US3529986A - Method for applying flock to a resin coated substrate - Google Patents

Method for applying flock to a resin coated substrate Download PDF

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Publication number
US3529986A
US3529986A US543332A US3529986DA US3529986A US 3529986 A US3529986 A US 3529986A US 543332 A US543332 A US 543332A US 3529986D A US3529986D A US 3529986DA US 3529986 A US3529986 A US 3529986A
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United States
Prior art keywords
flock
substrate
polyethylene
resin
polyolefin
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Expired - Lifetime
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US543332A
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English (en)
Inventor
George Kappas
Alfred B Zimmerman
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Millennium Petrochemicals Inc
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National Distillers and Chemical Corp
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Application filed by National Distillers and Chemical Corp filed Critical National Distillers and Chemical Corp
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    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H11/00—Non-woven pile fabrics

Definitions

  • Flock is a cut short fiber, such as wool, cotton, or man-made materials, such as nylon,
  • Flocked paper has been produced by first applying an adhesive to a suitable substrate and then applying the flock while vibrating or beating the substrate. The excess flock is removed after the adhesive has been allowed to dry or cure.
  • the adhesive material such as latex
  • a suitable substrate such as jute or burlap.
  • the flock is applied in such a way that it adheres to the adhesive material and provides a surface for the finished carpet or other textile.
  • One of these techniques is the electrostatic process which is particularly adapted to making items such as carpets and upholstery where high density and vertical orientation of fibers are required.
  • the charged flock is ejected from a hopper into an electrostatic field which directs the fiber onto the adhesive-coated substrate.
  • Another technique which may be used alone or in conjunction with the above-noted electrostatic technique, is one that utilizes beater bars. These rotating bars strike the back of the substrate so as to increase the penetration of the short fibers into the adhesive as well as to knock olf loose flock. The excess flock which still remains loosely embedded is then removed, for example, by using a vacuum.
  • the primary object of the present invention is to provide an improved technique for producing flocked products, particularly carpets.
  • polyolefins can be used as the adhesive for flocked products, such as carpets, to provide superior moldability. Such moldability is of fundamental importance in the production of carpets for automobiles since these carpets must be capable of being readily fitted to desired contours.
  • the use of polyolefins Patented Sept. 22, 1970 as the adhesive for retaining the flock provides a carpet having excellent fiber bond and pillingand abrasionresistance properties.
  • Other advantages are that the carpet has dimensional stability and freedom from odor. Further, the carpet can be readily cleaned or shampooed, it has resistance to moisture and mildew, and it possesses color stability. Additionally, there is no danger during fabrication from the use of flammable solvents.
  • the present invention in its broadest aspect provides a technique of incorporating flock into a substrate so that the finished article will have the appearance and texture of a tufted product. More specifically, the technique of the present invention comprises applying a thermoplastic organic polymer, such as polyethylene, to a substrate so that flocked material may adhere thereto.
  • a thermoplastic organic polymer such as polyethylene
  • polyethylene one form of same is a normally solid homopolymer as described in Fawcett, US. Pat. No. 2,153,553.
  • Such a polymer is a tough solid at normal temperatures with a fusion point of above about 250 F., corresponding in composition substantially to (CH and showing a crystalline structure by X-ray diffraction. Typically it has a molecular weight in excess of about 10,000.
