US4504537A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Rug underlay comprising open lattice with partially fused needle punched fiber layers
Assignee: No-Muv Corp Inc
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Filing: 1982-12-20
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Granted: 1985-03-12
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Expires: 2002-12-20
Abstract
Abstract A rug underlay comprising a central open lattice of stiffening material, and intermediate layer of fiber batting on each side of the lattice needle punched through the lattice, an upper outer corrugated layer of heat fused fibers, and a lower outer layer of elastomeric material embossed with ridges in a grid design. This article is used as a padding or an underlay for rugs or carpeting in a home or office.
Inventors
- 👤 Charles S. Mussallem, Jr.
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-30 07:10
CPC Classifications
B; B32; B32B; B32B5/00; B32B5/02; B32B5/06; B32B5/22; B32B5/24; B32B5/26; B32B25/00; B32B25/10; B32B25/12; B32B3/00; B32B3/26; B32B3/28; B32B37/00; B32B37/06; B32B37/10; B32B38/00; B32B38/06; D; D06; D06N; D06N7/00; D06N7/0063; D06N7/0089; B32B2262/00; B32B2262/02; B32B2262/0246; B32B2262/0253; B32B2309/00; B32B2309/08; B32B2309/10; B32B2309/105; B32B2471/00; Y; Y10; Y10T; Y10T428/00; Y10T428/23907; Y10T428/2395; Y10T428/23979; Y10T428/24; Y10T428/24479; Y10T428/2457; Y10T428/24612
Claims Analysis
Total Claims: 26
Claim 1
Independent Claim
82 words
A rug underlay comprising a central open lattice of stiffening material, an intermediate layer of fiber batting on each side of the lattice, needle punched through the lattice, the outside surface of one of said intermediate layers including partially heat fused fibers produced by fusing and corrugating the upper surface of one of said intermediate layers and the outside surface of the other of said intermediate layers being covered with a layer of elastomeric material embossed with ridges in a grid design.
Claim 2
Dependent Claim
82 words
A rug underlay comprising a central open lattice of stiffening material, an intermediate layer of fiber batting on each side of the lattice, needle punched through the lattice, the outside surface of one of said intermediate layers including partially heat fused fibers produced by fusing and corrugating the upper surface of one of said intermediate layers and the outside surface of the other of said intermediate layers being covered with a layer of elastomeric material embossed with ridges in a grid design.
Claim 3
Dependent Claim
12 words
A rug underlay of claim 1 wherein said stiffening material is polypropylene.
Claim 4
Dependent Claim
15 words
A rug underlay of claim 1 wherein said fiber batting and said fibers are polypropylene.
Claim 5
Dependent Claim
22 words
A rug underlay of claim 1 wherein said fiber batting and said fibers are a mixture of polypropylene and acrylic polymer fibers.
Claim 6
Dependent Claim
34 words
A rug underlay of claim 1 where said stiffening lattice is incorporated into a central layer of needle punched batting, and an intermediate layer is needle punched into each side of the central layer.
Claim 7
Dependent Claim
44 words
A rug underlay of claim 1 wherein said partially heat fused fibers are produced by applying a heated corrugation-producing surface to said outside surface of one of said intermediate layers to cause melting of the fibers on the heated surface of that intermediate layer.
Claim 8
Dependent Claim
21 words
A rug underlay of claim 1 wherein said layer is a rubbery material embossed with a square grid pattern of ridges.
Claim 9
Dependent Claim
22 words
A rug underlay of claim 7 wherein the rubbery material is a mixture of about 60% natural rubber and 40% synthetic latex.
Claim 10
Dependent Claim
83 words
A rug underlay comprising a central open lattice of stiffening material sandwiched between two compressed needle punched fibrous intermediate layers, the upper outer surface of one of said intermediate layers being partially heat fused fibers produced by fusing and corrugating the upper surface of one of said intermediate layers, and a lower outer layer of a rubbery material as the outside surface of the other of said intermediate layers with an embossed grid pattern on the outside surface of said lower outer layer.
Claim 11
Dependent Claim
83 words
A rug underlay comprising a central open lattice of stiffening material sandwiched between two compressed needle punched fibrous intermediate layers, the upper outer surface of one of said intermediate layers being partially heat fused fibers produced by fusing and corrugating the upper surface of one of said intermediate layers, and a lower outer layer of a rubbery material as the outside surface of the other of said intermediate layers with an embossed grid pattern on the outside surface of said lower outer layer.
Claim 12
Dependent Claim
13 words
A rug underlay of claim 9 wherein said fibrous layers comprise polypropylene fibers.
