CN106414826A - Flocked material and process to produce it - Google Patents

Abstract

The present invention concerns a process for the preparation of a flocked material for coating surfaces and structures such as the interiors of automobiles, objects for interior decorating (walls, sofas, armchairs, etc.), handbags, suitcases or other accessories, covers or cases for weapons, musical instruments or electronic devices, or to make carpets and/or rugs, and that comprises the use of bicomponent fibers of the ''island-in-the-sea'' type of limited length (microfibers). The process of the invention comprises a step of partial and selective dissolution of the sea component by an alkaline removal agent, which makes it possible to obtain a flocked material characterized by improved resistance to abrasion and a more appealing appearance compared to flocked products of the prior art.

Description

Flocking material and its production method

The object of the invention is a method for the preparation of flocking material starting from sea-island bicomponent fibers, and the flocking material obtained by this method. The flocked materials obtainable by means of this method can be used in various applications, such as coating surfaces and structures, such as motor vehicle interiors, objects for interior decoration (walls, sofas, armchairs, etc.), handbags, suitcases or other accessories , for coverings or cases for weapons, musical instruments or electronic devices, or for the manufacture of carpets and/or travel rugs.

Electrostatic flocking is a special method to obtain a raised effect on various surfaces (fabric, paper, plastic, metal, wood, etc.).

Flocking can be performed on two-dimensional webs, such as paper or fabric, as well as on three-dimensional objects (eg, eyeglass frames, drying racks, containers, interior components for motor vehicles).

In the flocking process, synthetic fibers (which are often already colored) are applied to a surface previously treated with the application of a specific glue. With the aid of an electrostatic field, the fibers penetrate the glue layer so that they orient themselves perpendicularly to the surface to be raised.

In order for the fibers to orient themselves in the electrostatic field, they must be cut uniformly, the length of which is usually related to the fiber size. The smaller the fiber diameter, the shorter its length will be.

Before flocking, the fibers require pretreatment for "activation", which is intended to predispose the fibers to electrical conductivity. Typically, solutions of metal salts are used; since they coat the fiber surface, they promote fiber orientation within an electrostatic field.

The linter dyeing process can also be carried out before or together with the activation step.

The flocking process therefore requires the following steps:

·Cutting fiber

・Optionally dyed

·Activated fiber

·Apply glue on the base fabric layer

Laying of cut fibers in an electrostatic stand with properly oriented fibers

·Dry and possibly reticulate the glue

• Brush fleece with compressed air to remove excess fibers.

It is very difficult to obtain flocked materials realized with microfibres, which are not possible in industrial processes if such fibers have to be cut to lengths too short, and they are very unstable and difficult in activation processes operate. Also, microfibers (which can be classified as microfibers) will have greater difficulty in penetrating the adhesive backing layer, thereby compromising the abrasion resistance of the flocked material.

However, the problem of using very short fibers for flocked surfaces has been solved in the industrial sector. In fact, flocked materials starting from sea-island bicomponent fibers of limited length and using the electrostatic flocking method as described above are already known in the industrial sector. Immediately after flocking the fibers on the substrate and drying the glue, the sea component in the sea-island fibers is usually removed by using a solvent such as trichlorethylene or an alkaline solution.

For example, in Examples 15 and 16 of patent no.GB1300268, a method for preparing a flocking material is disclosed, which consists of a base cloth made of nylon taffeta coated with a polyurethane The "sea-island type" composite fiber is flocked on the composite by means of electrostatic process; the island component in the composite fiber is nylon 6,6, and the sea component is polystyrene. Fibers were cut at a length of 3 mm and pretreated with sodium silicate and ammonium chloride prior to the electrostatic process. The flocked taffeta is dried and then dipped in a trichlorethylene bath at a temperature of 50-60°C to dissolve the sea components. Finally, it was washed with methanol and left to dry. U.S. patent no. 4574018 discloses a method of preparing flocked materials in which short sea-island bicomponent fibers are flocked by an electrostatic process on various base fabrics covered with adhesive (e.g. polyurethane adhesive) . After reticulation of the binder at high temperature, the sea component was partially removed by immersion in trichlorethylene or in a 3% NaOH solution.

In the prior art, the operability problem of producing microfibers for flocking materials is solved by using "sea-island" type fibers. The fibers are activated and layered over the base fabric layer prior to removing the sea component.

However, the main disadvantage of the prior art methods relates to the removal step of sea components. In fact, the Applicant has found that when using solvents similar to those known in the prior art, for example alkaline NaOH solution, the sea components are completely removed, that is to say even in the part is completely removed. In this regard, see Figure 1A, which shows the results of removal steps similar to those employed in the prior art, using solvent-containing solutions or even alkaline solutions. A value of 1 indicates a base layer of flocked fibers and can be of various types, while a value of 2 indicates a layer of adhesive (of various types) applied to the base layer 1 prior to flocking. During the electrostatic flocking process, the sea-island fibers (the value 3 represents the island component and the value 4 represents the sea component) which were previously cut to a suitable length and pretreated with inorganic salts were vertically oriented relative to the base fabric layer, and their A given portion of the length penetrates within the adhesive layer.

Once the adhesive is reticulated, if the flocking material is freed of the sea component by dipping or treating in an organic solvent such as trichlorethylene, or in an alkaline or acidic solution, the problem shown in Figure 1B is encountered : The sea component, even the part inserted in the adhesive layer is completely removed. This is the cause of major problems with the structural resistance and strength of the material, since essentially empty spaces are created between the binder and the island components in the undissolved fibers. As a result, the fibers tend to detach from the substrate as they are no longer "soaked" within the adhesive layer, causing the flocking material to "peel off". See Example 7.0 performed by the applicant, where the removal step was carried out by immersing the flocking material in a bath containing 8% NaOH. The result is a complete removal of the sea component, even in the parts impregnated in the binder, with the result that the remaining fibers are no longer firmly anchored to the base fabric layer, and will be lost in the jet dyeing machine during the next dyeing step with disperse dyes , which is easily removed by abrasion at a temperature of 120 °C and leads to reduction, complete removal of microfibers from the adhesive layer.