  • Other polymers can also be used, for example, foamable polyethylene, ethylene-vinyl acetate copolymers, and ethylene-methyl acrylate copolymers.
  • a variety of application methods may be utilized in applying the adhesive carrier to the substrate.
  • One preferred form of the technique involves the application of the polyolefin, such as polyethylene, as a powder onto a surface of the substrate.
  • molten polyolefin is extruded onto the substrate. This latter method, however, is particularly adapted for use with higher molecular weight polyolefins.
  • the polyethylene having been applied in powder form to a surface of the substrate as noted above is subjected to infrared or other heating whereby the powdered polyethylene melts to form a continuous superstratum.
  • the web constituted of the substrate with the applied superstratum or layer of polyethylene, is passed between rolls to smooth out the polyethylene.
  • the web is heated to melt the polyethylene.
  • the flock is then applied to the molten polyethylene and adheres thereto.
  • a series of mechanical heaters is used at a subsequent stage to insure adequate penetration by the flock and to remove any excess flock that has not adhered.
  • the figure is a schematic representation of apparatus suitable for carrying out one embodiment of the technique of the present invention.
  • FIG. 1 there is shown a complete layout for fabricating the flocked carpet or the like.
  • a series of stations 1, 2, 3, 4, 5 and 6 are illustrated. At these diiferent stations, one or more operations are per formed in forming the flocked product according to the instant technique.
  • Shown in this figure is a typical carrier member in the form of a continuous belt 7.
  • Belt 7 is moved in the direction shown by the arrow by means of a take-up roller 8. Subsequently, belt 7 passes a series of additional rolls 9, 10 and 11.
  • the substrate 12 is fed from a roll 13 onto the continuous belt 7 and moves therewith past the rolls 9, 10, and 11.
  • At station 1 which includes a feed hopper 14, a source of heat 15, and a pair of rolls 17 and 18 the polyolefin 16 which is contained in the feed hopper 14 is fed onto the substrate 12.
  • the substrate 12 passes through the heating tunnel or oven 15 containing a source of infrared radiation.
  • the continuous layer 16 of adhesive thus formed is subjected to a heating step at station 2 prior to the flocking operation.
  • the polymer surface becomes molten, resulting from the application of heat by sources 19 at a temperature of about 300 to 500 F.
  • electrostatic flocking is carried out.
  • an electrostatic flocking unit 20 provides an electrostatic field which directs the flock from a hopper onto the polyolefin coating.
  • the web of the substrate and the polymer coating 16 moves continuously at 90 to the fields force lines.
  • the fibers align with the field and strike end-on at 90 to the web.
  • a charged screen in the hopper (not shown) forms a positive pole, and a grounded plate over which web passes forms a negative pole. Most of the fibers thus directed adhere to the molten surface of the polymer coating, but some of them do not imbed in the polymer adhesive. Such excess is later removed.
  • beaters in the unit 21 carry out the next step in the process. These beaters are in the form of rotating bars which strike the back of the web and are used to increase the penetration of the flock into the polymer coating as well as to knock off loose flock.
  • another heating step is used after the application of the flock to the substrate. Depending upon the nature of the flock, the heating step is carried out for about 5 to 10 minutes at about 300 to 400 F. to allow the fiber and polymer to form a bond.
  • This post-heating step is performed at station 5 by means of heat source 22.
  • the excess fiber is removed after the web has been cooled, although some of the excess fiber as noted above can be recovered in the beater bar unit. The final fiber recovery cannot be made until the polymer has been cooled, a brushing action being required in this final fiber recovery which would damage the flocked material while it was still hot.
