DURABLE NATURAL FABRIC PRODUCTS

• US 20190309173A1
• Filed: 03/29/2019
• Published: 10/10/2019
• Est. Priority Date: 04/04/2018
• Status: Active Grant

• Current Assignee: Ziqiang Lu
• Original Assignee: Ziqiang Lu
• Inventors: Lu, Ziqiang
• Granted Patent: US 12,065,581 B2
• Time in Patent Office: Days
• CPC Class Codes: B32B 2250/02 2 layers
• CPC Class Codes: B32B 2250/20 All layers being fibrous or filamentary
• CPC Class Codes: B32B 2255/02 on fibrous or filamentary layer
• CPC Class Codes: B32B 2255/20 Inorganic coating
• CPC Class Codes: B32B 2255/26 Polymeric coating
• CPC Class Codes: B32B 2255/28 Multiple coating on one surface
• CPC Class Codes: B32B 2262/04 Cellulosic plastic fibres, e.g. rayon
• CPC Class Codes: B32B 2262/062 Cellulose fibres, e.g. cotton
• CPC Class Codes: B32B 2262/065 Lignocellulosic fibres, e.g. jute, sisal, hemp, flax, bamboo
• CPC Class Codes: B32B 2262/067 Wood fibres
• CPC Class Codes: B32B 2262/08 Animal fibres, e.g. hair, wool, silk
• CPC Class Codes: B32B 2262/14 Mixture of at least two fibres made of different materials
• CPC Class Codes: B32B 2307/4026 within the layer by addition of a colorant, e.g. pigments, dyes
• CPC Class Codes: B32B 2307/41 Opaque
• CPC Class Codes: B32B 2307/412 Transparent
• CPC Class Codes: B32B 2307/542 Shear strength
• CPC Class Codes: B32B 2307/546 Flexural strength; Flexion stiffness
• CPC Class Codes: B32B 2307/7145 Rot proof, resistant to bacteria, mildew, mould, fungi
• CPC Class Codes: B32B 2307/7265 Non-permeable
• CPC Class Codes: B32B 2307/732 Dimensional properties
• CPC Class Codes: B32B 2307/734 : Dimensional stability
• CPC Class Codes: B32B 2419/06 : Roofs, roof membranes
• CPC Class Codes: B32B 2471/04 : Mats
• CPC Class Codes: B32B 2479/00 : Furniture
• CPC Class Codes: B32B 2571/00 : Protective equipment
• CPC Class Codes: B32B 5/022 : Non-woven fabric
• CPC Class Codes: B32B 5/024 : Woven fabric
• CPC Class Codes: B32B 5/026 : Knitted fabric
• CPC Class Codes: B32B 5/08 : the fibres or filaments of a layer being of different substances , e.g. conjugate fibres, mixture of different fibres
• CPC Class Codes: B32B 5/10 : characterised by a fibrous or filamentary layer reinforced with filaments
• CPC Class Codes: B32B 5/26 : another layer next to it also being fibrous or filamentary relative arrangement of fibres or filaments of different layers B32B5/12
• CPC Class Codes: B32B 7/12 : using interposed adhesives or interposed materials with bonding properties
• CPC Class Codes: C08K 5/0025 : Crosslinking or vulcanising agents; including accelerators
• CPC Class Codes: C09D 129/14 : Homopolymers or copolymers of acetals or ketals obtained by polymerisation of unsaturated acetals or ketals or by after-treatment of polymers of unsaturated alcohols
• CPC Class Codes: C09D 131/04 : Homopolymers or copolymers of vinyl acetate
• CPC Class Codes: C09D 133/02 : Homopolymers or copolymers of acids; Metal or ammonium salts thereof
• CPC Class Codes: C09D 133/04 : Homopolymers or copolymers of esters C09D143/04 takes precedence
• CPC Class Codes: C09D 163/00 : Coating compositions based on epoxy resins; Coating compositions based on derivatives of epoxy resins
• CPC Class Codes: C09D 167/08 : Polyesters modified with higher fatty oils or their acids, or with natural resins or resin acids
• CPC Class Codes: C09D 175/04 : Polyurethanes
• CPC Class Codes: C09D 195/00 : Coating compositions based on bituminous materials, e.g. asphalt, tar, pitch
• CPC Class Codes: C09D 5/002 : Priming paints C09D5/08 takes precedence
• CPC Class Codes: C09J 131/04 : Homopolymers or copolymers of vinyl acetate
• CPC Class Codes: D06M 15/333 : of vinyl acetate; Polyvinylalcohol
• CPC Class Codes: D06M 2101/06 : cellulosic
• CPC Class Codes: D06M 2101/12 : Keratin fibres or silk
• CPC Class Codes: D06M 2101/14 : Collagen fibres
• CPC Class Codes: D06M 2200/12 : Hydrophobic properties
• CPC Class Codes: D06N 2201/042 : Cellulose fibres, e.g. cotton
• CPC Class Codes: D06N 2201/045 : Lignocellulosic fibres, e.g. jute, sisal, hemp, flax, bamboo
• CPC Class Codes: D06N 2201/06 : Animal fibres, e.g. hair, wool, silk
• CPC Class Codes: D06N 2203/045 : Vinyl (co)polymers
• CPC Class Codes: D06N 2209/128 : Non-permeable
• CPC Class Codes: D06N 2209/142 : Hydrophobic
• CPC Class Codes: D06N 2209/1628 : Dimensional stability
• CPC Class Codes: D06N 2211/06 : Building materials
• CPC Class Codes: D06N 2211/122 : Curtains
• CPC Class Codes: D06N 3/0006 : using woven fabrics
• CPC Class Codes: D06N 3/0015 : using fibres of specified chemical or physical nature, e.g. natural silk
• CPC Class Codes: D06N 3/04 : with macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
• CPC Class Codes: D06N 3/042 : Acrylic polymers D06N3/045 takes precedence
• CPC Class Codes: D06N 3/14 : with polyurethanes
• CPC Class Codes: D06N 3/183 : the layers are one next to the other
• CPC Class Codes: D06N 5/00 : Roofing materials comprising a fibrous web coated with bitumen or another polymer, e.g. pitch compositions of bituminous materials C08L95/00, roof covering E04D5/00, roofing underlays E04D12/002

