Abstract: The invention comprises a method of making synthetic turf. The method comprises applying an ethylene-vinyl acetate copolymer adhesive to a first primary surface of a tufted primary backing to form a coating thereon and wherein the primary backing is tufted with a plurality of synthetic filaments to form a face pile extending outwardly from a second primary surface of the synthetic turf opposite the first primary surface and heating the ethylene-vinyl acetate copolymer adhesive to a temperature above its melting point so that the ethylene-vinyl acetate copolymer adhesive melts and at least partially flows into the primary backing. The method also comprises heating a linear low-density polyethylene film to a temperature below the softening point of the film and pressing the heated linear low-density polyethylene film into contact with the polymer coated first primary surface of the tufted primary backing.

Abstract: The invention comprises a method of making synthetic turf. The method comprises applying an ethylene-vinyl acetate copolymer adhesive to a first primary surface of a tufted primary backing to form a coating thereon and wherein the primary backing is tufted with a plurality of synthetic filaments to form a face pile extending outwardly from a second primary surface of the synthetic turf opposite the first primary surface and heating the ethylene-vinyl acetate copolymer adhesive to a temperature above its melting point so that the ethylene-vinyl acetate copolymer adhesive melts and at least partially flows into the primary backing. The method also comprises heating a linear low-density polyethylene film to a temperature below the softening point of the film and pressing the heated linear low-density polyethylene film into contact with the polymer coated first primary surface of the tufted primary backing.

Abstract: The invention comprises a method of making synthetic turf. The method comprises applying a plurality of solid polyethylene polymer particles to a tufted primary backing of a tufted synthetic turf to form a coating thereon, wherein the solid polyethylene polymer particles have an average particle size of approximately 1 to approximately 1,000 microns and a melt index of approximately 50 to approximately 500 grams/10 minutes at 190° C. at a weight of 2.16 kg. and wherein the primary backing is tufted with a plurality of synthetic filaments to form a plurality of synthetic filaments extending outwardly from the side of the synthetic turf opposite the primary backing. The method also comprises heating the solid polyethylene particles to a temperature above their melting point so that the solid polyethylene polymer particles melt and at least partially flow into the primary backing and cooling the polyethylene polymer on the primary backing. A product made by the foregoing process is also disclosed.

Abstract: The invention comprises a method. The method comprises applying a composition to a tufted primary backing material, wherein the primary backing material has a first primary surface and a second primary surface, wherein tufts extend outwardly from the first primary surface and loop backs are formed on the second primary surface, and wherein the composition is applied to the loop backs and second primary surface of the tufted primary backing material. The composition comprises an aqueous polymer dispersion of colloidal thermosetting polymer particles or colloidal thermoplastic polymer particles and second thermoplastic polymer particles dispersed in the water, wherein the second thermoplastic polymer particles have an average particle size of approximately 200 micron to approximately 1,000 microns. The method further comprises heating the tufted primary backing material and aqueous polymer dispersion to remove water therefrom. A novel adhesive composition is also disclosed.

Abstract: The invention comprises a method. The method comprises applying to a primary backing and loop backs of a tufted synthetic turf a plurality of solid polymer particles having a particle size less than or equal to 1,000 microns such that a layer of solid polymer particles is formed across the width and length of the primary backing, wherein the polymer particles are applied to the primary backing at a rate of approximately 10 to approximately 18 ounces of polymer per square yard and wherein the solid polymer particles are thermoplastic polymer particles or a mixture of thermoplastic polymer particles and thermosetting polymer particles. The method also comprises heating the polymer particles on the primary backing and loop backs to a temperature at or above the melting temperature of the polymer particles and allowing the heated polymer particles to cool below their melting temperature wherein the tufted synthetic turf has bundle lock of at least 6.

Abstract: The invention comprises a method. The method comprises applying to a primary backing and loop backs of a tufted synthetic turf a plurality of solid polymer particles having a particle size less than or equal to 1,000 microns such that a layer of solid polymer particles is formed across the width and length of the primary backing, wherein the polymer particles are applied to the primary backing at a rate of approximately 5 to approximately 18 ounces of polymer per square yard and wherein the solid polymer particles are thermoplastic polymer particles or a mixture of thermoplastic polymer particles and thermosetting polymer particles. The method also comprises heating the polymer particles on the primary backing and loop backs to a temperature at or above the melting temperature of the polymer particles and allowing the heated polymer particles to cool below their melting temperature wherein the tufted synthetic turf has bundle lock of at least 6.

Abstract: The invention comprises a method. The method comprises applying a quantity of an aqueous dispersion of thermoplastic polymer particles to a primary backing and loop backs of a tufted carpet or a tufted synthetic turf, wherein the thermoplastic particles have an average particle size less than 1,000 microns. The method also comprises heating the aqueous dispersion to a temperature sufficient to remove water therefrom, and heating the thermoplastic particles on the primary backing and loop backs to a temperature at or above the melting temperature of the thermoplastic particles. The method further comprises allowing the heated thermoplastic polymer particles to cool below their melting temperature whereby the loop backs are adhered to the primary backing.

Abstract: The invention comprises a method of making synthetic turf. The method comprises applying a plurality of solid polyethylene polymer particles to a tufted primary backing of a tufted synthetic turf to form a coating thereon, wherein the solid polyethylene polymer particles have an average particle size of approximately 1 to approximately 1,000 microns and a melt index of approximately 50 to approximately 500 grams/10 minutes at 190° C. at a weight of 2.16 kg. and wherein the primary backing is tufted with a plurality of synthetic filaments to form a plurality of synthetic filaments extending outwardly from the side of the synthetic turf opposite the primary backing. The method also comprises heating the solid polyethylene particles to a temperature above their melting point so that the solid polyethylene polymer particles melt and at least partially flow into the primary backing and cooling the polyethylene polymer on the primary backing. A product made by the foregoing process is also disclosed.

Abstract: The invention comprises a method. The method comprises applying a composition to a tufted primary backing material, wherein the primary backing material has a first primary surface and a second primary surface, wherein tufts extend outwardly from the first primary surface and loop backs are formed on the second primary surface, and wherein the composition is applied to the loop backs and second primary surface of the tufted primary backing material. The composition comprises an aqueous polymer dispersion of colloidal thermosetting polymer particles or colloidal thermoplastic polymer particles and second thermoplastic polymer particles dispersed in the water, wherein the second thermoplastic polymer particles have an average particle size of approximately 200 micron to approximately 1,000 microns. The method further comprises heating the tufted primary backing material and aqueous polymer dispersion to remove water therefrom. A novel adhesive composition is also disclosed.

Abstract: The invention comprises a method. The method comprises applying a quantity of an aqueous dispersion of thermoplastic polymer particles to a primary backing and loop backs of a tufted carpet or a tufted synthetic turf, wherein the thermoplastic particles have an average particle size less than 1,000 microns. The method also comprises heating the aqueous dispersion to a temperature sufficient to remove water therefrom, and heating the thermoplastic particles on the primary backing and loop backs to a temperature at or above the melting temperature of the thermoplastic particles. The method further comprises allowing the heated thermoplastic polymer particles to cool below their melting temperature whereby the loop backs are adhered to the primary backing.