Abstract: Polyurethane cushions are formed on the surface of a textile such as carpet. The polyurethane is made in the reaction of a polyurethane forming composition that is frothed, and contains water as a blowing agent. The polyurethane forming composition is cured between the substrate and a containment layer, both of which prevent the blowing gasses from escaping during the curing process. The process allows low density attached cushions to be formed controllably.

Abstract: Carpet backing for residential, commercial and recreational carpet which exhibits a tuftbind greater than 4.5 kg, ASTM D 1335, contains a polyurethane reaction product of a polyisocyanate; an active hydrogen containing compound; and a polyol reaction product. Typically, the polyol reaction product is a reaction product of a polyol and a vegetable oil and contains less than about 50 percent by weight of unreacted vegetable oil. The vegetable oil is preferably selected from palm oil, safflower oil, canola oil, soy oil, cottonseed oil and rapeseed oil. In a preferred embodiment, the vegetable oil is blown. Typically, the amount of unreacted vegetable oil in the polyol reaction product is less than about 34 weight percent. The hard segment of the resulting polyurethane reaction product constitutes at least 20 weight percent of the polyurethane reaction product. The carpet backing of the invention may be used as a precoat, a laminate or foam coating.

Abstract: Carpet backing is prepared from carpet scrap by first comminuting the carpet scrap into fragments and then melting and fusing the carpet scrap fragments together to render molten fragments. The resulting molten fragments containing synthetic resins are then formed into agglomerates. The pellets are then ground into a fine powder. A slurry may be prepared from the ground powder and a carrier. The ground powder may, alternatively, be mixed with a polyurethane reactive mixture, aqueous polymer containing emulsion or a thermoplastic composition such as bitumen, polypropylene or polyethylene. The resulting polymeric coating is coated onto a substrate. The coated substrate is then hardened.

Abstract: The method forms a polyurethane article and involves dispersing polyurethane particles in a substantially aqueous liquid, mixing in a fine glass filler such as a post-consumer ground soda-lime glass, casting the filled dispersion and coalescing the particles by removing the liquid such that a polyurethane article having fused particles are formed. The polyurethane articles are useful as carpet backings.