Abstract

A natural fabric or textile product is coated and protected with a waterproofing composition comprising a crosslinking polyvinyl acetate (XPVAc or x-PVAc) emulsion polymer or adhesive applied and cured as a first coating layer or a primer and a coating layer of acrylic, alkyd, asphalt, emulsion polymer isocyanate, epoxy, lacquer, latex, polyurethane, urethane, or vinyl ester coated over the cured crosslinking polyvinyl acetate as a second coating layer or a topcoat. The natural fabric product is fabricated by weaving, knitting or felting the fibers, yarns or threads of vegetable or plant fibers from cotton, sisal, kenaf, hemp, jute, flax, reed, sugarcane, ramie, henequen, raffia, nettle, milkweeds, palm, coir, grass, Spanish moss, New Zealand flax, kapok, sugarcane, bamboo, or wood, or those of the protein fibers from wool, silk, spider threads, sea silk, or the combination thereof.

Claims

1. A waterproofing composition for a natural fabric or textile product comprising:

a crosslinking polyvinyl acetate adhesive applied and cured on the exterior surfaces of the natural fabric product as a first coating layer or a primer and a coating layer selected from the group consisting of acrylic, alkyd, asphalt, emulsion polymer isocyanate, epoxy, lacquer, latex, polyurethane, urethane, and vinyl ester applied over the cured crosslinking polyvinyl acetate adhesive as a second coating layer or a topcoat on said product,

wherein said product is woven, knitted, or fabricated from natural fibers, yarns, or threads;

said yarns or threads being twisted or spun from the natural fibers;

wherein said adhesive includes a polyvinyl acetate-based adhesive resin, a copolymer, a crosslinking agent, and a catalyst and is a Type I or Type II adhesive; and

wherein said composition forms into a coating film on at least a part of the exterior surfaces of said product as a protective coating and provides durable protection to said product.

2. The waterproofing composition of claim 1, wherein said product comprises warps and wefts in weave structure or pattern.

3. The waterproofing composition of claim 1, wherein said product includes S-spun yarns or threads, Z-spun yarns or threads, or the combination thereof.

4. The waterproofing composition of claim 1, wherein a natural fiber of said product has a minimum cellulose content of 15% in composition when said product is made from a vegetable or plant fiber.

5. The waterproofing composition of claim 1, wherein the moisture content of said product is less than 20% before coated with said adhesive.

6. The waterproofing composition of claim 1, wherein the crosslinking polyvinyl acetate adhesive has a solid content in the range of about 15% to about 70% by weight.

