US4715912A — Method for forming a layer of blown cellular uret…

Claim 1

Independent Claim 188 words

Method of producing a continuous layer of chemically blown foam cushion having a density of between approximately one and ten pounds per cubic foot on the back of a carpet product comprising the steps of: (a) preparing a mixture of reactive urethane forming agents, including isocyanate, polyol and water such that said mixture will undergo chemical blowing when heated sufficiently, and controlling the temperature of said mixture to a temperature of between approximately 60° and 100° F.; (b) providing a conveyor path; (c) depositing said mixture onto an elastomeric film moving along said conveyor path; (d) forming said mixture on said film into a uniform layer by means of an air knife; (e) preheating the lower surface of an uncoated carpet material to a temperature of approximately 100° to 300° F.; (f) bringing the lower surface of said preheated carpet into flush contact with said layer of said mixture on said film; (g) heating said mixture to cause chemical blowing thereof; (h) applying pressure to said layer of said mixture disposed between said carpet and said film; and (i) removing the coated carpet material from said conveyor path.

Claim 2

Dependent Claim 188 words

Method of producing a continuous layer of chemically blown foam cushion having a density of between approximately one and ten pounds per cubic foot on the back of a carpet product comprising the steps of: (a) preparing a mixture of reactive urethane forming agents, including isocyanate, polyol and water such that said mixture will undergo chemical blowing when heated sufficiently, and controlling the temperature of said mixture to a temperature of between approximately 60° and 100° F.; (b) providing a conveyor path; (c) depositing said mixture onto an elastomeric film moving along said conveyor path; (d) forming said mixture on said film into a uniform layer by means of an air knife; (e) preheating the lower surface of an uncoated carpet material to a temperature of approximately 100° to 300° F.; (f) bringing the lower surface of said preheated carpet into flush contact with said layer of said mixture on said film; (g) heating said mixture to cause chemical blowing thereof; (h) applying pressure to said layer of said mixture disposed between said carpet and said film; and (i) removing the coated carpet material from said conveyor path.

Claim 3

Dependent Claim 210 words

Method of producing a continuous layer of chemically blown foam cushion having a density of between approximately one and ten pounds per cubic foot on the back of a carpet product comprising the steps of: (a) providing a conveyor path; (b) providing a traversing mixer positioned above said conveyor path; (c) preparing a mixture comprising reactive urethane forming agents which will undergo chemical blowing when heated sufficiently and controlling the temperature of said mixture to a temperature of between approximately 60° and 100° F.; (d) dispensing said mixture from said traversing mixer onto an elastomeric film moving along said conveyor path; (e) forming said mixture on said film into a uniform layer by means of an air knife; (f) preheating the lower surface of an uncoated carpet material to a temperature of between approximately 100° and 300° F.; (g) bringing the lower surface of said preheated carpet into flush contact with said layer of said mixture on said film; (h) heating said mixture to cause chemical blowing thereof as said film, said mixture and said carpet move along said conveyor path; (i) passing said carpet, said mixture and said film under a gauge roll before said mixture is cured; and (j) removing the coated carpet material from said conveyor path.

Claim 4

Dependent Claim 210 words

Method of producing a continuous layer of chemically blown foam cushion having a density of between approximately one and ten pounds per cubic foot on the back of a carpet product comprising the steps of: (a) providing a conveyor path; (b) providing a traversing mixer positioned above said conveyor path; (c) preparing a mixture comprising reactive urethane forming agents which will undergo chemical blowing when heated sufficiently and controlling the temperature of said mixture to a temperature of between approximately 60° and 100° F.; (d) dispensing said mixture from said traversing mixer onto an elastomeric film moving along said conveyor path; (e) forming said mixture on said film into a uniform layer by means of an air knife; (f) preheating the lower surface of an uncoated carpet material to a temperature of between approximately 100° and 300° F.; (g) bringing the lower surface of said preheated carpet into flush contact with said layer of said mixture on said film; (h) heating said mixture to cause chemical blowing thereof as said film, said mixture and said carpet move along said conveyor path; (i) passing said carpet, said mixture and said film under a gauge roll before said mixture is cured; and (j) removing the coated carpet material from said conveyor path.

Claim 5

Dependent Claim 192 words

Method of producing a continuous layer of chemically blown foam cushion having a density of between approximately one and ten pounds per cubic foot on the back of a carpet product comprising the steps of: (a) providing a conveyor path; (b) preparing a mixture comprising reactive urethane forming agents which will undergo chemical blowing when heated sufficiently and controlling the temperature of said mixture to a temperature of between approximately 60° and 100° F.; (c) depositing said mixture onto an elastomeric film moving along said conveyor path; (d) forming said mixture on said film into a uniform layer; (e) preheating the back surface of an uncoated carpet material to a temperature of between approximately 100° and 300° F.; (f) bringing said back surface of said preheated carpet into flush contact with said layer of said mixture on said film; (g) heating said mixture to cause chemical blowing thereof as said film, said mixture and said carpet move along said conveyor path; (h) gauging the thickness of the combination of said carpet, said mixture and said film before said mixture is cured; and (i) removing the coated carpet material from said conveyor path.

Claim 6

Dependent Claim 192 words

Method of producing a continuous layer of chemically blown foam cushion having a density of between approximately one and ten pounds per cubic foot on the back of a carpet product comprising the steps of: (a) providing a conveyor path; (b) preparing a mixture comprising reactive urethane forming agents which will undergo chemical blowing when heated sufficiently and controlling the temperature of said mixture to a temperature of between approximately 60° and 100° F.; (c) depositing said mixture onto an elastomeric film moving along said conveyor path; (d) forming said mixture on said film into a uniform layer; (e) preheating the back surface of an uncoated carpet material to a temperature of between approximately 100° and 300° F.; (f) bringing said back surface of said preheated carpet into flush contact with said layer of said mixture on said film; (g) heating said mixture to cause chemical blowing thereof as said film, said mixture and said carpet move along said conveyor path; (h) gauging the thickness of the combination of said carpet, said mixture and said film before said mixture is cured; and (i) removing the coated carpet material from said conveyor path.