By developing the method of the present invention, the applicants have solved this drawback related to the dissolution step of sea components encountered in the prior art.

The present invention relates to the method for preparing flocking material by the bicomponent fiber of sea-island type, this method comprises the use viscosity range is 300mPa.s to 100.000mPa.s, preferably 400 to 64.000mPa. Steps for removing sea components. The remover is preferably in the form of a paste with the viscosity range indicated above and spread on the fibers after flocking of the fibers by electrostatic process and drying of the adhesive layer.

The remover, due to its viscosity, cannot penetrate within the adhesive layer in which the sea-island fibers are partially impregnated and therefore cannot affect that portion of the sea component impregnated within the adhesive layer. Therefore, the removal of sea components is a selective process and makes it possible to obtain flocked materials that provide good abrasion resistance and resistance to fiber removal, which is different from the known disadvantages in the industry sector of starting from sea-island fibers. Unlike flocked products which provide poor resistance to fiber removal by abrasion, those same fibers are not firmly anchored to the adhesive layer.

In a preferred embodiment of the method of the invention, a further measure can be taken to avoid corrosion of the sea component in the lower part of the fiber, and more even in the part impregnated in the adhesive layer; this measure Therein, prior to the application of the remover, the above-mentioned fiber portions are protected by using a removable resin applied by spreading, for example by air spraying. Removable resins can have the same formulation as the remover, but without the caustic (the caustic can be a caustic, an acid or a selective solvent). For example, the removable resin may generally consist of a solution of polyvinyl alcohol or an aqueous solution of a thickening agent which is preferably compatible with the sea components with which it comes in contact. Removable resins are more viscous than caustic pastes in order to prevent penetration between them.

Controlling the amount of removable resin deposited allows for finer adjustment of the fraction of fibers to be dissolved.

Referring now to Figure 2, it can be noted that the selective removal step of the present invention makes it possible to obtain a flocked material in which the sea component 4 is partially removed from the portion of fibers not impregnated in the adhesive layer. This constitutes a significant structural difference between the flocking material of the invention and that of the prior art, as can be seen by comparing FIGS. 2 and 1B , or FIGS. 5 and 6 .

The present invention therefore also relates to a flocking material obtainable by means of the method described hereinabove, wherein the sea component in the sea-island bicomponent fibers is partly removed from the fiber part not impregnated in the adhesive layer (Fig. 2 ).

Keeping the undissolved sea fraction on the outside of the adhesive layer also makes it possible to keep the fibers positioned more locally at the flocking points, and this results in a product with a more attractive appearance (a more uniform feel of pile).

The present invention should be described in detail below with reference to the accompanying drawings, wherein:

- Figure 1A shows the flocking material of the present invention before removing the sea component;

- Figure 1B shows a flocked material with sea-island bicomponent fibers after removal with prior art solvent solutions and/or alkaline solutions;

- Figure 2 shows the flocking material of the invention after the selective removal of sea components by means of the remover of the invention;

- Figure 3 is an SEM (scanning electron microscope) image of the flocking material of the present invention before removing the sea component;

- Figure 4 is an SEM image of the flocked material after selective surface removal of sea components;

- Figure 5 is a detail from Figure 4, where the intact structure is evident at the bottom of the emerging flocking fibers, while the sea component has been removed from the upper part by selective dissolution;

- Figure 6 is an SEM image of the flocked material after non-limiting removal of sea components by immersion in a NaOH bath;

- Figures 7 and 8 are details from Figure 6, where it can be observed that the microfibrils from which the sea component has been removed are not anchored to the glue layer at some points; Dimples were observed in the glue layer, left by fibers that lost their adhesive properties after the sea component dissolved.

The present invention relates to the method for starting to prepare flocking material by sea-island bicomponent fiber, the method comprises the following steps:

· Spinning sea-island bicomponent fibers;

cutting the fibers to lengths ranging from 0.1 mm to 3 mm, preferably 0.3 to 1.25 mm;

optionally dyeing the fibers with colorants, preferably disperse dyes;

Activate the fibers by applying an aqueous solution of inorganic salts;

application of adhesive on a base fabric layer made of woven or nonwoven fabric;

Laying of cut fibers on top of an adhesive coated backing layer by means of electrostatic deposition of properly oriented fibers;

· drying the adhesive and possibly reticulating it;

- optionally removing excess fiber;

Optionally apply a removable resin layer at the fiber base cloth to protect the flocking fiber base cloth;

Selective and partial removal of sea components in fibers by applying a remover with a viscosity ranging from 300 mPa.s to 100.000 mPa.s, preferably from 400 to 64.000 mPa.s;

- Optionally performing dyeing of the flocking material.

The viscosity of the remover and each other fluid was measured as reported in Example 8.0, unless otherwise stated.

According to the prior art, the spinning of sea-island bicomponent fibers is carried out, the method includes feeding two pure polymers or a mixture of two polymers to a spinneret so that one of the two polymer components ( The "sea") completely surrounds other components composed of various polymer filaments (preferably 16 microfilaments of circular and equal diameter) forming the various "islands". In this regard, the island component can be selected from: modified polyesters, cationic polyesters, nylon or other types of polyamides (PA), polyethylene (PE), polypropylene (PP), polytrimethylene terephthalate polybutylene terephthalate (PTT), polybutylene terephthalate (PBT), polyethylene terephthalate (PET), the latter being especially preferred.

The sea component can be solution dyed, that is to say dyed before spinning with the aid of specific colorants or pigments added during the spinning process.

