Permaback, Long Life, Bleach Proof Latex Coated Rugs

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

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

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.

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.

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 fleece) woven fabric or Non-Woven fabric of polypropylene fibers.

The pile yarns are usually selected from natural fiber yarns such as, cotton, linen, hemp, sisal, wool, silk, ramie, banana fiber or regenerated cellulose fiber yarns such as, viscose, bamboo, modal, rose or synthetic fiber yarns such as, nylon, polyester and polypropylene.

During the course of explorations of various latex applications available for usage on the tufted rugs, it was noticed that only natural and synthetic latex were applied at the back of the rugs to impart tuft lock and antiskid properties. The life of such coating is very short, in that the coating starts cracking and splitting after about 8-10 washes. Normally rugs are rarely washed; often only to shed them off dirt and remove stains. 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. Invariably these rugs get discarded and disposed.

The following are three known types of applications of latex to the back of a rug:

1. Spray Coating: coating of the rubber or latex solution with a spray gun. This is generally applied to table tufted rugs, with a latex coat density of 60-120 grams per square meter (“GSM”) for low GSM rugs (e.g., 300 GSM and below).

2. Lick Coating: normally carried out on a coating machine for machine tufted rugs, with a latex coat density of 300-450 GSM for medium GSM rugs (e.g., 300 to 450 GSM).

3. Foam Coating: foam coating is also carried out on a coating machine for machine tufted rugs, with a latex coat density of 600-900 GSM for high GSM rugs (e.g., 450 GSM and above).

In regular industrial practice the coating mixture generally consists of the following: readily available natural latex (e.g., rubber); synthetic latex (e.g., synthetic butadiene rubber); potassium oleate soap; water; an anti-oxidant (e.g., phenolic acid); a thickener (e.g., potassium acrylate/sodium polyacrylate); and a filler (e.g., calcium carbonate/magnesium carbonate).

During the application of the coating mixture a gel, such as ammonium acetate, may be used as a homogenizer. In addition, an accelerator or activator (such as a mix of sulphur and zinc oxide) is used as a catalyst for speeding up of the binding and curing. In the case of spray coating, the accelerator generally used is 6% of the latex weight and no gel or filler is used. In the case of lick coating, the quantum of accelerator is generally 4% on the weight of latex and no gel or filler is used in this case also. In the case of foam coating, the latex usually consists of 50% natural rubber and 50% synthetic latex and the filler used is 200% of the latex. The accelerator in this case generally constitutes 3.5% of the latex weight and the gel used is about 3%. The purpose of the gel is to gel the ingredients homogeneously in the foam.

A latex composition as disclosed in Publication No. GB1522881, which comprises (a) a natural or synthetic elastomeric latex; (b) a curing system which comprises an accelerating agent, which agent is inhibited in accelerating function in the presence of the base and (c), a volatile ammoniacal base, the composition being characterized by having a total solids content of 55 to 85% by weight and being free of a gelling agent capable of gelling the composition in storage.

Another latex composition is disclosed in Publication No. US20080050520, wherein the composition comprises an aqueous emulsion of a natural or synthetic film-forming polymer, hydrogen peroxide, a surfactant and an activating agent for hydrogen peroxide decomposition.

In all the above publications, the life of the coating of the rugs is about 10 washes, after which the latex coating at the back starts cracking and peels off. The white coating generally turns yellow and if any bleaching is used during washing the process of cracking accelerates.

In view of above, it is desirable to provide a process for manufacturing of long life, bleach safe, latex-coated rugs.

SUMMARY OF THE INVENTION

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.

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.

Disclosed is a latex-coated tufted rug comprising a composition of latex for coating on one side of the tufted rugs wherein, the latex composition comprises a natural latex in range of about 55%—about 75%; a synthetic latex in range of about 45%—about 25%; a filler in an amount of about 110 kg/391 kg of latex—about 145 kg/391 kg of latex; a thickener; an anti-oxidant; and, optionally, at least one industry acceptable ingredient.

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.

