JPH10168740A - Flocked products and method for producing the same - Google Patents

Abstract

(57) [Problem] To provide an extremely fine pile flocked product having a smooth surface touch, a high-grade suede appearance, and excellent durability such as friction and abrasion. There is provided an industrially valuable production method capable of easily obtaining an extra-fine pile by a simple physical treatment after flocking. The flocked product of the present invention has a pile having a pile length of 0.1 mm to 2 mm and a fineness of 0.01 to 0.7 d implanted on a base material, and an adhesive portion between the pile and the base material. It is characterized in that a plurality of piles are in a bundled state, and after planting a pile yarn composed of splittable micronizable fibers on the substrate, without substantially dividing the adhesive portion between the pile yarn and the substrate. The fiber can be manufactured by subjecting the pile yarn portion to physical treatment to make the ultrafine-divided type fibers finely divided and to form a pile that is finely divided.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a flocked product in which a microfiber pile is planted on a substrate and a method for producing the same. More particularly, the present invention relates to a flocked product with a fine fiber pile, which has a suede-like high-grade appearance, has a good surface touch, and has excellent adhesion and robustness, and a method for producing the same. .

[0002]

2. Description of the Related Art Conventionally, flocking products obtained by an electric flocking technique, also called flocking, have been used for various purposes. However, in order to stably pile a pile on a substrate at a high density, the thickness of pile fibers is large. There is a limit to the length of the sheath, and it is generally difficult to implant a thin and long pile due to entanglement.
In order to solve this problem, it has been proposed that a composite fiber such as a sea-island fiber is planted, then divided and thinned (Japanese Patent Publication Nos. 46-2782, 55-62265, and 55-62265). No. 56-154581).

[0003] By such a method, a flocked product having a high quality appearance such as a suede tone and a good surface touch, which has not been obtained in the past, can be obtained. For this reason, there is a problem that the adhesive strength is reduced by the influence of chemicals and temperature for the adhesive, or the adhesive strength is reduced due to the division of the adhesive-treated portion at the base of the pile, and the hair loss increases. JP-A-62-149963 discloses a flocking pile using a modified polyester containing 2 mol or more of sulfonic acid groups in the sea component of the sea-island type fiber, and a processing solution having a pH of 4 or less before splitting. It is disclosed that the sea component of the pile for flocking is embrittled. In this case, there is an advantage that the dyeing can be performed before the hair transplantation and an advantage that the hair can be divided by a relatively weak treatment. Is left.

[0004]

SUMMARY OF THE INVENTION In view of the above-mentioned problems of the prior art, an object of the present invention is to provide a good appearance even when the base material is implanted on a relatively hard material such as a molded product instead of a knitted fabric. An object of the present invention is to provide a flocked product having both surface touch, adhesion and durability, and an easy manufacturing process, and a method for manufacturing the same.

[0005]

Means for Solving the Problems The present invention has been made to achieve the above-mentioned object, and a flocked product of the present invention has a pile length of 0.1 mm to 2 mm and a fineness of 0.01 mm.
It is a flocked product characterized in that a pile of .about.0.7 d is planted, and a plurality of piles are bound at a bonding portion between the pile and the base material. And the flocked product of the present invention includes the following preferred embodiments.

(A) The base material is a molded product.

(B) The surface of the molded product is made of rubber, plastics, metal or ceramics.

(C) The pile is made of polyester fiber.

(D) The pile is made of polyamide fiber.

[0010] The method for producing a flocking product of the present invention is further characterized in that the method comprises the steps of:
Physically treating the pile yarn portion without substantially dividing the adhesive portion between the pile yarn and the base material to make the ultrafine splittable fibers fine and to form the split ultrafine pile. This is a method for producing a flocked product. The following preferred embodiments are also included in the method for producing a flocking product of the present invention.

(A) The fineness of the pile yarn is 1 to 20 d.

(B) The divided ultra-fine-thinning type fiber is a conjugate fiber.

(C) The physical treatment is a high-pressure fluid treatment, a high-pressure powder fluid treatment, brushing or abrasion treatment.

(D) The ultrafine splittable type fiber is subjected to an easy splitting process in advance.

