Core / sheath structure, method of manufacturing flocked products, and flocked products

Abstract

To provide molding or flocking products with a comfortable tactile feel.SOLUTION: The core / sheath structure constituting a molding material or a molding object that is a melt-cured product of the molding material, comprises a core having a linear shape and an outer surface and containing a first thermoplastic polymer, and a sheath covering the outer surface and containing a second thermoplastic polymer and at least one selected from a group consisting of fibers and particles dispersed in the second thermoplastic polymer. The flock product has a body having a surface that is a modeling material containing a thermoplastic polymer or a melt-cured product of the modeling material, an adhesive layer disposed on the surface, and a flock impinging on the adhesive layer.SELECTED DRAWING: Figure 2

Description

Technical Field

[0001] The present disclosure relates to a core / shell structure, a method for manufacturing a flocked product, and a flocked product.

Background Art

[0002] Patent Document 1 discloses a consumable filament. The consumable filament is melted and extruded in an additive manufacturing system. The consumable filament includes a core portion and a sheath portion that wraps the core portion. The core portion includes a matrix of a first base polymer and particles dispersed in the matrix. The sheath portion includes a second base polymer. The particles in the core portion are selected from metal particles, non-metal particles, magnetic particles, and combinations thereof, and may be ferrite particles (paragraph

[0005] ). The particles in the core portion do not penetrate the outer surface of the sheath portion (paragraph

[0074] ).

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] When a shaped object is manufactured using the consumable filament disclosed in Patent Document 1, the shaped object has a rubber-like touch, a plastic-like touch, etc., and does not have a comfortable touch.

[0005] The present disclosure has been made in view of this problem. One aspect of the present disclosure is to provide, for example, a shaped object or a flocked product having a comfortable touch.

Means for Solving the Problems

[0006] A core / sheath structure according to one aspect of the present disclosure is a core / sheath structure constituting a molded object which is a molding material or a molten cured product of the molding material, comprising: a core having a linear shape and an outer surface, comprising a first thermoplastic polymer; and a sheath covering the outer surface, comprising a second thermoplastic polymer and at least one selected from the group consisting of fibers and particles dispersed in the second thermoplastic polymer.

[0007] A method for manufacturing a floc product according to another aspect of the present disclosure comprises: a) placing an adhesive layer on the surface of a workpiece which is a molding material containing a thermoplastic polymer or a molded product which is a molten and cured product of the molding material; b) piercing a floc into the adhesive layer; and c) curing the adhesive layer after step b).

[0008] Another embodiment of the floc product of the present disclosure comprises a body which is a molded object having a surface and is a molded material containing a thermoplastic polymer or a molten cured product of the molded material, an adhesive layer disposed on the surface, and a floc embedded in the adhesive layer. [Brief explanation of the drawing]

[0009] [Figure 1] This is a schematic perspective view illustrating the molding material of the first embodiment. [Figure 2] This is a schematic cross-sectional view illustrating the molding material of the first embodiment. [Figure 3] This is a photograph of a cross-section of a prototype of the molding material according to the first embodiment. [Figure 4] This is a schematic cross-sectional view illustrating the molding material of a modified example of the first embodiment. [Figure 5] This is a schematic plan view illustrating the molded object according to the second embodiment. [Figure 6] This is a schematic cross-sectional view illustrating a linear body provided in the molded object of the second embodiment. [Figure 7] This is a scanning electron microscope (SEM) image of the entire cross-section of the linear body provided in the prototype of the fabricated object according to the second embodiment. [Figure 8]SEM photograph of the peripheral part of the cross section of the linear body provided in the prototype of the shaped object of the second embodiment. [Figure 9] It is an enlarged cross-sectional view schematically showing the vicinity of the interface between the shaped object of the second embodiment and the human skin that has come into contact with the shaped object. [Figure 10] SEM photograph of the cross section of the prototype of the shaped object of the second embodiment. [Figure 11] SEM photograph of the cross section of the prototype of the shaped object of the second embodiment. [Figure 12] SEM photograph of the cross section of the prototype of the shaped object manufactured using a monofilament. [Figure 13] SEM photograph of the cross section of the prototype of the shaped object manufactured using a monofilament. [Figure 14] SEM photograph of the upper surface of the prototype of the shaped object manufactured using a monofilament. [Figure 15] SEM photograph of the upper surface of the prototype of the shaped object manufactured using a monofilament. [Figure 16] SEM photograph of the prototype of the shaped object manufactured using the shaping material of the modified example of the first embodiment. [Figure 17] Microscopic photograph of a polyester monofilament. [Figure 18] Microscopic photograph of a polyester multifilament. [Figure 19] It is a side view schematically showing the three-dimensional (3D) printer used for manufacturing the shaped object of the second embodiment. [Figure 20] It is a plan view schematically showing the flocked product of the third embodiment. [Figure 21] It is an enlarged cross-sectional view schematically showing the vicinity of the interface between the flocked product of the third embodiment and the human skin that has come into contact with the flocked product. [Figure 22] It is a perspective view schematically showing the electrostatic deposition device used for manufacturing the flocked product of the third embodiment. [Figure 23] It is a flowchart showing the manufacturing process of the flocked product of the third embodiment. [Figure 24] This is a photograph of a prototype of the main body of the flock product of the third embodiment. [Figure 25] This is a photograph of a prototype of the flock product of the third embodiment.

Embodiments for Carrying out the Invention

[0010] Hereinafter, embodiments of the present disclosure will be described with reference to the drawings. In the drawings, the same or equivalent elements are denoted by the same reference numerals, and redundant descriptions are omitted.

[0011] 1 First Embodiment 1.1 Outline of the Modeling Material FIG. 1 is a perspective view schematically showing the modeling material of the first embodiment. FIG. 2 is a cross-sectional view schematically showing the modeling material of the first embodiment. FIG. 3 is a photograph of a cross-section of a prototype of the modeling material of the first embodiment.

