METHODS OF APPLICATION FOR DECORATIVE FLOCKING

APPLICATION METHODS:

Decorative flocking is done using any one of the following application methods:

·         Electrostatic

·         Beater bar/gravity

·         Spraying and

·         Transfers.

The electrostatic method is the most viable flocking method.

Flocking is an alternative decorating method for achieving unusual look. It costs slightly more than that produced by a standard screen print, and for textiles, it is less expensive than embroidery. This process uses dyed fibers of nylon that are charged with high voltage and driven into design. This process eliminates fiber shedding, which is common with most other flocked images. Standard flock transfers can also be made in house.

Basically the pre-press is the same as it is for the screen printing with only a few differences. The screens are made from coarser mesh counts and the line thickness of some of the art work is increased. The adhesive is printed, and a crystalline powder is applied to the transfer and then is sent through the dryer at a low temperature. This removes moisture from the adhesive, but does not melt crystalline powder. Excess powder is removed and the transfer is sent through the dryer for second time. This binds the powder chemically to the adhesive.

The most successful method to ensure a good dense coverage is a combination of electrostatic flock application with the use of beater bars to help increase the density of the coating.

FLOCKING - Introduction

HISTORY

Flock printing is an old technique which was already in use in China around 1000 BC. In Europe it became popular during the Middle Ages, where fiber dust was attached to sticky surfaces. In 1970s with the advent of improved technologies and adhesives the flocking method became popular method for decorating. In 80s and 90s the method lost its popularity. But in last few years the flocking method is once again in demand because the flocked surfaces reduce water condensation, act as good thermal insulators.

APPLICATION:

T-shirts, packaging for perfumes, car glove box, car head liners, floor coverings, model railway-landscapes, Eye liner brush, scrubbing pads, garments, greeting cards, trophies, toys, book-covers etc.

ADVANTAGES OF FLOCKED SURFACES ARE:

·         Pleasant appearance

·         Fibered grip

·         Persistence against bounces and scratches

·         Good sliding effect on even surfaces

·         Many other specialized properties.

THEORY:

Flock printing or flocking is a printing process in which short monofilament fibers of rayon, cotton, wool or another natural or synthetic material are applied to an adhesive-coated surface. This adds a velvet or brush (suede) like texture to the surface. Since the fibers can be dyed, flocking can also add a color to a printed area.

The fibers used in the process are known as flock. They can be applied to paper, plastic, metal, rubber, wood, textiles and even glass.

The diameter of the individual flock strand is only a few thousandths of a centimeter and ranges in length from 0.05 to 5mm. The adhesive that capture the fibers must have the same flexibility and resistance to wear as the substrate. The flocking process requires a special equipment that charges the flock particles causing them to stand erect. The fibers are then propelled and anchored into the adhesive at right angles to the substrate. The application is both durable and permanent.

SUMMARY
Flocking is an alternative decorating method for achieving unusual look. It costs slightly more than a standard screen print, and for textiles, it is less expensive than embroidery. Also with the advanced state of adhesive technology nearly any material can be flocked, making it easy to add new products to the textile production capabilities. Wallpaper, greeting cards, mouse pads, book and album covers, and posters can all be flock printed. The successful use of electrostatic flocking depends on tight control over the process and the environment. Detailed production records should be kept, so the process can be repeated. Retention of production samples is also an important factor for repeat jobs, product reliability, and quality control information.