(E) The ultrafine splittable fiber is a sea-island type composite fiber, and the easy splitting treatment is performed by embrittlement treatment of a sea component or partial sea removal treatment.

(F) The sea component of the sea-island composite fiber is made of a readily soluble alkali-soluble polyester or a hot-water-soluble polyester into which a sulfonic acid group has been introduced, and the heterodivision treatment is an embrittlement treatment under acidic conditions. There is.

[0017]

BEST MODE FOR CARRYING OUT THE INVENTION The flocked product of the present invention has a base material in which microfibers are planted at a relatively high density, and has a good suede-like appearance, a soft surface touch, and low friction and wear. There are suitable ranges for specific piles, thicknesses, lengths, densities, etc. to have excellent durability.

That is, the pile in the flocked product of the present invention is a fine fiber pile having a fineness of 0.01 to 0.7 d, preferably 0.01 to 0.2 d in pile thickness. When the pile thickness is less than 0.01 d fineness, there is a problem in pile breakage due to friction, coloring property in dyeing and fastness. If it exceeds 0.7d, the surface touch is insufficient.
In the present invention, the fineness of the pile is more preferably from 0.03 to
0.2d, particularly preferably 0.03 to 0.15d.

The pile length of the pile of the present invention is preferably 0.1 mm to 2 mm, more preferably 0.5 to 2 mm.
It is 1.5 mm, more preferably 0.7 to 1.5 mm. For example, when the pile length is in the range of 0.1 to 0.5 mm, a nubuck tone is obtained, and when the pile length exceeds 0.5 mm, a rich feeling of volume and a sense of quality can be obtained. If the pile length is too short, the volume feeling is poor, and if it is too long, the luxurious luster and appearance are lacking.

Further, in the present invention, the flock density of the pile is preferably 70 to 250 g / m ² , more preferably 80 to 200 g / m ² , and still more preferably 100 to 1 g / m ² .
It is 60 g / m ² . If the flocking density is low, the volume feeling is lacking, and there is a problem in abrasion. On the other hand, if the density is too high, the suede feeling tends to be poor.

In the present invention, the raised portion of the pile is composed of microfibers. At the bonding portion with the base material at the base of the pile, a plurality of piles are bundled and adhered in a bound state. It is characterized by not being converted.
In the present invention, the term "bound state" means that the ends of the divided and finely scalable type fiber pile planted on the base material are not thinned at the bonding portion of the flocking product, and the fibers are planted as thick fibers. In other words, it indicates that a plurality of extremely fine piles are bonded in a state of being bound at the bonding portion at the base. By flocking in this bundled state, fine and long piles can be flocking, and the adhesive area with the adhesive is maintained as compared with the case where the root is divided and finely divided to the root by a drug or the like, so that high adhesion to the base material is achieved. It has the characteristics of obtaining good wear resistance. When the base material is a cloth, such a structure tends to make it difficult to obtain a soft flocking cloth, but when the base material is relatively hard and the shape is almost fixed like a molded product, Since the root of the pile is not extremely thin, the above problems hardly occurred, and it was found that a flocked product excellent in durability and surface touch was obtained.

The substrate used for the flocking product of the present invention is not particularly limited, but rubbers such as natural rubber and synthetic rubber, thermoplastics such as polyolefin, ABS, acrylic, polyamide and polyester, phenolic resin and melamine. Thermosetting resins such as resins, metals, ceramics and the like are used, and molded products are particularly preferably used. In addition, the shape of the substrate is not limited as long as it is a shape that allows flocking. Although the surface condition is not particularly limited, it is preferable that the hairs are implanted on a substrate having a smooth surface in applications where the touch is important.

Although the pile material in the present invention is not particularly limited, polyester fibers such as polyethylene terephthalate and polybutylene terephthalate, nylon 6 and nylon 66 are preferable in view of appearance, surface touch, color fastness and ease of production. For example, polyamide fibers such as polyamide fibers are preferably used. The present invention includes, of course, modified materials based on copolymers, composites and additives based on these.

