Process of transferring a latex film onto a substrate

Claim 1

A continuous process for producing a film having a thickness from 0,001 to 0.05 inches from an aqueous compound comprising per 100 parts by dry weight of a latex containing from 50 to 75 weight % of a rubbery polymer comprising: (i) a homopolymer of C 4-6 aliphatic diolefins which may be unsubstituted or substituted by a chlorine atom; (ii) copolymers comprising (a) 20 to 80 weight percent of a C 8-12 vinyl aromatic monomer which may be unsubstituted or substituted by a C 1-4 alkyl radical or a chlorine or bromine atoms; (b) 80 to 20 weight percent of a C 4-6 aliphatic diolefin; and (c) 0 to 10 weight percent of one or more monomers selected from the group consisting of: C 3-6 ethylenically unsaturated carboxylic acids amides of C 3-6 ethylenically unsaturated carboxylic acids which amides may be unsubstituted or substituted at the nitrogen atom by up to two radicals selected from the group consisting of C 1-4 alkyl radicals and C 1-4 hydroxy alkyl radicals; C 1-6 alkyl and hydroxy alkyl esters of C 3-6 ethylenically unsaturated carboxylic acids; and C 3-6 ethylenically unsaturated aldehydes; and (iii) copolymers comprising (a) 60-99.5 weight percent of a C 1-4 alkyl or hydroxy alkyl ester of acrylic or methacrylic acid, (b) up to 40 weight percent of one or more monomers selected from the group consisting of C 8-12 vinyl aromatic monomers which may be unsubstituted or substituted by a C 1-4 alkyl radical or a chlorine or bromine atom; C 3-6 alkenyl nitriles, vinyl chloride, and vinylidene chloride; and (c) 0 to 10 weight percent of one or more monomers selected from the group consisting of: C 3-6 ethylenically unsaturated carboxylic acids amides of C 3-6 ethylenically unsaturated carboxylic acids which amides may be unsubstituted or substituted at the nitrogen atom by up to two radicals selected from the group consisting of C 1-4 alkyl radicals and C 1-4 hydroxy alkyl radicals; C 1-6 alkyl and hydroxy alkyl esters of C 3-6 ethylenically unsaturated carboxylic acids; and C 3-6 ethylenically unsaturated aldehydes; up to 80 parts by weight of a filler; on a surface of a flexible web substrate selected from the group consisting of webs of nonwoven natural or synthetic organic fibers having a weight of from 5 to 130 g/yd 2 ; batts of glass fibers having a density of from 5 to 12 lb/ft 3 ; and foamed backed carpet; which comprises: (a) applying a thin film of said aqueous compound to an endless carrier belt made of a material selected from the group consisting of C 2-3 polyolefins, C 2-3 polyolefin terephthalate resin, polyvinyl chloride and polyvinylidene chloride; (b) contacting said web and said coated carrier belt without drying said compound to bring said wet compound into direct contact with said web and maintaining them in relative position while passing them around at least a portion of the surface of a hot drum laminator at a temperature from 100° to 150° C. to dry said compound and transfer it to said substrate to produce a flexible web having a smooth-surfaced film strongly bonded thereto; and (c) delaminating said web from said carrier belt.