US3281258A - Process for gelling frothed rubber latices on fabrics - Google Patents
Process for gelling frothed rubber latices on fabrics Download PDFInfo
- Publication number
- US3281258A US3281258A US430041A US43004165A US3281258A US 3281258 A US3281258 A US 3281258A US 430041 A US430041 A US 430041A US 43004165 A US43004165 A US 43004165A US 3281258 A US3281258 A US 3281258A
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- Prior art keywords
- latex
- carpet
- frothed
- steam
- gelled
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- Expired - Lifetime
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- 238000000034 method Methods 0.000 title claims description 32
- 229920000126 latex Polymers 0.000 title description 84
- 239000004744 fabric Substances 0.000 title description 10
- 229920001971 elastomer Polymers 0.000 title description 7
- 239000005060 rubber Substances 0.000 title description 5
- 239000004816 latex Substances 0.000 claims description 80
- 239000011248 coating agent Substances 0.000 claims description 24
- 238000000576 coating method Methods 0.000 claims description 24
- 239000000463 material Substances 0.000 claims description 14
- 239000000203 mixture Substances 0.000 claims description 14
- 238000001035 drying Methods 0.000 claims description 5
- 230000000750 progressive effect Effects 0.000 claims description 4
- 238000004326 stimulated echo acquisition mode for imaging Methods 0.000 claims description 3
- 229920001512 foam latex Polymers 0.000 claims description 2
- 239000010410 layer Substances 0.000 description 22
- 238000004049 embossing Methods 0.000 description 19
- 230000001413 cellular effect Effects 0.000 description 6
- 238000009472 formulation Methods 0.000 description 5
- 239000002253 acid Substances 0.000 description 4
- 239000003349 gelling agent Substances 0.000 description 4
- 229920003052 natural elastomer Polymers 0.000 description 4
- 229920001194 natural rubber Polymers 0.000 description 4
- 238000010438 heat treatment Methods 0.000 description 3
- 150000003839 salts Chemical class 0.000 description 3
- 239000002562 thickening agent Substances 0.000 description 3
- NLXLAEXVIDQMFP-UHFFFAOYSA-N Ammonia chloride Chemical compound [NH4+].[Cl-] NLXLAEXVIDQMFP-UHFFFAOYSA-N 0.000 description 2
- KAKZBPTYRLMSJV-UHFFFAOYSA-N Butadiene Chemical compound C=CC=C KAKZBPTYRLMSJV-UHFFFAOYSA-N 0.000 description 2
- 244000043261 Hevea brasiliensis Species 0.000 description 2
- PPBRXRYQALVLMV-UHFFFAOYSA-N Styrene Chemical compound C=CC1=CC=CC=C1 PPBRXRYQALVLMV-UHFFFAOYSA-N 0.000 description 2
- 238000009825 accumulation Methods 0.000 description 2
- 239000000654 additive Substances 0.000 description 2
- 230000015572 biosynthetic process Effects 0.000 description 2
- 229920001577 copolymer Polymers 0.000 description 2
- 238000004132 cross linking Methods 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 239000000806 elastomer Substances 0.000 description 2
- 239000000945 filler Substances 0.000 description 2
- 239000003351 stiffener Substances 0.000 description 2
- 239000000126 substance Substances 0.000 description 2
- 229920003051 synthetic elastomer Polymers 0.000 description 2
- USFZMSVCRYTOJT-UHFFFAOYSA-N Ammonium acetate Chemical compound N.CC(O)=O USFZMSVCRYTOJT-UHFFFAOYSA-N 0.000 description 1
- 239000005695 Ammonium acetate Substances 0.000 description 1
- 229920000742 Cotton Polymers 0.000 description 1
- 239000005062 Polybutadiene Substances 0.000 description 1
- 239000004372 Polyvinyl alcohol Substances 0.000 description 1
- 229920000297 Rayon Polymers 0.000 description 1
- 239000002174 Styrene-butadiene Substances 0.000 description 1
- 150000001252 acrylic acid derivatives Chemical class 0.000 description 1
- XECAHXYUAAWDEL-UHFFFAOYSA-N acrylonitrile butadiene styrene Chemical compound C=CC=C.C=CC#N.C=CC1=CC=CC=C1 XECAHXYUAAWDEL-UHFFFAOYSA-N 0.000 description 1
- 229920000122 acrylonitrile butadiene styrene Polymers 0.000 description 1
- 239000004676 acrylonitrile butadiene styrene Substances 0.000 description 1
- 238000013019 agitation Methods 0.000 description 1
- 229940043376 ammonium acetate Drugs 0.000 description 1
- 235000019257 ammonium acetate Nutrition 0.000 description 1
- 235000019270 ammonium chloride Nutrition 0.000 description 1
- BFNBIHQBYMNNAN-UHFFFAOYSA-N ammonium sulfate Chemical compound N.N.OS(O)(=O)=O BFNBIHQBYMNNAN-UHFFFAOYSA-N 0.000 description 1
- 229910052921 ammonium sulfate Inorganic materials 0.000 description 1
- 235000011130 ammonium sulphate Nutrition 0.000 description 1
- 238000004873 anchoring Methods 0.000 description 1
