CN106414826A

CN106414826A - Flocked material and process to produce it

Info

Publication number: CN106414826A
Application number: CN201580024244.6A
Authority: CN
Inventors: C·C·阿米拉蒂; W·卡蒂纳利; D·佐皮特利
Original assignee: Alcantara SpA
Current assignee: Alcantara SpA
Priority date: 2014-05-09
Filing date: 2015-05-07
Publication date: 2017-02-15
Anticipated expiration: 2035-05-07
Also published as: JP6656174B2; EP3140448A1; US20170159215A1; KR20170002428A; EP3140448B1; JP2017515991A; CN106414826B; WO2015170277A1

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

Flocked material and its production method

The purpose of the present invention is to be the initial method preparing flocked material by sea-island bicomponent fibre, and by this The flocked material that method obtains.Can be used for various applications by the obtainable flocked material of this method, for example coating surface and Structure, such as interior of motor vehicles, interior decoration body (wall, sofa, armchair etc.), handbag, suitcase or other accessories, Covering for weapon or chest, music instruments or electronic device, or manufacture carpet and/or rug.

Electrostatic spinning is to obtain raising type effect on all kinds of surfaces (fabric, paper, plastics, metal, timber etc.) Specific process.

Can be on two-dimentional coiled material, such as paper or fabric, and (for example, spectacle-frame, clothes hanger hold in three-dimensional body Device, for the intraware of motor vehicles) on carry out flocking.

In flocking technique, synthetic fibers (it has usually been colored) are applied to the prior specific glue of applying and process On the surface crossed.By electrostatic field, fiber pervasion glue layer, so that themselves is orientated perpendicular to treating raised surfaces.

In order that fiber itself orientation in electrostatic field, they must equably cut, and its length is generally and fiber size Relevant.Fibre diameter is less, and its length will be shorter.

Before flocking, fiber requirements pretreatment is intended to tend in advance make fiber have conductance for " activation ", activation Rate.Usually, using metal salt solution；Because their coated fiber surfaces, they promote fiber to be orientated in electrostatic field.

Before activation step or together with activation step, also can carry out the dyeing of short flannel.

Flocking technique is therefore it is required that following step：

Cutting fibre

Optionally dye

Activated fiber

Glue is applied on bottom cloth layer

The fiber of cutting is laid in the electrostatic seat being rightly orientated fiber

It is dried and possibly make glue be in netted

Use compressed air brushing, to remove excess fibre.

It is very difficult to obtain the flocked material realized using superfine fibre, if this fiber must cut to too short length If, too short length is impossible in industrial technology, and they are highly unstable and be difficult in activating process operation. And, superfine fibre (it can be categorized as microfibre) will run into bigger difficulty, thus jeopardizing plant in penetration adhesive bottom cloth layer The wearability of down material.

However, having solved the problems, such as in industrial department using very chopped fiber for flocked surface.It is true that it is long Degree be restricted and electrostatic flocking method used as discussed above the flocked material being initial preparation by sea-island bicomponent fibre Industrial department has been known.Flocked fiber and after glue is dried followed by substrate, in sea-island fiber Sea component generally removes by using the solvent of such as trichloro ethylene or alkaline solution etc.

For example, disclose the preparation method of a flocked material in the embodiment 15 and 16 of patent no.GB1300268, It is made up of the base fabric of the nylon taffeta manufacture being coated with polyurethane binder, by electrostatic on described polyurethane binder Technique flocking " fabric of island-in-sea type " composite fibre；Island component in composite fibre is nylon 6,6, and sea component is polystyrene.Quiet Before galvanic process, cutting fibre at the length of 3mm, and with sodium silicate and ammonium chloride pretreatment.The taffeta of flocking is dried, so It is immersed at a temperature of 50-60 DEG C afterwards in trichloro ethylene bath, so that sea component is dissolved.Finally, simultaneously standing and drying is washed with methanol. United States Patent (USP) no.4574018 discloses the method preparing flocked material, wherein passes through electrostatic operation, with binding agent (for example, Polyurethane binder) the short sea of flocking-island bicomponent fibre in all kinds of base fabric that cover.Binding agent reticulates it at high temperature Afterwards, by dipping in trichloro ethylene or in 3%NaOH solution, part removes sea component.

By using " sea-island " fiber type in prior art, the operability solving the microfibre producing flocked material is asked Topic.Activated fiber, and be layered on bottom cloth layer in the front layer removing sea component.

However, the major defect of the method for prior art is related to the removal step of sea component.It is true that applicant sends out Existing, when using during with those similar solvents well known in the prior art, such as alkaline NaOH solution, sea component is gone completely Except that is to say, that the even part below adhesive phase is completely removed.With regard to this point, referring to Figure 1A, it shows makes Result with the solution containing solvent or those the similar removal steps even adopting in alkaline solution, with prior art. Numerical value 1 represents the bottom cloth layer of flocked fiber, and can have all kinds, and numerical value 2 represented before flocking, was applied to bottom cloth layer (various types of) adhesive phase on 1.In electrostatic spinning process, it is cut appropriate length in advance and uses inorganic salt The sea of pretreatment-island fiber (numerical value 3 represents that island component and numerical value 4 represent sea component) is vertical orientated with respect to bottom cloth layer, and it The given part of length permeate in adhesive phase.

