WO2015170277A1 - Flocked material and process to produce it - Google Patents
Flocked material and process to produce it Download PDFInfo
- Publication number
- WO2015170277A1 WO2015170277A1 PCT/IB2015/053345 IB2015053345W WO2015170277A1 WO 2015170277 A1 WO2015170277 A1 WO 2015170277A1 IB 2015053345 W IB2015053345 W IB 2015053345W WO 2015170277 A1 WO2015170277 A1 WO 2015170277A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- fibres
- adhesive
- sea
- fibre
- layer
- Prior art date
Links
- 239000000463 material Substances 0.000 title claims abstract description 62
- 238000000034 method Methods 0.000 title claims abstract description 51
- 230000008569 process Effects 0.000 title claims abstract description 43
- 239000003795 chemical substances by application Substances 0.000 claims abstract description 30
- 229920001410 Microfiber Polymers 0.000 claims abstract description 15
- 239000003658 microfiber Substances 0.000 claims abstract description 15
- 238000002360 preparation method Methods 0.000 claims abstract description 11
- 239000000835 fiber Substances 0.000 claims description 76
- 239000010410 layer Substances 0.000 claims description 68
- HEMHJVSKTPXQMS-UHFFFAOYSA-M Sodium hydroxide Chemical compound [OH-].[Na+] HEMHJVSKTPXQMS-UHFFFAOYSA-M 0.000 claims description 60
- 239000000853 adhesive Substances 0.000 claims description 59
- 239000003292 glue Substances 0.000 claims description 46
- 230000001070 adhesive effect Effects 0.000 claims description 34
- 239000012790 adhesive layer Substances 0.000 claims description 29
- 239000002585 base Substances 0.000 claims description 25
- 229920000139 polyethylene terephthalate Polymers 0.000 claims description 23
- 239000005020 polyethylene terephthalate Substances 0.000 claims description 23
- 239000004744 fabric Substances 0.000 claims description 22
- -1 polyethylene Polymers 0.000 claims description 21
- 238000004043 dyeing Methods 0.000 claims description 20
- 229920001296 polysiloxane Polymers 0.000 claims description 16
- 239000011347 resin Substances 0.000 claims description 15
- 229920005989 resin Polymers 0.000 claims description 15
- 229920000728 polyester Polymers 0.000 claims description 14
- 229920002635 polyurethane Polymers 0.000 claims description 14
- 239000004814 polyurethane Substances 0.000 claims description 14
- 230000004913 activation Effects 0.000 claims description 13
- 230000005686 electrostatic field Effects 0.000 claims description 13
- 239000007864 aqueous solution Substances 0.000 claims description 12
- 238000001035 drying Methods 0.000 claims description 12
- 239000002904 solvent Substances 0.000 claims description 12
- 239000004743 Polypropylene Substances 0.000 claims description 11
- 238000007654 immersion Methods 0.000 claims description 11
- 229920001155 polypropylene Polymers 0.000 claims description 11
- 239000000049 pigment Substances 0.000 claims description 10
- 239000000178 monomer Substances 0.000 claims description 9
- 229920001282 polysaccharide Polymers 0.000 claims description 9
- 239000005017 polysaccharide Substances 0.000 claims description 9
- 238000005520 cutting process Methods 0.000 claims description 8
- 239000004745 nonwoven fabric Substances 0.000 claims description 8
- 238000009987 spinning Methods 0.000 claims description 8
- 239000004952 Polyamide Substances 0.000 claims description 7
- 229920002647 polyamide Polymers 0.000 claims description 7
- 150000003839 salts Chemical class 0.000 claims description 7
- 239000002253 acid Substances 0.000 claims description 6
- 239000003513 alkali Substances 0.000 claims description 6
- 239000000758 substrate Substances 0.000 claims description 6
- 239000004677 Nylon Substances 0.000 claims description 5
- 239000002131 composite material Substances 0.000 claims description 5
- 229920001778 nylon Polymers 0.000 claims description 5
- 229920006395 saturated elastomer Polymers 0.000 claims description 5
- 239000004698 Polyethylene Substances 0.000 claims description 4
- 150000004676 glycans Chemical class 0.000 claims description 4
- BDAGIHXWWSANSR-UHFFFAOYSA-N methanoic acid Natural products OC=O BDAGIHXWWSANSR-UHFFFAOYSA-N 0.000 claims description 4
- 229920001707 polybutylene terephthalate Polymers 0.000 claims description 4
- 229920000573 polyethylene Polymers 0.000 claims description 4
- 229920000098 polyolefin Polymers 0.000 claims description 4
- 229920002215 polytrimethylene terephthalate Polymers 0.000 claims description 4
- 239000004150 EU approved colour Substances 0.000 claims description 3
- 229920002302 Nylon 6,6 Polymers 0.000 claims description 3
- 239000000654 additive Substances 0.000 claims description 3
- 238000004924 electrostatic deposition Methods 0.000 claims description 3
- 239000011159 matrix material Substances 0.000 claims description 3
- 229940006093 opthalmologic coloring agent diagnostic Drugs 0.000 claims description 3
- OSWFIVFLDKOXQC-UHFFFAOYSA-N 4-(3-methoxyphenyl)aniline Chemical compound COC1=CC=CC(C=2C=CC(N)=CC=2)=C1 OSWFIVFLDKOXQC-UHFFFAOYSA-N 0.000 claims description 2
- IMROMDMJAWUWLK-UHFFFAOYSA-N Ethenol Chemical compound OC=C IMROMDMJAWUWLK-UHFFFAOYSA-N 0.000 claims description 2
- XTXRWKRVRITETP-UHFFFAOYSA-N Vinyl acetate Chemical compound CC(=O)OC=C XTXRWKRVRITETP-UHFFFAOYSA-N 0.000 claims description 2
- 230000003213 activating effect Effects 0.000 claims description 2
- 125000002091 cationic group Chemical group 0.000 claims description 2
- 235000019253 formic acid Nutrition 0.000 claims description 2
- 229910017053 inorganic salt Inorganic materials 0.000 claims description 2
- 238000003780 insertion Methods 0.000 claims description 2
- 230000037431 insertion Effects 0.000 claims description 2
- FPYJFEHAWHCUMM-UHFFFAOYSA-N maleic anhydride Chemical compound O=C1OC(=O)C=C1 FPYJFEHAWHCUMM-UHFFFAOYSA-N 0.000 claims description 2
- 239000012942 water-based acrylic adhesive Substances 0.000 claims description 2
- 239000006185 dispersion Substances 0.000 claims 1
- 238000004090 dissolution Methods 0.000 abstract description 11
- 238000005299 abrasion Methods 0.000 abstract description 8
- 239000011248 coating agent Substances 0.000 abstract description 6