- 125000000129 anionic group Chemical group 0.000 description 1
- 239000003963 antioxidant agent Substances 0.000 description 1
- 239000010425 asbestos Substances 0.000 description 1
- NTXGQCSETZTARF-UHFFFAOYSA-N buta-1,3-diene;prop-2-enenitrile Chemical compound C=CC=C.C=CC#N NTXGQCSETZTARF-UHFFFAOYSA-N 0.000 description 1
- 229920005549 butyl rubber Polymers 0.000 description 1
- 239000003795 chemical substances by application Substances 0.000 description 1
- 239000011247 coating layer Substances 0.000 description 1
- 238000009833 condensation Methods 0.000 description 1
- 230000005494 condensation Effects 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 229910003460 diamond Inorganic materials 0.000 description 1
- 239000010432 diamond Substances 0.000 description 1
- 150000001993 dienes Chemical class 0.000 description 1
- 239000000975 dye Substances 0.000 description 1
- 239000000839 emulsion Substances 0.000 description 1
- 239000003365 glass fiber Substances 0.000 description 1
- 238000009434 installation Methods 0.000 description 1
- 238000004519 manufacturing process Methods 0.000 description 1
- 238000010907 mechanical stirring Methods 0.000 description 1
- 239000011490 mineral wool Substances 0.000 description 1
- 238000002156 mixing Methods 0.000 description 1
- 229920006173 natural rubber latex Polymers 0.000 description 1
- 239000004745 nonwoven fabric Substances 0.000 description 1
- 239000000123 paper Substances 0.000 description 1
- 239000000049 pigment Substances 0.000 description 1
- 229920000058 polyacrylate Polymers 0.000 description 1
- 229920002857 polybutadiene Polymers 0.000 description 1
- 229920001195 polyisoprene Polymers 0.000 description 1
- 229920000098 polyolefin Polymers 0.000 description 1
- 229920002689 polyvinyl acetate Polymers 0.000 description 1
- 239000011118 polyvinyl acetate Substances 0.000 description 1
- 229920002451 polyvinyl alcohol Polymers 0.000 description 1
- 235000019422 polyvinyl alcohol Nutrition 0.000 description 1
- 238000002360 preparation method Methods 0.000 description 1
- 239000002964 rayon Substances 0.000 description 1
- 229910052895 riebeckite Inorganic materials 0.000 description 1
- 238000004904 shortening Methods 0.000 description 1
- 239000011734 sodium Substances 0.000 description 1
- 229910052708 sodium Inorganic materials 0.000 description 1
- 235000015424 sodium Nutrition 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
- 239000003381 stabilizer Substances 0.000 description 1
- 230000000153 supplemental effect Effects 0.000 description 1
- 239000004753 textile Substances 0.000 description 1
- 229920002554 vinyl polymer Polymers 0.000 description 1
- 235000012773 waffles Nutrition 0.000 description 1
- 210000002268 wool Anatomy 0.000 description 1
- 239000002759 woven fabric Substances 0.000 description 1
Images
Classifications
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J9/00—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof
- C08J9/30—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof by mixing gases into liquid compositions or plastisols, e.g. frothing with air
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
- D06N7/00—Flexible sheet materials not otherwise provided for, e.g. textile threads, filaments, yarns or tow, glued on macromolecular material
- D06N7/0063—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf
- D06N7/0071—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf characterised by their backing, e.g. pre-coat, back coating, secondary backing, cushion backing
- D06N7/0073—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf characterised by their backing, e.g. pre-coat, back coating, secondary backing, cushion backing the back coating or pre-coat being applied as an aqueous dispersion or latex
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
- D06N7/00—Flexible sheet materials not otherwise provided for, e.g. textile threads, filaments, yarns or tow, glued on macromolecular material
- D06N7/0063—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf
- D06N7/0071—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf characterised by their backing, e.g. pre-coat, back coating, secondary backing, cushion backing
- D06N7/0086—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf characterised by their backing, e.g. pre-coat, back coating, secondary backing, cushion backing characterised by the cushion backing, e.g. foamed polyurethane
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J2321/00—Characterised by the use of unspecified rubbers
