Flocking is the application of short chopped lengths of fiber to a substrate coated

Flocking is the application of short chopped lengths of fiber to a substrate coated with an adhesive to which it adheres when it dries. Flocking can be used to create a variety of decorative effects, from simple polka dots and stripes to more complex patterns and logos. It can be applied to both natural and synthetic materials, such as fabrics, paper, plastic, and metal. The process can be performed manually or electrostatically.

Flocked fabric is a durable, attractive, and cost effective decoration for many different applications. It is often used on apparel, shoes, and bags, but can be applied to a wide range of other products, including packaging, furniture, and other interior design elements. Flocking can also add texture to the surface of a product, adding depth and visual interest. It is available in a variety of colors and can be used to create patterns and textures, or to highlight important text or graphics.

A flocked product is often made from either cut or ground fiber. Cut flock is normally composed of short lengths of cotton, silk, rayon, or other suitable fibers and materials. Ground flock consists of fibers that are ground into a powder. Both types of flock are normally dyed to produce a desired color.

The invention relates to a method for flock coating open, porous substrates in which practically all of the adhered fibers are more nearly vertical. This allows higher production rates and makes it possible to produce flocked articles having sharply defined areas of different colors or contrasting appearance.

In the present invention, a woven polyester-cotton osnaburg fabric is screen-printed with an adhesive print paste comprising a heat-developable first dye ingredient and then applied to a base web which has been previously coated with a permanent adhesive. The flock is then applied over the adhesive, preferably by vibration type, electrostatic or spraying procedures. When dry, the flock is cured in an oven having a temperature cycle that gradually raises the curing temperature to about 350° C.

After the curing cycle, the flocked article is washed to test for proper cure. If it is found that the adhesive does not completely cure, it should be cured again. The curing cycle should be repeated as needed until the product passes a wash test and a tensile strength test.

The preferred adhesives for use in this method are the two-part, solvent free epoxy and urethane compositions which, when mixed, are in a flowable liquid form, penetrate the porous substrate, wet the fibers, adhere to them and then shortly harden to a tough and well bonded state. The use of such an adhesive eliminates the need for a separate solvent and simplifies processing. In addition, these adhesives are flexible and durable. It is also possible to utilize hot melt adhesives which in a molten liquid form will penetrate the porous substrate, wet the flock and adhere thereto before rapidly cooling to a tough and well bonded state. However, the use of such an adhesive may cause problems in some products requiring flexibility or low temperature tolerances.