US6328833B1 — Face-up coating of carpet backs with polyurethane

Claim 1

Independent Claim 163 words

In a process for the preparation of tufted carpeting wherein a tuft bind adhesive is applied to tufts penetrating a primary backing, the improvement comprising employing a reactive polyurethane adhesive which is liquid at ambient temperature and comprises an isocyanate-functional component, an isocyanate reactive component and at least one latent polyurethane catalyst as the tuft bind adhesive, and reducing dripping during oven cure of said reactive polyurethane adhesive by viscosifying the exposed surface layer of said reactive polyurethane adhesive or curing or partially curing a curable composition on the exposed surface layer of said polyurethane adhesive such that flow of less viscous adhesive, prior to oven cure, located below said exposed surface layer through said exposed surface layer is reduced, wherein the step of viscosifying the exposed surface of the polyurethane adhesive is accomplished by contacting the surface of the polyurethane adhesive with a liquid viscosifying composition which causes rapid reaction of the surface of the polyurethane adhesive, thereby increasing the viscosity thereof.

Claim 2

Dependent Claim 163 words

In a process for the preparation of tufted carpeting wherein a tuft bind adhesive is applied to tufts penetrating a primary backing, the improvement comprising employing a reactive polyurethane adhesive which is liquid at ambient temperature and comprises an isocyanate-functional component, an isocyanate reactive component and at least one latent polyurethane catalyst as the tuft bind adhesive, and reducing dripping during oven cure of said reactive polyurethane adhesive by viscosifying the exposed surface layer of said reactive polyurethane adhesive or curing or partially curing a curable composition on the exposed surface layer of said polyurethane adhesive such that flow of less viscous adhesive, prior to oven cure, located below said exposed surface layer through said exposed surface layer is reduced, wherein the step of viscosifying the exposed surface of the polyurethane adhesive is accomplished by contacting the surface of the polyurethane adhesive with a liquid viscosifying composition which causes rapid reaction of the surface of the polyurethane adhesive, thereby increasing the viscosity thereof.

Claim 3

Dependent Claim 28 words

The process of claim 1 , wherein the viscosifying composition is a non-advancing skip coat composition applied to a secondary backing which is married to the polyurethane adhesive.

Claim 4

Dependent Claim 73 words

The process of claim 1 , wherein the viscosifying composition is a non-advancing skip coat comprising one or more of a)-d) a) water; b) a low viscosity, hydroxyl, amino, or hydroxyl and amino functional organic compound with a molecular weight of 300 Da or less; c) a polyether polyol or polyester polyol having a molecular weight greater than 300 Da; and d) a non-latent polyurethane catalyst, and e) optionally, a volatile organic solvent.

Claim 5

Dependent Claim 26 words

The process of claim 3 , wherein said non-latent polyurethane catalyst comprises a bismuth catalyst, a tin catalyst, a tertiary amine catalyst, or a mixture thereof.

Claim 6

Dependent Claim 43 words

The process of claim 2 , wherein the skip coat comprises a polyether polyol having a functionality of from about 2 to about 8 and a molecular weight in excess of 500 Da, and a catalyst mixture of dimethyltin dilaurate and triethylene diamine.

Claim 7

Dependent Claim 20 words

The process of claim 1 , wherein said viscosifying composition is applied directly to said reactive polyurethane adhesive exposed surface.

Claim 8

Dependent Claim 17 words

The process of claim 6 , wherein said viscosifying composition is sprayed onto said polyurethane adhesive surface.

Claim 9

Dependent Claim 58 words

The process of claim 1 wherein said viscosifying composition comprises a photocurable composition which cures to a viscous liquid or solid film, or wherein said viscosifying composition comprises a photo-activatable polyurethane catalyst, said process further comprising curing said photocurable composition or activating said photoactivatable catalyst by exposure to light prior to oven cure of said reactive polyurethane adhesive.

Claim 10

Dependent Claim 20 words

The process of claim 8 wherein said photocurable composition comprises one or more non-volatile unsaturated monomers and a photo-activatable catalyst.

Claim 11

Dependent Claim 16 words

The process of claim 9 wherein said unsaturated monomers comprise one or more diacrylates or poly(acrylates).

Claim 12

Dependent Claim 22 words

The process of claim 1 , wherein said viscosifying composition comprises a composition having reactive groups which react rapidly with isocyanate groups.

Claim 13

Dependent Claim 13 words

The process of claim 11 , wherein said reactive groups comprise amino groups.

Claim 14

Dependent Claim 35 words

The process of claim 1 , wherein said polyurethane adhesive further comprises from 30 parts by weight to 500 parts by weight of a filler relative to 100 parts by weight of the isocyanate-reactive component.

Claim 15

Dependent Claim 32 words

The process of claim 13 , wherein said filler is present in an amount of 100 parts by weight to 300 parts by weight relative to 100 parts by weight isocyanate-reactive component.

Claim 16

Dependent Claim 35 words

The process of claim 1 , wherein said polyurethane adhesive further comprises from 30 parts by weight to 500 parts by weight of a filler relative to 100 parts by weight of the isocyanate-reactive component.

Claim 17

Dependent Claim 35 words

The process of claim 11 , wherein said polyurethane adhesive further comprises from 30 parts by weight to 500 parts by weight of a filler relative to 100 parts by weight of the isocyanate-reactive component.

Claim 18

Dependent Claim 15 words

The process of claim 1 , wherein said polyurethane adhesive is supplied as a froth.

Claim 19

Dependent Claim 15 words

The process of claim 1 , wherein said polyurethane adhesive is supplied as a froth.

Claim 20

Dependent Claim 15 words

The process of claim 13 , wherein said polyurethane adhesive is supplied as a froth.

Claim 21

Dependent Claim 40 words

In a process for the face up cure of tufted carpeting, the improvement comprising selecting a greige good coated with polyurethane adhesive as a tuft bind adhesive and/or a secondary backing adhesive and employing the process of claim 1 .

Claim 22

Dependent Claim 40 words

In a process for the face up cure of tufted carpeting, the improvement comprising selecting a greige good coated with polyurethane adhesive as a tuft bind adhesive and/or a secondary backing adhesive and employing the process of claim 1 .

Claim 23

Dependent Claim 40 words

In a process for the face up cure of tufted carpeting, the improvement comprising selecting a greige good coated with polyurethane adhesive as a tuft bind adhesive and/or a secondary backing adhesive and employing the process of claim 11 .

Annuity Stage	Window Opens	Payment Deadline	Surcharge Period Until	Estimated Fee	Status
3.5 Years (Year 4)	2004-12-10	2005-06-11	2005-12-11	$2000.00	Window Closed / Lapsed
7.5 Years (Year 8)	2008-12-10	2009-06-11	2009-12-11	$3760.00	Window Closed / Lapsed
11.5 Years (Year 12)	2012-12-10	2013-06-11	2013-12-11	$7700.00	Window Closed / Lapsed

Face-up coating of carpet backs with polyurethane

Abstract

Inventors

Bibliographic Details

Claims Analysis

References Cited (Backward Citations)

USPTO Annuity & Maintenance Windows

Assigned Categories & Tags

Assign Category Tag