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
- D06N2205/00—Condition, form or state of the materials
- D06N2205/04—Foam
- D06N2205/045—Froth
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
- D06N2207/00—Treatments by energy or chemical effects
- D06N2207/04—Treatments by energy or chemical effects using steam
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
- D06N2209/00—Properties of the materials
- D06N2209/10—Properties of the materials having mechanical properties
- D06N2209/106—Roughness, anti-slip, abrasiveness
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24479—Structurally defined web or sheet [e.g., overall dimension, etc.] including variation in thickness
Definitions
- my method concerns the gelling by steam of a frothed latex back-coated carpet or rug and the subsequent embossing of the stiffened frothed latex with a suitable design thereby providing a cellular or sponge latex back-coated carpet or rug.
- a latex In the preparation of sponge or cellular elastomer backings for fabrics such as carpets and rugs, a latex is typically frothed to a desired density by mechanical or chemical means and then spread to a pedetermined depth on the back of a carpet or other support web. This frothed latex coating is then gelled or stiffened by the application of heat, such as by passing the coated carpet under radiant heaters or through a warm air oven at the desired temperatures. The stiffened latex is then compacted to the desired density and embossed with a particular design. Embossing and compacting is usually accomplished by passing the carpet between squeeze rolls with the roll in contact with the gelled latex backing usually engraved or cut to provide a design in the compacted, gelled, frothed back-coating.
- the embossed latex coated carpet is then dried and cured in the usual manner such as by passing through a warm air oven to provide a carpet having a cellular or sponge, latex designed, backing securely bonded to the carpet.
- a pre-coat is used on the back of the carpet to aid in anchoring the frothed latex backing to the carpet.
- This accumulation of ungelled froth can also cause trouble when it breaks through the surface of the gelled froth and also causes distortion of the gelled fro-th as it is being compacted and squeezed against the carpet back.
- radiant heat direct against the fabric carpet face such as for example, a tufted carpet face, can be a potential fire hazard should lint fall from the carpet face and onto the hot surface of the glowing radiant heaters.
- proper gellation of the frothed latex is accomplished by the employment of a long, warm air tunnel or oven following the application of radiant heat.
- this arrangement requires the installation of an additional drying oven and requires additional space for the processing operation.
- FIGURE 1 is the stepwise flow diagram of my method of fabricating an embossed sponge rubber backed carpet.
- FIGURE 2 is a fragmentary schematic illustration of the gelling and embossing steps of my method.
- a frothed lat-ex may be properly and rapidly gelled by the direct application of steam to the bottom of a froth-coated carpet.
- the application of wet steam directed upwardly against the carpet face permits a rapid gellation of the frothed latex to proceed upwardly from the back surface of the carpet to the top of the frothed layer and avoids the previous difficulties encountered by the formation of dry and overheated surface skin of the frothed latex.
- the rapid and progressive gellation upwardly from the back surface of the carpet also permits enhanced results to be attained in the embossing step and avoids the fire hazards of employing radiant heaters against the carpet face.
- the use of wet steam promotes the rapid transfer of heat into the carpet and frothed latex by the heat of the steam and by the latent heat of condensation of the steam. Accordingly, my invention not only avoids many of the difiiculties associated with the past practices of gellation, but also is a simple and inexpensive method of gellation.
- the gellation is extremely rapid with the froth gelling quickly in the layer against the back surface of the carpet. The surface above the carpet accordingly gells more slowly and is more receptive to the embossing than when heated for a rather long time with radiant heaters.
- live steam in my method permits a substantial shortening of the gelling area, improves the plasticity of the gelled froth to aid in easy embossing with a lower pressure being needed at the squeeze rolls and provides for higher processing speed.
