Abstract: An improved contoured resilient vehicle trim panel and method of making same which is suitable for use as a decorative headliner adjacent to the interior undersurface of the roof panel of vehicles. The trim panel comprises a composite laminar sheet consisting of a pair of imperforate thermoplastic films disposed in spaced-apart relationship and tenaciously bonded in supported relationship to the face surfaces of an intervening coextensive thermoplastic foam core layer. The films and the closed cell foam core are comprised of a thermoplastic polymer having a glass transition temperature of at least 200.degree. F. and a tensile modulus of at least 1.0.times.10.sup.5 psi. A variety of decorative coatings and films can be secured to the concave face of the laminar sheet so as to achieve the desired decorative appearance.

Abstract: The present invention relates to a method for producing a mixed flock fabric of different filaments in which highly curled filaments are straightened, sized, cut into a length of 0.1 to 0.4 inch and electrostatically flocked with non-sized fibres onto a substrate, so that when the size is removed, there is formed a mixed flock fabric having mixed, stiffened and individual fibres.

Abstract: New 1,4-bis-[azol-2'-yl]-naphthalene compounds, a process for their preparation as well as a process for optically brightening organic materials on using said compounds are disclosed.

Abstract: An artificial leather having chinchilla-like appearance and a natural suede-like feeling which comprising flocking piles of separable composite fibers which in transverse cross-section consist of at least three integral segments (A) of one polymer of polyamide and polyester wherein said segments diverge from each other substantially radially in the outward direction and extend to the perimeter of the fiber and wedge-shaped segments (B) of another polymer which fill the spaces between the segments (A) or consist of the above described segments (A), V-shaped segments (B') of the latter polymer and wedge-shaped segments (C) of the former polymer which fill the concavities of the V-shaped segments (B'), said V-shaped segments (B') and said wedge-shaped segments (C) filling the spaces between the segments (A), wherein all of the polymers extend to the perimeter of the fiber, on a substrate fabric applied with an adhesive, applying a swelling agent on the piles, brushing the thus treated piles to substantially sepa

Abstract: The disclosure is of a method of adhering a textile tennis ball cover to a tennis ball core. The method comprises providing a core and a textile tennis ball cover for the core. A hot-melt adhesive is also provided, disposed in association with the cover material. The cover and adhesive are assembled on the core and the hot-melt adhesive caused to melt and form a bond between core and covering material. Upon solidifying, the adhesive adheres the cover to the core of the tennis ball with a high degree of tenacity. The method of the invention is advantageous over the prior art commercial methods, in terms of efficiency and economics.

Abstract: This invention is concerned with the tack spinning of materials and has particular reference to the formation of tack spun materials by applying a thermoplastic polymer to a backing or carrier sheet to form a pattern or layer thereon and then heating the layer and contacting the layer with a second surface whereby separation of the carrier from the second surface results in separation of the thermoplastic polymer within its plane to draw fibres therefrom on progressive separation. The preferred embodiment of the invention involves two backing sheets prepared between a pair of nip rollers to form a sandwich structure with a layer of thermoplastic tack spinnable material and separating the same on the downstream side of the nip to provide the fibres disposed substantially transverse to the plane of the carrier sheet. The invention also describes novel apparatus for performing this operation.

Abstract: A plurality of substantially parallel filamentary textile materials are assembled in a bundle to make a textile pile element. One end of the bundle has a base joining the materials at one end in a stable condition whereas the other end of the bundle contains strands which are free and open. The textile materials are retained in parallel arrangement by the base which is located in a mesh. The mesh is a support comprised of a planar structure having openings for receiving the bases of the elements. The mesh may be prefabricated or assembled during fabrication of the pile article. A pile textile article is made from the elements by a process of fabrication which includes the steps of inserting the textile elements in the opening in the mesh to result in an article which has application to furniture, clothing, toys, hats and decorative items.