- 238000000576 coating method Methods 0.000 abstract description 6
- 241000839309 Thesea Species 0.000 abstract 1
- 244000144992 flock Species 0.000 description 92
- 239000013067 intermediate product Substances 0.000 description 34
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 15
- 238000001994 activation Methods 0.000 description 13
- 239000000243 solution Substances 0.000 description 11
- 239000001164 aluminium sulphate Substances 0.000 description 10
- 235000011128 aluminium sulphate Nutrition 0.000 description 10
- BUACSMWVFUNQET-UHFFFAOYSA-H dialuminum;trisulfate;hydrate Chemical compound O.[Al+3].[Al+3].[O-]S([O-])(=O)=O.[O-]S([O-])(=O)=O.[O-]S([O-])(=O)=O BUACSMWVFUNQET-UHFFFAOYSA-H 0.000 description 10
- 239000000047 product Substances 0.000 description 10
- 238000000151 deposition Methods 0.000 description 9
- 230000008021 deposition Effects 0.000 description 9
- 239000000986 disperse dye Substances 0.000 description 8
- 229920001285 xanthan gum Polymers 0.000 description 7
- OKKJLVBELUTLKV-UHFFFAOYSA-N Methanol Chemical compound OC OKKJLVBELUTLKV-UHFFFAOYSA-N 0.000 description 6
- 239000000975 dye Substances 0.000 description 6
- 238000009981 jet dyeing Methods 0.000 description 6
- 210000003632 microfilament Anatomy 0.000 description 6
- 230000009467 reduction Effects 0.000 description 6
- 239000004793 Polystyrene Substances 0.000 description 5
- 230000035515 penetration Effects 0.000 description 5
- UXVMQQNJUSDDNG-UHFFFAOYSA-L Calcium chloride Chemical compound [Cl-].[Cl-].[Ca+2] UXVMQQNJUSDDNG-UHFFFAOYSA-L 0.000 description 4
- 239000004372 Polyvinyl alcohol Substances 0.000 description 4
- XSTXAVWGXDQKEL-UHFFFAOYSA-N Trichloroethylene Chemical group ClC=C(Cl)Cl XSTXAVWGXDQKEL-UHFFFAOYSA-N 0.000 description 4
- 239000003518 caustics Substances 0.000 description 4
- 125000000524 functional group Chemical group 0.000 description 4
- 239000000203 mixture Substances 0.000 description 4
- 229920002451 polyvinyl alcohol Polymers 0.000 description 4
- 238000001878 scanning electron micrograph Methods 0.000 description 4
- UBOXGVDOUJQMTN-UHFFFAOYSA-N trichloroethylene Natural products ClCC(Cl)Cl UBOXGVDOUJQMTN-UHFFFAOYSA-N 0.000 description 4
- 238000005406 washing Methods 0.000 description 4
- ZWEHNKRNPOVVGH-UHFFFAOYSA-N 2-Butanone Chemical compound CCC(C)=O ZWEHNKRNPOVVGH-UHFFFAOYSA-N 0.000 description 3
- WEVYAHXRMPXWCK-UHFFFAOYSA-N Acetonitrile Chemical compound CC#N WEVYAHXRMPXWCK-UHFFFAOYSA-N 0.000 description 3
- 239000002318 adhesion promoter Substances 0.000 description 3
- 125000003118 aryl group Chemical group 0.000 description 3
- 239000003637 basic solution Substances 0.000 description 3
- 239000001110 calcium chloride Substances 0.000 description 3
- 229910001628 calcium chloride Inorganic materials 0.000 description 3
- 230000000052 comparative effect Effects 0.000 description 3
- 230000000694 effects Effects 0.000 description 3
- 238000010438 heat treatment Methods 0.000 description 3
- 239000000123 paper Substances 0.000 description 3
- 229920000642 polymer Polymers 0.000 description 3
- GJCOSYZMQJWQCA-UHFFFAOYSA-N 9H-xanthene Chemical compound C1=CC=C2CC3=CC=CC=C3OC2=C1 GJCOSYZMQJWQCA-UHFFFAOYSA-N 0.000 description 2
- CSCPPACGZOOCGX-UHFFFAOYSA-N Acetone Chemical compound CC(C)=O CSCPPACGZOOCGX-UHFFFAOYSA-N 0.000 description 2
- NLXLAEXVIDQMFP-UHFFFAOYSA-N Ammonia chloride Chemical compound [NH4+].[Cl-] NLXLAEXVIDQMFP-UHFFFAOYSA-N 0.000 description 2
- LFQSCWFLJHTTHZ-UHFFFAOYSA-N Ethanol Chemical compound CCO LFQSCWFLJHTTHZ-UHFFFAOYSA-N 0.000 description 2
- YNQLUTRBYVCPMQ-UHFFFAOYSA-N Ethylbenzene Chemical compound CCC1=CC=CC=C1 YNQLUTRBYVCPMQ-UHFFFAOYSA-N 0.000 description 2
- WYURNTSHIVDZCO-UHFFFAOYSA-N Tetrahydrofuran Chemical compound C1CCOC1 WYURNTSHIVDZCO-UHFFFAOYSA-N 0.000 description 2
- 239000004411 aluminium Substances 0.000 description 2
- 229910052782 aluminium Inorganic materials 0.000 description 2
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 2
- 239000006229 carbon black Substances 0.000 description 2
- 238000004040 coloring Methods 0.000 description 2
- 238000005260 corrosion Methods 0.000 description 2
- 230000007797 corrosion Effects 0.000 description 2
- 238000009472 formulation Methods 0.000 description 2
- 239000001023 inorganic pigment Substances 0.000 description 2
- 238000004519 manufacturing process Methods 0.000 description 2
- 229910052751 metal Inorganic materials 0.000 description 2
- 239000002184 metal Substances 0.000 description 2
- 239000002562 thickening agent Substances 0.000 description 2
- RYHBNJHYFVUHQT-UHFFFAOYSA-N 1,4-Dioxane Chemical compound C1COCCO1 RYHBNJHYFVUHQT-UHFFFAOYSA-N 0.000 description 1
- 239000004215 Carbon black (E152) Substances 0.000 description 1
- XDTMQSROBMDMFD-UHFFFAOYSA-N Cyclohexane Chemical compound C1CCCCC1 XDTMQSROBMDMFD-UHFFFAOYSA-N 0.000 description 1
- CTQNGGLPUBDAKN-UHFFFAOYSA-N O-Xylene Chemical compound CC1=CC=CC=C1C CTQNGGLPUBDAKN-UHFFFAOYSA-N 0.000 description 1
- ATTZFSUZZUNHBP-UHFFFAOYSA-N Piperonyl sulfoxide Chemical compound CCCCCCCCS(=O)C(C)CC1=CC=C2OCOC2=C1 ATTZFSUZZUNHBP-UHFFFAOYSA-N 0.000 description 1
- 239000004115 Sodium Silicate Substances 0.000 description 1
- 239000004809 Teflon Substances 0.000 description 1
- 229920006362 Teflon® Polymers 0.000 description 1
- NIXOWILDQLNWCW-UHFFFAOYSA-N acrylic acid group Chemical group C(C=C)(=O)O NIXOWILDQLNWCW-UHFFFAOYSA-N 0.000 description 1
- 239000003522 acrylic cement Substances 0.000 description 1
- 235000019270 ammonium chloride Nutrition 0.000 description 1
- 238000004873 anchoring Methods 0.000 description 1
- 238000010420 art technique Methods 0.000 description 1
- 230000004888 barrier function Effects 0.000 description 1
- 230000001680 brushing effect Effects 0.000 description 1
- 229910052799 carbon Inorganic materials 0.000 description 1
- 230000015556 catabolic process Effects 0.000 description 1
- 238000006731 degradation reaction Methods 0.000 description 1
- ZMXDDKWLCZADIW-UHFFFAOYSA-N dimethylformamide Substances CN(C)C=O ZMXDDKWLCZADIW-UHFFFAOYSA-N 0.000 description 1
- 230000009977 dual effect Effects 0.000 description 1
