Polyurethane Roller Coating Process for Carpet Backing

A method for preparing carpet utilizing polyurethane foam to anneal a secondary backing to a greige, having a face and an opposed backstitch side, said process comprising:

• (a) introducing polyol from a first source and isocyanate from a second source, together with a filler and a catalyst to create a polyurethane mixture;
• (b) creating a puddle of the polyurethane mixture held upon the surfaces of an application roller and a drive roller positioned transversely and adjacent to the backstitch side of the greige;
• (c) applying said polyurethane mixture with both of the said rollers as the greige is moved laterally with respect to the rollers to form a coating on the backstitch side of the greige that begins to cure into a polyurethane foam;
• (d) contacting a secondary backing to the polyurethane mixture coated backstitch side of the greige.

A method for preparing carpet utilizing polyurethane foam to anneal a secondary backing to a greige, having a face and an opposed backstitch side, said process comprising:

• (a) introducing polyol from a first source and isocyanate from a second source, together with a filler and a catalyst to create a polyurethane mixture;
• (b) creating a puddle of the polyurethane mixture resting directly upon both an application roller and a drive roller positioned transversely and adjacent to the backstitch side of the greige;
• (c) applying said polyurethane mixture with both of the said rollers as the greige is moved laterally with respect to the rollers to form a coating on the backstitch side of the greige that begins to cure into a polyurethane foam;
• (d) using the lateral movement of the greige to effect a wiping action on the application roller;
• (e) rotating the drive roller faster than the lateral movement of the greige to effect a wiping action on the drive roller;
• and
• (f) contacting a secondary backing to the polyurethane mixture coated backstitch side of the greige.