JPS6036378B2 - Partially flocked foam and its manufacturing method - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a partially flocked foam having an uneven pattern and a method for producing the same.

Recently, partially flocked bodies in which flocked piles of rayon, nylon, or the like are partially implanted on PVC leather or PVC foamed leather have come to be seen on the market.

Such partially flocked PVC leather or PVC foamed leather has a progressively new appearance that feels like a mixture of flocked suede-like parts and resin-coated leather-like parts.

However, such conventional products have the following drawbacks. Generally, as shown in FIG. 6, such partially flocked foam is made by embossing the part b to be flocked onto the surface of PVC leather or PVC foamed leather a to make a depression (FIG. 6A). Apply adhesive d to the entire surface of a, scrape off the excess adhesive with a doctor knife, etc., and fill adhesive d only into the recesses b where the flocking is to be done (opening in the same figure).
This is obtained by electrostatically flocking a pile e of rayon, nylon, etc. on the floor and then baking to harden the adhesive d (see figure C). Since this is a method of forming a pattern of concave portions, it is difficult to emboss the part b to be flocked at a sufficiently acute angle, and it is not possible to form a complicated pattern.

Then, the filling amount of the adhesive d seems to be insufficient, and since the heat resistance temperature of the leather a is low, the baking temperature is increased to 120°C at most.
It must be kept up to ℃. In addition, due to various reasons such as the plasticizer contained in the leather a being released, the pile adhesion becomes poor, resulting in an inferior product with poor friction fastness. As mentioned above, partial flocked bodies based on PVC leather or PVC foamed leather have poor pile adhesion, so it is recommended to perform embossing treatment on such partial flocked bodies to form an uneven pattern surface. However, there are problems such as a large amount of pile falling out during the embossing process and partial peeling of the adhesive layer of the pile at uneven edges, making it difficult to obtain a partially flocked body with an uneven pattern that has commercial value. This is the most difficult technique.

Furthermore, even if an embossing treatment is to be carried out, since such a partially flocked body is partially flocked with non-melting rayon pile or high melting point nylon pile as described above, unevenness will be formed in the flocked part by the high frequency wader. In this case, there is a problem in that the pile in the concave part does not fall down, and both the pile in the concave part and the pile in the convex part remain upright, and the boundary between the concave and convex parts becomes extremely unclear.Therefore, in order to solve this problem, Therefore, the embossing process must be carried out using conventional heated rolls, heated presses, etc. However, high-frequency welder embossing is extremely superior in that it can clearly emboss fine patterns in a short time at low temperatures compared to embossing by heating rows, heating presses, etc. Partially flocked bodies to which it is difficult to apply welder embossing treatment are not only very disadvantageous in terms of embossing treatment, but also subject to considerable restrictions on the size, shape, complex pattern, etc. of the uneven pattern. Furthermore, the partially flocked body based on PVC leather or PVC foamed leather as described above has the disadvantage that it hardens and loses its texture in the winter, and toxic plasticizers are exposed on the surface in the summer. Since they become active, there are hygiene issues as well.

The present invention has been made to provide a partially flocked foam and a method for manufacturing the same that can solve the above-mentioned problems all at once.
In a further preferred embodiment, a high frequency welder embossing process is used to form the uneven pattern surface and at the same time to partially change the color of the flocked area.

Hereinafter, the present invention will be explained in detail with reference to the drawings. That is, the partially flocked foam according to the present invention has a part that is flocked from a flocked pile of modacrylic fibers or a mixed pile of this and other flocked piles, and a part that is covered with a resin coat layer. , 2 polybutadiene resin or a polymer blend containing these as one component, the gist of which is that the partially flocked foam has an uneven pattern surface embossed by a high-frequency welder. It is roughly divided into three types depending on the type and condition of the pile in the flocked area.

One of them is a single flocked pile made only of modacrylic fibers adjusted to approximately the same length, which is partially flocked.

FIG. 1 is a vague sectional view showing the first embodiment, in which a single modacrylic pile IC as described above is attached to the surface of a foam base material 3 via an adhesive layer 2. The foam base material 3 is partially flocked, and the surface of the foam base material 3 except for the flocked portion A is coated with a resin coat layer 4. Of course, the flocked portion A may also be coated with resin. and,
Both the flocked part A and the non-flocked part B are subjected to high frequency welder embossing treatment to form an uneven pattern. When the partially flocked foam of the present invention is subjected to high-frequency welder embossing treatment, a three-dimensional uneven pattern with large unevenness steps is formed deep within the thickness of the foam base material 3 as shown in the figure. Ru.