- 230000005684 electric field Effects 0.000 description 1
- 238000004299 exfoliation Methods 0.000 description 1
- 239000012530 fluid Substances 0.000 description 1
- 238000009972 garment dyeing Methods 0.000 description 1
- 229930195733 hydrocarbon Natural products 0.000 description 1
- 150000002430 hydrocarbons Chemical class 0.000 description 1
- 239000003960 organic solvent Substances 0.000 description 1
- 230000000149 penetrating effect Effects 0.000 description 1
- 229920003023 plastic Polymers 0.000 description 1
- 239000004033 plastic Substances 0.000 description 1
- 239000002798 polar solvent Substances 0.000 description 1
- 229920001223 polyethylene glycol Polymers 0.000 description 1
- 229920002223 polystyrene Polymers 0.000 description 1
- 238000002203 pretreatment Methods 0.000 description 1
- 230000001681 protective effect Effects 0.000 description 1
- 238000004626 scanning electron microscopy Methods 0.000 description 1
- NTHWMYGWWRZVTN-UHFFFAOYSA-N sodium silicate Chemical compound [Na+].[Na+].[O-][Si]([O-])=O NTHWMYGWWRZVTN-UHFFFAOYSA-N 0.000 description 1
- 229910052911 sodium silicate Inorganic materials 0.000 description 1
- 239000008234 soft water Substances 0.000 description 1
- 238000005507 spraying Methods 0.000 description 1
- 238000003892 spreading Methods 0.000 description 1
- 230000007480 spreading Effects 0.000 description 1
- 230000003746 surface roughness Effects 0.000 description 1
- 229920002994 synthetic fiber Polymers 0.000 description 1
- YLQBMQCUIZJEEH-UHFFFAOYSA-N tetrahydrofuran Natural products C=1C=COC=1 YLQBMQCUIZJEEH-UHFFFAOYSA-N 0.000 description 1
- 238000007669 thermal treatment Methods 0.000 description 1
- 239000002023 wood Substances 0.000 description 1
- 239000008096 xylene Substances 0.000 description 1
Classifications
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04B—KNITTING
- D04B21/00—Warp knitting processes for the production of fabrics or articles not dependent on the use of particular machines; Fabrics or articles defined by such processes
- D04B21/02—Pile fabrics or articles having similar surface features
-
- 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
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
- D04H1/541—Composite fibres, e.g. sheath-core, sea-island or side-by-side; Mixed fibres
-
- 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
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
- D04H1/541—Composite fibres, e.g. sheath-core, sea-island or side-by-side; Mixed fibres
- D04H1/5416—Composite fibres, e.g. sheath-core, sea-island or side-by-side; Mixed fibres sea-island
-
- 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
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
- D06N7/00—Flexible sheet materials not otherwise provided for, e.g. textile threads, filaments, yarns or tow, glued on macromolecular material
- D06N7/0097—Web coated with fibres, e.g. flocked
Definitions
- the object of the present invention is a process for the preparation of a flocked material starting from bicomponent fibres of a sea-island type, as well as a flocked material obtained from this process.
- the flocked material that is obtainable by means of this process can be used for various applications, for example to coat surfaces and structures such as the interiors of motor vehicles, 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.
- Electrostatic flocking is a particular process that makes it possible to obtain a napped type of effect on various types of surfaces (fabrics, paper, plastic, metal, wood, etc.).
- Flocking can be carried out on two-dimensional, rolled materials such as paper or fabrics, as well as on three-dimensional objects (e.g. eyeglass frames, clothes hangers, containers, interior components for automobiles, etc.).
- objects e.g. eyeglass frames, clothes hangers, containers, interior components for automobiles, etc.
- the synthetic fibres which are normally already coloured, are applied to a surface that has been previously treated with the application of a specific glue.
- the fibres penetrate the layer of glue, orienting themselves perpendicularly to the surface to be napped.
- the fibres In order for the fibres to orient themselves in the electrostatic field, they must be cut uniformly, the length thereof normally being related to the size of fibre. The smaller the diameter of the fibre, the shorter its length will be.
- the fibres Prior to flocking, the fibres require pre-treatment for "activation", which is aimed at predisposing the fibre to electrical conductivity.
- activation which is aimed at predisposing the fibre to electrical conductivity.
- solutions of metal salts are used; as they coat the fibre surface, they facilitate the orientation of the fibre in the electrostatic field.
- a process of dyeing the flock can also be carried out.
- the flocking process thus requires the following steps:
- ultrafine fibres which can be classified as microfibres, would encounter more difficulty in penetrating the adhesive backing layer, thereby jeopardizing the abrasion resistance of the flocked material.
- examples 15 and 16 in patent no. GB1300268 discloses the preparation of a flocked material consisting of a base made of nylon taffeta coated with a polyurethane adhesive, on which "islands-in-a-sea" type of composite fibres are flocked by means of an electrostatic process; the island component of the composite fibres is nylon 6,6 and the sea component is polystyrene. Prior to the electrostatic process, the fibres are cut at a length of 3 mm and pre-treated with sodium silicate and ammonium chloride. The flocked taffeta is dried and then immersed in a bath of trichloroethylene at a temperature of 50- 60°C to dissolve the sea component.
- US patent no. 4574018 discloses a process for preparing a flocked material in which short sea-island bicomponent fibres are flocked by means of an electrostatic procedure, over a base of various type covered with an adhesive (e.g. a polyurethane adhesive). After reticulation of the adhesive at high temperature, the sea component is removed partially by means of immersion in trichloroethylene or in a 3% NaOH solution.
