GB2300593A - Carpet underlay - Google Patents
Carpet underlay Download PDFInfo
- Publication number
- GB2300593A GB2300593A GB9509673A GB9509673A GB2300593A GB 2300593 A GB2300593 A GB 2300593A GB 9509673 A GB9509673 A GB 9509673A GB 9509673 A GB9509673 A GB 9509673A GB 2300593 A GB2300593 A GB 2300593A
- Authority
- GB
- United Kingdom
- Prior art keywords
- carpet underlay
- polymeric material
- grid
- mesh
- underlay according
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Granted
Links
- 239000000463 material Substances 0.000 claims abstract description 44
- 229920001971 elastomer Polymers 0.000 claims abstract description 33
- 239000004753 textile Substances 0.000 claims abstract description 10
- 229920001821 foam rubber Polymers 0.000 claims abstract description 9
- 239000011230 binding agent Substances 0.000 claims abstract description 6
- 229920005830 Polyurethane Foam Polymers 0.000 claims abstract 4
- 239000011496 polyurethane foam Substances 0.000 claims abstract 4
- 229920000728 polyester Polymers 0.000 claims description 14
- 239000003365 glass fiber Substances 0.000 claims description 6
- 239000004816 latex Substances 0.000 claims description 6
- 229920000126 latex Polymers 0.000 claims description 6
- 229920002635 polyurethane Polymers 0.000 claims description 6
- 239000004814 polyurethane Substances 0.000 claims description 6
- 239000011347 resin Substances 0.000 claims description 4
- 229920005989 resin Polymers 0.000 claims description 4
- 239000000835 fiber Substances 0.000 claims description 3
- 239000008187 granular material Substances 0.000 claims description 2
- 239000010410 layer Substances 0.000 description 33
- 238000004519 manufacturing process Methods 0.000 description 6
- 239000000853 adhesive Substances 0.000 description 5
- 230000001070 adhesive effect Effects 0.000 description 5
- 238000010438 heat treatment Methods 0.000 description 5
- 239000013047 polymeric layer Substances 0.000 description 4
- 241000248459 Stentor Species 0.000 description 3
- 150000001875 compounds Chemical class 0.000 description 3
- 238000010276 construction Methods 0.000 description 3
- 239000004743 Polypropylene Substances 0.000 description 2
- 239000011521 glass Substances 0.000 description 2
- 238000009434 installation Methods 0.000 description 2
- 238000000034 method Methods 0.000 description 2
- 230000000704 physical effect Effects 0.000 description 2
- -1 polypropylene Polymers 0.000 description 2
- 229920001155 polypropylene Polymers 0.000 description 2
- 239000004604 Blowing Agent Substances 0.000 description 1
- 240000000491 Corchorus aestuans Species 0.000 description 1
- 235000011777 Corchorus aestuans Nutrition 0.000 description 1
- 235000010862 Corchorus capsularis Nutrition 0.000 description 1
- 229920002209 Crumb rubber Polymers 0.000 description 1
- 240000004752 Laburnum anagyroides Species 0.000 description 1
- 229920002472 Starch Polymers 0.000 description 1
- 238000004026 adhesive bonding Methods 0.000 description 1
- 238000007664 blowing Methods 0.000 description 1
- 238000003490 calendering Methods 0.000 description 1
- 238000001035 drying Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 238000004049 embossing Methods 0.000 description 1
- 239000006261 foam material Substances 0.000 description 1
- 238000009472 formulation Methods 0.000 description 1
- 239000011344 liquid material Substances 0.000 description 1
- 239000000203 mixture Substances 0.000 description 1
- 239000002245 particle Substances 0.000 description 1
- 229920000642 polymer Polymers 0.000 description 1
- 238000004080 punching Methods 0.000 description 1
- 230000002787 reinforcement Effects 0.000 description 1
- 230000000246 remedial effect Effects 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
- 235000019698 starch Nutrition 0.000 description 1
- 239000008107 starch Substances 0.000 description 1
- 239000000758 substrate Substances 0.000 description 1
- 229920001169 thermoplastic Polymers 0.000 description 1
- 239000004416 thermosoftening plastic Substances 0.000 description 1
- 239000002023 wood Substances 0.000 description 1
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B25/00—Layered products comprising a layer of natural or synthetic rubber
- B32B25/04—Layered products comprising a layer of natural or synthetic rubber comprising rubber as the main or only constituent of a layer, which is next to another layer of the same or of a different material
