Patent ID: 7279058
Filing Date: 2007-10-09
Classification: B29C,B32B

Abstract:
1. A method for constructing a three-layer composite carpet cushion underlayment having a foam layer positioned between a film layer and a fiber layer, comprising: providing a layer of film, said layer of film having a first side surface; applying a layer of uncured, heat-reactive foam to said first side surface of said layer of film; said layer of uncured, heat-reactive foam having a first side surface which contacts said first side surface of said layer of film and a second side surface; forming a resiliency-enhanced layer of fibers from a blend of fibers of various types and further comprising shoddy material; applying said layer of fiber to said second side surface of said layer of uncured, heat-reactive foam, said layer of fiber having a first side surface which contacts said second side surface of said layer of uncured, heat-reactive foam; and forming a three-layer composite carpet cushion underlayment by bonding said layer of uncured, heat-reactive foam to said layer of film and to said layer of fiber by curing said uncured, heat-reactive foam to form a layer of cured foam, said curing of said uncured, heat-reactive foam initiated after contact is established between said layer of uncured, heat-reactive foam and said layer of film and between said layer of uncured, heat-reactive foam and said layer of fiber; wherein the bond between said layer of cured foam and said layer of fiber is established generally simultaneously with the bond between said layer of cured foam and said layer of fiber; wherein said layer of cured foam enhances cushioning provided by said three-layer composite carpet cushion underlayment; and wherein said resiliency-enhanced layer of fibers enhances resistance to compression and loft maintenance of said tree-layer composite carpet cushion underlayment.