In another embodiment, the invention relates to a latex composition coating comprising natural latex in a range of about 55% to about 75%; synthetic latex in a range of about 45% to about 25%; a filler in an amount ranging from about 110 kg per 391 kg of latex to about 145 kg per 391 kg of latex; a thickener; an anti-oxidant; and, optionally, at least one industry-acceptable ingredient.

In another embodiment, the invention relates to a process of preparing a tufted rug having a latex coating comprising the steps of mixing a composition of natural latex and synthetic latex to form a latex mixture, wherein the latex mixture is made of about 55% to about 75% natural latex, and about 45% to about 25% synthetic latex; adding a filler in an amount ranging from about 110 kg per 391 kg latex to about 145 kg per 391 kg latex; incorporating a thickener and an anti-oxidant into the latex mixture; and applying the latex composition coating to a back of the tufted rug.

The natural latex can be, but is not limited to polyisoprene-ammonia centrifuged natural rubber. The synthetic latex can be, but is not limited to an aqueous dispersion of styrene and 1,3 butadiene (Bunatex® T 4320). The filler can be, but is not limited to, calcium carbonate, magnesium carbonate, or a mixture thereof. The thickener can be, but is not limited to, potassium acrylate, sodium polyacrylate, or a mixture thereof. The anti-oxidant can be, but is not limited to, phenolic acid.

The disclosed latex composition can also contain industry acceptable ingredients, including but not limited to, a gel as a homogenizer and an accelerator (or activator) as a catalyst to speed up binding and curing. The gel can be, but is not limited to, ammonium acetate. The accelerator can be, but is not limited to sulphur, zinc oxide, or a mixture thereof.

The disclosed latex composition enhances the latex coat life, prevents it from turning yellow during laundering, and is bleach proof.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 depicts a flowchart for one embodiment of a process for production of machine tufted rugs with a latex composition coating in accordance with the invention.

FIG. 2 depicts a flowchart for one embodiment for a process for preparing a latex composition in accordance with the invention.

DETAILED DESCRIPTION OF THE INVENTION

The invention will now be described in detail, along with certain preferred and optional embodiments so that various aspects thereof may be more fully understood and appreciated.

It must be noted that as used herein and in the appended claims, the singular forms “a,”, “an,” and “the” include plural reference unless the context clearly dictates otherwise.

It is understood that the disclosed invention is not limited to the particular methodology, protocols, and reagents described as these may vary. It is also to be understood that the terminology used herein is for the purpose of describing particular embodiments only, and is not intended to limit the scope of the present invention, which will be limited only by the appended claims.

Those skilled in the art will recognize, or be able to ascertain using no more than routine experimentation, many equivalents to the specific embodiments of the invention described herein. Such equivalents are intended to be encompassed by the appended claims.

Unless defined otherwise, all technical and scientific terms used herein have the same meanings as commonly understood by one of skill in the art to which the disclosed invention belongs.

For the purpose of this invention, the terms “natural latex” or “synthetic latex”, relate to rubber latex, irrespective of various trade names assigned. The terms “accelerator,” “gel,” and “fillers” are generic irrespective of trade names.

The current invention relates to reduction in the use of synthetic latex (in turn increasing the content of natural latex), reducing the content of a filling agent in addition to judiciously balancing the use of the accelerator, thickener and the anti-oxidant, in the recipe for latex coating of the rugs to impart ruggedness to with stand up to 50 washes, without cracking or splitting or peeling and is bleach safe. Further, the latex or rubber coating acts as anti-skid surface.

In accordance with an embodiment of the invention, a latex composition for coating one side of a tufted rug comprises a natural latex in range of about 55%—about 75%; a synthetic latex in range of about 45%—about 25%; a filler in an amount of about 110 kg/391 kg of latex—about 145 kg/391 kg of latex; a thickener; an anti-oxidant; and, optionally, at least one industry acceptable ingredient.

In one embodiment of the invention, the process or preparing a latex composition coating includes 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.

The natural latex can be, but is not limited to polyisoprene-ammonia centrifuged natural rubber. The synthetic latex can be, but is not limited to an aqueous dispersion of styrene and 1,3 butadiene (Bunatex® T 4320). The filler can be, but is not limited to, calcium carbonate, magnesium carbonate, or a mixture thereof. The thickener can be, but is not limited to, potassium acrylate, sodium polyacrylate, or a mixture thereof. The anti-oxidant can be, but is not limited to, phenolic acid.

