Patent US3713868A successfully refreshed from Google Patents.
US3713868A
Expired / Lapsed
US
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Acrylic-nitrile foam-backed fabric and method of preparation
Assignee: General Latex and Chemical Corp
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Filing: 1971-01-06
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Granted: 1973-01-30
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Expires: 1991-01-06
Abstract
Abstract An acrylic foam-coated fabric which is breathable, opaque, has excellent insulation properties and is resistant to water and dry-cleaning solvents, but which is flexible and has good hand and drape properties. The fabric has a densified foam coating of a cured acrylic-nitrile copolymer which contains an opaque filler material. The coated fabric is prepared by coating a fabric with an air-froth latex cross-linkable acrylic-nitrile polymer composition, drying the foam coating to a semirigid state, calendering the semirigid foam coating to crush and densify the coating; and thereafter, curing the densified foam coating. The fabric finds particular use for drapery material and surface coverings, such as upholstery fabric and clothing like rainwear and inserts.
Inventors
- 👤 P Gordon
- 👤 Torre A La
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-23 22:09
CPC Classifications
D; D06; D06N; D06N3/00; D06N3/0043; C; C08; C08J; C08J9/00; C08J9/30; D06M; D06M15/00; D06M15/19; D06M15/21; D06M15/263; D06M15/267; D06M15/285; D06M15/29; D06M15/31; D06M15/37; D06M15/39; D06M15/423; D06M15/53; D06M23/00; D06M23/04; Y; Y10; Y10T; Y10T428/00; Y10T428/249921; Y10T428/249953; Y10T428/249975; Y10T428/31504; Y10T428/31511; Y10T428/31855; Y10T428/3188; Y10T428/31935; Y10T442/00; Y10T442/30; Y10T442/3325; Y10T442/3366
Claims Analysis
Total Claims: 34
Claim 1
Independent Claim
209 words
A method of preparing a foamcoated sheet material, which method comprises: a. foaming an aqueous latex emulsion containing: i. a copolymer comprising from about 50 to 100 parts by weight of a lower alkyl acrylate; about 5 to 20 parts by weight of a nitrile selected from the group consisting of acrylonitrile and methacrylonitrile; about 0.5 to 5.0 parts by weight of a monomeric unsaturated carboxylic acid; and about 0.5 to 5.0 parts per weight of an acrylamide; ii. a cross-linking amount of a coreactive methylol amino compound; and iii. from about 0.1 to 10 percent by weight based on the weight of the monomers of a nonionic alkylphenoxypolyalkoxyalkanol surfactant containing from about 30 to 70 ethoxy groups; b. coating a thin layer of the foam latex onto one surface of a sheet material, the foam layer characterized by small but uniform bubble structure; c. drying the foam layer for a time insufficient to cross-link substantially the copolymer, said drying carried out without a breakdown in the bubble structure or collapse of the foam layer to provide a dry compressible foam layer; and d. cross-linking and curing the copolymer by heating the dried foam coating, thereby providing a sheet material having a cured and cross-linked thin foam coating thereon.
Claim 2
Independent Claim
209 words
A method of preparing a foamcoated sheet material, which method comprises: a. foaming an aqueous latex emulsion containing: i. a copolymer comprising from about 50 to 100 parts by weight of a lower alkyl acrylate; about 5 to 20 parts by weight of a nitrile selected from the group consisting of acrylonitrile and methacrylonitrile; about 0.5 to 5.0 parts by weight of a monomeric unsaturated carboxylic acid; and about 0.5 to 5.0 parts per weight of an acrylamide; ii. a cross-linking amount of a coreactive methylol amino compound; and iii. from about 0.1 to 10 percent by weight based on the weight of the monomers of a nonionic alkylphenoxypolyalkoxyalkanol surfactant containing from about 30 to 70 ethoxy groups; b. coating a thin layer of the foam latex onto one surface of a sheet material, the foam layer characterized by small but uniform bubble structure; c. drying the foam layer for a time insufficient to cross-link substantially the copolymer, said drying carried out without a breakdown in the bubble structure or collapse of the foam layer to provide a dry compressible foam layer; and d. cross-linking and curing the copolymer by heating the dried foam coating, thereby providing a sheet material having a cured and cross-linked thin foam coating thereon.
