WO2009056284A1 - Procédé pour la fabrication de tapis d'herbe artificielle - Google Patents

Procédé pour la fabrication de tapis d'herbe artificielle Download PDF

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Publication number
WO2009056284A1
WO2009056284A1 PCT/EP2008/009117 EP2008009117W WO2009056284A1 WO 2009056284 A1 WO2009056284 A1 WO 2009056284A1 EP 2008009117 W EP2008009117 W EP 2008009117W WO 2009056284 A1 WO2009056284 A1 WO 2009056284A1
Authority
WO
WIPO (PCT)
Prior art keywords
component
product
manufacturing process
polyurethane product
polyols
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/EP2008/009117
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English (en)
Inventor
Enrico Pozzi
Antonio Ausilio
Elisa Basei
Davide Agnelli
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Mapei SpA
Original Assignee
Mapei SpA
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Mapei SpA filed Critical Mapei SpA
Publication of WO2009056284A1 publication Critical patent/WO2009056284A1/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

Links

Classifications

    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N7/00—Flexible sheet materials not otherwise provided for, e.g. textile threads, filaments, yarns or tow, glued on macromolecular material
    • D06N7/0063—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf
    • D06N7/0071—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf characterised by their backing, e.g. pre-coat, back coating, secondary backing, cushion backing
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2203/00—Macromolecular materials of the coating layers
    • D06N2203/06—Macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
    • D06N2203/068—Polyurethanes
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2205/00—Condition, form or state of the materials
    • D06N2205/14—Fibrous additives or fillers
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2209/00—Properties of the materials
    • D06N2209/12—Permeability or impermeability properties
    • D06N2209/126—Permeability to liquids, absorption
    • D06N2209/128—Non-permeable