- steam is directed upwardly against the ungelled latex froth by the use of a steam box constructed to fit under the carpet with one open side in contact with the carpet face so that the carpet actually contacts the upper walls of the steam box and prevents the steam from escaping except upwardly through the carpet fabric and into the frothed latex.
- An open top steam box running the width of the carpet is particularly useful when a continuous width carpet is being steamed.
- a covered perforated top steam box may also be used.
- a perforated top steam box finds particular usefulness when coated strips running side by side are to be steamed in the manner described.
- a steam box with a top cover perforated with A holes spaced about /2" apart in staggered rows gives excellent results with coated strip material.
- a slight positive pressure within the steam box allows steam to be forced upwardly into the coated goods even though the top of the box is not completely covered with strips.
- Several parallel steam pipes perforated with suitable staggered rows of holes will also provide steam to the bottom of a coated carpet passed over the pipes.
- Steam may also be applied against the carpet face upsired body to the formulation.
- FIG- URE l A typical method of preparing a cured cellular latexbacked tufted carpet is schematically illustrated in FIG- URE l.
- a gellable and curable natural or synthetic elastomer or other polymeric latex solution is compounded with the desired additives such as curing and accelerating agents, dyes, fillers, pigments, antioxidants, stabilizers, thickeners, stiffening agents, gelling agents and the like.
- Suitable natural and synthetic elastomers which may be employed in the practice of my invention, include but are not limited to, those rubbery copolymers of styrene and butadiene (SBR), acrylonitrile-diene copolymers such as acrylonitrile-butadiene and acrylonitrile-butadienestyrene copolymers, natural rubbers, polybutadiene, polyisoprene, halogenated dienes likefchloroprene, butyl rubber and the like as well as other gellable and heat curable polymeric latices containing polyolefins, acrylates and the like.
- SBR styrene and butadiene
- acrylonitrile-diene copolymers such as acrylonitrile-butadiene and acrylonitrile-butadienestyrene copolymers
- natural rubbers polybutadiene, polyisoprene, halogenated dienes likefch
- Particularly useful latices for preparing rug and carpet backings include natural rubber and SBR and mixtures thereof as well as carboxylated latices, such as carboxylated SBR, carboxylated Buna N and the like.
- Carboxylated latices may be employed where it is desired to obtain both cross-linking and gelling by the use of heat and cross-linking additives through the latex.
- a typical formulation useful in providing a skid-resistant latex back-coating for a tufted carpet or rug is as follows:
- a gelling agent in an amount sufficient to aid in the stiffening and gelling of the latex when subject to heat.
- an acid or acid salt is often used as a gelling agent.
- Typical acid salts would include ammonium acetate, ammonium chloride, ammonium sulfate, sodium sili-cofluoride and other acid salts.
- stiffening agents such as polyvinyl acetate in emulsion form in an amount sufficient to impart the de- Additionally, thickeners Such as polyvinyl pyrilidone, polyvinylalcohol, polyacrylates and the like may also be employed.
- the latex is then frothed to a desired degree of density by rapid agitation and mechanical stirring to incorporate air therein, such as to a density of from about 250 to 600 grams per liter.
- One method of preparing a frothed I or foamed latex is to pump a latex solution into a machine and to inject air into the latex solution from a flow meter controlling the amount and pressure of the air thereby providing a uniform blend in a mixing chamber of air which is finely divided throughout the latex solution.
- the air frothed latex is then applied by a knifeor barcoater or other coating techniques including application from a roller coater to the back surface of a tufted carpet.
- the coating weight of the frothed latex employed may vary widely depending upon the type and character of the surface ultimately desired; however, in preparing skid-resistant carpets, a coating weight of 20 to 40 ounces per square yard of carpet is often employed with the depth of the frothed latex ranging from about /s to A of an inch. If desired, a thin coating of a pre-coating latex solution may be applied to the back surface of the carpet prior to the application of the frothed latex to enhance the bonding and adhesion of the final cured frothed latex coating to the carpet.
- a suitable pre-coat formulation would include a mixture of a carboxylated latex with a natural rubber latex blend highly loaded with from about 300 to 800 parts per parts of elastomer with a filler.
- the carpet is moved into a chamber wherein a gelling operation is carried out.