- B32B25/06—Layered products comprising a layer of natural or synthetic rubber comprising rubber as the main or only constituent of a layer, which is next to another layer of the same or of a different material of paper or cardboard
-
- A—HUMAN NECESSITIES
- A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
- A47G—HOUSEHOLD OR TABLE EQUIPMENT
- A47G27/00—Floor fabrics; Fastenings therefor
- A47G27/04—Carpet fasteners; Carpet-expanding devices ; Laying carpeting; Tools therefor
- A47G27/0437—Laying carpeting, e.g. wall-to-wall carpeting
- A47G27/0468—Underlays; Undercarpets
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B25/00—Layered products comprising a layer of natural or synthetic rubber
- B32B25/10—Layered products comprising a layer of natural or synthetic rubber next to a fibrous or filamentary layer
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B29/00—Layered products comprising a layer of paper or cardboard
- B32B29/002—Layered products comprising a layer of paper or cardboard as the main or only constituent of a layer, which is next to another layer of the same or of a different material
- B32B29/007—Layered products comprising a layer of paper or cardboard as the main or only constituent of a layer, which is next to another layer of the same or of a different material next to a foam layer
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B29/00—Layered products comprising a layer of paper or cardboard
- B32B29/02—Layered products comprising a layer of paper or cardboard next to a fibrous or filamentary layer
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B29/00—Layered products comprising a layer of paper or cardboard
- B32B29/08—Corrugated paper or cardboard
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
- B32B3/26—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer
- B32B3/30—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer characterised by a layer formed with recesses or projections, e.g. hollows, grooves, protuberances, ribs
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
- B32B5/028—Net structure, e.g. spaced apart filaments bonded at the crossing points
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/18—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
- B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
- B32B5/245—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it being a foam layer
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
- D06N7/00—Flexible sheet materials not otherwise provided for, e.g. textile threads, filaments, yarns or tow, glued on macromolecular material
- D06N7/0063—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf
- D06N7/0089—Underlays
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
- B32B2262/02—Synthetic macromolecular fibres
- B32B2262/0276—Polyester fibres
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
- B32B2262/10—Inorganic fibres
- B32B2262/101—Glass fibres
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2266/00—Composition of foam
- B32B2266/02—Organic
- B32B2266/0207—Materials belonging to B32B25/00
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2266/00—Composition of foam
- B32B2266/02—Organic
- B32B2266/0214—Materials belonging to B32B27/00
- B32B2266/0278—Polyurethane
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2305/00—Condition, form or state of the layers or laminate
- B32B2305/10—Fibres of continuous length
- B32B2305/18—Fabrics, textiles
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2471/00—Floor coverings
- B32B2471/02—Carpets
Landscapes
- Engineering & Computer Science (AREA)
- Textile Engineering (AREA)
- Laminated Bodies (AREA)
Abstract
A carpet underlay comprises a sheet of resiliently deformable polymeric material (3) having an upper backing layer, e.g. of crepe paper (9) and a grid or mesh (12) of substantially non-stretch, preferably textile material incorporated therein, preferably on its lower face. A release layer (5) may be provided on the lower face of the underlay. The grid prevents stretching of the polymeric material (2 or 3), and means that stitching does not need to be incorporated in the crepe paper. The polymeric material can be formed from rubber crumb incorporated in a binder, sponge rubber, latex foam, or polyurethane foam, and is preferably flat, but could be corrugated, ribbed, grooved, or dimpled.