The sea component can be chosen from: Nylon 6,6, co-polyesters with different contents of monomers soluble in alkali (so-called co-PES or TLAS), modified polyesters with intrachain insertion of polar monomers Olefins, wherein the polar monomer is preferably selected from vinyl alcohol, vinyl acetate, or maleic anhydride (so-called co-PS). Depending on the monomer content soluble in alkali, co-PES and co-PS can be easily removed by adding alkaline solution (low monomer content) or also in hot water (high monomer content).

Both the sea and island components may be used in admixture with an additional component selected from inorganic pigments for the island component, and polymers that are incompatible with the sea component. Among the externally added inorganic pigments for the island component, carbon black is particularly preferred. This makes it possible to achieve colored "fluff" in color shades ranging from gray to black even by adding only small amounts of colorants and which prove to be especially resistant to UV degradation.

Among the additional incompatible components for the sea component, polyvinyl alcohol for co-PES and polyethylene glycol with a molecular weight of 10,000 to 20,000 g/mol for co-PS are particularly preferred.

In a particularly preferred embodiment, the fibers used in the present invention consist of an island component made of PET and a sea component made of PA6,6 or co-PES.

The ratio of island component to sea component in bicomponent fibers enables fast and efficient spinning of both components by means of a spinneret. The island/sea ratio preferably ranges from 20/80 to 80/20, more preferably ranges from 50/50 to 80/20. Referring to certain sections, the fibers exhibit an island component content ranging from 8 to 96, preferably 8 to 40.

Immediately after the spinning step, the bicomponent fiber thus obtained is subjected to a drawing process in order to reduce its titer from the range of 6.5 to 19.4 dtex, preferably from the range of 9.2 to 17 dtex, to a titer in the range of 3 to 5 dtex. Stretching is preferably carried out with a draw ratio varying generally in the range 4-1, preferably in the range 3-1, more preferably in the range 2.5-1.

Immediately after the drawing step, the "tow" thus obtained is collected in a bin and undergoes cutting of continuous fibers to lengths ranging from 0.1 mm to 3.0 mm. The length of the fibers preferably ranges from 0.3 to 1.25 mm.

The cut fibers are subjected to an activation step, preferably by immersion in an aqueous bath containing inorganic salts, such as aluminum sulfate and/or calcium chloride. Fibers that have been cut and activated are defined as "lint". The length/diameter ratio of the linters must be in the range of 10:1 to 100:1, preferably 20:1 to 50:1.

This activation step makes the cut fibers more sensitive to the electrostatic field applied during the electrostatic deposition step, and thus enables a more precise orientation of the fibers in a direction perpendicular to the substrate and adhesive layer.

Preferably, the linter is left to dry, and after drying it has an inorganic salt content in the range of 0.5% to 2% of the starting weight.

The base fabric layer to which the adhesive layer is applied may be an orthogonal or woven fabric within a polyurethane matrix, or a nonwoven fabric, such as a spunbonded nonwoven nylon or polypropylene fabric, or a nonwoven elastic composite fabric ( hereinafter identified as "EVN base fabric"), such as polyester microfibres. The base fabric layers referred to above can be used as is or they can undergo a surface coating treatment to reduce their porosity which will change the thickness of the adhesive applied on the surface; the surface coating treatment can also speed up the adhesive Affixed to the surface of the base fabric layer. Alternatively, the backing layer may be a film made of polyolefin, eg polypropylene pretreated with plasma to render the surface hydrophilic and thus readily wettable by the adhesive, or it may be paper. The base fabric layer has a basis weight in the range of 40 g/m ² to 500 g/m ² , preferably 80 g/m ² to 350 g/m ² , and a thickness in the range of 0.10 mm to 2.0 mm, preferably 0.20 mm to 1.10 mm.

The adhesive placed on the backing layer is preferably selected from the group consisting of polyurethane adhesives (in solvent or water), water-based acrylic adhesives, and silicone glues; silicone glues and polyurethane adhesives are especially preferred.

Pigments-and/or additives that can accelerate the bonding of the bicomponent fibers can be added to the binder in order to obtain a shade-specific final flocking material, preferably conductive pigments that can accelerate the subsequent flocking process (so that the base fabric The layer is electrically conductive so that it is possible to neutralize the charge transported from the linter and thus keep the applied electrostatic field constant). These additives (also known as adhesion promoters) are functional groups that are compatible with the adhesive (or react with the latter's functional groups) and compatible with the sea component in the bicomponent fiber (or are The functional group of the molecule reacts), which allows it to penetrate into the glue. The adhesive layer can be applied by coating the entire surface of the base fabric layer (total application) or only a part thereof (patterned application) to a thickness of 0.05 mm to 0.50 mm, preferably 0.10 mm to 0.35 mm. In the case of a patterned application, the linters are deposited stably in areas with adhesive only, thereby achieving a pattern on the surface of the backing layer.

The electrostatic flocking of the flocking on the adhesive layer preferably takes place in an environment with a controlled and constant level of humidity in the range of 60% to 90%, preferably 70% to 80%. The applied electrostatic field is preferably in the range of 20 to 50 kV, preferably 20 to 40 kV.

In the case of patterned deposition, the amount of linter deposited is in the range of 50 to 250 g/cm ² , preferably 140 to 190 g/cm ² , relative to the area within which the adhesive is present.

The sea-island fibers have a denier ranging from 1.5 dtex to 10 dtex, preferably ranging from 3.0 dtex to 7 dtex.

The deposition rate is 2 to 7 m/min, preferably 2 to 4 m/min.

The linter fibers penetrate into the adhesive layer to a depth ranging from 40 microns to the entire thickness of the adhesive layer, depending on the adhesive used, its viscosity and the applied electric field.

Once deposition is complete, the material is placed in an oven to harden and set the adhesive for a period of time ranging from 2 to 10 minutes, preferably 3 to 5 minutes. The oven temperature range is preferably from 110°C to 200°C, preferably from 120 to 190°C.