Claim 7

Independent Claim 157 words

A method of forming a layer of blown cellular urethane on a carpet backing fabric comprising the steps of: guiding a polymeric film along a path; preparing a mixture of reactive urethane forming agents, including isocyanate, polyol and water; depositing the mixture of reactive urethane forming agents onto the film and shaping the mixture into a layer; applying the back surface of a carpet to the layer of the mixture of reactive urethane forming agents; and controlling the temperature and water content of the mixture of reactive urethane forming agents and the temperature of the carpet to cause the layer of the mixture of reactive urethane forming agents to undergo chemical blowing to provide a layer of urethane foam having a density of between approximately one and ten pounds per cubic foot, having a thickness of between approximately 1/10 inch and one inch and being substantially free of cells having a diameter of greater than 1/8 inch.

Claim 8

Independent Claim 157 words

A method of forming a layer of blown cellular urethane on a carpet backing fabric comprising the steps of: guiding a polymeric film along a path; preparing a mixture of reactive urethane forming agents, including isocyanate, polyol and water; depositing the mixture of reactive urethane forming agents onto the film and shaping the mixture into a layer; applying the back surface of a carpet to the layer of the mixture of reactive urethane forming agents; and controlling the temperature and water content of the mixture of reactive urethane forming agents and the temperature of the carpet to cause the layer of the mixture of reactive urethane forming agents to undergo chemical blowing to provide a layer of urethane foam having a density of between approximately one and ten pounds per cubic foot, having a thickness of between approximately 1/10 inch and one inch and being substantially free of cells having a diameter of greater than 1/8 inch.

Claim 9

Dependent Claim 22 words

The method of claim 4, wherein the mixture of reactive urethane forming agents is shaped into a layer by an air knife.

Claim 10

Independent Claim 221 words

A method of preparing a layer of chemically blown cellular polyurethane on the backside of a carpet in a reverse process by providing a mixture of reactive polyurethane forming agents, applying said mixture to a revolving carrier and adjusting the desired thickness of the layer, heating the carpet and applying the underside of the carpet to the upper side of the smoothed layer of the mixture, blowing and curing the mixture being in contact with the carpet by treatment with heat on the revolving carrier, characterized in that an endless conveyor belt is used as a carrier traveling in a convex path within the zone in which the mixture of reactive agents is applied and the carpet being preheated to a temperature of between 100° F. and 300° F. and resting on the layer of reactive agents on the conveyor belt is guided along a horizontal path during the heat treatment of blowing and curing the mixture and thereby the carpet is upwardly moved by the layer during blowing and the water content is adjusted for 0.01 to 5 weight parts per 100 weight parts glycol over and above the water normally present in the mixture to control the expansion of the mixture and the layer of polyurethane foam has a density of between one and ten pounds per cubic foot.

Claim 11

Independent Claim 221 words

A method of preparing a layer of chemically blown cellular polyurethane on the backside of a carpet in a reverse process by providing a mixture of reactive polyurethane forming agents, applying said mixture to a revolving carrier and adjusting the desired thickness of the layer, heating the carpet and applying the underside of the carpet to the upper side of the smoothed layer of the mixture, blowing and curing the mixture being in contact with the carpet by treatment with heat on the revolving carrier, characterized in that an endless conveyor belt is used as a carrier traveling in a convex path within the zone in which the mixture of reactive agents is applied and the carpet being preheated to a temperature of between 100° F. and 300° F. and resting on the layer of reactive agents on the conveyor belt is guided along a horizontal path during the heat treatment of blowing and curing the mixture and thereby the carpet is upwardly moved by the layer during blowing and the water content is adjusted for 0.01 to 5 weight parts per 100 weight parts glycol over and above the water normally present in the mixture to control the expansion of the mixture and the layer of polyurethane foam has a density of between one and ten pounds per cubic foot.

Claim 12

Dependent Claim 48 words

The method of claim 6 characterized in that the expansion of the layer to from 500% to 6400% of its original thickness during blowing is adjusted by controlling the mixture of reactive agents with reference to the catalyst system, the water content and the content of the isocyanate.

Claim 13

Dependent Claim 22 words

The method of claim 6 characterized in that the carpet is preheated to a temperature of between 140° F. and 180° F.

Claim 14

Dependent Claim 46 words

The method of claim 6 characterized in that a film of dried latex is first provided on the carrier, the mixture of the reactive agents is applied thereon and the carpet is removed from the carrier together with the blown polyurethane layer and the latex layer.

Claim 15

Dependent Claim 21 words

The method of claim 6 characterized in that 2 to 4 weight parts water per 100 weight parts glycol are used.

Annuity Stage	Window Opens	Payment Deadline	Surcharge Period Until	Estimated Fee	Status
3.5 Years (Year 4)	1990-12-28	1991-06-29	1991-12-29	$2000.00	Window Closed / Lapsed
7.5 Years (Year 8)	1994-12-28	1995-06-29	1995-12-29	$3760.00	Window Closed / Lapsed
11.5 Years (Year 12)	1998-12-28	1999-06-29	1999-12-29	$7700.00	Window Closed / Lapsed

Method for forming a layer of blown cellular urethane on a carpet backing

Abstract

Inventors

Bibliographic Details

Claims Analysis

References Cited (Backward Citations)

USPTO Annuity & Maintenance Windows

Assigned Categories & Tags

Assign Category Tag