Method for forming bi-layered fiber and foam carpet underlay

Details Method for forming bi-layered fiber and foam carpet underlay Method for forming bi-layered fiber and foam carpet underlay

2007-10-09

2007-10-09

Juska, Cheryl A. (Department: 1771)

Adhesive bonding and miscellaneous chemical manufacture

Methods

Surface bonding and/or assembly therefor

C156S275500, C156S275700, C156S321000

Reexamination Certificate

active

10061845

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.

REFERENCES:
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patent: 5082705 (1992-01-01), Rose
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patent: 6189279 (2001-02-01), Fiechtl
patent: 6253526 (2001-07-01), Murphy et al.
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patent: 2002/0071944 (2002-06-01), Gardner et al.
patent: 2005/0069694 (2005-03-01), Gilder et al.
patent: 2005/0126681 (2005-06-01), Morgan
patent: 2006/0106124 (2006-05-01), Fink et al.

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