- the frothed latex backcoating is progressively and rapidly gelled upwardly from the back surface of the carpet to the top of the frothed latex surface by the application of steam to the carpet face.
- the steam must penetrate the face of the carpet or fabric and move upwardly into the frothed latex coating.
- sufficient heat is employed, for example, 200 to 240 F. to obtain gellation of the frothed latex but insufficient to cure the frothed latex.
- gellation is accomplished by applying wet steam directly across the full width of the carpet and to the bottom of the carpet.
- FIGURE 2. is a fragmentary schematic view of the gelling and embossing operation of my method.
- the carpet 10 composed of a woven backing fabric 12 and having a plurality of V or tuft fibres 14 sittched therethrough to form a tufted carpet face downwardly disposed as the back surface thereof is coated with a frothed latex layer 16.
- the back-coated carpet is moved forward over support rollers 18 and 20 between which rollers is located an enclosed steam box 22 within a heating chamber or oven 24.
- the steam box is open at the top and extends across the full width of the carpet in the direction of travel of the carpet.
- the tops of the sidewalls of the rectangular steam box 22 are norm-ally placed in contact with the face of the carpet 10.
- Steam is introduced under slight pressure into the steam box and permitted to pass only upwardly against and through the carpet face to gell the latex layer 16. I have found it profitable to employ sufficient steam pressure to how the carpet slightly upward .over the open area of the steam box 22.
- a typical tufted carpet coated as described having about 12 feet in width and run at a speed of 12 feet per minute will provide for rapid gellation of the frothed latex back coating when the open top of the steam box is from one to three feet in width across the width of the carpet and steam equivalent to a 5 to 10 H1. boiler is employed.
- the steam pressure used should be insuflicient to lift the carpet from the edges of the box since this would tend to permit steam to escape.
- a black panel radiant electric heater 26 used to direct a slight amount of radiant heat downwardly onto the surface of the frothed la-tex.
- the use of a downwardly directed heating operation in combination with the open steam box 22 aids in rapid gellation and uniform gellation of the coating layer, but is not essential in carrying out the features of my invention.
- a speed of 12 feet per minute may be used with a steam box of about two feet in length in the direction of the travel of the carpet and with about six feet of overhead radiant heaters.
- gellation is obtained in about to 20 seconds without the formation of a dry surface skin.
- a conventional radiant .oven employed under similar conditions usually exceeds thirty feet in length and does not permit speeds as high as 10 to 12 feet per minute.
- the gelled or stiffened frothed latex layer is embossed and compacted.
- An embossing depth from about to A of an inch is often employed to obtain a desired design on the back-coating.
- the gelled back-coating may be embossed by passing it between an engraved top embossing roller 28 and a smooth bottom roller 30. These rollers, 28 and 30, may be heated or if sticking is a problem, may be unheated rollers located either within the chamber 24 or without the chamber 24.
- the engraved embossing roller 28 imparts a waffle or grid-like design onto the stiffened latex frothed back-coating to provide a rug or carpet enhanced skidresistant propertie as shown.
- the embossed back design as shown is characterized by a plurality of thin, rounded, grid-like projections or ribs in a square, rectangular, diamond or like design.
- the rounded projections 32 are designed to be placed in contact with the floor surface and to impart skid-resistant properties to the rub.
- the ribs or projections 32 are about to M inch in depth and are usually spaced a quarter inch or more apart or less than about A1, of the width of the intervening compacted spaces 34.
- This design permits the back-coating to possess a good cushioning property to the carpet.
- the waflle-like design coupled with the cellular nature of the backing and the entrapment of air in the intervening spaces between the rib provides a skid-resistant carpet having good cushioning effects.
- the uniform and rapid gellation of the frothed latex permitted by my discovery permits lower embossing pressures of about 5 to 15 pounds per inch of carpet width to be used, for example 5 to 12 pounds per inch of carpet width. The lower embossing pressure is accomplished because of the improved plasticity of the uniformly gelled froth by my rapid gellation method.
- My method permits the gelled fioth to be squeezed during the embossing operation with suflicient pressure to effect removal of all, substantially all, or a desired high portion of the entrained air, thus providing a firm, relatively thick solid latex backing having greater strength and scufi resistance than conventional low density or sponge rubber.
