US4957798A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Composite open-cell foam structure
Assignee: Columbia Insurance Co
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Filing: 1989-03-31
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Granted: 1990-09-18
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Expires: 2009-03-31
Abstract
Abstract A carpet underlay cushion structure is provided having a carrier layer of an open-cell, resilient polyurethane foam naterial substantially completely impregnated with a latex such as a non-carboxylated styrene-butadiene rubber or natural rubber, the foam material further having a woven substrate adhered thereto, the impregnated foam material being dried and cured to form a foamed, open-cell, resilient composite cushion structure wherein the open cells thereof partially comprise the carrier layer of polyurethane foam material.
Inventors
- 👤 John Bogdany
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-03 17:41
CPC Classifications
A; A47; A47G; A47G27/00; A47G27/04; A47G27/0437; A47G27/0468; B; B32; B32B; B32B5/00; B32B5/22; B32B5/24; B32B5/245; B32B27/00; B32B27/40; B32B5/02; B32B5/024; B32B5/18; D; D06; D06N; D06N7/00; D06N7/0063; D06N7/0089; B32B2260/00; B32B2260/04; B32B2260/048; B32B2266/00; B32B2266/02; B32B2266/0214; B32B2266/0278; B32B2266/06; B32B2305/00; B32B2305/02; B32B2305/022; B32B2307/00; B32B2307/50; B32B2307/51; B32B2317/00; B32B2317/22; B32B2319/00; B32B2375/00; B32B2471/00; B32B2471/02; D06N2203/00; D06N2203/06; D06N2203/068; D06N2205/00; D06N2205/04; Y; Y10; Y10T; Y10T428/00; Y10T428/23907; Y10T428/23979; Y10T428/249921; Y10T428/249953; Y10T428/249982; Y10T428/249994; Y10T428/249999
Claims Analysis
Total Claims: 22
Claim 1
Independent Claim
86 words
A carpet underlay cushion structure comprising: a carrier layer of open-cell, resilient polyurethane foam material, said resilient foam material being substantially completely and uniformly impregnated with a latex containing a polymer wherein said polymer is selected from the group consisting of non-carboxylated styrene-butadiene rubber, natural rubber, and a combination of styrene-butadiene and natural rubbers; the impregnated foam material being dried after said impregnation to produce a foamed, open-cell, resilient composite cushion structure wherein the open cells thereof partially comprise said carrier layer of polyurethane foam material.
Claim 2
Dependent Claim
86 words
A carpet underlay cushion structure comprising: a carrier layer of open-cell, resilient polyurethane foam material, said resilient foam material being substantially completely and uniformly impregnated with a latex containing a polymer wherein said polymer is selected from the group consisting of non-carboxylated styrene-butadiene rubber, natural rubber, and a combination of styrene-butadiene and natural rubbers; the impregnated foam material being dried after said impregnation to produce a foamed, open-cell, resilient composite cushion structure wherein the open cells thereof partially comprise said carrier layer of polyurethane foam material.
Claim 3
Dependent Claim
31 words
A carpet underlay cushion structure as defined in claim 1 further comprising a substrate securely adhered to said impregnated foam material, said substrate extending completely across at least one surface thereof.
Claim 4
Dependent Claim
32 words
A carpet underlay cushion structure as defined in claim 2 wherein said substrate is adhered to said foam material by an adhesive, said adhesive being a component independent of said polymer latex.
Claim 5
Dependent Claim
33 words
A carpet underlay cushion structure as defined in claim 2 wherein said substrate is adhered to said foam material by said polymer once said latex in said carpet underlay cushion structure is dried.
Claim 6
Dependent Claim
25 words
A carpet underlay cushion structure as defined in claim 4 wherein said substrate is substantially completely covered by said polymer when said latex is dried.
Claim 7
Dependent Claim
23 words
A carpet underlay cushion structure as defined in claim 5 wherein said polymer contained in said latex consists essentially of non-carboxylated styrene-butadiene rubber.
Claim 8
Dependent Claim
26 words
A carpet underlay cushion structure as defined in claim 6 wherein said carrier layer has a thickness in the range of about 80 to 650 mils.
Claim 9
Dependent Claim
27 words
A carpet underlay cushion structure as defined in claim 7 wherein said carrier layer has an initial density of less than about 1.5 pounds per cubic foot.