An embodiment of the latex composition coating according to the invention can also contain a gel as a homogenizer and an accelerator (or activator) as a catalyst to speed up binding and curing. The gel can be, but is not limited to, ammonium acetate. The accelerator can be, but is not limited to sulfur, zinc oxide, or a mixture thereof. The activator/accelerator can be present at from between about 3% to about 4%, and may be a combination of sulphur and zinc oxide. The gel (or homogenizer) can be present in an amount of between about 2.5% and about 5%, and may be added as an ammonium acetate 20% solution.

In one embodiment, the invention provides a process for production of latex-coated rugs comprising three stages. The first stage is tufting wherein, the backing fabric is creeled on to the machine at the back of the needle head and threaded up to the bed, where actual tufting by the needles is carried out. The requisite numbers of loop thread cheeses (cotton) are creeled on to the creel of an ALP Machine, MLCL machine or ACP machine, (ALL LOOP, MULTI LOOP CUT LEVEL and ALL CUT PILE machines, respectively). The yarn from the cheeses is threaded through the tubing and tufting needles of the machine as per design pattern fed in to the computer of the machine and tufting operation starts.

The second stage is coating, wherein, the tufted roll, from tufting step, are loaded on to the latex coating machine, where the coating is a continuous operation. The supply of the latex composition coating (both natural and synthetic latex mix), filler and thickener may be done through an automated system, during which time the application accelerator and gel are added to the foam. The thickness of the coat and controlling of the GSM may be done through microprocessor based programs. The embossing of the latex backing to introduce anti-skid property and baking and drying of latex are carried out by the system itself.

Latex preparation: Natural latex (Polyisoprene-Ammonia centrifuged natural rubber) is collected in a tank and potassium oleate soap, water, anti-oxidant are added and mixed together with slow speed stirrer (three spindle stirrer rotating at 20 rpm.). After 20 minutes, the synthetic latex SBR (Bunatex® T 4320—Aqueous dispersion of styrene and 1,3 Butadiene) is added and stirred for 20 minutes, then filler and thickener are added in a sequence, while continuing to stir the mix. The viscosity of the latex mix is checked and optimized at 4500 cPS (centipoise per second, 4 spindle, 20 rpm Brookfield™ viscometer). 4500 cPS is equivalent to 4.5 pascal's per second, i.e., 4.5 kg/meter second. Water at 20.2° C. has an absolute viscosity of 1 centipoise. Now the latex mixing is ready for application to coating.

Latex application: In one embodiment of this process, the latex mixture is applied on the back side of a tufted rug roll. This latex composition coating can be applied to any type of tufted yarn rug. The yarn may be drylon on the face, cotton yarn on the face, or nylon yarn on the face etc. To the latex coating mixture prepared as set forth above, an activator/accelerator at 4% (e.g., sulphur and zinc oxide) and gel at 3-4% (e.g., ammonium acetate 20% solution) is added and the mixture is applied on the back side of tufted roll. The thickness of the latex coating is checked to ensure correct grams per meter of the coating as described herein.

The coated rug passes through a steaming chamber and infra-red rays area for fixation and curing of the applied latex coating. The latex coating mixture cures at 125-130 degree Celsius temperature. The latex coated rug then passes through cooling zones and cools at 60 degree Celsius temperature and 40 degree Celsius respectively.

The third stage is cutting wherein; cutting of the tufted and coated rug fabric is carried out on the automatic infra-red guided cutting machine to the requisite size as per the specifications. Alternatively, some other known means of cutting may be used.

The cut and latex-coated rugs are further stitched on four sides on stitching machines with folders for guiding the piping cloth, or all the four sides are over locked with the piping cloth. The stitched rugs are then washed, dyed with reactive dyes, dried, checked, mended, folded, passed through needle detectors and packed in to poly bags before packing in to cartons.

A tufting machine may be used for production of the latex-coated rugs of the instant invention is selected from an All Loop (ALP) Machine, Multi Loop Cut Level (MLCL) Machine or All Cut Pile (ACP) Machine.

