Carpet with a foam polyurethane backing

Abstract

Abstract A TUFTED CARPET IS FORMED BY APPLICATION OF A LAYER OF TIXOTROPIC POLYURETHANE ADHESIVE BACKING COMPOSITION TO A PRIMARY BACKING MATERIAL SO THAT THERE IS SUBSTANTIALLY COMPLETE SATURATION OF THE BUNDLE WRAP WITHOUT PENETRATION OF THE COMPOSITION THROUGH THE PROMARY BACKING TO THE EXPOSED PORTION OF THE TUFTED MATERIAL. THE POLYURETHANE COMPOSITION IS PREPARED BY MIXING TOGETHER UNDER POLYMERIZATION CONDITIONS WATER, A POLYOL WITH A HYDROXYL NUMBER LESS THAN ONE HUNDRED, A DIISOCYANATE, A FILLER AND A CATALYST, AND OPTIONALLY A SURFACTANT. THE POLYURETHANE OBTAINED HAS A VISCOSITY OF BETWEEN 30,000 AND 100,000 CPS. AT 10 R.P.M. NO. 7 SPINDLE BROOKFIELD RVF VISCOMETER, A POT LIFE OF BETWEEN 20 TO 60 SECONDS AND IS EXPANDABLE FROM ABOUT 100 PERCENT TO ABOUT 400 PERCENT WHEN COMPLETELY REACTED. THE POLYURETHANE BACKING COMPOSITION IS APPLIED TO THE UNDERSIDE OF THE PRIMARY BACKING WITH A DOCTOR BLADE. UPON HEATING OR ALLOWING TO STAND AT ROOM TEMPERATURE, THE ADHESIVE COMPOSITION JELLS AND EXPANDS. SUBSEQUENT TO EXPANSION AND PRIOR TO CURING, COMPRESSIVE PRESSURE IS APPLIED TO THE EXPANDED POLYURETHANE BACKING COMPOSITION TO SELECTIVELY DISINTEGRATE AT LEAST A PORTION OF THE FOAMED CELLS IN THE POLYURETHANE AND OPTIONALLY FORM A PATTERN OR DESIGN.

Inventors

• 👤 Claude E Terry

Bibliographic Details