Patent ID: 6478995
Filing Date: 2002-11-12
Classification: A47L,B29C,B32B,Y10T

Abstract:
A method of forming a cushioned floor covering article comprising the steps of(a) laying at least one rubber sheet optionally comprising a blowing agent to form a closed-cell foam rubber structure upon vulcanization on one side of a die having at least a first and second side, wherein said die has portions thereof removed to allow for the entry of molten rubber, wherein said removed portions of said die include openings within both of said first and second side, and wherein said die is comprised of a material which can withstand vulcanization temperatures and pressures; (b) laying a carrier fabric having a tufted pile surface extending from one side of the carrier fabric onto said at least one rubber sheet of step â€œaâ€ , wherein the side of said carrier fabric from which said tufted pile does not extend is in contact with said at least one rubber sheet; (c) optionally, placing solid rubber reinforcing strips around at least one of the border edges of the rubber sheet; and (d) subjecting the composite comprising the at least one rubber sheet, the die, the carrier fabric, and the optional reinforcing strips to vulcanization temperatures and pressures to (1) attach said at least one rubber sheet to the side of the carrier fabric from which the pile surface does not extend, and (2) to form at least one integrated rubber protrusion through the removed portions of the die.