Selective removal of the sea component occurs by applying a removal agent on the flocking fibers, preferably in the form of a paste and having the viscosity indicated herein above. Removal agents include bases, such as NaOH, or acids, such as formic acid, preferably mixed with a polysaccharide, preferably a polysaccharide such as xanthan gum. Alternatively, the remover may also include a selective solvent for the sea component. Examples of solvents suitable for dissolving co-PS-based sea components consist of halogenated solvents such as trichlorethylene, perchlorethylene, chloroform, hydrocarbon solvents such as toluene, xylene, ethylbenzene, cyclohexane, and other polar Solvents such as N,N-dimethylformamide, acetone, dioxane, tetrahydrofuran, methyl ethyl ketone, acetonitrile, dimethyl sulfoxide, methanol and ethanol.

The concentration of acid or base may range from 1.5% to 20% by weight, preferably from 4% to 18% by weight. Polysaccharides, and especially xanthan gum, are preferably included in the paste in amounts ranging from 0.5% to 7% by weight.

Apply the remover on the flocking fibers in an amount ranging from 80 to 150 ^g /m2.

In a preferred embodiment of the present invention, before applying the remover, the removable resin can be applied by coating as a way to avoid sea component corrosion in the lower end portion of the fiber and more even in the portion impregnated in the adhesive layer further measures. The removable resin can have the same formulation as the remover, but without the caustic (which can be a caustic, acid or selective solvent). For example, the removable resin may generally consist of a solution of polyvinyl alcohol or an aqueous solution of a thickener which is preferably compatible with the sea components with which it comes in contact. The viscosity of the removable resin is preferably greater than that of the remover in order to prevent penetration between them. The viscosity of the removable resin preferably ranges from 1.000 mPa.s to 150.000 mPa.s.

Controlling the amount of removable resin deposited provides for finer adjustment of the fraction of linters to be dissolved.

Immediately after application of the remover, the material may be treated with a stream of saturated steam, with radio frequency, with microwaves, or thermally with hot air in order to accelerate the dissolution of the sea components. Immediately after this optional treatment (which can last from 5 to 15 minutes) (in the case of thermal treatment, at a temperature of 70-100°C), the remover and any removable resin can be removed by washing with water . In this way, selective and partial removal of the sea component results in that only a portion of the sea component not impregnated in the adhesive layer is removed, while the portion impregnated in the adhesive layer remains and is allowed to remain firmly Anchor the linter fibers to the substrate (see Figures 3-5, which show that there are no empty spaces between the island fibers and the adhesive layer). According to a variant of the procedure, immediately after the application of the remover, the material treated with a stream of saturated steam, radio frequency or microwave is further treated with hot air in an oven, the purpose of which is on the surface of the remover before washing with water. Creates a protective barrier.

In this way the flocking material can be rolled up, for example for its safe transport to a washing line, without compromising the quality of the final flocking material. Part of the fibers subjected to sea component removal revealed microfibers constituting island components, each of which had a fineness ranging from 0.04 dtex to 0.30 dtex. In this way, the flocking material is more resistant to possible abrasions that could cause fiber removal, and it turns out that based on the corroded fibers of the part, the microfibers are more locally localized at the flocking point, resulting in a more attractive appearance. product (felt the fluff more evenly). Furthermore, it is also possible to dye the flock material in a jet dyeing machine and then remove the excess dye without risk of losing the flock fibers. Alternatively, to produce flocked material without the mottled (flat appearance) effect, it can be dyed in machines used for garment dyeing or more generally for "open width dyeing", which allow particularly delicate materials to be pressed Dyed without placing them under severe mechanical stress (the material remains open and unraveled across its entire width without forming longitudinal or transverse creases).

Thus, the flocked material obtained using the method of the invention differs from the materials known in the prior art in that it does not exhibit empty spaces between the fibers and the adhesive layer, which could cause subsequent The prior art materials have poor resistance in the dyeing step, and generally poor abrasion resistance. The flocking material of the present invention presents itself as a finer material and offers greater durability over time than prior art flocking materials.

The object of the present invention is therefore a flocking material obtainable using the method of the invention.

Flocking material of the present invention comprises:

- a base fabric layer, which is preferably made of woven or non-woven fabric;

- an adhesive layer applied to the base fabric layer;

- a fibrous layer comprising a plurality of sea-island fibers, preferably oriented in a direction perpendicular to the base fabric layer, partially impregnated in the adhesive layer, with the sea component still present in the adhesive layer In that part of the fiber that is impregnated. On the contrary, the sea component is completely or partially absent in the part of the fibers which emerges from the adhesive layer.

The adhesive layer is present on the entire surface of the base fabric layer or on a part thereof (patterned flocking).

The thickness of the adhesive layer is in the range of 0.05mm to 0.50mm, preferably 0.10mm to 0.35mm.

A plurality of sea-island fibers are included within the adhesive layer to a depth ranging from 40 microns to the full thickness of the adhesive layer.

The island component in the sea-island fibers has a denier ranging from 0.04 to 0.30 dtex.

The flocking material of the present invention can be used in automotive, furnishing and consumer electronics to replace all parts currently coated with fabric, non-woven fabric or leather.

In particular, the flocking material of the invention can be used in various applications, such as coating surfaces and structures, such as the interior of motor vehicles, interior decoration objects (walls, sofas, armchairs, etc.), handbags, suitcases or other accessories, Covers or cases for weapons, musical instruments or electronics, or to make carpets and/or travel rugs.

Embodiment Examples and Comparative Examples

Example 0.1 White linters with PET/TLAS bicomponent fibers - 1.0mm

An island-in-the-sea bicomponent fiber linter is realized, where the island component is realized in PET and the sea component is realized in TLAS (copolyester soluble in alkali). The ratio of island component to sea component in the fiber was 57:43.

The fiber section showed 16 PET microfilaments of circular shape and equal diameter.

The linters are obtained by subsequent drawing, collecting the tow in a box, and cutting the continuous sea-island fibers to the desired length.

