KR101009385B1 - Manufacturing method of recyclable artificial turf structure and recycling method thereof - Google Patents

Abstract

PURPOSE: A method for manufacturing a recyclable artificial turf structure and a recycling method thereof are provided to easily collect a high molecular substance by using a simple recycling process. CONSTITUTION: A method for manufacturing a recyclable artificial turf structure is as follows. Roll-type first structures(210) are consecutively supplied to the top of an air bubble layer formed by woven or non-woven fabric of polyolefin fiber. Polyolefin resin is pressed in a film shape, and the pressed polyolefin resin films are consecutively supplied to be in gear with the bottom surface of the air bubble layer. A second structure with a support layer is obtained by fusing the polyolefin resin films and pressing the polyolefin resin films using a cooling roller.

Description

Manufacturing method of recyclable artificial turf structure and recycling method thereof {Manufacturing method of recyclable artificial turf structure and recycling method

Recyclable artificial turf structure, a method for manufacturing the same, and a method for recycling thereof, and more particularly, to an artificial turf structure made of the same polyolefin material except for silica sand or vermiculite, which is the first filler of the packed layer. It is about.

Artificial turf is a substitute for artificial grass made of synthetic fibers in the form of grass. Since it was first manufactured in the United States in 1956, it has been used mainly in sports fields such as baseball, soccer, and golf. It can be used in places such as indoor gardens or outdoor areas facing the north side of high-rise buildings with extremely limited sunshine hours.

In general, the artificial turf structure is composed of a bubble layer, a pile formed by injecting yarn on top of the bubble layer, and a support layer formed on the bottom surface of the bubble layer. It further comprises a filling layer formed by filling a filler such as. The pile was originally developed from nylon, but is increasingly being replaced by polyethylene or polypropylene to reduce friction. When the pile is formed by the Raschel method or the moquette method of weaving yarns, the bubble layer is mainly made of polyester (PET) bubble paper, and a polypropylene plain fabric has been developed due to the development of a tufting method to form piles in large quantities. Many types of bubble paper are used. As the support layer, most of the acrylic resin and styrene-butadiene rubber (SBR) are used as the layer for strengthening the shape stability of the artificial turf structure, reducing noise, strengthening the tear strength, and strengthening the pull strength of the pile. Research has been actively conducted. For example, a two-component reactive polyurethane material is commercially available as a material capable of high elasticity and high pull strength, and is commercially available. However, the two-component reactive polyurethane is expensive, and it is difficult to steadily maintain a suitable magnification in the continuous two-liquid reaction process, so that poor physical properties often occur.

On the other hand, artificial turf structure is destined to be replaced if it loses its function equivalent to natural grass after a certain period of time. Recently, due to the increase of the use of leisure life and the improvement of welfare level, the artificial turf has been increased and the excessive amount of industrial waste is removed. There is a fear of mass production. In order to prevent this, it is important to recycle the artificial turf structure that is past its expiration date.In general, the artificial turf structure is recycled due to a mixture of polyethylene or polypropylene, acrylic resin, styrene-butadiene rubber (SBR), polyurethane, and silica sand. This is often difficult or requires complex processes for recycling. Even if only the silica sand is separated separately, there is a problem that the application field of the recycled material is very limited because polymers having different physical properties such as polyethylene or polypropylene, acrylic resin, styrene-butadiene rubber (SBR), and polyurethane are mixed.

The present invention has been made to solve the conventional problems as one object of the present invention can easily recover the polymer material by a simple recycling process at the time of replacement, the recovered material has a uniform physical properties within a certain range An artificial turf structure is provided.

In addition, another object of the present invention to provide a method for producing the artificial turf structure is easy to recycle.

Another object of the present invention is to provide a method for recycling the artificial turf structure.

In order to achieve the object of the present invention, the present invention is a bubble layer formed of a woven or nonwoven fabric of polyolefin fibers; Pile formed by entering a polyolefin yarn on the bubble layer; A support layer formed by coating a polyolefin resin on a lower surface of the bubble layer; And a filling layer formed by sequentially stacking a first filler and a second filler between the top of the bubble layer and the pile, wherein the first filler is made of at least one material selected from silica sand and vermiculite, and the second Filler provides an artificial turf structure, characterized in that made of a polyolefin elastomer.