Abstract: Flock-coated metal sheet with excellent corrosion resistance and fabricability produced by applying an anticorrosive synthetic resin containing an anticorrosive pigment on the surface of a metal sheet such as a steel sheet to obtain an anticorrosive synthetic resin layer with a dried film thickness of 2 to 20 microns, coating said synthetic resin layer partially or completely with an elastic adhesive with a dried film thickness of 50 to 500 microns, and electrostatically flock-coating synthetic resin pile on said adhesive layer.

Abstract: A sheet material finished on at least one side with a coherent surface layer is formed by electrostatically spraying a solution or dispersion of plastics producing fibers from 0.1 to 30 microns in diameter. Then the mat is consolidated with heat and pressure, whereby the fibers form a tight bond with the surface of the support material which is thus finished.

Abstract: Cellular linear filaments are disclosed and include a substantially continuous, integral plastic hollow member having internal generally transverse partitions which divide the hollow member into cells. The wall of the hollow member can be continuous or can contain orifices, slits, windows and the like. The cells can be open or closed and uniformly or randomly spaced along the tubular member. The cells are defined by transverse partitions which can be integrally formed with the hollow member or they can be seals in the hollow member. Woven, non-woven and tufted materials including yarns made up in part or in total of the cellular linear element are also disclosed. The cellular linear element can be cut into discrete lengths to form pile-like elements which can be attached upright to a base to form a multi-element device.

Abstract: A transferable flocked fiber design material for decorative flocked fabric goods which includes a release support sheet, fibers releasably flocked on one surface of said support sheet through a water-soluble and water-dispersible adhesive and a thermoplastic and pressure-sensitive synthetic resin adhesive layer applied to the exposed ends of said fibers.

Abstract: Pile textile elements are disclosed in which heat fusible textile filamentary materials are assembled in a bundle wrapped in a plastic envelope. The filaments are held together at one end only of the bundle by fusing the ends of the filaments and the plastic envelope while they are in contact, under pressure, with a heated flat surface. The fused end of the bundle forms a base to facilitate handling of the pile textile element, and also facilitating securing the element to a suitable backing, such as a textile backing, furniture, bedding, etc., in a conventional manner.

Abstract: A sealing material comprising a sealing strip and a peeling tape overlying the sealing strip, with the peeling tape having substantially the same width as the sealing strip and having a low adhesiveness on both sides thereof, wherein one or both edges of the sealing strip are flocked with short fibers with or without a bonding layer.

Abstract: Flocked fabric products having a woven corduroy appearance, including method and apparatus for producing such fabrics wherein an indefinite length substrate sheet is transported in a generally horizontal path of travel through a coating apparatus where a mass of viscous adhesive material is applied to the upper surface of the sheet while support means located beneath the sheet prevent displacement of the sheet from its path of travel and provide dimensional stability thereto. Immediately downstream of the support means the upper surface of the sheet and the adhesive material thereon is contacted by the notched edge of a knife blade to dispose the adhesive mass in a plurality of parallel upstanding ribs having upwardly tapered sides in transverse cross-section.

Abstract: A no-gel latex foam is formed by curing a no-gel latex foam froth on a water vapor permeable foraminous support that has been coated with a flock. During curing, the foam froth dehydrates through an upper free surface and at its lower supported surface through the flock and the foraminous supporting means. When the cured foam is removed from the foraminous supporting means, a portion of the flock adheres to the foam undersurface and another portion of the flock is left as a residue.

Abstract: A composite board structure comprising a corrugated fiberboard consisting of at least one liner and at least one corrugated paper medium bonded to the liner by means of a layer of a hot melt adhesive material, the liner being covered with a facing web of a woven or unwoven fabric which has its fibers scatteringly filling in perforations formed in the liner and sticking to the layer of the hot melt adhesive material so as to be securely fastened to the liner without use of any adhesive material between the liner and the facing web.

