CN113774754A - 一种人工草坪铺设工艺及人工草坪 - Google Patents
一种人工草坪铺设工艺及人工草坪 Download PDFInfo
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Abstract
本发明提供了一种人工草坪铺设工艺及人工草坪,人工草坪,包括人造草丝层、填充层和基础层;所述基础层在最下方,填充层位于中间,人造草丝层铺设在填充层上方,所述人造草丝层包括人造草丝、基布和底基布,所述底基布为网状或直曲混合的编织布,人造草丝植入在基布上,形成半成品人造草坪,所述半成品人造草坪与底基布贴合,形成人工草坪。人工草坪的铺设工艺,具体为:位于最底部的压实度为预设值的基础层,铺设在所述基础层上的厚度不小于第一预设厚度的填充层,铺设在所述填充层上方的人造草丝层。
Description
技术领域
本发明涉及种植技术领域,尤其涉及一种人工草坪铺设工艺及人工草坪。
背景技术
人造草是以类似草的纤维化合物经过机械编制于聚丙烯基层上,可以在多种运动场中作为场地的地面材料。现有的人工草坪以聚丙烯(pp)材料为主,并填筑石英砂颗粒,草质较尼龙材料适于运动,耐磨损性能较好,但是草质较硬,在激烈运动中容易对人员产生擦伤,抗紫外线能力差。还有一种人工草坪以聚乙烯(PE)材料为主,填筑石英砂颗粒,同时填筑橡胶颗粒,具有天然草的弹性、柔软、运动性能大为改善,但是耐磨损能力差,含有较多金属杂质,环保性能差。
例如中国专利CN201910975734.4公开了一种高耐候人工草坪用复合草丝,包括草丝纤维、碳纤维丝及聚脲包覆层,碳纤维丝共两条,并以草丝纤维轴线对称分布在草丝纤维两侧,碳纤维丝与草丝纤维中心点位于同一直线方向上,聚脲包覆层分别报复在草丝纤维、碳纤维丝外,草丝纤维、碳纤维丝外表面处聚脲包覆层厚度不大于1毫米,剩余部分聚脲包覆层厚度不小于1.5毫米。其生产方法包括原料调配,拉丝塑性及合成作业。此种方法生产较为复杂,且不易大规模推广,无法全自动化规模生产。
发明内容
为克服现有技术中存在的人工草坪弹性差、生产方法复杂、容易积水以及隔热效果差导致使用年限缩短等问题,本发明提供了一种人工草坪铺设工艺及人工草坪。
本发明采用的技术方案为:一种人工草坪,包括人造草丝层、填充层和基础层;所述基础层在最下方,填充层位于中间,人造草丝层铺设在填充层上方,其创新点在于:所述人造草丝层包括人造草丝、基布和底基布,所述底基布为网状或直曲混合的编织布,人造草丝植入在基布上,形成半成品人造草坪,所述半成品人造草坪与底基布贴合,形成人工草坪。
在一些实施方式中,所述底基布的制作方法如下:
(1)将无纺布和网格布首先通过编制的方式制成网状或直曲混合编织布;以网格面向上的方式将编织布输送至撒粉装置;
(2)按照0.1-150g/m2的量将热熔胶粉均匀地分散在编织布上;
(3)撒粉结束后继续通过加热装置,使热熔胶粉熔融粘在编织布上,加热温度为120-200℃;
(4)自然冷却后得到底基布。
在一些实施方式中,所述人工草坪的制作方法如下:
(1)将人造草丝按照相应的行距及针距簇绒在基布上制成半成品人造草坪,簇绒时使网格面朝下;
(2)将底基布的网格面与半成品草坪的网格面贴在一起并经过加热辊,加热辊通过底基布对***加热,热熔胶粉再次熔融产生黏性,使底基布与半成品粘贴在一起;
(3)自然条件下冷却,打卷。
在一些实施方式中,所述人造草丝层还包括胶层,所述胶层涂覆在底基布的背面。
