FLOCK COVERING METHOD APPLIED TO PVC MEMBRANE/ FOIL COVERING MATERIAL WITH THERMOPLASTIC PROPERTIES AND FLOCK SEMI-FINISHED

PRODUCT ACHIEVED BY MEANS OF THIS METHOD

Technical Field of the Invention

The invention of the application is related to flock covering on PVC membrane/foil covering material with thermoplastic properties that can be covered especially on wooden products such as MDF, HDF, chipboard and wainscot and other industrial products and to the method of covering the formed flock surface with protective film/tape to prevent it from being damaged as it is processed as a semi-finished product in industrial use and to the flock semi-finished product achieved by means of this method.

Prior Art Related to the Technical Field of the Invention

Application of flock on different material and the process of flock covering are used in many different industries for various purposes.

The most commonly known methods in the known state of the art related to the different applications of the flock covering process are listed below:

1- Electrostatic / Mechanical flock covering method: This method is based on adhesive being applied onto the desired textile or textile-like surface using different techniques and the adhesive being flock covered by carrying out an electrostatic (AC/DC) or mechanical flocking process onto the adhesive and the flock covered surface being dried and the flock being fixed. The main technical problem related to this technique is that only material that have high heat resistance can be flocked using this method.

2- Flock transfer (paper / film ¹ ) method: In this method, a pre-flocked separator paper is used. Behind this paper also known as a transfer paper can be found an adhesive surface that holds the flocking fibers by melting on its own during the heat press process. By means of the heat press method, heat and pressure is applied onto the transfer paper and the transfer of the flocks to the surface applied to is achieved. Afterwards, the transfer paper is cooled and scraped off the surface applied to. Transfer papers may be of various colors, however the appearance of the flock surface achieved by means of the heat and pressure applied in this method is less thick and harder compared to flock printing and, for this reason, the velvet like texture expected from the flock is not achieved as the desired pile density and thickness is not attained.

3- Flock cabin / spray gun flocking method: This method enables flocking of material with deep three dimensional curves and indentations. In the basic application of the method, adhesive is applied on top of 3D objects by means of jetting/spraying method and the whole of the surface of the material is flock covered via flocking by means of flock guns or flock cabins. The main technical problem of this method is that as efficiency is quite low, it can only be applied on partial work and the velvet like texture expected from the flock is not achieved as the desired pile density and thickness is not attained.

Although flock covering on transfer paper is an applicable process, application on wooden products such as MDF, HDF, chipboard and wainscot is not preferred due to the final product achieved not being durable enough and it being vulnerable to deformation under normal conditions.

On the other hand, as PVC membrane/foil covering material provides sufficient durability to the final product obtained by means of flocking and prevents its deformation under normal conditions, they can be used in the flocking of wooden products such as MDF, HDF, chipboard and wainscot.

One of the methods of the known state of the art related to the flocking of wooden products such as MDF, HDF, chipboard and wainscot is the invention described in document number 2007/07763. In the invention of the application, in order to cover wooden products such as MDF, HDF, chipboard and wainscot, adhesive is applied by means of spraying onto PVC and similar material cut in sizes corresponding to the size of the product; and flock covering is carried out by means of electrostatic covering and this flock covered component is pressed to achieve the desired covering.

In the method described in 200707763, as the flocking process is carried out on the counter/unit wherein the covering of PVC material onto wooden products such as MDF, HDF, chipboard and wainscot is carried out, a comprehensive flocking process is not possible and, at the same time, low flock density is observed. For the velvet like texture to be formed, flock of 50-150 g/m ² needs to stick onto the surface of the product in accordance with the flock size and decitex. For this density to be achieved, the number of piles to which flock is supplied needs to be sufficient. This is only possible in an action that can be carried out in a full-fledged flocking process. Moreover, as the appropriate adhesive thickness cannot be achieved due to the adhesive material being applied to the surface by means of spraying; it becomes difficult for the flock fibers to stay vertically within the adhesive layer. As the flock fibers applied tilt sideways and overlap, an undesired flock texture is attained.

Moreover, in electrostatic application, the viscosity of the adhesive is a very important factor in ensuring that the flock fibers stick vertically to the adhesive. Accordingly, the sticking of the flock fibers to the adhesive is directly related to the layer thickness and flock size. Additionally, the maximum viscosity that can be provided by means of the spraying method is quite low and the layer thickness of the adhesive is not at the desired amounts. For this reason, the adhesion of the flock fibers to the surface is weak and the flock fibers stuck to the surface can be detached from the covering material as a result of the slightest impact or scratch. As a result, the method described in document 2007/07763 does not enable the flock fibers to stick vertically and strongly onto the surface and the basic conditions required to achieve the flock density to provide velvet like texture on the surface are not met.