In addition, as will be described later, the modacrylic pipe 10 has a large and low internal heat generation in a high-frequency electromagnetic field. 0 is a convex part A that has softened and fallen sideways, and is not in contact with the mold.
Pile 1 of 2 remains upright. For this reason,
The raised convex portion A2 of the pile 10 has a dull light color,
The recess A where the pile 10 has fallen sideways has a dense dark color. In this way, the partially flocked foam shown in FIG. 1 has an uneven pattern surface with large steps that has a new feel with a mixture of the leather-like resin coated part B and the suede-like flocked part A, Moreover, the suede-like flocked part A itself is
It has two colors, dark and light, and the boundary between the concave portion A and the convex portion A2 is clear.

In addition, this partially flocked foam can be manufactured by using a new adhesive application method to form the adhesive layer 2 into a partially flocked PVC leather or PVC foamed leather, as will be explained in detail later in the manufacturing method. It is much thicker than the foam (approximately 50 to 100 mm dry weight) and is formed by raising it, and the heat resistance temperature of the foam substrate 3 is high, so it is approximately 1.
Coupled with the fact that the adhesive layer 2 is baked at a relatively high temperature below the heat resistance temperature of the pile of 20 to 145 oo, the adhesive strength of the pile 10 is very high, and therefore the pile 10 hardly falls off. The color fastness to friction is also fully satisfactory. A second embodiment of the partially flocked foam of the present invention, as shown in FIG. 2, is one in which a mixed pile of long and short modacrylic fibers of different lengths is partially flocked.

That is, the partially flocked foam shown in FIG. 2 replaces the single pile made of modacrylic fiber in the first embodiment.
The structure is the same as that of the first embodiment except that the mixed long and short piles made of the same fiber were partially implanted, and the convex portion A2 of the flocked portion A has long piles 11 and short piles 110 mixed almost uniformly. Both the long and short piles have softened and fallen sideways in the recessed part of the high-frequency welder mold. In this second embodiment, when both the long and short piles 11 and 110 are of the same color, the concave portion A is dark colored and the convex portion A2 is similar to the first embodiment.
However, if the long pile 11 and the short pile 110 are different colored piles, the following color change effect will be exhibited. That is, the flocked part A before the high-frequency welder embossing process has a color similar to that of the long pile 11 because the short pile 110 that stands up is hidden by the long pile 11 that stands up and is difficult to see. , second
When high frequency welder emboss treatment is applied as shown in the figure,
In the convex portion A2 of the mold which is not pressed, both the long and short piles 11 and 110 remain erect as before empos treatment, and thus maintain a color similar to that of the long pile 11. In the recess A, both long and short piles 1
1 and 110 both fall sideways, so long pile 1
The short pile 110 is exposed from between the layers 1 and 1, and therefore the color of the long pile 11 and the short pile 110 is mixed. In this way, when partially transplanting mixed long and short piles with different colors,
The high-frequency welder embossing process makes it possible to simultaneously form an uneven pattern on the surface and to change the color of the embossed material in the flocked area A. The hair-planted part A has undergone such discoloration treatment.
recessed part A. It goes without saying that since the convex portion A2 and the convex portion A2 are color-coded, the boundary between the two is extremely clear. A third embodiment of the partially flocked foam of the present invention is a partially flocked mixed pile of modacrylic pile and conventional piles such as rayon and nylon.

FIG. 3 shows this third embodiment. According to this partially flocked foam, the modacrylic pile 12 and the conventional pile 120 both stand up at the convex part of the flocked part A, while the high frequency welder In the recess A, where the mold was pressed, only the modacrylic pile I2 softened and fell sideways, and the non-melting or high melting point secondary pile 12 remained erect. In such partially flocked foam, modacrylic pile 1
When the conventional pile 120 and the conventional pile 120 have different colors, a color change effect similar to that of the second embodiment described above can be achieved. That is, the third
As shown in the figure, when both piles 12 and 120 have approximately the same length, during high-frequency welder embossing treatment, the mold is not pressed and both piles 12 and 120 remain erect. A2 has both piles 12 and 1 20
The warm color of the mold is maintained, but the pressed recess of the mold A. Then, the modacrylic pile 12 that has fallen sideways is covered by the upright conventional pile 12 and changes color to the color of the conventional pipe 120. Although not shown, when the modacrylic pile 12 is longer than the conventional pile 120, the convex portion A2 exhibits the color of the modacrylic pile 12 and the concave portion A exhibits the color of the conventional pile 120 based on the same principle. In this way, the third embodiment also performs discoloration treatment on the concave portions at the same time as the high-frequency welder embossing treatment to clarify the boundaries of the concavities and convexities in the flocked area A, creating an even more beautiful and clear concavo-convex pattern surface. This is what we have prepared.

