Patent Application
20090047464
This invention relates to underlay for floor carpets, particularly foam based underlay, process of manufacture, thereof, and apparatus for use in said process.
Typical underlay or underpads for floor carpets is formed of a foam material, particularly, a polyurethane foam, either as virgin material, or as reclaimed and recycled material. The latter material is generally termed “chipfoam” and comprises small pieces or fragments of a plurality of used polyurethane foams of different sizes, shapes, densities and weights, and often containing pieces of harder materials, such as plastic materials. The underlay generally comes in about 13.7 m rolls having a width of about 1.83 m, a typical thickness of about 6.5-13 mm, and a density of about 3.5-10 tbs/cu. ft.
Although polyurethane chipfoam has been extensively used for a long time as underlay for floor carpets in residential, commercial and industrial buildings, it is prone to release gaseous toxic chemicals into the atmosphere of a room or the like through the carpet which rests on the underlay, to varying degrees from the date of its installation and continually over the life of the underfoam. Examples of such unwanted chemicals includes, formaldehyde, ammonia, hydrochloric acid and, particularly, butylated hydroxy toluene (BHT).
Production of these and more dangerous gaseous toxic chemicals, including carcinogens is enhanced in the event of a fire. To reduce the risk or likelihood of the foam burning, a fire retardant is commonly present.
Chipfoam further comprising a plastic film layer on the upper side face of the chipfoam, which contacts the bottom surface of the carpet, is also known and commercially available. The plastic layer is intended to provide a moisture barrier if a liquid spill penetrates the carpet backing.
Further, anti-microbial agents for microbe control and odour-treating agents to eliminate organic odours, which may emanate from the foam have been incorporated into the foam.
However, there is still a long-felt want to have a foam underlay which minimizes the release of the aforesaid toxic gaseous chemicals into the atmosphere of a room, or the like, through the carpet above the underlay and provide an improved moisture barrier.
The use of cross-linked closed cell polyolefin foams as sound insulation material in flooring systems has been described in Canadian Patent No. 2,454,972, issued 22 May 2007 to F. C. & F.
It is an object of the present invention to provide a foam underlay for floor carpeting having an improved moisture resistant and gaseous toxic chemical imperious barrier.
It is a further object to provide a process and apparatus for the manufacture of said improved underlay.
Accordingly, in one aspect the invention provides a carpet underlay for a floor carpet, said underlay comprising
Preferably, the base layer comprises a polyurethane foam; preferably having a thickness selected from 5.0 mm to 2.0 cm, and, more preferably, selected from 6.5 mm to 1.4 cm.
The polyolefin foam preferably comprises a cross-linked, closed-cell polyethylene, polypropylene or polyamide, or blends, thereof. Examples of such foams are manufactured by Toray Plastics (America), Inc., and Sekisui Voltek LLC, a division of Sekisui America Corp. Other suitable examples of closed cell polyolefin foams will be appreciated by those skilled in the art.
The polyolefin foam upper layer preferably has a thickness selected from 0.5 mm to 2.5 mm, and more preferably, 0.65 mm to 2.0 mm.
We have found that when the thickness of the cross-linked closed cell polyolefin foam layer is preferably not less than 0.5 mm, it smoothes out irregularities in the base foam layer caused by particles of different sizes, shapes and materials, particularly when the latter is a plastics material. This results in less abrasion of the underside of the carpet.
In preferred embodiments, either or both of the layers contain fire-retardant, anti-microbial and odour absorbing chemicals.
In a further aspect, the invention provides a process for the manufacture of an underlay as hereinabove defined.
Accordingly, in a further aspect the invention provides a process of forming a carpet underlay comprising
We have noticed that heat treatment of the polyolefin foam layer to the softening temperature of the foam, per se, causes expansion of the foam, while subsequent cooling of the foam effects contraction to its original dimensions. However, we have found that when the polyolefin foam layer and the base layer are heat treated to their softening temperatures for bonding, one to the other, for unnecessary, relatively long periods of time, the polyolefin foam layer is unable to satisfactorily contract and its upper surface becomes rippled. Without being bound by theory, we believe that this is a result of overheating because the feed rate of the two layers is too slow and/or the heating temperature is too high and, thus, effecting too much heat transfer.
Thus, while the process of the invention requires both layer foam materials to become soft and tacky for effective bonding, the heat transfer most preferably, should not be excessive as to cause the aforesaid rippling of the polyolefin layer. The presence of the ripples on the upper surface of the underlay presents a problem to the carpet installer and uneven surface contact with the carpet.
Accordingly, in a further aspect the invention provides a process as hereinabove defined wherein said foam base layer and said polyolefin foam layer are suitably heat treated at a temperature and feed rate as to effect bonding without the production of excessive amounts of ripples on said second surface of said polyolefin foam. A feed rate of at least 10 m per minute at an effective softening temperature is preferred.
In a further aspect, the invention provides apparatus for carrying out the process for the manufacture of an underlay as hereinabove defined.
Accordingly, the invention provides apparatus for manufacturing a carpet underlay comprising
In order that the invention may be better understood, preferred embodiments will now be described, by way of example only with reference to the drawings, wherein
With reference to
In alternative embodiments, an adhesive is used to effect bonding of layers 12 and 18. The underlay 10 may be manufactured in any suitable length and width as desired and rolled for transportation and subsequent handling by a carpet installer.
With reference to
Apparatus 100 has polyethylene foam feed rollers 102, polyurethane chipfoam rollers 104 forwarding polyolefin foam layer 18 having a thickness of 0.8 mm and polyurethane layer 12, respectively, past heater 106 to soften both materials which are pulled into abutment under contact pressure and bonded by rolls 108 at a feed rate of about 20 m per minute. Underlay product 10 is optionally cooled and collected on roll 110.
Although this disclosure has described and illustrated certain preferred embodiments of the invention, it is to be understood that the invention is not restricted to those particular embodiments. Rather, the invention includes all embodiments, which are functional or mechanical equivalence of the specific embodiments and features that have been described and illustrated.
