US 4,595,436 AGranted

Method for applying polyurethane backing

AssigneesPaul Walker, Glen F. Hamrick

InventorsPaul Walker, Glen F. Hamrick, B. Lamar Sosebee

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Abstract

A method and apparatus for making a foamed polyurethane cushion. The cushion may be a separate cushion for carpeting or other fabric, or may be bonded to carpeting. Components for forming a foamed polyurethane are cooled, and dispensed into a puddle on a moving sheet. The puddle is leveled by an air knife into a uniform coating; then, the moving sheet is passed around a roller and placed coated side down against a fabric. The resulting sandwich is held, and moved across a steam box. The steam causes the components to react and form a blown polyurethane. After the blowing is complete and before the foam is cured beyond its plastic state, the thickness of the foam is adjusted by pressing with a roller. The sheet, which is a thermoplastic, is heated to cause the sheet to blend into the completed foam.

Claims13

Dependent claims

A method for providing a cushion of foamed polyurethane having a fabric on at least one side of said cushion, said method including the step of coating one side of a first sheet with components for forming a foamed polyurethane, said components being such as to begin reaction on being heated by passing steam through said components so that said steam both heats said components and adds water for reaction with said components, inverting said first sheet and placing said coated one side of said first sheet down against a second sheet that is below the first sheet for forming a sandwich of said polyurethane forming components between the sheets, said second sheet comprising a fabric pervious to steam, moving said sandwich across a steam box and continuously steaming said sandwich for adding water, heating said components and initiating the reaction of said polyurethane forming components, and allowing complete reaction of said components with said first sheet on the upper surface.

Dependencies are inferred from the claim text.

Facts

Application: 06/646,415Filed 31 Aug 1984 · continuation in part
Priority: 22 Nov 1983
Granted: 17 Jun 1986
Term ends: Not estimatedThe source records don’t support an estimate.

Classification14 codes

B29C 44/3426
Heating or cooling: heating by introducing steam in the mould
B29C 44/467
Into an open space or onto moving surfaces, i.e. to make articles of indefinite length: foam spreading or levelling devices
D06N 3/14
With macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds , e.g. gelatine proteins:…
D06N 7/0086
Characterised by their backing, e.g. pre-coat, back coating, secondary backing, cushion backing: characterised by the cushion backing, e.g. foamed…