An adhesive is used when the pile of the present invention is implanted on the substrate, but the adhesive is not particularly limited. As the adhesive, preferably acrylic, polyurethane, polyester, polyamide, ethylene-
Adhesives such as vinyl acetate-based and synthetic rubber-based adhesives can be used.

Next, a method for producing the flocking product of the present invention will be described, but the present invention is not limited thereto.

The method for producing the flocking product of the present invention
After the electric flocking of the split-thinning type fiber pile yarn such as the composite fiber of ~ 20d, the pile portion is physically split and thinned without substantially splitting the adhesive portion.

The preferred pile yarn used for the flocking of the present invention is a composite fiber pile yarn which can be made fine. Representative examples of such composite fibers include sea-island composite fibers and split composite fibers.

In the sea-island composite fiber, one component, which is a sea component, is ultimately substantially removed to make it ultrafine. The island component may be a polyester-based or polyamide-based polymer as described above. Copolymers are preferably used. The sea component is not limited, but preferably a component that can withstand dyeing at the pile stage is preferable.Typically, a sulfonic acid group is introduced, an alkali easily soluble polyester fiber or a hot water soluble type. Examples include polyester-based fibers.
The preferred proportion of the sea component is 2 to 40% by weight, particularly preferably 5 to 20% by weight.

In the case of splittable conjugate fibers, splitting and ultrafine splitting is performed by exfoliating two components, and a conjugated fiber composed of polyester and polyamide is typically given.

In the present invention, the pile portion is made extremely thin without making the adhesive portion at the root of the pile yarn extremely thin, but physical means is preferably used as a dividing process for this purpose.

In order to easily make the ultrafine splitting by physical means, it is preferable that the conjugate fiber has been subjected to a process for facilitating the ultrafine splitting before the flocking, that is, an easy splitting process. In the case of the sea-island composite fiber, the easily splitting treatment includes embrittlement treatment of the sea component and partial sea removal treatment. In the case where the sea component is the above-mentioned sulfonic acid group-introduced, alkali-soluble type or hot water-soluble type polyester,
Easily dividing treatment is possible by industrially easy treatment such as heat treatment under acidic condition as embrittlement treatment and hot water treatment as partial seawater removal treatment. In the case of a splittable conjugate fiber, a treatment for swelling one of the components or a treatment for dissolving or decomposing a trace amount can be performed.

In the present invention, if such an easy splitting process is performed under strong conditions, the splitting can be made extremely fine by simple physical treatment after the flocking, but the splitting in the process up to the flocking deteriorates the flocking property. Therefore, it is necessary to take appropriate processing conditions.
In this sense, the separation method can be controlled under the processing conditions, the stability is most excellent, and the most preferable method is a sea-island having a sulfonic acid group-introduced, alkali-soluble type or hot water-soluble type polyester as a sea component. This is a method in which embrittlement treatment is performed on mold composite fibers under conditions of PH3 or less.

In the present invention, physical means is adopted as the dividing means after the implantation. Conventionally, chemical means such as a dissolving agent, a swelling agent and a decomposing agent are mainly used as means for making a composite fiber extremely fine, and in many cases, physical means are merely used as auxiliary means. It is difficult to reduce only the pile portion without minimizing the root portion intended by the present invention, and the adhesion force is easily reduced depending on conditions, and the process becomes complicated.

The physical dividing means preferably employed in the present invention includes high-pressure fluid treatment, high-pressure powder fluid treatment, brushing, rubbing and the like.

As the high-pressure fluid in the high-pressure fluid treatment, air or water is used. In the high-pressure powder fluid treatment, the fluid is treated with a powder fluid in which solid particles are added, and silica or alumina is used as the solid particles. , Nylon and the like are used, but since these may remain in the product, water-soluble powders, ice and dry ice which can be easily removed can also be used. Further, a metal brush is preferably used for brushing. As the rubbing treatment, a buffing treatment with emery paper can be mentioned, which is suitable when the pile length is relatively short.

In order to obtain the flocked product of the present invention, it is typically obtained by the following method.