[0012] The modeling material 1 of the first embodiment shown in FIGS. 1, 2, and 3 is used to manufacture a modeled object. When a modeled object is manufactured using the modeling material 1, the modeling material 1 is melted, a shape is given to the melted modeling material, and the shaped modeling material is hardened. Thereby, a modeled object that is a melt-hardened product of the modeling material 1 is manufactured. Therefore, the modeling material 1 is a consumable that is consumed to manufacture a modeled object.

[0013] The modeling material 1 is used, for example, to manufacture a modeled object by a three-dimensional (3D) printer and to manufacture a modeled object by a fused deposition modeling (FDM) method. However, the modeling material 1 may be used to manufacture a modeled object by a modeling device other than a 3D printer, and may be used to manufacture a modeled object by a modeling method other than the FDM method. The FDM method is also called the fused filament fabrication (FFF) method.

[0014] The molding material 1 has a linear shape and is thermoplastic. When the molding material 1 is used to manufacture an object, it is heated while being fed in the longitudinal direction. This causes the molding material 1 to melt. The molding material 1 is also flexible and elastic. A molding material 1 having these characteristics is also called a filament. When the molding material 1 is used to manufacture an object using a 3D printer, the molding material 1 has a circular cross-sectional shape and a diameter that is compatible with the 3D printer. The diameter is, for example, 1.75 mm or 2.85 mm. However, the molding material 1 may have a cross-sectional shape other than a circular shape, and may have a diameter other than 1.75 mm or 2.85 mm.

[0015] The main component of the molding material 1 is thermoplastic. This allows the molding material 1 to be melted and separated into multiple components. Furthermore, new molding materials or other types of products can be manufactured from the molding material 1. For this reason, the molding material 1 is recyclable.

[0016] Modeling material 1 can be sold directly to consumers who create their own models in the DIY market. Furthermore, models manufactured using modeling material 1 can be sold to regular consumers in regular stores and regular markets.

[0017] 1.2 Cross-sectional structure and material of the fabricated material As shown in Figures 1, 2, and 3, the molding material 1 has a two-layer structure and is composed of a core / sheath structure 101 comprising a core 111 and a sheath 112. The sheath 112 is also called a shell. The core / sheath structure 101 is also called a core / shell structure. The molding material 1 may have a multilayer structure of three or more layers. A molding material 1 having a multilayer structure of two or more layers is also called a multifilament. In contrast to multifilaments, a molding material having a single-layer structure is called a monofilament.

[0018] The core 111 has a linear shape. The core 111 is flexible. The core 111 has a circular cross-sectional shape. The core 111 may have a cross-sectional shape other than a circular cross-sectional shape. The sheath 112 covers the outer peripheral surface 111S of the core 111. Therefore, the sheath 112 is an outer layer positioned radially outward of the core 111 and is the outermost layer positioned radially outward of the molding material 1.

[0019] As shown in Figure 2, the core 111 comprises a first thermoplastic polymer 121. The sheath 112 comprises a second thermoplastic polymer 122, and at least one selected from the group consisting of fibers and particles (hereinafter referred to as "fibers / particles") 123.

[0020] The second thermoplastic polymer 122 forms the matrix. The fibers / particles 123 are dispersed in the second thermoplastic polymer 122, which forms the matrix. The fibers / particles 123 form protrusions on the surface of the manufactured object, giving the manufactured object a pleasant tactile feel.

[0021] The first thermoplastic polymer 121 and the second thermoplastic polymer 122 are the main components of the core 111 and the sheath 112, respectively.

[0022] The first thermoplastic polymer 121 and the second thermoplastic polymer 122 may be the same type of thermoplastic polymer or different types of thermoplastic polymers. Each of the first thermoplastic polymer 121 and the second thermoplastic polymer 122 may be a single type of thermoplastic polymer or a mixture of two or more types of thermoplastic polymers.

[0023] Each thermoplastic polymer comprises, for example, at least one selected from the group consisting of rigid components and flexible components, preferably including a flexible component.

[0024] The rigid component includes, for example, a thermoplastic resin.

[0025] Thermoplastic resins include, for example, at least one selected from the group consisting of acrylonitrile butadiene styrene (ABS), polylactic acid (PLA), polyethylene terephthalate (PET) and other polyester derivatives, polycarbonate (PC), polyvinyl alcohol (PVA), polyamide (PA), styrene-based polymers, polyvinyl chloride (PVC), and acrylic-based polymers.

[0026] The flexible component includes, for example, a thermoplastic elastomer. By including a thermoplastic elastomer in the core 111 or sheath 112, the flexibility and elasticity of the core 111 or sheath 112 are improved, and the flexibility and elasticity of the molding material 1 are improved. In addition, the flexibility and elasticity of the core or sheath provided in the manufactured molded object are improved, and the flexibility and elasticity of the manufactured molded object are improved.

[0027] The thermoplastic elastomer includes, for example, at least one selected from the group consisting of olefin-based thermoplastic elastomers (TPO), styrene-based thermoplastic elastomers (TPS), vinyl chloride-based thermoplastic elastomers (TPVC), amide-based plastic elastomers (TPAE), ester-based thermoplastic elastomers (TPEE), urethane-based thermoplastic elastomers (TPU), and acrylic elastomers, and preferably includes TPU.

[0028] The fiber / particle 123 includes at least one selected from the group consisting of natural and synthetic products. Examples of natural powders and fibers include ramie, cotton, wool, silk, and chitosan. Examples of mineral powders include chalk and calcium carbonate.

[0029] At least one of the core 111 and the sheath 112 may contain a reinforcing component. The inclusion of a reinforcing component in the core 111 or the sheath 112 improves the strength of the core 111 or the sheath 112, thereby improving the strength of the molding material 1. In addition, the strength of the core or the sheath provided in the manufactured molded object is improved, thereby improving the strength of the manufactured molded object. The reinforcing component includes, for example, a filler. The filler includes, for example, at least one selected from the group consisting of fibers, particles, fine particle powders, nanoparticles, nanofibers, and similar additives. The filler includes, for example, at least one selected from the group consisting of natural products and synthetic products.

