CA1261213A - Flocked thread - Google Patents

Abstract

ABSTRACT OF THE DISCLOSURE

Thread or yarn-like material is produced by electro-statically flocking it or covering it with fibers. Grounded base or carrier threads that are provided with adhesive are moved through an electrostatic field of high voltage, where the surfaces of the carrier threads are flocked all the way around with pre-treated short fibers (flock material). During the course of producing the flocked thread or yarn, selective lengths of the carrier threads are nonuniformly flocked in an irregular sequence, with the flock material, in different flock patterns.

Description

This is a division of our co-pending Canadian Patent A~plication No. 493,302, filed October 18, 1985.
The co-pending Application relates -to a method and apparatus for producing thread or yarn-like material by electro-statically flocking it or covering it with -Eibers. Grounded base or carrier threads -that are provided with adhesive are moved through an electrostatic field of high voltage, where the surfaces of the carrier threads are flocked all the way around with supplied, pretreated short fibers (flock material). The present invention relates to the flocked thread or yarn manufac-tured by such a method and wi-th such an apparatus.
Due to the uniform method of flocking and the uniform flock construction, the heretofore known flocked threads or yarns, which are processed on weaving machines, double-rib looms, knitting machines, power knitting looms, or non-woven machines, or are used for producing webs of clo-th, trim, fabric, knitted material, or other textile goods, have a surface which is visually uniform. By cross-weaving or patterning of the flocked threads, this surface can be interrupted only in intentional, uniformly constructed patterns or designs, or a design can be visually produced by different colors of the individual flocked threads.
The pattern of this design is preprogrammed. In -this manner, for example, herringbone patterns, diamond shapes, or checkered patterns are obtained. These patterns provide smooth, uniform, or cross-woven goods.
It is therefore an object of the present invention to .
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make it possible to produce a design of flocked threads having no repeated pattern. Nei-ther a pat-tern nor a design should be evid-ent. A satisfactory yet irregular surface pattern can be achieved by flocking the carrier threads during the course of the pro-duction process.
The invention provides a flocked thread or yarn pro-duced from a carrier thread and flock material comprising a flocked effect thread having different flock patterns in an arbitrary sequence over specific, selective lengths of said threads.
By differing structures of -the flock, flocked threads are produced which are distinguished by an intentionally uncon-trolled sequence of difEerent types of flocking, and by changing spacing between the different flocked areas. The design produced hereby has neither a pattern nor a fixed design. No repeated pattern is provided. Such a uniform irregularity provides a design with a liveness and fantasy. Up to now, a design having a high flock quality and such a completely novel pattern and character could not be produced.
The non-uniform flocking can be effected freely arbitrarily during the flocking process or by controlling the parameters for the flocking (material, dosage, tension) during the course of the process. The different flock patterns are differentiated from one another by length of the fibers, density of the fibers, and orientation of the fibers, i.e. whether or not they are disposed radially, relative to the carrier thread.
The irregularities can be achieved by regulating the :-, ~ -: - . .
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tension of the base or carrier -thread. As a result, -there is achieved ei-ther a radia] flocking all the way around, or a pre-dominantly irregular flocking all the way around, in other words, the fibers are not disposed about the thread radially relative to the surface of the -thread. Furthermore, the irregularities ean be achieved by regulating the high vol-tage oE the eleetrodes, by means of whieh an op-timum dense radial floeking, an irregular floeking and/or a low-density flocking is achieved. Furthermore, a deliberate irregular flock pattern can be controlled by selectively cutting in or cutting out one and/or the other of the existing dosing devices, which contain the different flock materials which are differentiated from one another in fineness, length, and color.
The deseribed method makes it possible to produee a floeked thread having a multiplieity of individual, suecessive flock eonstruetions with whieh no known produet ean compare with regard to force of expression and fantasy, while at the same time a high quality is maintained. The combination of the individual flock constructions concerns not only the respective lengths of the sections of the base or carrier thread, but also the differ-ing sequences in the flock thread.
Depending upon the subsequent application, or the method provided for processing the flocked thread, it is possible pur-suant to the present invention to adjust the thread size in the design. The thread is preferably between lO and 5000 meters.
As a result, the further user of the flocked thread is assured :~2~;~2~3 ~ 4 - 23549-381D

