymer is a polyamide.

In another embodiment, the first polymer is polyethylene terephthalate, commonly known by the abbreviation PET.

In another embodiment, the first polymer is polybutylene terephthalate, also known by the general abbreviation PBT. In another embodiment, the second polymer is a non-polar polymer. In another embodiment, the second polymer is polyethylene. In another embodiment, the second polymer is polypropylene.

In another embodiment, the second polymer is a mixture of the aforementioned polymers that may be used for the second polymer.

In another embodiment, the compatibilizer is maleic acid grafted to polyethylene or polyamide; polyethylene using an unsaturated acid such as maleic acid, glycidyl methacrylate, ricinoloxazoline maleinate or its anhydride, Maleic anhydride grafted onto a free radical initiated graft copolymer of SEBS, EVA, EPD or polypropylene; a graft copolymer of SEBS with glycidyl methacrylate; a graft copolymer of EVA with mercaptoacetic acid and maleic anhydride; EPDM graft copolymer using maleic anhydride; polypropylene graft copolymer using maleic anhydride; polyolefin grafted polyamide polyethylene or polyamide; and polyacrylic acid type compatibilizer.

In another embodiment, the polymer mixture comprises 80% to 90% by weight of the second polymer. In this example, the weight balance is such that the first polymer, optionally the second polymer, if present in the polymer mixture, the compatibilizer, and other chemicals or additions added to the polymer mixture. And an agent.

In another embodiment, the polymer mixture further comprises any one of waxes, blunting agents, UV stabilizers, flame retardants, antioxidants, pigments and combinations thereof. These additional ingredients listed are added to the polymer mixture to make artificial grass fibers flame retardant, having a green color so that the artificial grass more closely resembles turf, greater in daylight. It may be provided with a number of other desired properties such as stability.

In another embodiment, the step of making artificial grass fibers comprises weaving the monofilaments into the artificial grass fibers. That is, in some examples, artificial grass fibers are a combination of many fibers rather than a single monofilament. In another embodiment, the artificial grass fibers are yarns.

In another embodiment, the method further comprises bundling the drawn monofilaments together to create an artificial grass fiber.

In another embodiment, the method further comprises weaving, bundling, or spinning multiple monofilaments together to create an artificial lawn fiber. Multiple, for example 4-8, monofilaments can be formed or finished into a yarn.

In another aspect, the invention provides an artificial lawn manufacture according to any one of the foregoing methods.

In another aspect, the present invention provides an artificial lawn comprising an artificial lawn substrate and an artificial lawn fiber formed into tufts in the artificial lawn substrate. An artificial lawn substrate is, for example, a woven or other flat structure that can have a plurality of tufted fibers therein. The artificial lawn fiber comprises at least one monofilament. Each of the at least one monofilament comprises a first polymer in the form of a plurality of thread-like regions. Each of the at least one monofilament comprises a second polymer and the plurality of thread-like regions are embedded in the second polymer. Each of the at least one monofilament comprises a compatibilizer that surrounds each of the plurality of filamentous regions and separates the at least one first polymer from the second polymer. This artificial lawn may have the advantage of being extremely durable as multiple filamentous regions are embedded within the second polymer via the compatibilizer. Therefore, they are not capable of peeling. Having a second polymer surrounding the first polymer may provide a softer, harder artificial lawn with a feel similar to a real lawn. The artificial grass described herein differs in properties from co-extruded artificial grass. In co-extrusion, a core, typically 50-60 micrometers in diameter, may be surrounded by an outer cover or coating material having a diameter of about 200-300 micrometers. In this artificial lawn, there are many thread-like regions of the first polymer. The plurality of thread regions may not continue along the entire length of the monofilament. The artificial grass may also have the properties or characteristics provided by any of the method steps described above. In another embodiment, the plurality of thread regions have a diameter less than 20 micrometers. In another embodiment, the plurality of thread regions have a diameter of less than 10 micrometers. In another embodiment, the plurality of thread regions have a diameter of 1 micrometer to 3 micrometers.

