JPS6384668A - Production of flocked article - Google Patents

Abstract

PURPOSE:To settle the conventional problems elated to safety and sanitation and working environment at the same time by using the composite fiber wherein at least one component consists of a water-soluble polymer as the raw pile yarn to enable the removal by an aq. system. CONSTITUTION:When the flocked article is produced by using a pile yarn, the composite fiber consisting of at least two components at least one of which is formed with a water-soluble polymer (e.g., polyvinyl alcohol polymer) is used as the raw pile yarn, the raw pile yarn is flocked in the substrate, and then the water-soluble polymer is removed by the aq. system. As a result, since the removal by aq. system can be carried out, and the conventional problems related to safety and sanitation and working environment are settled at the same time. Besides, removal of the water-soluble polymer and dyeing can be simultaneously carried out, and hence the total cost can be remarkably reduced by the omission of stages.

Description

[Detailed Description of the Invention] [Industrial Application Field] Conventionally, as a method for flocking ultrafine fibers, a composite fiber composed of two or more components is used to make a pile yarn, and after flocking, at least one component is Means for dissolving and removing or swelling and dividing are known.

However, these methods require the use of chemicals to remove or divide one component. For example, JP-A-59-
When polystyrene is used as the sea component as disclosed in Japanese Patent Laid-Open No. 155745, it is necessary to perform ultra-fine treatment with trichlene after hair transplantation. When using hair transplantation, ultra-fine treatment with formic acid is required after hair transplantation. Handling these chemicals is dangerous and requires special equipment to dissolve and remove them. This created bottlenecks in terms of worker safety and health and manufacturing costs. In addition, because chemicals are used during the ultra-fine treatment, the adhesive used for pile flocking deteriorates or swells, making it difficult to handle the flocked pile. Ta. Therefore, there is a limit to the ability to safely and stably perform flocking.

[Problem that the invention seeks to solve]

The present inventors have arrived at the present invention as a result of intensive studies on a method for manufacturing flocked products that does not have the above-mentioned drawbacks. In particular, it is an object of the present invention to provide a method for producing a flocked product in which the process of making the flock fine after flocking or making it porous for lotus roots can be carried out simultaneously with the dyeing process.

(Means for solving problems) The present invention has the following configuration.

(1) When producing flocked products using pile yarn, the pile yarn is a composite fiber consisting of at least two components, of which at least one component is a water-soluble polymer. 1. A method for producing a flocked product, which is characterized by using a pile yarn as a base material, flocking it, and removing a water-soluble high molecular weight polymer in an aqueous system.

The present invention will be explained in more detail below.

The water-soluble polymer referred to in the present invention is a polymer that can be melt-spun and may be any polymer that can be easily dissolved in water or hot water, such as polyvinyl alcohol-based polymer, There are water-soluble polyamides (e.g. polyether amide polymers, polyether ester amide polymers), water-soluble polyesters (e.g. copolyester polymers of sodium 5-sulfoisophthalate), etc., but they have poor spinability or flocking properties. A copolymerized polyester of a polyetheramide-based polymer and sodium 5-sulfoisophthalate is preferably used. In particular, copolyester polyester of sodium 5-sulfoisophthalate, which is sparingly soluble in cold water and soluble in hot water, is suitable as the pile yarn for flocking.

In the present invention, these water-soluble high molecular weight polymers are used as at least one component of the pile yarn, and are used as composite fibers consisting of at least two or more high molecular weight polymer components. The structure of this composite fiber may be any type of composite fiber as long as the other remaining component becomes ultra-fine and/or porous like a shincon in the removal process after flocking described later, such as seabird type composite fiber, hollow Ring-shaped composite fibers, multifilament composite fibers, and composite fibers with fiber cross sections that are wood grain-like, mosaic-like, radial, or side-by-side are used.

In particular, sea-island composite fibers are suitable as pile yarns for flocking.

The main component of the composite fiber used in the present invention is a polymer that can be melt-spun into composite fibers and turned into ultrafine fibers and/or lotus root-like porous fibers in the step of removing the water-soluble polymer after flocking. In other words, a high molecular weight polymer having the ability to form frost fibers is preferable. For example, nylon 6, nylon 66, nylon 12, copolymerized nylon, polyamides such as polyphenylsulfonamide, polyesters such as polyethylene terephthalate, copolymerized polyethylene phthalate, polybutylene phthalate, copolymerized polybutylene terephthalate, polyolefins such as polyethylene, polypropylene, etc. is used. In particular, nylon 6, nylon 66, polyethylene terephthalate, and copolymerized polyethylene terephthalate are suitable as the pile yarn for flocking.