Once binding agent reticulates, if flocked material by organic solvent (such as trichloro ethylene) or alkalescence or Impregnate in acid solution or process and remove sea component, then run into the problem shown in Figure 1B：Sea component, or even in binding agent The part that layer is inserted into is completely removed.The reason this is the subject matter with the structural resistance of material and intensity, because Substantially absent space is produced between island component in binding agent and undissolved fiber.Therefore, fiber tends to from substrate Depart from, because they no longer " impregnate " in adhesive phase, thus leading to flocked material " peeling ".The reality carrying out referring to applicant Apply example 7.0, wherein pass through to impregnate flocked material in the bath containing 8%NaOH, be removed step.Result is whole removal sea Component, in addition in binding agent dipping partly in, result residual fiber be no longer firmly anchored on bottom cloth layer, and with In next staining procedure of disperse dyes in jet dyeing machine, at a temperature of 120 DEG C, it can be readily removable by abrasion, And lead to reduce, microfibre removes from adhesive phase completely.

By developing the method for the present invention, applicant solves the sea component dissolving step being related to run in prior art This shortcoming.

The present invention relates to the method preparing flocked material by the bicomponent fibre of sea-island, the method includes using viscosity Scope is 300mPa.s to 100.000mPa.s, the preferably remover of 400 to 64.000mPa.s, carries out selectivity and removes sea component Step.Remover preferably has the paste form of range of viscosities indicated above, and after fibre flocking, by electrostatic work Skill dry adhesion oxidant layer, dissipate on fiber upper berth.

Remover leads to permeate in adhesive phase because of its viscosity, wherein sea-island fiber partial immersion and therefore not The sea component of the part of dipping in adhesive phase can be affected.Therefore, removing sea component is selective process, and so that can Obtain the flocked material that good wearability and anti-fiber removal are provided, this is known with industrial department by sea-island fiber to be Initiate acquisition and shortcoming is because abrasion provides the implanted article difference of the anti-fiber removal of difference, because those identical fibers do not have It is firmly anchored on adhesive phase.

In a preferred embodiment of the present methods, corrosion can be avoided using further step in lower fiber ends portion Sea component in point, and more even ground in adhesive phase dipping partly in sea component；This measure is, is applying to go Before agent, by using being dissipated by paving, the removable resin for example being applied by aerial spraying, to protect mentioned above Fiber part.Removable resin can have and remover identical formula, but (caustic can be severe not to have caustic Property reagent, acid or selective solvent).For example, removable resin usually can be by the aqueous solution of poly-vinyl alcohol solution or thickening agent Composition, its sea component of contacting of their preferred pairs is compatible.The viscosity of removable resin is more than corrosivity paste, to prevent Permeate between them.

The removable amount of resin being deposited is controlled to be easy to more subtly adjust fiber part to be dissolved.

Referring now to Fig. 2 it is also important to note that the selective removal step of the present invention makes can obtain wherein never in adhesive phase Partly middle part removes the flocked material of sea component 4 to the fiber of interior dipping.Which constitute the flocked material of the present invention and existing skill Significant structural difference between the flocked material of art, because can be by comparing Fig. 2 and Figure 1B, or Fig. 5 and 6 finds out.

The present invention therefore further relates to the flocked material that can obtain by method described herein, wherein never viscous In mixture layer, partly middle part removes the sea component (Fig. 2) in sea-island bicomponent fibre to the fiber of dipping.

Keep undissolved sea component part also so that fiber more local positioning can be kept to plant outside adhesive phase At floss point, and this produces the product (feeling that fine hair is more uniform) with more attractive outward appearance.

Below referring also to accompanying drawing it should explain the present invention, wherein：

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

- Figure 1B shows after the solvent solution with prior art and/or alkaline solution remove, and has the double group in sea-island Divide the flocked material of fiber；

After-Fig. 2 shows by the remover selective removal sea component of the present invention, the flocked material of the present invention；

- Fig. 3 is SEM (scanning electron microscope) image of the flocked material of the present invention before removing sea component；

- Fig. 4 is the SEM image of flocked material after selective surface removes sea component；

- Fig. 5 is the details from Fig. 4, and wherein complete at the flocked fiber bottom occurring structure is obvious, and sea component Pass through selective dissolution to remove from upper part；

- Fig. 6 is by impregnating in bathing in NaOH, after non-limiting removal sea component, the SEM image of flocked material；

- Fig. 7 and 8 is the details from Fig. 6, and microfibre that sea component eliminate wherein can be observed not to be had at some points Anchor on glue layer；Result is especially apparent on surface (Fig. 8), wherein can observe shrinkage pool on glue layer, and this is in sea Lose what the fiber of its cohesive stayed after component dissolving.

The present invention relates to being the initial method preparing flocked material by sea-island bicomponent fibre, the method includes following steps Suddenly：

Spinning sea-island bicomponent fibre；

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, preferably use disperse dyeing fiber；

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

Binding agent is applied on the bottom cloth layer being made up of fabric or supatex fabric；

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

Dry adhesive is simultaneously possibly allowed to into net；

Optionally remove excess fibre；

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

It is 300mPa.s to 100.000mPa.s by applying range of viscosities, the preferably removal of 400 to 64.000mPa.s Agent, selectivity part remove the sea component in fiber；

Optionally enter to exercise flocked material dyeing.