The foam base material 3 used in the present invention is made of 1,2-polybutadiene resin or a polymer blend containing this as one component.
Patent Application No. 1983-120062 (
Tokuko Sho 52-3298) or Toku Iso Sho 51-8755
The thickness obtained by foaming according to the method of No. 3 (Japanese Unexamined Patent Publication No. 53-12963) is about 0.8 to 3. It is an endless foam of the same size as the ship.

There are various types of 1,2-polybutadiene resins, from low molecular weight liquid types to highly crystalline ones that are not processable. 100,000 or more, crystallinity of about 10-50%, 20
A low crystalline polymer with good thermal stability, moldability, photosensitivity, etc. with syndiotactic stereoregularity of 1% or more.
, 2-polyptadiene resin (for example, trade name JSR, RB-81 clam manufactured by Japan Synthetic Rubber Co., Ltd.) is preferably employed.

The polymers to be blended with this 1,2-polybutadiene resin include vinyl copolymers such as vinyl acetate-olefin, vinyl alcohol-olefin, and acrylate olefin, which are compatible and have relatively similar softening points. Combination etc. are preferably used, and when such organic polymers are blended, the embossing properties by high frequency welding are further improved. The blending ratio of such polymer and 1,2-polybutadiene resin is 3:7 to 7 by weight.
: It is preferable to set it in the range of 3. This is because if the polymer exceeds this upper limit, the texture of the foam will deteriorate or become sticky, while if it falls below this lower limit, no noticeable improvement in embossing properties will be observed. In addition, in some cases,
It is also possible to further blend polyolefins such as polyethylene, polypropylene, polybutene, etc. to adjust the feel of the foam. The partially flocked foam of the present invention using a foam of the above-mentioned 1,2-polybutadiene resin or a polymer blend containing the same as a base material has good Motomura's high frequency welder embossing properties. By high-frequency welder embossing, it is possible to easily form a concavo-convex pattern with a large three-dimensional effect that goes deep into the thickness of the base material, and has excellent flexibility, stretchability, drapeability, elasticity, and heat retention. It has excellent texture, does not harden even in winter, and is also excellent in terms of hygiene because it does not release plasticizer.

In addition, the flocking pile used in the present invention is a modacrylic pile or a mixed pile of this and other flocking piles as described above, and this modacrylic pile is made of a last-chain polymer containing 35 to 85% acrylonitrile. It is highly polar and has a low softening point. A particularly desirable representative example is 50% acrylonitrile and 50% vinyl chloride.
Flame-retardant piles made of long-chain polymers with both polar components are mentioned.This pile generates a large amount of internal heat in a high-frequency electromagnetic field, and has a low softening point of around 150 oo, so it is not suitable for high-frequency welders. When the mold is pressed by the boss treatment, it softens within a few seconds and falls sideways as described above. As already mentioned, other flocking piles to be mixed with the modacrylic pile include non-melting rayon piles, nylon piles having a high melting point, and the like, which have been commonly used in the past. These flocked piles are
In order to improve the feel of the flocked portion of the partially flocked foam, a material having a thickness and length that can be well compatible with the foam base layer 3, for example, a thickness of about 0.8 to 3.0 denier. It is possible to use a material having a degree and length of approximately 0.5 to 2.0, but preferably a length of 0.8 to 1.2. There are no particular restrictions on the materials of the resin coat layer 4 and the adhesive layer 2 for flocking, but it is preferable to use an acrylic resin or urethane resin surface coating agent that has a high adhesive strength with the foam base material 3. It is preferable to use adhesive. The dry weight of the resin coat layer 4 and the adhesive layer 2 is preferably 20 to 50 kg/m for the former and 50 to 100 m/cm for the latter. The partially flocked foam of the present invention detailed above is as follows:
The surface of the foam made of 1,2-polybutadiene resin or a polymer blend containing 1,2-polybutadiene resin as a component is partially or completely coated with resin, and then the resin-coated parts or the resin-uncoated parts are used for flocking with modacrylic fibers. The manufacturing method of the present invention, which consists of flocking a pile or a mixed pile of this and other piles for flocking, and then embossing it with a high-frequency welder to form an uneven pattern surface, can be easily and efficiently mass-produced. Ru.

