AU701339B2 - Coated fabric - Google Patents

Description

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AUSTRALIA

PATENTS ACT 1990 COMPLETE SPE C IF I CATION FOR A STANDARD PATENT

ORIGINAL

0r 0 0 *0 00 0 0 0 00n Name of Applicant: o i0 O 0o

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«m Ai PHILIP LAMOND SMITH 0 0* 0 Actual Inventor: Philip Lamond SMITH Address for Service: SHELSTON WATERS 60 Margaret Street SYDNEY NSW 2000 Invention Title: "COATED FABRIC" Details of Associated Provisional Application No: PM7149 dated 29th July 1994 The following statement is a full description of this invention, including the best method of performing it known to me:-

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2 The invention relates to coated surfaces having thermal insulating properties. In particular the present invention relates to a fabric coated with a composition comprising one or more acrylic polymers or copolymers, wherein the composition dries to form a flexible elastomeric membrane. This coated fabric has improved thermal insulating properties.

The conservation of energy has become increasingly important in the world today, particularly because of limited natural resources. As a result, i practices previously adopted particularly in the building industry have changed such that buildings are now designed and built to be more energy efficient than formerly. In particular, many homes in the southern I S. hemisphere are now built having a northerly aspect so as to take full advantage of the climate. In addition many forn.s of insulation materials such as roof insulation, blinds, curtains, carpets etc. are utilized to assist in maintaining a required temperature inside.

However the loss of energy remains high.

Increasing the thickness of blinds and curtains and having them closed may reduce heat ?osses but requires the use of artificial light during daytime, adding to energy costs. In addition, while fabrics such as wool and cotton have aesthetic appeal they do not achieve sufficient insulation, while other better insulating materials tend to lack aesthetic appeal.

Therefore, there remains a need for a fabric

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4i -3which has improved insulating properties so as to prevent energy loss and which, when used in the manufacture of curtains, blinds etc, will allow enough light to enter a room so as to reduce the necessity of requiring artificial lighting.

Accordingly, it is an object of the present invention to provide means for avoiding or at least ameliorating some of the above discussed disadvantages of the prior art.

In a first aspect, the invention provides a fabric coated with a composition including at least 29% by weight of one or more fillers and including one or more acrylic copolymers selected such that the composition dries to form a non-foamed elastomeric membrane.

In a second aspect, the invention provides a method for manufacturing of an insulating material comprising the steps of: i) laying a woven wool or wool blend fabric on a supporting surface; 2 ii) coating one side of the supported fabric with a composition including at least 29% by weight of one or more fillers and comprising one or more acrylic copolymers 5 selected such that the composition dries to form a non-foamed elastomeric membrane; iii) turning the fabric over; iv) coating the opposite side with said composition; and v) repeating steps (iii) and (iv) until the composition is applied ot in excess of 1kg per square metre.

Unless the context clearly requires otherwise, throughout the description and the claims, the words 'comprise', 'comprising', and the like are to be construed in an °inclusive sense as opposed to an exclusive or exhaustive sense; that is to say, in the sense i of "including, but not limited to".

The invention will now be more particularly described by way of examples only.

Throughout this specification, the term "fabric" is used to include materials such as wool and cotton; or an open weave polyester mesh having apertures preferably in the range of 1.5 mm to 2.5 mm 2 i Throughout this specification the term "coating composition" is defined to include any acrylic polymer or copolymer which can be applied in any conventional manner either directly onto the fabric or via a substrate and which composition dries to form a flexible elastomeric membrane.

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-1 i ta sr -7 4 9 9 99 4 4 9 9 9 9* 9 #999 In a preferred embodiments of the invention the acrylic polymer or copolymer composition has at least -4- 29% and preferably about 36% by weight of filler based on the total weight of the composition.

The fillers may be selected from the group consisting of barytes, mica, antimony trioxide, titanium dioxide, barium sulphate and combinations thereof.

Desirably, the fabric is a closed weave woven fabric and when the coating composition is applied on both sides of the fabric the coating composition adheres to the fabric. Preferably,the fabric is a blend of new 10 wool and polyester being in a ratio of 70:30 to 50:50, for example 60:40.