The characteristics of fibers and linters are as follows:

1 Stretch ratio 2.5/1

2- Denier 4.3dtex

3-Length 1.0mm

The linters thus defined undergo activation by means of immersion in an aqueous bath of aluminum sulphate; after drying, the aluminum sulphate content in the linters is equal to 1% of the starting weight.

The linter thus realized is called Thread 1 .

Example 0.1.1 Black linters with (PET+disperse dye)/TLAS bicomponent fibers

The linters were achieved using the same procedure as used for thread 1, with the variation that the linters were dyed with a black dye dispersed in water at a temperature of 120°C prior to the activation process, according to the prior art.

Subsequent activation left 1 wt% aluminum sulfate on the linters. The linter thus achieved is called thread 2 .

Example 0.2 Black linters with solution-dyed PET/TLAS bicomponent fibers - 0.3mm

Islands-in-the-sea bicomponent fiber linters were realized, where the islands component was realized in PET with an added carbon black content of 7%, and the sea component was realized in TLAS (copolyester soluble in alkali). The ratio of island component to sea component in the fiber was 57:43.

The fiber section showed 16 PET microfilaments of circular shape and equal diameter.

The linters are obtained by the subsequent process of drawing, collecting the tow in a box and cutting the continuous sea-island fibers to the desired length.

The characteristics of fibers and linters are as follows:

1 Stretch ratio 2.5/1

2- Denier 4.3dtex

3- Length 0.3mm

The linters thus defined undergo activation by means of immersion in an aqueous bath of aluminum sulphate; after drying, the aluminum sulphate content in the linters is equal to 1% of the starting weight.

The linter thus realized is called thread 3 .

Example 0.3 White linters with PET/PA6.6 bicomponent fibers - 0.5mm

Realization of island-in-the-sea type bicomponent fiber linters, where the island component is realized in PET and the sea component is realized in PA6,6. The ratio of island component to sea component in the fiber was 57:43.

The fiber section showed 16 PET microfilaments of circular shape and equal diameter.

The linters are obtained by the subsequent process of drawing, collecting the tow in a box and cutting the continuous sea-island fibers to the desired length.

The characteristics of fibers and linters are as follows:

1 Stretch ratio 3.0/1

2- Denier 3.8dtex

3- Length 0.5mm

The linters thus defined undergo activation by means of immersion in an aqueous bath of aluminum sulphate; after drying, the aluminum sulphate content in the linters is equal to 1% of the starting weight.

The linter thus realized is called thread 4 .

Example 0.4 White linters with PET/HWS bicomponent fibers - 1.0 mm

An island-in-the-sea type bicomponent fiber linter is realized, where the island component is realized in PET, and the sea component is realized in HWS polyester. The ratio of island component to sea component in the fiber was 57:43.

The fiber section showed 16 PET microfilaments of circular shape and equal diameter.

The linters are obtained by the subsequent process of drawing, collecting the tow in a box and cutting the continuous sea-island fibers to the desired length.

The characteristics of fibers and linters are as follows:

1 Stretch ratio 2.5/1

2- Denier 4.3dtex

3-Length 1.0mm

The linters thus defined undergo activation by immersion in an aqueous bath of aluminum sulphate in the presence of 0.5% calcium chloride; after drying, the aluminum linters undergo a weight gain of 1%.

The linter thus realized is called thread 5 .

Example 0.5 White linters with PET/TLAS bicomponent fibers - 1.0mm Type A

Islands-in-the-sea bicomponent fiber linters were achieved, and it was similar to that reported in Example 0.1, except that the bicomponent fibers used to achieve linters had the following characteristics:

1 total stretch ratio 3.5/1

2- Denier 3.1dtex

3- Length 0.5mm

4- The ratio of island component to sea component is equal to 55:45

5 - The fiber part contains 36 PET microfilaments of circular shape and equal diameter.

The linters thus obtained undergo activation by immersion in an aqueous bath of aluminum sulphate in the presence of 0.5% calcium chloride; after drying, the aluminum linters undergo a weight gain of 1%.

The linter thus realized is called thread 6 .

Embodiment 1.0EVN base cloth-silicone glue-1.0mm

Two-component ALAPATEC 30340 adhesive with a thickness of 0.2 mm and a viscosity of 50.000 mPa.s is applied on a base fabric layer with a thickness of 1.10 mm realized in a composite material made of PET microfibres with a 30% polyurethane matrix layer (100% silicone glue supplied by CHT).

This was followed by electrostatic and mechanical flocking in order to deposit the linters indicated as line 1; the linters penetrated an average of 60 microns into the glue layer.

Flocking took place in an environment with a controlled and constant humidity level of 65% exposed to an electrostatic field of 30 kV to enable deposition of 144 g/cm ² linters at a line velocity of 3.0 m/min.

The intermediate product thus determined was placed in a convection oven, web-laid at 150°C for 4 minutes, and referred to as FK01.0.

Example 1.1EVN base cloth-silicone glue-1.0mm

An intermediate product similar to that identified for FK01.0 (Example 1.0) was achieved using a two-component TUBICOAT PROTECT LSR adhesive (100% silicone gum supplied by CHT). The glue contains black pigment and has a viscosity of 35.000 mPa.s, a viscosity lower than ALPATEC 30340 to such an extent that the penetration of the flock indicated as line 1 is equal to the 0.2 mm thickness of the glue, and thus the flock is in contact with the surface of the base fabric layer.

This intermediate product is called FK 01.1.

Embodiment 1.2EVN base cloth-polyurethane glue-1.0mm

Using a two-component polyester-based polyurethane glue, which can be reticulated by heating, an intermediate product similar to that identified for FK01.0 (Example 1.0) was achieved. The glue contains black pigment and has a viscosity of 30.000 mPa.s, lower than the previous example to such an extent that the penetration of the linters, indicated as line 1, is equal to the 0.2 mm thickness of the glue, and thus the linters are in contact with the surface of the base fabric layer .

The intermediate product thus determined was placed in a convection oven, web-laid at 150°C for 4 minutes, and referred to as FK01.2.