As reported in embodiment 8.0, the viscosity of measurement remover and each other fluid, unless otherwise stated.

According to prior art, carry out the spinning of sea-island bicomponent fibre, the method include feeding two kinds of pure polymer or The mixture of person's two kinds of polymer is to spinneret, so that one of two kinds of polymer component (" extra large ") surrounds formation various " islands " completely The other components being made up of various polymer filaments (preferably 16 circular and isodiametric microfilaments).With regard to this point, island group Divide and be selected from：Modified poly ester, cationic polyester, nylon or other kinds of polyamide (PA), polyethylene (PE), polypropylene (PP), polytrimethylene's ester (PTT), polybutylene terephthalate (PBT), polyethylene terephthalate (PET), the latter is particularly preferred.

Sea component can be with solution dyeing that is to say, that before spinning, and that adds in spinning process is specific Toner or the lower dyeing of pigment auxiliary.

Sea component is selected from：Nylon 6,6, has co-poly ester (the so-called co- of solvable different content monomer in alkali PES or TLAS), it is inserted into the improved polyalkene of polar monomer in chain, wherein polar monomer is preferably selected from vinyl alcohol, vinyl acetate Ester, or maleic anhydride (so-called co-PS).Depending on solvable content of monomer in alkali, can be by adding aqueous slkali (low list Body burden) or also can be readily removable co-PES and co-PS in the hot water (high content of monomer).

Both Hai Yu island components can be used in mixed way with additional component, and described additional group is selected from the nothing for island component Machine pigment, and to sea component incompatible polymers.In the middle of the additional inorganic pigment for island component, particularly preferred charcoal Black.This makes even with adding only a small amount of coloring agent, achievable shade of color scope from ash to black coloring " fine hair " and Prove the coloring of especially uv-resistant degraded.

In the middle of the additional incompatible component for sea component, it is especially preferred for use in the polyvinyl alcohol of co-PES and is used for The molecular weight of co-PS is the Polyethylene Glycol of 10,000 to 20,000g/mol.

In especially preferred embodiment, island component that the fiber that used in the present invention is made up of PET and by PA The sea component composition that 6,6 or co-PES make.

In bicomponent fibre, island component makes it possible to by spinneret quickly and efficiently two kinds of spinning to the ratio of sea component Component.The ratio in described island/sea range preferably from 20/80 to 80/20, more preferably scope is 50/50 to 80/20.Referring to some Part, fiber shows that scope is 8 to 96, preferably 8 to 40 island group component.

After spinning process, drawing process is carried out to such bicomponent fibre obtaining, so as to make its fiber number from The scope of the scope of 6.5 to 19.4dtex, preferably 9.2 to 17dtex is reduced to the fiber number that scope is 3 to 5dtex.Preferably employ Generally in the range of 4-1, preferably in the range of 3-1, more preferably in the range of 2.5-1, the draw ratio of change, is stretched.

After stretching step, collect, in pond (bin), " tow " so obtaining, and experience cutting of continuous fiber Cut the length for 0.1mm to 3.0mm for the scope.The length range of fiber is preferably 0.3 to 1.25mm.

Activation step is carried out to cutting fibre, preferably by water-soluble containing inorganic salt, such as aluminum sulfate and/or calcium chloride In bath of liquid, dipping is activated.The fiber being cut and having activated is defined as " short flannel ".The length/diameter of short flannel must than scope Must be 10:1 to 100:1, preferably 20:1 to 50:1.

This activation step makes cutting fibre more sensitive to the electrostatic field applying in electrostatic precipitation step process, and And then fiber can be more accurately orientated on the direction vertical with substrate and adhesive phase.

Preferably, stand short flannel, be dried, and after drying, it have that scope is starting weight 0.5% to 2% inorganic salt content.

The bottom cloth layer that adhesive phase applies thereon can be positive intertexture or braided fabric in polyurethane-base body, or Person's supatex fabric, for example spunbond nonwoven nylon or polypropylene fabric, or non-woven elastic compound fabric (hereafter identifies For " EVN base fabric "), such as polyester microfiber.Bottom cloth layer indicated above can use as former state or they can experience surface coating Process, to reduce its porosity, this will change the thickness of the binding agent being applied from the teeth outwards；Surface coating process also can accelerate Binding agent is fixed on the surface of bottom cloth layer.Or, bottom cloth layer can be by polyolefin, for example, made with plasma pretreatment The thin film that surface hydrophilic and the polypropylene that therefore can easily be wetted by adhesive manufacture, or it can be paper.Bottom cloth layer Unit Weight scope is 40g/m²To 500g/m², preferably 80g/m²To 350g/m², and thickness range be 0.10mm to 2.0mm, excellent Select 0.20mm to 1.10mm.

The binding agent being placed on bottom cloth layer is preferably selected from：Polyurethane binder (in solvent or water), water-based acrylic compounds Binding agent, and silicone adhesive；Particularly preferably silicone adhesive and polyurethane binder.

