Method of manufacturing carpet pads from a polyurethane foam composition

A process of manufacturing padding material for underlying a carpet floor covering, the method comprising the steps of:

• feeding a first liner having a previously cured layer of polyurethane foam material with an exposed surface along a conveyor path;
• depositing an amount of uncured, resilient polymeric foam material on the exposed surface of the first liner as the first liner is fed along the conveyor path so that the foam material is deposited as a generally uniform layer over the exposed surface of the first liner;
• positioning a second liner sheet over the layer of polymeric foam material as the first liner is fed along the conveyor path so that the layer of previously cured polyurethane foam material and uncured polymeric foam material are sandwiched between the first liner and second liner sheet;
• feeding the sandwiched layers of foam material along the conveyor path between a pair of opposite facing parallel conveyor belts which are spaced apart so that the sandwiched layers of polymeric foam material are compressed;
• allowing the uncured polymeric foam layer to at least partly cure as the foam materials are compressed between the conveyor belts to thereby form a foam laminate;
• and
• wherein the previously cured polyurethane foam material is formed by reacting together:
• an organic isocyanate compound;
• organic compound having at least two active hydrogens, the organic compound being selected from the group consisting of organic acids, amines, hydroxy compounds including glycols, polyhydroxy compounds and mixtures thereof;
• a gas providing compound;
• and
• a filler material comprising finely ground used vehicle tires.