- the embossed gelled back-coating 16 is then cured and dried in a conventional warm-air oven such as at the temperature of about 250 to 450 -F. for 5 to 15 minutes, e.g. 325 F. for 6 minutes.
- My invention has been described in particular with reference to the back-coating of carpets and rugs with a frothed latex; however, my discovery may be profitably employed with and for the gellation of a wide variety of latex compositions coated upon porous support webs or mediums.
- the use of open steam passed upwardly through a porous medium may be employed for the rapid gellation or curing of a frothed or regular latex coating on porous woven or non-woven fabrics, such as cotton, canvas, wool, etc., glass fiber mats or mineral wool Webs, asbestos, rayon, paper or the like.
- My invention provides a simple, inexpensive and improved method of obtaining gellation of frothed and other latices without the disadvantages of the prior art method.
- a method of preparing a gelled foam latex coated fibrous sheet material which method comprises;
- the latex composition comprises an elastomeric latex, a gelling agent, and a polymeric thickening agent.
- the fibrous sheet material is a tufted carpet having a woven backing fabric and a plurality of tufts on the face surface and a plurality of stitches on the back surface, and wherein the frothed latex is applied to the back surface of the carpet, and the steam applied against the downward face surface.
- a method of preparing a tufted rug having a skidresistant embossed cellular backing, the rug comprising a backing fabric with a plurality of tufts on the face which method comprises:
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- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Textile Engineering (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Health & Medical Sciences (AREA)
- Medicinal Chemistry (AREA)
- Polymers & Plastics (AREA)
- Organic Chemistry (AREA)
- Materials Engineering (AREA)
- Dispersion Chemistry (AREA)
- Laminated Bodies (AREA)
- Treatments For Attaching Organic Compounds To Fibrous Goods (AREA)
- Carpets (AREA)
- Manufacture Of Porous Articles, And Recovery And Treatment Of Waste Products (AREA)
- Jellies, Jams, And Syrups (AREA)
- Central Heating Systems (AREA)
Priority Applications (10)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US430041A US3281258A (en) | 1965-02-03 | 1965-02-03 | Process for gelling frothed rubber latices on fabrics |
DET20240U DE1954017U (de) | 1965-02-03 | 1966-01-28 | Vorrichtung zum gelieren verschaeumter latices auf stoffen. |
BE675946D BE675946A (tr) | 1965-02-03 | 1966-02-02 | |
AT95666A AT273030B (de) | 1965-02-03 | 1966-02-02 | Verfahren und Vorrichtung zum Gelieren verschäumter Latices auf Stoffen |
LU50377A LU50377A1 (tr) | 1965-02-03 | 1966-02-02 | |
NL6601325A NL6601325A (tr) | 1965-02-03 | 1966-02-02 | |
FR48318A FR1466988A (fr) | 1965-02-03 | 1966-02-03 | Procédé et dispositif pour transformer en gel des mousses de latex déposées notamment sur des matières en fibres et nouveaux produits ainsi obtenus |
GB4779/66A GB1114347A (en) | 1965-02-03 | 1966-02-03 | Process for gelling latex-coated fabrics |
ES0322575A ES322575A1 (es) | 1965-02-03 | 1966-02-03 | Procedimiento y dispositivo para la gelificacion de reticulos esponjosos sobre materiales. |
CH152066A CH448957A (de) | 1965-02-03 | 1966-02-03 | Verfahren zum Wärmegelieren von insbesondere verschäumten Latices auf bahnförmigem textilem Fasermaterial sowie Anwendung des Verfahrens zur Behandlung der Rückseite von Teppichen |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US430041A US3281258A (en) | 1965-02-03 | 1965-02-03 | Process for gelling frothed rubber latices on fabrics |
Publications (1)
Publication Number | Publication Date |
---|---|
US3281258A true US3281258A (en) | 1966-10-25 |
Family
ID=23705831
