Composite carpet and foam laminate and method
AssigneeDetroit Gasket and Manufacturing Company
InventorRalph G. Doerfling
Life of this patent
Estimating the term…
Abstract
The method of this disclosure relates to the application of a foam layer, in fluid form, to either an impervious or a relatively porous substrate and to the formation of a contoured foam laminate using a relatively rigid foam. The method of applying foam to a porous substrate includes heating the substrate prior to the application of the fluid foam. Upon striking the heated substrate, the foam forms a blow barrier to prevent foam bleedthrough. The method also optionally includes forming the laminate in a die prior to completion of foaming.The laminate includes a flexible substrate, preferably a polyurethane foam layer and an optional lattice skrim located between the substrate and the exposed surface of the foam layer.
Claims8
An integral carpet-foam laminate, comprising:
- a resilient flexible carpet having a napped side and a relatively smooth backing, a relatively rigid polyurethane foam layer permanently affixed to said carpet backing and a grid-like porous flexible relatively nonresilient skrim located within said polyurethane foam layer with the polyurethane foam continuous through said skrim and located between and spaced from the carpet-polyurethane foam interface and the outer skin of said polyurethane foam layer.
In a method of forming a foam plastic backing on a substrate with a skrim integrally suspended in the plastic backing and located between the backing surface and the backing-substrate interface, the steps of:
- (1) laying a porous, grid-like skrim on a surface of the substrate;
- (2) depositing a foamable plastic material onto the substrate;
- through the grid-like skrim;
- (3) foaming the plastic material and causing the skrim to rise from the surface of the substrate within the foam backing;
- and then
- (4) curing the plastic material to form an integral backing on the substrate, with the skrim located between the exposed, foamed backing surface and the backing-substrate interface and with the foam continuous through the grid-like skrim.
Dependencies are inferred from the claim text.