When the coating composition is applied to both sides of the fabric, the fabric is supported on a work 1 surface and the coating composition is applied on one 15 side and allowed to dry to form an elastomeric membrane. The fabric is then turned over to expose the uncoated other side. This other side of the fabric may also be coated with the same acrylic composition. If the fabric is a woven worsted fabric, the second coating, if applied, is also allowed to dry to form a membrane which adheres to the first formed membrane through the openings in the now encapsulated fabric.

Coating compositions such as herein described are strongly adhesive to most surfaces prior to curing and therefore use of a release coating, for example a silicone wax, on the underlying flat worksurface is advantageous.

In manufacture of articles and as shutters, i 1 curtains, blinds etc. a selected fabric preferably a wool blend, is coated, for example by roller or spray, on the side in use facing the exterior with the coating composition comprising one or more acrylic polymers or copolymers. The composition dries to form a flexible elastomeric membrane.

Surprisingly, it has been found that these articles are substantially reflective of ultraviolet and infrared rays such that when they are closed not only is 10 the required temperature maintained but the light from outside is not completely blocked out from the room.

These articles will enable sufficient filtered light to enter the room during the day so that minimal artificial lighting is required. In addition the articles 15 manufactured according to this invention have an improved mildew resistance which is particularly useful in areas of high humidity.

Further, there is the added benefit of substantially blocking out the sun during the hot summer days while allowing filtered light in. The room then remains cool and eliminates the need to have air conditioners and/or fans circulating the air to create a cooling effect. During winter months or cooler times the reverse effect is achieved wherein the warm air is i 25 retained in the room without escaping out through the glass.

For aesthetic purposes shutters, curtains, blinds etc. may be made available in a range of colours to i

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6 compliment interior decor. Preferably, the wool blend is chosen from a fabric range wherein the composition is to 70% new wool and 30% to 50% polyester. (for example the Macquarie Aspect Pty Ltd Range.) In a preferred embodiment, the selected coating composition is a water-based acrylic polymer or acrylic copolymer which dries to form a flexible elastomeric membrane. Flame resistance is provided by including selected inorganic fillers or pigments which act as fire 10 retardants.

A suitable acrylic formulations for use in preparing a composition for coating the fabric is given by way of example in Example A:- 15 EXAMPLE A 4 i* 5*

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r i i i r i r Water Methocel J5MS Ammonia Terric N10 Carrybon L400 Foamaster KZ Barytes Mica Antimony Trioxide Titanium Dioxide Primal E-2300 Texanol Primal ASE WEIGHT (kilograms.) 140.0 2.6 2.6 2.2 2.8 3.2 54.6 150.0 104.0 80.0 400.0 52.0 60.0 1054.0 Kg.

r -i -7- "Methocel J5MS" is a trademark of Dow Chemicals relating to a methylcellulose.

"Terric N10" is a trademark of ICI relating to a surfactant.

"Carrybon L400" (dispersing agent) and "Foamaster NXZ" (defoamer) are trademarks of Diamond Shamrock.

"Primal" is a trademark of Rohm Haas.

Primal E-2300 is a water-based acrylic copolymer emulsion while Primal ASE 60 is an acrylic thickener.

10 "Texanol" is a glycol condensation agent obtainable from Swift Co.

The coating composition typically has a total solids content of about 60%. When the composition is coated on the mesh, the viscosity is such that the 15 composition will penetrate the mesh openings but can be built up in layers.

Another acrylic copolymer formulation which may be used is that sold by Emery Chemicals Pty. Limited (64, Mary Street, St. Peters, NSW 2044) under the trademark "Emerclad Firecheck". Although the exact composition of Emerclad Firecheck is not known it is described by the manufacturer as a water-based high solids acrylic copolymer having at least 30% of fillers and which dries to form a thick elastomeric membrane. Emerclad Firecheck is sold for use as a protective or decorative coating Sintended for application to walls and roofs and has outstanding fire-resistance.

Other elastomeric acrylic membrane forming i t *\i -8compositions and preferably those having a satisfactory level of fire and flame resistance, may be used.

Desirably the coating composition is applied to the fabric at between 18 and 22 0 C and is then allowed to dry and cure, preferably at 24°C with good ventilation.

