JPH05154033A - Flocked blanket and its manufacturing method - Google Patents

Abstract

PURPOSE:To omit complicated steps for simplifying the flocking process by a method wherein a matrix which is reinforced with mesh cloths undergoes electrostatic flocking process on both sides at the same time at the beginning stage of foaming process of polyurethane foam. CONSTITUTION:Raw mix liquid 20 is spouted between mesh cloths 24 and 25 through a slit-shaped nozzle 21. An electrostatic high-voltage is applied to mesh- like electrodes 27 and 29, and both sides of the mesh cloths 24 and 25, between which prepared polyurethane raw liquid at the beginning stage of foaming is sandwiched, is flocked to turn them into semi-product. The foamed product is discharged as product 43 by a roll 30 located above after pre-dried. Excess piles are sucked and collected by suction nozzles 41 and 42, and supplied to separating feeders 26 and 28. The product undergoes post-treatments such as rubbing, brushing and other processes. Therefore, complicated processes such as polyurethane foam milling process, mesh cloth binding process, adhesive coating process on both sides and others can be omitted. A blanket having an excellent air-permeability can be offered with a simple production process.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a blanket by a flocking process, and more specifically, a pile of nylon or the like is planted by using an electrostatic flocking method with a foamed elastic body such as polyurethane foam as a base material. Thus, the present invention relates to a method for producing a lightweight blanket having flexibility and breathability.

[0002]

2. Description of the Related Art Conventionally, there is a technique of slicing a block-shaped polyurethane foam into thin pieces, sandwiching a mesh-like mesh knitted fabric as a scrim, and applying an adhesive to both sides of the knitted fabric, to perform electrostatic flocking. The procedure was complicated as follows: [Production of polyurethane foam]-[Slice]-[Lamination of mesh netting]-[Application of adhesive on both sides]-[Flocking].

[0003]

The problems to be solved by the present invention include complicated steps such as a process of slicing polyurethane foam, a process of laminating mesh net cloth, a process of applying an adhesive on both sides in the production of a flocked blanket. It is an omission to provide a simpler manufacturing process.

[0004]

According to the present invention, nylon or other synthetic fiber netting is interposed as a reinforcing material in the middle or both sides of the polyurethane foam at the beginning of the foaming process of the polyurethane foam to be the base material, and The most main feature is to obtain a flocked blanket having breathability by simultaneously performing electrostatic flocking processing from both sides of the base material, planting a pile, and then drying. Further, instead of polyurethane foam, other effective materials such as rubber elastic body, polyethylene foam, etc. are used as a foam elastic body, and short pile fiber for flocking for electrostatic flocking is nylon or other effective synthetic fiber, wool, cotton, etc. It is characterized in that

The following table compares the performances of the conventional blanket made of wool and the flocked blanket of the present invention.

In the above table, the heat retention rate is the constant temperature method, the air permeability is the Brazier type method, the bending resistance is the 45 ° cantilever method, the compression modulus is the initial load of 50 g / cm ² , and the final load of 250 g / c.
It was measured in m ² . As is apparent from the above table, the flocked blanket of the present invention is superior in heat retention and flexibility to the conventional pure blanket, has a very good touch, and can withstand 200 times of washing. It has the drawback of good breathability, and the weight of one twin size is only 1.36kg.

[0007]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT A detailed description will be given with reference to the accompanying drawings showing an embodiment of the present invention. FIG. 1 is an enlarged plan view of the mesh net, and FIG.
FIG. 4 is a sectional view of a flocked blanket according to the present invention, FIG. 3 shows a flow sheet of a manufacturing process of a polyurethane foam as a base material, and FIG. 4 shows an apparatus of the present invention.

The length of one side of the braided hexagon of FIG.
3 mm and 1 is a braided yarn.

Reference numeral 2 is a polyurethane foam after completion of foaming, 3 and 4 are mesh nets on both sides of the polyurethane foam 2, and 5 is a short fiber (pile).

The flow sheet shown in FIG. 3 is a step of mixing the stock solutions. In the preparation step of the present manufacturing method, each stock solution is strictly selected and a preliminary test is conducted to establish accurate data, and the stock data of each stock solution is established. The measurement of the amount and the mixing ratio with isocyanate are also strictly performed.

In FIG. 3, 6 represents a polyol, 9 is methylene chloride and water as additives, 10 is a liquid A mixed with them, 7 is an additive such as silicon and stannas octoate, and 8 is a catalyst Dobco. Represents.

A solution 10 containing 100 parts by weight of the liquid A 10 and 0.3 parts of dabco as the catalyst 8 and 1.96 of the additive 7 and silicon and stanna octoate was added.

Reference numeral 15 is an isocyanate, 16 is a liquid B (isocyanate), and a liquid 18 is a liquid in which the actual amount of isocyanate required in advance calculated for the polyol 100, that is, the stoichiometric amount of isocyanate is measured as the liquid B.
In addition, 11, 12, 13, 14, and 17 indicate weighing.

The liquids represented by 18 and 19 are mixed and reacted x
Prepare the liquid. The above is the preliminary process of the present invention.

FIG. 4 shows a flocked blanket manufacturing process and apparatus of the present invention comprising a polyurethane solution discharge step (first step), a flocking step (second step), and a preliminary drying step (third step). In FIG. 4, the mesh net cloth 24 wound in a roll shape,
25 touches the surfaces of the rolls 22 and 23 facing each other and is pulled upward, but the gap is adjusted and regulated in consideration of the expansion ratio of the stock solution.

