Composite open-cell foam structure
AssigneeResilient System, Inc.
InventorJohn Bogdany
Life of this patent
Estimating the term…
Abstract
A carpet underlay cushion structure is provided having a carrier layer of an open-cell, resilient polyurethane foam naterial substantially completely impregnated with a latex such as a non-carboxylated styrene-butadiene rubber or natural rubber, the foam material further having a woven substrate adhered thereto, the impregnated foam material being dried and cured to form a foamed, open-cell, resilient composite cushion structure wherein the open cells thereof partially comprise the carrier layer of polyurethane foam material.
Claims19
A carpet underlay cushion structure comprising:
- a carrier layer of open-cell, resilient polyurethane foam material, said resilient foam material being substantially completely and uniformly impregnated with a latex containing a polymer wherein said polymer is selected from the group consisting of non-carboxylated styrene-butadiene rubber, natural rubber, and a combination of styrene-butadiene and natural rubbers;
- the impregnated foam material being dried after said impregnation to produce a foamed, open-cell, resilient composite cushion structure wherein the open cells thereof partially comprise said carrier layer of polyurethane foam material.
A carpet underlay cushion structure comprising:
- a carrier layer of open-cell, resilient polyurethane foam material, said resilient foam material being substantially completely and uniformly impregnated with a latex containing a polymer and greater than 80 percent total solids content;
- a substrate securely adhered to and extending completely across at least one surface of said impregnated foam material;
- the impregnated foam material and substrate being dried after said impregnation to produce a foamed, open-cell, resilient composite cushion structure wherein the open cells thereof partially comprise said carrier layer of polyurethane foam material.
A method for making a carpet underlay cushion structure comprising:
- applying, onto a carrier layer of open-cell, resilient polyurethane foam material, a latex containing a polymer selected from the group consisting of non-carboxylated styrene-butadiene rubber, natural rubber, and a combination of styrene-butadiene rubber, natural rubber, and a combination of styrene-butadiene rubber and natural rubber;
- substantially completely and uniformly impregnating said carrier layer with said latex;
- pressing a substrate made of a woven material onto a surface of said carrier layer;
- and
- drying and curing said latex to produce a foamed open-cell, resilient polymer structure wherein the open cells thereof partially comprise said foam material.
Dependencies are inferred from the claim text.