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Title:
POLYMERIC-COATED FABRIC LAYER, PRODUCT UTILIZING THE LAYER, AND METHOD OF MAKING THE SAME
Document Type and Number:
WIPO Patent Application WO/1984/003918
Kind Code:
A1
Abstract:
A polymeric-coated fabric layer, product utilizing the layer, and a method of making such layer. The layer (10) is adapted to be secured to a surface of a polymeric product, and comprises a fabric layer (11) having opposed sides (12, 13), and a layer of polymeric material (14) secured to one of the sides of the fabric layer (11) and having an outer surface (15) facing away from the fabric layer (11) for being secured to the surface of the product. The polymeric layer (14) comprises a foamed polymeric layer, whereby the outer surface (15) thereof is adapted to readily conform to the surface of the product when the surfaces are brought into contact with each other for securement therebetween.

Inventors:
ANDERSON JOHN F JR (US)
LONG DELMAR D (US)
Application Number:
PCT/US1984/000517
Publication Date:
October 11, 1984
Filing Date:
April 03, 1984
Export Citation:
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Assignee:
DAYCO CORP (US)
International Classes:
B29D29/10; F16G5/08; B32B5/00; B32B43/00; D06N7/00; F16G5/12; B29K105/08; (IPC1-7): F16G5/16; B32B5/18
Foreign References:
US3527654A1970-09-08
US3862291A1975-01-21
US4265962A1981-05-05
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Claims:
CLAIMS:
1. A polymericcoated fabric layer means which can be secured to a surface of a polymeric product, said fabric layer means comprising a fabric layer having oppose sides, and a layer of polymeric material secured to one of said sides of said fabric layer and having an outer surface facing away from said fabric layer for being secured to said surface of said product; the improvement characterized in that said polymeric layer (14) comprises a foamed polymeric layer, whereby said outer surface (15) thereof is adapted to readily conform to said surface of said product when said surfaces are brought into contact with each other for securement therebetween.
2. A iayer_jneans as set forth in claim 1, characterized in that said foamed polymeric layer (14) comprises a foamed latex layer.
3. A layer means as set forth in claim 1, characterized in that said foamed layer (14) has a plurality of openings (16) in said outer surface (15) thereof.
4. A layer means as set forth in claim 3, characterised by an overcoating (19) of polymeric material on said outer surface (15) that fills said openings (lδ) thereof.
5. A layer means as set forth in claim 1, characterized by another layer of polymeric material (17) secured to the other (13) of said sides of said fabric layer (11).
6. A layer means as set forth in claim 1, *gJ £ OMPI characterized in that said fabric layer (11) comprises a bias fabric layer.
7. A layer means as set forth in claim 1, characterized in that. said foamed layer (14) has a substantially impervious outer surface thereof.
8. A layer means as set forth in claim 7, characterized by an overcoating (19) of polymeric material on said outer surface (15) of saidfoamed layer (14).
9. A method of making a polymericcoated fabric layer means which can be secured to a surface of a polymeric product, said method comprising the steps of forming said fabric layer means to comprise a fabric layer having opposed sides, securing a layer of polymeric material to one of said sides of said fabric layer, and forming said layer of polymeric material to have an outer surface facing away from said fabric layer for being secured to said surface of said product; the improvement characterized by the step of forming said polymeric layer to comprise a foamed polymeric layer, whereby said outer surface thereof is adapted to readily conform to said surface of said product when said surfaces are brought into contact with each other for securement therebetween.
10. A method of making a layer means as set forth in claim 9, characterized by the step of apply¬ ing an overcoating of polymeric material on said outer surface of said foamed polymeric layer.
11. A method of making a layer means as set forth in claim 9, characterized ty the step of securing OMPI another layer of polymeric material to the other of said sides of said fabric layer.
12. A polymeric product having a polymeric coated fabric layer means secured to a surface of said polymeric product, said fabric layer means comprising a fabric layer having opposed sides, and a layer of polymeric material secured to one of said sides of said fabric layer and having an outer surface facing away from said fabric layer and being secured to said' surface of said product; the improvement characterized in that said polymeric layer (14) comprises a foamed polymeric layer, whereby said outer surface (15) thereof readily conforms to said surface of said pro¬ duct.
13. A product as set forth in claim 12, characterized by another layer of polymeric material (17) secured to the other (13) of said sides of said fabric layer (11), said other layer (17) defining an outside surface (18) of said product.
14. A product as set forth in claim 12, characterized in that said product comprises an end¬ less transmission belt construction (20).
15. A product as set forth in claim 14, characterized in that said fabric layer means (10) defines at least part of the outside surface of said belt construction (20).
Description:
POLYMERIC-COATED FABRIC LAYER, PRODUCT UTILIZING THE LAYER, AND METHOD OF MAKING THE SAME