In the artificial turf structure of the present invention, the polyolefin fiber, polyolefin yarn, polyolefin resin, and polyolefin elastomer are preferably made of polyolefin of the same material, and the polyolefin is selected from the group consisting of polyethylene, polypropylene, and polyisobutylene. It is characterized by any one.

In order to achieve another object of the present invention, the present invention comprises the steps of continuously supplying a roll-type first structure in which piles are formed by gathering polyolefin yarns on top of a bubble layer formed of a woven or nonwoven fabric of polyolefin fibers; Extruding the polyolefin resin into a film shape and continuously supplying the polyolefin resin to be engaged with the bubble layer bottom surface of the first structure; Obtaining a second structure in which a support layer is formed by applying heat to the polyolefin resin film engaged with the bottom surface of the bubble layer and melting the film; And laminating a first filler and a second filler sequentially between the top of the bubble layer of the second structure and the pile to form a filler layer, wherein the first filler is one or more materials selected from silica and vermiculite. It consists of, the second filler provides a method for producing an artificial turf structure, characterized in that made of a polyolefin elastomer.

In order to achieve another object of the present invention, the present invention provides a method for recycling the artificial turf structure comprising the step of separating the first filler by centrifugation after grinding or cutting the artificial turf structure according to the present invention to a unit size to provide. Here, an industrially useful polyolefin material may be obtained by melting the remaining components of the artificial turf structure separated from the first filler.

The artificial turf structure according to the present invention is formed of the same polyolefin material except for the first filler of silica and silica or vermiculite, all other components are formed of the same polyolefin material, and the specific gravity of silica sand or vermiculite is in the range of about 2.6 to 2.8 and the polyolefin material is Since the specific gravity ranges from about 0.8 to 0.9, the first filler can be easily separated by a simple unit operation such as centrifugation after grinding or cutting. When only the first filler is separated by the recycling process of the artificial turf structure and only the remaining ingredients are recovered, a recycled resin having a uniform range of physical properties can be obtained. Therefore, when using the environmentally friendly artificial turf structure according to the present invention can be significantly reduced the amount of industrial waste even when replacing artificial turf due to aging, it is possible to prevent environmental pollution. In addition, since the olefin-based material constituting the support layer of the artificial turf structure according to the present invention is a relatively economical material, it is possible to reduce the cost of the artificial turf structure, and since it is the same material as the bubble layer, it is strongly combined with the bubble layer to increase the pullout strength of the pile. Can be improved.

One aspect of the invention relates to an artificial turf structure that can be recycled. Hereinafter, the artificial turf structure according to the present invention will be described in more detail with reference to the accompanying drawings.

1 schematically shows a cross-sectional structure of an artificial turf structure according to an embodiment of the present invention. As shown in FIG. 1, the artificial turf structure according to the present invention includes a bubble layer 10, a pile 20 on the bubble layer, a support layer 30 formed on the bottom surface of the bubble layer, and an upper portion and a pile of the bubble layer. It comprises a filler layer 40 formed by sequentially stacking the first filler and the second filler in between. Here, the bubble layer, the pile, the support layer, and the second filler are all made of a polyolefin material. The polyolefin is a polymer compound produced by polymerization of olefins (chain hydrocarbon compound having one double bond), and specifically, polyethylene, polypropylene, Polyethylene-propylene copolymers, polyisobutylene and the like.

The bubble layer 10 serves to impart morphological stability of the artificial turf structure and firmly seat and fix the pile, and is formed of a woven or nonwoven fabric of polyolefin fibers, and preferably, polyolefin fibers to impart superior morphological stability. It is formed of a nonwoven fabric. At this time, the non-woven fabric of the polyolefin fiber can be produced by any one method selected from the group consisting of a spunbond method, melt brown method, needle punching method, and water yarn twist method.