[0030] At least one of the core 111 and the sheath 112 may contain a liquid additive in addition to the plasticizer. At least one of the core 111 and the sheath 112 may contain an additive for forming pores. By including an additive for forming pores in the core 111 or the sheath 112, numerous pores are formed in the core or sheath provided in the manufactured object, improving the flexibility, elasticity and permeability of the core or sheath provided in the manufactured object, and improving the flexibility, elasticity and permeability of the manufactured object. The additive for forming pores includes, for example, at least one selected from the group consisting of foaming agents and blowing agents. A foamed core / sheath structure filament in which either the core or the sheath is foamed and the other layer is not foamed has higher strength than a fully foamed structure filament because the non-foamed layer has higher strength and consistency.

[0031] The core 111 may contain particles, additives, mixtures, etc. that do not fall under the above-mentioned components. The particles, additives, mixtures, etc. are dispersed in the first thermoplastic polymer 121 which forms the matrix. The sheath 112 may contain particles, additives, mixtures, etc. that do not fall under the above-mentioned components. The particles, additives, mixtures, etc. are dispersed in the second thermoplastic polymer 122 which forms the matrix.

[0032] In the first example, the first thermoplastic polymer 121 is a TPU having a hardness of 70 Shore A. The second thermoplastic polymer 122 is a TPU having a hardness of 60 Shore A.

[0033] In the second example, the first thermoplastic polymer 121 is TPU, the second thermoplastic polymer 122 is PVA, and the fiber / particle 123 is a natural fiber.

[0034] In the third example, the first thermoplastic polymer 121 is TPU. The second thermoplastic polymer 122 is a mixture of TPU and PVA. The sheath 112 contains a foaming agent.

[0035] In the fourth example, the second thermoplastic polymer 122 is TPU, and the fibers / particles 123 are natural fibers.

[0036] In the fifth example, the first thermoplastic polymer 121 and the second thermoplastic polymer 122 are TPUs. The fibers / particles 123 are ramie fibers.

[0037] The ratio of the outer diameter of the sheath 112 to the diameter of the core 111 reflects the composition or mass fraction of the materials constituting the core 111 and the materials constituting the sheath 112, and can be controlled within a wide range from 1:1.01 to 1:10.

[0038] 1.3 Method for manufacturing molding materials The molding material 1 can be manufactured by co-extruding the material constituting the core 111 and the material constituting the sheath 112 using an appropriate feed block and nozzle. The same applies when the molding material 1 includes layers other than the core 111 and sheath 112.

[0039] For example, when the molding material 1 is manufactured, the material constituting the core 111 and the material constituting the sheath 112 are co-extruded in a co-extrusion line. The co-extrusion line comprises two extruders, a feed block / multi-manifold die head, and a nozzle. The two extruders each form two feeds, one consisting of the material constituting the core 111 and the other of the material constituting the sheath 112. The feed block / multi-manifold die head converges the two formed feeds. The nozzle co-extrudes the molding material 1 using the converged feeds.

[0040] 1.4 Variations Figure 4 is a schematic cross-sectional view illustrating a molding material for a modified example of the first embodiment.

[0041] In the first embodiment of the molding material 1 shown in Figures 1, 2, and 3, the core 111 is a solid body. In contrast, in the modified molding material 1M of the first embodiment shown in Figure 4, the core 111 is a porous body. Therefore, in the molding material 1M, a large number of pores are formed in the core 111. This improves the flexibility, pliability, elasticity, and breathability of the core 111, and thus improves the flexibility, pliability, elasticity, and breathability of the molding material 1M. Furthermore, it improves the flexibility, pliability, elasticity, and breathability of the core provided in the manufactured molded object, and thus improves the flexibility, pliability, elasticity, and breathability of the manufactured molded object. The porous core 111 mimics a multifilament.

[0042] 2. Second Embodiment 2.1 Outline of the Model Figure 5 is a schematic plan view illustrating the fabricated object according to the second embodiment.

[0043] The molded object 2 of the second embodiment shown in Figure 5 is manufactured using the molding material 1 of the first embodiment. Therefore, the molded object 2 is a molten and hardened product of the molding material 1.

[0044] Object 2 is a new type of textile or fabric. Object 2 constitutes, for example, clothing that can be worn on the body continuously. Clothing includes garments, hats, gloves, socks, footwear, accessories, etc. Object 2 may also constitute articles other than clothing.

[0045] Clothing may be a homemade item made by the consumer, a custom-made item made for a specific consumer, or a ready-made item made for an unspecified consumer. However, 3D printing is suitable for homemade and custom-made items.

[0046] The sculpture 2 can be sold to ordinary consumers in ordinary stores and ordinary markets.

[0047] The main part of the molded object 2 is thermoplastic. This allows the molded object 2 to be melted and separated into multiple components. Furthermore, new molded objects or other types of products can be manufactured from the molded object 2. For this reason, the molded object 2 is recyclable after use.

[0048] The properties of the molded object 2 can be adjusted by the materials constituting the molding material 1 used in manufacturing, the structure of the molding material 1 used in manufacturing, and the process parameters when manufacturing the molded object 2. The adjustments are made not only to improve the ease of manufacturing the molded object 2, but also to improve its flexibility, softness, strength, and breathability.

[0049] 2.2 Planar shape of the molded object As shown in Figure 5, the molded object 2 comprises a first linear body 201 and a second linear body 202.

[0050] Each first linear body 201 extends in a meandering manner in a first direction D1. The first linear bodies 201 are arranged in a second direction D2. Gaps exist between adjacent first linear bodies 201. Each second linear body 202 extends in a meandering manner in a second direction D2. The second linear bodies 202 are arranged in a first direction D1. Gaps exist between adjacent second linear bodies 202. The second direction D2 is perpendicular to the first direction D1. As a result, in a plan view, the first linear bodies 201 intersect with the second linear bodies 202. The fabricated object 2 also has a grid-like planar shape. The fabricated object 2 may have a structure different from the structure shown in Figure 5.

[0051] The second linear body 202 is positioned on top of the first linear body 201. The second linear body 202 is in contact with the first linear body 201.

[0052] 2.3 Cross-sectional structure and material of linear body Figure 6 is a schematic cross-sectional view illustrating the linear body provided in the molded object of the second embodiment. In Figure 6, the molded material is shown with a dashed line so that the size of the molded material in the first embodiment and the size of the linear body provided in the molded object of the second embodiment can be compared.