- an adhesive e.g. a polyurethane adhesive
- the sea-island fibres (number 3 indicates the island component and number 4 indicates the sea component), which have been previously cut to a suitable length and pre-treated with inorganic salts, are oriented perpendicularly with respect to the backing layer and a given portion of their length penetrates within the adhesive layer.
- Example 7.0 which was carried out by the Applicant, in which the removal step was performed by immersing the flocked material in a bath containing 8% NaOH.
- the result is total removal of the sea component, even in the part immersed in the adhesive, with the result that the remaining fibre is no longer securely anchored to the backing layer and it can be easily removed by abrasion, to the extent that in the next dyeing step in a jet dyeing machine at the temperature of 120°C with disperse dyes, and resulting reduction, the microfibre is completely removed from the adhesive layer.
- the invention concerns a process for the preparation of the flocked material starting from sea-island types of bicomponent fibres, comprising a step for selective removal of the sea component carried out using a removal agent that has a viscosity ranging between 300 mPa.s and 100.000 mPa.s, preferably between 400 and 64.000 mPa.s.
- the removal agent is preferably in the form of a paste having a viscosity within the ranges indicated above and that is spread on the fibres following flocking of the fibres by means of an electrostatic process and drying of the adhesive layer.
- the removal agent Owing to its viscosity, the removal agent is unable to penetrate within the adhesive layer where the sea-island fibres are partially immersed and therefore it is unable to affect that part of the sea component that is immersed in the layer of adhesive. Therefore, the removal of the sea component is a selective process and it makes it possible to obtain a flocked material that offers good abrasion resistance and resistance to fibre removal, unlike the flocked products known in the sector that are obtained starting from sea-island fibres and have the drawback of offering poor resistance to fibre removal by abrasion, as those same fibres are not securely anchored to the layer of adhesive.
- a further measure can be adopted to avoid corrosion of the sea component in the lower part of the fibres and even more so in the part immersed in the adhesive layer; this measure consists in protecting the above-mentioned portion of fibres by using a removable resin applied by spreading, for example by air-spraying, prior to applying the removal agent.
- the removable resin can have the same formulation as the removal agent, but without the corrosive agent (which can be a caustic agent, acid or selective solvent).
- the removable resin can consist of a solution of polyvinyl alcohol or an aqueous solution of a thickening agent in general, preferably compatible with the sea component with which it comes into contact. The viscosity of the removable resin is greater than that of the corrosive paste so as to prevent permeation between them.
- Controlling the amount of removable resin deposited allows for finer modulation of the fibre fraction to be dissolved.
- the selective removal step of the invention makes it possible to obtain a flocked material in which the sea component 4 has been partially removed from the portion of fibre that is not immersed in the adhesive layer.
- the invention thus also concerns a flocked material that can be obtained by means of the process described hereinabove, in which the sea component of the sea-island bicomponent fibre is partially removed from the portion of fibre that is not immersed in the adhesive layer ( Figure 2).
- FIG. 1 A shows the flocked material of the invention prior to removal of the sea component
- - Figure 1 B shows the flocked material with sea-island bicomponent fibres following removal with a solvent solution and/or base solution of the prior art
- FIG. 2 shows the flocked material of the invention after selective removal of the sea component by means of the removal agent of the invention
- FIG. 3 is a SEM (Scanning Electron Microscope) image of the flocked material of the invention prior to removal of the sea component;
- FIG. 4 is a SEM image of the flocked material following the selective superficial removal of the sea component
- FIG. 5 is a detail from Figure 4 where the intact structure is evident at the base of the emerging flocked fibers, whereas the sea component has been removed from the upper part by selective dissolution;
- FIG. 6 is a SEM image of the flocked material following non-selective removal of the sea component by immersion in a bath of NaOH;
- Figures 7 and 8 are details from Figure 6 in which it is possible to see that the microfibers with the sea component removed are not anchored to the layer of glue in some points; the effect is particularly evident on the surface ( Figure 8), where craters can be seen on the layer of glue, left by the fibers that have lost their adhesion following dissolution of the sea component.
- the present invention concerns a process for the preparation of a flocked material starting from sea-island bicomponent fibres, comprising the steps of:
- the spinning of the sea-island bicomponent fibres can be carried out according to prior-art techniques, which comprise the feeding of two pure polymers or two mixtures of polymers to a spinneret so that one of the two polymeric components ("sea") completely surrounds the other component constituted by various polymeric filaments (preferably 1 6 microfilaments of circular shape and equal diameter) that form the various "islands".
- the island component can be chosen from among: modified polyesters, cationic polyesters, nylon or other types of polyamides (PA), polyethylene (PE), polypropylene (PP), polytrimethylene terephthalate (PTT), polybutylene terephthalate (PBT) and polyethylene terephthalate (PET), the latter being particularly preferred.
- the island component can be solution-dyed, that is, dyed prior to spinning with the aid of specific colouring agents or pigments added during the spinning process.
- the sea component can be chosen from among: nylon 6,6, co-polyester (called co-PES or TLAS) with a different content of monomer soluble in alkali, modified polyolefins with insertion of polar monomers in the chain, the polar monomers preferably being selected from among vinyl alcohol, vinyl acetate or maleic anhydride (called co-PS).
- co-PES and co-PS can be easily removed by adding a solution of alkali (low monomer content) or also in hot water (high monomer content).
- Both the sea and island components can be used in a mixture with added components selected from among inorganic pigments for the island component, and incompatible polymers for the sea component.
- added inorganic pigments for the island component carbon black is particularly preferred. It makes it possible to achieve a coloured "flock" in shades of colour ranging from grey to black, with a colouring that proves to be particularly resistant to UV degradation, even by adding only small amounts of the colouring agent.
- polyvinyl alcohol for the co-PES and polyethylene glycols with average molecular weights between 10,000 and 20,000 g/mol for the co-PS are particularly preferred.
- the fibre used in the invention is made up of an island component made of PET and a sea component made of PA 6,6 or co-PES.
- the ratio of the island component to the sea component in the bicomponent fibre is such as to enable spinning of the two components by means of a spinneret rapidly and efficiently.
- Said island/sea ratio is preferably within the range of 20/80 to 80/20, more preferably within the range of 50/50 to 80/20.
- the fibre exhibits a number of island components ranging from 8 to 96, preferably 8 to 40.
- the bicomponent fibre thus obtained is subjected to a drawing process so as to reduce the titre thereof from a range of 6.5 to 1 9.4 dtex, preferably within the range of 9.2 to 1 7 dtex, to a titre ranging between 3 and 5 dtex.