  • the web constituted of the substrate, the polymer layer, and the flock is separated from the continuous belt 7. It is brought over a chilled roll 23 as illustrated and then finally over the roll 24 and past station 6 at which a vacuum is applied by unit 25 to remove the excess fiber as noted above. The finished web is then taken off the auxiliary roll 24.
  • the temperature that has been found suitable for cooling down the web at the chilled roll 23 is approximately 100 F.
  • polyethylene polyethylene
  • olefin homopolymers and copolymers e.g., of ethylene and other monomers, such as ethyl acrylate, methyl acrylate, and vinyl acetate are suitable.
  • the melt index of the selected polymer has an influence on the adhesion of the flock to the polymer.
  • Higher melt index polyethylene has been found to perform better in this system than low melt index polyethylene. This is due to two factors: (1) The higher melt index resin offers less resistance to fiber penetration and (2) the higher melt index resin has a longer open tack time, the surface of the resin being receptive to the fiber for a longer period of time after the heat source has been removed.
  • ethylene-vinyl acetate copolymers have been found well-suited to flocking applications in accordance with the broad technique of the present invention. For some applications these copolymers are better suited than polyethylene.
  • the ethylene-vinyl acetate copolymers have better adhesive properties than the homopolymers of ethylene, and this is particularly important for intermediate and long fiber flock. For very short flock applications, ethylene homopolymers are as well suited as the copolymers.
  • EXAMPLE I (A) parts of 16-mesh ethylene-vinyl acetate copolymer powder having a molecular weight greater than 20,000 was applied to burlap at a coating weight of 15 ounces per square yard. The burlap was heated under a high intensity infrared heater for one minute to melt the powder. The burlap was removed from the oven and nipped using a hand roller with moderate pressure to smooth and solidify the coating. The coated burlap, attached to a cardboard support, was placed in a laboratory hot-air circulating oven for ten minutes at 350 F.
  • the voltage was reduced to zero, and the burlap was placed in the 350 F. oven for seven minutes to achieve optimum adhesion of the flock to the polyolefin.
  • EXAMPLE II 100 parts of 16-mesh ethylene-vinyl acetate copolymer powder having a molecular weight greater than 10,000 was metered onto cotton fabric at a coating weight of 20 ounces per square yard. The fabric was placed in a laboratory hot-air circulating oven for ten minutes at 350 F. The fabric was then removed from the oven and nipped using a handroller with moderate pressure to smooth and solidify the coating. The coated fabric was attached to a cardboard support and placed back into the hot-air oven for ten minutes.
  • the fabric was placed in the 350 F. oven for seven minutes to achieve optimum adhesion of the flock to the polyolefin.
  • EXAMPLE III 100 parts of a polyethylene homopolymer having a molecular weight greater than 20,000 (SO-mesh, 2.0 melt index, 0.917 density) was metered onto burlap at a coating weight of 8 ounces per square yard. The burlap was then placed in a laboratory hot-air circulating oven for ten minutes at 350 F. The burlap was then removed from the oven and nipped using a hand roller with moderate pressure to smooth and solidify the coating. The coated burlap was then attached to a cardboard support and placed into the hot-air oven for ten minutes.
  • SO-mesh 2.0 melt index, 0.917 density
  • the fabric was placed in the 350 F. oven for seven minutes to achieve optimum adhesion of the flock to the polyethylene.
  • a process of producing a flocked product comprising the steps of (a) applying a powder of a 100% solid system of a resin from the group consisting of polyethylene and ethylene vinyl acetate copolymer to a substrate on a support,
  • polyolefin is polyethylene having a molecular weight greater than about 10,000.
  • step (d) is performed at a temperature within the range of from about 300 to about 500 F.
  • step (g) is to a temperature within the range of from about 300 to about 400 F.

