Method of producing a bio-based carpet material

Abstract

A method of making a bio-based carpet material that includes the steps of: providing a griege goods having a top surface and a bottom surface; applying a pre-coat material to the bottom surface of the griege goods to form a pre-coated griege good; and applying a backing material to the bottom surface of the pre-coated griege good. The backing material includes the reaction product of a backing material A-side that has an isocyanate and a backing material B-side that has a transesterified blown vegetable oil which is the result of a heated combination of a blown vegetable oil, a multifunctional compound and a catalyst.

1 . A method of making a carpet material comprising the steps of:
 providing tufts, a primary backing, a pre-coat and a backing material wherein the pre-coat comprises the reaction product of a pre-coat A-side comprising a pre-coat isocyanate and a pre-coat B-side comprising a pre-coat polyol derived from petroleum and wherein the backing material comprises the reaction product of a backing material A-side comprising a backing material isocyanate and a backing material B-side comprising the result of a heated combination of a first multifunctional polyol, a backing material vegetable oil, and a catalyst;   engaging the tufts and the primary backing thereby forming griege goods having a top surface and a bottom surface;   applying the pre-coat onto the bottom surface of the griege goods;   curing the pre-coat; and   applying the backing material to the bottom surface of the griege goods.   
   
   
       2 . The method of  claim 1  further comprising curing the backing material. 
   
   
       3 . The method of  claim 1 , wherein the pre-coat is cured using a curing oven and, wherein the curing oven temperature is about 180° F. to about 220° F. 
   
   
       4 . The method of  claim 3 , wherein the curing oven generates heat electrically or generates heat using a fossil fuel. 
   
   
       5 . The method of  claim 1 , wherein the backing material vegetable oil comprises a blown soybean oil. 
   
   
       6 . The method of  claim 1  further comprising subjecting the griege goods to a bow and weft straightening station thereby straightening the tufts. 
   
   
       7 . The method of  claim 1 , wherein the pre-coat comprising spraying the pre-coat A-side and the pre-coat B-side onto the bottom surface of the griege goods. 
   
   
       8 . The method of  claim 1 , wherein the backing material is applied by spraying the backing material A-side and the backing material B-side onto the bottom surface of the griege goods. 
   
   
       9 . The method of  claim 1 , wherein a bed plate and doctor blade level the pre-coat backing material after the pre-coat backing material is applied to the bottom surface of the griege goods. 
   
   
       10 . The method of  claim 1 , wherein the first multifunctional polyol comprises at least one multifunctional alcohol chosen from the group consisting of glycerin, butanediol, ethylene glycol, tripropylene glycol, dipropylene glycol, and aliphatic amine tetrol. 
   
   
       11 . The method of  claim 1 , wherein the backing material vegetable oil comprises a blown vegetable oil. 
   
   
       12 . The method of  claim 11 , wherein the backing material vegetable oil comprises at least one blown vegetable oil chosen from the group consisting of blown palm oil, blown safflower oil, blown sunflower oil, blown canola oil, blown rapeseed oil, blown cottonseed oil, blown linseed oil, and blown coconut oil. 
   
   
       13 . The method of  claim 1 , wherein the pre-coat B-side further comprises a cross-linking agent and a catalyst. 
   
   
       14 . The method of  claim 1 , wherein the backing material B-side further comprises a cross-linking agent and a catalyst. 
   
   
       15 . The method of  claim 1  further comprising substantially leveling the backing material using a bed plate and doctor blade and wherein an adhesive is applied to the bottom surface of the griege goods after the pre-coat and the top surface of the griege goods comprises exposed tufts. 
   
   
       16 . The method of  claim 1 , wherein the backing material is pre-formed and the backing material is engaged to the bottom surface of the griege goods by the adhesive. 
   
   
       17 . The method of  claim 16 , wherein the backing material is applied to the bottom surface of the griege goods by pressure rolling the backing material into contact with the adhesive. 
   
   
       18 . The method of making a bio-based carpet material comprising the steps of:
 providing a griege goods having a top surface and a bottom surface;   applying a pre-coat material to the bottom surface of the griege goods to form a pre-coated griege good; and   applying a backing material to the bottom surface of the pre-coated griege good; and wherein   the backing material comprises the reaction product of a backing material A-side comprising an isocyanate and a backing material B-side comprising a transesterified blown vegetable oil which is the result of a heated combination of a blown vegetable oil, a multifunctional compound, and a catalyst.   
   
   
       19 . The method of  claim 18 , wherein the backing material vegetable oil comprises at least one blown vegetable oil chosen from the group consisting of blown palm oil, blown safflower oil, blown sunflower oil, blown canola oil, blown rapeseed oil, blown cottonseed oil, blown linseed oil, and blown coconut oil. 
   
   
       20 . The method of  claim 18 , wherein the backing material vegetable oil comprises a blown soybean oil.