Can accelerate the pigment-of bicomponent fibre bonding and/or additive can be added in binding agent, in order that obtaining color Adjust special final flocked material, preferably can accelerate subsequent flocking technique conducting pigment (make bottom cloth layer conductive so that can in With the electric charge of conveying from short flannel and and then keep the applied electrostatic field constant).These additives (also referred to as adhesion promotion Agent) be have the functional group (or functional group reactionses with the latter) compatible with binding agent and with bicomponent fibre in sea component The molecule of compatible functional group's (or functional group reactionses with the latter), this makes it will penetrate in glue.Can be by coating The whole surface (all applying) of bottom cloth layer or its only only a part (composition applying) common 0.05mm to 0.50mm, preferably The thickness of 0.10mm to 0.35mm, thus apply adhesive phase.In the case that composition applies, short flannel is only stably deposited on Have in the region of binding agent, thus realizing pattern in base fabric layer surface.

Electrostatic spinning short flannel is 60% to 90% preferably having scope over the binder layer, preferably 70% to 80% control Occur in the environment of system and constant level humidity.The electrostatic field being applied range preferably from 20 to 50kV, preferably 20 to 40kV.

In the case of Patterned deposition, the short flannel amount scope being deposited is 50 to 250g/cm², preferably 140 to 190g/cm², The area existing in it with respect to binding agent.

The Denier range of sea-island fiber is 1.5dtex to 10dtex, and preferred scope is 3.0dtex to 7dtex.

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

Short velvet fiber infiltrates into the depth that scope is 40 microns of whole thickness arriving adhesive phase in adhesive phase, and this takes Certainly in the binding agent being used, its viscosity and the electric field being applied.

Once completing to deposit, then this material is placed in baking oven, simultaneously fixed adhesive scope is 2 to 10 minutes for hardening, excellent Select the time period of 3 to 5 minutes.Oven temperature ranges preferably from 110 DEG C to 200 DEG C, preferably 120 to 190 DEG C.

By remover applied on flocked fiber, preferably paste form and there is the removal of indication viscosity above herein , there is the selective removal of sea component in agent.Remover includes alkali, such as NaOH, or acid, such as formic acid, they preferably with polysaccharide, The polysaccharide of preferably such as xanthan gum etc mixes.Or, remover may also comprise the selective solvent for sea component.It is suitable for The example of the solvent of dissolving co-PS- base sea component is by halogenated solvent, such as trichloro ethylene, perchloroethylene, chloroform, hydrocarbon solvent, example As toluene, dimethylbenzene, ethylbenzene, hexamethylene, and other polar solvents, such as Ν, Ν-dimethylformamide, acetone, dioxane, Oxolane, butanone, acetonitrile, dimethyl sulfoxide, methanol and ethanol composition.

The concentration range of acid or alkali can be 1.5% to 20wt%, preferably 4% to 18wt%.Polysaccharide, and especially xanthan gum Preferably it is included in paste with the consumption that scope is 0.5% to 7wt%.

Applying amount ranges on flocked fiber is 80 to 150g/m²Remover.

In a preferred embodiment of the invention, before applying remover, can apply to can remove resin by coating, make Be in the end portion of fiber and more even ground impregnate within the adhesive layer partly interior avoid sea component corrosion enter one The measure of step.Removable resin can have and remover identical formula, but (described caustic can be severe not to have caustic Property reagent, acid or selective solvent).For example, removable resin usually can be by the water of poly-vinyl alcohol solution or thickening agent Solution composition, the sea component that they preferably contact with it is compatible.The viscosity of removable resin is preferably greater than the viscous of remover Degree, to prevent infiltration between them.The range of viscosities of removable resin is preferably 1.000mPa.s to 150.000mPa.s.

Control the removable amount of resin being deposited to provide and more subtly adjust short flannel part to be dissolved.

After applying remover, available saturated steam flowing, with radio frequency, with this material of microwave treatment, or with hot This material of air heat treatment, to accelerate sea component dissolving.Immediately this optional process (it is sustainable 5 to 15 minutes) After (in the case of heat treatment, at a temperature of 70-100 DEG C), can be by washing with water, by remover with any can remove Resin removes.In such a way, selectivity and part remove sea component and bring：Only it is not impregnated with binding agent in the layer one Point sea component is removed, and in adhesive phase the part of dipping retain and allow to maintain securely grappling short velvet fiber to base On bottom (referring to Fig. 3-5, they show the space that there is not sky between island fiber and adhesive phase).Change according to this operation Logical scheme, after applying remover, with saturated steam flowing, the material that radio frequency or microwave treatment are crossed in baking oven further With hot air treatment, its objective is before washing with water, protective barrier layer is produced on the surface of remover.

Flocked material can be wound in such a way, such as it safely to be transported washing line, and do not jeopardize The quality of final flocked material.The few fibers that experienced sea component removal manifest the microfibre constituting island component, and they are each From have scope be 0.04dtex to 0.30dtex fiber number.In such a way, flocked material is more resistant to possible abrasion, institute State abrasion and can cause fiber removal, and prove the corrosion fiber based on this part, microfibre more local positioning at flocking point, Thus producing the product (feeling that fine hair is more uniform) with more attractive outward appearance.And, also can be in jet dyeing machine Dyeing flocked material, then removes excess dye, and does not lose the risk of flocked fiber.Or, in order to produce, there is no speckle The flocked material of point (flat outward) effect, it can be for clothing dyeing or the machine more generally for " open width dyeing " Interior dyeing, described machine allows especially exquisite material pressurization dyeing and they is not placed in (material under serious mechanical stress Material keeps opening to scatter and do not form vertical or horizontal folding line on its whole width).