在一些实施方式中,所述基础层为水泥基、沥青基或硬沙地。
在一些实施方式中,所述人造草丝包括草茎和草叶,所述草茎为短粗型,所述草叶为罗圈型草叶,所述草叶包括若干弧形叶层叠,所述弧形叶从上往下层叠,且两两相邻的弧形叶均连接,层叠高度为2-8cm。
在一些实施方式中,所述人造草丝包括以下重量份的组分:40-50份聚氨酯弹性树脂、2-8份阻燃剂、1-4份偶联剂和40-50份连续纤维。
在一些实施方式中,所述填充层为改性聚烯烃热塑性弹性体。
本发明的另一个目的是提供一种人工草坪的铺设工艺,其创新点在于:位于最底部的压实度为预设值的基础层,铺设在所述基础层上的厚度不小于第一预设厚度的填充层,铺设在所述填充层上方的人造草丝层。
在一些实施方式中,还包括铺设在所述人造草丝层上方并在所述人造草丝层根部形成第二预设厚度的砂垫层。
与现有技术相比,本发明的有益效果是:
(1)在本发明中,本发明改变了传统技术中需要涂覆胶水的步骤,通过加热贴合的方式,更大程度上实现量产,加快生产效率,此外,本发明的底基布加工为网状或直曲混合的编织布,使得人工草坪的耐磨损能力大大提高。
(2)在本发明中,所述底基布可以为添加有阻燃母粒、热反射功能填料和恒温相变材料等等功能性材料的PP或PE底布。上述底基布设置有热熔胶粉,本发明巧妙的在底基布编织的过程中,直接输送至撒粉装置,进而经过加工装置,不仅使得后续黏贴的步骤轻便简单且无需人工核对,并且实现了全自动化流水线,还避免了胶水直接涂覆带来的易脱落等问题,延长了人造草坪的使用寿命。
(3)在本发明中,人工草坪的制作方法与现有技术相比,通过第一步和第二步的创造性的加工,使得制作方式简单有效,而且制作效率高,产品质量好,通过熔融的热熔胶粉进行黏贴,黏贴牢固,改变了现有技术中需要使用胶水涂覆进行黏贴带来的涂覆不均匀,胶水黏贴不牢固以及操作麻烦的弊端。
(4)在本发明的此实施方式中,人造草丝的形状设计具有创造性,首先,草茎为短粗型,可以增加人造草丝的承受能力,对于外界的压力可以进行很好的承压,其次,草叶为罗圈型草叶,且草叶为弧形叶从上往下层叠,一来可以进行很好的过滤降水,具有弹性透水的作用,很好的解决积水等问题,保证人造草丝自身的抗水性,二来,层叠的弧形叶可以消减压力及突然的重力作用,可
以大大延长人造草丝的使用寿命,保护人造草丝不容易被破坏。
附图说明
图1是人工草坪整体结构示意图;
图2是人造草丝结构示意图。
具体实施方式
以下结合附图和实施例,对本发明进行进一步详细说明。应当理解,此处所描述的具体实施例仅用以解释本发明,并不用于限定本发明。
本发明披露了一种人工草坪,如图1所示:包括人造草丝层100、填充层200和基础层300;所述基础层300在最下方,填充层200位于中间,人造草丝层100铺设在填充层200上方,作为本发明的一个创新点:所述人造草丝层100包括人造草丝、基布和底基布,所述底基布为网状或直曲混合的编织布,人造草丝植入在基布上,形成半成品人造草坪,所述半成品人造草坪与底基布热贴合,形成人工草坪。在本发明中,本发明改变了传统技术中需要涂覆胶水的步骤,通过加热贴合的方式,更大程度上实现量产,加快生产效率,此外,本发明的底基布加工为网状或直曲混合的编织布,使得人工草坪的耐磨损能力大大提高。
具体的,为了更好的贴合人造草丝层,底基布的选择和制作也尤为重要,在本发明中,所述底基布的制作方法如下:
