Patent ID: 7785437

Claim:
A method, for making rebonded carpet pad, comprising: mixing zinc pyrithione with a polyol to form an antimicrobial polyol mixture concentrate; blending the antimicrobial polyol mixture concentrate with a binder stream to form a binder; selecting a percentage of zinc pyrithione mixed with the polyol and an addition ratio of the antimicrobial polyol mixture concentrate with the binder stream to provide an overall concentration of zinc pyrithione in the binder of at least about 7500 ppm; mixing the binder with foam particles; shaping the mixture of binder and foam particles into a block, curing the binder and slicing the block to a thickness to form carpet pad; and laminating a 0.45 to 0.5 mil monolayer blown film to at least one side of the carpet pad; wherein laminating a film to at least one side of the carpet pad comprises: forming an 0.45 to 0.5 mil monolayer blown film; and thermally laminating the film to at least one side of the carpet pad; wherein the film comprises an effective amount of an antimicrobial compound, and wherein the antimicrobial compound comprises zinc pyrithione; and wherein the net effective concentration of zinc pyrithione in the film is from about 500 ppm to 850 ppm.