Resilient composite open-cell foam structure and method of making same

• US 5,114,773 A
• Filed: 08/17/1990
• Issued: 05/19/1992
• Est. Priority Date: 03/02/1988
• Status: Expired due to Term

• Current Assignee: Columbia Insurance Company (Berkshire Hathaway Incorporated)
• Original Assignee: Resilient Systems Inc. (International Business Machines Corporation)
• Inventors: Bogdany, John
• Primary Examiner(s): VAN BALEN, WILLIAM
• Application Number:
  US07/568,770
• Time in Patent Office: 641 Days
• Field of Search: 427/244, 331/54, 331/170
• US Class Current: 428/95
• CPC Class Codes: A47G 27/0468 Underlays; Undercarpets
• CPC Class Codes: B32B 5/18 characterised by features of a layer of foamed material
• CPC Class Codes: D06N 7/0089 Underlays
• CPC Class Codes: Y10T 428/23979 Particular backing structure or composition
• CPC Class Codes: Y10T 428/249953 Composite having voids in a component [e.g., porous, cellular, etc.]
• CPC Class Codes: Y10T 428/249982 With component specified as adhesive or bonding agent
• CPC Class Codes: Y10T 428/249994 Composite having a component wherein a constituent is liquid or is contained within preformed walls [e.g., impregnant-filled, previously void containing component, etc.]
• CPC Class Codes: Y10T 428/249999 Differentially filled foam, filled plural layers, or filled layer with coat of filling material

Abstract

A carpet underlay cushion structure is provided having a carrier layer of open-cell resilient foam material having an initial thickness, said resilient foam material being substantially completely and uniformly impregnated with an impregnant composition containing a polymer which is cured after said impregnation, wherein the open cells of said carpet underlay cushion structure partially comprise said foam material of said carrier layer, and wherein said cured polymer impregnant retains said carpet underlay cushion structure comprising said carrier layer and said cured polymer impregnant at a finished thickness less than said initial thickness of said carrier layer, and wherein the carpet underlay cushion structure possesses substantially the mechanical and physical properties of the polymer impregnant and wherein said carpet underlay cushion structure retains an open cell configuration at said finished thickness.

Claims

1. A carpet underlay cushion structure comprising:

a carrier layer of open-cell resilient foam material having an initial thickness, said resilient foam material being substantially completely and uniformly impregnated with an impregnant composition containing a polymer which is cured after said impregnation, wherein the open cells of said carpet underlay cushion structure partially comprise said foam material of said carrier layer, and wherein said cured polymer impregnant retains said carpet underlay cushion structure comprising said carrier layer and said cured polymer impregnant at a finished thickness less than said initial thickness of said carrier layer, and wherein the carpet underlay cushion structure possesses substantially the mechanical and physical properties of the polymer impregnant and wherein said carpet underlay cushion structure retains an open cell configuration at said finished thickness.

2. A composite open-cell foam structure as recited in claim 1, wherein said polymer-containing composition comprises a thermosetting resin.

3. A composite open-cell foam structure as recited in claim 1 wherein said polymer-containing composition comprises a thermoplastic polymer.

4. A composite open-cell foam structure as recited in claim 1 wherein said polymer-containing composition is an aqueous solution prior to curing.

5. A composite open-cell foam structure as defined in claim 1 wherein said polymer-containing composition is non-aqueous prior to curing.

6. A composite open-cell foam structure as recited in claim 2 wherein said polymer-containing composition is an aqueous solution prior to curing.

7. A composite open-cell foam structure as defined in claim 2 herein said polymer-containing composition is non-aqueous prior to curing.

8. A composite open-cell foam structure as recited in claim 3 wherein said polymer-containing composition is an aqueous solution prior to curing.

9. A composite open-cell foam structure as defined in claim 3 wherein said polymer-containing composition is non-aqueous prior to curing.

10. A composite open-cell foam structure as recited in claim 1, wherein said carrier layer of open-cell resilient foam material is a polyurethane.

11. A composite open-cell foam structure as recited in claim 1 wherein said thickness of said structure is from about 10% to 90% of said initial thickness of said carrier layer.

12. A composite open-cell foam structure as recited in claim 10 wherein said thickness of said structure is from about 10% to 90% of said initial thickness of said carrier layer.

13. A composite open-cell foam structure as defined in claim 1, wherein said polymer-containing composition comprises polyvinyl chloride.

14. A composite open-cell foam structure as defined in claim 1, wherein said polymer-containing composition comprises PVAC.

15. A composite open-cell foam structure as defined in claim 1, wherein said polymer-containing composition comprises polypropylene.

16. A composite open-cell foam structure as defined in claim 1, wherein said polymer-containing composition comprises vinyl acetate.

22. A carpet underlay cushion structure as recited in claim 1, wherein said structure is bonded to a back of a section of carpet.

17. A method for making a carpet underlay cushion structure, especially adapted for use as a padding material, comprising:

substantially uniformly impregnating a carrier layer of open-cell, resilient foam material with an impregnant comprising a fluid composition containing a polymer, said carrier layer having an initial thickness, thereby forming a composite open-cell foam structure.

then compressing said open-cell composite foam structure comprising said carrier layer impregnated with said fluid composition to a desired thickness while said impregnant is in a state permitting said composite open-cell foam structure to be plastically deformed, and

subsequently releasing from compression said composite open-cell foam structure when said impregnant is in a substantially non-plastically deformable state.

18. A method for making a composite open-cell foam structure as defined in claim 17, wherein said polymer-containing fluid composition comprises a thermosetting resin, and wherein said step of compressing said open-cell composite foam structure is performed at a temperature below a thermosetting temperature of said thermosetting resin, and wherein said subsequent releasing step is performed after said composite open-cell foam structure is heated to a temperature above said thermosetting temperature and held for a time sufficient to allow said resin to be thermoset.

19. A method for making a composite open-cell foam structure as defined in claim 17, wherein said polymer-containing fluid composition comprises a thermoplastic material, and wherein said step of compressing said open-cell composite foam structure is performed when a temperature of said open-cell composite foam structure is above a thermoplastic temperature of said thermoplastic polymer, and wherein said subsequent releasing step is performed when said open-cell composite structure is below said thermoplastic temperature.

20. A method for making a carpet underlay cushion structure comprising:

substantially uniformly impregnating a carrier layer of open-cell resilient foam material with an impregnant comprising a fluid composition containing a thermosetting resin, said carrier layer having an initial thickness, thereby forming a composite open-cell foam structure;

then compressing said composite open-cell foam structure comprising said carrier layer impregnated with said fluid composition to a desired thickness,

heating said composite open-cell foam structure to a temperature above a thermosetting temperature of said thermosetting resin while said composite open-cell foam structure is maintained in compression at said desired thickness;

holding said composite open-cell foam structure in compression at said temperature above said thermosetting temperature for a time sufficient to permit said resin to thermoset; and

subsequently releasing from compression said composite open-cell foam structure.

21. A method for making a carpet underlay cushion structure comprising:

substantially uniformly impregnating a carrier layer of open-cell resilient foam material with an impregnant comprising a fluid composition containing a thermoplastic material, said carrier layer having an initial thickness, thereby forming a composite open-cell foam structure;

heating said composite open-cell foam structure comprising said carrier layer impregnated with said fluid composition to a temperature above a thermoplastic temperature of said thermoplastic material;

then compressing said composite open-cell foam structure to a desired thickness while said structure is at said temperature above said thermoplastic temperature;

cooling said composite open-cell foam structure to a temperature below said thermoplastic temperature; and

subsequently releasing from compression said composite open-cell foam structure.