Patent GB-923142-A (GB)
Title: Improvements relating to materials suitable for use as floor coverings and the like
Inventor: SAUL WALTER
Filed: 1958-08-23
Abstract: 923,142. Coated fabrics; laminates. SEMPEX Ltd. Aug. 14, 1959 [Aug. 23, 1958], No. 27130/58. Class 140. A composite material is produced by applying a loop pile fabric formed from continuous filament yarn to a layer of vulcanizable natural or synthetic rubber composition containing a blowing agent, the loop pile being on the side remote from the rubber composition layer, and effecting vulcanization and concurrent blowing of the rubber composition layer and attachment of this layer to the loop pile fabric by application of heat. The loop pile fabric may be a plain knitted fabric with portions of the yams raised, and may be formed from continuous filament nylon, polyester, polyvinyl chloride, polyacrylonitrile yam, or may be a fabric having an integral backing of, for example, cotton, having a nylon loop pile. The loop pile fabric and layer of vulcanizable rubber composition may be fed continuously through a heating chamber in such a manner that as the rubber is heated to effect vulcanization, it expands and becomes firmly adhered to the loop pile fabric. As shown, the fabric 7 and layer 3 may be fed through heating chamber 4 by means of two conveyer belts 5, 8, the lowermost travelling surface of belt 8 being in contact with the loop pile surface of the fabric and being parallel with and vertically above the uppermost travelling surface of the belt 5 carrying the layer of rubber composition. An adhesive composition may be applied to the appropriate surface of the layer of rubber composition and/or fabric before application of the fabric to the layer of rubber composition. The adhesive composition may comprise a latex of a copolymer of butadiene, styrene and vinyl pyridine in admixture with an alkaline solution of resorcinol and formaldehyde, a copolymer of butadiene and acrylonitrile mixed with a phenolic resin, or a solution of neoprene or natural rubber with vulcanizing ingredients. The rubber composition may be of natural or synthetic rubber, e.g. natural crepe rubber, neoprene, butyl rubber or butadiene-styrene. The blowing agent may be sodium bicarbonate. The assembled layer of rubber composition and loop pile fabric may be inserted between two flat platens equipped with means for heating them to effect blowing and vulcanization of the rubber compositions, the separation of the two platens being adjusted according to the degree to which the rubber composition is to be allowed to expand when blowing and vulcanization takes place, e.g. at between 110‹ and 160‹ C. The loop pile fabric may be embossed, printed, or formed from differently-coloured yarns. The layer of vulcanizable rubber composition may be provided with a backing of textile fabric, e.g. hessian, or a non-cellular rubber composition sheeting, applied to the face of the rubber composition remote from that carrying the loop pile fabric. Electrical resistance wires may be inserted in the layer of vulcanizable rubber composition before applying the layer of loop pile fabric thereto. The composite material may be cut into individual portions like tiles for use as a floor covering, or in upholstery and motor car trim. Specification 917,523 is referred to.