Technical Field This invention relates to an improved poly¬ meric-coated fabric layer means and a polymeric product utilizing such fabric layer means, as well as to a method and apparatus for making such a fabric layer meanSo Background Art

It is known in the art to provide a polymer¬ ic-coated fabric layer means which 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 example, see the U.S. Patent to Long, No. 4,062,989, and the U.S. 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, such as for being secured to a surface of an endless transmission belt construction and the like.

In particular, it is well known that the addition of polymeric material, such as rubber, to a given surface, such as a fabric layer, to build gauge is readily accomplished by the calendering process using dry rubber compounds. Producing a comparable structure by applying liquid polymeric coatings can be accomplished, but only in multiple passes due in major

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part to the potential for the development of surface skin, thereby causing one or both of two major problems, namely, blisters or interfacial film failureo

It is also well known that liquid polymeric compounds or solvents that have low viscosities (e.g. - less than 5,000 CPS) can release their serum with¬ out the formation of the surface skin. However, the problem of utilizing such compounds is to provide some means of encapsulating the compounds in an isolated manner in order to allow for such evaporation.

Accordingly, it is believed according to the teachings of this invention that such low viscosity polymeric compounds can be readily utilized for coat¬ ing a fabric layer, with the resulting product having sufficient gauge or thickness, if a gauge-building layer means is first secured to the fabric layer be¬ fore the polymeric layer is secured thereto.

For example, one embodiment of this inven¬ tion provides a polymeric-coated fabric layer means which comprises a fabric layer having opposed sides, a layer of polymeric material secured to one of the sides of the fabric layer and having an outer surface facing away from the one side of the fabric layer, and a gauge-building layer means having been secured to the one side of the fabric layer before the polymeric lay¬ er is secured thereto; the gauge-building layer means has a plurality of voids therein, and the polymeric layer fills the voids of the gauge-building layer means.

Accordingly, it is an object of this invention to provide an improved polymeric-coated fabric layer

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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 pro- vide a method of making such a polymeric-coated fabric layer means, the method of this invention hav¬ ing one or more of the novel features of this inven¬ tion as set forth above or hereinafter shown or de¬ scribed. Another object of this invention is to pro¬ vide an apparatus for making such a polymeric-coated fabric layer means, the apparatus of this invention having one or more of the novel features of this in¬ vention 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 features of the invention, and its tech¬ nical advantages, can be seen from the following de- scription of preferred embodiments, together with the claims and the accompanying drawings, in which:

FIG. 1 is a broken away cross-sectional per¬ spective view of the polymeric-coated fabric layer means of this invention ; FIG. 2 is a cross-sectional view of an endless

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 of FIG. lj

FIG. 4 is a schematic, fragmentary, reduced top view of the apparatus of FIG. 3;

FIG. 5 is a view similar to FIG. 1 and illu- strates another embodiment of the polymeric-coated fabric layer means of this invention;

FIG. 6 is a view similar to FIG. 3 and illustrates another embodiment of the method and apparatus of this invention for forming the polymeric- coated fabric layer means illustrated in FIG. 5; and

FIG. 7 is a reduced, fragmentary, top view of the method and apparatus illustrated in FIG. 6. Best Modes 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 com- binations thereof to provide a polymeric-coated fabric layer means for other uses and/or other products as desired.

Therefore, this invention is not to be limited to only the embodiments illustrated in the

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drawings, because the drawings are merely utilized to illustrate one of the wide variety of uses of this inventio .

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 sides 12 and 13, and a layer 14 of gauge-build- ing 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 15o The gauge-building layer means 14 of this inven¬ tion comprises a foamed polymeric layer, such as a foamed latex layer, which has an open cellular struc¬ ture throughout the same, as represented generally by the reference numeral 16 in FIGo 1. A polymeric layer 19 is subsequently secured to the side 12 of the fabric layer 11 by being overcoated on the gauge-building layer 14, whereby the polymeric material fills the voids or openings 16 of the gauge-building layer 14, such polymeric layer 19 being any suitable, polymeric material, such as a latex or the like. It is believed that such cellular structure 16 of the foamed polymeric layer 14 readily permits the layer 19 to initially have a relatively low viscosity and still be held in position by the gauge-building layer 14 for subsequent drying thereof, as will be apparent hereinafter and for the reasons previously set forth.

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The layer 19 defines an outer surface 19' for the layer means 10, which is adapted to be secured to a surface of a polymeric product in a manner similar to other 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.

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 outside surface 18 thereof, which will subsequently provide an outside surface of the product utilizing such layer m ^β ans 10.

However, it is to be understood that the polymeric layer 17 could have its surface 18 secured

to the polymeric product, while the surface 19' of the polymeric layer 19 defines the outside surface of the product utilizing the layer means 10 of this in¬ vention. Also, the particular surface of the layer means 10 that is to be secured to the polymeric pro¬ duct could be provided with the tacky layer of the aforementioned copending U.S» Patent application, Serial No. 350,969, filed February 22, 1982,to enhance the securement therebetween.

