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Method-for-preparing-a-smooth-surfaced-tough-elastomeric-coated-fibrous-batt

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Method for preparing a smooth surfaced tough elastomeric coated fibrous batt

Details

Inventors: Morton, L. Keith;
Assignee: Evode Tanner Industries, Inc. (Greenville, SC)
Primary Examiner: Beck; Shrive
Assistant Examiner: Bareford; Katherine A.
Attorney, Agent or Firm: Keck; Harry B.

A process for providing a relatively smooth, tough, elastomeric coating over one surface of a fibrous batt employs a heated ironing surface which engages an uncured coating of a composition of cross-linkable elastomeric aqueous emulsion applied as a foam or froth to an exposed surface of a fibrous batt. The heated belt causes dewatering and cure of a film of the coating which is in contact with the ironing surface. The fibrous batt thereafter is heated in a curing oven to drive off substantially all of the moisture and substantially cure all of the elastomeric coating composition. The resulting coated fibrous batt has a smoother and tougher surface than similar batts formed from similar compositions without the interposed ironing treatment. A preferred ironing element comprises a continuous stainless steel belt.

DETAILED DESCRIPTION I claim: 1.
A method for developing a generally smooth, tough, elastomeric surface coating over one surface of a batt of fibrous insulation, comprising: a.
applying a foamed or frothed cross-linkable elastomeric aqueous emulsion coating composition to said one surface of a batt at a substantially uniform concentration coating over said one surface; b.
engaging a hot, smooth ironing surface with said coating to dry and compress said cross-linkable emulsion coating and to develop a cured, smooth surface film over the exposed area of said coating; c.
separating said ironing surface from engagement with said coating and thereafter heating said batt and coating until said coating is substantially dried and fully cured; d.
recovering said batt of fibrous insulation having a cured elastomeric cross-linked coating over one surface of said batt, said coating having a generally smoother and tougher exposed surface compared to a corresponding coating of the same cross-linkable elastomeric coating composition on the same batt at the same concentration which has not been exposed to said hot, smooth, ironing surface prior to heating said batt and coating to achieve a final cure of said coating.
2.
The method of claim 1 wherein said cross-linkable elastomeric coating composition is a water based, flame retardant composition containing an acrylic latex.
3.
The method of claim 1 wherein said cross-linkable elastomeric coating composition is applied to said batt in the form of a froth or foam having a cup-weight of 55 to 255 grams.
4.
A method for developing a generally smooth, tough elastomeric surface coating over one surface of a batt of fibrous insulation, comprising: a.
applying a foamed or frothed cross-linkable elastomeric aqueous emulsion coating composition to said one surface of said pad; using a doctor blade to develop uniform concentration of said cross-linkable elastomeric aqueous emulsion coating; b.
engaging a heated ironing surface at a temperature above the curing temperature of said composition with the exposed surface of said coating to dry and compress the exposed surface and to heat cure the exposed surface of said coating to achieve surface curing of said coating; c

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