[0053] The linear bodies 210 shown in Figure 6 are the first linear bodies 201 and the second linear bodies 202 described above.

[0054] The linear body 210 is formed by stretching the molding material 1 in the longitudinal direction. Therefore, as shown in Figure 6, the linear body 210 is also composed of a core / sheath structure 221 comprising a core 231 and a sheath 232. However, the diameter of the linear body 210 is smaller than the diameter of the molding material 1. Also, the diameter of the core 231 is smaller than the diameter of the core 111. Furthermore, the thickness of the sheath 232 is thinner than the thickness of the sheath 112.

[0055] The core 231 and sheath 232 provided in the linear body 210 are derived from the core 111 and sheath 112 provided in the molding material 1, respectively. Therefore, the core 231 has a linear shape. The sheath 232 covers the outer circumferential surface 231S of the core 231. The core 231 contains a first thermoplastic polymer 121. The sheath 232 contains a second thermoplastic polymer 122 and fibers / particles 123. The fibers / particles 123 are dispersed in the second thermoplastic polymer 122. The core 231 and sheath 232 provided in the linear body 210 may each contain the components that the core 111 and sheath 112 provided in the molding material 1 may contain. The core 231 may be a porous material.

[0056] Figure 7 is an electron microscope (SEM) image of the entire cross-section of the linear body provided in the prototype of the fabricated object according to the second embodiment. Figure 8 is an SEM image of the peripheral part of the cross-section of the linear body provided in the prototype of the fabricated object according to the second embodiment.

[0057] In the SEM image of Figure 7, although a clear interface between the core 231 and the sheath 232 cannot be confirmed, almost no fibers / particles 123 can be seen in the region that will become the core 231, while dispersed fibers / particles 123 can be seen in the region indicated by the arrow that will become the sheath 232. Similarly, in the SEM image of Figure 8, although a clear interface between the core 231 and the sheath 232 cannot be confirmed, almost no fibers / particles 123 can be seen in the region that will become the core 231, while dispersed fibers / particles 123 can be seen inside the circle that will become the sheath 232. Therefore, from the SEM images of Figures 7 and 8, it can be understood that the sheath 232 contains fibers / particles 123, and that the fibers / particles 123 are dispersed in the second thermoplastic polymer 122. Furthermore, the reason why a clear interface between the core 231 and the sheath 232 cannot be confirmed is that the second thermoplastic polymer 122, which is the main component of the sheath 232, is similar to the first thermoplastic polymer 121, which is the main component of the core 231, and may even be the same as the first thermoplastic polymer 121.

[0058] Figure 9 is an enlarged cross-sectional view schematically illustrating the vicinity of the interface between the fabricated object of the second embodiment and the human skin that came into contact with the fabricated object.

[0059] As shown in Figure 9, the linear body 210 comprises a linear body 241 and a projection 242.

[0060] The linear body 241 constitutes the main part of the linear body 210. The projection 242 protrudes from the outer surface 241S of the linear body 241, forming characteristic irregular irregularities on the outer surface of the linear body 210.

[0061] The fibers / particles 123 include intersecting fibers / intersecting particles 251 that intersect with the outer circumferential surface 241S of the linear body 241. One end of the intersecting fibers / intersecting particles 251 is embedded in the second thermoplastic polymer 122 that constitutes the linear body 241. This fixes the intersecting fibers / intersecting particles 251 to the linear body 241 and prevents them from falling off. The remainder of the intersecting fibers / intersecting particles 251 protrudes from the outer circumferential surface 241S of the linear body 241 and is covered by the second thermoplastic polymer 122 that constitutes the projection 242. This prevents the exposure of the intersecting fibers / intersecting particles 251 and prevents human skin 261 from directly contacting the intersecting fibers / intersecting particles 251. The projection 242 comprises the remainder of the intersecting fibers / intersecting particles 251 and the second thermoplastic polymer 122 that covers the remainder of the intersecting fibers / intersecting particles 251. The second thermoplastic polymer 122 constituting the linear body 241 and the second thermoplastic polymer 122 constituting the protrusions 242 are continuous and integrated.

[0062] The irregular irregularities that are formed are similar to those formed when the packing density of fibers / particles dispersed in the matrix is ​​high. These irregularities can be described as "peaks and valleys." In the linear body 210, the protrusions 242 become peaks, and the areas between adjacent protrusions 242, i.e., regions rich in the second thermoplastic polymer 122, become valleys.

[0063] The size of the irregular bumps and dips that are formed can be controlled by the shape and size of the fibers / particles 123. Therefore, the surface roughness of the fabricated object 2 can be controlled by the shape and size of the fibers / particles 123.

[0064] When human skin 261 comes into contact with the molded object 2, the human skin 261 comes into contact with the projection 242, and a gap 262 is formed between the human skin 261 and the outer surface 241S of the linear body 241. An airflow can be generated in the formed gap 262. Therefore, when human skin 261 comes into contact with the molded object 2, the airflow generated in the gap 262 can quickly dry the human skin 261 and cool it well. As a result, the molded object 2 does not have a rubbery or plastic-like feel, but has a cloth-like feel and a comfortable tactile sensation.

[0065] Furthermore, when human skin 261 comes into contact with the molded object 2, the human skin 261 can gently bend the protrusion 242. Also, since the human skin 261 only makes weak contact with the surface of the molded object 2, the frictional force generated between the human skin 261 and the molded object 2 is small. As a result, the molded object 2 has a soft tactile feel.

[0066] Figures 10 and 11 are SEM images of cross-sections of prototypes of the fabricated object according to the second embodiment.

[0067] In the SEM images of Figures 10 and 11, it can be seen that the projection 242 protrudes from the sheath 112 and forms irregular irregularities on the outer surface of the linear body 210.

[0068] Figures 12 and 13 are SEM images of the cross-section of a prototype object manufactured using monofilament. Figures 14 and 15 are SEM images of the top surface of a prototype object manufactured using monofilament.