7. The waterproofing composition of claim 1, wherein the dry coating thickness of said adhesive applied on said product is in the range between about 0.001 inch and about 0.050 inch.

8. A natural fabric or textile product including at least one exterior surface, said exterior surface receiving a waterproofing composition comprising at least a crosslinking polyvinyl acetate adhesive applied and cured on said product as a first coating layer or a primer, wherein said product is woven, knitted, or fabricated from natural fibers, yarns, or threads;

said yarns or threads being twisted or spun from the natural fibers;

wherein said product at least comprises a warp composition element in the formed weave structure;

wherein the crosslinking polyvinyl acetate adhesive at least includes a polyvinyl acetate-based adhesive resin, a crosslinking agent and a catalyst, and is a Type I or Type II adhesive;

wherein said composition forms into a coating film on at least one portion of the exterior surfaces of said product as a protective coating to provide durable protection to said product.

9. The natural fabric product of claim 8, wherein said adhesive has been cured after applied on said product prior to contacting any other products.

10. The natural fabric product of claim 8, wherein said adhesive has a minimum Fruehauf wet shear strength of 175 psi when applied and cured on said product as a topcoat for an indoor application.

11. The natural fabric product of claim 8, wherein said adhesive has a minimum Fruehauf wet shear strength of 325 psi when applied and cured on said product as a topcoat for a semi-outdoor or outdoor application.

12. The natural fabric product of claim 8, wherein the cured crosslinking polyvinyl acetate primer on said product is further coated with a regular paint or coating selected from the group of consisting of acrylic, alkyd, asphalt, emulsion polymer isocyanate, epoxy, lacquer, latex, polyurethane, urethane, and vinyl ester as a second coating layer or a topcoat of said product.

13. The natural fabric product of claim 8, wherein said adhesive is applied onto said product by roller coating, spray coating, impregnation soaking, dipping, brush coating, curtain coating, extrusion coating, or manually coated with a brush or a roller.

14. The natural fabric product of claim 8, wherein the coating layer of said adhesive after applied on said product is heated at the surface temperature of about 80°

F. to about 250°

F. until said adhesive is cured.

15. The natural fabric product of claim 14, wherein the heating sources include electricity, microwave, steam, hot water, solar heating, oil heating, and ceramic heating.

16. The natural fabric product of claim 8, wherein said adhesive provides stiffness to said product by filling the gaps and voids of said product and bonding adjacent weave fibers or yarns on the exterior surfaces or at the surface layers of said product when applied and cured.

17. The natural fabric product of claim 8, wherein said adhesive substantially improves the water resistance and dimensional stability of said product when applied and cured on said product.

18. The natural fabric product of claim 8 being pretreated with a chemical preservative or biocide selected from the group of consisting of a copper-, chromium-, arsenic-, zinc-, tin-, or titanium-based compound or complex, a boron-, nitrogen-, sulfur-, chloride-, phosphate-, or silicate-based compound or complex, or the combination thereof to improve the biodegradation resistance to fungi, molds or mildews, termites, and ants during service.

19. The natural fabric product of claim 18, wherein the crosslinking polyvinyl acetate adhesive when applied and cured on the treated fabric product seals and fixes the preservative or biocide in said product by bonding and chelating with the preservative or its active ingredients on the exterior surfaces or at the surface layers of said product.

20. A natural fabric or textile product comprising:

a crosslinking polyvinyl acetate adhesive applied and cured on the exterior surfaces of said product as a first coating layer or a primer and a coating layer selected from the group of acrylic, alkyd, asphalt, emulsion polymer isocyanate, epoxy, lacquer, latex, polyurethane, urethane, and vinyl ester applied over the cured crosslinking polyvinyl acetate adhesive as a second coating layer or a topcoat, wherein said product is woven, knitted, or fabricated from natural fibers, yarns, or threads;

said yarns or threads being twisted or spun from said fibers;

wherein said product comprises warps and wefts in weave structure or pattern;

wherein said composition forms into a coating film on at least a part of the exterior surfaces of said product as a protective coating to provide durable protection to said product;

wherein said adhesive includes a polyvinyl acetate-based adhesive polymer, a copolymer, a crosslinking agent, and a catalyst and is a Type I or Type II adhesive;

wherein said adhesive provides stiffness or rigidity to said product by filling the gaps or voids of said product and bonding the fibers, threads or yarns at the exterior surfaces or the surface layers of said product when applied and cured; and

wherein said adhesive substantially improves the water resistance and dimensional stability of said product when applied and cured on said product.