- Drawing is carried out preferably with drawing ratios generally varying in the range of 4-1 , preferably in the range of 3-1 , more preferably in the range of 2.5-1 .
- the "tow” thus obtained is collected in bins and undergoes cutting of the continuous fibre to a length ranging between 0.1 mm and 3.0 mm.
- the length of the fibre preferably ranges between 0.3 and 1 .25 mm.
- the cut fibre is subjected to an activation step preferably by means of immersion in a bath of aqueous solution comprising inorganic salts, for example aluminium sulphate and/or calcium chloride.
- Fibre that has been cut and activated is defined as "flock".
- the length/diameter ratio in the flock must be within the range of 1 0:1 and 1 00:1 , preferably between 20:1 and 50:1 .
- This activation step makes the cut fibre more sensitive to the electrostatic field applied during the electrostatic deposition step and thus enables a more precise orientation of the fibres in a direction perpendicular to the substrate and to the adhesive layer.
- the flock is left to dry and after drying it has an inorganic salt content within the range of 0.5% and 2% of the initial weight.
- the backing layer on which a layer of adhesive agent is applied can be an orthogonal fabric or a knit fabric, or a non-woven fabric such as a spun-bonded non-woven nylon or polypropylene fabric, or a non-woven elastomeric composite fabric (hereinafter identified as "EVN base"), for example polyester microfiber in a polyurethane matrix.
- ESN base non-woven elastomeric composite fabric
- the backing layers indicated above can be utilized as is or they can undergo a surface coating treatment to eliminate the porosity thereof, which would alter the thickness of the applied adhesive agent on the surface; the surface coating treatment can also facilitate fixing of the adhesive agent to the surface of the backing layer.
- the backing layer can be a film made of a polyolefin, such as polypropylene pre-treated with plasma to make the surface hydrophilic and thus easily wettable with the adhesive agent, or it can be paper.
- the backing layer has a unit weight ranging between 40 g/m 2 and 500 g/m 2 , preferably between 80 g/m 2 and 350 g/m 2 , and a thickness ranging between 0.1 0 mm and 2.0 mm, preferably between 0.20 mm and 1 .10 mm.
- the adhesive agent placed on the backing layer is preferably chosen from among: a polyurethane adhesive (in a solvent or water), a water-based acrylic adhesive, and a silicone glue; silicone glues and polyurethane adhesives are particularly preferred.
- a pigment - and/or additives capable of facilitating adhesion with the bicomponent fibre - can be added to the adhesive agent for the purpose of giving the final flocked material specific shades of colour, preferably a conductive pigment capable of facilitating the subsequent flocking process (making the backing layer conductive makes it possible to neutralize the charges transported from the flock and thus keep the electrostatic field applied constant).
- These additives which are also called adhesion promoters, are molecules possessing functional groups compatible with the adhesive agent (or that react with the functional groups of the latter) and functional groups compatible with the sea component (or that react with the functional groups of the latter) of the bicomponent fibre that is made to penetrate into the glue.
- the layer of adhesive agent can be applied by coating the entire surface of the backing layer (full application) or only part of it (patterned application), for a thickness within the range of 0.05 mm to 0.50 mm, preferably 0.1 0 mm to 0.35 mm.
- the flock is stably deposited only in areas with the adhesive agent, thus realizing patterns on the surface of the backing layer.
- the electrostatic flocking of the flock on the adhesive agent layer preferably takes place in an environment with a controlled and constant level of humidity ranging between 60% and 90%, preferably between 70% and 80%.
- the electrostatic field applied is preferably within the range of 20 to 50 kV, preferably 20 to 40 kV.
- the amount of flock deposited ranges between 50 and 250 g/cm 2 , preferably between 140 and 190 g/cm 2 , relative to the area in which the adhesive agent is present in the case of patterned deposition.
- the titre of the sea-island fibre ranges from 1 .5 dtex to 10 dtex, preferably within the range of 3.0 dtex to 7 dtex.
- the deposition rate is between 2 and 7 m/min, preferably between 2 and 4 m/min.
- the flock fibres penetrate within the adhesive layer to a depth ranging from 40 microns to the entire thickness of the layer of adhesive agent, depending upon the adhesive agent used, its viscosity and the applied electrical field.
- the material Upon completion of deposition, the material is placed in an oven to harden and fix the adhesive agent, for a period of time ranging from 2 to 10 minutes, preferably 3 to 5 minutes.
- the oven temperature is preferably in the range of 1 1 0°C and 200°C, preferably 120 to 1 90°C.
- the removal agent comprises a base, for example NaOH, or an acid, for example formic acid, preferably mixed with a polysaccharide, preferably a polysaccharide such as xanthan.
- the removal agent can also comprise a selective solvent for the sea component.
- solvents suitable for dissolving a co-PS-based sea component consist of halogenated solvents such as trichloroethylene, perchloroethylene, chloroform, hydrocarbon solvents such as tuolene, xylene, ethylbenzene, cyclohexane, and other polar solvents such as ⁇ , ⁇ -dimethylformamide, acetone, dioxane, tetrahydrofuran, methyl ethyl ketone, acetonitrile, dimethy sulphoxide, methanol and ethanol.
- halogenated solvents such as trichloroethylene, perchloroethylene, chloroform
- hydrocarbon solvents such as tuolene, xylene, ethylbenzene, cyclohexane
- other polar solvents such as ⁇ , ⁇ -dimethylformamide, acetone, dioxane, tetrahydrofuran, methyl e
- the base or acid concentration may range between 1 .5% and 20% by weight, preferably between 4% and 18% by weight.
- the polysaccharide, and particularly the xanthan, is preferably contained in the paste in an amount ranging from 0.5% to 7% by weight.
- the removal agent is applied on the flocked fibres in an amount ranging between 80 and 150 g/m 2 .
- a removable resin prior to applying the removal agent, can be applied by coating, as a further measure to avoid corrosion of the sea component in the lower part of the fibres and even more so in the part immersed in the adhesive layer.
- the removable resin can have the same formulation as the removal agent, but without the corrosive agent (which can be a caustic agent, acid or a selective solvent).
- the removable resin can consist of a solution of polyvinyl alcohol or an aqueous solution of a thickening agent in general, preferably compatible with the sea component with which it comes into contact.
- the viscosity of the removable resin is preferably greater than that of the removal agent so as to prevent permeation between them.
- the viscosity of the removable resin preferably ranges between 1 .000 mPa.s and 150.000 mPa.s.
- Controlling the amount of removable resin deposited allows for finer modulation of the flock fraction to be dissolved.
- the material can be treated with a saturated vapour current, with radio frequencies, with microwaves or thermally treated with hot air, so as to facilitate dissolution of the sea component.
- the removal agent and any removable resin can be removed by washing with water.