Embodiment 1.3EVN base cloth-polyurethane glue-0.5mm

Using a linter, indicated as thread 6, instead of thread 1, and an aromatic two-component polyester-based polyurethane glue (which can be reticulated by heating), a similar intermediate product as determined for FK 01.0 (Example 1.0) was achieved. intermediate product. The glue has a viscosity of 29.000 mPa.s, and the penetration of the linters represented by line 6 is equal to the 0.2 mm thickness of the glue, and thus the linters are in contact with the surface of the base fabric layer.

The intermediate product thus determined was placed in a convection oven, web-laid at 150°C for 4 minutes, and referred to as FK01.3.

Example 2.0 EVN Base Fabric - Silicone Glue with Adhesion Promoter - 1.0mm

Using a two-component TUBICOATPROTECT LSR adhesive (100% silicone glue supplied by CHT) which already contains black pigments and TLAS-specific adhesion promoters, the intermediate Product-similar intermediate products. The glue has a viscosity of 35.000 mPa.s, and the penetration of the linters indicated as line 3 is equal to the 0.2 mm thickness of the glue (thus the linters are in contact with the surface of the base fabric layer).

This intermediate product is called FK 02.0.

Example 3.0 Fabric Base - Acrylic Adhesive - 1.0mm

Place a layer of TUBVINIL401H adhesive (water-based acrylic base fabric supplied by CHT) with a thickness of 0.15mm on a 100% PET cloth base fabric layer with a unit weight of 82g/m2, and use the linter indicated as line ² . Electrostatic flocking.

Flocking takes place in an environment with a controlled and constant humidity level of 65% exposed to an electrostatic field of 30 kV, so that 165 g/cm ² linters can be deposited at a line speed of 3.5 m/min.

The product was then placed in a convection oven at 170°C for 3 minutes to dry and set the adhesive.

The linters penetrate into the adhesive to the point of contact with the underlying fabric layer.

This intermediate product is called FK 03.0.

Example 4.0 Removable Base Cloth - Silicone Adhesive - 1.0mm

A layer of two-component TUBICOAT PROTECT LSR adhesive (100% silicone glue supplied by CHT) with a thickness of 0.4 mm containing black pigment (see example 1.1) was placed on the Teflon strip with surface roughness.

This is followed by electrostatic flocking with the linter indicated as thread 1 .

Flocking took place in an environment with a controlled and constant humidity level of 65% exposed to an electrostatic field of 40 kV, so that 210 g/cm ² linters could be deposited at a line speed of 2.2 m/min.

The product was then placed in a convection oven at 140°C for 6 minutes to dry and set the adhesive.

The linters penetrate into the adhesive to the point of contact with the underlying film.

This intermediate product is called FK 04.0.

Embodiment 4.1PP base cloth-polyurethane glue-1.0mm

On a PP film with a thickness of 120 micrometers that was pretreated with plasma to make the surface hydrophilic, an aromatic two-component polyester-based polyurethane glue layer (which can be reticulated by heating) containing a black pigment and with a thickness of 0.4 mm was placed.

This is followed by electrostatic flocking with the linter indicated as thread 1 .

Flocking took place in an environment with a controlled and constant humidity level of 65% exposed to an electrostatic field of 40 kV, so that 210 g/cm ² linters could be deposited at a line speed of 2.2 m/min.

The product was then placed in a convection oven at 140°C for 3 minutes to dry and set the adhesive.

The linters penetrate into the adhesive to the point of contact with the underlying film.

This intermediate product is known as FK 04.1.

Example 5.0 Spun-bonded base fabric-silicone glue-PA 6,6-0.5mm

A layer of TUBICOAT PROTECT LSR two-component adhesive (100% silicone glue supplied by CHT) with a thickness of 0.2 mm was placed on the spunbond PP fabric with a basis weight of 90 g/m ² .

This is followed by electrostatic flocking with a linter indicated as line 4.

Flocking took place in an environment with a controlled and constant humidity level of 80% exposed to an electrostatic field of 22 kV, so that 191 g/cm ² linters could be deposited at a line speed of 2.5 m/min.

The product was then placed in a convection oven at 150°C for 5 minutes to dry and set the adhesive.

The linters penetrate 150 microns into the adhesive.

This intermediate product is called FK 05.0.

Embodiment 6.0 fabric base cloth-PUD glue-HWS-1.0mm

A layer of two-component TUBICOATPROTECT LSR adhesive (100% silicone glue supplied by CHT) with a thickness of 0.2 mm was placed on a 100% PET cloth with a basis weight of 82 g/m ² .

This is followed by electrostatic flocking with linters indicated as line 5 .

The flocking takes place in an environment with a controlled and constant humidity level of 75% exposed to an electrostatic field of 25 kV so as to be able to deposit 150 g/cm ² linters at a line velocity of 3.0 m/min.

The product was then placed in a convection oven at 150°C for 4 minutes to dry and set the adhesive.

The linters penetrate 150 microns into the adhesive.

This intermediate product is known as FK 06.0.

Example 7.0 - Dissolving + dyeing in NaOH bath (comparative example)

Washing of intermediate products FK01.0, FK 01.1, FK 01.2, FK 02.0, FK 03.0, FK 04.0 and FK 04.1 containing TLAS as a component of linters in a bath containing 8% NaOH (w/w) Wash in a bath of 8% (w/w) NaOH at 80°C for 15 minutes, then in cold water and dry in a convection oven.

In the intermediate products FK 01.0 and FK 03.0 it was evident that the linters were detached from the glue layer, leaving amber bare areas where only the glue and the substrate were present.

In the intermediate products FK 01.1, FK 01.2, FK 02.0, FK 04.0 and FK 0.041, the linters remain on the product surface, and the sea component is completely removed, including the part impregnated in the glue; therefore, the bonding surface Limited to only microfiber base fabrics. For this reason, just in the subsequent dyeing step, in a jet dyeing machine with disperse dyes, at a temperature of 120°C, microfiber flocked products tend to be easily removed by abrasion and lead to reduction, the microfibres are completely removed from the glue removed.