Technical Field This invention relates to an improved poly¬ meric-coated fabric layer means and a polymeric pro¬ duct utilizing such fabric layer mean , as well as to a method for making such a fabric layer means. Background Art It is known in the art to provide a polymer¬ ic-coated fabric layer means for being secured to a surface of a polymeric product. The fabric layer means comprises a fabric layer having opposed sides, and a layer of polymeric material which is secured to one of the sides of the fabric layer and has an outer surface facing away from the fabric layer for being secured to the surface of the product. For example, SG--- the U.S. Patent to Long, No. 4,062,989, and the U.^ Patent to Long et al, No. 4,205,559, Disclosure of the Invention

It is one feature of this invention to pro¬ vide an improved polymeric-coated fabric layer means which can be secured to a surface of a polymeric pro¬ duct, such as an endless transmission belt construction and the like.

In particular, one of the major problems in the making of a polymeric-coated fabric layer means for use in V-belt constructions has been to provide suffi¬ cient building tack; currently, such systems employ various resins, rosins, or oils to impart the

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necessary tack.

However, it is believed according to the teachings of this invention that the tack of a poly¬ meric-coated fabric layer means may be greatly i - proved, without the use of tackifying additives, by placing the polymeric material on the fabric layer for better conformability of the surface of the resulting fabric layer means to the surface of the polymeric product when the two surfaces are brought into contact with each other for securement therebetween.

It is believed that such positioning of the polymeric material on the surface of the fabric layer can be accomplished by applying a foamed polymeric layer on the surface of the fabric layer; this foamed layer, due to its cellular structure, allows for ex¬ cellent surface conformability of its surface with a surface of the polymeric product. The foamed polymeric layer is utilized by itself, or is filled with an over¬ coating of polymeric material which provides a uniform surface that tends to smooth out surface irregularities in the fabric layer and thus allows for better polymeric contact when its surface is brought against the surface of the polymeric product.

For example, one embodiment of this invention provides a polymeric-coated fabric layer means which can be secured to a surface of a polymeric product; the fabric layer means comprises a fabric layer having opposed sides, and a layer of polymeric material which is secured to one of the sides of the fabric layer and has an outer surface facing away from the fabric layer

for being secured to the surface of the product; the polymeric layer comprises a foamed polymeric layer, whereby the outer surface thereof is adapted to readily conform to the surface of the product when the surfaces are brought into contact with each other for securement therebetween.

Accordingly, it is an object of this inven¬ tion to provide an improved polymeric-coated fabric layer means having one or more of the novel features of this invention as set forth above or hereinafter shown or described.

Another object of this invention is to provide a method of making such a polymeric-coated fabric layer means, the method of this invention having one or more of the novel features of this invention as set forth above or hereinafter shown or described.

Another object of this invention is to pro¬ vide an improved product utilizing such a polymeric- coated fabric layer means, the product of this inven- tion having one or more of the novel features of this invention as set forth above or hereinafter shown or described. Brief Description of the Drawings

The eatures of the invention, and its tech- nical advantages, can be seen from the following descrip¬ tion of preferred embodiments, together with the claims and the accompanying drawings, in which:

FIGo 1 is a broken away cross-sectional per¬ spective view of the polymeric-coated fabric layer means of this invention;

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FIG. 2 is a cross-sectional view of an end¬ less power transmission belt construction or the like utilizing the layer means of this invention that is illustrated in FIG. 1; FIG. 3 is a schematic view illustrating the method and apparatus of this invention for making the polymeric-coated fabric layer means for FIG, 1; and

