Method of forming foam layers on carpeting

Claim 1

THE METHOD OF CONCURRENTLY PROVIDING TWO FLAT PIECES OF CARPETING WITH BACKING LAYERS OF FOAMED POLYURETHANE RESIN, SAID LAYERS BOTH HAVING OPEN CELLED FACES OF HIGH COEFFICIENT OF FRICTION, WHICH COMPRISES SPREADING UPON THE BACK OF ONE OF THE LAYERS, A LAYER OF LIQUID, FOAMABLE MIXTURE COMPRISING 100 PARTS BY WEIGHT OF A POLYESTER OF A SATURATED DICARBOXYLIC ACID AND A DIHYDRIC ALCOHOL, SAID POLYESTER BEING OF A HYDROXYL NUMBER OF ABOUT 60 TO 80 AND AN ACID NUMBER BELOW 12; ABOUT 20 TO ABOUT 100 PARTS BY WEIGHT OF TOLYLENE DIISOCYANATE; ABOUT 0.1 TO ABOUT 5 PARTS BY WEIGHT OF WATER; 0.1 TO 10 PARTS BY WEIGHT OF AN EMULSIFYING AGENT; AND 0.2 TO 5 PARTS BY WEIGHT OF A TERTIARY AMINE, WHICH IS A CATALYST OF THE REACTION OF THE POLYESTER AND THE TOLYLENE DIISOCYANATE TO FORM POLYURETHANE RESINS; APPLYING THE SECOND PIECE OF CARPETING WITH THE BACK THEREOF IN CONTACT WITH THE FOAMABLE MIXTURE, ALLOWING THE MIXTURE TO FOAM AND CURE, WHILE LIMITING THE SEPARATION OF THE TWO PIECES OF CARPETING TO PREDETERMINED DISTANCE AND THEN SLICING THE FOAMED AND CURED LAYER APART IN A PLANE INTERMEDIATE OF THE PIECES OF CARPETING TO PROVIDE TWO UNITS, EACH HAVING A NON-SLIP BACK OF FOAMED POLYURETHANE RESIN FORMED IN SITU THEREUPON, THE BACK BEING OF A THICKNESS OF ABOUT 1/8 INCH TO ABOUT 1/2 INCH AND THE CELLS IN THE FACE BEING OPENED BY THE SPLITTING OPERATION AND HAVING EDGES IN A COMMON PLANE.

Claim 2

THE METHOD OF CONCURRENTLY PROVIDING TWO FLAT PIECES OF CARPETING WITH BACKING LAYERS OF FOAMED POLYURETHANE RESIN, SAID LAYERS BOTH HAVING OPEN CELLED FACES OF HIGH COEFFICIENT OF FRICTION, WHICH COMPRISES SPREADING UPON THE BACK OF ONE OF THE LAYERS, A LAYER OF LIQUID, FOAMABLE MIXTURE COMPRISING 100 PARTS BY WEIGHT OF A POLYESTER OF A SATURATED DICARBOXYLIC ACID AND A DIHYDRIC ALCOHOL, SAID POLYESTER BEING OF A HYDROXYL NUMBER OF ABOUT 60 TO 80 AND AN ACID NUMBER BELOW 12; ABOUT 20 TO ABOUT 100 PARTS BY WEIGHT OF TOLYLENE DIISOCYANATE; ABOUT 0.1 TO ABOUT 5 PARTS BY WEIGHT OF WATER; 0.1 TO 10 PARTS BY WEIGHT OF AN EMULSIFYING AGENT; AND 0.2 TO 5 PARTS BY WEIGHT OF A TERTIARY AMINE, WHICH IS A CATALYST OF THE REACTION OF THE POLYESTER AND THE TOLYLENE DIISOCYANATE TO FORM POLYURETHANE RESINS; APPLYING THE SECOND PIECE OF CARPETING WITH THE BACK THEREOF IN CONTACT WITH THE FOAMABLE MIXTURE, ALLOWING THE MIXTURE TO FOAM AND CURE, WHILE LIMITING THE SEPARATION OF THE TWO PIECES OF CARPETING TO PREDETERMINED DISTANCE AND THEN SLICING THE FOAMED AND CURED LAYER APART IN A PLANE INTERMEDIATE OF THE PIECES OF CARPETING TO PROVIDE TWO UNITS, EACH HAVING A NON-SLIP BACK OF FOAMED POLYURETHANE RESIN FORMED IN SITU THEREUPON, THE BACK BEING OF A THICKNESS OF ABOUT 1/8 INCH TO ABOUT 1/2 INCH AND THE CELLS IN THE FACE BEING OPENED BY THE SPLITTING OPERATION AND HAVING EDGES IN A COMMON PLANE.