Abstract: A suede-like sheet material characterized by being formed of a base cloth and ultrafine fibers of a denier less than 0.5 per filament, said ultrafine fibers being entangled with each other and covering at least one surface of the base cloth, wherein a portion of said ultrafine fibers is stuffed into the gaps in the network of the base cloth, at least a portion of said ultrafine fibers being entangled with the component fibers of the base cloth, and said base cloth and ultrafine fibers being substantially integrated with each other.

Abstract: A process for manufacturing transfer sheets is disclosed in which short fibers are temporarily stuck to a base sheet to form a short fiber layer to which two kinds of adhesives are applied to a desired design or letter to be transferred. When the transfer sheet thus made is put on a clothes or the like and heat and pressure are applied, the short fibers are transferred to the clothes only where coated with the adhesive.

Abstract: An ornamented article of clothing constituting a fabric substrate which forms at least a part of an article of clothing has applied to it in a pattern, with the aid of a stencil, an area of predetermined configuration such as a design, a character or a phrase in the form of an adhesive coating composed of a film-forming solid and a liquid solvent. The adhesive coating bonds to the substrate as by permeation into interstices thereof so that when the coating dries it will firmly adhere thereto. While the coating still is wet there are applied to the coating particles composed of a plastic material which is attackable by one or more constitutents of the still-wet adhesive, specifically the solvent or a plasticizer incorporated in the plastic solid. This attack on the surfaces of the particles causes the particles to bond to the adhesive coating.

Abstract: Amazingly beautiful decorative objects can be made by a method comprising the steps of (1) producing a chemically pure, over-saturated solution of potassium aluminosilicate, (2) coating substrates to be decorated with flock, (3) introducing the substrates into the solution, (4) removing the substrates from the solution after crystals have grown on the substrates, (5) drying the crystals, (6) coating the crystals with a transparent brilliant liquid plastic, and, optionally, (7) dyeing the plastic, either before or after it has dried. Alternatively, dye may be introduced directly into the solution.

Abstract: In the manufacture of flocked textiles by applying a polymer emulsion, flocking and drying, a heat-sensitized polymer emulsion is used and the emulsion coat is first only gelled, by heating, in the zone adjoining the textile substrate, and is then flocked and dried at an elevated temperature.

Abstract: A pressure sensitive laminate and method of making same for effecting an image transfer and attachment which includes a carrier layer having releasably bonded thereto a coloring pigment or dye, and a complementary adhesively backed laminate which is normally maintained in spaced relationship by a spacer interposed between the carrier and covering layers whereby the transfer is effected by applying a predetermined pressure for bringing the adhesive backed layer into intimate contact with the releasable pigment of the carrier layer in the area of applied pressure only. Upon stripping the covering layer from the carrier layer with the pigment adhered thereto along the area of intimate contact, the covering layer can be readily applied to a given surface.

Abstract: The disclosure herein is concerned with critical electron-beam radiation parameters and beam-passage rates and adjustments that have been found to enable high-speed curing of adhesives used to bond flock and similar materials to heat-sensitive substrates that otherwise inherently limit the degree of thermal curing that may be employed as by other means, and consequently limit the speed of curing.

Abstract: A self-sealing fuel tank which utilizes elongated nonself-adhering polymer ibers attached to the inner surface of the tank wall and interwoven to form a carpet-like liner for efficiently sealing large tears and cored holes. After penetration of the tank wall by a large or tumbling projectile, escaping fluid causes nearby elongated fibers to be swept into the hole, thereby choking the escaping fluid flow. Conventional small caliber self-sealant incorporated in the tank wall then flows into the hole choked by fibers and completes the seal.

Abstract: A weatherseal is made by extruding a resin base with a relatively thick, flat support portion and a relatively thin, portion U-shaped in cross section and joined to opposite side edges of the support portion to arch over the center of the support portion. While the resin material is still plastic, a pressure differential expands the U-shaped portion to reduce the thickness of the walls of the U-shaped portion, and then each side of the U-shaped portion is cut at a predetermined distance from the support to leave a pair of thin, spaced-apart resilient fins. Then fibrous pile material is secured to the support between the fins to form a double-fin, pile weatherseal.