that a satisfactory, irregularly ordered pattern of the fabric, knitted goods, etc. will be obtained without having to fear that a pattexn will evolve.
I'he Elock constructions in the selected sequence can be altered to desired lengths of preferably 5 cm to 7 m. As a result, the visually perceived color impressions are also altered at the same time.
Along specific yet selective lengths of secti.ons of the flocked thread obtained, not only densely radially disposed but also irregular flocking, partially with long and partially with short flock fibers, are obtained in a sometimes dense and some-times not so dense flock arrangement. As a result, each thus obtained flocked thread is particularly effective. In this respect a new flocked fancy or effect thread is obtained. The deliberate irregularity in construction and sequence can be achieved by flocking the threads, during production, by a series of adjustable factors. This is effected in an apparatus which essentially com-prises flock transport means preferably having a plurality of supply and dosing means which contain different flock constructions;
the apparatus also contains two spaced apart electrodes connected to sources of high voltage, which can be varied. A thread dispens-ing mechanism with a tensioning device for regulating the tension-ing of the thread is also provided. The base or carrier threads are moved through this apparatus, and are preferably irregularly flocked in a controlled manner.
These and other features and advantages of the present .

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invention, will appear more clearly :Erom -the following specific-ation in conjunction with the accompanying drawing, in which:
Figure 1 shows one exemplary embodiment of a variety of different flock patterns Eor a flocked effect yarn;
Figure 2 schematically illustrates one embodiment of the device for producing a flocked effect thread; and Figure 3 shows a flocked effect thread comprised of different abutting flock patterns.

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De~cription of Preferred Embodiment~
Referring now to the drawlng in detail, Figure 1 illu~trate~ avariety of different flock or fiber con~tru~tion arrangements, knowml as flock patterns.
Th~ carrierthread i8 designate~ by ~he reference numeral 19, and the flock or fiber~ are designated by the reference numeral 20. The following exemplary flock patternfi are illustrated:
Pattern 21: A thread surface which is d~n~ely a~d radially flocked or covered wi~h fiber~ all t~e wa~ around, with the cut lellgth of the flock being approxi-mately 0.5 to 1 mm, and with the flock density being 100%;
Pattern 22: A threa~ whlch is radially flock2d les~ den~ely, wlth the cut len~th o the ~lock b2ing approximately 0.5 to 1 mm, ~nd the flock denslty being approximately 85 - 90%;
Pat~ern 23: ~ densely, lrregularly flocked thre~d, wi~h a cut le~g~h of the flock of approxl~ately 0.5 to 1 mm, and a flock density of 98 ; 100%;
Pattern 24: A le~s den~ely, lrregularly flocked thread, with a cut length o~ the flock o~ approximately O.S to 1 mm3 and'a _ 6 _ ' ~ .
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1Ock ~ensity oE 85 - 90%;
In Patterns 23 and 24, the flock iB
not ~lsposed at an anGle of e~entlally 90 t~ the core of ~he ~hread, but ra~her extend~ ln par~ ~o an an~le with deviate~ considerably therefrom, an~ even at 30 to the core;
Pattern 25: A thread which i.~ den6ely radially flocked all ~he way around, w~th a cut le~gth of the 1Ock of approx$mately 1 to 1.5 mm, and a flock density ~f lOO~b;
Pa~tern 26: A le~8 den~ly radially flocked thread, with a cut length of the ~lock o~
approximat~ly 1 to l.S ~m, and a 1Ock den~ity of ~pproximat~ly 85 - 90~b;
Pattern 27: A densely, irregularly ~locked thread, with a cut length o the flock o~
approxima~ely 1 to 1.5 mm, and flock den~i~y of 9B 100%; and Pat~ern 28: A lesa densely, ~rregularly flocked thread, with a cut length of the flock o~ approximately 1 to loS
and a ~lock d~n~lty o 85 - 90Z.
The same explanat~o~ provided in connection wl~h Pa~tern 24 regardin~ th~ angl~ of the flock applie~