Description
CARPET VNDERLAY This invention relates to carpet underlay. The invention is particularly concerned with carpet underlay primarily for contract use which incorporates a resilient layer of sponge rubber material, or latex foam and/or reconstituted crumb rubber, located between a backing, which is located on the upper face of the resilient layer, and preferably a release layer on the underside of the resilient layer, known as a facing.
The purpose of the backing is to act as a tensile member, giving reinforcement with respect to break strength, puncture resistance, lack of elongation under load and related properties. Without this tensile layer, the carpet underlay would be difficult, or impossible, to handle, especially since the resilient layer is often ribbed, convoluted or corrugated.
Materials commonly used as backing include woven jute (hessian), non-woven textiles formed from glass, polyester or polypropylene fibres and stitched crepe craft paper. Of these backing materials, the latter, often known as TEXTRON (Registered Trade Mark), is the most common, particularly for high quality products.
TEXTRON stitched craft paper backing has been in production for about 20 years. Whilst details of its specification have changed in minor respects over that period, its basic construction has remained, in principle, unaltered. The TEXTRON material consists of a crepe paper (which is corrugated by a wet or a dry process) into which a plurality of spaced rows of yarns (preferably of polyester) have been stitched to provide a plurality of warps. The warps cross the corrugations and prevent the backing stretching in this direction, whereas the wefts run parallel to or inclined at one or more angles to the corrugations, and prevent stretching in that direction. The
TEXTRON material has an attractive and textile-like appearance, is pleasant to handle, has sufficient bulk, and has an adequate level of physical properties such as tear, break and elongation resistance.However, it is relatively expensive since the polyester stitching cost is high. The stitching process is slow and the yarn is costly when compared to the crepe paper part of the material.
The release layer or facing is usually formed of a very light non-woven, usually spun-bonded polyester textile of the order of 20gms per sq.metre weight. The function of this facing textile layer is to ensure release from the substrate floor when at the end of the installation's working life, the carpet/underlay is peeled up from the adhesive used to maintain its position on the floor. It achieves this, although usually sacrificially disintegrating. The release layer is provided to prevent break up of the sponge rubber. This is a possibility which must be avoided, since if rubber adheres to the floor, its removal is a costly and time-consuming task. Traces of polyester fibre remaining on the floor present no difficulties, since new adhesive can be applied directly over it.
Although the use of spun-bonded polyester on the underside, and stitched creped paper on the upper side, is now established through several years of use, there are some disadvantages. One is in the manufacturing process for the underlay. Since the polyester release layer is very light (dictated by economics), when it is applied to the resilient rubber layer in the production process, elaborate precautions must be taken to avoid creasing, and even with these, high scrap rates may be experienced. Another disadvantage is that on occasions the spun bond polyester fails to disintegrate properly and provide acceptable release at the end of the installation's use, so that some rubber still adheres, requiring remedial work. A further disadvantage is the high cost of the upper backing layer of stitched crepe paper.
These disadvantages are overcome in the present invention in which, according to the broadest aspect, we provide a carpet underlay comprising a sheet of resiliently deformable polymeric material such as rubber having on its upper face a backing which may be formed of crepe paper or the like, and incorporating therein, e.g. on its lower facem a grid or mesh of textile material, which is preferably nonstretchable.
Preferably, the textile material is formed of lightweight glass fibres, having a similar cross-section to the fibres of the known spun-bonded polyester textile fibres of the release layer. However, the glass fibres are very much stronger, and thus perform not only the task of acting as a release layer, but also, being of a non-stretch character, they make it unnecessary for the stitching to be provided in the crepe paper backing, thus considerably reducing the price of this backing layer. It is envisaged that the glass fibres could be PVC coated, or that polyester fibres could be used instead of glass fibres.
