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Permaback, Long Life, Bleach Proof Latex Coated Rugs

a technology of bleach-proof latex and rugs, applied in weaving, automatic machines, transportation and packaging, etc., can solve the problems of short cracking and splitting of coatings, cracking and peeling of latex, etc., and achieves the effect of preventing yellowing and prolonging the life of latex coatings

Inactive Publication Date: 2012-08-09
MANDAWEWALA RAJESH RAMESHKUMAR
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

[0017]Disclosed is a method of modifying the latex coating recipe of a rug using a mixture of natural latex, synthetic latex, accelerator, gel and filler having anti-oxidant property, thus imparting bleach proof durability, and the ability to withstand up to 50 washes or more. Rugs that use the long life latex composition coating of the present invention have been referred to by the applicants as “Permaback” rugs.
[0018]The disclosed invention provides a lower content of synthetic latex and filler, which makes the coating more supple, less brittle and more resilient to withstand stress and strain during washing thereby enhancing the durable life of the rug.
[0020]The invention also relates to a process of preparing a latex composition for coating on one side of the tufted rugs comprising the steps of mixing natural latex in a range of about 55%—about 75% and synthetic latex in a range of about 45%—about 25% to form a latex mixture; adding a filler in a range from about 110 kg / 391 kg latex—about 145 kg / 391 kg latex, thereby increasing the suppleness, resiliency of the coat, and incorporating a thickener and an anti-oxidant into the latex mixture, wherein the coat life is enhanced, the coat is prevented from turning yellow during laundering, and the coat is bleach proof.
[0025]The disclosed latex composition enhances the latex coat life, prevents it from turning yellow during laundering, and is bleach proof.

Problems solved by technology

The life of such coating is very short, in that the coating starts cracking and splitting after about 8-10 washes.
However after some washes the latex becomes brittle and starts cracking and peeling.
These cracked and peeled areas allow moisture / water to enter the surface from below, thereby staining the rug surface, causing undesirable patches.
The cracking also results in mildew formation leading to an offensive odor.
The white coating generally turns yellow and if any bleaching is used during washing the process of cracking accelerates.

Method used

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  • Permaback, Long Life, Bleach Proof Latex Coated Rugs
  • Permaback, Long Life, Bleach Proof Latex Coated Rugs
  • Permaback, Long Life, Bleach Proof Latex Coated Rugs

Examples

Experimental program
Comparison scheme
Effect test

example 1

Particulars of Latex Coating Mixture with Cotton Yarn Tuft

Latex Composition Recipe for Drylon Tufted Rug:

[0054]

Trial lotMixing quantityPartParticular(391 kgs latex)Part ANatural latex (Polyisoprene-60%Ammonia centrifuged naturalrubber)SBR (Bunatex ® T 4320 - Aqueous40%dispersion of styrene and 1,3Butadiene)Potassium Oleate soap10 kgs Water9 kgsAnti Oxidant Phenolic Acid2 kgsFiller Calcium / magnesium120 kgs Carbonate MgCO3 / CaCO3Thickener Potassium Acrylate / 2 kgsSodium polyacrylatePart BGEL Ammonium Acetate 3%(duringapplication)Part CAccelerator Mix Of Sulphur and 3%(duringZinc Oxideapplication)

Technical Specifications:

[0055]

DesignSANNYPartyWILMachine 3 / 16 cutYarn6 / 6 OE 3.2 TPI S TWIST 100% COTTONmaterial codeFCC0788053MPFDN01Size21 × 34Backing110 ppCoating typefoam coatlatex typenatural and synthetic latex mixture (Permaback)Process routeReactive dyeingpercentage %ozgsminchcmgm / 100 mtrGmTufting width151384tuft yarn gsm28958backing width165420backing gsm3110Length100tuft rugs gsm311068...