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US430041A Expired - Lifetime US3281258A (en) | 1965-02-03 | 1965-02-03 | Process for gelling frothed rubber latices on fabrics |
Country Status (9)
Country | Link |
---|---|
US (1) | US3281258A (tr) |
AT (1) | AT273030B (tr) |
BE (1) | BE675946A (tr) |
CH (1) | CH448957A (tr) |
DE (1) | DE1954017U (tr) |
ES (1) | ES322575A1 (tr) |
GB (1) | GB1114347A (tr) |
LU (1) | LU50377A1 (tr) |
NL (1) | NL6601325A (tr) |
Cited By (18)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US3862291A (en) * | 1971-02-23 | 1975-01-21 | Burlington Industries Inc | Foam backed drapery fabrics and method of making the same |
US3967012A (en) * | 1972-01-10 | 1976-06-29 | Gundermann Gmbh & Co. Kg | Method of making a sealing and insulating coating |
US4061822A (en) * | 1971-03-12 | 1977-12-06 | Rohm And Haas Company | Crushed foam coated leather and leather-like materials |
US4145463A (en) * | 1972-08-21 | 1979-03-20 | Albright & Wilson Limited | Flameproofing of textiles |
US4325196A (en) * | 1977-12-16 | 1982-04-20 | G.A.O. Gesellschaft Fur Automation Und Organisation Mbh | Multilayer identification cards with relief-like surface |
US4362774A (en) * | 1979-12-27 | 1982-12-07 | Burlington Industries, Inc. | Drapery fabric foam backing |
US4559243A (en) * | 1981-10-14 | 1985-12-17 | Firma Carl Freudenberg | Absorbent planar structure and method of its manufacture |
US4595617A (en) * | 1984-05-31 | 1986-06-17 | Gencorp Inc. | Carpet tiles having a filled flexible frothed vinyl polymer backing and their method of manufacture |
US4634730A (en) * | 1984-05-31 | 1987-01-06 | Gencorp Inc. | Carpet tiles |
US4889670A (en) * | 1988-03-01 | 1989-12-26 | Basf Aktiengesellschaft | Process for manufacturing green and ceramic foam |
US4974431A (en) * | 1989-11-28 | 1990-12-04 | Interface, Inc. | Device for treating materials with steam |
US5051273A (en) * | 1990-01-16 | 1991-09-24 | Nippon Oil And Fats Company, Limited | Method of preparation of a patterned decorative material |
US5164219A (en) * | 1990-01-16 | 1992-11-17 | Nippon Oil And Fats Company, Limited | Method of preparation of a patterned decorative material |
US5221508A (en) * | 1991-11-25 | 1993-06-22 | Pitney Bowes Inc. | Method of felting open cell polychloroprene latex foam in reduced time |
WO1999052651A1 (en) * | 1998-04-16 | 1999-10-21 | Lockheed Martin Energy Research Corporation | A method for modifying a workpiece surface using a high heat flux process |
US6162309A (en) * | 1998-04-21 | 2000-12-19 | Burlington Industries, Inc. | Reinforced foam backed carpet |
US6274203B1 (en) * | 1997-10-06 | 2001-08-14 | Ichikintechnical Co., Ltd | Process for the production of artificial leather |
US20100251883A1 (en) * | 2009-04-07 | 2010-10-07 | Plasan Sasa Ltd. | Safety apparatus for providing protection against an explosion and vehicle comprising same |
Families Citing this family (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
BE758464A (fr) * | 1969-11-05 | 1971-05-04 | Polymer Corp | Procede d'obtention de couches caoutchouteuses sur l'envers de tissus |
DE3333694A1 (de) * | 1983-09-17 | 1985-03-28 | Nitex GmbH, 3002 Wedemark | Bahnfoermiges material aus kunststoff und latexschaum, insbesondere zur herstellung von einlegesohlen und verfahren zu seiner herstellung |
Citations (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US2590849A (en) * | 1947-12-31 | 1952-04-01 | Dungler Julien | Method for drying fibrous sheet material |
US2817597A (en) * | 1954-11-29 | 1957-12-24 | Kendall & Co | Decorative cushion fabric and process of making same |
US3210447A (en) * | 1963-07-08 | 1965-10-05 | Allen Ind | Process for making patterned foam padding material |
-
1965
- 1965-02-03 US US430041A patent/US3281258A/en not_active Expired - Lifetime
-
1966
- 1966-01-28 DE DET20240U patent/DE1954017U/de not_active Expired