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Laminated Bodies (AREA)
  • Application Of Or Painting With Fluid Materials (AREA)
US543332A 1966-04-18 1966-04-18 Method for applying flock to a resin coated substrate Expired - Lifetime US3529986A (en)

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US54333266A 1966-04-18 1966-04-18

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BE (1) BE697160A (ref)
FR (1) FR1528798A (ref)
GB (1) GB1138666A (ref)

Cited By (26)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3775205A (en) * 1968-12-20 1973-11-27 American Cyanamid Co Textile adhesive
US3903345A (en) * 1969-03-13 1975-09-02 Robert C Baker Sheet material for packet technology
US4122219A (en) * 1974-05-14 1978-10-24 Basf Aktiengesellschaft Flocking of textile sheet materials
US20020009571A1 (en) * 2000-07-24 2002-01-24 Abrams Louis Brown Flocked transfer and article of manufacture including the application of the transfer by thermoplastic polymer film
US20030186019A1 (en) * 2000-07-24 2003-10-02 High Voltage Graphics, Inc. Flocked transfer and article of manufacture including the application of the transfer by thermoplastic polymer film
US20030207072A1 (en) * 2000-07-24 2003-11-06 Abrams Louis Brown Co-molded direct flock and flock transfer and methods of making same
US20030205073A1 (en) * 1999-08-10 2003-11-06 Sumitomo Corporation Electrostatically fiber planted steel sheet and production process therefor
US20040055692A1 (en) * 2002-07-03 2004-03-25 Abrams Louis Brown Flocked stretchable design or transfer
US6929771B1 (en) 2000-07-31 2005-08-16 High Voltage Graphics, Inc. Method of decorating a molded article
US20050268407A1 (en) * 2004-05-26 2005-12-08 Abrams Louis B Process for high and medium energy dye printing a flocked article
US6977023B2 (en) 2001-10-05 2005-12-20 High Voltage Graphics, Inc. Screen printed resin film applique or transfer made from liquid plastic dispersion
US20070110949A1 (en) * 2005-11-17 2007-05-17 High Voltage Graphics, Inc. Flocked adhesive article
US7351368B2 (en) 2002-07-03 2008-04-01 High Voltage Graphics, Inc. Flocked articles and methods of making same
US20080095973A1 (en) * 2006-10-17 2008-04-24 High Voltage Graphics, Inc. Laser textured flocked substrate
US7393576B2 (en) 2004-01-16 2008-07-01 High Voltage Graphics, Inc. Process for printing and molding a flocked article
US7413581B2 (en) 2002-07-03 2008-08-19 High Voltage Graphics, Inc. Process for printing and molding a flocked article
US7465485B2 (en) 2003-12-23 2008-12-16 High Voltage Graphics, Inc. Process for dimensionalizing flocked articles or wear, wash and abrasion resistant flocked articles
US7749589B2 (en) 2005-09-20 2010-07-06 High Voltage Graphics, Inc. Flocked elastomeric articles
US7799164B2 (en) 2005-07-28 2010-09-21 High Voltage Graphics, Inc. Flocked articles having noncompatible insert and porous film
US8007889B2 (en) 2005-04-28 2011-08-30 High Voltage Graphics, Inc. Flocked multi-colored adhesive article with bright lustered flock and methods for making the same
US8206800B2 (en) 2006-11-02 2012-06-26 Louis Brown Abrams Flocked adhesive article having multi-component adhesive film
US8354050B2 (en) 2000-07-24 2013-01-15 High Voltage Graphics, Inc. Co-molded direct flock and flock transfer and methods of making same
US8475905B2 (en) 2007-02-14 2013-07-02 High Voltage Graphics, Inc Sublimation dye printed textile
US9012005B2 (en) 2009-02-16 2015-04-21 High Voltage Graphics, Inc. Flocked stretchable design or transfer including thermoplastic film and method for making the same
US9175436B2 (en) 2010-03-12 2015-11-03 High Voltage Graphics, Inc. Flocked articles having a resistance to splitting and methods for making the same
US9193214B2 (en) 2012-10-12 2015-11-24 High Voltage Graphics, Inc. Flexible heat sealable decorative articles and method for making the same

Citations (15)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2222539A (en) * 1934-12-11 1940-11-19 Behr Manning Corp Method of and apparatus for making pile-surfaced sheets
US2303202A (en) * 1939-09-27 1942-11-24 Nat Automotive Fibres Inc Carpet manufacture
US2328904A (en) * 1941-04-02 1943-09-07 Collins & Aikman Corp Method of attaching and straightening flock
US2527501A (en) * 1949-03-28 1950-10-24 Walter R Saks Process of producing flocked articles
US2639808A (en) * 1947-03-13 1953-05-26 Du Pont Packaging of tacky materials
US2655895A (en) * 1950-09-18 1953-10-20 Elfsuede Inc Flocking machine
US2696445A (en) * 1947-03-10 1954-12-07 Velveray Corp Process and apparatus for flocking fabric
US2784630A (en) * 1955-01-28 1957-03-12 Method of making flocked fabric and flocked vinyl
US2963381A (en) * 1955-10-11 1960-12-06 Heberlein Patent Corp Porous fabrics and methods for producing the same
US2963746A (en) * 1957-03-22 1960-12-13 Ici Ltd Manufacture of porous sheet material from powdered polymers
US3252732A (en) * 1963-01-29 1966-05-24 Stevens & Co Inc J P Laminated lining material
US3275487A (en) * 1963-01-07 1966-09-27 Jerome H Lemelson Method and automatic apparatus for producing pile surfaced plastic sheeting
US3342902A (en) * 1965-07-21 1967-09-19 Sun Oil Co Hot melt adhesive having pressure sensitivity comprising atactic polypropylene, ethylene-vinyl acetate copolymer, and a polyterpene
US3356521A (en) * 1964-09-17 1967-12-05 Hercules Inc Electrostatic flocking process using modified stereoregular polypropylene fibers
US3366503A (en) * 1967-01-23 1968-01-30 Eagle Picher Ind Inc Process of embedding flock in a polyethylene substrate

