Here we answer some common questions about flock and the flocking process. Choose from the list of frequently asked questions. If you don't find what you're looking for, please contact us. We are happy to help. The flock that Cellusuede manufactures is a precision cut synthetic fiber of small diameter (from .0003" to .020"). The diameter of the fiber is typically described by the term "denier," which is defined as the weight in grams of a single filament 9000 meters long. Our cut length capabilities range from .015" (0.38mm) to 0.5" (12.7mm). The flock is made from continuous filament, called tow, which is cut to the length required. The cut flock is then dyed to the proper color, and a final chemical treatment, called the finish, is applied to give the flock flow characteristics, electrostatic properties, and moisture retention as required by the customer. top--> Flock as a surface treatment can provide a warmth and plushness that other treatments (fabric wrapping, felt, soft touch paints) cannot duplicate with the same ease and investment of time and money. Color, feel, function can all be enhanced by flocking. Flock on a welcome or logo mat creates a vivid styling impression and acts to improve the function of the mat. Also, flock in an automotive interior application can soften the look and feel of bare molded plastic and can reduce noise and rattles in gloveboxes, center consoles and dashboard and door trim parts. Flock on paint pads allows the pad to absorb paint and allows the painter to paint more accurately and evenly with a minimum of brushmarks or drips. The possibilities are endless. top--> What about functional and industrial uses? Flock can be used as a reinforcement fiber in the molding and extrusion of plastics to improve strength, control cracking or breaking behavior, or to control the molding and flow characteristics of the plastics during manufacture. Flock can be added to paper during processing to not only add an impression of texture and richness, but can be used as a reinforcement to improve tear strength. Flock has even been used as a flow control additive for an epoxy adhesive use in the fuel system of the SR-71 Blackbird, the highest flying, fastest jet airplane in history. From low tech to high tech, flock is everywhere! top--> There are two major types of flock application, with several sub-classifications. The two primary techniques are mechanical (including gravity drop, vibration, windblown or a combination) and electrostatic (including AC, DC electrostatic/air assist). The mechanical methods are the least demanding in terms of engineering and probably the easiest to get started. The fiber density on the substrate is somewhat less than the density from a typical electrostatic process, and the fibers are not as well oriented, giving the flocked surface a felt-like appearance. The electrostatic methods generally will produce a denser coating with much more vertical orientation of the fibers, acheiving a more velvet-like feel and appearance. Whichever method is used, a layer of adhesive must be applied first. top--> What types of adhesives are best? Several types of adhesives are used for flocking, including water-based, solvent-based, plastisols, epoxies and so on. The application of the adhesive is somewhat dependent on the shape and type of substrate. Typical methods include spraying or dipping for objects, silk screening for garments and flat sheets, roller coating for mats and flat goods, doctor blades for continuous textiles, among others. The glue should be receptive to the flock and should be applied evenly and consistently. The glue should also be formulated to give you the behavior and performance you need (abrasion resistance, solvent resistance, stiff or flexible film, etc.). top--> What about fiber performance? What is the best fiber for me? Let's look at some common flock fiber types of the same cut length and the same denier and compare some basic properties:
Softness - Rayon > Nylon or polyester > Acrylic
Cost (generally) - Nylon > Rayon > Acrylic or Polyester Physical characteristics like softness and abrasion resistance will also be affected by increasing or decreasing the thickness (denier) and cut length of the fiber. Typically, longer fibers feel softer than shorter fibers, and thinner fibers feel softer than thicker fibers. However, there is a delicate balance between the thickness of the fiber and the maximum achievable cut length that will determine the efficiency of the flocking manufacturing and application process. top--> |
Abrasion Resistance
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