[0069] In the SEM images of Figures 12, 13, 14, and 15, it can be confirmed that the surface of the linear body on the prototype of the fabricated object made using monofilament is smooth, clean, and free from significant irregularities. In the SEM images of Figures 14 and 15, the white spots are dust particles.

[0070] The molded object 2, possessing the characteristics described above, has flexibility, strength, breathability, wicking properties, controlled roughness and smoothness, a cloth-like feel, and a comfortable tactile sensation. Furthermore, the color of the molded object 2 can be changed.

[0071] Figure 16 is an SEM image of a prototype of a fabricated object manufactured using a fabrication material of a modified example of the first embodiment. Figure 17 is a micrograph of a polyester monofilament. Figure 18 is a micrograph of a polyester multifilament.

[0072] The polyester monofilament shown in Figure 17 is strong, hard, and rigid. Therefore, polyester monofilament cannot be used for clothing. Furthermore, if this monofilament is used, it is impossible to create irregular bumps and ridges on the surface of the printed object.

[0073] On the other hand, the polyester multifilament shown in Figure 18 is soft and not rigid. Therefore, polyester monofilament can be used for clothing. Furthermore, when this multifilament is used, irregular bumps and ridges can be formed on the surface of the printed object. However, when using polyester monofilament, it is not possible to print objects using a 3D printer.

[0074] In the SEM image in Figure 16, it can be seen that irregular irregularities are formed on the surface of the object manufactured by a 3D printer using the molding material 1M, in which the core 111 is a porous material.

[0075] 2.4 Manufacturing method of molded objects Figure 19 is a schematic side view illustrating a 3D printer used for manufacturing the object according to the second embodiment.

[0076] The 3D printer 271 shown in Figure 19 prints an object 2 using the FDM method with a printing material 1. Hereafter, the printing material 1 will be referred to as filament 1.

[0077] A filament spool 281 is attached to the 3D printer 271. The 3D printer 271 also includes a print head 282, a drive mechanism 283, and a plate 284.

[0078] The filament spool 281 supplies the filament 1.

[0079] The print head 282 melts the supplied filament 1 to produce a molten material and extrudes the produced molten material 288. The print head 282 is positioned vertically above the upper surface 284S of the plate 284. Therefore, the extruded molten material 288 falls and is supplied onto the upper surface 284S of the plate 284. The molten material 288 may be supplied directly onto the upper surface 284S of the plate 284, or it may be supplied onto the upper surface 284S of the plate 284 on top of molten material already supplied on the upper surface 284S of the plate 284 or on top of the cured molten material of said molten material.

[0080] The drive mechanism 283 moves the print head 282 in a direction parallel to the upper surface 284S of the plate 284. This moves the position to which the molten material 288 is supplied. The drive mechanism 283 can set the position to which the molten material 288 is supplied to any position within the printing range.

[0081] Plate 284 supports the supplied molten material 288. The supported molten material 288 hardens to become a molten hardened material. Plate 284 supports the molten hardened material.

[0082] When the 3D printer 271 prints the object 2, it causes the print head 282 to extrude molten material 288 while the drive mechanism 283 moves above the linear region on which the linear body 210 to be attached to the object 2 is to be printed. As a result, linear molten material is formed on the linear region. The formed linear molten material hardens to become the linear body 210.

[0083] The print head 282 includes a filament feeder 291, a heater 292, and a nozzle 293.

[0084] The filament 1 supplied to the print head 282 is inserted into the filament feeder 291. The filament feeder 291 feeds the inserted filament 1 lengthwise and inserts it into the heater 292.

[0085] The heater 292 heats the inserted filament 1 to generate molten material 288 and supplies the generated molten material 288 to the nozzle 293.

[0086] The nozzle 293 discharges the supplied molten material 288.

[0087] When the print head 282 melts the filament 1 to produce molten material 288, the core / sheath structure is maintained. Therefore, the linear body 210 has a core / sheath structure 221. However, because the filament 1 is stretched, the diameter of the linear body 210 becomes smaller than the diameter of the filament 1. Also, the thickness of the sheath 232 becomes thinner than the thickness of the sheath 112. For example, the diameter of the linear body 210 becomes about 1 / 4 of the diameter of the filament 1. Also, the thickness of the sheath 232 becomes about 1 / 4 of the thickness of the sheath 112. In this case, the filament 1 with a diameter of 1.75 mm becomes a linear body 210 with a diameter of about 0.40 mm. Also, the sheath 112 with a thickness of 0.2 mm becomes a sheath 232 with a thickness of about 0.05 mm.

[0088] The size of the fibers / particles 123 included in the sheath 112 provided on the filament 1, for example, the length of the fibers or the diameter of the particles, is selected to be sufficiently smaller than the thickness of the sheath 232 provided on the linear body 210 to be printed. As a result, it is unlikely that the fibers / particles 123 will penetrate the core 231 when the object 2 is printed. Therefore, most of the fibers / particles 123 remain in the sheath 232, and some of the fibers / particles 123 become crossing fibers / crossing particles 251 that intersect with the outer surface 111S of the linear body 241.

[0089] 3. Third Embodiment 3.1 Overview of Floc Products Figure 20 is a schematic plan view illustrating the floc product of the third embodiment. Figure 21 is an enlarged cross-sectional view schematically illustrating the vicinity of the interface between the floc product of the third embodiment and human skin that comes into contact with the floc product.

[0090] The flocked product 3 of the third embodiment, as illustrated in Figures 20 and 21, is a product in which a molded object manufactured using a molding material is subjected to flocking.

[0091] Flock product 3 is a new type of textile or fabric. Flock product 3 constitutes, for example, clothing that can be worn on the body continuously. Clothing includes garments, hats, gloves, socks, footwear, accessories, etc. Flock product 3 may also constitute articles other than clothing.

[0092] Clothing may be homemade by consumers, made to order for specific consumers, or ready-made for unspecified consumers. However, the manufacture of objects using 3D printers and the manufacture of flocked products 3 by flocking are suitable for homemade and made-to-order items.

