Articles having Anti-blocking surface using flock alternative
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Solution Overview
Problem
The textile industry faces safety, environmental, and health issues with conventional flocking techniques due to flammability, explosion risks, and health hazards from fine flock dust, necessitating a safer alternative.
Innovation Solution
A non-foamed aqueous composition comprising hollow glass particles and a water-soluble or water-dispersible film-forming organic polymeric binder is applied to finished fabric surfaces, providing anti-blocking and tactile properties without the use of conventional flock.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional flocking techniques are used to provide soft feel and texture on finished fabrics, then the tactile properties are improved, but safety hazards (flammability, explosion risk) and health risks (fine dust inhalation) worsen
Solution Approach 1:
The patent changes the physical state and composition parameters of the coating material from combustible flock fibers to non-combustible hollow glass particles with specific size ranges (5-100 μm) and density characteristics, eliminating flammability while maintaining tactile properties through controlled particle morphology and surface characteristics
Solution Approach 2:
The patent creates a composite coating system combining hollow glass particles with adhesive compositions and optional polymeric binders, forming a multi-component material system that provides both tactile benefits and safety improvements by replacing organic flock materials with inorganic particle-based composites
2Ease of operation
If conventional flock is applied to adhesive compositions to create flocked fabrics, then the soft feel and decorative properties are improved, but environmental pollution and cleanup complexity worsen
Solution Approach 1:
The patent modifies the material composition parameters by substituting organic flock fibers with inorganic hollow glass particles, changing the environmental behavior from polluting (combustible dust, microplastics) to non-polluting (inert, non-combustible particles that do not enter food chains)
Solution Approach 2:
The patent converts the previously harmful fine dust generation into a beneficial fine particle application system where the hollow glass particles, due to their controlled size and non-combustible nature, provide tactile benefits without the harmful environmental and health effects of conventional flock dust
3Object-affected harmful factors
If hollow glass particles are used as flock alternative, then safety and environmental properties are improved, but achieving equivalent tactile properties becomes more difficult
Solution Approach 1:
The patent optimizes multiple parameters of the hollow glass particles including size distribution (5-100 μm), density, shell thickness, and surface characteristics to replicate the tactile properties of conventional flock, demonstrating that precise parameter control can achieve sensory equivalence while maintaining safety benefits
Solution Approach 2:
The patent develops composite formulations combining hollow glass particles with specific adhesive compositions and polymeric binders, creating a multi-component system that works synergistically to achieve tactile properties comparable to conventional flock while maintaining the safety advantages of inorganic particles
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution offers a safer, effective alternative to flocking that maintains desirable feel and texture while enhancing anti-blocking and other practical properties, eliminating the need for dangerous flocking operations.
Implementation Method 1
having an anti-blocking characteristic and masking any tacky feel of the finished fabric on the treated at least one of the two finished surfaces
Implementation Method 2
a water-soluble or water-dispersible film-forming organic polymeric binder that has a glass transition temperature of less than 25° C.
Implementation Method 3
a treatment on at least one of the two finished surfaces in the form of a dry non-foamed aqueous composition disposed on at least one of the two finished surfaces
Data Source
AI summary
An article has a finished fabric with two finished surfaces, and a treatment on at least one of the finished surfaces, which is a dry non-foamed aqueous composition as a flock substitute at 0.5-15 g/m2. It has an anti-blocking characteristic and masks any tacky feel of the finished fabric on the treated surfaces. The dry non-foamed aqueous composition includes: (i) hollow glass particles of 5-100 μm average particle size in an amount of 10-99 weight %, which hollow glass particles have an impact strength of greater than 50 MPa; (ii) a water-soluble or water-dispersible film-forming organic polymeric binder with a Tg of less than 25° C.; (iii) a crosslinking agent if needed; and (iv) porous particles in an amount of less than 0.01 weight %. The weight ratio of the (i) hollow glass particles to the (ii) water-soluble or water-dispersible film-forming organic polymeric binder is from 1:5 to and including 10:1.