Abstract: A flame-retardant material, and a method for making same, which comprises: (1) a reinforcing ply of textile material; (2) at least one sheet of foam bonded to a face of the reinforcing ply; (3) a layer of flock fibers adhered to the foam thereby covering the exposed face of the foam; and (4) a flame-retardant adhesive system disposed in two layers between said flock fibers and the foam sheeting.

Abstract: An article of manufacture comprising a heat and pressure consolidated assembly comprising, in superimposed relationship,1. a thermoset resin impregnated, decorative paper layer and2. a thermoset resin impregnated paper sheet havingA. a dry adhesive coating positioned on one side thereof andB. flocked fiber implanted in said adhesive in generally a perpendicular orientation to said sheet,Is disclosed.

Abstract: A laminate component comprising1. a thermosetting resin impregnated paper sheet,2. a dry adhesive coating positioned on one side of said sheet and3. flocked fibers implanted in said adhesive, and a method for the production thereof, are disclosed.

Abstract: A soft, pliable, fiber-reinforced surface flock foamed latex sheet comprising a fibrous sheet or scrim base material, a foamed latex and a flocking in which the foam latex comprises up to about 98 weight percent of the foamed latex sheet.

Abstract: A carpet fitting, such as a cover strip, threshold guard, edging piece, threshold strip or joining strip of which, in use, a surface is exposed to view. Such exposed surface is coated with flock by electrostatic deposition. Further surface areas may be so coated. The flock may be selected to blend with the carpet and the flock coating assists in preventing persons from slipping on the fitting.

Abstract: Textile adhesive compositions. More particularly, aqueous adhesive compositions comprising a plasticizing agent and a dispersed polyurethane polymer, the method of using the adhesive composition in textile applications and the textile materials thus obtained.

Abstract: A process for producing a flocked fabric laminate by coating an auxiliary substrate with a temporary adhesive binder, flocking the coated auxiliary substrate with flock fibers, coating the flock fibers with a curable flock adhesive binder, marrying a substrate backing layer to the binder coated flock, permanently setting the flock adhesive binder, and then removing the auxiliary substrate from the fabric laminate whereby the flock remains secured to the substrate backing layer is disclosed. Flocked fabric laminates obtained by such method are also described.

Abstract: A process for producing a laminate by coating a continuous first layer of a film forming material onto a release sheet, distributing flock fibers uniformly onto the first layer, drying the first layer to form a film and secure the flock fibers thereto in a substantially upstanding position, coating the tips of the flock fibers with a flock adhesive, marrying the flocked film to a substrate backing layer such that the coated tips contact the said substrate layer, permanently setting the flock adhesive, and then removing the release sheet. Laminates obtained by such method are also described.

Abstract: A wallcovering comprising a fabric-backed, lightweight laminate is disclosed wherein the fabric is coated with various pigmented polymer coatings to which is applied a film of metallized polyethylene terephthalate. The metallized film is then flocked. Printed designs may be applied thereto prior to the addition of the flock.

Abstract: The invention contemplates expanded-plastic coated fabric wherein the exposed surface of the expanded plastic is characterized by a random distribution of torn cellular pockets and by a random distribution of projecting free ends of flock elements which are rooted to the plastic at their other ends. Various methods of making the fabric are described, with different "hand" or "feel" depending upon the method and upon the materials and their dimensions.

Abstract: A pattern is printed with adhesive as a design on certain selected areas of a shrinkable substrate and the adhesive is dried. Flock is preferably applied to the selected design prior to drying. Supplemental adhesive is then applied to other areas ("background" areas) of the substrate, and is dried. Preferably such supplemental adhesive is applied over the surface of the entire substrate and over the adhering flock that has already been applied, and the entire substrate plus existing flock is covered with additional flock, followed by drying of the adhesive.The entire substrate thus prepared is then subjected to shrinkage, causing differential shrinkage of the design areas and the background areas, and producing a fabric having a novel three-dimensional pattern or design.The fabric product preferably has a plurality of upstanding flock fibres and the substrate is shrunken more tightly in some areas than in others.