Patent Citations (15)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2222539A (en) * 1934-12-11 1940-11-19 Behr Manning Corp Method of and apparatus for making pile-surfaced sheets
US2303202A (en) * 1939-09-27 1942-11-24 Nat Automotive Fibres Inc Carpet manufacture
US2328904A (en) * 1941-04-02 1943-09-07 Collins & Aikman Corp Method of attaching and straightening flock
US2696445A (en) * 1947-03-10 1954-12-07 Velveray Corp Process and apparatus for flocking fabric
US2639808A (en) * 1947-03-13 1953-05-26 Du Pont Packaging of tacky materials
US2527501A (en) * 1949-03-28 1950-10-24 Walter R Saks Process of producing flocked articles
US2655895A (en) * 1950-09-18 1953-10-20 Elfsuede Inc Flocking machine
US2784630A (en) * 1955-01-28 1957-03-12 Method of making flocked fabric and flocked vinyl
US2963381A (en) * 1955-10-11 1960-12-06 Heberlein Patent Corp Porous fabrics and methods for producing the same
US2963746A (en) * 1957-03-22 1960-12-13 Ici Ltd Manufacture of porous sheet material from powdered polymers
US3275487A (en) * 1963-01-07 1966-09-27 Jerome H Lemelson Method and automatic apparatus for producing pile surfaced plastic sheeting
US3252732A (en) * 1963-01-29 1966-05-24 Stevens & Co Inc J P Laminated lining material
US3356521A (en) * 1964-09-17 1967-12-05 Hercules Inc Electrostatic flocking process using modified stereoregular polypropylene fibers
US3342902A (en) * 1965-07-21 1967-09-19 Sun Oil Co Hot melt adhesive having pressure sensitivity comprising atactic polypropylene, ethylene-vinyl acetate copolymer, and a polyterpene
US3366503A (en) * 1967-01-23 1968-01-30 Eagle Picher Ind Inc Process of embedding flock in a polyethylene substrate

