A process and system for making a laminated surface covering and the surface covering itself are described. The covering includes several layers bonded to each other. The system performs the process. One example of the process includes passing a first material across a first conveyor, passing a second material across a second conveyor, passing a bonding material across a third conveyor, contacting the first material and the second material to the bonding material, and heating at least one of the first material and the second material. The process also includes introducing the first material, the second material, and the bonding material into a pressure zone such that the bonding material is introduced between a bottom surface of the first material and a top surface of the second material. The process applies pressure to bond the first material and second material together via the bonding material to produce a laminated material.

A laminated surface covering including a facing material made of vinyl and a backing material comprising a rubber component. The rubber component comprising at least a matrix of bonded rubber granules. A bonding material disposed between the facing material and the backing material. The facing material configured to melt at a temperature between 165? F. and 248? F. infiltrating the backing material thereby essentially encasing the rubber granules of the matrix and providing fire retardation and smoke suppression qualities.

The invention comprises a method. The method comprises applying to a primary backing and loop backs of a tufted synthetic turf a plurality of solid polymer particles having a particle size less than or equal to 1,000 microns such that a layer of solid polymer particles is formed across the width and length of the primary backing, wherein the polymer particles are applied to the primary backing at a rate of approximately 5 to approximately 18 ounces of polymer per square yard and wherein the solid polymer particles are thermoplastic polymer particles or a mixture of thermoplastic polymer particles and thermosetting polymer particles. The method also comprises heating the polymer particles on the primary backing and loop backs to a temperature at or above the melting temperature of the polymer particles and allowing the heated polymer particles to cool below their melting temperature wherein the tufted synthetic turf has bundle lock of at least 6.8 pounds and the tufted synthetic turf has a water permeability of at least 10 inches of water per hour.

The invention comprises a method. The method comprises applying a quantity of an aqueous dispersion of thermoplastic polymer particles to a primary backing and loop backs of a tufted carpet or a tufted synthetic turf, wherein the thermoplastic particles have an average particle size less than 1,000 microns. The method also comprises heating the aqueous dispersion to a temperature sufficient to remove water therefrom, and heating the thermoplastic particles on the primary backing and loop backs to a temperature at or above the melting temperature of the thermoplastic particles. The method further comprises allowing the heated thermoplastic polymer particles to cool below their melting temperature whereby the loop backs are adhered to the primary backing.

A synthetic turf field includes a top layer of synthetic turf material, and a coconut crumb infill under the synthetic turf material. An infill material is made of coconut crumb material from inner shells of coconuts, the crumbs having a sized range of less than 10 millimeters.

Disclosed are tufted carpet structures, including synthetic turf structures, such as synthetic grass structures, that include a polyurethane backing coating formed from a polyether carbonate polyol.

A process and system for making a laminated surface covering and the surface covering itself are described. The covering includes several layers bonded to each other. The system performs the process. One example of the process includes passing a first material across a first conveyor, passing a second material across a second conveyor, passing a bonding material across a third conveyor, contacting the first material and the second material to the bonding material, and heating at least one of the first material and the second material. The process also includes introducing the first material, the second material, and the bonding material into a pressure zone such that the bonding material is introduced between a bottom surface of the first material and a top surface of the second material. The process applies pressure to bond the first material and second material together via the bonding material to produce a laminated material.

Coconut crumb can serve as an infill material on synthetic turf fields in the place of tire crumb. The crumbs are less than 10 mm big and have smooth corners and edges. The process of producing the coconut crumb involves successive grinding or milling processes that reduce the inner hard shell of the coconut to particles of an appropriate size for infill, while screening out the unwanted material from being included in the infill.

A process and system for making a laminated surface covering and the surface covering itself are described. The covering includes several layers bonded to each other. The system performs the process. One example of the process includes passing a first material across a first conveyor, passing a second material across a second conveyor, passing a bonding material across a third conveyor, contacting the first material and the second material to the bonding material, and heating at least one of the first material and the second material. The process also includes introducing the first material, the second material, and the bonding material into a pressure zone such that the bonding material is introduced between a bottom surface of the first material and a top surface of the second material. The process applies pressure to bond the first material and second material together via the bonding material to produce a laminated material.

The invention comprises a method. The method comprises applying a quantity of an aqueous dispersion of thermoplastic polymer particles to a primary backing and loop backs of a tufted carpet or a tufted synthetic turf, wherein the thermoplastic particles have an average particle size less than 1,000 microns. The method also comprises heating the aqueous dispersion to a temperature sufficient to remove water therefrom, and heating the thermoplastic particles on the primary backing and loop backs to a temperature at or above the melting temperature of the thermoplastic particles. The method further comprises allowing the heated thermoplastic polymer particles to cool below their melting temperature whereby the loop backs are adhered to the primary backing.