In some embodiments, it is preferred that the known spun-bonded polyester fibre release layer be provided as well as the grid or mesh. This assists in release from adherence to a floor, whereas the grid also ensures that traces of the resiliently deformable polymeric layer are not left on the floor.
The polymeric material may be formed from sponge rubber, rubber crumb or granules, recycled from rubber tyres or other sources, supported in a resin, latex, polyurethane, or other binder material, or a polyurethane, either in the form of a slab slit from virgin slab stock, or in reconstituted form (e.g. reconstituted chips bound with a binder, e.g. of polyurethane) or of similar construction, but is preferably sponge rubber or latex foam. Normally, both surfaces of the polymeric material would be substantially flat, although it is envisaged at least one may be corrugated or convoluted, ribbed or grooved.
In the case of sponge rubber, a sheet of uncured unblown rubber compound is callendered, and is then laid upon a support surface, or upon a facing layer on said surface, prior to it being passed through a heating device, e.g. an oven. A backing, e.g. of crepe paper, is applied to the top surface, either on entry into the oven, or part way down the oven. In the oven, the solid (but viscoelastic) compound is blown and cured to form the finished sponge product. This is then removed from the oven and wound up.
If the sponge material is to be convoluted or corrugated, it is preferably passed through the heating device on a chain mat. Blowing occurs in the oven in a generally known manner.
Instead of supporting the viscoelastic unblown, uncured rubber compound on a chain mat, it is envisaged that the mat could be replaced by the grid or mesh, and this could then be used to support and transport the material through the heating device (e.g. oven). For this purpose, the grid or mesh could be in a long (indeterminate) length, and be advanced through the heating device with the aid of a stentor, which would grip the edges of the grid or mesh, and hold it taut. The viscoelastic polymeric material would flow into the apertures in the grid or mesh, prior to curing, and thus leave a pattern on the surface of the final cured, blown sponge rubber. The backing could be applied to the other surface, as described above.
By altering the weave of the grid or mesh, so the pattern on the underside of the final sponge rubber underlay could be selected. It is envisaged that a different density of warp could be provided in the grid or mesh at the centre of the grid or mesh from that at the longitudinal edges.
Preferably, the edges should be stronger than the central region, to assist in transporting the product through the heating device. It is envisaged that dense edge regions could act as selvedges, for gripping by the stentor, and which would not be covered with the unblown, uncured polymeric compound, and which could subsequently be trimmed off and recycled.
In the case of latex foam, a liquid material (latex), which is whipped up to generate gas bubbles and then spread on the backing, e.g. crepe paper, is then fed into an oven generally in known manner. If a ribbed, grooved or wavy surface is desired, the foam material is spread flat on the backing with a contoured comb-like knife, which may be moved to and fro to give a wave-like form to the grooves or waves.
The grid or mesh is applied to the latex material either as it moves into the oven, or after it has moved partly through the oven, and is partially cured.
The mesh or grid can be applied to the polymeric material on its own, or with the release layer. While it is possible to apply these two layers separately, it is preferred to laminate the two webs together beforehand.
This can be done either during manufacture of the grid or mesh, immediately following the gluing together of the wefts and webs, or in a subsequent combining operation, using adhesive. By combining the grid or mesh with the known release layer, the latter becomes easier to handle.
The creped paper on its own (i.e. without stitching) is of low cost and is acceptable to the consumer, but apart from puncture resistance, does not have adequate physical properties. In particular, its resistance to elongation is very poor and the amount by which it stretches when subject to load during underlay manufacture and in fitting is unacceptable. However, by incorporating the grid or mesh in the manufacturing process, stretching is substantially reduced.
Several alternative embodiments of underlay according to the present invention are now described, by way of example only, with reference to the accompanying drawings, in which:
FIGURE 1 is a perspective view, with parts broken away, of a flat sponge rubber underlay according to a first embodiment of the invention;
FIGURE 2 is a section through the underlay shown in
Figure 1; and
FIGURE 3 is a section through a flat underlay formed of rubber crumb bonded with latex according to a second embodiment of the invention.