In another embodiment, the artificial grass fibers extend a predetermined length beyond the artificial grass substrate. The plurality of thread regions has a length that is less than half the predetermined length. In another embodiment, the plurality of thread regions have a length of less than 2 mm.

It will be appreciated that one or more of the foregoing embodiments of the present invention may be combined, unless the combined embodiments are mutually exclusive.

In the following, several embodiments of the invention are described in more detail, by way of example only, with reference to the drawings.
FIG. 1 shows a flow chart illustrating an example of a method of manufacturing an artificial lawn. FIG. 2 shows a flow chart illustrating one method of making a polymer blend. FIG. 3 shows a flow chart illustrating a further example of how to make a polymer mixture. FIG. 4 shows a diagram illustrating a cross section of the polymer mixture. FIG. 5 shows a further example of a polymer mixture. FIG. 6 illustrates the extrusion of a polymer mixture into monofilaments. FIG. 7 shows a cross section of a small piece of monofilament. FIG. 8 illustrates the effect of drawing a monofilament. FIG. 9 shows an electron micrograph of a cross section of a drawn monofilament. FIG. 10: shows the example of a cross section of the example of an artificial lawn.

Elements labeled with similar numbers in these figures are either equivalent elements or perform the same function. The elements discussed above are not necessarily discussed in later figures if they have equivalent functions.

FIG. 1 shows a flow chart illustrating an example of a method of manufacturing an artificial lawn. First, in step 100, a polymer mixture is created. The polymer mixture is at least a three phase system. The polymer mixture comprises a first polymer. The polymer mixture further comprises a second polymer and a compatibilizer. The first polymer and the second polymer are immiscible. In other examples, there may be multiple additional polymers, such as a third polymer, a fourth polymer, or even a fifth polymer that are also immiscible with the second polymer. It may also be a plurality of additional compatibilizers used either in combination with the first polymer or in combination with an additional third, fourth or fifth polymer. The first polymer forms a plurality of polymer beads surrounded by a compatibilizer. The polymeric beads may also be formed by additional polymers that are immiscible within the second polymer.

The plurality of polymer beads are surrounded by the compatibilizer and are within or mixed with the second polymer. In the next step 102, the polymer mixture is extruded into monofilaments. Next, in step 104, the monofilament is quenched or rapidly cooled. Next, in step 106, the monofilament is reheated. In step 108, the reheated monofilament is drawn to transform the polymeric beads into filamentous regions and form the monofilament into artificial grass fibers. Multiple additional steps are also performed on the monofilaments to form artificial grass fibers. For example, monofilaments are spun or woven into a yarn having the desired properties. Next, at step 110, the artificial grass fibers are incorporated into an artificial grass substrate. Step 110 can be, for example, but not limited to, forming artificial grass fibers into tufts or weaving them into an artificial grass substrate. Next, at step 112, a plurality of artificial grass fibers are bonded to the artificial grass substrate. For example, a plurality of artificial lawn fibers are glued or held in place by a coating or other material. Step 112 is an optional step. For example, step 112 may not need to be performed if multiple artificial grass fibers were woven into the artificial grass substrate.

FIG. 2 shows a flow chart illustrating one method of making a polymer blend. In this example, the polymer mixture is a three-phase system and comprises a first polymer, a second polymer and a compatibilizer. The polymer mixture may be pigmented, provide fire or UV resistance, or may be provided with a plurality of others, such as additives, to improve the flow properties of the polymer mixture. First, in step 200, a first mixture is formed by mixing a first polymer with a compatibilizer.

Multiple additional additives may also be added during this step. Next, in step 202, the first mixture is heated. Next, in step 204, the first mixture is extruded. Next, in step 206, the extruded first mixture is then granulated or cut into pieces. Next, in step 208, the granulated first mixture is mixed with the second polymer. At this time, a plurality of additional additives may also be added to the polymer mixture. Finally, in step 210, the granulated first mixture is heated with the second polymer to form a polymer mixture. The heating step and the mixing step may occur simultaneously.

