IL28904A - Process for producing a coated fibrous or non-fibrous flexible sheet material - Google Patents

Description

PROCESS FOR PRODUCING A COATED FIBROUS OR NON -FIBROUS FLEXIBLE SHEET MATERIAL si namo rmwy nsisa Λ Τ H*»»^ v nn This invention relates to a novel process for producing a coated substrate and the composite articles coated by such a method. More particularly, it relates to the coating of fibrous or non-fibrous flexible sheet material, such as textile fabrics of woven, knitted, felted or other construction, plastic films, fiber glass, paper and the like as well as other flexible sheet material with a froth, of a polymeric emulsion and air or an inert gas, that produces a durable uniform opaque backing on the fabric or film at much lower weights than conventional coatings without excess penetration or strike through that might cause undesirable stiffne Polymeric materials such as acrylics, reactive acrylics, vinyl chloride homopolymers and copolymers, styrene-butadiene copo ymers, vinylidene chloride, vinyl acetate homopolymers and copolym styrene-butadiene-acrylonitrile terpolymers have been employed in the textile industry in the production of coating fabrics to furni said fabrics with a coated backing. In accordance with convention methods now in use, a drapery or other fabric or substrate is trea with a liquid (as distinguished from a frothed or foamed) emulsion of a polymeric material and then the coating on the treated fabric is cured and dried. However, such resultant coated fabrics have a number of limitations and deficiencies, for example, heretofore conventional polymeric coatings produced by the above method have exhibited disadvantages such as having a tendency to unduly penetr or strike through the fabric causing a stiffening or hardening of the coated fabric, and may fail to provide a complete uniform backing. Fabric coatings lacking such uniform opaqueness provide only a poor barrier against sunlight, thereby subjecting the fabric to eventual color and strength degradation and' are poor insulators against weather elements such as heat, cold and draughts as well. In order to overcome these deficiencies, conventional polymeric formulations may have to be coated onto the fabrics or other substrate in high weight amounts to insure opaqueness. Such high weight coatings may result in bulky fabrics that are objectionably stiff and more expensive than the frothed polymeric coatings.

Previous attempts to apply foamed polymeric backings to various substrates have resulted in backings having poor adhesion and were unable to withstand repeated laundering and dry cleaning.

We have now discovered that the above mentioned disadvantages may be readily and easily overcome by our unique and advantageous method of coating a fabric or other substrate.

The process of the invention produces a fabric or other substrate having a low weight, durable, uniform, opaque backing without excess penetration to the face of the fabric or substrate, and having a crushed, frothed polymeric latex backing in place of conventional fabric liners or other shielding material. The backing is an excellent barrier to light degradation of the fabric or other 28904/2 substrate and it possesses other desirable propertjes, such as good thermal insulation, good resistance t© deterioration from aging or abrasion, and good resistance to repeated washing and dry cleaning operations. The coated fabrics or other substrates are soft and pliable.

The present invention provides a process for producin g a coated fabric or substrate having an adherent liner, i. e. , coating or backing of a crushed polymeric froth which comprises (1) foaming an emulsion-polymerized latex composition containing a water-soluble organic surfactant; (2) applying the resultant froth directly to the fabric or substrate; (3) partially drying the polymeric froth and fabric or substrate to a moisture content in a 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; (4) 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 (5) finally curing and drying the resultant crushed polymeric frothed backing adhering to the fabric or substrate in order to produce a coated fabric or substrate that is soft and pliable and which has a durable low weight uniformly opaque backing with very little penetration or strike through.

It could hardly b¾ foreseen that utilization of the present frothed and crushed polymeric materials would result in a J©¾t, curable fabric or substrates having the unique properties described above. Indeed, one would expect just the opposite, since it would appear that a frothed backing by its nature would be very susceptibl to degradation and not be durable to aging, abrasion or repeated laundering and dry cleaning operations. Moreover, it would appear that crushing a frothed backing on the fabric or ilm would result in an increased penetration or strike through of the coating.

