Abstract: A method and apparatus for making a foamed polyurethane cushion. The cushion may be a separate cushion for carpeting or other fabric, or may be bonded to carpeting. Components for forming a foamed polyurethane are cooled, and dispensed into a puddle on a moving sheet. The puddle is leveled by an air knife into a uniform coating; then, the moving sheet is passed around a roller and placed coated side down against a fabric. The resulting sandwich is held, and moved across a steam box. The steam causes the components to react and form a blown polyurethane. After the blowing is complete and before the foam is cured beyond its plastic state, the thickness of the foam is adjusted by pressing with a roller. The sheet, which is a thermoplastic, is heated to cause the sheet to blend into the completed foam.

Abstract: A method for applying a blown polyurethane coating to carpeting or other sheet material. The method includes the step of adding a filler to the polyurethane components to assure that the liquid does not unduly penetrate porous goods. The mixed polyurethane components are then placed in a puddle on the sheet material and leveled to a uniform coating. Steam is passed through the sheet material and the coating to initiate the reaction of the components. The steam also adds water to the coating, so the formulation is such that additional water is needed, and the needed water is added by the steaming. After the polyurethane has completed blowing, and before the polyurethane has cured beyond its plastic state, the foam may be compressed to decrease the thickness. A second sheet of material can be placed over the polyurethane to prevent the polyurethane from adhering to the compressing roller.

Abstract: A reactive polyurethane mixture is applied by a high pressure airless spray applicator directly onto the primary backing of a moving substrate such as a carpet web. The applied reactive mixture is allowed to foam to an approximate predetermined thickness and density. While the blown or foamed backing layer still possesses substantial residual tackiness, it is compressed or regauged to a precise uniform thickness and simultaneously is provided with either an embossed or a smooth surface. The tack of internal cell walls of the blown backing layer retains the layer at the regauged thickness. Curing of the regauged backing layer by externally applied heat and/or by the heat of the exothermic reaction in the applied mixture is completed. Detackifying agents are applied to the regauging devices and/or to the applied backing layer to prevent adherence of the layer to the regauging devices. A surface skin formed of the detackifying agents is cured on the regauged backing layer.