Claim 10
Dependent Claim
28 words
A carpet underlay cushion structure as defined in claim 5 wherein said polymer contained in said latex consists essentially of a combination of styrene-butadiene rubber and natural rubber.
Claim 11
Dependent Claim
26 words
A carpet underlay cushion structure as defined in claim 9 wherein said carrier layer has a thickness in the range of about 80 to 650 mils.
Claim 12
Dependent Claim
27 words
A carpet underlay cushion structure as defined in claim 10 wherein said carrier layer has an initial density of less than about 1.5 pounds per cubic foot.
Claim 13
Dependent Claim
91 words
A carpet underlay cushion structure comprising: a carrier layer of open-cell, resilient polyurethane foam material, said resilient foam material being substantially completely and uniformly impregnated with a latex containing a polymer and greater than 80 percent total solids content; a substrate securely adhered to and extending completely across at least one surface of said impregnated foam material; the impregnated foam material and substrate being dried after said impregnation to produce a foamed, open-cell, resilient composite cushion structure wherein the open cells thereof partially comprise said carrier layer of polyurethane foam material.
Claim 14
Dependent Claim
91 words
A carpet underlay cushion structure comprising: a carrier layer of open-cell, resilient polyurethane foam material, said resilient foam material being substantially completely and uniformly impregnated with a latex containing a polymer and greater than 80 percent total solids content; a substrate securely adhered to and extending completely across at least one surface of said impregnated foam material; the impregnated foam material and substrate being dried after said impregnation to produce a foamed, open-cell, resilient composite cushion structure wherein the open cells thereof partially comprise said carrier layer of polyurethane foam material.
Claim 15
Dependent Claim
20 words
A carpet underlay cushion structure as defined in claim 12 wherein said polymer in said latex comprises non-carboxylated styrene-butadiene rubber.
Claim 16
Dependent Claim
19 words
A carpet underlay cushion structure as defined in claim 12 wherein said polymer in said latex comprises natural rubber.
Claim 17
Dependent Claim
25 words
A carpet underlay cushion structure as defined in claim 12 wherein said polymer in said latex comprises a combination of styrene-butadiene rubber and natural rubber.
Claim 18
Independent Claim
104 words
A method for making a carpet underlay cushion structure comprising: applying, onto a carrier layer of open-cell, resilient polyurethane foam material, a latex containing a polymer selected from the group consisting of non-carboxylated styrene-butadiene rubber, natural rubber, and a combination of styrene-butadiene rubber, natural rubber, and a combination of styrene-butadiene rubber and natural rubber; substantially completely and uniformly impregnating said carrier layer with said latex; pressing a substrate made of a woven material onto a surface of said carrier layer; and drying and curing said latex to produce a foamed open-cell, resilient polymer structure wherein the open cells thereof partially comprise said foam material.
Claim 19
Independent Claim
104 words
A method for making a carpet underlay cushion structure comprising: applying, onto a carrier layer of open-cell, resilient polyurethane foam material, a latex containing a polymer selected from the group consisting of non-carboxylated styrene-butadiene rubber, natural rubber, and a combination of styrene-butadiene rubber, natural rubber, and a combination of styrene-butadiene rubber and natural rubber; substantially completely and uniformly impregnating said carrier layer with said latex; pressing a substrate made of a woven material onto a surface of said carrier layer; and drying and curing said latex to produce a foamed open-cell, resilient polymer structure wherein the open cells thereof partially comprise said foam material.
Claim 20
Dependent Claim
24 words
A method as recited in claim 16 further comprising applying an adhesive to said substrate prior to pressing said substrate onto said carrier layer.
Claim 21
Dependent Claim
20 words
A method as recited in claim 17 wherein said application of said latex is accomplished by a reverse roll application.
Claim 22
Dependent Claim
42 words
A method as recited in claim 18 wherein said impregnation of said carrier layer is accomplished by passing said carrier layer, after said latex has been applied, through a pair of squeeze rolls which compress said carrier layer by a predetermined amount.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1993-09-17 | 1994-03-19 | 1994-09-18 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1997-09-17 | 1998-03-19 | 1998-09-18 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2001-09-17 | 2002-03-19 | 2002-09-18 | $7700.00 | Window Closed / Lapsed |