However, contrary to such obvious initial assumptions, applicants have discovered that just the opposite occurs.

Emulsion-polymerized latex compositions employed as the starting materials in the practice of the instant inventions compri a mixture of a polymerized latex emulsion or mixtures thereof with a water-soluble surfactant, i.e., a soap or emulsifier or detergent or mixtures thereof. Criticality of the instant invention does not lie in the particular ingredients per se of the emulsion-polymerized latex compositions nor in the relative amounts of such ingredients. However, it is obvious that such conditions and factors as the particular properties desired in the resultant coated fabric or substrate, because of the fabric or substrates desired end use; the cost and availability of different ingredients; the applicability of various ingredients to the different types of coating machinery that may be used; etc., will most probably dictate a preference for one ingredient over the other and/or the relative amounts of such ingredients. For example, it has been found that emulsion-polymerized latex compositions containing about 100 parts by dry weight of the polymerized latex esnJsion to about 0.5 to 10 parts by dry weight, preferably about 3 - 5 parts, of the soap or surfactant are normally sufficient to arrive at coated fabrics or substrates having the desired properties discussed above.

The polymerized latex emulsion utilized in the instant starting compositions may be any natural or synthetic latex emulsion preferably one which contains about 40% to about 70% by weight of solids. Such polymerized latex emulsions are well known and readil recognizable in the art. These latexes are conventionally prepared by polymerizing at least two ethylenically unsaturated monomers. Examples of such monomers that may be mentioned are acrylic acid, methacrylic acid, itaconic acid, fumaric acid, maleic acid, ethyl acid maleate, 2-sulfoethyl acrylate, 2-sulfoethyl methacrylate, 2-aminoethyl methacrylate hydrochloride, 2-aminoethyl acrylate hydrochloride, vinyl benzylamine, glycidyl methacrylate, hydroxy-styrene, acrolein, methacroleln, allyl alcohol, vinylbenzyl alcohol, 2-hydroxyethyl acrylate, -2-hydroxyethyl methacrylate acrylamide, bis-N-methylol acrylamide, N-methylolacrylamide, N-methylolmeth-acrylamide, bis-N-me h lolmethacrylamide, methacrylamide, Ν-β-hydro ethyl acrylamide, Ν-β-hydroxyethyl methacrylamide, β-hydroxypropyl acrylate, β-hydroxypropylmethacrylate, liitaydroxypropyl acrylate, hydroxypropyl methacrylate, 6-hydroxyhexyl acrylate, 6-hydroxy-hexyl methacrylate, sodium styrene sulfonate, sodium a-methylstyrene sulfonate, 2-«iethylaminoethyl acrylate hydrochloride, 2-methylaraino-ethyl methacrylate hydrochloride, 3-methylaminopropyl acrylate hydrochloride, 3-methylarainopropyl methacrylate hydrochloride, 3-*iethylaminobutyl acrylate hydrochloride, 3-methylaminobutyl methacrylate hydrochloride, 3-ethylaminopropyl acrylate hydrochlorid and styrene sulfonamide.