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 thereof has a substantially trapezoidal cross-sectional configuration which is defin¬ ed by a pair of opposed flat parallel top and bottom surfaces 22 and 23, with a pair of angled side sur¬ faces 24 and 25 disposed therebetween. The belt con- struetion 20 has the conventional tension section 26, compression section 27, and load-carrying section 28 disposed intermediate the tension section 26 and com¬ pression section 27 in a manner well known in the art. As is conventional in the art, the opposed angular surfaces 24 and 25 of the belt construction 20 are each adapted to have a friction layer, which com¬ 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 ^'

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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 either the side 18 or the side 19' thereof can be 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.

However, it is believed that by utilizing the foamed layer 14 of this invention with the over- coating 19 for being secured to the surfaces 22, 23, 24, and 25 of the belt body 21, excellent adhesion will be provided between the layer 19 and the belt body 21 during the subsequent vulcanizing or curing operation of the belt construction 20 since the cellu- lar construction 16 of the foamed layer 14 readily

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permits the layer 19 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. This feature is disclosed and claimed in applicants' copending U.S. Patent applica¬ tion, Serial No. 482,363, filed April 5, 1983, whereby such copending patent application is being incorpor¬ ated into this application by this reference thereto. 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 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 means 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 gauge-buil ing means on the side 13 of the fabric layer 11, 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 the entire hose construction, 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 disclosed in this application, because it is believed that the same 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.

While the layer means 10 of this invention is hereinafter illustrated and described as being formed by a particular method and apparatus as illu¬ strated 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 bein 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 inven¬ tion for forming the layer means 10 of FIG. 1 is gen¬ erally 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. Thereafter, the

foamed polymeric material 14, in liquid form, is applied to the top surface 12 of the fabric sheet 11, while simultaneously the polymeric material 17, in liquid form, is applied to the bottom surface 13 of the fabric sheet 11. Respective coating means, generally indicated by the reference numerals 35 and 36 in FIG. 3, are used. The liquid materials 14 and 17 are respectively doctor¬ ed by suitable doctor means 37 and 38 disposed on opposite sides of the now coated fabric sheet 11 to produce the coated fabric layer means of this inven¬ tion, 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. The method and apparatus 31 of this invention is also adapted to provide the overcoat 19 on the gauge-building 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 sur¬ face 15 of the foamed layer 14, or merely causes the " coating 19 to just fill the openings 16 in the side 15

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of the foamed layer 14, as desired.

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 overcoating 19, with¬ out curing the layers 14, 17, and 19, before the polymeric-coated fabric layer means 10 of this inven¬ tion is wound into a supply roll 40 thereof, with a sheet 41 wound therewith to prevent the wound poly- meric-coated fabric layer means 10 of this invention from securing to itself in the roll 40, as is well known in the art.

Therefore, it can be seen that when it is desired to utilize the layer means 10 of this inven- tion, a sufficient quantity thereof can be dispensed from the supply roll 40 thereof to be utilized either by itself, when subsequently heat cured, or remaining uncured or in combination with a polymeric product, such as by forming the belt construction 20 in the manner previously described, whereby it can be seen that this invention provides an improved polymeric- coated fabric layer means 10 that canprises a fabric layer 11 having opposed sides 12 and 13, a layer of polymeric material 19 secured to the side 12 of the fabric layer 11 and having an outer surface 19* facing away from the fabric layer 11, and a gauge-building layer means 14 secured to the one side 12 of the fabric layer 11 before the polymeric layer 19 is se¬ cured thereto, the gauge-building layer means 14 having a plurality of voids 16 therein filled with the polymeric

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layer 19.

Another improved polymeric-coated fabric layer means of this invention is generally indicated by the reference numeral 10A in FIGS. 5-7. Parts thereof similar to the layer means 10 previously de¬ scribed are indicated by like reference numerals, followed by the reference letter "A".

As illustrated in FIG. 5, the layer means 10A comprises the fabric layer 11A having opposed sides 12A and 13A, with the side 12A having a gauge- building layer means (generally indicated by the reference numeral 14A) secured thereto in a manner hereinafter set forth; a polymeric layer 19A fills the voids 16A in the gauge-building layer means 14A in a manner hereinafter set forth to define one of the opposed sides 19'A of the layer means 10A. In addition, the layer means 17A can be secured to the other side 13A of the fabric layer 11A to define the other opposed side 18A of the layer means 10A. The gauge-building layer means 14A of this invention comprises a plurality of elongated fibers 45 that have the long dimensions thereof oriented so as to be disposed substantially transverse to side 12A of the fabric layer 11A in order to provide thickness to the gauge-building layer means 14A and define the voids 16A therebetween which are filled by the poly¬ meric material or layer 19A in a manner hereinafter set forth. The polymeric material 19A is adapted to have a low viscosity, since the gauge-building layer means 14A will hold the polymeric material 19A in place

during a subsequent drying thereof.

