US4657790A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Polyurethane backed carpet
Assignee: TEXTILE RUBBER AND CHEMICAL COMPANY Inc
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Filing: 1985-07-08
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Granted: 1987-04-14
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Expires: 2005-07-08
Abstract
Abstract A process for preparing a substrate backed with a polymer derived from an organic polyisocyanate, said process comprising the steps of (a) forming a precoat layer of a precoat reaction mixture comprising a substantially difunctional polyahl and a substantially difunctional organic polyisocyanate, (b) separately forming a capcoat layer of a capcoat reaction mixture comprising a polyahl and a polyisocyanate, (c) contacting said precoat layer with one surface of said substrate before said precoat layer is cured to a tack-free state, (d) contacting said capcoat layer with one surface of said precoat layer before at least one of said precoat layer and capcoat layer is cured to a tack-free state, (e) completing curing said capcoat and precoat layer, and (f) cooling the resulting polymer-backed substrate to a temperature less than about 35° C. before any mechanical distortion thereof, wherein steps (a)-(f) are carried out under conditions such that mechanically induced stress in the substrate, precoat layer and capcoat layer is minimized. Another aspect of this invention is a polymer backed-substrate comprising (a) a substrate (b) attached to a surface of said substrate a precoat layer of a polymer formed by the reaction of a substantially difunctional polyahl and a substantially difunctional organic polyisocyanate, which precoat layer is overcoated with (c) a capcoat layer comprising a polymer formed by the reaction of a polyahl and an organic polyisocyanate.
Inventors
- 👤 Phillip L. Wing
- 👤 James K. Jennings
- 👤 Terry L. Lamb
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-03 11:41
CPC Classifications
B; B32; B32B; B32B37/00; B32B37/14; B32B37/24; D; D06; D06N; D06N7/00; D06N7/0063; D06N7/0071; D06N7/0076; D06N2203/00; D06N2203/06; D06N2203/068; D06N2205/00; D06N2205/20; D06N2209/00; D06N2209/16; D06N2209/1628; Y; Y10; Y10T; Y10T428/00; Y10T428/23907; Y10T428/23979
Claims Analysis
Total Claims: 20
Claim 1
Independent Claim
160 words
A process for preparing a substrate backed with a polymer derived from an organic polyisocyanate, said process comprising the steps of (a) forming a precoat layer of a precoat reaction mixture comprising a substantially difunctional polyahl and a substantially difunctional organic polyisocyanate, (b) separately forming a capcoat layer of a capcoat reaction mixture comprising a polyahl and a polyisocyanate, (c) contacting said precoat layer with one surface of said substrate before said precoat layer is cured to a tack-free state, (d) contacting said capcoat layer with one surface of said precoat layer before at least one of said precoat layer and capcoat layer is cured to a tack-free state, (e) completing curing said capcoat and precoat layer, and (f) cooling the resulting polymer-backed substrate to a temperature less than about 35° C. before any mechanical distortion thereof, wherein steps (a)-(f) are carried out under conditions such that mechanically induced stress in the substrate, precoat layer and capcoat layer is minimized.
Claim 2
Dependent Claim
160 words
A process for preparing a substrate backed with a polymer derived from an organic polyisocyanate, said process comprising the steps of (a) forming a precoat layer of a precoat reaction mixture comprising a substantially difunctional polyahl and a substantially difunctional organic polyisocyanate, (b) separately forming a capcoat layer of a capcoat reaction mixture comprising a polyahl and a polyisocyanate, (c) contacting said precoat layer with one surface of said substrate before said precoat layer is cured to a tack-free state, (d) contacting said capcoat layer with one surface of said precoat layer before at least one of said precoat layer and capcoat layer is cured to a tack-free state, (e) completing curing said capcoat and precoat layer, and (f) cooling the resulting polymer-backed substrate to a temperature less than about 35° C. before any mechanical distortion thereof, wherein steps (a)-(f) are carried out under conditions such that mechanically induced stress in the substrate, precoat layer and capcoat layer is minimized.
Claim 3
Dependent Claim
21 words
The process of claim 1 wherein precoat layer is contacted with said substrate before said capcoat and precoat layers are contacted.
Claim 4
Dependent Claim
24 words
The process of claim 2 wherein said precoat layer is at a temperature of about 35° to 75° C. when step (d) is conducted.
Claim 5
Dependent Claim
23 words
The process of claim 2 wherein the capcoat layer is formed and partially cured on a conveyor belt prior to conducting step (d).
Claim 6
Dependent Claim
25 words
The process of claim 4 wherein the partially cured capcoat layer is laminated to the precoated substrate on a conveyor belt under a foam blanket.
Claim 7
Dependent Claim
22 words
The process of claim 1 wherein said precoat and capcoat layers are contacted before said precoat layer is contacted with the substrate.
Claim 8
Dependent Claim
34 words
The process of claim 1 wherein the precoat reaction mixture comprises a polyahl mixture comprising a major portion of a relatively high molecular weight polyol and a minor portion of low molecular weight diol.
Claim 9
Dependent Claim
34 words
The process of claim 7 wherein the precoat reaction mixture comprises a substantially difunctional organic polyisocyanate which is a prepolymer of an excess of an organic diisocyanate and a relatively low molecular weight diol.
Claim 10
Dependent Claim
29 words
The process of claim 8 wherein the precoat reaction mixture comprises from about 150-500 parts by weight of an inorganic filler per 100 parts by weight of polyahl mixture.
Claim 11
Dependent Claim
35 words
The process of claim 1 wherein the capcoat reaction mixture comprises a polyahl mixture comprising a relatively high molecular weight diol, a relatively high molecular weight triol, and at least one low molecular weight polyol.
Claim 12
Dependent Claim
26 words
The process of claim 10 wherein the capcoat reaction mixture comprises from about 100-500 parts by weight inorganic filler per 100 parts by weight polyahl mixture.
Claim 13
Dependent Claim
17 words
The process of claim 1 wherein the precoat layer weighs about 10 to 30 oz/yd 2 .
Claim 14
Dependent Claim
17 words
The process of claim 12 wherein the capcoat layer weighs about 30 to 70 oz/yd 2 .
Claim 15
Dependent Claim
23 words
The process of claim 1 wherein a scrim is inserted between the substrate and precoat layer and/or between the precoat and capcoat layer.
Claim 16
Dependent Claim
11 words
The process of claim 1 wherein the substrate is a carpet.
Claim 17
Dependent Claim
12 words
The process of claim 15 wherein the substrate is a broadloom carpet.
Claim 18
Dependent Claim
32 words
The process of claim 24 comprising the additional step of (g) cutting the polymer-backed substrate into carpet tiles after the polymer-backed substrate is cooled to a temperature less than about 35° C.
Claim 19
Dependent Claim
148 words
A process for preparing a substrate-backed with a polymer, said process comprising the steps of (a) forming a precoat layer of a precoat reaction mixture comprising a curable linear polymerforming composition, (b) separately forming a capcoat layer of a capcoat reaction mixture comprising a curable polymerforming composition, (c) contacting said precoat layer with one surface of said substrate before said precoat layer is cured to a tack-free state, (d) contacting said capcoat layer with one surface of said precoat layer before at least one of said precoat layer and capcoat layer is cured to a tack-free state, (e) completing curing said capcoat and precoat layer, and (f) cooling the resulting polymer-backed substrate to a temperature less than about 35° C. before any mechanical distortion thereof, wherein steps (a)-(f) are carried out under conditions such that mechanically induced stress in the substrate, precoat layer and capcoat layer is minimized.
Claim 20
Dependent Claim
148 words
A process for preparing a substrate-backed with a polymer, said process comprising the steps of (a) forming a precoat layer of a precoat reaction mixture comprising a curable linear polymerforming composition, (b) separately forming a capcoat layer of a capcoat reaction mixture comprising a curable polymerforming composition, (c) contacting said precoat layer with one surface of said substrate before said precoat layer is cured to a tack-free state, (d) contacting said capcoat layer with one surface of said precoat layer before at least one of said precoat layer and capcoat layer is cured to a tack-free state, (e) completing curing said capcoat and precoat layer, and (f) cooling the resulting polymer-backed substrate to a temperature less than about 35° C. before any mechanical distortion thereof, wherein steps (a)-(f) are carried out under conditions such that mechanically induced stress in the substrate, precoat layer and capcoat layer is minimized.
References Cited (Backward Citations)
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1990-04-13 | 1990-10-13 | 1991-04-14 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1994-04-13 | 1994-10-13 | 1995-04-14 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1998-04-13 | 1998-10-13 | 1999-04-14 | $7700.00 | Window Closed / Lapsed |