FIG. 3 shows a flow chart illustrating a further example of how to make the polymer mixture 400. In this example, the polymer mixture further comprises at least a third polymer. The third polymer is immiscible with the second polymer and the polymer mixture is at least a four phase system. The third polymer further forms a plurality of polymer beads surrounded by the compatibilizer with the second polymer. First, in step 300, a first mixture is formed by mixing a first polymer and a third polymer with a compatibilizer. At this time, a plurality of additional additives may be added to the first mixture. Next, in step 302, the first mixture is heated. The heating step and the mixing step of the first mixture may be performed at the same time. Next, in step 304, the first mixture is extruded. Next, in step 306, the extruded first mixture is granulated or cut into pieces. Next, in step 308, the first mixture is mixed with the second polymer. At this time, a plurality of additional additives may be added to the polymer mixture. Then, finally, in step 310, the heated first mixture and the second polymer are heated to form a polymer mixture. The heating step and the mixing step may be performed simultaneously.

FIG. 4 shows a diagram illustrating a cross section of the polymer mixture 400. The polymer mixture 400 comprises a first polymer 402, a second polymer 404 and a compatibilizer 406. The first polymer 402 and the second polymer 404 are immiscible. The first polymer 402 is not as abundant as the second polymer 404. First polymer 402 is shown surrounded by compatibilizer 406 and dispersed within second polymer 404. The first polymer 402 surrounded by the compatibilizer 406 forms a number of polymer beads 408. The plurality of polymer beads 408 may be spherical or elliptical in shape and they may also be irregularly shaped depending on how well the polymer mixture is mixed and depending on temperature. Polymer mixture 400 is an example of a three-phase system. The three phases are regions of the first polymer 402. The second phase region is the compatibilizer 406 and the third phase region is the second polymer 404. Compatibilizer 406 separates first polymer 402 from second polymer 404.

FIG. 5 shows a further example of a polymer blend 500. The example shown in FIG. 5 is similar to the example shown in FIG. However, the polymer mixture 500 further comprises a third polymer 502. Some of the polymer beads 408 are here composed of a third polymer 502. The polymer mixture 500 shown in FIG. 5 is a four phase system. The four phases are composed of a first polymer 402, a second polymer 404, a third polymer 502 and a compatibilizer 406. The first polymer 402 and the third polymer 502 are immiscible with the second polymer 404. The compatibilizing agent 406 separates the first polymer 402 from the second polymer 404 and the third polymer 502 from the second polymer 404.

In this example, the same compatibilizer 406 is used for both the first polymer 402 and the third polymer 502. In several other examples, different compatibilizers 406 can be used for the first polymer 402 and the third polymer 502.

FIG. 6 illustrates the extrusion of polymer blends into monofilaments. An amount of polymer mixture 600 is shown. Within the polymer mixture 600 are a number of polymer beads 408. The plurality of polymer beads 408 may be made of one or more polymers that are immiscible with the second polymer 404 and are separated from the second polymer 404 by a compatibilizer. A screw, piston or other device is used to push the polymer mixture 600 into the holes 604 in the plate 602. This causes the polymer mixture 600 to be extruded into monofilaments 606. Monofilament 606 is shown as also including a plurality of polymer beads 408. The second polymer 404 and the plurality of polymer beads 408 are extruded together. In some examples, the second polymer 404 will not be as viscous as the plurality of polymer beads 408, and the plurality of polymer beads 408 will tend to be centered in the monofilament 606. This may result in a concentration of filamentous regions in the core region of the monofilament 606, which may result in desired properties for the final artificial grass fiber.

FIG. 7 shows a cross section of a small piece of monofilament 606. The monofilament is again shown as comprising a second polymer 404 having a plurality of polymer beads 408 mixed therein. The plurality of polymer beads 408 are separated from the second polymer 404 by a compatibilizer 406 (not shown). A portion of monofilament 606 is heated and then stretched along the length of monofilament 606 to form a plurality of threadlike structures. This is illustrated by arrow 700, which indicates the direction of stretching.

FIG. 8 illustrates the effect of stretching the monofilament 606. In FIG. 8, an example of a cross section of stretched monofilament 606 is shown. The plurality of polymer beads 408 in FIG. 7 are stretched to form a plurality of thread-shaped structures 800. The amount of deformation of the plurality of polymer beads 408 depends on how much the monofilament 606' is stretched.