Claim 3
Dependent Claim
18 words
The method of claim 1 wherein the thin foam coating is dried at a temperature of approximately 165*-270*F.
Claim 4
Dependent Claim
30 words
The method of claim 1 which includes densifying the dried foam layer prior to cross-linking by reducing the foam thickness of the dry foam coating about 20 to 80 percent.
Claim 5
Dependent Claim
44 words
The method of claim 3 wherein the foam coated onto the surface of the material has a foam density ranging from about 7 to 30 lbs. per cubic foot and after densifying, a foam density of about 12 to 54 lbs. per cubic foot.
Claim 6
Dependent Claim
20 words
The method of claim 1 wherein the nonionic surfactant is an alkylphenoxypolyethoxyethanol containing from about 30 to 70 ethoxy groups.
Claim 7
Dependent Claim
17 words
The method of claim 1 wherein the nonionic surfactant is substantially the sole surfactant of the composition.
Claim 8
Dependent Claim
142 words
The method of claim 1 wherein the foamable latex composition comprises: an aqueous emulsion of a copolymer consisting essentially of from about 75 to 85 parts by weight of a lower alkyl acrylate; about 10 to 15 parts by weight of a nitrile selected from the group consisting of acrylonitrile and methacrylonitrile; about 0.5 to 5.0 parts by weight of a monomeric unsaturated carboxylic acid selected from the group consisting of acrylic acid, methacrylic acid, itaconic acid, fumaric acid and maleic acid; about 0.5 to 5.0 parts per weight of an amide selected froM the group consisting of acrylamide and methylolacrylamide; and from about 5.0 to 25.0 parts of a melamine cross-linking resin; and from about 0.1 to 10 percent by weight based on the weight of the monomers of an alkylphenoxypolyethoxyethanol nonionic surfactant containing from about 30 to 70 ethoxy groups.
Claim 9
Dependent Claim
26 words
The method of claim 1 which includes cross-linking the copolymer by heating to a temperature of about 300* to 375*F to cross-link and cure the copolymer.
Claim 10
Independent Claim
248 words
A method of preparing a crushed foamcoated sheet material, which method comprises: a. foaming an aqueous latex emulsion of a copolymer comprising from about 50 to 100 parts by weight of a lower alkyl acrylate; about 5 to 20 parts by weight of a nitrile selected from the group consisting of acrylonitrile and methacrylonitrile; about 0.5 to 5.0 parts by weight of a monomeric unsaturated carboxylic acid; about 0.5 to 5.0 parts per weight of an acrylamide; a cross-linking amount of an amino-aldehyde resin; and from about 0.1 to 10 percent by weight based on the weight of the monomers of an alkylaryl polyether alcohol nonionic surfactant containing from 30 to 100 ethoxy groups; b. coating a thin layer of the foam latex onto one surface of a sheet material, the foam layer characterized by small but uniform bubble structure; c. drying the foam layer at a temperature of less than about 300*F and for a time insufficient to cross-link substantially the copolymer, but sufficient to dry the thin foam coating, said drying carried out without a breakdown in the bubble structure or collapse of the foam layer to provide a dry compressible foam layer; d. densifying the thin dried foam coating on the sheet material by the application of pressure to reduce the thickness of the foam coating; and e. heating the densified foam coating to a temperature to cross-link and cure the copolymer, thereby providing a sheet material having a cured, densified thin foam coating thereon.
Claim 11
Independent Claim
248 words
A method of preparing a crushed foamcoated sheet material, which method comprises: a. foaming an aqueous latex emulsion of a copolymer comprising from about 50 to 100 parts by weight of a lower alkyl acrylate; about 5 to 20 parts by weight of a nitrile selected from the group consisting of acrylonitrile and methacrylonitrile; about 0.5 to 5.0 parts by weight of a monomeric unsaturated carboxylic acid; about 0.5 to 5.0 parts per weight of an acrylamide; a cross-linking amount of an amino-aldehyde resin; and from about 0.1 to 10 percent by weight based on the weight of the monomers of an alkylaryl polyether alcohol nonionic surfactant containing from 30 to 100 ethoxy groups; b. coating a thin layer of the foam latex onto one surface of a sheet material, the foam layer characterized by small but uniform bubble structure; c. drying the foam layer at a temperature of less than about 300*F and for a time insufficient to cross-link substantially the copolymer, but sufficient to dry the thin foam coating, said drying carried out without a breakdown in the bubble structure or collapse of the foam layer to provide a dry compressible foam layer; d. densifying the thin dried foam coating on the sheet material by the application of pressure to reduce the thickness of the foam coating; and e. heating the densified foam coating to a temperature to cross-link and cure the copolymer, thereby providing a sheet material having a cured, densified thin foam coating thereon.