First, the single fiber denier is 1 to 1 as the composite fiber.
At 20d, the denier of the pile after division is 0.01 to 0.
The pile length is 0.1 to 2 mm using a 7d pile yarn.
To a predetermined cut length. In this case, in the case of a pile yarn having a long cut length, a fiber having a large single yarn denier is used.
For example, if the pile length is about 0.1 to 0.5 mm, 1
d or more, but when the pile length is 2 mm, the single yarn is preferably 7d or more. The pile fiber yarn is
Straight fibers without crimping are excellent in flocking, but weak crimping may be provided as long as the flocking is not impaired.

Next, in the present invention, after pretreatment for easy splitting and dyeing by a conventional method, electrodeposition treatment for imparting electric flocking property is carried out, and thereafter, preferably, a mistake is made with a sieve or the like. A sorting operation for removing the cut is performed to obtain an electroplanting pile. Where a. A cutting step, b. Easy division processing, c. The order of dyeing is not particularly limited, and the electrodeposition treatment can be performed last.

In the present invention, the flocking method may be a known method, and after the flocking, drying and curing are performed if necessary, and a physical splitting process is performed and excess pile is removed.

The flocked product of the present invention has excellent durability,
It can be suitably used for various purposes such as automobile interior parts and decorations, toys, furniture, footwear, and bags.

[0041]

【Example】

(Examples 1 to 6 and Comparative Example 1) Sea-island fibers composed of polyethylene terephthalate in which the island component is polyethylene terephthalate and the sea component is copolymerized with 8 mol% of ethylene pentasodium sulfoisophthalate unit (single yarn 6 denier, island component 9
0% by weight, 10% by weight of sea component, 70 islands)
As shown in the figure, the cut length was changed within the range of 0.2 to 2.2 mm, and the pile was washed with water to obtain a pile yarn. These pile yarns are immersed in an aqueous solution of 15 g / liter of maleic acid for 110 hours.
The mixture was treated at 30 ° C. for 30 minutes, and the sea component was easily fragile. Then, it is dyed black with a disperse dye at 130 ° C. for 60 minutes by a conventional method, washed by reduction, immersed in an electrodeposition treatment liquid (containing sodium silicate, colloidal silica, and an antistatic agent) whose pH has been adjusted to 4, and dried. Then, the resultant was screened with a sieve to obtain a pile yarn for electroplanting.

Separately, a self-crosslinking type acrylic emulsion adhesive was applied to an acrylic resin plate, and the pile yarn was electro-flocked by an up method (30,000 V). This at 90 ° C for 10
After drying for a minute, the pile portion of the flocking product was strongly brushed with a brass brush to obtain a flocking product in which the pile yarn was divided. Table 1 shows the results.

[0043]

[Table 1] With the flocked product of the present invention, a suede style flocked product having a very soft surface touch and exhibiting a so-called lighting effect was obtained. Microscopic observation revealed that the pile portion was almost divided and extremely fine, but the adhesive portion at the base of the pile was not divided and adhered. As for the durability, the abrasion test according to the Taber method showed a high durability of 4-5 class.

Here, the abrasion test by the Taber method is to take a test piece having a diameter of about 120 mm, make a hole of about 6 mm in the center thereof, and fix it to a turntable of an ASTMD type Taber abrasion tester. The test is a method of visually judging the degree of wear after rotating 150 times with a load of 500 g using a CS-10 wear wheel. The larger the durability, the larger the value.

(Comparative Example 2) In Example 1, flocking was performed without performing the acid treatment. The surface touch was rough and hard even when the brush was brushed strongly. Microscopic observation revealed that the pile part was partly divided, but the thick pile yarn remained mostly, and the structure of the present invention was not obtained.

(Comparative Example 3) A flocked product was prepared in the same manner as in Example 1, and then treated with a 1.5% aqueous sodium hydroxide solution at 98 ° C for 20 minutes. The flocking product obtained after washing and drying is completely divided and ultrafine, and the surface touch is soft,
There was hair loss in the adhesive peeling test with cellophane tape, and the durability was poor with the second grade in the abrasion test. Microscopic observation revealed that the root was also divided, and a floating pile that was not adhered was observed.