example2

[0064]A process for making a latex-coated rug in accordance with the invention comprises use of dope dyed, micro denier, cabled and heat set polyester yarn, or micro denier per filament, cabled, heat set, yarn dyed, antimicrobial treated polyester yarn, for tufting of rugs, thereby eliminating the process of batch dyeing after the formation of rugs, further ensuring that the rugs are bleach safe, quick drying, anti-skid, long life and stain resistant. Such a process of making a latex-coated rug in accordance with the invention comprises the following steps:[0065](a) Tufting of micro-denier, dope dyed, cabled and heat-set polyester filament, or micro denier per filament, cabled, heat set, yarn dyed, antimicrobial treated polyester yarn, on cheeses, which is creeled on tufting machine to form a tufted fabric roll;[0066](b) loading the tufted rolls of step (a) on a latex coating machine followed by application of the latex composition coating to form a latex-coated rug fabric;[0067](c)...

example 3

Latex Composition Recipe for Drylon Yarn Tuft.

[0075]

Trial lotMixing QuantityPartParticular(391 kgs latex)Part ANatural latex (Polyisoprene-60%Ammonia centrifuged naturalrubber)SBR (Bunatex ® T 4320 -40%Aqueous dispersion of styreneand 1,3 Butadiene)Potassium Oleate soap10 kgs Water9 kgsAnti-Oxidant Phenolic Acid2 kgsFiller Calcium / magnesium120 kgs Carbonate MgCO3 / CaCO3Thickener Potassium Acrylate / 2 kgsSodium polyacrylatePart BGEL Ammonium Acetate 3%(duringapplication)Part CAccelerator Mix Of Sulphur and 3%(duringZinc Oxideapplication)

Technical Specification:

[0076]

DesignGEMINYIPartyWILMachine 3 / 16 cutYarn1200 / 2 DENIER 1 DPF 3.3 TPI S-TWIST 100%DRYLONmaterial codeFCC0787053MPFDN01Size21 × 34Backing100 ppCoating typefoam coatlatex type“PERMABACK”Process routeWashing and softnesspercentage %Ozgsminchcmgm / 100 mtrgmTufting width151384tuft yarn gsm28958backing width165420backing gsm3110Length100tuft rugs gsm311068grey tufted rugs wt / 100 mtr409498yarn waste1yarn wt369143yarn scrap1846backin...

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Abstract

The present invention discloses a novel process and composition for latex-coated rugs. The novel latex composition coating contains a mixture of natural latex, synthetic latex, accelerator, gel and filler having anti-oxidant property.

Description

FIELD OF INVENTION[0001]The present invention relates to enhancing the useful life of rugs. More particularly, the present invention is directed to a bleach proof rug coating for enhancing the useful life of rugs.BACKGROUND AND PRIOR ART OF INVENTION[0002]Rugs are thick woven floor mats of shaggy or thick piled surface. Rugs are tufted floor coverings used in specific areas of application. Rugs may have thick piles on one or both sides of the backing fabric. The thick piled surface is also sheared to give the surface soft velvety touch.[0003]Rugs may have tufting on one surface, and latex or rubber coating on the other surface to hold the tufts in place; as otherwise the tufts may get dislodged from the backing fabric. Further, the latex or rubber coating acts as anti-skid surface.[0004]Rugs are formed with a backing fabric and pile yarns for tufting. The backing fabric is normally a cotton canvas or HDPE (High Density Poly Ethylene) or PP (Polypropylene, with or without Nylon fleec...

Claims

the structure of the environmentally friendly knitted fabric provided by the present invention; figure 2 Flow chart of the yarn wrapping machine for environmentally friendly knitted fabrics and storage devices; image 3 Is the parameter map of the yarn covering machine
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Application Information

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IPC IPC(8): D03D27/00D06Q1/02D06M15/693
CPCC09D107/00D06N7/0073D06N2209/106C08L9/08C08K3/26Y10T428/23979
Inventor MANDAWEWALA, RAJESH RAMESHKUMAR
Owner MANDAWEWALA RAJESH RAMESHKUMAR
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