- selective and partial removal of the sea component is brought about: only the portion of the sea component that is not immersed in the layer of adhesive agent is removed, while the part immersed in the adhesive layer remains and allows for maintaining secure anchoring of the flock fibers to the substrate (see Figures 3-5, which show the absence of empty spaces between the island fibres and the adhesive layer).
- the material treated with a saturated vapour current, radio frequencies or microwaves is further treated with hot air in an oven for the purpose of creating a protective barrier on the surface of the removal agent before washing with water.
- the flocked material becomes more resistant to possible abrasions which could cause removal of the fibres and the microfibre proves to be more localized at the flocking point based on the fraction of corroded fibre, thus giving rise to a product with a more appealing appearance (the nap is perceived as being more uniform).
- the flocked material can also be dyed in a jet dyeing machine and the excess dye then removed without risking a loss of flocked fibre.
- a flocked material can be dyed in a machine for garment dyeing or more generally for "open-width dyeing", which permits pressurized dyeing of particularly delicate materials without subjecting them to significant mechanical stress (the material remains spread open for its entire width without forming lengthwise or crosswise folds).
- the flocked material that is obtained using the process of the invention differs from the materials known in the prior art in that it does not exhibit empty spaces between the fibres and the layer of adhesive, which could contribute to the poor resistance of the prior art materials in the subsequent dyeing steps and poor resistance to abrasion in general.
- the flocked material of the invention presents itself as a finer material compared to those of the prior art and offering greater durability over time.
- an object of the invention is a flocked material obtainable using the process of the invention.
- the flocked material of the invention comprises:
- a backing layer preferably made of fabric or non-woven fabric
- a fibrous layer comprising a plurality of sea-island fibres that are preferably oriented in a direction perpendicular to the backing layer, partially immersed in the adhesive layer and having the sea component still present in the portion of fibres immersed within the adhesive layer.
- the sea component is instead totally or partially absent in the section of fibres that emerges from the adhesive layer.
- the adhesive layer is present on the entire surface of the backing layer or on a portion thereof (patterned flocking).
- the adhesive layer is of a thickness ranging between 0.05 mm and 0.50 mm, preferably between 0.10 mm and 0.35 mm.
- the plurality of sea-island fibres are included within the adhesive layer for a depth that ranges from 40 microns to the entire thickness of the adhesive layer.
- the island component of the sea-island fibres has a titre in the range of 0.04 to 0.30 dtex.
- the flocked material of the invention can be used in the field of automobiles, furnishings and consumer electronics, replacing all parts currently coated with fabrics, non-wovens or leathers.
- the flocked material of the invention can be used for various applications, for example to coat surfaces and structures such as interiors of motor vehicles, 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.
- Example 0.1 White flock with PET/TLAS bicomponent fibre - 1.0 mm
- An "island-in-the-sea" type of bicomponent fibre flock is realized, in which the island component is realized in PET and the sea component is realized in TLAS (co-polyester soluble in alkali).
- TLAS co-polyester soluble in alkali
- the ratio of the island component to the sea component in the fibre is 57:43.
- the section of the fibre reveals 16 PET microfilaments of circular shape and equal diameter.
- the flock is obtained by means of the subsequent procedures of drawing, collecting the tow in bins and cutting the continuous sea-island fibre to the desired length.
- the flock thus defined undergoes activation by means of immersion in a bath of an aqueous solution of aluminium sulphate; after drying, the content of aluminium sulphate in the flock is equal to 1 % of the initial weight.
- Thread 1 The flock thus realized is called Thread 1.
- Example 0.1.1 Black flock with (PET+disperse dyes)/TLAS bicomponent fibre
- the flock is realized with the same procedure used for Thread 1 , with the variant that prior to the activation process the flock is dyed with black dye dispersed in water at a temperature of 120°C in accordance with the prior art.
- Thread 2 1 % aluminium sulphate by weight on the flock.
- the flock thus realized is called Thread 2.
- An "island-in-the-sea" type of bicomponent fibre flock is realized, in which the island component is realized in PET with added Carbon Black in the amount of 7% and the sea component is realized in TLAS (co-polyester soluble in alkali). The ratio of the island component to the sea component in the fibre is 57:43.
- the section of the fibre reveals 16 PET microfilaments of circular shape and equal diameter.
- the flock is obtained by means of the subsequent procedures of drawing, collecting the tow in bins and cutting the continuous sea-island fibre to the desired length.
- the flock thus defined undergoes activation by means of immersion in a bath of an aqueous solution of aluminium sulphate; after drying, the content of aluminium sulphate in the flock is equal to 1 % of the initial weight.
- Example 0.3 White flock with PET/PA6.6 bicomponent fibre - 0.5 mm
- An “island-in-the-sea” type of bicomponent fibre flock is realized, in which the island component is realized in PET and the sea component is realized in PA 6,6.
- the ratio of the island component to the sea component in the fibre is 57:43.
- the section of the fibre reveals 16 PET microfilaments of circular shape and equal diameter.
- the flock is obtained by means of the subsequent procedures of drawing, collecting the tow in bins and cutting the continuous sea-island fibre to the desired length.
- the flock thus defined undergoes activation by means of immersion in a bath of an aqueous solution of aluminium sulphate; after drying, the content of aluminium sulphate in the flock is equal to 1 % of the initial weight.
- Example 0.4 White flock with PET/HWS bicomponent fibre - 1 .0mm
- An "island-in-the-sea" type of bicomponent fibre flock is realized, in which the island component is realized in PET and the sea component is realized in HWS polyester.
- the ratio of the island component to the sea component in the fibre is 57:43.
- the section of the fibre reveals 1 6 PET microfilaments of circular shape and equal diameter.
- the flock is obtained by means of the subsequent procedures of drawing, collecting the tow in bins and cutting the continuous sea-island fibre to the desired length.
- the flock thus defined undergoes activation by means of immersion in a bath of an aqueous solution of aluminium sulphate, in the presence of 0.5% calcium chloride; after drying, the aluminium flock undergoes a 1 % increase in weight.
- the flock thus obtained undergoes activation by means of immersion in a bath of an aqueous solution of aluminium sulphate, in the presence of 0.5% calcium chloride; after drying, the aluminium flock undergoes a 1 % increase in weight.
- a layer of bicomponent ALAPATEC 30340 adhesive (1 00% silicone glue supplied by CHT) having a thickness of 0.2 mm and a viscosity of 50.000 mPa.s is applied onto a backing layer realized in a composite material made of PET microfibre with 30% of a polyurethane matrix and having a thickness of 1 .1 0 mm.
- Electrostatic and mechanical flocking follows so as to deposit the flock indicated as Thread 1 ; on average the flock penetrates into the layer of glue by 60 microns.