Other monomers that may be mentioned are the alkenyl- aromatic compounds (the styrene compounds) , the derivatives of ethyienically unsaturated acids such as the acrylic esters, acryl nitriles, maleic esters, fumaric esters, unsaturated alcohol este unsaturated ketones, the conjugated olefins and other compounds containing one or more ethylenic linkages capable of addition polymerization. Specific examples of such ethyienically unsatura aralkyl styrenes such as compounds are styrene,, a-methylstyrene,/ar-«aethylstyrene, ar-ethy styrene, a-ar-dimethylstyrene, ar,ar-dimethylstyrene, ar-t-butyl wherein "ar" represents additional aromatic substitution styrene,/ vinylnaphthalene, methoxystyrene, cyanostyrene, acetyl-styrene, monochlorostyrene, dichlorostyrene and other halostyrene methyl methacrylate, ethyl acrylate, butyl aerylate, hexyl aeryla 2-ethylhexyl acrylate, lauryl methacr late, phenyl acrylate, aer lonitrile, methacrylonitrile, ethyl a-chloroacrylate, diethyl maleate, polyglycol raaleate, vinyl chloride, vinyl bromide, vinyl chloride vinylidene bromide, vinyl methyl ketone, methyl isoprope ketone, vinyl ethyl ester, 1,3-butadiene^/isoprene kJnldl k&id /like( the It will be noted that/said monomers may or may not sulph contain pendant reactive substituent groups such as carboxy, IsUiM primary amino, secondary amino, carboxamido, methylolcarboxamido, ph su-Wionamido, primary hydroxy1, secondary hydroxyl, phenolic hydro aldehydic, and epoxy groups or which have substituent groups whic subsequent to polymerization, can be converted to such reactive substituent groups, e.g., ester, nitrile, amide, or salt groups which can be hydrolyzed to reactive acid, amine, or hydroxyl grou Among the more th may be used in order to n¾j?¾ optimum results, particularly with regard to sunlight degradation and repeated laundering and dry cleaning operations are those latexes commonly referred to as reactive latexes such as carboxylated latexes, especially acrylic latexes, and non-reactive latexes, such as halogenated vinyl latexes, preferably vinyl chloride latexes and vinylidene chlorid latexes, which due to their fire retardant properties and affinit for fiberglass provide fire resistant fabrics or substrates.

Again such latexes are readily recognizable to those skilled in the art and may be found under such trade names as Union Carbide's Ucar 891, Goodrich Rubber Company's Hycar 2671 and Hycar 2679 and Rohm & Haas Latexes 32 and 87, and the like.

The expression "water-soluble/surfactantM employed in the description of this invention includes any natural or synthet foaming aid or foaming stabilizer such as soaps, emulsifiers, wetting agents, detergents and the like, as well as various mixtu of such foaming agents. Examples of such foaming agents that may be mentioned as representative are the alkali metal and alkaline earth metal salts of higher fatty acids as well as the ammonium and amino salts of said fatty acids, the ammonium, amino, alkali and alkaline earth metal salts of aliphatic sulfates, such as lauryl sulfate, as well as nonlonic surfactants such as Igepals and the like. From the standpoint of optimum results, it is pref red to utilize soaps of the higher fatty acids containing from ab 12 to about 24 carbon atoms. Specific examples of the higher fat acids that may be used for such soaps or salts, are lauric, palmi stearic, tall fatty acids, rosin fatty acid, and the like, or other commercial mixed fatty acids. Additional foam stabilize may also be present if desired, for example, superamides and the li The emulsion-polymerized latex composition starting material may be foamed or frothed by any of the known conventional mechanical or chemical foaming processes. While it is preferred to accomplish foaming by the air whipping method due to its easy procedure which may be carried out around room temperature and its production of a very fine, uniform cell structure froth, other meth such as releasing a non-coagulating gas such as nitrogen or causing the decomposition of a gas-liberating material to chemically react with an ingredient in the composition with the liberation of a non-coagulable gas as a reaction product or by use of an apparatus having commercially available foam heads and the like, may also be employed.

For all intents and purposes the volume of the instant latex composition is generally increased from 1/2 to 8 1/2 time's it original volume by the foaming or frothing step.

The resultant frothed polymeric latex may then be applied or substrate directly to the fabric or film/by any method utilizing any conventional procedure, apparatus or machinery known to the art. The technique or method of applying the froth to the fabric or substrat is not in any way critical and obviously depends merely upon the judicious choice of the operator and equipment at hand. Once applied to the fabric or substrate, the frothed polymer latex may be leveled to the desired thickness which will satisfy that ultimat thickness dictated by economic considerations, theequipment used and the desired end result. Leveling of the frothed coating may be accomplished by using a doctor knife or roll or the like.