Examples may relate to the manufacture of artificial grass, also called synthetic grass. In particular, the invention relates to the production of a plurality of grass-mimicking fibers. The plurality of fibers are immiscible and are composed of first and second polymers that differ in material properties such as stiffness, density, and polarity, and a compatibilizer.

In the first step, the first polymer is mixed with the compatibilizer. Color pigments, UV and heat stabilizers, processing aids, and other substances known from the art as such, can be added to the mixture. This may result in a granular material consisting of a two-phase system in which the first polymer is surrounded by a compatibilizer.

In the second step, the three-phase system is formed by adding the second polymer to the mixture, so that in this example, the amount of the second polymer is about 80-90 weight percent of the three-phase system, The amount of the first polymer is 5% by mass to 10% by mass of the three-phase system, and the amount of the compatibilizing agent is 5% by mass to 10% by mass of the three-phase system. The use of extrusion techniques results in a mixture of droplets or beads of the first polymer surrounded by a compatibilizer dispersed in the polymer matrix of the second polymer. In a practical implementation, a so-called masterbatch is formed containing the granulation of the first polymer and the compatibilizer. The masterbatch may also be referred to herein as a "polymer mixture." The granulated mixture is dissolved and a mixture of the first polymer and the compatibilizer is formed by extrusion. The resulting strands are comminuted into granules. The resulting granulation and granulation of the second polymer are then used in a second extrusion to produce thick fibers that are then drawn into the final fibers.

The melt temperature used during multiple extrusions depends on the type of polymers and the compatibilizer used. However, the melting temperature is typically between 230°C and 280°C.

Monofilaments, which may also be referred to as monofilaments or fibrillated tapes, are produced by sending the mixture to an extrusion line for fiber production. The molten mixture is passed through an extrusion device, i.e., a spinneret plate or a wide slot nozzle, shaped the molten stream into a single fiber or tape shape, quenched or cooled in a water spinning bath and spun at different rotation speeds. It is dried and stretched by passing it through a plurality of heated godets and/or heating ovens.

The monofilament or tape is then annealed online in a second step through a further heating oven and/or a set of heated godets.

By this procedure, the beads or droplets of the first polymer surrounded by the compatibilizer are longitudinally stretched to form a plurality of fibril-like linear structures, however, these are the second polymer. Remains fully embedded in the polymer matrix of.

FIG. 9 shows a micrograph of a cross section of a drawn monofilament made using the example method described above. The horizontal white lines in the stretched monofilament 606 are a plurality of threadlike structures 800. Some of these thread-like structures are labeled 800. The plurality of thread-like structures 800 can be shown as forming a plurality of linear structures of the first polymer within the second polymer.

The resulting fiber may have a softness that combines several advantages: durability and long-term elasticity. In the case of different stiffness and bending properties of the polymers, the fibers may exhibit better elasticity in the case of the stiff first polymer, which means that the fibers will spring back once they are stepped on. A plurality of filamentous fiber structures, which can be incorporated into the polymer matrix, provide the polymer reinforcement of the fibers.

Limit determination due to the composite formed by the first and second polymers is prevented by embedding the plurality of short fibers of the second polymer in the matrix provided by the first polymer. Moreover, complex coextrusions that require several extrusion heads to feed a single composite spinneret device are not required.

The first polymer can be a polar material such as polyamide, while the second polymer can be a non-polar polymer such as polyethylene. Alternatives to the first polymer are polyethylene terephthalate (PET) or polybutylene terephthalate (PBT) for the second polymer polypropylene. Finally, materials consisting of three polymers are possible (eg PET, PA and PP). PP creates the matrix and the other creates a plurality of linear fiber structures independent of each other. The compatibilizer can be maleic anhydride grafted to polyethylene or polyamide.