The pile 20 serves to impart characteristics similar to natural grass to the artificial turf structure, and is formed by incorporating polyolefin yarn on the bubble layer. More specifically, the method of attracting the yarn includes a tufting method of forming a loop pile of a predetermined shape by tufting a polyolefin yarn on the bubble layer, a mocket method of forming a bubble layer and a pile at the same time, or a Raschel method.

The support layer 30 serves to enhance the shape stability of the artificial turf structure, reduce noise, strengthen tear strength, and strengthen the pull strength of the pile, and is formed by coating a polyolefin resin on the lower surface of the bubble layer. More specifically, the polyolefin resin film is engaged with the lower surface of the bubble layer and then coated through a heating and pressing process. Since the olefin-based material forming the support layer of the artificial turf structure according to the present invention is a relatively economical material, it is possible to reduce the cost of the artificial turf structure and is the same material as the bubble layer so that it is strongly combined with the bubble layer to improve the pull strength of the pile. Can be. In this case, the polyolefin forming the support layer preferably has a lower melting point than the polyolefin forming the bubble layer. In this case, the polyolefin resin film is easily melted and pressed to facilitate the formation of the support layer, and moreover, the change in the physical properties of the bubble layer during the formation of the support layer. Can be minimized.

The filler 40 is composed of a first filler layer 41 and a second filler layer 42 formed by sequentially stacking a first filler and a second filler between the upper and piles of the bubble layer. The first filler is filled at the top of the bubble layer, and between the piles, and acts as a buffer to mitigate the impact from the ground during exercise, and is made of one or more materials selected from silica sand and vermiculite. Quartz sand is quartz grain sand containing silicon dioxide (SiO ₂ ), anhydrous silicic acid. There are coastal silica, mountain silica, and artificial silica. Vermiculite is a mineral belonging to a monoclinic system with a mica-like crystal structure, also called vermiculite. When vermiculite is used as a filler, it is crushed to a size similar to that of silica sand. The second filler is filled in the gaps between the piles on the top of the first filler layer, provides a resilient force and has a function similar to that of movement in natural grass, and is made of a polyolefin elastomer. When the polyolefin elastomer is used as a filler, it is used in the form of a chip having an appropriate size.

Another aspect of the present invention relates to a method for manufacturing a recycled artificial turf structure, the method for manufacturing an artificial turf structure according to the present invention is a pile of polyolefin yarn on the top of the bubble layer formed of a woven or nonwoven fabric of polyolefin fibers to pile the pile Continuously feeding the formed roll-type first structure; Extruding the polyolefin resin into a film shape and continuously supplying the polyolefin resin to be engaged with the bubble layer bottom surface of the first structure; Obtaining a second structure in which a support layer is formed by applying heat to the polyolefin resin film engaged with the bottom surface of the bubble layer and melting the film; And forming a filling layer by sequentially laminating a first filler and a second filler between the upper part of the bubble layer of the second structure and the pile. Here, the first filler is made of one or more materials selected from silica sand and vermiculite, and the second filler is made of a polyolefin elastomer. Hereinafter, the artificial turf structure manufacturing method according to the present invention through the accompanying drawings will be described in more detail.

FIG. 2 is a process diagram schematically illustrating a method of manufacturing a second structure by forming a support layer from a first structure composed of a pile and a bubble layer. First, a roll-type first structure 210 including a bubble layer having a pile formed thereon is prepared and then continuously supplied. In this case, the first structure is supplied with the pile (ie, the upper portion of the bubble layer) facing downward, and then a support layer is formed on the lower surface of the bubble layer. In the middle of the direction in which the first structure is supplied, an extrusion line 220 is disposed in which polyolefin resin is extruded into a shape and continuously supplied. The polyolefin resin film that is extruded and supplied to the lower surface of the continuously fed first structure is engaged and then passes through a heat supply means 230 such as an electric heater. At this time, heat generated from the heat supply means is transferred to the polyolefin resin film and serves to melt the polyolefin resin to the extent that it does not flow. Thereafter, the first structure including the molten polyolefin resin film is passed between the cooling rollers 240 to complete the second structure 250 in which the support layer is formed, and wound up by the winding machine 260. At this time, while the first structure passes through the cooling roller, the polyolefin resin film and the bubble layer are bonded by compression, and the polyolefin resin film is maintained in the state of being bonded to the bubble layer by cooling. After the second structure is completed, the artificial filler structure is manufactured by filling the first filler and the second filler between the bubble layer and the pile.

