Method of producing a bio-based carpet material

1. A method of making a carpet material comprising:

providing tufts, a primary backing material, and a pre-coat wherein the pre-coat material 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 vegetable oil, a pre-coat cross-linker, and a pre-coat catalyst;

engaging the tufts and the primary backing thereby forming griege goods having a top and bottom surface;

applying the pre-coat onto the bottom surface of the griege goods; and

curing the pre-coat.

2. The method of claim 1 further comprising:

providing a backing material 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 a backing material vegetable oil, a backing material cross-linker and a backing material catalyst; and

applying the backing material to the bottom surface of the griege goods.

3. The method of claim 2 further providing curing the backing material.

4. The method of claim 3 , comprising subjecting the griege goods to a bow and weft straightening station thereby straightening the tufts.

5. The method of claim 2 , wherein the pre-coat material is cured using a curing oven.

6. The method of claim 5 , wherein the curing oven temperature is about 180° F. to about 220° F.

7. The method of claim 5 , wherein the curing oven generates heat electrically.

8. The method of claim 5 , wherein the curing oven generates heat using a fossil fuel.

9. The method of claim 2 , wherein the application of the pre-coat is applied to the griege goods by spraying of the pre-coat A-side and the pre-coat B-side onto the bottom surface of the griege goods.

10. The method of claim 2 , wherein the backing material vegetable oil comprises a blown vegetable oil.

11. The method of claim 2 , wherein a first bed plate and a first doctor blade level the pre-coat.

12. The method of claim 11 , wherein a second bed plate and a second doctor blade level the backing material.

13. The method of claim 2 , wherein the application of the pre-coat comprises spraying the pre-coat A-side and the pre-coat B-side onto the bottom surface of the griege goods.

14. The method of claim 13 , wherein the application of the backing material comprises spraying the backing material A-side and the backing material B-side onto the bottom surface of the griege goods.

15. The method of claim 2 , wherein an adhesive is applied to the bottom surface of the griege goods.

16. The method of claim 15 , 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 claim 1 , wherein the pre-coat vegetable oil comprises at least one vegetable oil chosen from the group consisting of palm oil, safflower oil, sunflower oil, canola oil, rapeseed oil, cottonseed oil, linseed oil, and coconut oil.

19. The method of claim 1 , wherein the pre-coat vegetable oil comprises a blown vegetable oil.

20. The method of claim 1 , wherein the backing material vegetable oil comprises at least one vegetable oil chosen from the group consisting of palm oil, safflower oil, sunflower oil, canola oil, rapeseed oil, cottonseed oil, linseed oil, and coconut oil.

21. The method of claim 1 , wherein the pre-coat cross-linker comprises at least one cross-linker chosen from the group consisting of ethylene glycol, 1,4 butanediol, diethanol amines, ethanol amines, tripropylene glycol, and aliphatic amine tetrol.

22. The method of claim 21 , wherein the backing material cross-linker comprises at least one cross-linker chosen from the group consisting of ethylene glycol, 1,4 butanediol, diethanol amines, ethanol amines, tripropylene glycol, and aliphatic amine tetrol.

23. The method of claim 1 further comprising:

providing a backing material 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 a polyol derived from petroleum; and

applying the backing material to the bottom surface of the griege goods.

24. The method of claim 23 further comprising curing the backing material.

25. The method of claim 23 , wherein the pre-coat material is cured using a curing oven.

26. The method of claim 25 , wherein the curing oven temperature is about 180° F. to about 2200° F.

27. The method of claim 25 , wherein the curing oven generates heat electrically.

28. The method of claim 25 , wherein the curing oven generates heat using a fossil fuel.

29. The method of claim 23 , comprising subjecting griege goods to a bow and weft straightening station thereby straightening the tufts.

30. The method of claim 23 , wherein the application of the pre-coat is applied to the griege goods by spraying of the pre-coat A-side and the pre-coat B-side onto the bottom surface of the griege goods.

31. The method of claim 23 , wherein the pre-coat vegetable oil comprises at least one vegetable oil chosen from the group consisting of palm oil, safflower oil, sunflower oil, canola oil, rapeseed oil, cottonseed oil, linseed oil, and coconut oil.

32. The method of claim 23 , wherein the pre-coat vegetable oil comprises a blown vegetable oil.

33. The method of claim 23 , wherein the backing material vegetable oil comprises at least one vegetable oil chosen from the group consisting of palm oil, safflower oil, sunflower oil, canola oil, rapeseed oil, cottonseed oil, linseed oil, and coconut oil.

34. The method of claim 23 , wherein the backing material vegetable oil comprises a blown vegetable oil.

35. The method of claim 23 , wherein a first bed plate and a first doctor blade level the pre-coat.

36. The method of claim 35 , wherein a second bed plate and a second doctor blade level the backing material.

37. The method of claim 23 , wherein the application of the pre-coat comprises spraying the pre-coat A-side and the pre-coat B-side onto the bottom surface of the griege goods.

38. The method of claim 37 , wherein the application of the backing material comprises spraying the backing material A-side and the backing material B-side onto the bottom surface of the griege goods.

39. The method of claim 23 , wherein the backing material B-side further comprises a cross-linker and a catalyst.

40. The method of claim 1 further comprising:

providing a backing material comprising the reaction product of a backing material A-side comprising a backing material isocyanate and a backing material B-side comprising the reaction product of an esterified polyol and a backing material vegetable oil wherein the esterified polyol comprises the reaction product of a first multifunctional compound and a second multifunctional compound; and

applying the backing material to the bottom surface of the griege goods.

41. The method of claim 40 , wherein the backing material vegetable oil comprises a blown vegetable oil.

42. The method of claim 40 , wherein the backing material vegetable oil comprises at least one vegetable oil chosen from the group consisting of palm oil, safflower oil, sunflower oil, canola oil, rapeseed oil, cottonseed oil, linseed oil, and coconut oil.

43. The method of claim 40 , wherein the pre-coat cross-linker comprises at least one cross-linker chosen from the group consisting of ethylene glycol, 1,4 butanediol, diethanol amines, ethanol amines, tripropylene glycol, and aliphatic amine tetrol.