FIGo 4 is a schematic, fragmentary, reduced top view of the apparatus of FIG. 3. Best Mode for Carrying Out the Invention

While the various features of this invention are hereinafter illustrated and described as being particularly adapted to provide a polymeric-coated fabric layer means for making particular products, it is to be understood that the various features of this invention can be utilized singly or in various combinations thereof to provide a polymeric-coated fabric layer means for other uses and/or for other products as desired. Therefore, this invention is not to be limited to only the embodiment illustrated in the drawings, because the drawings are merely utilized to illustrate one of the wide variety of uses of this invention. Referring now to FIG. 1, the improved poly¬ meric-coated fabric layer means of this invention is generally indicated by the reference numeral 10, and comprises a suitable fabric layer 11 of a type well known in the art, such as a bias fabric layer, having opposed sides12 and 13, and a layer 14 of polymeric

material. The layer 14 is secured to the side 12 of the fabric layer 11 in a manner hereinafter set forth to define an outer, substantially flat surface 15 which can be secured to a surface of a polymeric pro- duct, as will be hereinafter described. The polymeric layer 14 of this invention comprises a foamed polymeric layer, such as a foamed latex layer, which has an open cellular structure throughout the same, as represented generally by the reference numeral 16 in FIG. 1. It is believed that such cellular structure 16 of the foamed polymeric layer 14 permits the surface 15 there¬ of to readily conform to the surface of the polymeric product to which the layer means 10 is to be secured when the surface 15 thereof is brought into contact with the surface of the polymeric product for secure¬ ment therebetween; it is believed that the layer 14 need not have a tackifying additive provided therein for this securement purpose, as is the case in some prior known polymeric-coated fabric layer means. For example, see the copending U.S. Patent application of Delmar D. Long, one of the co-inventors of this invention, Serial No. 350,969, filed February 22, 1982, wherein a tacky layer is provided for such securement purposes. Since this copending patent application describes the various uses of polymeric- coated fabric layer means, and a method and apparatus for making the same which is similar to this invention, as will be apparent hereinafter, this copending patent application is being incorporated into this disclosure by this reference thereto.

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In addition, the aforementioned U.S. Patents, No. 4,062,989 to Long and No. 4,205,559 to Long et al, are also being incorporated into this disclosure by this reference thereto, as such U.S. Patents disclose other types of polymeric-coated fabric layer means for uses similar to the uses of the polymeric-coated fabric layer means 10 of this invention.

If desired, another layer 17 of polymeric material, such as a latex, can be secured to the other side 13 of the fabric layer 11 so as to define an out¬ side surface 18 thereof, which will subsequently pro¬ vide an outside surface of the product utilizing such layer means 10.

Also, it is believed according to the teachings of this invention that the foamed layer 14 can have its outside surface 15 overcoated with poly¬ meric material 19, such as a suitable latex, that substantially fills the open cells or openings 16 in the surface 15 as illustrated in FIG. 1. Such over- coating 19 can even extend outwardly beyond the sur¬ face 15 to completely coat the same in addition to filling the openings 16 thereof, if desired, with such overcoating 19 defining the outer surface 19* as illu¬ strated in FIG. 1. However, it is to be understood that the overcoating 19 need not be applied to the surface 15 of the layer means 14, as it is believed that the sur¬ face 15 of the layer 14, with or without the overcoat¬ ing 19, allows for better conformability of the con- tacting surface of the fabric layer means 10 to a

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surface of a polymeric product utilizing such layer means 10 without the use of a tactifying additive in the fabric layer means 10 of this invention.

For example, reference is now made to FIG. 2, wherein a product of this invention is generally indicated by the reference numeral 20, and comprises an endless power transmission belt of a typical "V" type. The polymeric body 21 of the belt has a sub¬ stantially trapezoidal cross-sectional configuration which is defined by a pair of opposed flat parallel top and bottom surfaces 22 and 23, with a pair of angled side surfaces 24 and 25 disposed therebetween.. The belt construction 20 has the conventional tension section 26, compression section 27, and load-carrying section 28 disposed intermediate the tension section 26 and compression section 27 in a manner well known in the art.