(Examples 7 to 9 and Comparative Example 4) Sea-island fibers of the same polyester as in Example 1 with an island component of nylon 6 and a sea component with the same polyester as in Example 1 (single denier 10%, island component 80% by weight, sea component 20)
(% By weight, 70 islands) were cut as shown in Table 2 while changing the cut length (0.8 to 2.5 mm) and washed with water to obtain a pile yarn. This pile yarn was treated in an aqueous solution of acetic acid 10 g / liter at 120 ° C. for 30 minutes to subject the sea component to brittle brittleness. Then, at 100 ° C., 60
It was immersed in an electrodeposition treatment liquid (containing sodium silicate, colloidal silica, and an antistatic agent) dyed in a gray shade and adjusted to a pH of 4, dried, and screened with a sieve to obtain a pile thread for electroplanting.

Next, a polyurethane-based solvent-type adhesive solution was applied to the ABS resin plate, and the pile yarn was electro-flocked by an up method (30,000 V). This was dried at 90 ° C. for 10 minutes, and the pile portion of the obtained flocking product was strongly brushed with a stainless steel brush to obtain a flocking product in which pile yarns were divided. Table 2 shows the results.

[0049]

[Table 2] With the flocked product of the present invention, a suede style flocked product having a very soft surface touch and exhibiting a so-called lighting effect was obtained. Microscopic observation revealed that the pile portion was almost divided and extremely fine, but that the adhesive portion at the base was not divided but adhered. As for the durability, the abrasion test according to the Taber method showed a high durability of 4-5 class.

[0050]

According to the present invention, since the surface touch is smooth and has a high-grade suede appearance and excellent durability such as friction and abrasion, it is used for automobiles, vehicle interiors, decoration, toys, furniture and footwear. A flocked product in which a very fine pile is planted, which can be applied to various uses such as, for example, is obtained. In addition, the production method also has a great industrial value because an extremely fine pile can be easily obtained by a simple physical treatment after flocking.

──────────────────────────────────────────────────の Continued on the front page (51) Int.Cl. ⁶ Identification code FI // D01F 8/14 D06M 13/20 5/04 (72) Inventor Yutaka Masuda 1-1-1 Sonoyama Toray, Otsu City, Shiga Prefecture Toray Inside Shiga Plant

Claims (12)

[Claims] 1. A pile having a pile length of 0.1 mm to 2 mm.
And a pile having a fineness of 0.01 to 0.7 d is planted, and a plurality of piles are bound at a bonding portion between the pile and the base material. 2. The flocked product according to claim 1, wherein the base material is a molded product. 3. The flocking product according to claim 2, wherein the surface of the molded product is made of rubber, plastics, metal or ceramics. 4. The flocking product according to claim 1, wherein the pile is made of polyester fiber. 5. The flocked product according to claim 1, wherein the pile is made of polyamide fiber. 6. A pile yarn made of splittable microfibrillable fibers is planted on a base material, and then the pile yarn portion is subjected to a physical treatment without substantially dividing an adhesive portion between the pile yarn and the base material. A method for producing a flocking product, comprising dividing a microfiber capable of being divided into microfibers to form a microfiber pile. 7. The method according to claim 6, wherein the pile yarn has a fineness of 1 to 20 d. 8. The method for producing a flocked product according to claim 7, wherein said splittable micronizable fiber is a conjugate fiber. 9. The method according to claim 7, wherein the physical treatment is high-pressure fluid treatment, high-pressure powder fluid treatment, brushing or scraping treatment. 10. The split-thinning type fiber which has been subjected to easy splitting processing in advance.
10. The method for producing a flocked product according to any one of claims 9 to 9. 11. The fiber according to claim 7, wherein the ultrafine splittable fiber is a sea-island composite fiber, and the easy splitting treatment is performed by embrittlement treatment of a sea component or partial sea removal treatment. A method for producing a flocked product according to any one of the above. 12. The sea component of the sea-island type composite fiber is made of a readily soluble alkali-soluble polyester or a hot-water-soluble polyester into which a sulfonic acid group has been introduced, and the heterodivision treatment is embrittlement treatment under acidic conditions. The method for producing a flocked product according to claim 11, wherein: