Abstract: Disclosed are continuous compression molding processes for producing a flexible polyurethane foam laminate and laminates produced thereby, which may be suitable for use, for example, as a carpet underlayment.

Abstract: Disclosed are continuous compression molding processes for producing a flexible polyurethane foam laminate and laminates produced thereby, which may be suitable for use, for example, as a carpet underlayment.

Abstract: This invention relates to freeze-stable aromatic diisocyanates, an to processes for the preparation of these freeze-stable aromatic diisocyanates. The preferred aromatic diisocyanate is preferably diphenylmethane diisocyanate. These freeze-stable aromatic diisocyanates comprise a blend of an aromatic diisocyanate, with 2,2,4-trimethyl-1,3-pentanediol diisobutyrate, and have an NCO group content of from about 6% to about 29% by weight. Suitable aromatic diisocyanates contain one or more of the following modifying groups: allophanate groups, carbodiimide groups, uretonimine groups, biuret groups, dimer groups, isocyanurate groups, urea groups and/or urethane groups. Prepolymers of these modified aromatic diisocyanates are also suitable for the present invention.

Abstract: The present invention relates to tufted goods comprising a greige good having fibers tufted into a primary backing, a precoat which is adhered to the back surface of the greige good, and a flexible film which is laminated to the back surface of the precoat. The flexible film is treated via corona-discharge prior to being laminated to the precoat. This invention also relates to a process for producing tufted goods. This process comprises treating a flexible film via corona-discharge, contacting the treated flexible film with the uncured or partially cured back surface of a precoated greige good, and curing the article. Optional embodiments of this invention include having a foam layer between the precoat and the flexible film, or having a foam layer on the back surface of the flexible film. An alternate embodiment of this invention comprises substituting a foam layer for the precoat.

Abstract: The present invention relates to an improved process for the production of artificial turf, and the improved artificial turf. In accordance with this process, fibers are treated via corona discharge, tufted into a primary backing to form a greige good, and a precoat is applied to the back surface the greige good. Suitable fibers are polyolefins, and suitable precoats are reactive polyurethane mixtures. The fibers may be treated by corona discharge either before they are tufted into the primary backing to form the greige good or after the are tufted into the primary backing. Artifical turfs of the present invention comprise a greige good having fibers tufted into a primary backing, with the fibers being treated by corona discharge either before or after being tufted into the primary backing, and a precoat which is attached by its face surface to the back surface of the greige good.

Abstract: The present invention relates to an improved process for the production of artificial turf, and the improved artificial turf. In accordance with this process, fibers are treated via corona discharge, tufted into a primary backing to form a greige good, and a precoat is applied to the back surface the greige good. Suitable fibers are polyolefins, and suitable precoats are reactive polyurethane mixtures. The fibers may be treated by corona discharge either before they are tufted into the primary backing to form the greige good or after the are tufted into the primary backing. Artifical turfs of the present invention comprise a greige good having fibers tufted into a primary backing, with the fibers being treated by corona discharge either before or after being tufted into the primary backing, and a precoat which is attached by its face surface to the back surface of the greige good.

Abstract: The present invention relates to composite structures comprising an open weave, natural or synthetic fabric or backing having fibers and a urethane froth foam, wherein the fibers of the fabric or backing are at least partially penetrated and/or embedded by the urethane froth. This invention also relates to a process for the production of a composite structure comprising A) applying a reactive urethane froth to an open weave, natural or synthetic fabric or secondary backing having fibers, B) passing the fabric or backing coated with the reactive urethane froth under a doctoring device such that the reactive urethane froth at least partially penetrates and/or embeds the fibers of the fabric or backing, and C) curing the reactive urethane froth.

Abstract: This invention relates to a process for the production of patterned polyurethane foam as a backing for tufted goods. This process comprises applying a puddle of a reactive polyurethane mixture to the back side of a greige good, passing the greige good coated with the reactive polyurethane mixture under a doctoring device and curing the polyurethane backed greige good. In one embodiment of the present invention, the doctoring device is patterned or an attachment to the doctoring device is patterned, and forms a corresponding pattern in the polyurethane coating as it passes under the doctoring device. In another embodiment, a woven secondary backing is laminated to the reactive polyurethane mixture after passing under the doctoring device, and pressure is applied against the face of the tufted good such that the urethane is pushed through the windows of the secondary backing. This pressure forms beads of polyurethane on the underside of the woven secondary backing.

Abstract: Improvements in tuft bind and/or elongation of tufted carpet may be achieved by selecting, as components of a tuft bind adhesive, one or more of: i) a polyol component comprising a low or ultra-low unsaturation polyoxypropylene polyol optionally containing up to 30 weight percent oxyethylene moieties, and ii) a chain extender component comprising 2-methyl-1,3-propanediol.

Abstract: Tufted carpeting can be manufactured employing polyurethane adhesives and cured face up without dripping, when one or more drip-reducing process steps of adding a non-Newtonian thickener to the adhesive or forming a viscosified or cured film on the outer surface of the adhesive are practiced prior to entry of the greige good into the curing oven.

Abstract: Laminated carpeting consisting of a secondary backing adhered to a greige good of yarn tufted into a primary backing are prepared from polyurethane adhesives by single puddle processes which allow for lowered use of polyurethane while producing carpets exhibiting excellent delamination strength. Preferably, a reactive polyurethane system is employed as a primary adhesive, and the secondary backing is skip-coated with a minor amount of a non-advancing skip coat.

Abstract: Tufted carpeting can be manufactured employing polyurethane adhesives and cured face up without dripping, when one or more drip-reducing process steps of adding a non-Newtonian thickener to the adhesive or forming a viscosified or cured film on the outer surface of the adhesive are practiced prior to entry of the greige good into the curing oven.

Abstract: Improvements in tuft bind and/or elongation of tufted carpet may be achieved by selecting, as components of a tuft bind adhesive, one or more of: i) a polyol component comprising a low or ultra-low unsaturation polyoxypropylene polyol optionally containing up to 30 weight percent oxyethylene moieties, and ii) a chain extender component comprising 2-methyl-1,3-propanediol.

Abstract: The amount of high molecular weight impurity present in a polyether polyol produced by alkoxylation of an active hydrogen-containing initiator using an epoxide such as propylene oxide and a substantially amorphous highly active double metal cyanide complex catalyst may be advantageously lowered by having a non-protic Lewis acid present during the epoxide polymerization. The use of halides such as zinc chloride and aluminum chloride is especially effective for such purposes. In a preferred embodiment, minor amounts of water are also present during polymerization. The higher purity polyether polyols thereby produced are particularly useful in the preparation of slab and molded polyurethane foams, which tend to collapse or become excessively tight when elevated levels of high molecular tail are present in the polyether polyol.

Abstract: Stabilizer precursors and preformed stabilizers having induced unsaturation, and prepared from low intrinsic unsaturation-containing polyoxyalkylene polyether polyols may be used to form polymer polyols of higher solids content, lower viscosity, and superior filterability and particle size than polymer polyols prepared from stabilizers derived from polyols having higher intrinsic unsaturation, even when the latter are coupled to form high molecular weight stabilizers.