Definitions

  • the present invention relates to a manufacturing process for artificial grass carpets.
  • the drawback of natural compared with artificial grass carpets is its high cost of maintenance, due, for example, to the need for daily watering, weekly cutting in order to regularize its height, and the need to limit its use to areas with sufficient natural lighting.
  • the back of the artificial grass consists of:
  • the latex is applied to the carpet in one of two ways: a. the roller on which the carpet runs is immersed in a latex bath; b. the latex is distributed by a mobile applicator. The excess material must then be removed with a doctor blade to regularize its thickness.
  • the drying of the latex takes place in a tunnel of ovens, usually 15-50 m long, in which the carpet remains for approx. 3-10 min, running at the rate of approx. 2-4 m/min.
  • the heat cycle involves temperatures of between 120 and 150 0 C.
  • the function of the water-based product is to impregnate the substrate, thus fixing the tufts without compromising the dimensional stability of the carpet.
  • the SBR-based aqueous product is replaced by a two- or three-component polyurethane product, which is similarly applied, the components being pre-mixed through a foaming machine.
  • the two or three components polyurethane product is distributed onto the rear of the turf carpet, coupled with a non-woven fabric, using a foaming machine and it is regularized by a doctor blade as used for the SBR latex.
  • the object of the invention is a novel technology and novel specific polyurethane products for the manufacture of artificial grass.
  • the technology involves spraying onto the rear of the artificial grass carpet with a two- or three-component polyurethane product that crosslinks rapidly, even at low temperatures, to give a compact, elastic, uniform film of coating-adhesive, with no bubbles, which is resistant to water and bonds the tufts firmly to the synthetic primary turf carpet.
  • the two or three-component polyurethane product preferably consists of a system wherein part A comprises one or more polyols, fillers, catalysts and additives, etc., and part B consists of the isocyanate component.
  • Component A of the two-component polyurethane product preferably consists of one or more polyols, in particular diols and/or triols or polyether polyols obtained by polymerisation preferably of propylene oxide, with a molecular mass ⁇ 5,000 Daltons in the proportion of 15% to 60%, and mineral fillers in the proportion of 85% to 40% by weight.
  • One of the polyols can be a vegetable oil or one of its derivatives; preferably it is the castor oil, in the percentage by weight of between 0% and 100% of the polyol mixture.
  • the mineral fillers of component A consist of carbonates, sulphates, silicates, oxides of alkaline earth metals, and other usual fillers, possibly combined with one another, calcium carbonate preferably being used as the main filler. Microspheres or any kind of scraps can also be used as fillers.
  • the additives, included in component A in minor proportions, may be organic or inorganic pigments, preferably carbon black, chemical or physical dryiers, antisettling and antifoaming agents, antifungus, antioxidants or UV stabilizers, and catalysts.
  • Component A of the three-component polyurethane products has the same composition of that one described above for the two component polyurethane product apart the catalyst(s) which is introduced into the component C.
  • the catalyst in component A of the two component polyurethane product is selected from tertiary amines and/or organometallic compounds in the proportion of 0.001 to 3% by weight of the polyurethane product.
  • the catalyst is preferably selected from triethylenediamine, morpholine, DBU (l,8-Diazabicyclo(5.4.0.)undec-7-ene), compounds of tin, bismuth, titanium and zirconium, preferably triethylenediamine or tin compounds such as tin dibutyldilaurate or di-n-butyltinbis(mercaptoaceticacidisooctyl ester).
  • organometallic catalysts can decompose during the storage and affect important changes of the reactivity of the 2 component product.
  • the catalyst composition can be carried out if necessary by diluting the catalyst in a small amount of polyol.
  • the ratio of the components (A+B) to the component C can vary from 100 to 0.1 to 100 to 5 by weight.
  • Component B of the two-component polyurethane product typically consists of an isocyanate prepolymer obtained from one or more polyols,
  • NCO content of between 5 and 25%, preferably between 10 and 20%.
  • the viscosity of the two-component polyurethane when parts A and B (without catalyst) are mixed is under 10,000 mPa.s at +50 0 C, and preferably ⁇ 6000 mPa.s at +50 0 C.
  • the two component polyurethane product is sprayed with nozzles fed by pressurised pumps, and preferably by low-pressure gear pumps, which produce an A/B mixing ratio by weight of between 1 : 1 and 10: 1.
  • Components A and B and -in the case of a three component polyurethane product- component C are fed separately and mixed at the spraying head through a static or dynamic mixer.
  • the material is then sprayed evenly onto the rear of the primary artificial grass. Ratio and distribution are driven by a computer assisted equipment.
  • Components A and B, or A, B and C penetrate deeply into the tufts of artificial grass, and react by bonding the yarns firmly to the primary turf carpet.
  • Piston pumps and gear pumps, airless nozzles and nozzles with assisted air, are suitable to feed the two components A and B or the three component A, B and C.
  • Low pressure gear pumps with assisted air are preferable for continuous robotised processing.
  • Suitable gear pumps, mixing heads and computer assisted equipment for two or three- component polyurethane products are available by Maxver s.r.l. (San Cesario sul Panaro, Italy).
  • the running speed of the carpet on the production line should be at least lm/minute, preferably is between 2 and 15 m/min, and most preferable is between 6 and 12 m/min for consumption of between 500 and 1500 g/m 2 , and preferably between 700 and 900 g/m .
  • Crosslinking can be performed at room temperature, but is normally carried out in a heated tunnel at temperatures of between +40 and +120 0 C, preferably between 80 0 C and 120 0 C, and more preferably between 80 and 100 0 C.
  • the polyurethane product (without catalyst) must have a viscosity of less than approx. 10,000 mPa.s, and preferably less than 6000 mPa.s, measured at the temperature of use.
  • the application temperature should be between +15 and +80 0 C, and preferably between +30 and +65°C.
  • the adhesive into the perforated primary turf carpet (based on polypropylene, for example) will be achieved, and the artificial grass (based on, for example, polypropylene, polyethylene, polyethylene/polypropylene, polyamide, etc.) will present an very good tuft lock.
  • a two-component polyurethane product consists of: Part A: Filled polyol
  • Ingredients 3, 4 and 5 are gradually added to ingredients 1 and 2 in a disperser, until dispersion is complete.
  • Viscosity 120,000 mPa.s at 23°C Specific gravity 1.8 g/cc
  • Ingredients 1 and 3 are fed, in that order, into a steel reactor equipped with a stirrer, operating in a dry nitrogen atmosphere. Under stirring, the temperature of the solution is raised from room temperature to 40-45 0 C. Ingredients 2 and 4 are then fed in, in that order, the temperature is raised to + 60 0 C, and stirring is continued for 6 hours.
  • Viscosity A+B approx. 5000 mPas at +50 0 C (measured without catalyst) Part A and Part B are pre-heated at the temperatures of +80 0 C and
  • thermoheated tubes to the spray gun, which operates with low-pressure compressed air and it is equipped with a static mixer.
  • the two-component polyurethane product is sprayed regularly and evenly onto the rear of a polypropylene primary turf carpet (type Soccerpro Diamond from Limontasport, Cologno al Serio, Bergamo, Italy) without fleece, which runs at 4 m/min at the consumption rate of approx. 850 g/sq.m.
  • Crosslinking is completed in the oven after six min at 80 0 C.
  • the product At the exit of the oven the product is perfectly crosslinked, and the turf presents a tuft lock, after 2 days at +23 0 C, of about 5 daN (according to ISO 4919).
  • the coverage of the artificial grass loops and the penetration between the yarns are optimal.
  • Zone A - MDI monomer 24.7 ⁇ g /cu.m
  • Zone B - MDI monomer 16.9 ⁇ g /cu.m
  • the TLV of MDI is 51 ⁇ g /cu.m.
  • a test for diaminodiphenylmethane was also conducted in the same area and on the chimney of the plant. Two Carbotrap tubes in series were used for this purpose; the products of thermal desorption were then analysed by gas chromatography. The aromatic amine was not detected in any case.
  • a two-component polyurethane product consists of:
  • Part A Filled polyol
  • Ingredients 3, 4 and 5 are gradually added to ingredients 1 and 2 in a disperser, until dispersion is complete.
  • Viscosity 60,000 mPas at 23 0 C
  • Ingredients 1 and 2 are fed into a steel reactor equipped with a stirrer, operating in a dry nitrogen atmosphere. Under stirring, the temperature of the solution is raised from room temperature to +60 0 C, and stirring is continued for two hours.
  • Viscosity A+B approx. 4000 mPas at +50 0 C (measured without catalyst).
  • the two component polyurethane product sprayed on a mold using the same laboratory equipment indicated in the example 1 at 1 mm thickness, shows after a curing of three min at 100 0 C following properties:
  • the two component polyurethane product applied at 850 g/sq.m on the rear of a polypropylene primary turf carpet (we use the same Soccerpro Diamond from Limontasport indicated in example 1) shows after curing of three min at 100 0 C following properties:
  • test method SM 022 a resistance to fungal growth (test method SM 022 a) carried out on free film of polymer:

Landscapes

  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Polyurethanes Or Polyureas (AREA)
  • Artificial Filaments (AREA)

Abstract

L'invention porte sur un procédé pour la fabrication d'herbe artificielle, qui comprend la pulvérisation, sur l'arrière du tapis de gazon primaire, d'un produit de polyuréthane à deux ou à trois composants, qui se réticule rapidement, même à de basses températures, de façon à donner un film d'un adhésif de revêtement, lequel film est compact, élastique, uniforme et sans bulles, présente une résistance aux produits chimiques et à l'eau améliorée et lie fermement les touffes au tapis primaire. L'invention porte également sur des produits spécifiques pour ce procédé.
PCT/EP2008/009117 2007-10-30 2008-10-29 Procédé pour la fabrication de tapis d'herbe artificielle Ceased WO2009056284A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
ITMI20072092 ITMI20072092A1 (it) 2007-10-30 2007-10-30 Nuova tecnologia e prodotti per la manifattura di tappeti in erba sintetica
ITMI2007A002092 2007-10-30

Publications (1)

Publication Number Publication Date
WO2009056284A1 true WO2009056284A1 (fr) 2009-05-07

Family

ID=40313895

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/EP2008/009117 Ceased WO2009056284A1 (fr) 2007-10-30 2008-10-29 Procédé pour la fabrication de tapis d'herbe artificielle

