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AssigneeCustom Coating, Inc.
InventorsWilliam C. Poteet, Claude E. Terry, Glen F. Hamrick, Francis G. Walls
Estimating the term…
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. The process achieves a great savings of energy and is fast and economical.
In a method of producing a cushion backing on a substrate, the steps of advancing a substrate and applying directly to one surface thereof an exothermically reactive foamable composition adapted to blow unconfined into a cellular layer on the substrate during a blowing cycle to a thickness greater than the final desired maximum thickness of the cellular layer, and regauging the blown cellular layer after the blowing cycle thereof and while the walls of the internal cells of said layer are tacky to thereby regauge the cellular layer to a permanently reduced and highly uniform thickness across the breadth of said substrate.
A method of producing a cushion backing on a carpet substrate comprising mixing substantially polyol with diisocyanate to create a reactive foamable polyurethane composition, applying said reactive foamable polyurethane composition directly to the primary backing of the carpet substrate, allowing said reactive foamable polyurethane composition to blow unconfined into a cellular backing layer having a thickness greater than the desired maximum thickness of the cellular backing layer, regauging said cellular backing layer by means of a regauging device at the end of the blowing cycle of such layer to obtain a uniform reduced thickness of the backing layer across the breadth of said substrate, and completing the curing of the backing layer subsequent to said regauging.
Apparatus for producing a cushion backing on a moving flexible substrate comprising means to support and advance the substrate, means for directly applying a foamable reactive polyurethane composition onto the moving substrate to form by unconfined blowing a cellular polyurethane backing layer having a thickness greater than the maximum desired thickness of the backing layer, said applying means being spaced from one surface of the moving substrate, and a regauging means substantially downstream from said polyurethane applying means and adapted to regauge substantially the applied polyurethane backing layer after the blowing cycle and before complete curing thereof on said substrate to a permanently reduced thickness.
Apparatus for producing a cushion backing on a moving flexible substrate comprising means to support and advance the substrate, means for directly applying an exothermic reactive foamable composition onto the moving substrate to form by unconfined blowing a cellular backing layer having a thickness greater than the maximum desired thickness of the backing layer, said applying means being spaced from one surface of the moving substrate, and a regauging means substantially downstream from said foamable composition applying means and adapted to regauge substantially the applied exothermic reactive foamable backing layer after the blowing cycle and before complete curing thereof on said substrate to a permanently reduced thickness.
Dependencies are inferred from the claim text.