(1)将无纺布和网格布首先通过编制的方式制成网状或直曲混合编织布;以网格面向上的方式将编织布输送至撒粉装置;所述撒粉装置内放置热熔胶粉,
(2)按照0.1-150g/m2的量将热熔胶粉均匀地分散在编织布上;作为进一步优选的,在本发明中,热溶胶粉的量为70-75g/m2。
(3)撒粉结束后继续通过加热装置,使热熔胶粉熔融粘在编织布上,加热温度为120-200℃;作为进一步优选的,在本发明中,加热温度为160℃。
(4)自然冷却后得到底基布。
在本发明中,所述底基布可以为添加有阻燃母粒、热反射功能填料和恒温相变材料等等功能性材料的PP或PE底布。
上述底基布设置有热熔胶粉,本发明巧妙的在底基布编织的过程中,直接输送至撒粉装置,进而经过加工装置,不仅使得后续黏贴的步骤轻便简单且无需人工核对,并且实现了全自动化流水线,还避免了胶水直接涂覆带来的易脱落等问题,延长了人造草坪的使用寿命。
作为进一步优选的,在本发明的此实施方式中,所述人工草坪的制作方法如下:
(1)将人造草丝按照相应的行距及针距簇绒在基布上制成半成品人造草坪,相应的行距及针距按照客户或者场地要求而定,依据的是现有技术,在此不再赘述;值得注意的是,簇绒时使网格面朝下;
(2)将底基布的网格面与半成品人造草坪的网格面贴在一起并经过加热辊,加热辊通过底基布对整体加热,底基布上的热熔胶粉再次熔融产生黏性,使底基布与半成品人造草坪粘贴在一起;
(3)自然条件下冷却,打卷。
在本发明中,人工草坪的制作方法与现有技术相比,通过第一步和第二步的创造性的加工,使得制作方式简单有效,而且制作效率高,产品质量好,通过熔融的热熔胶粉进行黏贴,黏贴牢固,改变了现有技术中需要使用胶水涂覆进行黏贴带来的涂覆不均匀,胶水黏贴不牢固以及操作麻烦的弊端。
作为进一步优选的,所述人造草丝层也可以包括有胶层,所述胶层涂覆在底基布的背面(该背面是指与人造草坪黏贴层的相反面),在本发明中,胶层并不是起到将底基布与半成人造草坪进行黏贴的作用,而是起固定作用涂层。
作为进一步优选的,在本发明中,所述基础层为水泥基、沥青基或硬沙地。
作为本发明的另一个实施方式中,作为本发明的另一个创新点,如图2所示:所述人造草丝包括草茎1和草叶2,所述草茎1为短粗型,所述草叶2为罗圈型草叶,所述草叶2包括若干弧形叶20层叠,所述弧形叶20从上往下层叠,且两两相邻的弧形叶20均连接,层叠高度为2-8cm。在本发明的此实施方式中,人造草丝的形状设计具有创造性,首先,草茎为短粗型,可以增加人造草丝的承受能力,对于外界的压力可以进行很好的承压,其次,草叶为罗圈型草叶,且草叶为弧形叶从上往下层叠,一来可以进行很好的过滤降水,具有弹性透水的作用,很好的解决积水等问题,保证人造草丝自身的抗水性,二来,层叠的弧形叶可以通过层叠构造和层叠高度消减压力及突然的重力作用,可以大大延长人造草丝的使用寿命,保护人造草丝不容易被破坏。
在本发明的此实施方式中,本发明的所述人造草丝的草茎1以及弧形叶20的原料都是包括以下重量份的组分:40-50份聚氨酯弹性树脂、2-8份阻燃剂、1-4份偶联剂和40-50份连续纤维。作为进一步优选的,在本发明中,原料都是包括以下重量份的组分:45份聚氨酯弹性树脂、6份阻燃剂、4份偶联剂和45份连续纤维。在本发明中,本发明的人造草丝是具有天然草运动性能的化工制品,具有舒缓疲劳,具有减震、减压的作用,本发明采用弹性透水技术,使人造草坪不仅符合物理性能要求,而且地坪不积水。
具体的,在本发明中,所述填充层为改性聚烯烃热塑性弹性体。使人造草坪更有弹性,更有效的保护运动者。