FIG. 10 shows an example of a cross section of an example of the artificial grass 1000. The artificial lawn 1000 includes an artificial lawn base 1002. The artificial lawn fiber 1004 is formed in a tuft shape in the artificial lawn base 1002. A coating 1006 is shown at the base of the artificial grass substrate 1002. The coating may help bond or secure the artificial grass fibers 1004 to the artificial grass substrate 1002. The coating 1006 may be optional. For example, a plurality of artificial grass fibers 1004 are instead woven into the artificial grass substrate 1002. Various types of glues, coatings or adhesives can be used for coating 1006. A plurality of artificial grass fibers 1004 are shown extending a distance 1008 above the artificial grass substrate 1002. Distance 1008 is essentially the height of the pile of artificial grass fibers 1004. The length of the plurality of filamentous regions within the plurality of artificial lawn fibers 1004 is less than or equal to half the distance 1008.
List of reference numerals 100 Creating a polymer mixture 102 Extruding the polymer mixture into monofilaments 104 Quenching the monofilaments 106 Reheating the monofilaments 108 Elongating the reheated monofilaments to form a plurality of polymer beads into a plurality of thread-like regions Forming a monofilament into an artificial grass fiber 110 and incorporating the artificial grass fiber into an artificial grass carpet 112 optionally bonding a plurality of artificial grass fibers to the artificial grass carpet 200 a first polymer phase Forming a first mixture by mixing with a solubilizer 202 Heating the first mixture 204 Extruding the first mixture 206 Granulating the extruded first mixture 208 Granulating the first mixture with a second polymer Mix 210 Heat the granulated first mixture with the second polymer to form a polymer mixture

300 forming a first mixture by mixing a first polymer and a third polymer with a compatibilizer 302 heating the first mixture 304 extruding the first mixture 306 granulating the extruded first mixture 308 first Mixing Mixture with Second Polymer 310 Heating First Mixed Mixture with Second Polymer to Form Polymer Mixture 400 Polymer Mixture 402 First Polymer 404 Second Polymer 406 Compatibilizer 408 Polymer Beads 500 Polymer Mix 502 Third polymer 600 Polymer mixture 602 Plate 604 Hole 606 Monofilament 606' Stretched monofilament 700 Direction of stretching 800 Plural filamentous structures 1000 Artificial lawn 1002 Artificial lawn carpet 1004 Artificial lawn fiber (pile)
1006 Coating 1008 Pile height

Claims (25)