Cited By (37)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3775205A (en) * 1968-12-20 1973-11-27 American Cyanamid Co Textile adhesive
US3903345A (en) * 1969-03-13 1975-09-02 Robert C Baker Sheet material for packet technology
US4122219A (en) * 1974-05-14 1978-10-24 Basf Aktiengesellschaft Flocking of textile sheet materials
US20030205073A1 (en) * 1999-08-10 2003-11-06 Sumitomo Corporation Electrostatically fiber planted steel sheet and production process therefor
US7211298B2 (en) * 1999-08-10 2007-05-01 Sumitomo Corporation Electrostatically fiber planted steel sheet and production process therefor
US8354050B2 (en) 2000-07-24 2013-01-15 High Voltage Graphics, Inc. Co-molded direct flock and flock transfer and methods of making same
US7381284B2 (en) 2000-07-24 2008-06-03 High Voltage Graphics, Inc. Flocked transfer and article of manufacture including the application of the transfer by thermoplastic polymer film
US7402222B2 (en) 2000-07-24 2008-07-22 High Voltage Graphics, Inc. Flocked transfer and article of manufacture including the flocked transfer
US7390552B2 (en) 2000-07-24 2008-06-24 High Voltage Graphics, Inc. Flocked transfer and article of manufacturing including the flocked transfer
US20030186019A1 (en) * 2000-07-24 2003-10-02 High Voltage Graphics, Inc. Flocked transfer and article of manufacture including the application of the transfer by thermoplastic polymer film
US20030207072A1 (en) * 2000-07-24 2003-11-06 Abrams Louis Brown Co-molded direct flock and flock transfer and methods of making same
US20020009571A1 (en) * 2000-07-24 2002-01-24 Abrams Louis Brown Flocked transfer and article of manufacture including the application of the transfer by thermoplastic polymer film
US7364782B2 (en) 2000-07-24 2008-04-29 High Voltage Graphics, Inc. Flocked transfer and article of manufacture including the application of the transfer by thermoplastic polymer film
US7338697B2 (en) 2000-07-24 2008-03-04 High Voltage Graphics, Inc. Co-molded direct flock and flock transfer and methods of making same
US7344769B1 (en) 2000-07-24 2008-03-18 High Voltage Graphics, Inc. Flocked transfer and article of manufacture including the flocked transfer
US7632371B2 (en) 2000-07-24 2009-12-15 High Voltage Graphics, Inc. Flocked transfer and article of manufacture including the application of the transfer by thermoplastic polymer film
US6929771B1 (en) 2000-07-31 2005-08-16 High Voltage Graphics, Inc. Method of decorating a molded article
US6977023B2 (en) 2001-10-05 2005-12-20 High Voltage Graphics, Inc. Screen printed resin film applique or transfer made from liquid plastic dispersion
US7351368B2 (en) 2002-07-03 2008-04-01 High Voltage Graphics, Inc. Flocked articles and methods of making same
US20040055692A1 (en) * 2002-07-03 2004-03-25 Abrams Louis Brown Flocked stretchable design or transfer
US7410682B2 (en) 2002-07-03 2008-08-12 High Voltage Graphics, Inc. Flocked stretchable design or transfer
US7413581B2 (en) 2002-07-03 2008-08-19 High Voltage Graphics, Inc. Process for printing and molding a flocked article
US7465485B2 (en) 2003-12-23 2008-12-16 High Voltage Graphics, Inc. Process for dimensionalizing flocked articles or wear, wash and abrasion resistant flocked articles
US7393576B2 (en) 2004-01-16 2008-07-01 High Voltage Graphics, Inc. Process for printing and molding a flocked article
US20050268407A1 (en) * 2004-05-26 2005-12-08 Abrams Louis B Process for high and medium energy dye printing a flocked article
US8007889B2 (en) 2005-04-28 2011-08-30 High Voltage Graphics, Inc. Flocked multi-colored adhesive article with bright lustered flock and methods for making the same
US7799164B2 (en) 2005-07-28 2010-09-21 High Voltage Graphics, Inc. Flocked articles having noncompatible insert and porous film
USRE45802E1 (en) 2005-07-28 2015-11-17 High Voltage Graphics, Inc. Flocked articles having noncompatible insert and porous film
US7749589B2 (en) 2005-09-20 2010-07-06 High Voltage Graphics, Inc. Flocked elastomeric articles
US8168262B2 (en) 2005-09-20 2012-05-01 High Voltage Graphics, Inc. Flocked elastomeric articles
US20070110949A1 (en) * 2005-11-17 2007-05-17 High Voltage Graphics, Inc. Flocked adhesive article
US20080095973A1 (en) * 2006-10-17 2008-04-24 High Voltage Graphics, Inc. Laser textured flocked substrate
US8206800B2 (en) 2006-11-02 2012-06-26 Louis Brown Abrams Flocked adhesive article having multi-component adhesive film
US8475905B2 (en) 2007-02-14 2013-07-02 High Voltage Graphics, Inc Sublimation dye printed textile
US9012005B2 (en) 2009-02-16 2015-04-21 High Voltage Graphics, Inc. Flocked stretchable design or transfer including thermoplastic film and method for making the same
US9175436B2 (en) 2010-03-12 2015-11-03 High Voltage Graphics, Inc. Flocked articles having a resistance to splitting and methods for making the same
US9193214B2 (en) 2012-10-12 2015-11-24 High Voltage Graphics, Inc. Flexible heat sealable decorative articles and method for making the same

Also Published As

Publication number Publication date
GB1138666A (en) 1969-01-01
BE697160A (ref) 1967-10-02
FR1528798A (fr) 1968-06-14

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