As is conventional in the art, the opposed angular surfaces24 and 25 of the belt construction 20 are each adapted to have a friction layer, which con- prises a fabric that is impregnated with a polymeric composition, and which is secured thereon by such friction layer either being disposed only on the sur¬ faces 24 and 25 thereof, or by having the entire outside surface of the belt body 21 wrapped with the friction layer.

In any event, it can be seen that the belt construction 20 illustrated in FIG. 2 is completely wrapped by a strip of the polymeric-coated fabric layer means 10 of this invention in such a way that

the opposed ends 29 and 30 of the layer means 10 are disposed and secured in overlapping relation, such as on the top surface 22 of the belt construction 20 as illustrated in FIG. 2; this is conventional in the belt making art.

When utilizing the layer means 10 of this invention for forming the belt construction 20 of FIG. 2, it can be seen that the side or surface 15 or 19' of the layer means 10 is disposed in contact with the outer surfaces 22, 23, 24, and 25 of the polymeric body 21 of the belt construction 20 so as to readily conform to such surfaces 22, 23, 24, and 25 during a subsequent heat curing or vulcanizing of the belt construction 20 after the layer means 10 has been wrapped on the belt body 21 in a manner well known in the art of making belt constructions.

It is believed that by utilizing the foamed layer 14 of this invention, whether the same has the overcoating 19 or not, excellent adhesion will be pro- vided between the layer 14 and the belt body 21 during the subsequent vulcanizing or curing operation of the belt construction 20, since the cellular construction 16 of the foamed layer 14 readily permits the layer 14 to conform to the surfaces 22, 23, 24, and 25 of the belt body 21 not only during the wrapping of the layer means 10 against the belt body 21, but also during the subsequent heat curing and vulcanizing operation.

As illustrated in FIG. 2, the outer surface 18 of the layer 17 provides the contact facing of the belt construction 20 at the driving or driven sides 24

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and 25 thereof, as is conventional in the art.

While the layer means 10 of this invention has been previously described as forming an outside surface of a belt product, it is to be understood that the layer cόieans 10 of this invention can provide not only an outside surface thereof, but also in addition thereto, or in lieu thereof, could form part of an inner layer of the belt product if desired. In fact, the layer 17 could also be a foamed polymeric layer in a manner similar to the layer 14 so as to provide good conformability on both sides of the fabric layer 11 of the layer means 10 if desired.

Also, while the layer means 10 of this in¬ vention has been previously described as forming a part or parts of a belt construction or the like, it is to be understood that there are other products that can utilize the layer means 10 of this invention. For example, the layer means 10 can provide part of a printing blanket, part.of a hose construction, as well as be utilized for making tine entire hose construc¬ tion, gasket means, etc., whereby it can be seen that the layer means 10 of this invention can be utilized as a product itself, or with other products not dis¬ closed in this application, because it is believed that the sane is readily adapted to be utilized where any such polymeric-coated fabric layer means is presently being used, or where such polymeric-coated fabric layer means could possibly be used. hile the layer means 10 of this invention is hereinafter illustrated and described as being formed

by a particular method and apparatus as illustrated in FIGS. 3 and 4, it is to be understood that this invention is not to be limited to the specific method and apparatus illustrated in FIGS. 3 and 4, as the same is merely being disclosed as a believed-to-be possible method and apparatus for making the layer means 10 of this invention.

Therefore, reference is now made to FIGS. 3 and 4, wherein a method and apparatus of this in- vention for forming the layer means 10 of FIG. 1 is generally indicated by the reference numeral 31, and will now be described.