本发明的另一个目的是提供一种人工草坪的铺设工艺,其创新点在于:位于最底部的压实度为预设值的基础层,铺设在所述基础层上的厚度不小于第一预设厚度的填充层,铺设在所述填充层上方的人造草丝层。在本发明中,基础层的预设值为0.1-0.15m,填充层的预设值为0.15-0.2m。工艺的创新点是改变了传统的编织方式,使人工草坪形状更接近于自然草。
在本发明的此实施方式中,还包括铺设在所述人造草丝层上方并在所述人造草丝层根部形成第二预设厚度的砂垫层。所述砂垫层的填充厚度为0.04-0.06m。
上述说明示出并描述了本发明的优选实施例,如前所述,应当理解本发明并非局限于本文所披露的形式,不应看作是对其他实施例的排除,而可用于各种其他组合、修改和环境,并能够在本文所述发明构想范围内,通过上述教导或相关领域的技术或知识进行改动。而本领域人员所进行的改动和变化不脱离本发明的精神和范围,则都应在本发明所附权利要求的保护范围内。
Claims (10)
1.一种人工草坪,包括人造草丝层、填充层和基础层;所述基础层在最下方,填充层位于中间,人造草丝层铺设在填充层上方,其特征在于:所述人造草丝层包括人造草丝、基布和底基布,所述底基布为网状或直曲混合的编织布,人造草丝植入在基布上,形成半成品人造草坪,所述半成品人造草坪与底基布贴合,形成人工草坪。
2.根据权利要求1所述的人工草坪,其特征在于:所述底基布的制作方法如下:
(1)将无纺布和网格布首先通过编制的方式制成网状或直曲混合编织布;以网格面向上的方式将编织布输送至撒粉装置;
(2)按照0.1-150g/m2的量将热熔胶粉均匀地分散在编织布上;
(3)撒粉结束后继续通过加热装置,使热熔胶粉熔融粘在编织布上,加热温度为120-200℃;
(4)自然冷却后得到底基布。
3.根据权利要求2所述的人工草坪,其特征在于:所述人工草坪的制作方法如下:
(1)将人造草丝按照相应的行距及针距簇绒在基布上制成半成品人造草坪,簇绒时使网格面朝下;
(2)将底基布的网格面与半成品草坪的网格面贴在一起并经过加热辊,加热辊通过底基布对***加热,热熔胶粉再次熔融产生黏性,使底基布与半成品粘贴在一起;
(3)自然条件下冷却,打卷。
4.根据权利要求3所述的人工草坪,其特征在于:还包括胶层,所述胶层涂覆在底基布的背面。
5.根据权利要求3或4所述的人工草坪,其特征在于:所述基础层为水泥基、沥青基或硬沙地。
6.根据权利要求3或4所述的人工草坪,其特征在于:所述人造草丝包括草茎和草叶,所述草茎为短粗型,所述草叶为罗圈型草叶,所述草叶包括若干弧形叶层叠,所述弧形叶从上往下层叠,且两两相邻的弧形叶均连接,层叠高度为2-8cm。
7.根据权利要求6所述的人工草坪,其特征在于:所述人造草丝包括以下重量份的组分:40-50份聚氨酯弹性树脂、2-8份阻燃剂、1-4份偶联剂和40-50份连续纤维。
8.根据权利要求7所述的人工草坪,其特征在于:所述填充层为改性聚烯烃热塑性弹性体。
9.一种权利要求1所述的人工草坪的铺设工艺,其特征在于:位于最底部的压实度为预设值的基础层,铺设在所述基础层上的厚度不小于第一预设厚度的填充层,铺设在所述填充层上方的人造草丝层。
10.根据权利要求9所述的人工草坪的铺设工艺,其特征在于:还包括铺设在所述人造草丝层上方并在所述人造草丝层根部形成第二预设厚度的砂垫层。
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