The partial drying 3tep of the instant invention is carried out merely by subjecting the frothed polymeric latex adhering to the fabric or substrate to heat in order to obtain a frothed coating having a moisture content of about 3 to about 20% by weight. The manner in which heat is applied is not critical, since all that is required is that sufficient heat be used to dry the frothed latex to the desired moisture content without effecti complete curing of said frothed latex coating. For example, the desired moisture content may be obtained by allowing the frothed fabric or substrate to dehydrate at room temperature, or by placin it in a hot air oven or by use of radiant heat or by use of any suitable textile drying apparatus. Since higher temperatures accelerate the rate of drying and removal of water, the drying step is generally carried out at from 150eP to 400°F, preferably at from 250eF to about 300eF for about 1/2 to about 4 minutes. The instant drying step should not be confused with the conventio gelation procedure utilized by the prior art, for while gelation ia the process of inversion of the two phases of a system contain a liquid continuous phase and a solid discontinuous phase without the removal of water as illustrated by U. S. patent 3,215,647, th instant drying step may be defined as a coagulation procedure in which at least about 80% by weight of the moisture content is physically removed from the frothed polymeric latex coating.

The crushing step of this invention is essential to provide the necessary and desirable durability properties of the coated fabric or substrate as well as providing a means for reduc the bulky nature and difficult handling problems of conventional non-crushed foam coated drapery fabrics. The crushing of the partially dried frothed polymeric latex coating may proceed by passing the partially dried froth coated fabric or substrates through any conventional crushing or calendering textile apparatus known in the art using hard rolls, hard and soft rolls or pad roll and the like under such conditions of pressure and speed that will provide the desired thickness required by the ultimate intended end use of the coated fabric or substrate. By the term "crushing" as used in this invention, we mean the application of sufficient pressure for sufficient time to obtain a compressed frothed backin with a final density between 30 and 65 pounds per cu. ft. in which the cellular structure of the froth will not return to more than about 125 of its crushed from, described above.

The drying and curing steps of the instant invention may be carried out by conventional known procedures. For example, operable temperatures employed for drying may range from about 32e to just above the film-forming temperature of the polymer used in making the crushed-froth backing, whichever is higher, to just below the melting point or decomposition temperature of the polyme used in making the crushed-froth backing, which is lower. Since higher temperatures accelerate the rate of cure as well as the rat of complete drying, temperatures below room temperatures are seldo employed. Generally the curing step is carried out at from about 200°F to about 400°F, normally from about 280*F todiout 320°F and from about 30 seconds to about 4 minutes. It should be noted that conventional vulcanizing agents, together with other additives suc as catalysts or accelerators, while not required for the practice of the instant invention, may if desired be utilized in the instant curing step.

It should be understood that various modifica ions of the above detailed description of this invention may be readily accomplished by the use of various additional auxiliary agents, proportions and combinations, that while not required for the practice of the instant invention, may be employed if desired to give products with properties desired for specific applications* and are intended to be covered by the scope of this invention. For example, for the sake of cost reduction or for other reasons, common filler additives such as clays, barytes, whiting, aluminum hydrate* silica, and the like may be employed as well as whiteners and bright ners such as titanium dioxide, etc. Moreover, dyestuffs, inorganic the and organic pigments and/like may be used for the sake of aesthetic beauty of the final product. Moreover, viscosity can be increased by the use of thick¾ers such as Gantrez, alkali metal polyacrylates, natural gum3, etc., while plasticizers such as tricresylphosphate and the like are normally employed when the emulsion-polymerized latex is derived from a halogenated vinyl latex. Furthermore, detackifiers such as waxes, dusting talc, silicone oils, aliphatic oils, thermosetting resins, soluble polyethylene polymers, poly¬ ethylene emulsions and the like, while also not essential may be used, if desired, for the purpose of eliminating or at least materially reducing any tackiness or tacky feeling that may be exhibited by die backing of the final coated fabric or substrate.