Therefore, it is different from material well known in the prior art using the flocked material that the method for the present invention obtains to be, Between fiber and adhesive phase, it does not show the space of sky, and described empty space can be caused existing in subsequent staining procedure There is the resistance of technologic material difference, and usually poor wearability.Compared with the flocked material of prior art, the flocking material of the present invention Material itself presents as finer material and provides durability bigger as time go on.

Therefore, the purpose of the present invention is using the obtainable flocked material of the method for the present invention.

The flocked material of the present invention includes：

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

- it is applied to adhesive phase on bottom cloth layer；

- fibrous layer containing multiple seas-island fiber, described fibrous layer is preferably upwardly oriented in the side vertical with bottom cloth layer, portion Divide and be immersed in adhesive phase, and sea component is still present in the part fiber of dipping in adhesive phase.Sea component phase In the anti-few fibers being not present in wholly or in part exposing from adhesive phase.

Adhesive phase is present in the whole surface of bottom cloth layer or (composition flocking) in its part.

The thickness range of adhesive phase is 0.05mm to 0.50mm, preferably 0.10mm to 0.35mm.

Include multiple seas-island fiber in adhesive phase, its depth bounds is the whole thickness from 40 microns to adhesive phase Degree.

Island component in sea-island fiber has the fiber number that scope is 0.04 to 0.30dtex.

Can be substituted using the flocked material of the present invention in ornaments and consumer electronics and use fabric at present in motor vehicles, non-woven Fabric or all parts of leather coating.

Especially, the flocked material of the present invention can be used for various applications, such as coating surface and structure, such as motor vehicles Inside, upholstery object (wall, sofa, armchair etc.), handbag, suitcase or other accessories, for the covering of weapon Thing or chest, music instruments or electronic device, or manufacture carpet and/or rug.

The embodiment of embodiment and comparative example

Embodiment 0.1 has the white flock -1.0mm of PET/TLAS bicomponent fibre

Realize sea-island bicomponent fibre short flannel, in PET, wherein realize island component, and (solvable in alkali in TLAS Copolyesters) in realize sea component.It is 57 in this fiber lagoon island component to the ratio of sea component:43.

Fiber part shows 16 circular and isodiametric PET microfilaments.

By subsequent stretching, collection tow in case, and cut the operation of continuous sea-island fiber to Len req, obtain Obtain short flannel.

The feature of fiber and short flannel is as described below：

1 draw ratio 2.5/1

2- fiber number 4.3dtex

3- length 1.0mm

Impregnate by the water-soluble bath of liquid of aluminum sulfate, so defined short flannel experience activation；After drying, in short flannel Interior sulphuric acid aluminium content is equal to the 1% of starting weight.

The short flannel so realized is referred to as line (Thread) 1.

Embodiment 0.1.1 has the black short flannel of (PET+ disperse dyes)/TLAS bicomponent fibre

Using the same processes being used with line 1, realize short flannel, change is according to prior art, before activating process, Being used in scattered black dyes in water at a temperature of 120 DEG C makes flock coloration.

With postactivated, 1wt% aluminum sulfate is left on short flannel.The short flannel so realized is referred to as line 2.

Embodiment 0.2 has the black short flannel -0.3mm of the PET/TLAS bicomponent fibre of solution-dyeing

Realize sea-island bicomponent fibre short flannel, wherein in the PET with the additional white carbon black that content is 7%, realize island group Point, and realize sea component in TLAS (solvable copolyesters in alkali).It is 57 in this fiber lagoon island component to the ratio of sea component: 43.

Fiber part shows 16 circular and isodiametric PET microfilaments.

By subsequent stretching, the operation collected tow in case and cut continuously sea-island fiber to Len req, obtain Short flannel.

The feature of fiber and short flannel is as described below：

1 draw ratio 2.5/1

2- fiber number 4.3dtex

3- length 0.3mm

The short flannel so realized is referred to as line 3.

Embodiment 0.3 has the white flock -0.5mm of PET/PA6.6 bicomponent fibre

Realize sea-island bicomponent fibre short flannel, in PET, wherein realize island component, and in PA6, in 6, realize sea component. It is 57 in this fiber lagoon island component to the ratio of sea component:43.

Fiber part shows 16 circular and isodiametric PET microfilaments.

The feature of fiber and short flannel is as described below：

1 draw ratio 3.0/1

2- fiber number 3.8dtex

3- length 0.5mm

The short flannel so realized is referred to as line 4.

Embodiment 0.4 has the white flock -1.0mm of PET/HWS bicomponent fibre

Realize sea-island bicomponent fibre short flannel, in PET, wherein realize island component, and realize extra large group in HWS polyester Point.It is 57 in this fiber lagoon island component to the ratio of sea component:43.