Example 8.0 Dissolving + Dyeing with NaOH Paste in Air

Using a scraper at a rate of 100 g/m2 ^on the linter side of the intermediate products FK01.0, FK 01.1, FK 01.2, FK 02.0, FK 03.0, FK 04.0 and FK 04.1 containing TLAS as a component of linters , to dispense a thickened NaOH formulation (removal agent).

The caustic paste, 16% of which consists of NaOH and 0.5% of DENIMCOL SPEC FTL (xanthan polysaccharide supplied by CHT), has a pseudoplastic behavior and a viscosity of about 400 mPa.s under applied conditions.

Viscosity was measured using a Brookfield DVIII rotational viscometer with a small sample adapter fitting and an SC4-28 spindle at 20°C at a speed of about 5 rpm (equivalent to a shear rate of 5 s ^-1 ).

The intermediate product coated with the caustic paste was heat treated in an oven at 80°C for 10 minutes, then washed in cold water and placed in a convection oven to dry.

SEM analysis showed that the sea component was only superficially affected (SEM image of sample FK 01.1 in Figure 3).

Example 9.0 - Dissolving with NaOH paste in steam

Dispensing thickening at a rate of 100 g/m2 ^on the linter side of intermediate products FK 01.0, FK 01.1, FK 01.2, FK 01.3, FK 02.0, FK 04.0 and FK 04.1 containing TLAS as a component of linters NaOH preparation (removal agent).

The caustic paste (4% of which consists of NaOH and 2% of DENIMCOL SPEC FTL (xanthan polysaccharide supplied by CHT)) has a pseudoplastic behavior and a viscosity of about 28.000 mPa.s under application conditions.

The intermediate product coated with the caustic paste was treated with a stream of saturated steam at atmospheric pressure for 3 minutes, then washed in cold water and placed in a convection oven to dry.

In the intermediate products FK 01.1, FK 01.2, FK 01.3, FK 02.0, FK 04.0 and FK 04.1, in the non-impregnated part of the linter in contact with the caustic paste the inner sea component is completely removed, thereby exposing the microfibres, while the other Parts still have a microfibrous nature and also ensure the adhesion of the fiber bundles to the backing layer (Figures 4 and 5, SEM images of the FK 01.1 sample).

The intermediate product FK 01.0 had patches lacking linters on the surface, which was caused by insufficient penetration of linters in the silicone glue.

The intermediate product FK 03.0 showed lint and glue loss on most surfaces.

The dyeing was then performed at 120° C. in a jet dyeing machine with disperse dyes, and the excess dye was subsequently reduced only on the intermediate products FK01.1, FK 01.2, FK 01.3, FK 02.0, FK04.0 and FK 04.1.

Example 9.1 - Dissolving + open width dyeing with NaOH paste in steam

The sea components of the intermediate products FK 01.1 , FK 01.2, FK 01.3, FK 02.0, FK 04.0 and FK 04.1 were removed as described in Example 9.0. The intermediate product is then dyed using a disperse dye in water at 120° C. by means of a dyeing machine for open-width dyeing, and the excess dye is subsequently reduced. In this way, a dyed flock material is obtained which is characterized by a more homogeneous and homogeneous appearance.

Example 10.0 Binary Coating and Steam

On the intermediate products FK 01.1, FK 01.2, FK 02.0 and FK 04.0, by means of an air knife, a PVA formulation in water with a viscosity of 54.000 mPa.s is applied, the purpose of which is to apply 30 g/ ^m2 of solution layer.

Subsequently, the thickened NaOH formulation was dispensed on the flocked side of the intermediate product FK 01.1 at a rate of 100 g/m ² by means of a cylindrical doctor blade. The caustic paste (removal agent) (4% of which consists of NaOH and 2% of DENIMCOL SPEC FTL (xanthan polysaccharide supplied by CHT)) has a pseudoplastic behavior and a viscosity of about 28.000 mPa under applied conditions .s.

The intermediate products FK01.1, FK 01.2, FK 02.0 and FK 04.0 coated with the caustic paste were treated with a saturated stream of steam for 3 minutes at atmospheric pressure, washed in cold water and placed in a convection oven to dry.

The sea component proved to be hydrolyzed only in the tip portion of the flocking fibers, that is to say, about 1/5 of the exposed length.

Example 11.0 - Dissolution in water and RF-HWS

An aqueous solution of 1.5% DENIMCOL SPEC FTL (xanthan polysaccharide supplied by CHT) was dispensed on the flock side of the intermediate product FK 06.0 by means of a doctor blade at a rate of 120 g/m ² . The viscosity of the solution under the conditions of application is about 20.000 mPa.s.

This intermediate product was then subjected to radio frequency using a parallel electric field with a potential difference equal to 1.0 kV and washed in cold water.

This was followed by immersion in a 10% calcium chloride solution for 8 minutes at a temperature of 50° C. in order to remove residual sea components ( HWS) are not soluble in the linter part impregnated with silicone glue.

The intermediate product remains intact as it passes through the next dyeing step for dyeing with disperse dyes in a jet dyeing machine at 120°C and reduced to eliminate excess dye.

Comparative Example 12.0 - Dissolution and MW (Microwave) in NaOH

With the aid of a spatula, at a rate of 100 g/m ² , on the linter side of the intermediate product FK 01.1, dispense the thickened NaOH preparation, then heat in a microwave oven with a power equal to 5 KW for 2 minutes, wash in cold soft water, and Dry in a convection oven.

The caustic paste (removal agent) (1.0% of which consists of NaOH and 2.0% of DENIMCOL SPEC FTL (xanthan polysaccharide supplied by CHT)) has a pseudoplastic behavior and a viscosity of about 2.000 mPa under applied conditions .s.