Claim 13
Dependent Claim
22 words
A rug underlay of claim 10 wherein said fibrous layers consist essentially of a mixture of polypropylene fibers and acrylic polymer fibers.
Claim 14
Dependent Claim
20 words
A rug underlay of claim 9 wherein said central open lattice includes an open square lattice of synthetic plastic filament.
Claim 15
Dependent Claim
12 words
A rug underlay of claim 12 wherein the synthetic plastic is polypropylene.
Claim 16
Dependent Claim
31 words
A rug underlay of claim 9 wherein said fibrous layers are prepared by needle punching a batting of fibers into a contiguous fibrous layer to produce a thin compressed fibrous layer.
Claim 17
Dependent Claim
97 words
A rug underlay comprising a central layer of polypropylene fiber needle punched and compressed into an open lattice, square pattern of polypropylene filament, an intermediate layer of polypropylene fiber on each side of the central layer, needle punched and compressed into the central layer, the outside surface of one of said intermediate layers being a corrugated pattern of partially heat fused fibers, and an outer layer of rubbery material bonded to the outside surface of the other of said intermediate layers, the outside surface of said outer layer being embossed with a square grid pattern of ridges.
Claim 18
Dependent Claim
97 words
A rug underlay comprising a central layer of polypropylene fiber needle punched and compressed into an open lattice, square pattern of polypropylene filament, an intermediate layer of polypropylene fiber on each side of the central layer, needle punched and compressed into the central layer, the outside surface of one of said intermediate layers being a corrugated pattern of partially heat fused fibers, and an outer layer of rubbery material bonded to the outside surface of the other of said intermediate layers, the outside surface of said outer layer being embossed with a square grid pattern of ridges.
Claim 19
Dependent Claim
25 words
A rug underlay of claim 15 wherein each of said needle punched layers of fiber is a mixture of polypropylene fiber and acrylic polymer fiber.
Claim 20
Independent Claim
166 words
A method of preparing a rug underlay which comprises subjecting a stiffening lattice and a first layer of fiber batting to the action of a needle punch press until the fiber batting is intertwined with the lattice and the resulting structure is compressed into a first thin layer, subjecting the opposite surface of the thin layer and a second layer of fiber batting to the action of a needle punch press until the fiber batting is intertwined with the first thin layer and the resulting structure is compressed into a second thin layer slightly thicker than the first thin layer, repeating the previous step sufficient times to successively alternate sides of the resulting layer to produce the desired thickness of a compressed fiber structure, subjecting the upper surface of the compressed fiber structure to heat and pressure to produce a corrugated surface of partially heat fused fibers, and bonding to the lower surface of the compressed fiber structure a grid embossed layer of a rubbery material.
Claim 21
Independent Claim
166 words
A method of preparing a rug underlay which comprises subjecting a stiffening lattice and a first layer of fiber batting to the action of a needle punch press until the fiber batting is intertwined with the lattice and the resulting structure is compressed into a first thin layer, subjecting the opposite surface of the thin layer and a second layer of fiber batting to the action of a needle punch press until the fiber batting is intertwined with the first thin layer and the resulting structure is compressed into a second thin layer slightly thicker than the first thin layer, repeating the previous step sufficient times to successively alternate sides of the resulting layer to produce the desired thickness of a compressed fiber structure, subjecting the upper surface of the compressed fiber structure to heat and pressure to produce a corrugated surface of partially heat fused fibers, and bonding to the lower surface of the compressed fiber structure a grid embossed layer of a rubbery material.
Claim 22
Dependent Claim
17 words
The method of claim 17 wherein the compressed fiber structure is about 1/4 to 1/2 inch thick.
Claim 23
Dependent Claim
36 words
The method of claim 17 wherein said stiffening lattice is a sheet of open lattice spaced polypropylene filaments forming a mesh of small rectangular open spaces between filaments bonded to each other at points of intersection.
Claim 24
Dependent Claim
14 words
The method of claim 17 wherein the fibers of the batting are polypropylene fibers.
Claim 25
Dependent Claim
20 words
The method of claim 17 wherein the fibers of the batting are mixtures of polypropylene fibers and acrylic polymer fibers.
Claim 26
Dependent Claim
21 words
The method of claim 17 wherein the rubbery material is a mixture of about 60% natural rubber and 40% synthetic latex.
References Cited (Backward Citations)
US4360554A
Cited
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1988-03-11 | 1988-09-10 | 1989-03-12 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1992-03-11 | 1992-09-10 | 1993-03-12 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1996-03-11 | 1996-09-10 | 1997-03-12 | $7700.00 | Window Closed / Lapsed |