An All Loop (ALP) Machine having gauge of 3/16 inch or ⅜ inch, resulting in production of linear loops, with the capability of having loop densities in a range of 16 to 80 per sq. inch, and capable of introducing pile heights of 3 mm to 34 mm, can be employed for manufacturing the latex-coated rug in accordance with the invention. The creel capacity of the said machine is 1728 cheeses.

A Multi Loop Cut Level (MLCL) machine having a gauge of ⅛ inch, resulting in production of linear loops, with the ability to produce loop densities in a range of 20 to 80 per sq. inch and loop height of 3 to 20 mm and cut pile height of 4 to 22 mm, can be employed for manufacturing a latex-coated rug in accordance with the invention. The creel capacity of the said machine is 2592 cheeses.

All Cut Pile (ACP) machine having ⅛″ gauge, capable of introducing pile height from 3 mm to 34 mm, with a pile density of 20 to 96 per sq. inch can be employed for manufacturing a latex-coated rug in accordance with the invention. The creel capacity of said machine is 2592 cheeses.

All Cut Pile (ACP) machine having 3/16 inch gauge, capable of introducing pile height from 3 to 34 mm and density of 18 to 88 per sq. inch can be employed for manufacturing a latex coated rug in accordance with the invention. The creel capacity of said machine is 1728 cheeses.

The process for making drylon latex-coated rugs as described above further includes coating of the rugs with the latex composition coating on a remote side of the rug to impart anti-skid and long life properties and to hold the tufts intact. The latex coating is carried out on continuous latexing machine, wherein the latex composition comprises a mixture of synthetic and natural latex and filler.

The instant invention is more specifically explained by following examples. However, those skilled in the art will recognize or be able to ascertain, using no more than routine experimentation, many equivalents to the specific embodiments of the invention described herein. Such equivalents are intended to be encompassed by the examples and claims appended hereinafter.

EXAMPLES

Comparative Example 1

	Quantity (391 kgs latex)
			Recipe in
			accordance
			with an
		Normal	embodiment
		Industrial	of
Part	Particular	Recipe	the invention
Part A	Natural latex (Polyisoprene-	50%	55-75%
	Ammonia centrifuged natural
	rubber)
	SBR (Bunatex ®	50%	45%-25%
	T 4320 - Aqueous dispersion
	of styrene and 1,3 Butadiene)
	Potassium Oleate soap	12	kg	8-22	kg
	Water	22	kg	8-25	kg
	Anti-Oxidant Phenolic Acid	3	kg	1.5-4.5	kg
	Filler Calcium/magnesium	200	kg	110-145	kg
	Carbonate MgCO3/CaCO3
	Thickener Potassium	3	kg	1.5-4.5	kg
	Acrylate/Sodium polyacrylate
Part B	GEL Ammonium Acetate	2.5%-4%	2.5%-4%
(during
application)
Part C	Accelerator Mix of Sulphur	3%-4%	3%-4%
(during	and Zinc Oxide
application)

Example 1

Particulars of Latex Coating Mixture with Cotton Yarn Tuft

Latex Composition Recipe for Drylon Tufted Rug:

Trial lot
		Mixing quantity
Part	Particular	(391 kgs latex)
Part A	Natural latex (Polyisoprene-	60%
	Ammonia centrifuged natural
	rubber)
	SBR (Bunatex ® T 4320 - Aqueous	40%
	dispersion of styrene and 1,3
	Butadiene)
	Potassium Oleate soap	10 kgs
	Water	9 kgs
	Anti Oxidant Phenolic Acid	2 kgs
	Filler Calcium/magnesium	120 kgs
	Carbonate MgCO3/CaCO3
	Thickener Potassium Acrylate/	2 kgs
	Sodium polyacrylate
Part B	GEL Ammonium Acetate	3%
(during
application)
Part C	Accelerator Mix Of Sulphur and	3%
(during	Zinc Oxide
application)

Technical Specifications:

	Design	SANNY
	Party	WIL
	Machine	3/16 cut
	Yarn	6/6 OE 3.2 TPI S TWIST 100% COTTON
	material code	FCC0788053MPFDN01
	Size	21 × 34
	Backing	110 pp
	Coating type	foam coat
	latex type	natural and synthetic latex mixture (Permaback)
	Process route	Reactive dyeing
	percentage %	oz	gsm	inch	cm	gm/100 mtr	Gm
Tufting width				151	384
tuft yarn gsm		28	958
backing width				165	420
backing gsm		3	110
Length					100
tuft rugs gsm		31	1068
grey tufted rugs wt/100 mtr						409498
yarn waste	1
yarn wt						369143
yarn scrap						1846
backing wt						46460
backing waste	1
backing scrap						4269
backing area
Coating
coating gsm		24	814
coated rugs gsm		55	1881
coated rugs wt/100 MTR						721546
coated rugs wt/mtr
solid coating wt						312048
solid contain	65
liquid coating						480074
Natural latex	93	Part A				167546
SBR						111857
Potassium Oleate soap						12002
Water						11042
Anti Oxidant						2400
Filler						144022
Thickener						2400
Accelerator	3	Part B				14402
Gel	3	Part C				14402
grey rugs width				22	55	1
finish rugs width				21	53	53
grey rugs length				35	89
finish rugs length				34	86	86
grey gsm		55	1881
finish gsm		55	1872
rugs wt(for rectangle						1897	921
and square)
Utilization	97
fibre loss due to	11
processing
wt loss							52
finish wt(rectangle/							869
square)

The yarn used in the above example is 100% cotton NE 6's open end spun yarn cabled six folds to get 6/6's yarn of resultant count NE 1's, with a TPI of 3.2 in S direction.

The dyeing of the made up rugs is carried out in the pocket dyeing machines of capacity 130 kg/250 Kg/1000 Kg, depending on the batch size.

The materials to liquor ratio are 1:10 and the dispensing of dyes, chemicals and axillaries is through automated dispensing system.

In the bleaching and dyeing, the operating temperature ranges from about 95° C. to about 100° C. In a preferred embodiment, the temperature is about 95° C.

The liquor ratio is a ratio of the material (weight) to water (volume). The liquor ratio should be sufficient to facilitate free movement of the Rugs. The liquor ratio ranges from about 1:5 to about 1:30. In a preferred embodiment the liquor ratio is 1:10.

Rotation of the rugs promotes uniform application of the color. A continual overflow of water is also desired.

After dyeing and washing, the liquor is drained and fresh water is injected for rinsing to eliminate all the dissolved impurities. The water is at a temperature ranging from about 55° C. to about 100° C. Preferably, the water is at a high temperature, such as 100° C. This rinsing step also ensures that loose fibers drain out along with the drain water.

After unloading the material from the pocket dyeing rinsing vessel, the material is hydro-extracted in a hydro-extractor in the standard manner to reduce the moisture from 200% to 60%. Then the material is dried through a hot air piece dryer. The drying is carried out at about 100-110° C. for about 60 to 120 minutes.

Example2

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:

• • (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;
  • (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;
  • (c) cutting the latex-coated rug fabric of step (b) on an infra-red guided cutting machine as per pre-determined specification to form rugs;
  • (d) stitching the rug(s) of step (c) on four sides using a stitching machine;
  • (e) washing, checking, mending and folding and packing the stitched rugs of step (d), in poly bags and;
  • (f) Packing the packed rugs of step (e) in cartons.

Latex Composition Recipe for Drylon Tufted Rug.