The manufacturing method of the present invention will be explained below with reference to FIGS. 4 and 5.
2 or Japanese Patent Application No. 51-87553, the thickness is 0.8 to 3. A foam base material 30 made of 1,2-polyptadiene resin or a polymer blend containing 1,2-polyptadiene resin as one component, which has been previously produced in the form of a foamed sheet on the side of the ship, is first supplied to a resin coating step 1, where the foam is coated. The surface coating treatment agent 40 of the urethane resin or acrylic resin described above is applied to the entire surface of the base material 30 or to the other part B excluding the part A' where hair is to be implanted.
The coating is applied and dried so that the dry weight is about 20 to 5 M/kg.

In this case, the coating means 400 may be any conventionally known means. Resin coating layer 40 in resin coating step 1
The foam base material 30 on which `` is partially formed is then supplied to a rolling machine for an adhesive adhesion process, where the uncoated portion A to be flocked is coated with the aforementioned urethane-based or acrylic resin flocking adhesive. 20 is deposited in raised form so that the dry weight is approximately 50 to 100 days/day.

This adhesive 20 is attached by a rotary screen method using a special roller 200 as shown in FIG. This roller 200 has a roller surface with countless meshes 201 through which the adhesive filled inside can spill out.
The photosensitive resin coat 202 is uniformly coated with a photosensitive resin.
A concave section 203 is formed by partially irradiating the area with light and having a shape that corresponds to the area A' which is not irradiated with light, that is, the area A' where the hair is to be implanted. When applying the adhesive 20 by rolling the roller 20, the adhesive 20 should pass through the mesh 201 from inside the roller and fill the concave joints 203, so that the foam base material 30 should be flocked in a raised state. It can be applied to part A'.
Therefore, by increasing the thickness of the photosensitive resin coat 202 on the surface of the roller 200 and forming deep concave portions 203, a large amount of the adhesive 20 can be applied as described above. By applying a large amount of the adhesive 20 in this way, the adhesive strength of the pile to be flocked in the next flocking process will be improved. The attached foam base material 30 is then sent to the flocking process m, where a modacrylic pile as described above or a mixed pile of this and other flocking piles is applied to the part to be flocked with the adhesive 20 applied. Hair is transplanted to.

For this hair transplantation, any conventionally known hair transplantation method can be adopted. To give an example, the pile is electrostatically flocked using the up or down method under a high voltage of about 3 volts or more, and
There is a method of pre-drying at 11000 for several minutes and then baking at about 120145 oo for about 2 to 1 minute. In the present invention, the foam substrate 30 is made of a material having a high heat resistance temperature as described above.
Since it is a foamed product of 2-polybutadiene resin or a polymer blend containing polybutadiene resin as one component, it is possible to use the above-mentioned relatively high temperature baking temperature that does not soften the modacrylic pile, and therefore, a large amount of adhesive can be used. The adhesive strength of the pile is extremely high. The partially flocked foam base material 30 is finally sent to a high frequency welder embossing process N, where a textured surface is formed to form the partially flocked foam of the present invention.

As already mentioned, the foam base material 30 and the modacrylic pile have good embossing properties by high-frequency welding, so the embossing process usually takes about several seconds, and at most about several tens of seconds. In addition, the frequency used may be 27.12M, 40.48M, or 41.14M as certified by the Radio Control Act, and the output power may be in the range of 1 to 100KW, depending on the area of the recess that presses the mold. You can select it as appropriate. Through this high frequency welder embossing process,
The area where the mold is press-welded is deeply depressed, and the modacrylic pile at that area softens and falls sideways, but as in the embodiment shown in Figs.
Alternatively, when a mixed pile of modacrylic pile and a conventional flocked pile of a different color is partially flocked, the recesses are also color-changed at the same time in this embossing process, as described above. Note that if the foam base material 30 is thick, it may be preferable to preheat it before high-frequency welder embossing treatment. Next, an example of the manufacturing method of the present invention will be described.

(Example) Foaming ratio 5 times thickness 1.0 m using 1,2-polybutadiene resin [trade name RB820; manufactured by Memoto Synthetic Rubber ■] as a base material
/ Desk, Medium 1 The endless foam of the desk was laminated onto a fabric (sufgens) using a two-component solvent-type polyurethane adhesive using a reverse coater.