As illustrated in FIG. 3, the fabric layer 11 is fed from a supply roll 32 thereof through a liquid 33 that impregnates and lubricates the threads thereof so that the same can be readily stretched on a tenter frame 34 in a direction transverse to the longitudinal direction of the fabric sheet 11. There¬ after, the foamed polymeric material 14, in liquid form, is applied to the top surface 12 of the fabric sheet, while simultaneously the polymeric material 17, in liquid form, is applied to the bottom surface 13 of the fabric sheet 11. Respective coating means, gen¬ erally indicated by the reference numerals 35 and 36 in FIG. 3, are used. The liquid materials 14 and 17 are respectively doctored by suitable doctor means 37 and 38 disposed on opposite sides of the now coat¬ ed fabric sheet 11 to produce the coated fabric layer means of this invention, which is generally indicated by the reference numeral 10 in FIG. 3. The coatings

14 and 17 are sufficiently liquid to impregnate the fiber bundles of the fabric layer 11 so as to provide good adhesion of the layers 14 and 17 to the fabric layer 11. The coated sheet 11 is now passed through a heating means , generally indicated by the reference numeral 39 , for substantially drying the coatings 14 and 17, without curing the same, so that the polymeric- coated fabric layer means 10 can be wound into a supply roll 40 thereof , with a sheet 41 wound therewith to prevent the wound polymeric-coated fabric layer means 10 of this invention from securing to itself in the roll 40, as is well known in the art.

The method and apparatus 31 of this invention is also adapted to provide the overcoat 19 on the layer means 14 of the polymeric-coated fabric layer means 10 if desired. For example, such overcoating 19 can be applied in liquid form by a suitable applicator means (generally indicated by the reference numeral 42 in FIG. 3) , and can be doctored by suitable doctor means 43 which either provides a thickness to the overcoating 19 above the entire surface 15 of the foamed layer, or merely causes the coating 19 to just fill the openings 16 in the side 15 of the foamed layer 14, as desired. In any event, after the overcoating 19 is applied to the side 15 of the foamed layer 14, the polymeric-coated fabric layer means 10 is passed through a heating means 44 which -substantially dries the over¬ coating 19 , without curing the coatings 14, 17, and 19 , before the polymeric-coated fabric layer means 10 of

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this invention is wound into the supply roll 40 thereof.

Therefore, it can be seen that when it is desired to utilize the layer means 10 of this invention, a sufficient quantity thereof can be dispensed from the supply roll 40 thereof to be utilized either ty itself, after subsequent curing thereof, or remaining uncured or in combination with a polymeric product, such as by forming the belt construction 20 in the manner pre¬ viously described, whereby it can be seen that this invention provides an improved polymeric-coated fabric layer means 10 for being secured to a surface of a polymeric product, the fabric layer means 10 compris¬ ing a fabric layer 11 having opposed sides 12 and 13, and a layer of polymeric material 14 secured to the side 12 of fabric layer 11 and having an outer surface 15 facing away from the fabric layer 11 for being secured to the surface of the product, the polymeric layer 14 comprising a foamed polymeric layer, whereby the outer surface 15 thereof is adapted to readily con- form to the surface of the product when the surfaces are brought into contact with each other for secure¬ ment; therebetween.

While the layer means 10 of this invention has been previously described as having open cells or openings 16 in the surface 15 of the foamed layer 14, it is to be understood that other ty es of suitable , foamed polymeric materials can be utilized for making the layer means 10 of this invention. For exanple, a foamed polymeric material, such as a foamed latex, can be provided for the layer 14, wherein the outer

surface 15 thereof is substantially free of openings 16 so as to be substantially impervious, as is illu¬ strated in FIG. 1 between the areas of the openings 16. Such layer means 10 can have the substantially imper- vious outer surface 15 of the foamed layer 14 disposed in contact with the desired surface of a polymeric product, or such impervious surface 15 can be first overcoated with the polymeric layer 19 as previously described. In any event, it is believed that such layer means 10, with the substantially impervious outer surface 15 of the foamed layer 14, will be adapt¬ ed to readily conform to the surface of a polymeric product, when the surface 15 or 19' of the layer means 10 is brought into contact therewith, because of the cellular structure, whether open, closed, or in vari¬ ous combinations thereof, of the foamed layer 14 as previously described, and for the same purposes.

Accordingly, it can be seen that this inven¬ tion not only provides an improved polymeric-coated fabric layer means, and method of making the same, but also this invention provides an improved product utilizing such a layer means.

While the forms and methods of this invention now preferred have been illustrated and described as required, it is to be understood that other forms and method steps can be utilized and still fall within the scope of the appended claims.