Fiber part shows 16 circular and isodiametric PET microfilaments.

The feature of fiber and short flannel is as described below：

1 draw ratio 2.5/1

2- fiber number 4.3dtex

3- length 1.0mm

By in the presence of 0.5% calcium chloride, impregnate in the water-soluble bath of liquid of aluminum sulfate, so defined short flannel experience is lived Change；After drying, the weightening of aluminum short flannel experience 1%.

The short flannel so realized is referred to as line 5.

Embodiment 0.5 has the white flock -1.0mm A type of PET/TLAS bicomponent fibre

Realize sea-island bicomponent fibre short flannel, and it is similar to being reported in embodiment 0.1, except that real The bicomponent fibre that existing short flannel is used has following characteristics：

1 total drawing ratio 3.5/1

2- fiber number 3.1dtex

3- length 0.5mm

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

5- fiber part contains 36 circular and isodiametric PET microfilaments.

By in the presence of 0.5% calcium chloride, impregnate in the water-soluble bath of liquid of aluminum sulfate, the short flannel experience so obtaining is lived Change；After drying, the weightening of aluminum short flannel experience 1%.

The short flannel so realized is referred to as line 6.

Embodiment 1.0EVN base fabric-silicone adhesive -1.0mm

Realize in the composite being made up of the PET microfibre with 30% polyurethane matrix and thickness is 1.10mm Bottom cloth layer on apply thickness be bi-component ALAPATEC 30340 adhesive phase that 0.2mm and viscosity are 50.000mPa.s (by 100% silicone adhesive of CHT supply).

Subsequently electrostatic mechanical flocking, so that deposition is expressed as the short flannel of line 1；It is micro- that short flannel averagely penetrates in glue layer 60 Rice.

There is flocking in having in 65% control and the environment of consistent humidity level under the electrostatic field being exposed to 30kV, So that 144g/cm can be deposited under the line rate of 3.0m/min²Short flannel.

Place, in convection oven, the intermediate products so determining, become net 4 minutes at 150 DEG C, and be referred to as FK 01.0.

Embodiment 1.1EVN base fabric-silicone adhesive -1.0mm

Using bi-component TUBICOAT PROTECT LSR binding agent (100% silicone adhesive supplied by CHT), realize and FK The intermediate products that intermediate products determined by 01.0 (embodiment 1.0) are similar to.This glue contains black pigment and viscosity is 35.000mPa.s, viscosity is less than ALPATEC 30340, and its degree makes the infiltration being expressed as the short flannel of line 1 be equal to glue 0.2mm thickness, is contacted with base fabric layer surface with therefore short flannel.

This intermediate products is referred to as FK 01.1.

Embodiment 1.2EVN base fabric-polyurethane glue -1.0mm

Using bi-component polyester based polyurethanes glue (it can be by being heated into net), realize and FK01.0 (embodiment 1.0) Determined by intermediate products be similar to intermediate products.This glue contains black pigment and viscosity is 30.000mPa.s, and viscosity is less than Embodiment above, the infiltration that its degree makes to be expressed as the short flannel of line 1 is equal to the 0.2mm thickness of glue, and therefore short flannel with Base fabric layer surface contacts.

Place, in convection oven, the intermediate products so determining, become net 4 minutes at 150 DEG C, and be referred to as FK 01.2.

Embodiment 1.3EVN base fabric-polyurethane glue -0.5mm

Using the short flannel being expressed as line 6, rather than line 1, and aromatics bi-component polyester based polyurethanes glue (it can by plus Heat becomes net), realize and the similar intermediate products of intermediate products determined by FK 01.0 (embodiment 1.0).The viscosity of this glue is 29.000mPa.s, and the infiltration being expressed as the short flannel of line 6 is equal to the 0.2mm thickness of glue, and therefore short flannel and base fabric layer surface Contact.

Place, in convection oven, the intermediate products so determining, become net 4 minutes at 150 DEG C, and be referred to as FK 01.3.

Silicone adhesive-the 1.0mm of embodiment 2.0EVN base fabric-have adhesion promotor

Using bi-component TUBICOAT containing the special adhesion promotor of black pigment and TLAS in it PROTECT LSR binding agent (100% silicone adhesive supplied by CHT), realize with FK 01.1 (embodiment 1.1) determined by Between product be similar to intermediate products.The viscosity of this glue be 35.000mPa.s, and be expressed as line 3 short flannel infiltration be equal to glue The 0.2mm thickness (therefore short flannel is contacted with base fabric layer surface) of water.

This intermediate products is referred to as FK 02.0.

Embodiment 3.0 fabric substrate-acrylic adhesives -1.0mm

It is 82g/m in Unit Weight²100%PET cloth bottom cloth layer on place thickness be 0.15mm TUBVINIL 401H adhesive phase (the water-borne acrylic type base fabric supplied by CHT), and electrostatic spinning is carried out using the short flannel being expressed as line 2.

Planting having in 65% control and the environment of consistent humidity level under the electrostatic field being exposed to 30kV Floss, so that 165g/cm can be deposited under the line rate of 3.5m/min²Short flannel.

Subsequently product is placed in 3 minutes in the convection oven at 170 DEG C, is dried and fixed adhesive.