The mixed stock solution 20 is discharged between the mesh nets through a slit-shaped discharge port 21.

Designated by 26 and 28 are pile separating / supplying devices.
7 and 29 are reticulated electrodes, to which electrostatic high voltage is applied, and hair is planted on both side surfaces of the mesh reticulated in the middle of the prepared polyurethane stock solution in the initial stage of foaming.

The surplus pile is sucked by the suction nozzles 41 and 42, passes through the suction ducts 39 and 40, further passes through the electric fans 35 and 37, passes through the suction pipes 36 and 38, and is collected in the cyclones 31 and 32. Are separated.

The separated piles are cycle-supplied to the separation and supply devices 26 and 28, respectively, and the air is supplied to the outlet pipes 33 and 34.
Is discharged by.

Two mesh nets (scrim) 24, 2
The polyurethane inserted in No. 5 is flocked at the beginning of foaming and becomes a semi-finished product. This process is a and b. The product after the foaming is preliminarily dried and then sent out as a product 43 by the upper roll 30.

In the present invention, the first to third steps are the main steps, and when viewed in section, in FIG. 4, b is a discharge zone of a polyurethane mixed solution, c is a flocking zone, and d is a preliminary drying zone. Is.

After the third step, the work for removing the residual pile is performed to obtain a finished product.

For post-processing of the product, rubbing, brushing, etc. are performed.

In addition, the insect repellent treatment or the like is performed according to the intended use of each product.

In the case of the white pile flocked cloth, it is possible to print on the flocked surface with a desired design, and it is possible to finish it into a beautiful product.

The blanket of the present invention has endless uses, not only as a blanket, in view of its many characteristics such as lightness, heat retention and air permeability.

The pile used in the present invention is not limited to nylon, and synthetic fibers such as polyester yarn, polyamine yarn, acrylic yarn and natural fibers such as wool and cotton can also be used.

It is desirable that the pile has good separation and a specific resistance (surface leakage resistance) of 10 ⁹ Ω / cm or less and good flyability.

Therefore, the fineness is 2 denier or less, and the length is preferably 2 mm or less.

The pile manufacturing technology is required to be as flexible and elastic as possible for manufacturing blankets.

Next, the undiluted solution of polyurethane foam, the types of which are polyether, auxiliary foaming agent, foam stabilizer, catalyst, water, organometallic catalyst, etc. Mix and foam by so-called cold cure.

The selection of a catalyst is extremely important for the production of polyurethane foam, and a rise time of Rise time is preferably as long as possible.

Since a fast-reacting product reacts at the moment when the solutions A and B are mixed, the reaction can be controlled very easily by using the secondary amine, and a fine cell foam can be formed.

Flocking is done in the Flocking zone, which is often done early in foaming,
It is desirable that the foaming be completed by the time it finishes passing through the Pre-heating zone.

Rise time and Flocking
The closeness of time is important, and the length of each time and the relationship are adjusted.

It is desirable to automatically control the mixing of the stock solution of the foam, the mixing of the isocyanate, and the discharge thereof.

The machine speed of the present invention is preferably 3 to 5 m / min.

[0038]

[Effects] According to the present invention, since electrostatically-implanted flocking is performed in the early stage of the foaming process of polyurethane foam, complicated steps such as polyurethane foam slicing, mesh netting, and adhesive application on both sides can be omitted. It is possible to provide a blanket which is excellent in heat retention and flexibility by a simple manufacturing process, has a very good touch, and has excellent breathability.

[Brief description of drawings]

FIG. 1 is an enlarged plan view of a mesh net.

FIG. 2 is a cross-sectional view of a flocked blanket manufactured according to the present invention.

FIG. 3 is a flow sheet of a polyurethane foam manufacturing process which is a preliminary step of the present invention.

FIG. 4 is a side view showing the outline of the device of the present invention.

[Explanation of symbols]

 1 Braided yarn 2 Polyurethane foam after foaming 3,4 Mesh mesh on both sides of polyurethane foam 5 Short small fibers (pile) 6 Polyol 7,9 Additives 8 Catalyst 10 A liquid 11,12,13,14,17 Weighing 15 Isocyanate 16 B liquid (isocyanate) 18,18'B liquid weighed liquid 19,19'A liquid mixed with additives and catalyst 20 Mixed stock liquid 21 Discharge port 22,23 Guide roll 24,25 Mesh mesh 26, 28 Pile separating and supplying device 27, 29 Mesh electrode 30 Delivery roll 31, 32 Cyclone 33, 34 Outlet pipe 35, 37 Electric fan 36, 38 Blow pipe 39, 40 Suction pipe 41, 42 Excess pile suction port 30 Delivery roll 43 Product a Area just before foaming b Area to be flocked c Pre-drying area

Claims (3)

[Claims] 1. A polyurethane foam to be a base material. At the beginning of a foaming process, nylon or other synthetic fiber mesh is interposed as a reinforcing material in the middle or both side surfaces of the polyurethane foam, and both sides of the base material are simultaneously treated. A method for producing a flocked cloth having breathability, which comprises subjecting to electrostatic flocking and then drying. 2. The production of flocked cloth according to claim 1, wherein instead of the polyurethane foam to be the base material, another effective material such as a rubber elastic body or a polyethylene foam body is used as a foamed elastic body. Method. 3. Short-fiber piles for flocking are subjected to electrostatic flocking from both sides of the base material in the early stage of the foaming process of the polyurethane foam to be the base material. The method for producing a flocked cloth according to claim 1, which is a short and small fiber made of, for example,