Patent ID: 7279065

Claim:
A method for forming a bi-layered carpet underlay suitable for installation between a subfloor and a carpet, the method comprising: forming a homogeneous blend of fibers comprised of carrier fibers and binder fibers, said binder fibers comprising between about five percent by volume and about fifty percent by volume of said homogeneous blend of fibers; forming a non-woven fiber batt from said homogeneous blend of fibers, wherein formation of said non-woven fiber batt comprises bonding binder fibers to each other and to carrier fibers, said non-woven fiber batt having a surface; providing a cured layer of re-bonded foam particles, said cured layer of re-bonded foam particles having a surface; applying an adhesive to said surface of said non-woven fiber batt or to said surface of said cured layer of re-bonded foam particles; disposing said surface of said non-woven fiber batt with said surface of said cured layer of re-bonded foam particles; and bonding said surface of said non-woven fiber batt to said surface of said cured layer of re-bonded foam particles to form a bi-layered carpet underlay.