静电植绒工艺简介

Brief introduction of electrostatic flocking technology

尽管目前植绒产品繁多，设备也各不相同，植绒工艺流程大体如下:进料、上浆、植绒、预烘、焙烘、刷毛、后整理、成品。流程示意图如下：

Although there are many flocking products and different equipment, flocking process is generally as follows: feeding, sizing, flocking, pre-baking, baking, brushing, finishing, finished products. The schematic diagram of the process is as follows:

1.上浆。根据产品和底材性质,选择不同性能的粘合剂。根据不同材料和性能可以选用水性聚氨酯粘合剂或丙烯酸类粘合剂。如橡胶、塑料、钢材、玻璃、木材等为底材时，主要考虑粘接牢度。服装用而料,既要考虑耐水洗牢度,又要考虑手感柔软以及透气、透湿性能等。粘度太小植上的绒毛可能倾斜,粘度太大则妨碍植入深度,降低强度。涂层量大,会使手感差,且延长烘燥时间;涂层量少,则摩擦牢度降低。调整适当的粘度和涂层量才能确保植绒质量。

1. sizing. According to the properties of products and substrates, different properties of adhesives are selected. Waterborne polyurethane adhesives or acrylic adhesives can be selected according to different materials and properties. For example, rubber, plastics, steel, glass, wood and so on, the adhesive fastness is mainly considered. The fastness to washing and the softness of handle, air permeability and moisture permeability should be taken into account. The viscosity is too small, the fuzz on the plant may tilt, and the viscosity is too large, which will hinder the implant depth and reduce the strength. A large amount of coating will cause poor touch and prolong drying time. The coating will be less and the rubbing fastness will be reduced. The proper viscosity and coating amount can be adjusted to ensure the quality of flocking.

上浆方式目前主要采用辊筒法和刮刀法。对于植花(局部植绒),则采用圆网或平网印浆法对花纹部印浆,要求均匀、边界清晰,不能有起泡或空白点,植绒后形成植绒花纹。

The main way of sizing is roller and scraper. For flocking (local flocking), the circular screen or flat screen printing pulping method is used to print on the pattern part, which requires uniform, clear boundary, no blistering or blank spots, and flocking pattern is formed after flocking.

2.植绒。植绒方式主要有提升式、下落式、侧植式和上下拼植式四种。提升式:绒毛在输送带上进入电场,在静电作用下绒毛自下而上飞升插入底材粘合涂层中粘合剂中。提升法被植物在上方,下落法加工物在下方。提升法需要两条输送装置,即被加工物输送和绒毛输送,结构复杂,传送时张力较大,若强力不大的织物就很难加工。不连续生产,则提升法比较好,因为绒毛在静电场作用下一部分植入粘合剂中,多余的绒毛会自然落下,植绒表面浮绒较少。下落法则另加一个吸绒装置,将在绒面的浮绒吸去,目前多数植绒机均采用下落式。侧植式适用于片块状物体的植绒,提升下落拼植法适用于线状物体的植绒。

2. flocking. There are four ways of flocking: lifting, falling, side planting and up and down. Lifting type: The fluff enters the electric field on the conveyor belt, and under the action of static electricity, the fluff flies up and down into the binder in the substrate adhesive coating. The lifting method is placed above and below the processing plant. The lifting method requires two conveying devices, namely, the conveying of processed fabrics and the conveying of wool. The structure is complex and the tension is large when conveying. If the fabric is not strong enough, it is difficult to process. In discontinuous production, the lifting method is preferable, because a part of the fluff is implanted into the adhesive under the action of electrostatic field, the excess fluff will fall naturally, and the flocking surface is less fluffy. The falling rule adds a sucking device to suck the floss off the flock surface. At present, most flocking machines adopt the falling type. The side planting type is suitable for flocking of block like objects, and the lifting and falling planting method is suitable for flocking of linear objects.