Another aspect of the present invention relates to a method for recycling an artificial turf structure according to the present invention, wherein the method for recycling an artificial turf structure according to the present invention is made by cutting the artificial turf structure according to the present invention to a unit size and then centrifuging it. 1 separating the filler. The artificial turf structure according to the present invention is composed of all polyolefin materials except silica sand or vermiculite used as the first filler. In general, the silica or vermiculite has a specific gravity in the range of about 2.6 to 2.8, and the polyolefin material has a specific gravity in the range of about 0.8 to 0.9, so that the first filler can be separated only by the centrifugation unit operation. Aged artificial turf structures are first ground or cut into unit sizes to facilitate centrifugation or to reduce the burden of centrifugation. The artificial turf structure may be easily crushed or cut by a conventional grinder or cutter, and the unit size of the cutting may be variably determined by the capacity of the centrifuge, etc. Preferably, the cut artificial turf structure fragments are uniform in the centrifuge. It is large enough to be mixed. Since the remaining material separated from the first filler by centrifugation is all made of a polyolefin-based material, it can be melted and used directly for forming a plastic product (for example, a support layer film of artificial turf structure). It can also be sold as raw materials in pellet form. In addition, when the artificial turf structure is crushed from the beginning, it can be sold as a raw material for plastic products without undergoing a melting process.

FIG. 1 schematically illustrates a cross-sectional structure of an artificial turf structure according to an embodiment of the present invention, and FIG. 2 schematically illustrates a method of manufacturing a second structure by forming a support layer from a first structure including a pile and a bubble layer. The process chart shown.

* Description of Major Symbols in Drawings *

DESCRIPTION OF SYMBOLS 10 Bubble layer 20 File 30 Support layer 40 Filling layer

210: first structure 220: polyolefin resin film extrusion line

230: heat supply means 240: first structure 250: cooling roller 240

250: second structure formed support layer 260: winding machine

Claims (8)

Continuously feeding a roll-type first structure in which piles are formed by gathering polyolefin yarns on top of a bubble layer formed of a woven or nonwoven fabric of polyolefin fibers; Extruding the polyolefin resin into a film shape and continuously supplying the polyolefin resin to be engaged with the bubble layer bottom surface of the first structure; Obtaining a second structure in which a support layer is formed by applying heat to the polyolefin resin film engaged with the bottom surface of the bubble layer and melting the film; And And laminating a first filler and a second filler between the upper part of the bubble layer of the second structure and the pile to form a filler layer. The first filler is made of at least one material selected from silica and vermiculite, the second filler is a method for producing artificial turf structure, characterized in that made of a polyolefin elastomer. 2. The polyolefin fiber, polyolefin yarn, polyolefin resin, and polyolefin elastomer of claim 1, wherein the polyolefin is any one selected from the group consisting of polyethylene, polypropylene, and polyisobutylene. Method for producing artificial turf structure, characterized in that. The method of claim 1, wherein the non-woven fabric of the polyolefin fibers forming the bubble layer is produced by any one method selected from the group consisting of spunbond method, melt brown method, needle punching method, and water yarn interlocking method. Method of producing an artificial turf structure. The method of claim 1, wherein the method of incorporating the polyolefin yarn on the top of the bubble layer is any one selected from the group consisting of a tufting method, a moquette method, and a Raschel method. The method of claim 1, wherein the polyolefin resin forming the support layer has a lower melting point than the polyolefin fibers forming the bubble layer. delete A method of recycling an artificial turf structure comprising the step of separating the first filler by pulverizing or cutting the artificial turf structure prepared by the method of any one of claims 1 to 5, and then centrifuging. 8. The method of claim 7, further comprising the step of melting the remaining components of the artificial turf structure separated from the first filler to obtain a polyolefin material.

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