Moreover, the process described in document number 2007/07763 has low efficiency and is a discrete process. PVC and similar covering material is flock covered after being cut in sizes corresponding to the wooden products such as MDF, HDF, chipboard and wainscot is carried out. In this invention, the product actually achieved is flocked MDF, HDF, chipboard and wainscot.

Another method that is part of the known state of art related to flock covering onto PVC and similar covering material can be found in document number CN101953620 (A). The PVC covering material disclosed in the invention is formed of a PVC base used for 1. PVC foam web layer or glass fiber fabric layer, 2. PVC foam layer and PVC anti-slip layer. The invention describes a PVC flocking carpet achieved by means of flock covering of PVC composite material formed of multiple layers. The final product attained is not a semi ^¬ finished product that can be used in other industrial fields.

Objectives and Brief Description of the Invention

Contrary to methods of the known state of the art, the flock semi-finished product of the invention is a semi-finished product achieved by means of flock covering on PVC membrane/foil covering material with thermoplastic properties that can be used to cover especially wooden products such as MDF, HDF, chipboard and wainscot and other industrial products and the attained flock surface is covered with top surface protective film/tape to prevent it from being damaged during its processing as a semi-finished product in industrial use.

The invention of the application enables the flock covering onto PVC membrane/foil and similar material with thermoplastic properties and for this material to be produced such that the material is not damaged by heat; and by this means, the invention enables flock covering onto the material at 50-150 g/m ² density and prevents flock flaking due to impact or scratching by increasing its adhesion to the flock surface.

Moreover, top surface protective film/tape is applied to the flock covered PVC membrane/foil and similar material to prevent the flock surface from being damaged during covering onto wooden products such as MDF, HDF, chipboard and wainscot.

Method of the invention of applying flock on PVC membrane/foil covering material with thermoplastic properties and achieving the flock semi-finished product by means of this method is characterized in that: · A new semi-finished product that is patterned and has a velvet like texture is achieved by means of applying flock covering onto PVC membrane/foil covering material with thermoplastic properties and other covering materials used in other branches of industry which are applied onto the surfaces of wooden products such as MDF, HDF, chipboard and wainscot as color and pattern.

· It enables flock covering at low heat to as to enable that PVC membrane/foil and similar material with thermoplastic properties are not damaged.

• A new semi-finished product that enables the flock covering of wooden products such as MDF, HDF, chipboard and wainscot is achieved.

• This new semi-finished product can be used in other sectors and applications outside of the above mentioned application.

• Facilitation in use/application in wood processing and other industries is achieved by means of the semi-finished product attained via flock covering in the mass production of PVC membrane/foil and similar material with thermoplastic properties.

• Top surface protective film/tape is applied to the attained semi-finished product during processing in industry to prevent the flock surface from being deformed or getting dirty.

• Flock density of 50-150 g/m ² is attained so as to enable the semi-finished flock attained via flock covering of PVC membrane/foil and similar material with thermoplastic properties to stick strongly and in a vertical position and provide a surface with a velvet like texture.

Definition of the Figures Describing the Invention The figures provided for method of applying flock on PVC membrane/foil covering material with thermoplastic properties developed by means of this invention and the flock semifinished product achieved by means of this method to be better understood and the related explanations have been provided below.

Figure 1: General view of the line for applying flock on PVC membrane/foil covering material with thermoplastic properties.

Figure 2: General view of the line for applying protective film/tape covering.

Figure 3: Sectional view of the semi-finished product achieved by means of the method of applying flock on PVC membrane/foil covering material with thermoplastic properties.

Figure 4: Sectional view of the semi-finished product covered in top surface protective film/tape.

Definition of the Components/Parts/Pieces Forming the Invention

For the method of applying flock on PVC membrane/foil covering material with thermoplastic properties developed by means of this invention and the flock semi-finished product achieved by means of this method to be better understood, the parts in the figures have been individually numbered as specified below.

