Preparation of filled reactive polyurethane carpet backing formulations using an in-line continuous mixing process
AssigneeThe Dow Chemical Company
InventorsJames K. Jennings, Randall C. Jenkines, Larry W. Mobley
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Abstract
The present invention is a continuous process for preparing formulations useful for making filled polymer carpet backings. The present invention particularly incorporates polyisocyanate as a reactive diluent in a continuous process for preparing filled polyurethane polymers. Use of the present invention allows production of carpet backings that incorporate high loadings of filler materials.
Claims19
A process for preparing a polyurethane-forming reactive mixture used for preparing a polyurethane-backed article comprising:
- continuously and simultaneously metering
- (a) an isocyanate-reactive material;
- (b) a polyisocyanate;
- and
- (c) a filler;
- to a means for mixing (a), (b), and (c), wherein the means for mixing (a), (b), and (c), is a low-shear or no-shear mixer, and wherein a thermal rise of less than 40.degree. F. is observed.
A process for preparing a polyurethane-backed article comprising the steps:
- (i) simultaneously metering:
- (a) an isocyanate-reactive material;
- (b) a polyisocyanate;
- and
- (c) a filler;
- to a means for mixing (a), (b), and (c), thereby forming a polyurethane-forming reactive mixture, wherein the means for mixing (a), (b), and (c) is a low-shear or no-shear mixer;
- (ii) delivering the reactive mixture of step (i) to a pump;
- (iii) pumping the reactive mixture to a second mixing means;
- (iv) mixing the reactive mixture with a polyurethane catalyst and optional components to form a polyurethane-forming composition;
- (v) delivering the polyurethane-forming composition to form a coating on a surface of a substrate;
- and
- (vi) curing the polyurethane-forming composition on the surface of the substrate.
Dependencies are inferred from the claim text.