- - While the above mentioned additive agents, if employed, are generally added to the emulsion-polymerized latex composition, they may be added at a later stage in the process. fl?h# following examples are illustrative of the present invention. It is to be understood that all parts, percentages and proportions referred to herein and in the appended claims are by weight unless otherwise indicated.

EXAMPLE I An emulsion-polymerized late composition was prepared by thoroughly blending 100 parts (dry basis) of an acrylic latex emusion, Hycar 2679, obtained from B. F. Goodrich Co. with 3 1/2 parts (dry basis) of a water-soluble ammonium stearate surfactant. The latex composition was then mechanically foamed into a stable froth having an extremely small bubble size by air-whipping the composition in a planetary mixer. The resultant polymeric froth was then applied directly to one side of a drapery fabric and leveled using a doctor knife to obtain a smooth uniform surface of about 1/8 of an inch in thickness. The thus treated fabric was placed in an oven and partially dried at 280eF for about 3 minutes until about 8096 of the moisture in the froth adhering to the fabric was driven off. The partially dried froth was then crushed by passing the coated fabric through calendering rolls under a pressur of about 2Q000 pounds at the nip until the cellular structure of the froth waa completely compressed at the nip and on leaving the calendering rolls the coating had a height of about 0.02 inches.

The resultant crushed polymeric frothed backing adhering to the fabric was then finally cured and dried by subjecting it to a temperature of about 325°F for 11/2 minutes. A durable, soft and pliable coated drapery fabric was obtained having an off-white, slightly tacky, uniform opaque crushed polymeric backing liner having excellent light fastness, washing and dry-cleaning properties For comparison purposes the hk& above process was repeated, only this time the partiall dried polymeric frothed backing was not crushed and a drapery fabric was obtained containing a non-crushed polymeric foam backing, which differs from its above crushed polymeric counterpart in that it does not possess as good durability properties.

Similar results may be obtained by substituting other wate ammonium lauryl t£, ammonium oleate, potassium oleate, potassium stearate, sodivim stearate, and/ khk/ /liHH I for the above ammonium stearate detergent.

EXAMPLE II The procedure in Example I was repeated utilizing an emulsion-polymerized latex composition comprising 100 parts (dry basis) of Hycar 2679, an acrylic latex emulsion.3 1/2 parts (dry basis) of water-soluble ammonium stearate detergent and IS parts (dry basis) of titanium dioxide as a filler and whitening agent. A durable soft and pliable coated drapery fabric, similar to the product of Example I was obtained, having enhanced whiteness and opaqueness· For comparison purposes, the / Hbfe/ above process was repeated, only this time the partiall dried polymeric frothed backing was not crushed and a drapery fabri was obtained containing a non-crushed polymeric foam backing which differs from its above crushed polymeric counterpart in that it does not ossess as good durability properties* Similar results may be produced using other additives and fillers such as, clay, whiting, barytes, hydrate, blancfix, llthophone, magnesium silicate, and the like, with or in place of the above titanium dioxide.

EXAMPLE III The procedure in Example IX was repeated except that 5 parts (dry basis) of Cyrax 933, a melamine formaldehyde detackifier supplied by American Cyanamide, was also blended into the emulsion-polymerized latex starting composition. A durable soft and pliable coated drapery fabric, similar to the product of Example XI was obtained which was essentially tack-free.

For corr parison purposes, the h¼ above process was repeated, only this time the partial dried polymeric frothed backing was not crushed and a drapery fabri was obtained with a non-crushed polymeric foam backing, which diffe from its above crushed polymeric counterpart in that it does not possess as good durability properties.

Similar non-tacky coated drapery fabric products may be obtained by replacing Cyrax 933 with other conventional de-tackifie such as waxes, oil, silicone oils, /urea-formaldehyde resin kk& hMd /iiJkU 13 - EXAMPLE IV The procedure in Example III was carried out except that before crushing and the de-tackifier was coated on the frothed latex composition' after it had been applied to the fabric instead of being added directly to the emulsion-polymerized latex starting composition* No noticeable difference in properties was observed betwe the resultant coated drapery fabric and the coated drapery fabric produced by the process of Example XXX.