Following the microwave treatment, the sea component in the portion of the fibers emerging from the glue proved to be completely removed, exposing the microfibers, while it remained in the portion anchored to the base fabric layer. Dyeing was then carried out at 120° C. in a jet dyeing machine using disperse dyes, followed by reduction of excess dye.

Claims (21)

1. it is the initial method preparing flocked material by sea-island bicomponent fibre, the method comprises the steps：

The bicomponent fibre of spinning fabric of island-in-sea type；

It is 0.1mm to 3mm that fiber is cut into scope, the preferably length of 0.3 to 1.25mm；

Optionally use coloring agent coloured fibre；

By applying the aqueous solution containing inorganic salt, activated fiber；

On bottom cloth layer, the bottom cloth layer be preferably made up of fabric or supatex fabric applies binding agent；

By the electrostatic precipitation being rightly orientated fiber, in the fiber of the bottom cloth layer upper strata paving cutting with adhesive coated；

Dry adhesive is simultaneously optionally allowed to into net；

Optionally remove excess fibre；

Optionally apply to can remove resin bed, to protect fiber base cloth at fiber base cloth；

It is 300mPa.s to 100,000mPa.s by applying range of viscosities, the preferably remover of 400 to 64,000mPa.s, Sea component in selectivity part removal fiber；

Optionally enter to exercise flocked material dyeing.

2. the method for claim 1 wherein that the island group in bicomponent fibre is selected from：Modified poly ester, cationic polyester, nylon or Other kinds of polyamide (PA), polyethylene (PE), polypropylene (PP), polytrimethylene's ester (PTT), gathers to benzene Dioctyl phthalate fourth diester (PBT), and polyethylene terephthalate (PET).

3. the method for claim 1 or 2, the wherein sea component in bicomponent fibre is selected from：Nylon 6,6, has solvable in alkali Different content monomer co-poly ester, and be inserted into the improved polyalkene of polar monomer in chain, wherein polar monomer is preferably selected from Vinyl alcohol, vinyl acetate, or maleic anhydride.

4. the method for aforementioned any one claim, wherein after spinning process, bicomponent fibre experiences stretching step, excellent Being selected in scope is 4-1, and preferred scope is 3-1, and more preferably scope is to be stretched under the draw ratio of change in 2.5-1.

5. the method for aforementioned any one claim, wherein said activation step includes leaching in the water-soluble bath of liquid containing inorganic salt The fiber of stain cutting.

6. the method for claim 5, wherein after activation processing, the fiber drying of standing cutting, and after drying, they There is scope is starting weight 0.5% to 2% inorganic salt content.

7. the method for aforementioned any one claim, wherein adhesive phase applying bottom cloth layer thereon is by positive intertexture or volume Woven fabric or supatex fabric, the nonwoven nylon of preferred spunbonded or polypropylene fabric, or nonwoven Stretchable composite fabric, excellent It is selected in the polyester microfiber in polyurethane-base body, or the thin film being made up of polyolefin, preferably polypropylene or paper forms.

8. the method for aforementioned any one claim, the binding agent being wherein placed on bottom cloth layer is selected from：In water or solvent dispersion Internal polyurethane binder, water-borne acrylic type binding agent and silicone adhesive.

9. the method for claim 8, wherein will promote the pigment of subsequent flocking steps, preferably conducting pigment, and/or can promote The additive of bicomponent fibre bonding is added in described adhesive.

10. the method for aforementioned any one claim, is 60% to 90% wherein in controlled and scope, preferably 70% to In the environment of 80% consistent humidity level, it is 20 to 50kV using scope, the preferably electrostatic field of 20 to 40kV, occur described The electrostatic spinning of cutting fibre over the binder layer.

The method of 11. claim 10, wherein in substrate, the scope of the cutting fibre amount of deposition is 50 to 250g/cm², preferably 140 to 190g/cm².

The method of 12. aforementioned any one claim, wherein said remover includes alkali, preferably NaOH, or acid, preferably first Acid, preferably they are mixed with polysaccharide.

The method of 13. aforementioned any one claim, applying amount ranges wherein on flocked fiber is 80 to 150g/m²'s Described remover.

The method of 14. aforementioned any one claim, wherein after applying remover, with saturated steam flowing, with radio frequency, uses Microwave or with this material of hot-air heat treatment.

The method of 15. aforementioned any one claim, the viscosity of wherein said removable resin bed is more than described remover Viscosity, preferred scope is 1,000mPa.s to 150,000mPa.s.

16. 1 flocked material, it includes：

- bottom cloth layer, described bottom cloth layer is preferably made up of fabric or supatex fabric；

- it is applied to adhesive phase in base fabric layer surface or its part；

- fibrous layer containing multiple seas-island fiber, described fibrous layer is preferably upwardly oriented in the side vertical with bottom cloth layer, and part is soaked In adhesive phase, sea component is still present in adhesive phase in the part fiber of dipping stain, and sea component completely or Part is not present in the few fibers that expose from adhesive phase.

The flocked material of 17. claim 16, the thickness range of wherein said adhesive phase is 0.05mm to 0.50mm, preferably 0.10mm to 0.35mm.

The flocked material of 18. claim 16 or 17, wherein includes the plurality of sea-island fiber, its depth in adhesive phase Scope is the whole thickness from 40 microns to adhesive phase.

It is 0.04 that island component in the flocked material of 19. claim 16-18 any one, wherein sea-island fiber has scope Fiber number to 0.30dtex.

Purposes in motor vehicles, ornaments and consumer electronics field for the flocked material of 20. claim 16-19 any one, from And substitute and use fabric at present, all parts of supatex fabric or leather coating.

The flocked material of 21. claim 16-19 any one is used for being coated with the surface of interior of motor vehicles and structure, internal dress Jewelry body (wall, sofa, armchair etc.), handbag, suitcase or other accessories, the covering for weapon or chest, music Instrument or electronic device, or manufacture the purposes of carpet.