Abstract: Blood-contacting surfaces of artificial implant devices which have been flocked with fibers of a blood-compatible polymeric material to promote formation of a stable and viable biological lining when the device has been implanted in a living body, are treated to strengthen the bonds between the fibers and the substrate surface and to interlock the fibers with each other so as to substantially reduce the possibility of fiber separation and release from the substrate surface into the blood stream. The treatment is effected by applying to the flocked surface a dilute solution of an adhesive material in a solvent therefor, the content of the adhesive material in the treating solution being controlled so as to be sufficient to coat the fibers only at their points of contact with each other and with the substrate surface.

Abstract: A peg-board comprising a body secured to a sheet of a resiliently deformable material, the sheet having a flock-like finish and being formed with a plurality of similar apertures therethrough, and the apertures being arranged as a regular lattice of intersecting rows and columns, whereby an elongate pin formed on a character, and having a lateral dimension greater than the largest lateral dimension of an aperture, can be pushed through one of said apertures and be firmly gripped by a resilient deformation of at least the sheet.

Abstract: Multicolored pile materials, and particularly pile carpets, comprising a fabricated backing and a fabricated pile face having: (1) upper pile face portions which have a predetermined color; and (2) lower pile face portions which have a color which is different and darker than the predetermined color of the upper pile face portions, whereby unusual multicolored effects are obtained; and, more specifically, multicolored pile fabrics, and particularly pile carpets, comprising a fabricated backing and a fabricated pile face having: (1) upper pile face portions which are substantially white in color; and (2) lower pile face portions which have a color which is different and darker than white, whereby unusual multicolored, frosted effects are obtained. Processes for making such multicolored or frosted pile materials are also included.

Abstract: A bonded non-woven fabric comprises a non-woven layer containing multicomponent, preferably bicomponent, fibers or filaments bonded to each other at cross-over points by means of adhesive derived from at least one of the components, with flock fibers bonded to at least some of the fibers or filaments of the non-woven layer, said flock fibers being oriented in all directions and some, preferably most of the flock fibers penetrating into or through the non-woven layer.A method of making such non-woven fabrics comprises forming and bonding a non-woven layer of multicomponent fibers or filaments, applying adhesive thereto, applying flock fibers, preferably as a suspension in a gaseous fluid, and finally drying or curing the adhesive.

Abstract: A contoured article having three dimensional surface effects is disclosed herein, such as a headliner or floor covering for a vehicle. The contour of the article and at least one three dimensional decorative surface are incorporated into the article during molding. The three dimensional surface preferably is an exact replica of the surface of a textile product. Further, the final article may be surface decorated, if desired. A process for producing a contoured article having a three dimensional decorative surface is also disclosed and claimed herein. The process involves the provision of a master mold, the cavities of which define both the contour and the three dimensional surface design. A foamable composition is cast into one section of the master mold after which the mold sections are brought into register while the composition is fused or cured in situ, conforming to the contour and three dimensional surface cavities of the mold.

Abstract: A flocked fabric is produced by coating a knitted or woven fabric with an acrylic resin emulsion foam which is then partially dried and collapsed by squeezing. A self-cross-linking acrylic resin emulsion is screen printed as closely spaced dots on the coated fabric and polyester flock fibers having a flocking finish are deposited into the dot-carrying fabric while being oriented by an electrostatic field and the product is exposed to a hot air stream and high frequency dielectric field to dry and effect the cross-linking of the resin. The flock is produced by melt spinning pigment containing polyester and collecting them into bunches which are packaged on spools. The filament bundles are withdrawn from the spools and gathered into a tow which is cut by a fiber cutter to form the prefinished flock.

Abstract: A synthetic suede is disclosed comprising a flexible backing having a multiplicity of upstanding flock fibers adhered to the base, and a fatty acid radical cationic softener substantially uniformly distributed over at least portions of the fibers at or near their ends. Typical cationic softeners include the fatty acid quaternary ammonium softeners.