For comparison purposes, the fl¾e above process was repeated, only this time the partial dried polymeric frothed backing was not crushed and a drapery fabri was obtained containing a non-crushed polymeric foam backing which differs from its above crushed polymeric foamed counterpart* in that it does not possess as good durability properties..

EXAMPLE V An emulsion-polymerized latex composition was prepared by thoroughly blending 100 parts (dry basis) of an acrylic latex which emulsion^' Hycar"2671,/was obtained from B. F. Goodrich Co. with 3 1/2 parts (dry basis) of a water-soluble ammonium stearate surfactant and 15 parts (dry basis) of titanium dioxide. The latex composition was then mechanically foamed into a stable froth- having an extremely small bubble size by air-whipping the composition in a planetary mixer. The resultant polymeric froth was then applied directly to a drapery fabric and leveled using a doctor knife to obtain a smooth uniform surface of about 1/8 of an inch in thicknes The thus treated fabric was placed in an oven and partially dried at 280°P for about 1 1/2 minutes until about 80% of the moisture in the froth adhering to the fabric was driven off. The partially dried froth was then crushed by passing the coated fabric through calendering rolls under pressure of 20,000 pounds at the nip until the cellular structure of the froth was completely compressed at the nip and on leaving the calendering rolls the coating had a height of about 0.02 inches. The resultant crushed polymeric frot backing adhering to the fabric was then finally cured and dried by subjecting it to a temperature of about 325°F for 1 1/2 minutes A durable soft and pliable coated drapery fabric was obtained havi white, slightly tacky uniformly opaque crushed polymeric backing or liner with excellent light fastness, washing and dry cleaning properties.

For comparison purposes, the TU above process was repeated, only this time the parti ly dried polymeric frothed backing was not crushed and a drapery fabric was obtained containing a non-crushed and a drapery fabric was obtained containing a non-crushed polymeric foam backing, which differs from its above crushed polymeric counterpart in that it does not possess as good durability properties.

EXAMPLE VI An emulsion-polymerized latex composition was prepared by thoroughly blending 100 parts (dry basis) of an acrylic latex emulsion, Ucar 891, obtained from Union Carbide Corp., with 4 1/2 parts (dry basis) of a water-soluble ammonium stearate detergent and 15 parts (dry basis) of titanium dioxide. The latex compositi was then mechanically foamed into a stable froth having an extreme small bubble size by air-whipping the composition in a planetary mixer. The resultant polymeric froth was then applied directly to a drapery fabric and using a doctor knife to obtain a smooth uniform surface of about 1/8 of an inch in thickness. The thus treated fabric was placed in an oven and partially dried at 280eP for about 11/2 minutes until about 80% of the moisture in the froth adhering to the fabric was driven off. The partially dried froth was then crushed by passing the coated fabric through calendering rolls under pressure of 20«000 pounds at the nip until the cellular structure of the froth was completely compressed at the nip and on leaving the calendering rolls the coating had a height of 0.02 inches/. The resultant crushed polymeric frothed backing adhering to the fabric was then inally cured and dried by subjecting it to a temperature of about 325°P for 11/2 minutes. Ά durable soft and pliable coated drapery fabric was obtained having white, slightly tacky uniform opaque crushed polymeric backing or liner with excellent light fastness, washing and dry cleaning properties.

For comparison purposes, the J¾h(qf above process was repeated, only this time the partiall dried polymeric frothed backing was not crushed and a drapery fabri was obtained containing a non-crushed polymeric oam backing, which differs from its above crushed polymeric counterpart in that it does not possess as good durability properties.

