Foam coated fabrics

Claim 2

A flame retardant, drapable and substantially light impermeable fabric suitable for use as a curtain, window shade or the like comprising a tightly woven fiberglass fabric substrate which is coated on at least one surface thereof with one or more layers of a flame retardant foam coating composition, wherein at least one of the foam coating layers is opaque and is comprised of a cured layer of flame retardant polymeric latex foam; wherein the foam coating renders the fabric substantially impermeable to light and is applied to the surface of the fiberglass substrate in an amount sufficient to make the fabric non-abrasive, abrasion resistant, and the coated fabric sewable and drapable.

Claim 3

The fabric according to claim 1 wherein the foam coating composition is comprised on a dry-weight basis and based on about 100 parts of a foamable polymer latex, of about 2 to about 10 parts plasticizer, about 1 to about 10 parts of a flame retardant, about 10 to about 50 parts pigment, filler, and dispersant for the pigment and filler.

Claim 4

The fabric according to claim 1 wherein the coating is comprised of at least three coating layers, wherein the innermost coating layer is white in color, the intermediate coating layer is grey or black in color and the outermost coating layer is white; wherein in each of the coating layers the pigment is dispersed in a coating composition comprised on a dry-weight basis of about 100 parts of a foamable polymer latex, and based on the weight of the polymer latex, about 2 to about 10 parts plasticizer, about 1 to about 10 parts flame retardant, about 10 to about 50 parts pigment, surfactant, about 25 to about 75 parts filler, and dispersant for the pigment.

Claim 5

The fabric according to claim 3 wherein the fiberglass substrate is comprised of C, D, E or D/E glass fibers.

Claim 6

The fabric according to claim 3 wherein the polymer latex is an acrylic polymer latex.

Claim 7

The fabric according to claim 3 wherein the foam coating comprises up to about 3 ounces per square yard of the fiberglass fabric base.

Claim 8

The fabric according to claim 3 wherein the surface of the fabric opposite to the foam coated surface is coated with a face coat of a flame retardant and plasticized polymeric coating composition which is present in an amount sufficient to render the surface of said fiberglass fabric nonabrasive and abrasion resistant.

Claim 9

The fabric according to claim 8 wherein the face coat is comprised on a dry-weight basis and based on 100 parts of a foamable acrylic polymer, of about 25 to 75 parts filler, about 5 to about 25 parts plasticizer, and about 3 to about 10 parts antimony trioxide or antimony pentaoxide.

Claim 10

A curtain comprised of the fabric of claim 3.

Claim 11

A window shade comprised of the fabric of claim 3.

Claim 12

The fabric according to claim 1 wherein the surface of the fiberglass fabric opposite to the foam coated surface is coated with a face coat of a flame retardant and plasticized polymeric coating composition which is present in an amount sufficient to render the surface of said fiberglass fabric nonabrasive and abrasion resistant.

Claim 13

A curtain comprised of the fabric of claim 1.

Claim 14

A window shade comprised of the fabric of claim 1.

Claim 15

A flame retardant, drapable and substantially light impermeable fabric suitable for use as a curtain, window shade or the like comprising a tightly woven fiberglass fabric substrate which is coated on at least one surface thereof with one or more layers of a flame retardant foam coating composition, wherein at least one of the foam coating layers is opaque and is comprised of a cured layer of flame retardant polymeric latex foam; wherein the foam coating renders the fabric substantially impermeable to light and is applied to the surface of the fiberglass substrate in an amount sufficient to make the fabric non-abrasive, abrasion resistant, and the coated fabric sewable and drapable; and wherein the coating is comprised of at least three coating layers, wherein the innermost coating layer is white in color, the intermediate coating layer is grey or black in color and the outermost coating layer is white; wherein in each of the coating layers the pigment is dispersed in a coating composition comprised on a dry-weight basis of about 100 parts of a foamable polymer latex, and based on the weight of the polymer latex, about 2 to about 10 parts plasticizer, about 1 to about 10 parts flame retardant, about 10 to about 50 parts pigment, surfactant, about 25 to about 75 parts filler, and dispersant for the pigment.

Claim 16

A flame retardant, drapable and substantially light impermeable fabric suitable for use as a curtain, window shade or the like comprising a tightly woven fiberglass fabric substrate which is coated on at least one surface thereof with one or more layers of a flame retardant foam coating composition, wherein at least one of the foam coating layers is opaque and is comprised of a cured layer of flame retardant polymeric latex foam; wherein the foam coating renders the fabric substantially impermeable to light and is applied to the surface of the fiberglass substrate in an amount sufficient to make the fabric non-abrasive, abrasion resistant, and the coated fabric sewable and drapable; and wherein the coating is comprised of at least three coating layers, wherein the innermost coating layer is white in color, the intermediate coating layer is grey or black in color and the outermost coating layer is white; wherein in each of the coating layers the pigment is dispersed in a coating composition comprised on a dry-weight basis of about 100 parts of a foamable polymer latex, and based on the weight of the polymer latex, about 2 to about 10 parts plasticizer, about 1 to about 10 parts flame retardant, about 10 to about 50 parts pigment, surfactant, about 25 to about 75 parts filler, and dispersant for the pigment.

Claim 19

The method according to claim 15 wherein said foam coating is comprised of at least three layers, wherein the pigment in the innermost coating layer renders said coating white and said innermost coating layer is cured prior to the application of the intermediate coating layer; the pigment in the intermediate coating layer renders said coating opaque and is cured prior to the application of the outermost coating layer; and the pigment in the outermost coating layer renders the coating white; and wherein the thickness of each foam layer prior to curing is about 15 to about 40 mils.

Claim 20

The method according to claim 16 wherein the volume of the composition which comprises the innermost foam coating is about three times the volume of said composition prior to being foamed; the volume of the composition comprising the intermediate coating layer is about four times the volume of said composition prior to being foamed; and the volume of the outermost coating layer is about five times the volume of the composition prior to being foamed.