Abstract: A method of making a flocked fabric wherein metal flock fibers are secured to a base. The fibers may be secured as by adhesive, metal fusion bonding, etc. The flock fibers may be metal fusion bonded to each other, may be maintained in spaced relationship, may be provided in tufts, etc.

Abstract: The invention provides new copolymers of (I) monounsaturated or diunsaturated addition polymerizable polyester monomers and (II) vinyl monomers. The resulting copolymer is considered to be a vinyl polymer (e.g., an acrylic polymer) containing a pendant polyester plasticizer as an integral part of the polymer. It is not essential that the copolymer be crosslinked or thermoset, and yet the plasticizer is a permanent part of the polymer--not subject to being leached out of the polymer, as is the case with an external plasticizer. While thermosetting or crosslinked compositions are known which bind external plasticizers to the substrate, the very object of attaining flexibility is to a large extent defeated by the binding agent itself when present in large amounts. Also provided are new monomers in the form of unsaturated polyesters having one or two double bonds per molecule.

Abstract: A breathable flame resistant fabric construction having a pile surface providing desired hand and dyeability, along with the porosity necessary to provide breathability. The fabric construction is formed by bonding flock fibers to the surface of a fiberglass base fabric by means of a polymeric adhesive which in the presence of heat will release flame quenching gases, blocking the flow of oxygen to the normally flammable flock fibers. It has been found that if the base fabric is first coated with a plasticizer before applying the polymeric adhesive, such as employed to secure the flock fibers to the fiberglass, the subsequently applied adhesive will coat the fiberglass yarns constituting the fabric without producing an adhesive film extending over the spaces between yarns, leaving air passing interstices in the fiberglass base fabric, and additionally improve the hand of the base fabric by providing for an increase in "elastic slippage" (i.e.

Abstract: The flocked filamentary element of this invention is a three-component system including: (1) a strength-imparting component in the form of a core-strand having a denier no greater than 40, and including at least one polymeric filament; (2) an adhesive component adhering the filaments of the core-strand together (when the core-strand includes more than one filament), and providing a layer around the periphery of the core-strand; and (3) an outer flock of substantially individualized cellulosic fibers, such as wood pulp fibers, adhered to the adhesive layer. The individualized cellulosic fibers have an average fiber length in the papermaking range, i.e., less than one-quarter inch (6.35 millimeters) and greater than about one millimeter, and constitute over 50% of the weight of the filamentary element. Fibrous structures, such as non-woven webs, woven webs, knit fabrics and yarns, formed from a plurality of the filamentary elements also constitute a part of the invention.

Abstract: A process for making a porous flocked fabric by coating one side of a loosely interlaced substrate with a flock binder. The coated side of the substrate is flocked and the binder is allowed to migrate or strike through to the opposite side of the substrate. A particulate material, e.g., flock, ground flock, talc, etc., is then applied to said opposite side and the binder is permanently set. The product obtained by this process is also described.

Abstract: The invention comprises a method for texturizing a flocked fabric by first wetting the flocked portion and/or its supporting fabric and adhesive, orienting the wet flock in a pre-determined design pattern by continuously, rapidly and vigorously contacting the flock with a plurality of flexible beaters and drying the fabric.

Abstract: A three dimensional, decorative material is disclosed and claimed herein, having good dimensional definition and capable of virtually unlimited design. A process for producing the three dimensional composite is also disclosed and claimed herein. The process originates with the manufacture of a master mold which can be produced with virtually any design, and preferably is made into a continuous belt. An elastomeric foam composition is then cast into the cavities of the master mold and fused in situ, whereby a three dimensional material is produced. Thereafter, a suitable adhesive is applied to the design side of the material and flock fibers or some other decorative substances are deposited thereon. After curing of the adhesive, any excess fibers are removed, and the material may be cut into suitable lengths, provided with a contact adhesive on the reverse side or the like.