The fineness of the composite fiber is preferably 1 denier or more and 100 denier or less. Particularly preferably, it is 3 deniers or more and 20 deniers or less. If the fiber is less than 1 denier, the fibers will be too thin and the electro-flocking property will be poor, and if it exceeds 100 denier, the fiber will be too thick and there will be a problem with the flightability in electro-flocking. After the water-soluble polymer is removed from the composite fibers, the fibers can be roughly divided into two types: ultrafine fibers and lotus root-like porous fibers. In the former case, create flocked products that are flexible and smooth to the touch. In the latter case, the surface of the flocked product has micro-craters, creating a flocked product that has a sticky touch, water absorption, and hygroscopicity that are different from those of ultrafine fibers. All of these things are only possible through composite fibers, and clearly demonstrate the value of composite fibers. The thickness of the ultrafine fiber after removal of the water-soluble polymer is preferably 0.5 denier or less. If it exceeds 0.5 denier, the suppleness of ultrafine fibers will be lost.

The ratio of water-soluble polymer in the composite fiber is 5%
The content is 80% by weight or less. If it is less than 5% by weight, it is too low and the remaining components tend to merge into islands. On the other hand, 80
Exceeding the weight ratio increases the amount of components to be removed, and the surface quality of the flocked product after removing the water-soluble polymer becomes rough, which is also disadvantageous in terms of cost. The number of islands in the seabird type composite fiber is preferably 4 or more. If it is less than 4, the characteristics of an ultrafine fiber cannot be exhibited, and its value as a composite fiber is low.

Further, although the composite fiber may be crimped, it is preferable to use it without crimping from the viewpoint of flocking property.

In the present invention. Before cutting the pile yarn for flocking, it is also possible to bond it with an adhesive or heat treatment at a temperature higher than the melting point of the outer polymer to make the conjugate fibers extremely thick in the form of a bundle. Furthermore, by removing the water-soluble polymer, it is also possible to use a mixture of a conjugate fiber that is made ultra-fine and a lotus root-like porous conjugate fiber.

Next, a method for manufacturing flocked products will be described.

First, the flocking pile yarn of the composite fiber is cut into an appropriate length by a conventionally known method.

The length of the cut pile is determined by the thickness of the composite fiber, the thickness of the ultrafine fiber after removing the water-soluble polymer, the flocking conditions of the cut pile, etc., but is preferably 0.5 seconds.
Above, it is 30 nm or less, more preferably 10 mm or less. If the pile length is less than 0.5 mm, the pile length is too short and almost sinks into the contacting agent layer, making it difficult to express the effect of the ultrafine fibers, and if it exceeds 30 mm, the pile will collapse.
Moreover, even if flocked, it becomes easy to handle and the quality as a flocked product deteriorates. The present invention also includes scouring the pile with an aqueous solution of a nonionic activator before flocking, and then treating it with a treatment solution consisting of sodium silicate, colloidal silica, and isopropyl phosphate potash, and performing dehydration, drying, etc. . Next, as a substrate on which the pile of the present invention is flocked, woven fabric,
Many materials are used, including nonwoven fabrics, sheet materials made of fiber aggregates and resins, sheet materials made of polymeric materials, artificial leather-like sheet materials, metal foils, wood boards, and sheet materials made of inorganic materials. .

Next, as the adhesive for bonding the pile and the base of the present invention,
Any polyurethane may be used as long as it can withstand the water-soluble polymer removal treatment after flocking or the dyeing finishing treatment, but ether type or ester type polyurethane is preferably used from the viewpoint of processability.

Conventionally known methods can be used to flock the pile of the present invention onto a substrate coated with an adhesive.

In particular, electric flocking using the up method is preferably used.

Next, a method for removing water-soluble polymers, which is the key point of the present invention, will be described. The water-soluble polymer can be removed in an aqueous system. However, treatment with a weakly alkaline aqueous solution may be used to improve removal efficiency. Furthermore, the most preferred method is to remove the water-soluble polymer at the same time as dyeing. As described above, by using a water-soluble polymer as the removal component, the removal component can be easily removed using ordinary hot water. Moreover, there is no need to install special equipment and it can be removed at the same time as dyeing during the dyeing process, so there are no health and safety issues and it is advantageous in terms of cost.Furthermore, since no organic solvents or strong alkalis are used, adhesives can be removed at the same time as dyeing. Since the hair does not deteriorate or swell, the problem of hair transplanted hair moths coming back undone can be greatly reduced. Conventionally, this process was carried out using toluene when polyethylene was used as the component to be removed, trichlene when polystyrene was used, and highly concentrated alkali when polyester was used. A separate treatment process was required, and treatment required equipment for safety, health, and the environment. There are many problems in terms of safety and cost. Furthermore, the adhesive that adheres the pile to the substrate may swell due to treatment with organic solvents or strong alkalis.
It also solves the problem of the flocked pile becoming curly due to deterioration of the adhesive itself.

The present invention will be explained in more detail with reference to Examples below.
This makes the present invention more clear, and the present invention is not limited thereto. In the examples, parts and %
References herein refer to weight unless otherwise specified.