Referring to the drawings, like components in the various views are identified by the same reference numerals.
In the embodiment of Figure 1, the underlay 1 comprises a flat sheet of sponge rubber 3 having a plain lower surface 5, and a backing 9 in the form of crepe paper attached to its upper surface. On the underside of the flat resilient layer 3 is a facing 15 of spun bonded polyester.
This is a known material, and allows the underlay easily to be released when it is adhered to a floor, e.g. of concrete or wood by the application of adhesive to the underside of the facing 15; when the underlay is pulled up, part of the facing 15 will remain adhered to the floor, and part to the underside of the flat sheet 2 or 3, and very little, if any, of the rubber sheet 2 or 3 will remain adhered to the floor.
Between the facing 15 and the resilient sheet layer 2 or 3, a grid or mesh 12 of textile material is provided.
(This could be provided instead of the facing or release layer 15). This grid 12 is woven from non-stretch fibres, such as glass fibre, and the grid pattern is such that the rectangular (they could have other shapes) apertures are of 2-10mm square. The grid is much stronger than the spunbonded facing 15, and it ensures that only very small quantities of the resilient sheet 2 or 3 can be left on a floor when the underlay has to be removed for replacement.
Furthermore, because of its non-stretch properties, when it has been bonded to the resilient sheet 2 or 3, it prevents stretching, and this in turn means that the crepe paper 9 need not have stitching in it to stop or resist stretching.
This results in a considerable cost saving. However, the crepe paper is required to provide bulk, puncture resistance, and a pleasant appearance.
The underlay shown in Figures 1 and 2 is manufactured by taking a pre-laminated sheet of grid or mesh 12 and facing 15, and laying the facing on a chain or other type of endless support. A calendered sheet of uncured rubber incorporating a blowing agent therein is then laid onto the laminate 12, 15, and shortly prior to the rubber/laminate being fed into an oven, the crepe paper 9 is applied to the top surface. On passing through the oven, the various layers adhere to each other, and the rubber is converted into sponge rubber and cured.
Instead of being formed with a sponge rubber layer 3, the underlay could incorporate a latex foam layer. This would be manufactured by laying a sheet of crepe paper on an endless support, then metering a whipped up latex foam onto the paper layer, and subsequently passing the product through an oven. The grid or mesh layer 12 would be applied on entry of the product into the oven, or while the product is in the oven.
In the alternative embodiment shown in Figure 3, the underlay comprises a resiliently deformable (resilient) polymeric material layer 2 made up of ground-up rubber crumb or particles 6 bonded together with latex, resin, polyurethane, or other binder (not shown).
It will be understood that many variations from the embodiments described with reference to the drawings are possible. Both the crepe paper and the release layer and grid can be of any appropriate weight and the degree of creping can be varied, and the finish and other characteristics can be varied. Virgin pulp, recycled pulp or modified conventional paper formulations containing, for example, polypropylene fibres to enhance tensile and tear strength, can be used for the crepe paper. The crepe paper can be replaced by other paper types similarly treated to texturise, "bulk-up" and improve puncture resistance, e.g.
by embossing, punching, grooving, etc., and the term "crepe" paper should be interpreted accordingly. Furthermore, a wide variety of adhesives will be acceptable. These include starch-based products widely used within the paper industry, thermoplastic types, and a variety of glass and resins from natural sources.
It is also envisaged that the polymeric material could be polyurethane, in sheet form cut from virgin slab stock, or reconstituted.
In the illustrated embodiments, the resilient polymeric material layers 2 and 3 are substantially flat, although the upper faces thereof are shown as having "flowed" into the corrugations of the crepe paper 9.