EXAMPLE An emulsion-polymerized latex composition was prepared by thoroughly blending 100 parts (dry basis) of a vinyl chloride emulsio polymer, Geon 352, with 35 parts (dry basis) of tricresyl phosphate plasticizer, 3 1/2 parts (dry basis) of a water-soluble ammonium stearate detergent and 15 parts (dry basis) of titanium "Geon" is a Trade Mark, dioxide. / The latex composition was then mechanically foamed into a stable froth having an extremely small bubble size by air-whippi the composition in a planetary mixer. The resultant polymeric froth \tf s then applied directly to a fiberglass drapery fabric and leveled using a doctory knife to obtain a smooth uniform surface of about 1/8 of an inch in thickness. The thus treated fabric was placed in an oven and partially dried at 280eF for about 1 1/2 minutes until about 80% of the moisture in the froth adhering to the fabric was driven off. The partially dried froth was then crushed by passing the coated fabric through calendering rolls under pressure of 20«000 pounds at the nip until the cellular structure of the froth was completely compressed at the nip and on leaving the calendering rolls had a height of about 0.02 inches.

The resultant crushed polymeric frothed backing adhering to the fabric was then finally cured and dried by subjecting it to a temperature of about 325°Fibr 1 1/2 minutes. A durable soft and pliable coated fiberglass fabric which is non-flammable with a white* crushed polymeric backing or liner having excellent light fastness* washing and dry cleaning properties was obtained.

For comparison purposes, the flmel above process was repeated, only this time the partia ly dried polymeric frothed backing was not crushed and a drapery fabric was obtained containing a non-crushed polymeric foam backing which differs from its above crushed polymeric counterpart in that it does not possess as good durability properties.

An emulsion-polymerized latex composition was prepared by thoroughly blending 100 parts (dry basis) of a vinyl chloride emulsion, Geon 332, with 35 parts (dry basis) of tricresyl phosph plasticizer, 4 1/2 parts (dry basis) of a water-soluble ammonium stearate surfactant and 15 parts (dry basis) of titanium dioxide.

The latex composition was then mechanically foamed into a stable froth having an extremely small bubble size by air-whipping the composition in a planetary mixer. The resultant polymeric froth was then applied directly to a fiberglass drapery fabric and ]ϊΙ-¾β using a doctor knife to obtain a smooth uniform surface of about 1/8 of an inch in thickness. The thus treated fabric was placed in an oven and partially dried at 280°F for about 1 1/2 minutes until about 80% of the moisture in the froth adhering to the fabric was driven off. The partially dried froth was then crushe by passing the coated fabric through calendering rolls under pressure of 20,000 pounds at the nip until the cellular structure of the froth was completely compressed at the nip and on leaving about the calendering rolls had a height of/0.02 inches'. The resultant crushed polymeric frothed backing adhering to the fabric was then finally cured and dried by subjecting it to a temperature of abou 325°F for 1 1/2 minutes. ; A durable soft and pliable coated fiber glass fabric which is non-flammable, was obtained having a white, crushed polymeric backing liner having excellent light fastness, washing and dry cleaning properties.

For comparison purposes, the /Tn® above process was repeated, only this time the part ly dried polymeric frothed backing was not crushed and a drapery fabric was obtained containing a non-crushed polymeric foam back which differs from its above crushed polymeric counterpart in th it does not possess as good durability properties.

A coated drapery fa ric having a colored backing liner was obtained by following the procedure of Example XX except that 1/2 parts (dry basis) of phthalocyanine green pigment was also blended with the emulsion-polymerized latex starting composition in order to obtain a durable soft and pliable drapery fabric hav a green, slightly tacky uniform opaque backing liner. It is obv that coated drapery fabrics having various colored crushed polym backing liners may be obtained merely by varying the dyestuff or pigment used.

For comparison purposes, the The above process was repeated, only this time the part dried polymeric frothed backing was not crushed and a drapery fa was obtained containing a non-crushed polymeric foam backing, wh di fers from its above crushed polymeric counterpart in that it does not possess as good durability properties.