A suitable coating thickness is built up by successive coacs applied to both sides of the fabric, preferably applied in alternate directions. Prior to being rolled up, the coated fabric should be treated with 10 talc to prevent successive layers sticking to each other before the sheet is fully cured.

i The coating fabric preferably has a weight in excess of 1 Kg/sq.m. more preferably in excess of 3 kilograms/sq.m. and most preferably of from 4 15 kilograms/sq.m. The product desirably has a thickness in excess of 1 mm.

By way of example a sample of polyester mesh coated with Emerclad Firecheck in accordance with the invention had the following properties: Tensile Strength 850 N/5 cm Width 1.83 meters Weight 4.57 Kg. linear meter Fire Flame Resistance Persistence Time Flame Test Av. less than 1 sec.

Persistence Time Glow Test Av. 0 secs.

In the Fire and Flame resistance tests the material is required to be incapable of propagating flame. Test i pieces are held in a burner flame for 20 seconds and the j -9time of persistence of flame or glow measured under standard conditions.

The flame resistance and permeability of coated fabric according to the preferred embodiments of the invention meets the specifications laid down by the Building Code of Australia and in many respects are superior to presently available coated fabrics.

In this respect the coated fabrics are of lesser weight and of less costly construction than prior art 10 coated fabrics. In addition they are more flexible and Sresistant to damage by movement. Material according to the invention is resistant to infrared and ultraviolet I radiation, chemical attack and bacterial or mould attack.

The coated fabric of the invention may be cut to S 15 conform with the intended use with a sharp blade. In particular, the coated fabric may be cut and formed so as to to form shutters and the like.

Surprisingly it has been found that the coating composition has improved solvent resistant properties.

This property is particularly useful especially where harsh solvents are used to remove stains in environments such as bathrooms and kitchens.

In the manufacture of articles such as cupboards for kitchens the coating composition, being strongly adhesive to most fabrics, is applied to the outerside of an open weave polyester mesh. Either before drying or after dryingbut with an adhesive, the coated mesh may be adhered to craftwood, preferably chipboard. The insert 10 formed with the coated mesh on either one side or both sides of the craftwood is then mounted in a frame and then installed. It has been found that stains can be readily removed from the coated fabric using harsh solvents without damaging the surface.

In some applications for example use in decorative panels or doors the coating may be up to 10 mm in thickness.

Those skilled in the art will by routine test based 10 upon this disclosure, be able to formulate suitable S"i substitute acrylic elastomeric compositions suitable for pp embodying the invention herein described. Such variations in composition are comprehended with the scope of this disclosure.

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Claims (9)

1. A fabric coated with a composition including at least 29% by weight of one or more fillers and including one or more acrylic copolymers selected such that the composition dries to form a non-foamed elastomeric membrane.

2. A fabric according to claim 1 wherein the fabric is closely woven from yarns containing from 50% to 70% of wool.

3. A fabric according to claim 1 or 2 wherein the composition is applied at in excess of 1 kg per square metre.

4. A fabric according to any one of the preceding claims wherein the composition is i applied at in excess of 3kg per square metre.

5. A fabric according to any one of the preceding claims wherein the composition is applied at from 4 to 5kg per square metre. 0

6. A fabric according to any one of the preceding claims adhered to a wood or chipboard panel.

7. A fabric substantially as herein described with reference to the example.

8. A method for manufacture of an insulating material comprising the steps of: laying a woven wool or wool blend fabric on a supporting surface; 9ii) coating one side of the supported fabric with a composition including at least 29% by weight of one or more fillers and comprising one or more acrylic copolymers selected such that the composition dries to form a non-foamed elastomeric membrane; iii) turning the fabric over; iv) coating the opposite side with said composition; and

12- v) repeating steps (iii) and (iv) until the composition is applied at in excess of 1kg per square metre. 9. A method according to claim 8 wherein successive coats are applied to each side in alternate directions. 10. A fabric substantially as herein described with reference to the examples. 11. A curtain or blind manufactured from a fabric according to any one of the claims 1 to 7. 12. A decorative fabric according to any one of claims 1 to 7. DATED this 12th day of November 1998 PHILIP LAMOND SMITH Attorney: STUART M. SMITH SFellow Institute of Patent Attorneys of Australia S. 15 of BALDWIN SHELSTON WATERS oo i o ABSTRACT A fabric coated with a composition comprising one or more acrylic polymers or copolymers selected such that the composition dries to form an elastomeric membrane. so* 0 4.