Country Status (2)

Country Link
IT (1) ITMI20072092A1 (fr)
WO (1) WO2009056284A1 (fr)

Cited By (11)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20100129571A1 (en) * 2008-11-25 2010-05-27 Precisionjet, Inc. Method for making artificial turf
US20100129570A1 (en) * 2008-11-25 2010-05-27 Precisionjet, Inc. Method for making artificial turf
CN101921569A (zh) * 2010-08-18 2010-12-22 江苏共创人造草坪有限公司 一种用于人造草坪背胶的蓖麻油改性聚氨酯胶粘剂组合物
WO2011003529A1 (fr) * 2009-07-07 2011-01-13 Bayer Materialscience Ag Polyuréthanne et son utilisation
US8968502B1 (en) * 2009-11-06 2015-03-03 John H. Bearden Method for coating a tufted athletic turf backing
KR101587741B1 (ko) * 2014-12-02 2016-01-22 케이앤비준우 주식회사 친환경 폴리우레탄 인조잔디 백코팅 조성물 및 이를 이용한 인조잔디 매트 제조방법
EP3219847A1 (fr) * 2016-03-18 2017-09-20 Advanced Polymer Technologies Corp. Utilisation d'un mélange de polyols comprenant du pbd pour créer un gazon artificiel à base de pu
WO2017158183A1 (fr) * 2016-03-18 2017-09-21 Advanced Polymer Technology Corp. Utilisation d'un mélange de polyols comprenant du pbd pour créer un gazon artificiel à base de pu
EP3222766A1 (fr) * 2016-03-22 2017-09-27 Polytex Sportbeläge Produktions-GmbH Machine de fabrication de gazon artificiel
US10870128B2 (en) 2016-03-18 2020-12-22 Advanced Polymer Technologies Corp. Using a polyol mixture comprising PBD for creating a PU-based artificial turf
US20250250729A1 (en) * 2020-09-16 2025-08-07 Columbia Insurance Company Patterned Tufted Articles, Surface Coverings Comprising Same, And Systems And Methods Of Making And Using Same

Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3730822A (en) * 1971-03-29 1973-05-01 Goodyear Tire & Rubber Composite of fabric with flexible backing
US3895149A (en) * 1973-07-05 1975-07-15 Atlantic Richfield Co Carpet backed with thixotropic polyurethane adhesive
DE3013447A1 (de) * 1980-04-05 1981-10-08 Teppich-Werk Neumünster, 2350 Neumünster Textiles flaechengebilde
WO1998008893A1 (fr) * 1996-08-28 1998-03-05 The Dow Chemical Company Sous-couches de tapis, couches stratifiees, et couches de mousse preparees a partir de formulations de polyurethanne comprenant des cendres volantes
WO2000037737A1 (fr) * 1998-12-22 2000-06-29 Bayer Antwerpen N.V. Revetement face vers le haut des envers de tapis a l'aide de polyurethane
US20020074073A1 (en) * 2000-11-03 2002-06-20 Glen Hamrick Polyurethane coating process for carpet backing
US20050260351A1 (en) * 1998-09-17 2005-11-24 Urethane Soy Systems Company, Inc. Method for producing a bio-based carpet material
WO2008073808A1 (fr) * 2006-12-11 2008-06-19 Dow Global Technologies Inc. Matériaux de tapis biologiques

Patent Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3730822A (en) * 1971-03-29 1973-05-01 Goodyear Tire & Rubber Composite of fabric with flexible backing
US3895149A (en) * 1973-07-05 1975-07-15 Atlantic Richfield Co Carpet backed with thixotropic polyurethane adhesive
DE3013447A1 (de) * 1980-04-05 1981-10-08 Teppich-Werk Neumünster, 2350 Neumünster Textiles flaechengebilde
WO1998008893A1 (fr) * 1996-08-28 1998-03-05 The Dow Chemical Company Sous-couches de tapis, couches stratifiees, et couches de mousse preparees a partir de formulations de polyurethanne comprenant des cendres volantes
US20050260351A1 (en) * 1998-09-17 2005-11-24 Urethane Soy Systems Company, Inc. Method for producing a bio-based carpet material
WO2000037737A1 (fr) * 1998-12-22 2000-06-29 Bayer Antwerpen N.V. Revetement face vers le haut des envers de tapis a l'aide de polyurethane
US20020074073A1 (en) * 2000-11-03 2002-06-20 Glen Hamrick Polyurethane coating process for carpet backing
WO2008073808A1 (fr) * 2006-12-11 2008-06-19 Dow Global Technologies Inc. Matériaux de tapis biologiques