Claim 12
Dependent Claim
18 words
The method of claim 9 wherein the thin foam coating is dried at a temperature of approximately 165*-270*F.
Claim 13
Dependent Claim
45 words
The method of claim 9 wherein densification of the dried foam layer is accomplished by passing the sheet material containing the dried foam layer between pressure rolls wherein the foam thickness of the lightly cross-linked dry foam coating is reduced about 20 to 80 percent.
Claim 14
Dependent Claim
44 words
The method of claim 9 wherein the foam coated onto the surface of the material has a foam density ranging from about 7 to 30 lbs. per cubic foot and after densification, a foam density of about 12 to 54 lbs. per cubic foot.
Claim 15
Dependent Claim
16 words
The method of claim 9 wherein the densification and curing steps are carried out substantially simultaneously.
Claim 16
Dependent Claim
20 words
The method of claim 9 wherein the nonionic surfactant is an alkylphenoxypolyethoxyethanol containing from about 30 to 100 ethoxy groups.
Claim 17
Dependent Claim
17 words
The method of claim 9 wherein the nonionic surfactant is substantially the sole surfactant of the composition.
Claim 18
Dependent Claim
140 words
The method of claim 9 wherein the foamable latex composition comprises: an aqueous emulsion of a copolymer consisting essentially of from about 75 to 85 parts by weight of a lower alkyl acrylate; about 10 to 15 parts by weight of a nitrile selected from the group consisting of acrylonitrile and methacrylonitrile; about 0.5 to 5.0 parts by weight of a monomeric unsaturated carboxylic acid selected from the group consisting of acrylic acid, methacrylic acid, itaconic acid, fumaric acid and maleic acid; about 0.5 to 5.0 parts per weight of an amide selected from the group consisting of acrylamide and methylolacrylamide; about 5 to 25 parts of a melamine-formaldehyde cross-linking resin; and from about 0.1 to 10 percent by weight based on the weight of the monomers of an aLkylphenoxypolyethoxyethanol nonionic surfactant containing from about 30 to 70 ethoxy groups.
Claim 19
Dependent Claim
26 words
The method of claim 9 wherein the densified foam coating is heated to a temperature of about 300 to 375*F to cross-link and cure the copolymer.
Claim 20
Independent Claim
103 words
A method of preparing a foamcoated material characterized by enhanced resistance to dry-cleaning solvents and permeability to moisture vapor, which method comprises: a. coating a thin layer of a foamed latex composition onto a fabric, the composition comprising: i. a cross-linkable copolymer of a lower alkyl acrylate, a monomeric carboxylic acid, an acrylamide, and an acrylonitrile; ii. an inert filler material; and iii. an amino-aldehyde resin in an amount of about 5 to 25 parts of resin per 100 parts of copolymer to coreact with the copolymer, and an alkyl aryl polyether alcohol nonionic surfactant containing from about 30 to 70 ethoxy groups.
Claim 21
Independent Claim
103 words
A method of preparing a foamcoated material characterized by enhanced resistance to dry-cleaning solvents and permeability to moisture vapor, which method comprises: a. coating a thin layer of a foamed latex composition onto a fabric, the composition comprising: i. a cross-linkable copolymer of a lower alkyl acrylate, a monomeric carboxylic acid, an acrylamide, and an acrylonitrile; ii. an inert filler material; and iii. an amino-aldehyde resin in an amount of about 5 to 25 parts of resin per 100 parts of copolymer to coreact with the copolymer, and an alkyl aryl polyether alcohol nonionic surfactant containing from about 30 to 70 ethoxy groups.
Claim 22
Dependent Claim
45 words
The method of claim 18 wherein the composition contains a copolymer of 50 to 100 parts of an alkyl acrylate, 5 to 20 parts of an acrylonitrile, 0.5 to 5.0 parts of a monomeric unsaturated carboxylic acid, and 0.5 to 5.0 parts of an acrylamide.
