Resilient composite open-cell foam structure and method of making same
First Claim
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.
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Accused Products
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.
74 Citations
22 Claims
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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. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 22)
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17. A method for making a carpet underlay cushion structure, especially adapted for use as a padding material, comprising:
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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. - View Dependent Claims (18, 19)
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20. A method for making a carpet underlay cushion structure comprising:
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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.
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21. A method for making a carpet underlay cushion structure comprising:
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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.
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Specification