Short flannel is penetrated into and reaches the point being contacted with following tissue layer in binding agent.

This intermediate products is referred to as FK 03.0.

The removable base fabric of embodiment 4.0-silicone adhesive-1.0mm

The Teflon strip have surface roughness is placed containing black pigment (referring to embodiment 1.1) and thickness is The bi-component TUBICOAT PROTECT LSR adhesive phase (100% silicone adhesive supplied by CHT) of 0.4mm.

This is followed by with being expressed as the short flannel electrostatic spinning of line 1.

Planting having in 65% control and the environment of consistent humidity level under the electrostatic field being exposed to 40kV Floss, so that 210g/cm can be deposited under the line rate of 2.2m/min²Short flannel.

Subsequently product is placed in 6 minutes in the convection oven at 140 DEG C, is dried and fixed adhesive.

Short flannel penetrates into the point reaching in binding agent with following film contacts.

This intermediate products is referred to as FK 04.0.

Embodiment 4.1PP base fabric-polyurethane glue -1.0mm

The thickness making surface hydrophilic with plasma pretreatment be 120 microns PP thin film on place contain black face Material and aromatics bi-component polyester based polyurethanes glue layer (it can be by being heated into net) for 0.4mm for the thickness.

Subsequently product is placed in 3 minutes in the convection oven at 140 DEG C, is dried and fixed adhesive.

This intermediate products is referred to as FK 04.1.

The spunbond base fabric of embodiment 5.0-silicone adhesive-PA 6,6-0.5mm

It is 90g/m in Unit Weight²Spunbond PP fabric on place thickness be 0.2mm TUBICOAT PROTECT LSR Two component adhesive layer (100% silicone adhesive supplied by CHT).

This is followed by with being expressed as the short flannel electrostatic spinning of line 4.

Planting having in 80% control and the environment of consistent humidity level under the electrostatic field being exposed to 22kV Floss, so that 191g/cm can be deposited under the line rate of 2.5m/min²Short flannel.

Subsequently product is placed in 5 minutes in the convection oven at 150 DEG C, is dried and fixed adhesive.

Short flannel penetrates into 150 microns in binding agent.

This intermediate products is referred to as FK 05.0.

Embodiment 6.0 fabric substrate-PUD glue-HWS-1.0mm

It is 82g/m in Unit Weight²100%PET cloth on place thickness be 0.2mm bi-component TUBICOAT PROTECT LSR adhesive phase (100% silicone adhesive supplied by CHT).

This is followed by with being expressed as the short flannel electrostatic spinning of line 5.

Planting having in 75% control and the environment of consistent humidity level under the electrostatic field being exposed to 25kV Floss, so that 150g/cm can be deposited under the line rate of 3.0m/min²Short flannel.

Subsequently product is placed in 4 minutes in the convection oven at 150 DEG C, is dried and fixed adhesive.

Short flannel penetrates into 150 microns in binding agent.

This intermediate products is referred to as FK 06.0.

Dissolving+the dyeing (comparative example) in NaOH bathes of embodiment 7.0-

The intermediate products FK as sea component in short flannel is washed containing TLAS in the bath containing 8%NaOH (w/w) In 01.0, FK 01.1, FK 01.2, FK 02.0, FK 03.0, FK 04.0 and FK 04.1, containing 8% (w/w) NaOH's In bath, wash 15 minutes at 80 DEG C, then wash in cold water, be placed in being dried in convection oven.

It will therefore be apparent that short flannel departs from from glue layer in intermediate products FK 01.0 and FK 03.0, thus staying wherein There is the amber exposed region of only glue and substrate.

In intermediate products FK 01.1, FK 01.2, FK 02.0, FK 04.0 and FK 0.041, short flannel is retained in product On surface, and sea component is completely removed, including the part of dipping in glue；Therefore, adhesive surface is limited to Only in the base fabric of microfibre.For this reason, just in subsequent staining procedure, in the jet dyeing machine using disperse dyes, For at a temperature of 120 DEG C, microfibre implanted article tends to easily remove by abrasion, and leads to reduce, and microfibre is complete Remove from glue.

Embodiment 8.0 uses NaOH paste dissolving+dyeing in atmosphere

Using scraper, in 100g/m²Speed under, the intermediate products FK of sea component in containing TLAS as short flannel On the short flannel side of 01.0, FK 01.1, FK 01.2, FK 02.0, FK 03.0, FK 04.0 and FK 04.1, distribution thickening NaOH preparation (remover).

(its 16% is made up of with 0.5% by the DENIMCOL SPEC FTL (Huang supplied by CHT corrosivity paste NaOH Xanthan polysaccharide) constitute) there is pseudo plastic behaviour and the viscosity under applying condition is about 400mPa.s.

Using the Brookfield DVIII rotating cylinder viscometer with little sample adapter accessory and SC4-28 spindle, At 20 DEG C, (be equivalent to 5s in the speed of about 5rpm^-1Shear rate) under, measure viscosity.

The intermediate products being coated with corrosivity paste heat treatment 10 minutes at 80 DEG C in baking oven, then wash in cold water Wash and be placed in being dried in convection oven.

Sem analysis show sea component, and only surface is affected (SEM image of sample F K 01.1 in figure 3).