Claim 23
Dependent Claim
21 words
The method of claim 18 wherein the densified foam coating is cross-linked at a temperature of from about 300* to 375*F.
Claim 24
Dependent Claim
18 words
The method of claim 18 wherein densifying reduces the foam coating thickness of about 20 to 80 percent.
Claim 25
Dependent Claim
33 words
The method of claim 18 wherein the aminoaldehyde resin is a melamine or urea-formaldehyde resin in an amount of from about 5 to 25 parts of resin per 100 parts of the copolymer.
Claim 26
Dependent Claim
21 words
The method of claim 18 wherein the latex emulsion contains from about 0.5 to 10.0 parts by weight of ammonium stearate.
Claim 27
Dependent Claim
28 words
The method of claim 18 wherein the latex emulsion contains from about 40 to 200 parts by weight of mineral fillers to impart opacity to the sheet material.
Claim 28
Dependent Claim
52 words
The method of claim 18 wherein the lower acrylate is ethyl acrylate, butyl acrylate or 2-ethylhexyl acrylate and combinations thereof; the acrylonitrile is acrylonitrile or methacrylonitrile; the carboxylic acid is acrylic acid, methacrylic acid, itaconic acid, fumaric acid and maleic acid and combinations thereof; and the acrylamide is acrylamide or methylol acrylamide.
Claim 29
Dependent Claim
23 words
The method of claim 18 wherein the nonionic surfactant is a C8-C9 alkylphenoxypolyethoxyethanol, which surfactant is substantially the sole surfactant of the composition.
Claim 30
Dependent Claim
134 words
A foam-coated sheet material containing on one surface thereof a dried cross-linked copolymeric foam layer, the foam layer characterized by a generally open-cell uniform bubble structure, the copolymer cross-linked only in an amount sufficient to provide a stable compressible foam layer, the copolymer comprising from about 50 to 100 parts by weight of a lower alkyl acrylate; about 5 to 20 parts by weight of a nitrile selected from the group consisting of acrylonitrile and methacrylonitrile; about 0.5 to 5.0 parts by weight of a monomeric unsaturated carboxylic acid; about 0.5 to 5.0 parts per weight of an acrylamide; a cross-linking amount of an amino-aldehyde resin; and from about 0.1 to 10% by weight based on the weight of the monomers of a nonionic alkylphenoxypolyalkoxyalkanol surfactant containing from about 30 to 70 ethoxy groups.
Claim 31
Dependent Claim
134 words
A foam-coated sheet material containing on one surface thereof a dried cross-linked copolymeric foam layer, the foam layer characterized by a generally open-cell uniform bubble structure, the copolymer cross-linked only in an amount sufficient to provide a stable compressible foam layer, the copolymer comprising from about 50 to 100 parts by weight of a lower alkyl acrylate; about 5 to 20 parts by weight of a nitrile selected from the group consisting of acrylonitrile and methacrylonitrile; about 0.5 to 5.0 parts by weight of a monomeric unsaturated carboxylic acid; about 0.5 to 5.0 parts per weight of an acrylamide; a cross-linking amount of an amino-aldehyde resin; and from about 0.1 to 10% by weight based on the weight of the monomers of a nonionic alkylphenoxypolyalkoxyalkanol surfactant containing from about 30 to 70 ethoxy groups.
Claim 32
Dependent Claim
32 words
The foam-coated sheet material of claim 27 wherein the sheet material is a woven fabric, and wherein the foam layer has a density of about 7 to 30 pounds per cubic foot.
Claim 33
Dependent Claim
39 words
The foam-coated sheet material of claim 27 wherein the copolymer is a cross-linked and cured copolymer and the foam layer is characterized by a densified and crushed open-cellular structure, which fabric is suitable for use as a drapery fabric.
Claim 34
Dependent Claim
33 words
The material of claim 29 wherein the aminoaldehyde resin is a melamine or urea-formaldehyde resin in an amount of from about 5 to 25 parts of resin per 100 parts of the copolymer.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1976-01-30 | 1976-07-31 | 1977-01-30 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1980-01-30 | 1980-07-31 | 1981-01-30 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1984-01-30 | 1984-07-31 | 1985-01-30 | $7700.00 | Window Closed / Lapsed |