It’s an artificial lawn,
With artificial grass base,
Artificial grass fibers incorporated into the artificial grass base,
Equipped with
The artificial lawn fiber is a yarn formed from monofilament,
The monofilament comprises a polymer mixture, the polymer mixture is at least four-phase system, the polymer mixture, the first polymer, second polymer, a third polymer and compatibilizer, wherein the first polymer and the each third polymer, said a second polymer immiscible, said first polymer and said third polymer respectively, to form a plurality of thread-like region surrounded by the compatibilizing agent within the second polymer , Artificial grass. The artificial lawn according to claim 1, wherein the plurality of thread-shaped regions includes a plurality of crystalline portions and a plurality of amorphous portions. The artificial lawn according to claim 1 or 2 , wherein the third polymer is a polar polymer. The artificial lawn according to any one of claims 1 to 3, wherein the third polymer is one of polyamide, polyethylene terephthalate (PET), and polybutylene terephthalate (PBT). The artificial lawn according to any one of claims 1 to 4 , wherein the polymer mixture comprises 1% by weight to 30% by weight of the first polymer and the third polymer in combination. The artificial lawn according to any one of claims 1 to 4 , wherein the polymer mixture comprises 1 wt% to 20 wt% of the first polymer and the third polymer in combination. The artificial lawn according to any one of claims 1 to 4 , wherein the polymer mixture comprises 5% by weight to 10% by weight of the first polymer and the third polymer in total. It’s an artificial lawn,
With artificial grass base,
Artificial grass fibers incorporated into the artificial grass base,
Equipped with
The artificial lawn fiber is a yarn formed from monofilament,
The monofilament comprises a polymer mixture, the polymer mixture being at least a three-phase system, the polymer mixture comprising a first polymer, a second polymer and a compatibilizer, wherein the first polymer and the second polymer are , Immiscible, said first polymer forming a plurality of thread-like regions surrounded by said compatibilizer within said second polymer,
The polymer mixture comprises 30% by weight of the first polymer from 1% by weight, artificial turf. 9. The artificial lawn according to claim 8, wherein the polymer mixture comprises 1% to 20% by weight of the first polymer. 9. The artificial lawn according to claim 8, wherein the polymer mixture comprises 5% to 10% by weight of the first polymer. The artificial lawn according to any one of claims 1 to 10 , wherein the first polymer is a polar polymer. The artificial lawn according to any one of claims 1 to 11 , wherein the first polymer is one of polyamide, polyethylene terephthalate (PET), and polybutylene terephthalate (PBT). The artificial lawn according to any one of claims 1 to 12 , wherein the second polymer is a non-polar polymer. The artificial lawn according to any one of claims 1 to 13 , wherein the second polymer is one of polyethylene, polypropylene, and a mixture thereof. The compatibilizer is maleic acid grafted onto polyethylene or polyamide; free of polyethylene, SEBS, EVA, EPD or polypropylene using an unsaturated acid such as maleic acid, glycidyl methacrylate, ricinol oxazoline maleate or an anhydride thereof. Maleic anhydride grafted to a radical-initiated graft copolymer; SEBS graft copolymer with glycidyl methacrylate; EVA graft copolymer with mercaptoacetic acid and maleic anhydride; EPDM graft copolymer with maleic anhydride; maleic anhydride The artificial lawn according to any one of claims 1 to 14 , which is one of a polypropylene graft copolymer using an acid; a polyolefin grafted polyamide polyethylene or polyamide; and a polyacrylic acid type compatibilizer. It’s an artificial lawn,
With artificial grass base,
Artificial grass fibers incorporated into the artificial grass base,
Equipped with
The artificial lawn fiber is a yarn formed from monofilament,
The monofilament comprises a polymer mixture, the polymer mixture being at least a three-phase system, the polymer mixture comprising a first polymer, a second polymer and a compatibilizer, wherein the first polymer and the second polymer are , Immiscible, said first polymer forming a plurality of thread-like regions surrounded by said compatibilizer within said second polymer,
The polymer mixture, wherein the second polymer comprises 90 wt% to 80 wt%, artificial turf. 17. The artificial body according to any one of claims 1 to 16 , wherein the polymer mixture further comprises any one of waxes, blunting agents, UV stabilizers, flame retardants, antioxidants, pigments and combinations thereof. grass. The artificial turf fiber, to the artificial grass fibers were woven, spun, twisted, was rolled back, or combined with one another, with at least one of monofilaments, claims 1-17 The artificial lawn according to any one of 1. 19. The artificial lawn according to any one of claims 1 to 18 , wherein the artificial grass fibers are tufted into the artificial grass substrate and a plurality of the artificial grass fibers are bonded to the artificial grass substrate. The artificial lawn according to any one of claims 1 to 18 , wherein the artificial lawn fibers are woven into the artificial lawn substrate. 21. The artificial lawn according to any one of claims 1 to 20 , wherein the plurality of filamentous regions have a diameter of less than 50 micrometers. It’s an artificial lawn,
With artificial grass base,
Artificial grass fibers incorporated into the artificial grass base,
Equipped with
The artificial lawn fiber is a yarn formed from monofilament,
The monofilament comprises a polymer mixture, the polymer mixture being at least a three-phase system, the polymer mixture comprising a first polymer, a second polymer and a compatibilizer, wherein the first polymer and the second polymer are , Immiscible, said first polymer forming a plurality of thread-like regions surrounded by said compatibilizer within said second polymer,
Wherein the plurality of thread areas have a diameter of less than 20 micrometers, artificial turf. 21. The artificial lawn according to any one of claims 1 to 20 , wherein the plurality of thread-like regions have a diameter of 1 to 3 micrometers. The artificial turf fibers, beyond the artificial grass base extends a predetermined length, said plurality of thread-like regions has a length of less than half of the predetermined length, any of claims 21 23 The artificial grass described in paragraph 1. The artificial lawn according to any one of claims 21 to 23 , wherein the plurality of thread-like regions have a length of less than 2 mm.

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