Method for preparing a smooth surfaced tough elastomeric coated fibrous batt

A method for developing a generally smooth, tough elastomeric surface coating over one surface of a batt of fibrous insulation, comprising:

• a. applying a foamed or frothed cross-linkable elastomeric aqueous emulsion coating composition to said one surface of said pad;
• using a doctor blade to develop uniform concentration of said cross-linkable elastomeric aqueous emulsion coating;
• b. engaging a heated ironing surface at a temperature above the curing temperature of said composition with the exposed surface of said coating to dry and compress the exposed surface and to heat cure the exposed surface of said coating to achieve surface curing of said coating;
• c. separating said ironing surface from engagement with said coating and thereafter passing said batt and coating through a heated chamber maintained at a sufficient temperature to cause substantially complete drying and curing of said coating composition;
• d. recovering from said heating chamber said fibrous batt with a generally smooth, tough elastomeric coating over said one surface.

A continuous process for developing a generally smooth, tough elastomeric surface coating over one surface of a batt of fibrous insulation, comprising:

• a. advancing a continuous batt of fibrous insulation at a uniform velocity sequentially through (i) a coating applicator;
• (ii) a thermal ironing zone;
• and (iii) a heat chamber;
• b. applying a frothed or foamed cross-linkable elastomeric aqueous emulsion composition uniformly across said one surface of said moving batt;
• c. engaging a continuously moving, hot ironing surface with said elastomeric cross-linkable coating, advancing said ironing surface at the same velocity as said batt, whereby no shear stress develops between said ironing surface and said coating, whereby the exposed surface of said coating is cured as a result of heat transfer from said ironing surface;
• d. thereafter heating said batt and said coating in said heating chamber to a temperature sufficient to substantially dry and cure said cross-linkable elastomeric coating as a smooth, tough coating.