In order to demonstrate the unique properties possesse by the coated drapery fabrics of tHs invention* the product of Example XX was subjected to the ultra-violet light of a conventi fadeometer and after 200 hours the drapery fabric exhibited no visible colored physical degradation. Moreover* the drapery fab of Example XX was also subjected to a series of 6 repeated comme cial laundering and dry cleaning applications without any notice degradation to the crushed polymeric backing liner. 1 to IX While the above examples/ deal primarily with coating drapery fabrics, since these final products are of preferred inter it is obvious that the invention may be used to obtain a crushed polymeric frothed backing liner on any fibrous or non-fibrous flexible sheet materials and that the final coated product will find utility in many fields. For example, the final coated products may be used for upholsteringe, table cloths, shower curtains, wearing apparel, place mats, and the like.

Another unique and unobvious feature of the instant invention is that for the first time, so far as applicants are aware a cured non-crushed polymeric foam may be obt ined without the necessity of employing the conventional gelation step or gelation aids or vulcanizing agents, hitherto employed in the preparation of cured polymeric foams. Thus, applicants have also discovered backing a unique process for preparing cured non-crushed polymeric foams^ which entials following the novel coating process of this inventio backin but omitting the crushing step. While the cured non-crushed foams produced by applicante* invention do not furnish as durable a back liner as their crushed polymeric frothed counterparts, they are widely useful as backing liners for substrates which do not requir high durability to repeated laundering and dry cleaning operations.

In this Specification the term "coating" is sometimes referred to as "backing" or "liner" and no difference is intended thereby.

In the Examples the crushed foam has the physical characteristics as hereinbefore defined by the term "crushing".

Claims (3)

1. f t Λ 28904/2 fibrous or non-fibrous flexible shee material 1. A process for producing a coated &jhp£f./aW h iving an adherent coating of a crushed polymeric froth backing which comprises (a) foaming an emulsion polymerized latex composition containing a water-soluble organic surfactant; (b) applying the sheet material resultant polymeric froth directly to the said $W9W ( (c) partiall drying the froth and p]k £f^¾1/e/to a moisture content in a range of 3 t© 20% by weight and retaining the froth in its expanddd form during the drying process without gelation or the use of crosslmking agents; partially dried polymeric froth adhering to the^if^i^i ^un^ormly under high pressure to a density of 30 to 65 pounds per cubic foot such that on release of pressure the layer does ot recover to more than 125% of its compressed thickness; and (e) ' drying and curing the resultant crushed polymeric froth sheet material coated kbMtHHel.

2. A process as claimed in Claim 1, wherein the crushing sheet material ©r compressing is effected by passing the ^ /^ aW and foam layer between calender rolls at high pressure.

3. A process according to claim 2, wherein the pressure is 20, 000 lbs at the hip between the rollers. process according to any preceding claim, wherein the ^iil/}^i iije( is a drapery fabric. 5. A process according to any preceding claim, wherein the polymerized latex emulsion is a reactive latex selected from carboxy- lated latexes and halogenated vinyl latexes and the detergent is selected from alkali metal, alkaline earth metal, ammonium and amino salts of higher fatty acids and mixtures thereof. 6. A process according to Claim 5, wherein the latex is an acrylic latex polymer. 7. A process according to claim 5, wherein the latex is a polyvinyl chloride latex polymer 8. A process according to any one of claims 5 to S, wherein 28904/2 sheet material 9. A composite article composed of a /sj3fa/slt†$4$ with an adherent coating of a crushed polymeric froth produced according to the process as defined in any one of claims 1 to 8. 10. A process as defined in Claim 1, in which a detackifying agent selected from waxes, dusting talc, silicone oils, aliphatic oils, thermosetting resins, soluble ethylene polymers, and polyethylene emulsions, is employed and which has, been added to the coating prior to the final step of drying and curing the crushed polymeric freth. sheet material 11. The process for producing a coated h hki ii^ as claimed in any one of claims 1 to 8 or claim 10 substantially as herein described and exemplified in Examples I to IX. sheet material 12. A composite article composed of with an adherent coating of a crushed polymeric froth produced by the process claimed in Claim 11. S. HOROWITZ & CO. AGENTS FOR APPLICANTS