Trial lot
		Mixing Quantity
Part	Particular	(391 kgs latex)
Part A	Natural latex (Polyisoprene-	60%
	Ammonia centrifuged natural
	rubber)
	SBR (Bunatex ® T 4320 -	40%
	Aqueous dispersion of styrene
	and 1,3 Butadiene)
	Potassium Oleate soap	10 kgs
	Water	9 kgs
	Anti-Oxidant Phenolic Acid	2 kgs
	Filler Calcium/magnesium	120 kgs
	Carbonate MgCO3/CaCO3
	Thickener Potassium	2 kgs
	Acrylate/Sodium
	polyacrylate
Part B	GEL Ammonium Acetate	3%
(during application)
Part C	Accelerator Mix Of Sulphur	3%
(during application)	and Zinc Oxide

A process for making a drylon latex-coated rug in accordance with the invention as set forth above is illustrated in this example, wherein the dope dyed, micro denier per filament, is in range of 1.0 to 5.0 DPF and with filaments of 600×2, 1200×2, 1800 and 2400 filaments, up on cabling wherein, the range is from 150 to 3600 filaments and or 75×2 to 1800×2. The drylon filaments as used in the process are dope dyed during the process of filament extrusion and the dope dyeing is carried out by adding color master batch during extrusion of spinning process. The dope dyed filaments impart bleach safe and good color fastness to the rug.

In accordance with the process for making a drylon latex-coated rug as set forth in the above example, the micro denier per filament, is in range of 1.0 to 5.0 DPF, with 600×2, 1200×2, 1800 and 2400 filaments, up on cabling wherein, the range is from 150 to 3600 filaments and or 75×2 to 1800×2 are heat set and dyed in pressure vessels. The drylon filaments as used in this process are yarn dyed after the process of extrusion, cabling and heat setting the yarn dyed filaments impart bleach safe and good color fastness to the said rug.

The process for making drylon latex coated rugs as described above further includes coating of the rugs with the latex composition on a remote side to impart anti-skid and long life properties and to hold the tufts intact. The latexing is carried out on continuous latexing machine, wherein the latex composition comprises a mixture of synthetic and natural latex and filler.

Example 3

Latex Composition Recipe for Drylon Yarn Tuft.

	Trial lot
		Mixing Quantity
Part	Particular	(391 kgs latex)
Part A	Natural latex (Polyisoprene-	60%
	Ammonia centrifuged natural
	rubber)
	SBR (Bunatex ® T 4320 -	40%
	Aqueous dispersion of styrene
	and 1,3 Butadiene)
	Potassium Oleate soap	10 kgs
	Water	9 kgs
	Anti-Oxidant Phenolic Acid	2 kgs
	Filler Calcium/magnesium	120 kgs
	Carbonate MgCO3/CaCO3
	Thickener Potassium Acrylate/	2 kgs
	Sodium polyacrylate
Part B	GEL Ammonium Acetate	3%
(during
application)
Part C	Accelerator Mix Of Sulphur and	3%
(during	Zinc Oxide
application)

Technical Specification:

Design	GEMINYI
Party	WIL
Machine	3/16 cut
Yarn	1200/2 DENIER 1 DPF 3.3 TPI S-TWIST 100%
	DRYLON
material code	FCC0787053MPFDN01
Size	21 × 34
Backing	100 pp
Coating type	foam coat
latex type	“PERMABACK”
Process route	Washing and softness
	percentage %	Oz	gsm	inch	cm	gm/100 mtr	gm
Tufting width				151	384
tuft yarn gsm		28	958
backing width				165	420
backing gsm		3	110
Length					100
tuft rugs gsm		31	1068
grey tufted rugs wt/100 mtr						409498
yarn waste	1
yarn wt						369143
yarn scrap						1846
backing wt						46460
backing waste	1
backing scrap						4269
backing area
Coating
coating gsm		24	814
coated rugs gsm		55	1881
coated rugs wt/100 MTR						721546
coated rugs wt/mtr
solid coating wt						312048
solid contain	65
liquid coating						480074
Natural latex	93	Part A				167546
SBR						111857
Potassium Oleate soap						12002
Water						11042
Anti-Oxidant						2400
Filler						144022
Thickener						2400
Accelerator	3	Part B				14402
Gel	3	Part C				14402
grey rugs width		22″		22	55	1
finish rugs width		21″		21	53	53
grey rugs length		35″		35	89
finish rugs length		34″		34	86	86
grey gsm		55	1881
finish gsm		55	1872
rugs wt(for rectangle and						1897	921
square)
Utilization	97
fiber loss due to	1
processing
wt loss							5
finish wt(rectangle/							916
square)

The rugs produced according to Example 3 were tested under laboratory laundering as per AATCC method 135, prescribed for textiles.