Embodiment 9.0- uses NaOH paste to dissolve in steam

The intermediate products FK 01.0 of sea component, FK 01.1, FK 01.2, FK 01.3 in containing TLAS as short flannel, On the short flannel side of FK 02.0, FK 04.0 and FK 04.1, in 100g/m²Speed under, distribution thickening NaOH preparation (remove Agent).

(its 4% is made up of with 2% by the DENIMCOL SPEC FTL (xanthan supplied by CHT corrosivity paste NaOH Glue polysaccharide) constitute) there is pseudo plastic behaviour and the viscosity under applying condition is about 28.000mPa.s.

Use saturated vapor stream process with the intermediate products of corrosivity paste coating 3 minutes under atmospheric pressure, then in cold water Middle washing is placed in being dried in convection oven.

In intermediate products FK 01.1, FK 01.2, FK 01.3, FK 02.0, FK 04.0 and FK 04.1, with corrosion Property paste contact the partly interior sea component that is not impregnated with of short flannel be removed completely, thus exposing microfibre, and other parts are still There is microfibre property and also assure that fibre bundle is adhered on bottom cloth layer (Figure 4 and 5, the SEM image of FK 01.1 sample).

Intermediate products FK 01.0 occurs lacking the patch (patch) of short flannel from the teeth outwards, this is because short flannel is in silicone adhesive Caused by interior infiltration is not enough.

Intermediate products FK 03.0 shows short flannel and glue loss on most of surfaces.

Then, in the jet dyeing machine with disperse dyes, dyeed at 120 DEG C, and subsequent reduction only in Between product F K01.1, the excess dye on FK 01.2, FK 01.3, FK 02.0, FK04.0 and FK 04.1.

Embodiment 9.1- uses NaOH paste dissolving+open width dyeing in steam

As described in embodiment 9.0, remove intermediate products FK 01.1, FK 01.2, FK 01.3, FK 02.0, FK 04.0 and FK 04.1 sea component.Then the disperse dyes in water are used, by the dye for open width dyeing at 120 DEG C Color machine, makes intermediate products dye, and subsequently reduces excess dye.In such a way, the flocked material of dyeing, its feature are obtained It is more all even uniform outward appearance.

Embodiment 10.0 binary coating and steam

By gas scraper, applying viscosity on intermediate products FK 01.1, FK 01.2, FK 02.0 and FK 04.0 is PVA preparation in the water of 54.000mPa.s, its objective is only to apply at the base fabric of flocked fiber 30g/m²Solution layer.

Subsequently, by cylindrical cutter, in 100g/m²Speed under, on the flocking side of intermediate products FK 01.1 distribute The NaOH preparation of thickening.(its 4% is made up of with 2% by DENIMCOL SPEC FTL corrosivity paste (remover) NaOH (xanthan gum polysaccharide supplied by CHT) is constituted) there is pseudo plastic behaviour and the viscosity under applying condition is about 28.000mPa.s.

Under atmospheric pressure, with intermediate products FK01.1, the FK 01.2 of the coating of saturated vapor stream process corrosivity paste, FK 02.0 and FK 04.0 3 minutes, then washs in cold water, is placed in being dried in convection oven.

Sea component prove only flocked fiber top part that is to say, that exposed length about 1/5 in hydrolysis.

Embodiment 11.0- dissolves and RF-HWS in water

By scraper, in 120g/m²Speed under, on the flocking side of intermediate products FK 06.0 distribute 1.5% The aqueous solution of DENIMCOL SPEC FTL (xanthan gum polysaccharide supplied by CHT).Under applying condition, the viscosity of solution is about 20.000mPa.s.

Then adopt electric potential difference to be equal to the parallel electric field of 1.0kV, radio frequency is carried out to this intermediate products, then washes in cold water Wash.

This impregnates 8 minutes followed by a temperature of 50 DEG C in 10% calcium chloride solution, in order that by not hard Wash with water in the case of salt dissolving, and by being dried in convection oven, so that residual sea component (HWS) is impregnated in silicone adhesive Short flannel is partly interior soluble.

Intermediate products keep complete, because it passes through next staining procedure for using in jet dyeing machine at 120 DEG C Disperse dyeing, and reduce, to eliminate excess dye.

Comparative example 12.0- dissolves and MW (microwave) in NaOH

By scraper, in 100g/m²Speed under, on the short flannel side of intermediate products FK 01.1, distribution thickening NaOH Preparation, is then equal in the microwave oven of 5KW in power and heats 2 minutes, washs in cold soft water, and dry in convection oven Dry.

Corrosivity paste (remover) (its 1.0% be made up of NaOH with 2.0% by DENIMCOL SPEC FTL (by The xanthan gum polysaccharide of CHT supply) constitute) there is pseudo plastic behaviour and the viscosity under applying condition is about 2.000mPa.s.

Followed by after microwave treatment, the partly interior sea component of the fiber that manifests from glue proves to be completely removed, Thus exposing microfibre, simultaneously it be retained in anchor to partly interior on bottom cloth layer.Then contaminate in the injection using disperse dyes In color machine, dyeed at 120 DEG C, subsequently reduced excess dye.

Claims

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；

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.