- Flocking takes place in an environment with a controlled and constant level of humidity at 65%, exposed to an electrostatic field of 30 kV so as to enable the deposition of 144 g/ cm 2 of flock at a line rate of 3.0 m/min.
- the intermediate product thus identified is placed in a convective oven to reticulate for 4 minutes at 150°C and it is called FK 01.0.
- Example 1 An intermediate product similar to the one identified as FK 01.0 (Example 1 .0) is realized, using bicomponent TUBICOAT PROTECT LSR adhesive (100% silicone glue, supplied by CHT).
- the glue contains a black pigment and has a viscosity of 35.000 mPa.s, which is lower than that of ALPATEC 30340, to the extent that penetration of the flock indicated as Thread 1 equals the thickness of 0.2 mm of the glue and the flock is therefore in contact with the surface of the backing layer.
- the intermediate product is called FK 01.1 .
- Example 1.2 EVN base - polyurethane glue - 1.0 mm
- An intermediate product similar to the one identified as FK 01.0 (Example 1 .0) is realized, using an aromatic, bicomponent, polyester-based polyurethane glue that can be reticulated by heating.
- the glue contains a black pigment and has a viscosity of 30.000 mPa.s, which is lower than that of the preceding examples, to the extent that penetration of the flock indicated as Thread 1 equals the thickness of 0.2 mm of the glue and the flock is therefore in contact with the surface of the backing layer.
- the intermediate product thus identified is placed in a convective oven to reticulate for 4 minutes at 150°C and it is called FK 01.2.
- Example 1.3 EVN base - polyurethane glue - 0.5 mm
- An intermediate product similar to the one identified as FK 01.0 (Example 1 .0) is realized, using the flock indicated as Thread 6, rather than Thread 1 , and an aromatic, bicomponent, polyester-based polyurethane glue that can be reticulated by heating.
- the glue has a viscosity of 29.000 mPa.s, and penetration of the flock indicated as Thread 6 equals the thickness of 0.2 mm of the glue and the flock is therefore in contact with the surface of the backing layer.
- the intermediate product thus identified is placed in a convective oven to reticulate for 4 minutes at 150°C and it is called FK 01.3.
- Example 2.0 EVN base - silicone glue with adhesion promoter - 1.0 mm
- Example 1 .1 An intermediate product similar to the one identified as FK 01.1 (Example 1 .1 ) is realized, using bicomponent TUBICOAT PROTECT LSR adhesive (100% silicone glue, supplied by CHT), which already contains within it a black pigment and an adhesion promoter specific for TLAS.
- the glue has a viscosity of 35.000 mPa.s, and penetration of the flock indicated as Thread 3 equals the thickness of 0.2 mm of the glue (the flock is therefore in contact with the surface of the backing layer).
- the intermediate product is called FK 02.0.
- a layer of TUBVINIL 401 H adhesive of a thickness of 0.15 mm (water-based acrylic base, supplied by CHT) is placed on a 1 00% PET cloth backing layer having a unit weight of 82g/m 2 and electrostatic flocking is carried out with the flock indicated as Thread 2.
- Flocking takes place in an environment with a controlled and constant level of humidity at 65%, exposed to an electrostatic field of 30 kV so as to enable the deposition of 165 g/cm 2 of flock at a line rate of 3.5 m/min.
- the product is placed in a convection oven at 170°C for 3 minutes to dry and fix the adhesive.
- the flock penetrates into the adhesive to the point of coming into contact with the underlying layer of fabric.
- the intermediate product is called FK 03.0.
- the product is placed in a convection oven at 140°C for 6 minutes to dry and fix the adhesive.
- the flock penetrates into the adhesive to the point of coming into contact with the underlying film.
- the intermediate product is called FK 04.0.
- Example 4.1 PP base - polyurethane glue - 1.0 mm
- a layer of aromatic, bicomponent, polyester-based polyurethane glue that can be reticulated by heating, containing a black pigment and having a thickness of 0.4 mm is placed over a film of PP having a thickness of 120 microns that has been pre-treated with plasma to make the surface hydrophilic.
- Flocking takes place in an environment with a controlled and constant level of humidity at 65%, exposed to an electrostatic field of 40 kV so as to enable the deposition of 210 g/cm2 of flock at a line rate of 2.2 m/min.
- the product is placed in a convection oven at 140°C for 3 minutes to dry and fix the adhesive.
- the flock penetrates into the adhesive to the point of coming into contact with the underlying film.
- the intermediate product is called FK 04.1.
- Flocking takes place in an environment with a controlled and constant level of humidity at 80%, exposed to an electrostatic field of 22 kV so as to enable the deposition of 191 g/crm 2 of flock at a line rate of 2.5 m/min.
- the product is placed in a convection oven at 150°C for 5 minutes to dry and fix the adhesive.
- the flock penetrates into the adhesive by 150 microns.
- the intermediate product is called FK 05.0.
- Flocking takes place in an environment with a controlled and constant level of humidity at 75%, exposed to an electrostatic field of 25 kV so as to enable the deposition of 150 g/crm 2 of flock at a line rate of 3.0 m/min.
- the product is placed in a convection oven at 150°C for 4 minutes to dry and fix the adhesive.
- the flock penetrates into the adhesive by 150 microns.
- the intermediate product is called FK 06.0.
- the intermediate products FK 01 .0, FK 01 .1 , FK 01 .2, FK 02.0, FK 03.0, FK 04.0 and FK 04.1 containing TLAS as the sea component in the flock, were washed in a bath containing 8% NaOH (w/w) at a temperature of 80°C for 15 minutes, and then washed in cold water and placed in a convection oven to dry.
- a preparation of thickened NaOH (removal agent) is dispensed using a doctor blade at a rate of 100 g/m 2 on the flock side of the intermediate products FK 01 .0, FK 01 .1 , FK 01 .2, FK 02.0, FK 03.0, FK 04.0 and FK 04.1 containing TLAS as the sea component of the flock.
- the corrosive paste 16% of which is constituted by NaOH and 0.5% of which by DENIMCOL SPEC FTL (Xanthan polysaccharide supplied by CHT), has a pseudoplastic behaviour and a viscosity of about 400 mPa.s under application conditions.
- Viscosity was measured using a Brookfield DVIII rotational viscometer at 20°C, with a Small Sample Adapter accessory and an SC4-28 spindle, at a speed of about 5 rpm, corresponding to a shear rate of 5 s '
- the intermediate products coated with the corrosive paste were thermally treated at 80°C for 10 minutes in an oven and then washed in cold water and placed in a convection oven to dry.
- a preparation of thickened NaOH (removal agent) was dispensed using a doctor blade at a rate of 100 g/m 2 on the flock side of the intermediate products FK 01 .0, FK 01 .1 , FK 01 .2, FK 01 .3, FK 02.0, FK 04.0 and FK 04.1 containing TLAS as the sea component of the flock.