[0093] The main component of floc product 3 is thermoplastic. This allows floc product 3 to be melted and separated into multiple components, enabling the manufacture of new floc products or other types of products from floc product 3. Therefore, floc product 3 is recyclable after use. This improves sustainability and circularity for the global environment. Other types of products manufactured may be co-extruded filaments. Recycling to co-extruded filaments can be done with minimal degradation of properties, depending on the presence or absence of fibers in the polymer.

[0094] 3.2 Structure of Flock Products As shown in Figures 20 and 21, the flock product 3 comprises a main body 301, an adhesive layer 302, and a flock 303.

[0095] The main body 301 is a molded object manufactured using a molding material, that is, a molded object which is a molten and hardened product of the molding material. The molding material may be a molding material having a single-layer structure, a molding material 1 of the first embodiment having a multilayer structure, or any other molding material, but it may contain a thermoplastic polymer. The main body 301 is manufactured by a 3D printer. The main body 301 may also be the molding material itself.

[0096] The adhesive layer 302 is placed on the surface 301S of the main body 301 and covers the surface 301S of the main body 301. The adhesive layer 302 adheres the flock 303 to the surface 301S of the main body 301 and fixes the flock 303 on the surface 301S of the main body 301.

[0097] The flock 303 penetrates the adhesive layer 302. One end of the flock 303 is embedded in the adhesive layer 302. The remaining portion of the flock 303 is positioned outside the adhesive layer 302. As a result, the flock 303 protrudes from the adhesive layer 302.

[0098] As shown in Figure 21, when human skin 311 comes into contact with the flock product 3, the human skin 311 comes into contact with the flock 303, and a gap 321 is formed between the human skin 311 and the surface of the structure consisting of the main body 301 and the adhesive layer 302. An airflow can be generated in the formed gap 321. Therefore, when human skin 311 comes into contact with the flock product 3, the airflow generated in the gap 321 can quickly dry the human skin 311 and cool it effectively. For this reason, the flock product 3 does not have a rubbery feel, a plastic-like feel, etc., but has a cloth-like feel and a comfortable feel.

[0099] Furthermore, when human skin 311 comes into contact with the flock product 3, the human skin 311 can gently bend the flock 303. Also, since the human skin 311 only makes weak contact with the surface of the flock product 3, the frictional force generated between the human skin 311 and the flock product 3 is small. As a result, the flock product 3 has a soft feel.

[0100] The main body 301 contains a thermoplastic polymer. Preferably, the thermoplastic polymer is a thermoplastic polyurethane. The properties of the main body 301 can be adjusted by the molding material used in its manufacture.

[0101] The adhesive layer 302 consists of a cured adhesive.

[0102] The adhesive is adjusted to fit the main body 301 and the flock 303.

[0103] The adhesive is either a thermoplastic adhesive or a thermosetting adhesive, preferably a thermosetting adhesive. If the adhesive is a thermosetting adhesive, the durability of the adhesive layer 302 can be improved. On the other hand, if the adhesive is a thermoplastic adhesive, electrostatic deposition of the floc 303 can be easily performed.

[0104] The adhesive is a polymer adhesive, preferably a polyurethane-based adhesive or an acrylic-based adhesive, and more preferably a polyurethane-based adhesive. If the adhesive is a polyurethane-based adhesive, flexible polyurethane is included in the adhesive layer 302, which can prevent the adhesive layer 302 from impairing the flexibility of the flock product 3.

[0105] Polyurethane adhesives are, for example, aqueous or solvent-based polyurethane dispersions or liquid polyurethanes.

[0106] Floc 303 comprises at least one selected from the group consisting of fibers and particles. Floc 303 comprises at least one selected from the group consisting of natural products and synthetic products. Natural products include, for example, at least one selected from the group consisting of cotton, wool, and viscose. However, natural products may also include substances other than cotton, wool, and viscose. Synthetic products comprise at least one selected from the group consisting of polyester, polyamide (nylon), polyurethane, polylactic acid (PLA), polyethylene, and polypropylene. Synthetic products may also include substances other than polyester, polyamide, polyurethane, polylactic acid, polyethylene, and polypropylene.

[0107] Flock fibers have a length of, for example, 0.1 mm to 5 mm, and preferably 0.4 mm to 0.8 mm. If the length of the flock fibers is shorter than this range, the flock fibers may become embedded in the polymer and not protrude from the surface, thus not affecting the surface texture. Also, if the portion of the flock fibers protruding from the surface is too short, the fibers will remain upright, giving a prickly texture. If the length of the flock fibers is longer than this range, the weight of the fibers will increase, which may result in insufficient fiber deposition during the flocking process. If the flock fibers are too long, the fibers will lie flat, which may result in a loss of the fluffy texture.

[0108] Flocked fibers typically have a diameter of several micrometers to several hundred micrometers. If the diameter of the flocked fibers is smaller than this range, generally speaking, a large amount of dust will be generated during the manufacturing process, and if this dust reaches the lungs, it poses a risk of causing lung disease. For the end user of the product, this problem does not occur because the flocked fibers adhere to the surface of the printed fabric. Also, the strength of the fibers weakens, leading to durability problems. If the diameter of the flocked fibers is larger than this range, it may be difficult to flock (embed or disperse) the fibers into the polymer because it is not suitable for the thickness of the sheath. Furthermore, fibers that are too thick give a rough texture, losing softness and worsening the tactile feel.

[0109] In the first example, the main body 301 is manufactured using a monofilament made of TPU. The adhesive is a polyurethane-based adhesive. The flock 303 is made of cotton fiber. As a result, the main body 300 becomes soft, and the surface of the flock product 3 has a comfortable feel, making the flock product 3 a comfortable garment.

[0110] As shown in Figures 20 and 21, the floc product 3 comprises a first linear body 331 and a second linear body 332.

[0111] Each first linear body 331 extends in a meandering manner in a first direction D1. The first linear bodies 331 are arranged in a second direction D2. Gaps exist between adjacent first linear bodies 331. Each second linear body 332 extends in a meandering manner in a second direction D2. The second linear bodies 332 are arranged in a first direction D1. Gaps exist between adjacent second linear bodies 332. The second direction D2 is perpendicular to the first direction D1. As a result, in a plan view, the first linear bodies 331 intersect with the second linear bodies 332. Furthermore, the flock product 3 has a grid-like planar shape.