- 1966-02-02 LU LU50377A patent/LU50377A1/xx unknown
- 1966-02-02 BE BE675946D patent/BE675946A/xx unknown
- 1966-02-02 NL NL6601325A patent/NL6601325A/xx unknown
- 1966-02-02 AT AT95666A patent/AT273030B/de active
- 1966-02-03 ES ES0322575A patent/ES322575A1/es not_active Expired
- 1966-02-03 CH CH152066A patent/CH448957A/de unknown
- 1966-02-03 GB GB4779/66A patent/GB1114347A/en not_active Expired
Patent Citations (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US2590849A (en) * | 1947-12-31 | 1952-04-01 | Dungler Julien | Method for drying fibrous sheet material |
US2817597A (en) * | 1954-11-29 | 1957-12-24 | Kendall & Co | Decorative cushion fabric and process of making same |
US3210447A (en) * | 1963-07-08 | 1965-10-05 | Allen Ind | Process for making patterned foam padding material |
Cited By (20)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US3862291A (en) * | 1971-02-23 | 1975-01-21 | Burlington Industries Inc | Foam backed drapery fabrics and method of making the same |
US4061822A (en) * | 1971-03-12 | 1977-12-06 | Rohm And Haas Company | Crushed foam coated leather and leather-like materials |
US3967012A (en) * | 1972-01-10 | 1976-06-29 | Gundermann Gmbh & Co. Kg | Method of making a sealing and insulating coating |
US4145463A (en) * | 1972-08-21 | 1979-03-20 | Albright & Wilson Limited | Flameproofing of textiles |
US4325196A (en) * | 1977-12-16 | 1982-04-20 | G.A.O. Gesellschaft Fur Automation Und Organisation Mbh | Multilayer identification cards with relief-like surface |
US4362774A (en) * | 1979-12-27 | 1982-12-07 | Burlington Industries, Inc. | Drapery fabric foam backing |
US4559243A (en) * | 1981-10-14 | 1985-12-17 | Firma Carl Freudenberg | Absorbent planar structure and method of its manufacture |
US4595617A (en) * | 1984-05-31 | 1986-06-17 | Gencorp Inc. | Carpet tiles having a filled flexible frothed vinyl polymer backing and their method of manufacture |
US4634730A (en) * | 1984-05-31 | 1987-01-06 | Gencorp Inc. | Carpet tiles |
US4889670A (en) * | 1988-03-01 | 1989-12-26 | Basf Aktiengesellschaft | Process for manufacturing green and ceramic foam |
US4974431A (en) * | 1989-11-28 | 1990-12-04 | Interface, Inc. | Device for treating materials with steam |
US5051273A (en) * | 1990-01-16 | 1991-09-24 | Nippon Oil And Fats Company, Limited | Method of preparation of a patterned decorative material |
US5164219A (en) * | 1990-01-16 | 1992-11-17 | Nippon Oil And Fats Company, Limited | Method of preparation of a patterned decorative material |
US5221508A (en) * | 1991-11-25 | 1993-06-22 | Pitney Bowes Inc. | Method of felting open cell polychloroprene latex foam in reduced time |
US6274203B1 (en) * | 1997-10-06 | 2001-08-14 | Ichikintechnical Co., Ltd | Process for the production of artificial leather |
WO1999052651A1 (en) * | 1998-04-16 | 1999-10-21 | Lockheed Martin Energy Research Corporation | A method for modifying a workpiece surface using a high heat flux process |
US6162309A (en) * | 1998-04-21 | 2000-12-19 | Burlington Industries, Inc. | Reinforced foam backed carpet |
US6794009B1 (en) | 1998-04-21 | 2004-09-21 | Mohawk Brands, Inc. | Reinforced foam backed carpet |
US20100251883A1 (en) * | 2009-04-07 | 2010-10-07 | Plasan Sasa Ltd. | Safety apparatus for providing protection against an explosion and vehicle comprising same |
EP2238874A1 (en) * | 2009-04-07 | 2010-10-13 | Plasan Sasa Ltd | Safety apparatus for providing protection against an explosion and vehicle comprising same |
Also Published As
Publication number | Publication date |
---|---|
AT273030B (de) | 1969-07-25 |
CH152066A4 (tr) | 1967-09-15 |
LU50377A1 (tr) | 1966-04-26 |
DE1954017U (de) | 1967-01-26 |
GB1114347A (en) | 1968-05-22 |
BE675946A (tr) | 1966-06-16 |
ES322575A1 (es) | 1967-01-16 |
CH448957A (de) | 1968-04-11 |
NL6601325A (tr) | 1966-08-04 |
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