ES347091A1 - Process for producing a coated substrate - Google Patents

Abstract

A substrate with an adherent coating of a crushed polymeric froth is produced by (a) forming an emulsion-polymerized latex composition containing a water-soluble organic surfaotant (b) applying the resultant polymeric froth directly to the substrate (c) partially drying the froth and substrate to a moisture content in the range of 3 to 20% by weight and retaining the froth in its expanded form during the drying process without gelation or the use of cross-linking agents (d) crushing or compressing the partially dried polymeric froth adhering to the substrate uniformly under high pressure to a density of 30 to 65 pounds per cubic foot such that on release of pressure the layer does not recover to more than 125% of its compressed thickness and (e) drying and curing the resultant crushed polymeric froth coated substrate. The polymerized latex emulsion may be reactive latex selected from carboxylated latexes and halogenated vinyl latexes, examples of which are given, and the detergent is selected from alkali metal, alkaline earth metal, ammonium and amino salts of higher fatty acids and mixtures thereof, e.g. ammonium stearate. The latex may be of acrylic or polyvinyl chloride latex polymer. A detackifying agent selected from waxes, dusting talc, silicone oils, aliphatic oils, thermosetting resins, soluble ethylene polymers, and polyethylene emulsions, may be employed and are added to the coating prior to the final step of drying and curing the crushed polymeric froth. The crushing or compressing may be effected by passing the substrate and foam layer between calender rolls at high pressure, e.g. 20.000 Ibs at the nip between the rollers. The substrate may be a fibrous or non-fibrous flexible sheet material, such as drapery fabric, textile fabrics of woven knitted, felted or other construction, plastics film, fibre glass or paper.