Cited By (20)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20100129571A1 (en) * 2008-11-25 2010-05-27 Precisionjet, Inc. Method for making artificial turf
US20100129570A1 (en) * 2008-11-25 2010-05-27 Precisionjet, Inc. Method for making artificial turf
US8647452B2 (en) * 2008-11-25 2014-02-11 John H. Bearden Method for making artificial turf
WO2011003529A1 (fr) * 2009-07-07 2011-01-13 Bayer Materialscience Ag Polyuréthanne et son utilisation
US8968502B1 (en) * 2009-11-06 2015-03-03 John H. Bearden Method for coating a tufted athletic turf backing
CN101921569A (zh) * 2010-08-18 2010-12-22 江苏共创人造草坪有限公司 一种用于人造草坪背胶的蓖麻油改性聚氨酯胶粘剂组合物
KR101587741B1 (ko) * 2014-12-02 2016-01-22 케이앤비준우 주식회사 친환경 폴리우레탄 인조잔디 백코팅 조성물 및 이를 이용한 인조잔디 매트 제조방법
US10870952B2 (en) * 2016-03-18 2020-12-22 Advanced Polymer Technologies Corp. Using a polyol mixture comprising PBD for creating a PU-based artificial turf
WO2017158183A1 (fr) * 2016-03-18 2017-09-21 Advanced Polymer Technology Corp. Utilisation d'un mélange de polyols comprenant du pbd pour créer un gazon artificiel à base de pu
KR20180108846A (ko) * 2016-03-18 2018-10-04 어드벤스드 폴리머 테크놀로지 씨오알피. Pu계 인조 잔디를 제조하기 위한 pbd를 포함하는 폴리올 혼합물의 용도
US10870128B2 (en) 2016-03-18 2020-12-22 Advanced Polymer Technologies Corp. Using a polyol mixture comprising PBD for creating a PU-based artificial turf
EP3219847A1 (fr) * 2016-03-18 2017-09-20 Advanced Polymer Technologies Corp. Utilisation d'un mélange de polyols comprenant du pbd pour créer un gazon artificiel à base de pu
KR102215563B1 (ko) 2016-03-18 2021-02-10 어드벤스드 폴리머 테크놀로지 씨오알피. Pu계 인조 잔디를 제조하기 위한 pbd를 포함하는 폴리올 혼합물의 용도
US11473249B2 (en) 2016-03-18 2022-10-18 Advanced Polymer Technologies Corp. Using a polyol mixture comprising PBD for creating a PU-based artificial turf
US12152352B2 (en) 2016-03-18 2024-11-26 Advanced Polymer Technologies Corp. Using a polyol mixture comprising PBD for creating a PU-based artificial turf
EP3222766A1 (fr) * 2016-03-22 2017-09-27 Polytex Sportbeläge Produktions-GmbH Machine de fabrication de gazon artificiel
WO2017162643A1 (fr) * 2016-03-22 2017-09-28 Polytex Sportbeläge Produktions-Gmbh Machine de fabrication de gazon artificiel
CN109196156A (zh) * 2016-03-22 2019-01-11 保利特斯运动涂层生产有限责任公司 用于制造人造草皮的机器
US10738401B2 (en) 2016-03-22 2020-08-11 Polytex Sportbelage Produktions-Gmbh Machine for manufacturing artificial turf
US20250250729A1 (en) * 2020-09-16 2025-08-07 Columbia Insurance Company Patterned Tufted Articles, Surface Coverings Comprising Same, And Systems And Methods Of Making And Using Same

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