1. PVC membrane/foil covering material

2. Appending unit

3. Accumulator unit

4. Covering knife unit

5. Adhesive raw material

6. Weight measurement device

7. Flocking fiber

8. Flocking unit

9. Rotating design cylinder 10. Drying unit

11. Cooling cylinders

12. Brushing unit

13. Coiling unit

14. Flock covered semi-finished product

15. Platform feeding unit

16. Pressing unit (assembly)

17. Film/tape feeding unit

18. Top surface protective film/tape

19. Semi-finished product covered in top surface protective film/tape

Detailed Description of the Invention

The method of the invention of applying flock on PVC membrane/foil covering material with thermoplastic properties and the flock semi-finished product achieved by means of this method are basically based on the principle of covering PVC membrane/foil covering material (1) with thermoplastic properties with flocking fiber (7) continuously on the same production line by means of electrostatic/mechanical flocking method and covering the formed flock surface with top surface protective film/tape (18) and achieving a semi-finished product.

The method of the invention of applying flock on PVC membrane/foil covering material with thermoplastic properties is formed of two stages:

• In the first stage, flocking fiber (7) is covered on PVC membrane/foil covering material (1) by means of electrostatic/mechanical flocking method.

• In the second stage, the top surface (flocked surface) of the covering material (1) of which the surface is covered with flocking fibers (7) is covered with top surface protective film/tape (18).

The first stage is carried out on a single production line that is shown in Figure 1. The second stage is carried out on the production line shown in Figure 2.

The first stage of the method of the invention consists of the below process steps: · PVC membrane/foil covering material (1) 0,10-0,80 mm thick and 1000-1600 mm wide of any polymer and cellulosic material being put in on the platform feeding unit (15), • PVC membrane/foil covering material (1) being bonded to the guide paper by being appended with heat-resistant tape in the appending unit (2) using the accumulator unit (3) during production without stopping the machine,

• The water based acrylic or water based polyurethane adhesive (5) containing cross- linker that enables the polymerization of the PVC membrane/foil/paper covering material (1) at critical temperature being applied on the PVC membrane/foil covering material (1) appended to the guide paper at the covering knife unit (4) at 200-1200 g/L density and 50-150 g/m ² basis weight by means of plastering on the steel cylinder using the covering knife,

• The fixation of the adhesive (5) bring provided at 60-90°, which is the critical temperature for the PVC membrane/foil and similar covering material (1),

• Measuring of the amount of adhesive at unit area (8) using the weight measurement device (6),

• Entry of the PVC membrane/foil and similar covering material (1) to which adhesive (5) is applied to the flocking unit (5),

• The colored or natural, polyamide 6.6, viscose, acrylic or polyester structured flocking fibers (7) sticking onto the adhesive at an angle of 90° in a manner so as to form flocking concentration at 50-150 g/m ² grams by means of the electrostatic/mechanical flocking method applied onto the adhesive (5) in the flocking unit (8),

• Measuring of the unit area flocking fiber (7) during the flocking process using the weight measurement device (6) in order for the amount of the flocking fiber (7) to be controlled,

• The flocks being pressed by the rotating design cylinder (9) after the flocking process to achieve patterns on the flocked surface when patterned production is desired,

• The adhesive (5) being dehydrated and polymerized in the drying unit (10) to enable the flocking fibers (7) to be bonded to the adhesive (5),

• The material (1) obtained from the drying unit (10) passing from the cooling cylinders (11) for cooling,

• Brushing and removal of flock residual on the material (1) that has not stuck from the surface in the brushing unit (12) following the cooling process,

• The obtained semi-finished product (14) being winded to a bobbin in the cooling unit (13).

The semi-finished product winded on the bobbin is transferred to the second stage of the method of the invention containing the below processes. The semi-finished product (14) on the bobbin being put in the platform feeding unit (15),

The semi-finished product (14) being bonded to the guide paper in the appending unit (2),

The semi-finished product (14) being stretched by means of the tension cylinder, The semi-finished product being transferred to the pressing unit (16) formed of the rubber cylinder 80-90 shore hard,

The top surface protective film/tape (18) that is 10-200 microns thick and the surface of which that sticks onto the flocking fibers (7) contains water or solvent based adhesives being stretched and supplied to the pressing unit (16 ) from the film/tape feeding unit (17) by means of the tension cylinders,

The semi-finished product (14) and the top surface protective film/tape (18) being brought together at the pressing unit (16) formed of the rubber cylinder,

The rubber cylinder being pressed on the steel cylinder by means of the piston mechanism, enabling the top surface protective film/tape (18) and flock semi-product

(14) that meet at the pressing point to be bonded under a 0.4-3 bar pressure.

The semi-finished product covered in top surface protective film/tape (19) being winded around the bobbin in the coiling unit (13) following the bonding process.