Whether or not this occurs depends on the state of the polymeric material when it is laid on the paper (or vice versa). Obviously, latex foam laid onto crepe paper 9 will flow into the corrugations. However, if the paper 9 is laid onto the callendered rubber 3 after it is partially cured in the oven, only the tips of the corrugations will adhere to the rubber. However, if the paper 9 is applied to the rubber when the rubber is completely uncured, outside the oven, the product will cook as shown in Figures 1 and 2.
It is envisaged that instead of the polymeric material layer 2 or 3 being substantially flat, it could be convoluted, ribbed or otherwise contoured. This could be achieved using a known process although it is envisaged that it would be difficult to achieve in view of the presence of the web or mesh 12. However, if the facing layer 15 (of spun bonded polyester) was omitted, the lower face of the underlay could be given a dimpled effect by allowing the polymeric material partially to flow through the mesh 12, and designing the endless support means, e.g. chain, for feeding the product into the oven, accordingly.
Instead of using a chain to support the polymeric material, the mesh itself could be used for this purpose.
This could be achieved through the oven using a stentor, and, by selecting various different mesh or grid constructions, different contours or patterns could be formed on the underside of the underlay, as described earlier herein. Basically, the grid or mesh would end up within the underlay, as a result of the uncured polymeric material which eventually forms the sponge rubber flowing partially through the apertures in the grid or mesh.
It is also envisaged that the grid or mesh 12, instead of being on the underface of the polymeric layer, or within it, could be located between the crepe paper backing 9 and the polymeric layer. This would then allow the bottom face of the polymeric layer to be ribbed, corrugated, convoluted or otherwise formed with a particular pattern.
Claims (13)
1. A carpet underlay comprising a sheet of resiliently deformable polymeric material having on its upper face a backing formed of crepe paper or the like, and incorporating therein a grid or mesh of generally non-stretchable material.
2. A carpet underlay according to claim 1, wherein the grid or mesh is on the lower face of the polymeric material.
3. A carpet underlay according to claim 1 or 2, wherein the grid or mesh is formed of a textile material.
4. A carpet underlay according to claim 3, wherein the textile material is formed of lightweight glass fibres.
5. A carpet underlay according to any one of claims 14, wherein a spun-bonded polyester fibre release layer is provided on the lower face thereof.
6. A carpet underlay according to any one of claims 15, wherein the polymeric material is sponge rubber.
7. A carpet underlay according to any one of claims 15, wherein the polymeric material is formed from ground rubber crumb or granules, supported in a resin, latex, polyurethane, or other binder material.
8. A carpet underlay according to any one of claims 15, wherein the polymeric material is a polyurethane foam material.
9. A carpet underlay according to claim 8, wherein the polyurethane foam material is formed from a slab slit from virgin stock.
10. A carpet underlay according to claim 8, wherein the polyurethane foam material is formed from reconstituted chips bound with a binder.
11. A carpet underlay according to any one of claims 15, wherein the polymeric material is latex foam.
12. A carpet underlay according to any one of the preceding claims, wherein a face thereof is corrugated, convoluted, ribbed, grooved, dimpled or formed with another pattern.
13. A carpet underlay substantially as hereinbefore described with reference to Figures 1 and 2 or Figure 3 of the accompanying drawings.