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~ 2 ~ 3 to the Pattern~ 27 and 28~
An Pxemplary, inventive apparatus for flocking or coveri~g the thread with fibers is ~hown ~n Figure 2. This apparatus comprise~: An endles3 conveyer 15; flock storage mean~ 2, 3, an~ 4, whlch are associated with the ~nput si~e of the flocking chamber 11, mak available dif~erent ~lock materlals, and are formed of the con~aine~s 5, 7, and 9 and the dosing dPvices 6, 8, and 10; the flocking chamber 11, which contains an upper el~ctrode 1~ and a lower electrode 13 that can be connected ~o high '' voltage; the spool wlthdrawal frame 16; the dryin~
means 17; and the tensioning device 18 for regulating the tens ion of the thread, wlth the tensioning device 18 and the frame 16 form~ng the dispensing mechanism. The electrostatic field i3 des~gnated by the reference numeral 14.
The baAe or carrier thread3 19 are moved through tlle invent~ve apparatus, and are variou~ly flocked with the 10ck or f~bers 20 ln the flocking chamber 11.
Th~ flocked fancy or effec~ thread 30 illustrated ln Figure 3 compri~e~ different flock Patterns 21 - 28 that have been flocked in an irregular sequence. From one ~lock construction to the nex~, the de~ign units, in other word~ for the actual ~locking and.
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''' ~ 3 transi~lon to a succ~edln~ flockin~ of a dlfferent ~ype, have ~lme uni~s of, for example, 0.2 meters of thread per second, a changing high voltage of, for example, 50 KY ~o 40 ICV, changing thread tenQlons of, or example, 400 grams to 800 grams or to 200 or 600 grams, and changing dosages.
In connectlo~ with Figure 3, the followin~
symbol~ are used: R - Design unit, U - transitlon, overlap, E - lligh volta~e, F - ~hread tension, and D - dosage, ~or oxample, Dl, D2, etc.
As a resul~ of the different con~rolsttime units, with each of the individual parameter~ ~he ~ransi~lons or overlap~, an~ the distances be~ween ~he respec~ive flock pat~ern constructions, differ grea~ly in the pertainlng sections of thread length. Such ~locked e~fect threads do not per~it an undeQ~red pattern to result when the ~hreads are subsequently used to form fabrics or othPr textile goods.
Application~ or the inventively ~locked ~hreads ~o include the upholstery industry, especially for automob~le uphols~ery.
As shown for the exemplary floclced thread 30 of Fl~ure 3, the carrier thread is ~irst ~locked radially an~ densely all the way around, at a thread ~ension F
of 400 ~ and an electr~cal high volt~ge E of 50 RV, with ~lock materlal at a do~age Dl and along a thread g _ ... ..

length 29 11 with flock o~ short fiber3 ln con~ormity wi~h ~he ~lock Pa~tern 21. The carrier thread, after a firs~ chan~e o tl~e electrical hi~h volt~ge ~ to 40 KV, is then flocke~ leas densely, ~o ~ctual flock construc~ion exis~s a~ the overlap locat~on U.
There now follows a flockiLng with fibers pursuant to the flock Pattern 22 and a further high volt~ge change E ~o S0 KV, accompanied in the mean-~ime by a changed thread tension F to 600 g and ~
thereby e~fected irregular ~locking pursuant ~o the flock Pattern 23.
The dosage ls thereupon changed from Dl to D~
accompanied by the high voltage E of 40 KV and re-duced thread tension F, whereupon 1Ocking with longer flber~ yet less density o~cur~ radially along a thread len~th 2~ 12 pursuant to the flock Pattern 26.
The sequenc~ oE ~loeking with different flock constru~tion~ and type of flock,.wlth changing ; parameters relative to the thr~ad tension F, the ; 20 high volta~e E, and the material or ~he dosages D
thereof, continues ln the illustrated sequence o~
Elock Pattern 28, 25, atc.
Th~ design unit R is thus achievedg for example after 1000 ~econds, during continuous production o the flocked eff2ct thread 30, and has a length of approxima~ely 236 me~ers; thls de~gn uni~c la repeated during produetion o~ further length~ o~ the flocked , ~ ~ . ;.

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~6~ 3 effec~ thread de~i~n.
The present invention is, of cour~e, ir~ no way res~ricted to ~he specific disclosure of the specif ication srld drawin~s, bu~ al~o encomp~s~es any modiflcations withirl the ~cope o~ the apperlded claims.

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Claims

THE EMBODIMENTS OF THE INVENTION IN WHICH AN EXCLUSIVE
PROPERTY OR PRIVILEGE IS CLAIMED ARE DEFINED AS FOLLOWS:

1. A flocked thread or yarn produced from a carrier thread and flock material comprising a flocked effect thread having different flock patterns in an arbitrary sequence over specific, selective lengths of said thread.