The following is the result.

Table #3 below describes the latex coat appearance after 50 washes as per AATCC laundering method 135.

1) Testing method: AATCC-135
				WASH WITH 1.5
				OZ CLORAX
		WASH WITH 1.5 OZ	WASH WITH 1.5 OZ	AND 1.5 OZ
		CLORAX AND 1.5 OZ	CLORAX AND 1.5 OZ	DETERGENT
LATEX	COLOUR	DETERGENT(AFTER	DETERGENT(AFTER	(AFTER 50
TYPE	OF TUFT	10 WASH)	25 WASH)	WASH)
ORDINARY	EXPRESSO	LATEX TURNS TO	LATEX TURNS TO	LATEX TURNS
LATEX		YELLOWER &	YELLOWER &	TO YELLOWER
		CRACKS	CRACKS	& CRACKS
				ALSO DAMAGE
				THE RUGS
PERMA	EXPRESSO	NO YELLOWING	NO YELLOWING AND	NO
BACK		AND THE LATEX	THE LATEX COAT IS	YELLOWING
LATEX		COAT IS INTACT	INTACT	AND THE
				LATEX COAT
				IS INTACT
2) Testing method: AATCC-135
		WASH WITH 6 OZ	WASH WITH 6 OZ	WASH WITH 6 OZ
		CLORAX AND 6 OZ	CLORAX AND 6 OZ	CLORAX AND 6 OZ
LATEX	COLOUR	DETERGENT(AFTER	DETERGENT(AFTER	DETERGENT(AFTER
TYPE	OF TUFT	10 WASH)	25 WASH)	50 WASH)
ORDINARY	EXPRESSO	LATEX TURNS TO	LATEX TURNS TO	LATEX TURNS TO
LATEX		YELLOWER &	YELLOWER &	YELLOWER &
		CRACKS	CRACKS	CRACKS ALSO
				DAMAGE THE
				RUGS
PERMA	EXPRESSO	NO YELLOWING	NO YELLOWING	NO YELLOWING
BACK		AND THE LATEX	AND THE LATEX	AND THE LATEX
LATEX		COAT IS INTACT	COAT IS INTACT	COAT IS INTACT
3) Testing method: AATCC-135
		NORMALLAUNDRY	NORMALLAUNDRY	NORMALLAUNDRY
LATEX	COLOUR	WASH (AFTER 10	WASH (AFTER 25	WASH (AFTER 50
TYPE	OF TUFT	WASH)	WASH)	WASH)
ORDINARY	EXPRESSO	LATEX TURNS TO	LATEX TURNS TO	LATEX TURNS TO
LATEX		YELLOWER &	YELLOWER &	YELLOWER &
		CRACKS	CRACKS	CRACKS ALSO
				DAMAGE THE
				RUGS
PERMA	EXPRESSO	NO YELLOWING	NO YELLOWING	NO YELLOWING
BACK		AND THE LATEX	AND THE LATEX	AND THE LATEX
LATEX		COAT IS INTACT	COAT IS INTACT	COAT IS INTACT

Having now fully described the invention, it will be understood by those of ordinary skill in the art that the same can be performed within a wide and equivalent range of conditions, formulations and other parameters without affecting the scope of the invention or any embodiment thereof All patents, patent applications, and publications cited herein are fully incorporated by reference in their entirety.

Claims

1. A tufted rug having a latex composition coating on one side of the tufted rug, the latex composition coating comprising:

a. natural latex in a range of about 55% to about 75%;

b. synthetic latex in a range of about 45% to about 25%;

c. a filler in an amount ranging from about 110 kg per 391 kg of latex to about 145 kg per 391 kg of latex;

d. a thickener; and

e. an anti-oxidant.

