Method of applying a theromplastic polymer coating

1. A method comprising:

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;

heating the aqueous dispersion to a temperature sufficient to remove water therefrom;

heating the thermoplastic particles on the primary backing and loop backs to a temperature at or above the melting temperature of the thermoplastic particles;

placing a secondary backing in contact with the heated thermoplastic polymer particles on the primary backing; and

allowing the heated thermoplastic polymer particles to cool below their melting temperature whereby the primary and secondary backings are adhered together.

2. The method of claim 1 , wherein the thermoplastic polymer particles have a particle size of approximately 1 micron to approximately 100 microns.

3. The method of claim 1 , wherein the thermoplastic polymer particles have an average particle size of approximately 1 micron to approximately 80 microns.

4. The method of claim 1 , wherein the aqueous dispersion comprises:

approximately 50% to approximately 90% by weight water;

approximately 1% to approximately 10% by weight dispersion agent; and

approximately 5% to approximately 40% by weight thermoplastic polymer particles.

5. The method of claim 4 , wherein the aqueous dispersion further comprises one or more of a plasticizer, a foaming agent, a thickener, a lubricant, a wetting agent, a colorant, a fire retardant or filler.

6. The method of claim 1 , wherein the aqueous dispersion comprises:

approximately 60% to approximately 80% by weight water;

approximately 3% to approximately 5% by weight dispersion agent; and

approximately 20% to approximately 40% by weight thermoplastic polymer particles.

7. The method of claim 1 , wherein the aqueous dispersion comprises:

approximately 65% to approximately 67% by weight water;

approximately 3% to approximately 5% by weight dispersion agent; and

approximately 30% by weight thermoplastic polymer particles.

8. The method of claim 1 , wherein the step of heating the aqueous dispersion to remove water therefrom comprises heating to a temperature of approximately 150° F. to approximately 350° F.

9. The method of claim 1 , wherein the step of heating the aqueous dispersion to remove water therefrom comprises heating to a temperature of approximately 175° F. to approximately 275° F.

10. The method of claim 1 , wherein the step of heating the aqueous dispersion to remove water therefrom comprises heating to a temperature of approximately 212° F.

11. The method of claim 1 , wherein the thermoplastic polymer particles comprise polypropylene, polyethylene, thermoplastic polyester, polystyrene, polyvinylchloride, thermoplastic polyurethanes, thermoplastic copolymers thereof or mixtures thereof.

12. The method of claim 1 , wherein the thermoplastic polymer particles are recycled polymers.

13. The method of claim 1 , wherein the aqueous dispersion is applied to the primary backing and the loop backs in the form of a foam.

14. A method comprising:

preparing a foam of an aqueous dispersion of thermoplastic polymer particles, wherein the thermoplastic polymer particles have a particle size of approximately 50 microns to approximately 100 microns;

applying a quantity of the foamed aqueous dispersion to a primary backing and loop backs of a tufted carpet or tufted synthetic turf;

heating the aqueous dispersion on the primary backing and loop backs to a temperature sufficient to remove water therefrom;

heating the thermoplastic particles on the primary backing and loop backs to a temperature at or above their melting temperature;

cooling the heated thermoplastic polymer particles to below their melting temperature whereby the loop backs are adhered to the primary backing; and

applying a secondary backing to the primary backing while the thermoplastic particles are still at or above their melting temperature.

15. The method of claim 14 , wherein the step of heating the aqueous dispersion to a temperature sufficient to remove water therefrom comprises heating to a temperature of approximately 212° F. to approximately 350° F.

16. The method of claim 14 , wherein the step of heating the aqueous dispersion to a temperature sufficient to remove water therefrom comprises heating to a temperature of approximately 212° F. to approximately 275° F.

17. The method of claim 16 , wherein the thermoplastic polymer particles comprise polypropylene, polyethylene, polyester, polystyrene, polyvinylchloride, thermoplastic polyurethanes, thermoplastic copolymers thereof or mixtures thereof.

18. A method comprising:

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 of approximately 1 micron to approximately 1,000 microns;

heating the aqueous dispersion to a temperature sufficient to remove water therefrom;

heating the thermoplastic particles on the primary backing and loop backs to a temperature at or above the melting temperature of the thermoplastic particles;

placing a secondary backing in contact with the heated thermoplastic polymer particles on the primary backing; and

allowing the heated thermoplastic polymer particles to cool below their melting temperature whereby the primary and secondary backings are adhered together.

19. The method of claim 18 , wherein the thermoplastic polymer particles have an average particle size of approximately 10 microns to approximately 1,000 microns.