Abstract: The present invention provides processes for producing re-bonded polyurethane foam constructs that are useful in applications such as carpet underlayments. According to the invention, a tertiary amine is employed as a catalyst either alone, or preferably in combination with other catalysts in a binder which comprises an organic isocyanate and a polyol. Inclusion of a tertiary amine as a catalyst dramatically increases production throughput.

Abstract: Tufted or woven article having a unitary backing is prepared by applying to the underside of a tufted or woven textile article, a polyurethane-forming composition comprising(A) a relatively high molecular weight polyether polyol;(B) a relatively low molecular weight polyol;(C) an organic polyisocyanate or polyisothiocyanate;(D) an inorganic filler component.The present invention describes a carpet comprising (I) a primary backing; (II) a yarn tufted or woven through said primary backing thereby creating a yarn bundle on the underside of the resultant tufted or woven textile article and (III) a polyurethane composition applied to the underside thereby encapsulating the yarn bundles and adhering the yarn bundles to the primary backing; said polyurethane composition comprising the catalyzed reaction product of the composition described above.