US 7,678,719 B2 · Method for forming bi-layered fiber and foam carpet underlay

Abstract

The present invention relates to a method for forming a bi-layered carpet underlay. More particularly, the method includes bonding a layer of non-woven fibers and a layer of re-bonded foam particles together to form the bi-layered carpet underlay. The layers of the carpet underlay can be bonded together with the use of adhesives, by heating a surface of one or both layers to a soft bondable state for lamination between the layers, by applying a film having adhesive surfaces between the layers, or by other suitable bonding means. The bi-layered carpet underlay combines the soft cushioning resilience of foam with the high durability bridging ability of fiber to provide a carpet underlay that maintains its height or thickness and firmness, while imparting softness and cushioning effects over an extended period of wear.

Claims16

Dependent claims

A bi-layered carpet underlay comprising:

a cured layer of re-bonded foam particles, having a thickness suitable for providing soft cushioning resilience and a surface;
and
a thermal bonded non-woven fiber batt, having a thickness suitable for providing durable cushioning support and a surface;
wherein:
said layer of re-bonded foam particles and said non-woven fiber batt each are at least about ¼ inch thick;
said non-woven fiber batt comprises a homogeneous blend of carrier and binder fibers, said binder fibers comprising between about five percent by volume and about fifty percent by volume of said homogeneous blend;
and
said surface of said nonwoven fiber batt is disposed against and bonded to said surface of said cured layer of re-bonded foam.

5 more elements

Dependencies are inferred from the claim text.

Facts

Application

11/858,691Filed 20 Sep 2007 · continuation

Priority

30 Jan 2001

Published

US 2008/0008862 A110 Jan 2008

Granted

16 Mar 2010

Term ends

Not estimatedThe source records don’t support an estimate.

Classification24 codes

B32B 37/12
Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding: characterised by using adhesives
A47G 27/0468
Laying carpeting, e.g. wall-to-wall carpeting: underlays; Undercarpets
D06N 7/0089
Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs,…:…
B32B 37/04
Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding: characterised by the partial melting of at least one layer

Family

Application60/265,003Us provisional application · filed 30 Jan 2001

Application10/061,845Parent of this continuation · filed 30 Jan 2002

US 2008/0008862 A1Pre-grant publication · published 10 Jan 2008

US 7,279,065 B1Parent of this continuation

US 7,678,719 B2This patent

From the US filing history. Foreign family members aren’t listed.

Method for forming bi-layered fiber and foam carpet underlay

Life of this patent

Method for forming bi-layered fiber and foam carpet underlay

Life of this patent

Abstract

Claims16