Next, a surface treatment paint for synthetic leather (trade name: Hanies 681 Kasei-Ki) was applied to the entire surface of the foam using a reverse coater, and the foam was completely dried. Thereafter, this original fabric was subjected to the next flocking process. That is, as in the process shown in FIG.
Apply UV-curable paint to the surface of the cylinder shown in the figure (having 60 mesh pores), cure the patterned areas other than the areas where you want flocking with UV rays, and seal the pongee holes with this film.In other words, the sealed areas are flocked. (The unsealed part will be the part to be flocked.)
A cage is inserted inside this cylinder, and adhesive is continuously applied to the tip of this cage. As the cylinder rotates, the emulsion type acrylic acid ester adhesive, which is the glue for flocking, is scraped off by the scage and passes through the pongee holes of the cylinder, and a predetermined pattern is thickly printed on the surface of the foam. Ru. Next, this raw fabric was provided to the hair transplantation room with a thickness of 2 denier and a length of 1.0 skin/cm.
The modacrylic pile on the skin is partially transplanted using the down method.
Next, this is introduced into a drying chamber, and the adhesive is cross-linked and cured to firmly fix the pile. Thereafter, this partially flocked foam is introduced between flat plate-shaped high-frequency heating electrodes with a suitable uneven pattern on the surface, and when a predetermined high-frequency voltage is applied and pressed, it is embossed, resulting in the results shown in Figures 1 to 3. An embossed body is obtained. In addition, there are cases in which the flat plate shape having an uneven pattern has a pattern that matches only the flocked part, a case that has a pattern that covers the flocked part and the painted part, and a case that has a pattern that matches only the painted part. The partially flocked embossed foam obtained in this way has the properties of Motomura's foam, which are lightweight, flexible, highly elastic, and has good heat retention, as well as a leather-like or suede-like texture on the surface. Due to the synergistic effect of the appearance and the rich three-dimensional embossed pattern, it can be used in many applications that require fashion. For example, it is useful for bags, bags, handrail parts, wall hanging materials, wall lumber, ceiling materials, and many other miscellaneous goods. When used in architectural interiors, it becomes a new material that possesses heat retention, adsorption, sound absorption, and design properties at the same time. As can be understood from the above explanation, the partially flocked foam of the present invention has high adhesive strength for flocked piles, is excellent in terms of fastness to friction, and can be subjected to high-frequency welder embossing treatment, which is advantageous in terms of manufacturing method. The boundary formed by the pile is clear and has a three-dimensional effect, and the surface has a progressively new uneven pattern in which a leather-like resin-coated part and a suede-like flocked part are mixed, and a specific mixed pile is partially flocked. For example, it also has the advantage of being able to change the color of the recesses in the flocked areas at the same time through high-frequency welder embossing.

This partially flocked foam is hygienic because it does not release plasticizer, does not harden in winter, is extremely lightweight, and has excellent texture, flexibility, stretchability, drape, and elasticity. , and has excellent heat retention properties. Therefore, the partially flocked foam of the present invention can be used in a wide variety of applications, from bags, accessories, clothing, etc. to interior and exterior materials. On the other hand, since the manufacturing example of the present invention includes a high-frequency welder embossing process, it is very efficient and advantageous compared to those using ordinary heated rolls or heated presses. Since the pattern can be clearly formed, there are practical benefits such as removing the conventional restrictions on embossed patterns.

[Brief explanation of drawings]

1, 2, and 3 are all schematic enlarged partial sectional views showing different embodiments of the partially flocked foam of the present invention, FIG. 4 is an explanatory diagram of the manufacturing method of the present invention, and FIG. 5 is a diagram of the present invention. A perspective view of a roller for applying adhesive used in the manufacturing method, Figure 6 is a conventional PV
It is an explanatory diagram of a manufacturing method of C leather or PVC foamed leather partially flocked foam. (Explanation of main symbols in the drawings) A...Flocked part, A'...
Part to be flocked, B...Resin coated part, A. ... Concave portion, A2... Convex portion, 10, 11, 110, 12, 120.
...Pile, 2...Adhesive layer, 20...Adhesive, 3
... Foam base material, 4,40'... Resin coat layer, 2
00...Loaf o Figure 1 Figure 2 Figure 3 Figure 6 Figure 4 Figure 5

Claims (1)

[Scope of Claims] 1. 1,2-polybutadiene resin or the like having a part flocked with a flocked pile of modacrylic fibers or a mixed pile of other flocked piles and a part covered with a resin coating layer. 1. A partially flocked foam, which is a foam made of a polymer blend containing as one component, the foam having an uneven pattern surface embossed by a high-frequency welder. 2. The surface of the foam made of 1,2-polybutadiene resin or a polymer blend containing 1,2-polybutadiene resin as one component is partially or completely coated with resin, and then modacrylic fibers are flocked on the resin-coated parts or the non-resin-coated parts. 1. A method for producing a partially flocked foam, which comprises flocking a mixed pile of flocking pile or other flocking pile, and then embossing it with a high-frequency welder to form an uneven pattern surface.