While the fibers 45 can comprise any suitable fibers, such as conventional reinforcing fibers for polymeric material, the same can be of a material which readily permits the same to be electrostatically flocked in an oriented manner onto the surface 12A of the fabric layer 11A in order to be secured thereto in an upstanding manner to provide the thickness or gauge for the gauge-building layer 14A. For example, reference is now made to FIGS.

6 and 7, wherein the method and apparatus of this in¬ vention for forming the layer means 10A is generally indicated by the reference numeral 31A. Parts thereof similar to the apparatus 31 of FIGS. 3 and 4 previously described are indicated by like reference numerals, followed by the reference letter "A".

As illustrated in FIG. 6, after the fabric layer 11A has been transversely stretched by the tenter frame 34A, the liquid coating 17A is applied to the side 13A thereof by the applicator means 36A, and is doctored by the doctor means 38A in the manner pre¬ viously described.

It is believed that the side 12A of the fabric layer 11A will now have sufficient liquid polymeric material thereon which is provided by the coating means 17A impregnating and exuding through the fabric layer 11A, as well as provided by the bath 33A, so that the fiber means 45 will adhere thereto when the same engage the side 12A. of the fabric layer 11A. In particular, it is ^' believed that the fibers

45 can be supplied by a unit 46 that blows the fibers 45 between a pair of electrically and oppositely charg¬ ed plates 47 and 48 that are disposed on opposite sides of the fabric layer 11A and that create an electrostatic field therebetween in a manner well known in the art to cause the fibers 45 to align with their long dimensions extending between the plates 47 and 48, so that when the same fall by gravity and contact the surface 12A of the fabric sheet 11A, the fibers 45 are disposed with their long dimensions substantially transverse thereto and will be adapted to be secured thereto in the upstanding oriented manner as illustrat¬ ed in FIG. 6 as long as the same are disposed in the electrostatic field created between the plates 47 and 48. Thus, the fabric layer 11A with the fibers 45A being held in their oriented condition by the electro¬ static field is carried through the heating means 39A to cause the heating means 39A to sufficiently dry the layer 17A, without curing thereof, as well as to set the polymeric material on the side 12A of the fabric layer 11A to cause the fibers 45 to remain secured in the upstanding arrangement when the same pass out from beneath the plates 47 and 48 and thereby are no longer influenced by the electrostatic field thereof. In this manner, the plates 47 and 48 can extend into the heating means 39A a sufficient dis¬ tance to permit the setting up of the polymeric materi¬ al on the side 12A of the fabric layer 11A to sufficient¬ ly hold the fibers 45 in their oriented and upstanding condition.

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Thereafter, the voids 16A between the fibers 45 on the layer 11A are filled by the liquid polymeric material 19A being fed or coated onto the side 12A of the fabric layer HA by the applicator means 42A. The material 19A is subsequently doctored by the doctor means 43A, so that the voids 16A in the gauge-building layer means 14A will have been completely filled by the polymeric material 19A to define the side 19'A of the layer means 10A. As illustrated in FIG. 6, the coating 19A that now fills the voids 16A between the fibers 45 is sufficiently dried, without curing of the layers 17A and 19A, as the layer means 10A passes through the heating means 44A, so that the layer means 10A can be wound into the supply roll 40A thereof, with or with¬ out the interleaving strip 41A, to prevent sticking together of the coils of the layer means 10A in the supply roll 40A.

The completed layer means 10A of this in- vention can be utilized in the same manner, and for the same purpose, as the layer means 10 previously described, and therefore a further description of the use of the layer means 10A is unnecessary.

Accordingly, it can be seen that this in- vention provides a polymeric-coated fabric layer means 10 or 10A which comprises a fabric layer 11 or 11A having opposed sides 12, 13, or 12A, 13A, a layer 19 or 19A of polymeric material secured to one of the sides of the fabric layer and having an outer surface 19* or 19*A facing away from the one side of the

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fabric layer, and a gauge-building layer means 14 or 14A secured to the one side of the fabric layer 11 or 11A before the polymeric layer 19 or 19A is secured thereto; the gauge-building layer means 14 or 14A has a plurality of voids 16 or 16A therein, with the polymeric layer 19 or 19A filling the voids 16 or 16A of the gauge-building layer means 14 or 14A.

While the layer means 10 and 10A has each been illustrated and described as having only one gauge-building layer means 14 or 14A disposed thereon, it is to be understood that one or more layer means 14 or 14A, or combinations thereof, can be provided in stacked relation, with or without the voids 16 or 16A in any particular layer means 14 or 14A being filled with polymeric material. For example, the layers could be stacked to provide a foamed layer 14, and then a flocked layer 14A that is filled with polymeric material 19A; a foamed layer 14, then a flocked layer 14A, and then a foamed layer 14 that is filled with polymeric material 19; a flocked layer 14A and then a* foamed layer 14 that is filled with polymeric material 19; etc., whereby each combination will provide a polymeric-coated fabric layer means that has different characteristics. Accordingly, it. can be seen that this inven¬ tion not only provides an improved polymeric-coated fabric layer means and method and apparatus for 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.

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