An aqueous polyurethane dispersion includes particles of polyurethane in water, wherein the polyurethane is derived from an organic diisocyanate, a hydrophilic monomer, a neutralizer, a chain extender, and a polyester resin, the polyester resin being a random copolymer having randomly distributed subunits of formula 1: ##STR00001##
where: R is ethylene, octylene, or decylene, a is from about 40 to about 100 mole % of the polyester resin, b is from 0 to about 30 mole % of the polyester resin, c is from 0 to about 30 mole % of the polyester resin, and a+b+c=100 mole % of the polyester resin.

Textiles backed with a polyurethane cushion are produced by applying a layer of frothed polyurethane-forming mixture to a surface of the textile. The mixture contains both water and a physical blowing agent. The layer expands due to the action of the water and the physical blowing agent and cures to form an attached cushion having a density of 176 g/L or less.

An internally emulsified polyurethane dispersion, which is prepared by using a combined chain extender system of a hydrophilic amino siloxane compound and a polyetheramine compound, is provided. The internally emulsified polyurethane dispersion can be used to prepare a synthetic leather product having good anti-stickiness, wrinkle resistance, color fastness and superior mechanical properties. A laminated synthetic leather article prepared with said internally emulsified polyurethane dispersion as well a method for preparing the synthetic leather article are also provided.

A task to be achieved by the invention is to provide a foamed sheet having excellent retention of foam, hand feeling, and peel strength. The present invention provides a foamed sheet which is formed from a water dispersion of a urethane resin (X), wherein the water dispersion has a urethane resin (X) content of 50 to 80% by mass, and the water dispersion contains no organic solvent. Further, the present invention provides a synthetic leather having at least a substrate (i) and a polyurethane layer (ii), wherein the polyurethane layer (ii) is formed from the above-mentioned foamed sheet. The foamed sheet preferably has a density of 200 to 1,000 kg/m.sup.3.

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.

A waterborne polyurethane dispersion for the polyurethane foam of synthetic leather application, derived from (1) a prepolymer derived from the reaction of reactants comprising at least one aromatic isocyanate compound, an ethylene oxide-capped polyether triol, at least one polyether diol, and at least one polyester diol; (2) water; and (3) surfactant, is disclosed. The waterborne polyurethane dispersion can be used to prepare a synthetic leather product having superior wrinkle resistance, hand-feeling and peel strength. A synthetic leather article prepared with said waterborne polyurethane dispersion is also disclosed.

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.

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 precoat composition, a carpet composition comprising the inventive precoat composition layer and methods of making same are disclosed. The inventive precoat composition comprises a thermoplastic dispersion and a filler. The carpet composition comprising the inventive precoat layer exhibits exceptional wet delamination strength.

A method for making an artificial turf, the method comprising: providing a carrier (308) and an artificial turf fiber (501) incorporated into the carrier such that a first portion of the artificial turf fiber (506) protrudes to a back side of the carrier, a second portion of the artificial turf fiber (302) protrudes to a front side of the carrier, and a third portion of the artificial turf fiber (504) is inside the carrier; preparing a polyurethane (PU) foam reaction mixture (210) containing a reactive foam stabilizer (RFS), applying the PU foam reaction mixture on the back side of the carrier (308) to cover the artificial turf fiber (506) protruding to the back side of the carrier (308) and hardening the PU foam reaction mixture to form a flexible PU backing securing the turf fiber in place.