Priority Applications (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
GB9509673A GB2300593B (en) | 1995-05-12 | 1995-05-12 | Carpet underlay |
GB9513716A GB2299781A (en) | 1995-03-29 | 1995-07-05 | Carpet underlay and backing therefor |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
GB9509673A GB2300593B (en) | 1995-05-12 | 1995-05-12 | Carpet underlay |
Publications (3)
Publication Number | Publication Date |
---|---|
GB9509673D0 GB9509673D0 (en) | 1995-07-05 |
GB2300593A true GB2300593A (en) | 1996-11-13 |
GB2300593B GB2300593B (en) | 1998-07-15 |
Family
ID=10774393
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
GB9509673A Expired - Fee Related GB2300593B (en) | 1995-03-29 | 1995-05-12 | Carpet underlay |
Country Status (1)
Country | Link |
---|---|
GB (1) | GB2300593B (en) |
Cited By (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
GB2362098A (en) * | 2000-05-10 | 2001-11-14 | Milliken & Co | Carpet underlay |
NL1028891C2 (en) * | 2005-04-28 | 2006-10-31 | Deco Home Bruins & Heidbuurt V | Carpet underlay, comprises substrate supporting adjacent tiles comprising stiff and resilient layers |
US10604946B2 (en) | 2012-05-10 | 2020-03-31 | Michael Freedman & Associates, Inc. | Method of manufacturing an acoustical flooring tile |
Citations (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US4957798A (en) * | 1988-03-02 | 1990-09-18 | Resilient System, Inc. | Composite open-cell foam structure |
-
1995
- 1995-05-12 GB GB9509673A patent/GB2300593B/en not_active Expired - Fee Related
Patent Citations (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US4957798A (en) * | 1988-03-02 | 1990-09-18 | Resilient System, Inc. | Composite open-cell foam structure |
Cited By (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
GB2362098A (en) * | 2000-05-10 | 2001-11-14 | Milliken & Co | Carpet underlay |
NL1028891C2 (en) * | 2005-04-28 | 2006-10-31 | Deco Home Bruins & Heidbuurt V | Carpet underlay, comprises substrate supporting adjacent tiles comprising stiff and resilient layers |
US10604946B2 (en) | 2012-05-10 | 2020-03-31 | Michael Freedman & Associates, Inc. | Method of manufacturing an acoustical flooring tile |
Also Published As
Publication number | Publication date |
---|---|
GB9509673D0 (en) | 1995-07-05 |
GB2300593B (en) | 1998-07-15 |
Similar Documents
Publication | Publication Date | Title |
---|---|---|
US3655501A (en) | Flexible materials | |
ES2634916T5 (en) | A panel comprising a polymeric composite layer and a reinforcing layer | |
US3528874A (en) | Heat-insulating fabric and method of preparing it | |
KR100206690B1 (en) | Low stretch and dimensionally stable floor covering | |
US6013342A (en) | Self-adhesive sheet with non-slip properties | |
US20080261004A1 (en) | Textile Surface Coverings and Methods for Making Them | |
US20070286982A1 (en) | Surface coverings and methods | |
ATE140373T1 (en) | PATTERNED, TUFTED, FUSS BONDED CARPET AND CARPET FLOW AND METHOD FOR THEIR PRODUCTION | |
US5174228A (en) | Non-woven reinforcement structure | |
US20040170799A1 (en) | Heat-insulating material and method of making the same | |
US3755051A (en) | High-loft, nonwoven paneling material and covering | |
CN101501271A (en) | Surface coverings and methods | |
GB2300593A (en) | Carpet underlay | |
EP0912341B1 (en) | Method for producing a composite material and material obtained by means of said method | |
US3705063A (en) | Method of producing high-loft,nonwoven paneling material and covering | |
US20230234329A1 (en) | Decorative panel comprising a textile decorative layer | |
GB2299293A (en) | Carpet underlay and backing therefor | |
GB2299781A (en) | Carpet underlay and backing therefor | |
KR200242887Y1 (en) | Bubble type hollow panel | |
US20240068243A1 (en) | Dimensionally stable floor covering and method for the production thereof | |
US3649433A (en) | Parallel strand reinforced cellular floor covering | |
WO1999055954A2 (en) | Floor covering with inverted tufted or sewn face | |
CA1222683A (en) | Floatable sheet material and method of making | |
JPH05133082A (en) | Sound insulating floor material | |
JPS62500442A (en) | Coated abrasive sheet material with superior base material |
Legal Events
Date | Code | Title | Description |
---|---|---|---|
732E | Amendments to the register in respect of changes of name or changes affecting rights (sect. 32/1977) | ||
PCNP | Patent ceased through non-payment of renewal fee |
Effective date: 20030512 |