2. The tufted rug of claim 1, wherein the natural latex is polyisoprene-ammonia centrifuged natural rubber.

3. The tufted rug of claim 1, wherein the synthetic latex is an aqueous dispersion of styrene and 1,3-butadiene.

4. The tufted rug of claim 1, wherein the filler is a mixture of calcium carbonate and magnesium carbonate.

5. The tufted rug of claim 1, wherein the thickener is a mixture of potassium acrylate and sodium polyacrylate.

6. The tufted rug of claim 1, wherein the anti-oxidant is phenolic acid.

7. The tufted rug of claim 1, further comprising potassium oleate soap and water.

8. The tufted rug of claim 1, further comprising at least one industry-acceptable ingredient.

9. The tufted rug of claim 8, wherein the at least one industry-acceptable ingredient comprises an activator/accelerator and a homogenizer.

10. The tufted rug of claim 9, wherein the homogenizer is ammonium acetate.

11. The tufted rug of claim 9, wherein the activator/accelerator is a mixture of sulfur oxide and zinc oxide.

12. The tufted rug of claim 1, further comprising a plurality of tufts made of material selected from the group consisting of a natural fiber yarn, a regenerated cellulose fiber, and a synthetic fiber yarn.

13. The tufted rug of claim 11, wherein the natural fiber yarn is selected from the group consisting of cotton, linen, hemp, sisal, wool, silk, ramie, and banana fiber.

14. The tufted rug of claim 11, wherein the synthetic fiber yarn is selected from the group consisting of viscose, bamboo, modal, rose or such as, nylon, polyester, a polyester filament yarn, and polypropylene.

15. A latex coating composition comprising:

a. natural latex in a range of about 55% to about 75%;

b. synthetic latex in a range of about 45% to about 25%;

c. a filler in an amount ranging from about 110 kg per 391 kg of latex to about 145 kg per 391 kg of latex;

d. a thickener; and

e. an anti-oxidant.

16. The latex composition coating of claim 15, wherein the natural latex is polyisoprene-ammonia centrifuged natural rubber.

17. The latex composition coating of claim 15, wherein the synthetic latex is an aqueous dispersion of styrene and 1,3-butadiene.

18. The latex composition coating of claim 15, wherein the filler is a mixture of calcium carbonate and magnesium carbonate.

19. The latex composition coating of claim 15, wherein the thickener is a mixture of potassium acrylate and sodium polyacrylate.

20. The latex composition coating of claim 15, wherein the anti-oxidant is phenolic acid.

21. The latex composition coating of claim 15, further comprising potassium oleate soap and water.

22. The latex composition coating of claim 15, further comprising at least one industry-acceptable ingredient.

23. The latex composition coating of claim 22, wherein the at least one industry-acceptable ingredient comprises an activator/accelerator and a homogenizer.

24. The latex composition coating of claim 23, wherein the homogenizer is ammonium acetate.

25. The latex composition coating of claim 23, wherein the activator/accelerator is a mixture of sulfur oxide and zinc oxide.

26. A process of preparing a latex composition coating comprising the steps of:

a. mixing a composition of natural latex and synthetic latex to form a latex mixture, wherein the latex mixture is made of about 55% to about 75% natural latex, and about 45% to about 25% synthetic latex;

b. adding a filler in an amount ranging from about 110 kg per 391 kg latex to about 145 kg per 391 kg latex; and

c. incorporating a thickener and an anti-oxidant into the latex mixture.

27. The process of claim 26, further comprising the step of adding at least one industry-acceptable ingredient.

28. A process of preparing a tufted rug having a latex coating comprising the steps of:

a. mixing a composition of natural latex and synthetic latex to form a latex mixture, wherein the latex mixture is made of about 55% to about 75% natural latex, and about 45% to about 25% synthetic latex;

b. adding a filler in an amount ranging from about 110 kg per 391 kg latex to about 145 kg per 391 kg latex;

c. incorporating a thickener and an anti-oxidant into the latex mixture; and

d. applying the latex composition coating to a back of the tufted rug.

29. The process of claim 26, further comprising the steps of

e. curing the latex composition coating on the back of the tufted rug;

f. cutting the tufted rug to a desired size; and

g. stitching the sides of the tufted rug to form a finished tufted rug having a latex composition coating.

30. The process of claim 26, wherein the latex composition coating is applied in a continuous process.

31. The process of claim 26, further comprising adding at least one industrially-acceptable ingredient to the latex composition coating before application to the back of the tufted rug.