植绒室的心脏是高压静电发生器。通常要求直流电压达20-200千瓦,两电极之间的距离按公式E二V/H可求得,式中:E为电场强度(v/m)；v为极板电压(v)；H为极板短离(m),一般为10厘米以内,电场强度1-5千瓦/厘米,绒毛以100-200厘米/秒的速度垂直插入底材表面的粘合剂中。为了确保车速较快时的植绒质量，可采用多套静电发生器,或者增加打击振动装置,来补充静电力的不足。

The heart of the flocking chamber is a high-voltage electrostatic generator. Usually requires a DC voltage of 20-200 kW, the distance between the two electrodes can be calculated according to the formula E 2V/H, formula: E for the electric field strength (v/m); V for the plate voltage (v); H for the plate short distance (m), generally less than 10 cm, electric field strength of 1-5 kW/cm, Plush at a speed of 100-200 cm/sec into the substrate surface of the adhesive. In order to ensure the quality of flocking when the speed is fast, several sets of electrostatic generators or additional striking vibration devices can be used to supplement the shortage of electrostatic force.

3.热固。植绒完毕后需进行热处理,以使绒毛、粘合剂和底材牢固结合。一般都有两个阶段:预烘和焙烘,具体视粘合剂种类而定。加热方式也有多种,通常采用热风循环方式较好,既可达到粘合剂交联温度,又能使粘合剂中水分尽快脱离。烘燥温度还应注意到底材性质,防止材质在较高温度下会变形。热处理在烘箱中完成,其质量对植绒牢度影响较大。为了确保热处理的温度和时间,若车速较快时,应适当加长烘箱长度。

3. thermosetting. After the flocking is finished, heat treatment is necessary to make the wool, adhesive and substrate firmly combined. Generally, there are two stages: pre drying and baking, depending on the type of adhesive. There are also many heating methods, usually hot air circulation is better, not only can reach the crosslinking temperature of the adhesive, but also can make the moisture in the adhesive as soon as possible to separate. Drying temperature should also pay attention to the properties of the material to prevent deformation of the material at higher temperature. Heat treatment is completed in oven, and its quality has a great influence on flocking fastness. In order to ensure the temperature and time of heat treatment, the oven length should be lengthened properly if the speed is fast.

4.刷毛。在植绒后虽吸去浮绒,但在间隙中还有残余绒毛,一般采用毛刷逆底材运动走向的方式,进行一次刷毛清洗。也有采用机械拍打、吹风等方式相结合进行处理,则效果更佳。如不需后整理加工,则刷毛后即可得到成品。

4. brush hair. After flocking, although the suction of fluff, but there are still residual fluff in the gap, generally using the brush against the substrate movement direction, a brush cleaning. There is also a combination of mechanical flapping and blow drying to achieve better results. If no finishing is needed, the finished product can be obtained after bristling.

5.后整理.后整理的目的是锦上添花和提高产品附加值。例如:全面植绒(又称满地植绒)虽然赋予产品绒的风格,但美中不足色彩单一,于是采用印花(或转移印花)加工方法,印上各种彩色图案,而成为印花植绒产品；通过轧辊热压(轧辊上刻有凸型图案)压花(轧花),使局部绒毛在高温下变形固化,成为轧花植绒产品;利用喷管上若干小孔,喷出过热蒸汽使绒毛受热变形,且喷汽口横向有规则地往复与织物纵向直线运动,形成了一定形状的几何图案,成为喷花植绒产品;利用磨毛工艺,将植绒织物表面绒毛磨细,达到仿魔皮绒效果;采用化学处理法(仅对复合纤维)将植绒产品浸渍在溶液中,溶去“海”部分纤维,形成仿桃皮绒、仿丝绒产品,等等。以上仅列举了一部分后整理方法。总的来说目前后整理方法很多,但开发力度还不够,有很多课题需要我们探索研究。

5. finishing. The purpose of finishing is to add icing on the cake and improve the added value of products. For example: Full flocking (also known as full flocking) although giving the style of the product, but the United States is not a single color, so the use of printing (or transfer printing) processing methods, printed on a variety of color patterns, and become a printed flocking products; through roller hot pressing (roller engraved with convex pattern) embossing (rolling), so that local flocking deformation and solidification at high temperature The superheated steam is ejected from a number of holes in the nozzle to make the fluff deformed, and the nozzle moves regularly in a straight line with the fabric, forming a geometric pattern of a certain shape and becoming a flocking product. The surface fluff of flocking fabric is ground down to imitate the effect of magic skin by using the flocking technology. Fruit; Chemical treatment (only for composite fiber) will be immersed in the solution of flocking products, dissolve the "sea" part of the fiber, forming a peach skin, velvet-like products, and so on. Above is only a list of finishing methods. Generally speaking, there are many post-finishing methods, but the development efforts are not enough, there are many topics that need us to explore and study.