Permaback, Long Life, Bleach Proof Latex Coated Rugs

Abstract

The present invention discloses a novel process and composition for latex-coated rugs. The novel latex composition coating contains a mixture of natural latex, synthetic latex, accelerator, gel and filler having anti-oxidant property.

1 . A tufted rug having a latex composition coating on one side of the tufted rug, the latex composition coating comprising:
 a. natural latex in a range of about 55% to about 75%;   b. synthetic latex in a range of about 45% to about 25%;   c. a filler in an amount ranging from about 110 kg per 391 kg of latex to about 145 kg per 391 kg of latex;   d. a thickener; and   e. an anti-oxidant.   
     
     
         2 . The tufted rug of  claim 1 , wherein the natural latex is polyisoprene-ammonia centrifuged natural rubber. 
     
     
         3 . The tufted rug of  claim 1 , wherein the synthetic latex is an aqueous dispersion of styrene and 1,3-butadiene. 
     
     
         4 . The tufted rug of  claim 1 , wherein the filler is a mixture of calcium carbonate and magnesium carbonate. 
     
     
         5 . The tufted rug of  claim 1 , wherein the thickener is a mixture of potassium acrylate and sodium polyacrylate. 
     
     
         6 . The tufted rug of  claim 1 , wherein the anti-oxidant is phenolic acid. 
     
     
         7 . The tufted rug of  claim 1 , further comprising potassium oleate soap and water. 
     
     
         8 . The tufted rug of  claim 1 , further comprising at least one industry-acceptable ingredient. 
     
     
         9 . The tufted rug of  claim 8 , wherein the at least one industry-acceptable ingredient comprises an activator/accelerator and a homogenizer. 
     
     
         10 . The tufted rug of  claim 9 , wherein the homogenizer is ammonium acetate. 
     
     
         11 . The tufted rug of  claim 9 , wherein the activator/accelerator is a mixture of sulfur oxide and zinc oxide. 
     
     
         12 . The tufted rug of  claim 1 , further comprising a plurality of tufts made of material selected from the group consisting of a natural fiber yarn, a regenerated cellulose fiber, and a synthetic fiber yarn. 
     
     
         13 . The tufted rug of  claim 11 , wherein the natural fiber yarn is selected from the group consisting of cotton, linen, hemp, sisal, wool, silk, ramie, and banana fiber. 
     
     
         14 . The tufted rug of  claim 11 , wherein the synthetic fiber yarn is selected from the group consisting of viscose, bamboo, modal, rose or such as, nylon, polyester, a polyester filament yarn, and polypropylene. 
     
     
         15 . A latex coating composition comprising:
 a. natural latex in a range of about 55% to about 75%;   b. synthetic latex in a range of about 45% to about 25%;   c. a filler in an amount ranging from about 110 kg per 391 kg of latex to about 145 kg per 391 kg of latex;   d. a thickener; and   e. an anti-oxidant.   
     
     
         16 . The latex composition coating of  claim 15 , wherein the natural latex is polyisoprene-ammonia centrifuged natural rubber. 
     
     
         17 . The latex composition coating of  claim 15 , wherein the synthetic latex is an aqueous dispersion of styrene and 1,3-butadiene. 
     
     
         18 . The latex composition coating of  claim 15 , wherein the filler is a mixture of calcium carbonate and magnesium carbonate. 
     
     
         19 . The latex composition coating of  claim 15 , wherein the thickener is a mixture of potassium acrylate and sodium polyacrylate. 
     
     
         20 . The latex composition coating of  claim 15 , wherein the anti-oxidant is phenolic acid. 
     
     
         21 . The latex composition coating of  claim 15 , further comprising potassium oleate soap and water. 
     
     
         22 . The latex composition coating of  claim 15 , further comprising at least one industry-acceptable ingredient. 
     
     
         23 . The latex composition coating of  claim 22 , wherein the at least one industry-acceptable ingredient comprises an activator/accelerator and a homogenizer. 
     
     
         24 . The latex composition coating of  claim 23 , wherein the homogenizer is ammonium acetate. 
     
     
         25 . The latex composition coating of  claim 23 , wherein the activator/accelerator is a mixture of sulfur oxide and zinc oxide. 
     
     
         26 . A process of preparing a latex composition coating comprising the steps of:
 a. mixing a composition of natural latex and synthetic latex to form a latex mixture, wherein the latex mixture is made of about 55% to about 75% natural latex, and about 45% to about 25% synthetic latex;   b. adding a filler in an amount ranging from about 110 kg per 391 kg latex to about 145 kg per 391 kg latex; and   c. incorporating a thickener and an anti-oxidant into the latex mixture.   
     
     
         27 . The process of  claim 26 , further comprising the step of adding at least one industry-acceptable ingredient. 
     
     
         28 . A process of preparing a tufted rug having a latex coating comprising the steps of:
 a. mixing a composition of natural latex and synthetic latex to form a latex mixture, wherein the latex mixture is made of about 55% to about 75% natural latex, and about 45% to about 25% synthetic latex;   b. adding a filler in an amount ranging from about 110 kg per 391 kg latex to about 145 kg per 391 kg latex;   c. incorporating a thickener and an anti-oxidant into the latex mixture; and   d. applying the latex composition coating to a back of the tufted rug.   
     
     
         29 . The process of  claim 26 , further comprising the steps of
 e. curing the latex composition coating on the back of the tufted rug;   f. cutting the tufted rug to a desired size; and   g. stitching the sides of the tufted rug to form a finished tufted rug having a latex composition coating.   
     
     
         30 . The process of  claim 26 , wherein the latex composition coating is applied in a continuous process. 
     
     
         31 . The process of  claim 26 , further comprising adding at least one industrially-acceptable ingredient to the latex composition coating before application to the back of the tufted rug.