Patent ID: 7638008

Claim:
A method for preparing carpet using a polyurethane annealing system having a puddle of a polyurethane mixture supported by both a drive roller and an application roller spaced apart transversely above a greige, the greige having a face and an opposed backstitched side, said process annealing a secondary backing to the greige by: (a) introducing polyol from a first source and isocyanate from a second source, together with a filler and a catalyst to create a polyurethane mixture; (b) creating a puddle of the polyurethane mixture contacting both the application roller and the drive roller above the backstitch side of the greige; (c) applying said polyurethane mixture with both of the application roller and the driver roller as the greige is moved laterally with respect to the rollers to form a coating on the backstitch side of the greige that begins to cure into a polyurethane foam; and (d) contacting a secondary backing to the polyurethane mixture coated backstitch side of the greige.