- the corrosive paste 4% of which is constituted by NaOH and 2% of which by DENIMCOL SPEC FTL (Xanthan polysaccharide supplied by CHT), has a pseudoplastic behaviour and a viscosity of about 28.000 mPa.s under application conditions.
- the intermediate products coated with the corrosive paste were treated with a saturated vapour current at atmospheric pressure for 3 minutes and then washed in cold water and placed in a convection oven to dry.
- Dyeing was then carried out in a jet dyeing machine with disperse dyes at 120°C and subsequent reduction of excess dye only on intermediate products FK01 .1 , FK 01 .2, FK 01 .3, FK 02.0, FK 04.0 and FK 04.1 .
- Example 9.1 Dissolution with NaOH paste in vapour + open-width dyeing
- the sea component of intermediate products FK 01 .1 , FK 01 .2, FK 01 .3, FK 02.0, FK 04.0 and FK 04.1 was removed as described in Example 9.0.
- the intermediate products were then dyed by means of a dyeing machine for open-width dyeing, using disperse dyes in water at 1 20°C and subsequent reduction of excess dye. In this manner, dyed flocked materials were obtained, characterized by a more uniform and even appearance.
- a preparation of PVA in water with a viscosity of 54.000 mPa.s was applied onto the intermediate products FK 01 .1 , FK 01 .2, FK 02.0 and FK 04.0 by means of an air doctor blade, with the aim of applying a layer of 30 g/m 2 of solution only at the base of the flocked fibres.
- a preparation of thickened NaOH was dispensed by means of a cylinder doctor blade at a rate of 100 g/m 2 on the flocked side of intermediate product FK 01 .1 .
- the corrosive paste (removal agent) 4% of which is constituted by NaOH and 2% of which by DENIMCOL SPEC FTL (Xanthan polysaccharide supplied by CHT), has a pseudoplastic behaviour and a viscosity of about 28.000 mPa.s under application conditions.
- the intermediate products FK 01 .1 , FK 01 .2, FK 02.0 and FK 04.0 coated with the corrosive paste were treated with a saturated vapour current at atmospheric pressure for 3 minutes and then washed in cold water and placed in a convection oven to dry.
- the sea component proved to be hydrolyzed only in the apical part of the flocked fibres, that is, for about 1 /5 of the emerged length.
- DENIMCOL SPEC FTL Xanthan polysaccharide supplied by CHT
- the viscosity of the solution under application conditions was about 20.000 mPa.s.
- the intermediate product was then subjected to radio frequencies with a parallel field, with a difference in electric potential equal to 1 .0 kV, and then washed in cold water.
- a preparation of thickened NaOH was dispensed by means of a doctor blade at the rate of 100 g/m 2 on the flock side of intermediate product FK 01 .1 , then heated for 2 minutes in a microwave oven with power equal to 5 KW, washed in cold soft water and dried in a convection oven.
- the corrosive paste (removal agent), 1 .0% of which is constituted by NaOH and 2.0% of which by DENIMCOL SPEC FTL (Xanthan polysaccharide supplied by CHT), has a pseudoplastic behaviour and a viscosity of about 2.000 mPa.s under application conditions.
Abstract
Description
Claims
Priority Applications (5)
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KR1020167031244A KR20170002428A (en) | 2014-05-09 | 2015-05-07 | Flocked material and process to produce it |
US15/309,578 US20170159215A1 (en) | 2014-05-09 | 2015-05-07 | Flocked material and process to produce it |
CN201580024244.6A CN106414826B (en) | 2014-05-09 | 2015-05-07 | Flocked material and method for producing same |
JP2016567218A JP6656174B2 (en) | 2014-05-09 | 2015-05-07 | Flocked material and its manufacturing process |
EP15728177.5A EP3140448B1 (en) | 2014-05-09 | 2015-05-07 | Flocked material and process to produce it |
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ITMI2014A000847 | 2014-05-09 | ||
ITMI20140847 | 2014-05-09 |
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PCT/IB2015/053345 WO2015170277A1 (en) | 2014-05-09 | 2015-05-07 | Flocked material and process to produce it |
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US (1) | US20170159215A1 (en) |
EP (1) | EP3140448B1 (en) |
JP (1) | JP6656174B2 (en) |
KR (1) | KR20170002428A (en) |
CN (1) | CN106414826B (en) |
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GB201718851D0 (en) * | 2017-11-15 | 2017-12-27 | Smith & Nephew | Flocked conformable circuit boards for sensor enabled wound therapy dressings and systems |
CN108642713A (en) * | 2018-07-09 | 2018-10-12 | 合肥洁诺医疗用品有限公司 | A kind of preparation method of medical antibacterial non-woven fabrics |
CN110079879A (en) * | 2019-04-29 | 2019-08-02 | 吴江精美峰实业有限公司 | A kind of sea-island fibre and the method and composite spining module for being used to prepare sea-island fibre |
CN110152956A (en) * | 2019-05-31 | 2019-08-23 | 锦州希尔达汽车零部件有限公司 | A kind of production method of the high light shine implanted article of automotive upholstery |
CN110393639A (en) * | 2019-08-29 | 2019-11-01 | 上海纺织建筑设计研究院有限公司 | A kind of paper diaper guide layer of grassplot structure and preparation method thereof |
CN114892421A (en) * | 2021-06-26 | 2022-08-12 | 上海九裕纺织科技有限公司 | Production process based on flocking on film and application thereof |
CN114016211A (en) * | 2021-10-18 | 2022-02-08 | 北京熵图医疗科技合伙企业(有限合伙) | Medical non-woven material without breaking package and with high antibacterial performance and preparation method |
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- 2015-05-07 JP JP2016567218A patent/JP6656174B2/en not_active Expired - Fee Related
- 2015-05-07 KR KR1020167031244A patent/KR20170002428A/en not_active Application Discontinuation
- 2015-05-07 EP EP15728177.5A patent/EP3140448B1/en not_active Not-in-force
- 2015-05-07 WO PCT/IB2015/053345 patent/WO2015170277A1/en active Application Filing
- 2015-05-07 US US15/309,578 patent/US20170159215A1/en not_active Abandoned
- 2015-05-07 CN CN201580024244.6A patent/CN106414826B/en not_active Expired - Fee Related
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Also Published As
Publication number | Publication date |
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JP2017515991A (en) | 2017-06-15 |
EP3140448A1 (en) | 2017-03-15 |
CN106414826B (en) | 2020-03-06 |
JP6656174B2 (en) | 2020-03-04 |
CN106414826A (en) | 2017-02-15 |
US20170159215A1 (en) | 2017-06-08 |
KR20170002428A (en) | 2017-01-06 |
EP3140448B1 (en) | 2018-01-10 |
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