〔Example〕

Example 1 Terephthalic acid 61.2 mol% as a water-soluble polymer
A copolymerized polyester consisting of 26.3 mol% of isophthalic acid and 112.5 mol% of 5-sodium sulfoisophthalate was used as a sea component, and polyethylene terephthalate was used as an island component, and melt spinning was performed using a conventionally known sea-island type spinneret. An undrawn yarn having a component ratio of 10%, an island component ratio of 90%, a seat count of 36 islands, and a fineness of 10.5 d was obtained. Next, the yarn was stretched 3.times.5 times in a liquid bath at 65.degree. C. to obtain pile yarn for flocking with a fineness of 3 d. Both spinning and stretching were successfully processed without any processing problems. The obtained yarn was cut into 1 m 1 Tl, and after scouring the cut pile with an aqueous solution containing a nonionic activator, it was immersed in a treatment solution consisting of sodium silicate, colloidal silica, and inpropyl phosphate potash, dehydrated, After drying, it was made into a pile for electric flocking. The surface electrical leakage resistance of this pile was 2×10 8 Ω·Cm. A blended plain fabric of 65% polyester and 35% rayon (fabric weight 120g/T112) is used as the base fabric for flocking, and a polyether type polyurethane DMF solution (solid content 26.5%, 100,000 CpS 72) is used as an adhesive on the surface.
5°C) to 300g/m2 using a knife coater, and flocked with an up-method electroplating M/C (voltage 30,000cm,
distance between electrodes 10 cm). There were no problems with the flying properties of the pile, and the flocking process was successfully completed. The flocking density of the pile was 140C1/m2.

After flocking, it is dried at 120°C, then the sea component is removed and dyed at the same time using a circular jet dyeing machine at a processing temperature of 120'C, and after reduction cleaning, an amino silicone softener is applied (Toray Silicon Co., Ltd.) SM-8702) and finished. The obtained flocked product had a calf suede appearance, with extremely fine short piles of 0.075 d being densely and tightly flocked. The flocking density was 120 g/m2, and there was no swelling of the adhesive and almost no pile was observed to fall off during the dyeing process.

Comparative Example 1 The same processing as in Example 1 was performed up to electric flocking, except that polystyrene was used for the sea component, and then, after the sea component was removed with Trichlorine, the dyeing and finishing process was performed in the same manner as in Example 1. . The flocking density of this item is 105g/Tn
2, the surface quality was inferior to that of Example 1, and the commercial value was low. In addition, the use of trichlene to remove sea components caused the adhesive to swell, resulting in piles falling off and excessive time being wasted cleaning the sea removal equipment. Furthermore,
The use of trichlene as a solvent for sea removal required special equipment, and also required a large amount of expense in terms of safety and health.

Example 2 A conventionally known sea-island type cap with a copolyamide consisting of N-6: 20% 1, N-66: 20%, and polyethylene glycol diammonium adipate: 60% as a sea component and polyethylene terephthalate as an island component. The sea component ratio is 15% and the island component ratio is 85%.
An undrawn yarn having a number of seats of 70 and a fineness of 13.5 d was obtained. Then, it was stretched 2.7 times on a hot plate at 120° C. to obtain a pile fiber for flocking with a fineness of 5 d. The obtained raw yarn is 1,51
The fibers were cut to a length of T1m, scoured with an aqueous solution containing a nonionic activator, dehydrated, and dried to obtain pile fibers for flock processing. The surface electrical leakage resistance of this pile is 1゜5X108Ω
・I missed it in cm.

65% polyester, 35% rayon as the base fabric for flocking
% blended plain weave fabric (basis weight 120Q/m2) was used, and 300g of polyester-type polyurethane DMF solution (solid content 25%, 90,000 cps/25°C) was applied to the surface as an adhesive.
/Tr12 using a knife coater and flocking with an up-method electroplating M/C (voltage 30,000 mm, distance between electrodes 10
Cm). There were no problems with the flying properties of the pile, and the flocking process was successfully completed. The flocking density of the pile is 200 CI
/Tr12. After flocking, it was dried at 120°C, and then sea component removal and dyeing were simultaneously carried out using a circular jet dyeing machine at a processing temperature of 100°C. After reduction washing, an amine silicone softener was applied to finish. The obtained flocked cloth (
The flocked product) is a calf suede-like material with 0.061 d of ultra-fine short pile that is densely and tightly flocked. The flocking density was 165Q/Tr12, and there was no swelling of the adhesive and almost no pile was observed to fall off during the dyeing process.

(Effects of the Invention) Since the present invention uses composite fibers in which at least one component is a water-soluble polymer as the pile yarn, the following effects can be obtained.

(1) Water-based removal becomes possible, and conventional problems such as safety, health, and working environment are solved at once.

(2) It becomes possible to remove the water-soluble polymer at the same time as dyeing, and the total cost can be significantly reduced by omitting the process.

(3) Since the adhesive does not swell or dissolve, the edges of the pile after flocking are firm and there is almost no chance of the flock falling off.

(4) Therefore, the amount of adhesive used can be reduced and the scope of use can be expanded.

(5) The resulting processed product has improved flocked pile density, flexibility, uniformity, surface quality, and durability.

Claims (1)

[Claims] (1) When producing flocked products using pile yarn, the pile yarn is a composite fiber consisting of at least two components, of which at least one component is a water-soluble polymer. 1. A method for producing a flocked product, which comprises using a pile yarn as a base material and then removing a water-soluble high molecular weight polymer in an aqueous system.