Non-slip supportive carpet underlay
A multilayered carpet cushion underlay structure is provided having a primary sheet of resilient viscoelastic polyurethane foam adhered to a non-woven fabric carrier. The composite material additionally features a subjacent surface having an arrangement of polymeric fictionalizing projections that provide optimal resistance to slippage.
1. A supportive, non-slip carpet underlay comprising:
a multilayered composite material, comprising:
(a) a top facing layer composed of a first and second stratum of unsupported polymeric foam, wherein the second stratum has greater cubic density than the cubic density of the first stratum;
(b) an intermediate fabric carrier composed from entangled synthetic or recycled needle-punched filaments, wherein the subjacent surface of the second stratum of unsupported polymeric foam is bonded to the uppermost surface of the fabric carrier with an interjoining layer of adhesive; and
(c) a base layer of non-slip polymeric resin disposed upon the lowermost surface of the intermediate fabric carrier.
2. The supportive, non-slip carpet underlay according to claim 1 , wherein the top facing layer of unsupported polymeric foam is produced from a resin selected from the group consisting of polyurethane, latex, styrene-butadiene rubber, polyvinyl chloride, and ethylene vinyl acetate compound formulations.
3. The supportive, non-slip carpet underlay according to claim 1 , wherein the first stratum and second stratum of polymeric foam are bonded to one another with adhesive.
4. The supportive, non-slip carpet underlay according to claim 1 , wherein the top facing layer of polymeric foam has a thickness of about 0.25 to 0.50 inches.
5. The supportive, non-slip carpet underlay according to claim 1 , wherein the top facing layer of polymeric foam has a cubic density that exceeds 3 lb/ft 3 to 4.5 lb/ft 3 .
6. The supportive, non-slip carpet underlay according to claim 2 , wherein the top facing layer of polymeric foam is compounded with an antioxidant.
7. The supportive, non-slip carpet underlay according to claim 1 , wherein the intermediate fabric carrier is needle-punched to a dimension of about 0.25 to 0.50 inches in thickness.
8. The supportive, non-slip carpet underlay according to claim 1 , wherein the synthetic filaments are selected from the group consisting of polyolefins, polyamids, polyacrylics, polyesters, polyaldehydes, polycarbonates and mixtures thereof.
9. The supportive, non-slip carpet underlay according to claim 1 , wherein the intermediate fabric carrier has a density greater than the top facing layer of polymeric foam.
10. The supportive, non-slip carpet underlay according to claim 1 , wherein the interjoining layer of adhesive is selected from the group consisting of acrylic polymers, polyamides, polyolefins, and polyurethane resins.
11. The supportive, non-slip carpet underlay according to claim 1 , wherein the base layer of non-slip polymeric resin is selected from the group consisting of polyvinyl chloride, elastomeric latex, and styrene-butadiene resin formulations.
12. The supportive, non-slip carpet underlay according to claim 1 , wherein the base layer of non-slip polymeric resin is screen printed with a pattern of projections on the lowermost surface of the intermediate fabric carrier.
13. The supportive, non-slip carpet underlay according to claim 12 , wherein the screen printed pattern of projections is a high friction structure, wherein the projections are spaced at a distance to afford optimal resistance to slippage.
14. The supportive, non-slip carpet underlay according to claim 11 , wherein the base layer of non-slip polymeric resin is embossed with a grid structure on the lowermost surface of the intermediate fabric carrier.
15. The supportive, non-slip carpet underlay according to claim 14 , wherein the embossed grid is a high friction structure and wherein the elements of the grid are spaced at a distance to afford optimal resistance to slippage.
16. The supportive, non-slip carpet underlay according to claim 11 , wherein the base layer of non-slip polymeric resin is about 0.03125 to 0.0625 inches in thickness.
17. The supportive, non-slip carpet underlay according to claim 8 , wherein the top facing layer of unsupported polymeric foam is compounded with an antioxidant selected from the group consisting of liquid arylamines, liquid phosphites, and phenolic antioxidants.