[0112] The second linear body 332 is positioned on top of the first linear body 331. The second linear body 332 is in contact with the first linear body 331.

[0113] The flock product 3, possessing the characteristics described above, is soft, comfortable, breathable, wicking, has controlled roughness and smoothness, and has a cloth-like and comfortable feel. In other words, flocking can transform 3D printed objects into truly wearable textiles or fabrics. Furthermore, the color of the flock product 3 can be changed.

[0114] 3.3 Method for manufacturing floc products Figure 22 is a schematic perspective view illustrating an electrostatic deposition apparatus used in the manufacture of a floc product according to the third embodiment.

[0115] The electrostatic deposition apparatus 341 shown in Figure 22 is an upward-type electrostatic deposition apparatus that launches flocs 303 from vertically downward to vertically upward. The electrostatic deposition apparatus 341 may be an electrostatic deposition apparatus other than an upward-type electrostatic deposition apparatus. For example, the electrostatic deposition apparatus 341 may be a downward-type electrostatic deposition apparatus that launches flocs 303 from vertically upward to vertically downward.

[0116] As shown in Figure 22, the electrostatic deposition apparatus 341 comprises a first electrode 351, a second electrode 352, a chamber 353, and a power supply 354.

[0117] The first electrode 351 has a flat plate shape. The first electrode 351 is installed horizontally.

[0118] The second electrode 352 has a flat grid shape. The second electrode 352 is positioned vertically above the first electrode. The second electrode 352 is installed horizontally. Therefore, the second electrode 352 is parallel to the first electrode 351. The second electrode 352 is grounded.

[0119] Chamber 353 houses the first electrode 351 and the second electrode 352.

[0120] The power supply 354 generates a high DC voltage. The positive electrode 361 of the power supply 354 is electrically connected to the first electrode 351. The negative electrode 362 of the power supply 354 is electrically connected to the second electrode 352 and grounded. As a result, the generated high DC voltage is applied between the first electrode 351 and the second electrode 352.

[0121] When the floc 303 is to be electrostatically deposited onto the workpiece 371, the floc 303 is placed on the upper surface 351S of the first electrode 351. The workpiece 371 is also placed above the second electrode 352. Subsequently, the power supply 354 applies a high DC voltage between the first electrode 351 and the second electrode 352. This charges the floc 303, and the charged floc 303 flies from the upper surface 351S of the first electrode 351, through the second electrode 352, to the workpiece 371. In doing so, the charged floc 303 passes through the gap formed in the second electrode 352. Upon reaching the workpiece 371, the floc 303 adheres to it. This results in the electrostatic deposition of the floc 303 onto the workpiece 371.

[0122] Figure 23 is a flowchart showing the manufacturing process of the flock product according to the third embodiment.

[0123] When flock product 3 is manufactured, steps S101 to S106 shown in Figure 23 are performed. Step S101 is a primary process in which the main body 301 is printed using a 3D printer. Steps S102 to S105, which follow step S101, are secondary processes performed on the surface of the printed main body 301 to modify the tactile feel and appearance of the surface of the main body 301 by electrostatic deposition, or electrostatic flocking.

[0124] In step S101, the main body 301, which will be processed, is manufactured. The main body 301 is manufactured by a 3D printer using the FDM method. However, the main body 301 may be manufactured by a molding device other than a 3D printer, or by a molding method other than the FDM method.

[0125] In the subsequent step S102, an adhesive layer 302 is placed on the surface 301S of the main body 301. This creates a workpiece 371 consisting of the main body 301 and the adhesive layer 302. In this process, a liquid adhesive is applied to the surface 301S of the main body 301 by a spray method, brushing method, roller coating method, doctor blade method, etc. This forms a thin adhesive layer 302 that spreads over the entire surface 301S of the main body 301. The adhesive to be applied is selected to be suitable for electrostatic deposition. The placed adhesive layer 302 promotes adhesion between the floc 303 and the main body 301.

[0126] In the subsequent step S103, the floc 303 and workpiece 371 are introduced into the chamber 353. At this time, the floc 303 is placed on the upper surface 351S of the first electrode 351. The workpiece 371 is positioned vertically above the second electrode 352.

[0127] In the following step S104, the floc 303 is embedded in the adhesive layer 302. The floc 303 is embedded in the adhesive layer 302 by electrostatic deposition. At this time, the power supply 354 applies a high DC voltage between the first electrode 351 and the second electrode 352. As a result, the floc 303 becomes charged, and the charged floc 303 flies from the upper surface 351S of the first electrode 351, through the second electrode 352, to the workpiece 371. Upon reaching the workpiece 371, the floc 303 adheres to the adhesive layer 302. As a result, the floc 303 adheres to the surface 301S of the main body 301 via the adhesive layer 302, covering the surface 301S of the main body 301. This provides a new tactile sensation. One end of the attached floc 303 is embedded in the adhesive layer 302 and fixed to the adhesive layer 302. The remaining portion of the attached floc 303 is positioned outside the adhesive layer 302. As a result, the floc 303 protrudes from the adhesive layer 302. Therefore, the floc 303 is pierced into the adhesive layer 302 in a state where it protrudes from the adhesive layer 302. If the floc 303 is a fiber, the floc 303 is pierced into the adhesive layer 302 in a state that is approximately perpendicular to the surface 301S of the main body 301.

[0128] In the subsequent step S105, the adhesive layer 302 is cured. During this process, the adhesive layer 302 is dried and scorched by heating or other means.

[0129] In the following step S106, cleaning is performed. During this step, any excess floc 303 that is not adhered to the main body 301 by the adhesive layer 302 is removed. This completes the floc product 3.

[0130] Flocking may be performed manually using a handheld electrostatic coating device or similar.

[0131] Figure 24 is a photograph of a prototype of the main body provided in the flock product of the third embodiment. Figure 25 is a photograph of a prototype of the flock product of the third embodiment.

[0132] Comparing the main body 301 before flocking, shown in Figure 24, with the flocked product 3 after flocking, shown in Figure 25, it can be seen that flocking allows for the formation of complex irregularities on the surface of the flocked product 3.

[0133] Step S102, in which the adhesive layer 302 is placed on the surface 301S of the main body 301, and step S104, in which the floc 303 is inserted into the adhesive layer 302, take only a very short time, for example, only 3-10 minutes. If the process is automated, further time reductions are possible. However, step S105, in which the adhesive layer 302 is cured, takes a long time, for example, several hours. However, the time required for step S105 can be reduced by selecting the adhesive.

[0134] The state of the floc 303 covering the surface 301S of the main body 301 can be adjusted by adjusting the electrostatic deposition parameters in step S104. For example, by adjusting these parameters, the entire surface 301S of the main body 301 can be uniformly covered with floc 303, or the surface 301S of the main body 301 can be covered with floc 303 such that the density of the floc 303 has a gradient.

[0135] The texture of flock product 3 can be adjusted by adjusting the type, dTex, and length of flock 303. The density of flock 303 can be adjusted by adjusting the properties of the body 301, the adhesive, the properties of flock 303, and the process conditions.

[0136] The flock 303 is less affected by the material of the main body 301, but this can be adjusted by the choice of adhesive. This allows for the manufacture of flock products 3 suitable for various applications.

[0137] The properties of flock product 3 are less affected by the properties of the main body 301 and can be adjusted by the selection of adhesive. This is because the adhesive layer 302 functions as an intermediate layer connecting the flock 303 to the main body 301.

[0138] Two or more types of floc 303 may be combined in order to obtain the structure and properties of the floc product 3 that cannot be obtained with a single type of floc 303.

[0139] To carry out the manufacturing method of the flocked product described above, a factory may be established to perform the primary and secondary processes described above, according to customer requirements or seasonal collections. Alternatively, a factory may be established to perform only the secondary process described above, according to customer requirements. In this case, the main body 300 is provided by the customer.

[0140] This disclosure is not limited to the embodiments described above, and may be replaced with configurations that are substantially the same as those shown in the embodiments, configurations that produce the same effects, or configurations that can achieve the same purpose. [Explanation of Symbols]

[0141] 1. Printing Material (Filament), 101 Core / Sheath Structure, 111 Core, 112 Sheath, 121 First Thermoplastic Polymer, 122 Second Thermoplastic Polymer, 123 Fibers / Particles, 1M Printing Material, 2. Printed Objects, 201 First Linear Body, 202 Second Linear Body, 210 Linear Body, 221 Core / Sheath Structure, 231 Core, 232 Sheath, 241 Linear Body Body, 242 Protrusions, 251 Cross Fibers / Cross Particles, 261 Human Skin, 271 3D Printer, 281 Filament Spool, 282 Print Head, 283 Drive Mechanism, 284 Plate, 288 Molten Material, 3. Floc Products, 301 Body, 302 Adhesive Layer, 303 Floc, 311 Human Skin, 331 First Linear Body, 332 Second linear body, 341 electrostatic deposition apparatus, 351 first electrode, 352 second electrode, 353 chamber, 354 power supply, 361 positive electrode, 362 negative electrode.

Claims

1. An adhesive layer is placed on a surface of a processing object, which is a molding material containing a thermoplastic polymer or a molded object that is a molten and hardened product of the molding material; Sticking flock into the adhesive layer; piercing the adhesive layer with the flock and then curing the adhesive layer; A method for producing a flock product comprising the steps of:

2. The flock is pierced into the adhesive layer by electrostatic deposition. A method for producing the flock product of claim 1.

3. The flock is charged with electricity, so that the flock is pierced into the adhesive layer. A method for producing the flock product according to claim 2.

4. The flock is pierced into the adhesive layer in a state where the flock protrudes from the adhesive layer. A method for producing a flock product according to any one of claims 1 to 3.

5. The floc comprises at least one of fibers and particles. A method for producing a flock product according to any one of claims 1 to 4.

6. The flock comprises at least one of cotton, wool and viscose. A method for producing a flock product according to any one of claims 1 to 5.

7. The flock comprises at least one of polyester, polyamide, polyurethane, polylactic acid (PLA), polyethylene, and polypropylene. A method for producing a flock product according to any one of claims 1 to 5.

8. The flock comprises flock fibers of 0.4 mm to 8 mm. A method for producing a flock product according to any one of claims 1 to 7.

9. The workpiece contains thermoplastic polyurethane, The adhesive layer comprises polyurethane. A method for producing a flock product according to any one of claims 1 to 8.

10. The flock comprises fibers, The flock penetrates the adhesive layer in a state substantially perpendicular to the surface of the workpiece. A method for producing a flock product according to any one of claims 1 to 9.

11. The adhesive layer includes a thermosetting adhesive. A method for producing a flock product according to any one of claims 1 to 10.

12. A main body having a surface, the main body being a modeling material including a thermoplastic polymer or a molten and hardened product of the modeling material; an adhesive layer disposed on the surface; flock stuck into the adhesive layer; A flock product comprising:

13. The flock at least partially protrudes from the adhesive layer.

13. The flock product of claim 12.

14. The flock product comprises clothing, The flocking forming the projections is adapted to contact the skin of the person wearing the garment.

14. A flock product according to claim 12 or 13.

15. The floc comprises at least one of fibers and particles. A flock product according to any one of claims 12 to 14.

16. the body comprises a thermoplastic polyurethane; The adhesive layer comprises polyurethane. A flock product according to any one of claims 12 to 15.

17. The flock comprises at least one of cotton, wool and viscose. A flock product according to any one of claims 12 to 16.

18. The flock comprises at least one of polyester, polyamide, polyurethane, polylactic acid (PLA), polyethylene, and polypropylene. A flock product according to any one of claims 12 to 16.

19. The flock comprises flock fibers of 0.4 mm to 8 mm. A flock product according to any one of claims 12 to 18.

20. The flock comprises fibers, The flock penetrates the adhesive layer substantially perpendicular to the surface of the body. A method for producing a flock product according to any one of claims 12 to 19.

21. The adhesive layer includes a thermosetting adhesive. A method for producing a flock product according to any one of claims 12 to 20.

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