Durable, liquid impermeable and moisture vapor permeable carpet pad
View Patent ↗A carpet pad comprises a two-layer structure of a cushion and a barrier film formed of a synthetic polymeric material free of any fibrous substrate laminated thereto. The barrier film may be directly bonded to the cushion or bonded thereto using a layer of adhesive. The carpet pad is simultaneously impermeable to liquid deposited onto the pad from above the barrier film and permeable to moisture vapor at a moisture vapor transmission rate of at least 14.6 grams per square meter per twenty-four hours (14.6 g/m 2 /24 hours). The carpet pad is sufficiently durable to maintain liquid impermeability as measured by a Vetterman Drum Wear Test/Staining/Stain Cleaning Test after at least ten thousand cycles or under a pressure of at least eight pounds per square inch (0.56 kg per square meter) as measured by a Modified Mullen Bursting Strength Test.
1. A carpet pad consisting essentially of:
a cushion having an upper and lower surface thereon, and,
a barrier film formed of a synthetic polymeric material directly bonded to the upper surface of the cushion,
the carpet pad being simultaneously
impermeable to liquid deposited onto the pad from above the barrier film, and
permeable to moisture vapor at a moisture vapor transmission rate of at least 14.6 grams per square meter per twenty-four hours (14.6 g/m 2 /24 hours),
the pad being sufficiently durable to maintain liquid impermeability under a pressure of at least eight pounds per square inch (0.56 kg/m 2 ) as measured by a Modified Mullen Bursting Strength Test,
whereby the carpet pad does not absorb liquid deposited onto the pad from above the upper surface of the barrier film and allows moisture from below the lower surface of the cushion to pass through the pad.
2. The carpet pad of claim 1 wherein the cushion is formed of a synthetic, non-cellulosic material.
3. The carpet pad of claim 1 wherein the barrier film has a thickness in the range from 0.5 to 1.5 mils.
4. The carpet pad of claim 1 wherein the barrier film is formed from a resilient polymeric material.
5. The carpet pad of claim 1 wherein the barrier film is formed from an elastomeric polymeric material.
6. The carpet pad of claim 5 wherein the barrier film is formed from a material selected from the group consisting of vulcanized silicone rubber, silicone polymer, polyurethanes, polyether/polyester, polyether/amides, polyvinyl alcohol, and copolymers and blends thereof.
7. The carpet pad of claim 1 wherein the barrier film is formed from a perfluoroalkyl polymeric material.
8. The carpet pad of claim 1 wherein the barrier film is formed of butylene/poly(alkylene ether) phthalate.
9. A carpet pad consisting essentially of:
a cushion having an upper and lower surface thereon, and,
a barrier film formed of a synthetic polymeric material directly bonded to the upper surface of the cushion,
the carpet pad being simultaneously
impermeable to liquid deposited onto the pad from above the barrier film, and
permeable to moisture vapor at a moisture vapor transmission rate of at least 14.6 grams per square meter per twenty-four hours (14.6 g/m 2 /24 hours),
the pad being sufficiently durable to maintain liquid impermeability after a Vetterman Drum Wear Test/Staining/Stain Cleaning Test of at least ten thousand cycles,
whereby the carpet pad does not absorb liquid deposited onto the pad from above the upper surface of the barrier film and allows moisture from below the lower surface of the cushion to pass through the pad.
10. The carpet pad of claim 9 wherein the cushion is formed of a synthetic, non-cellulosic material.
11. The carpet pad of claim 9 wherein the barrier film has a thickness in the range from 0.5 to 1.5 mils.
12. The carpet pad of claim 9 wherein the barrier film is formed from a resilient polymeric material.
13. The carpet pad of claim 9 wherein the barrier film is formed from an elastomeric polymeric material.
14. The carpet pad of claim 13 wherein the barrier film is formed from a material selected from the group consisting of vulcanized silicone rubber, silicone polymer, polyurethanes, polyether/polyester, polyether/amides, polyvinyl alcohol, and copolymers and blends thereof.
15. The carpet pad of claim 9 wherein the barrier film is formed from a perfluoroalkyl polymeric material.
16. The carpet pad of claim 9 wherein the barrier film is formed of butylene/poly(alkylene ether) phthalate.
17. A carpet pad consisting essentially of:
a cushion having an upper and lower surface thereon;
a barrier film formed of a synthetic polymeric material; and
a layer of adhesive material bonding the film to the upper surface of the cushion,
the carpet pad being simultaneously
impermeable to liquid deposited onto the pad from above the barrier film, and
permeable to moisture vapor at a moisture vapor transmission rate of at least 14.6 grams per square meter per twenty-four hours (14.6 g/m 2 /24 hours),
the pad being sufficiently durable to maintain liquid impermeability under a pressure of at least eight pounds per square inch (0.56 kg/m 2 ) as measured by a Modified Mullen Bursting Strength Test,
whereby the carpet pad does not absorb liquid deposited onto the pad from above the upper surface of the barrier film and allows moisture from below the lower surface of the cushion to pass through the pad.
18. The carpet pad of claim 17 wherein the barrier film has a first predetermined melting temperature, and
wherein the adhesive is formed of a second polymeric material having a second, lower, melting temperature, thereby to bond thermally the film to the upper surface of the cushion.
19. The carpet pad of claim 18 wherein the adhesive is a solid adhesive introduced between the film and the upper surface of the cushion.
20. The carpet pad of claim 17 wherein the adhesive is a liquid adhesive introduced between the film and the upper surface of the cushion.
21. The carpet pad of claim 17 wherein the cushion is formed of a synthetic, non-cellulosic material.
22. The carpet pad of claim 17 wherein the barrier film has a thickness in the range from 0.5 to 1.5 mils.
23. The carpet pad of claim 17 wherein the barrier film is formed from a resilient polymeric material.
24. The carpet pad of claim 17 wherein the barrier film is formed from an elatomeric polymeric material.
25. The carpet pad of claim 24 wherein the barrier film is formed from a material selected from the group consisting of vulcanized silicone rubber, silicone polymer, polyurethanes, polyether/polyester, polyether/amides, polyvinyl alcohol, and copolymers and blends thereof.
26. The carpet pad of claim 17 wherein the barrier film is formed from a perfluoroalkyl polymeric material.
27. The carpet pad of claim 17 wherein the barrier film is formed of butylene/poly(alkylene ether) phthalate.
28. A carpet pad consisting essentially of:
a cushion having an upper and lower surface thereon;
a barrier film formed of a synthetic polymeric material; and
a layer of adhesive material bonding the film to the upper surface of the cushion,
the carpet pad being simultaneously
impermeable to liquid deposited onto the pad from above the barrier film, and
permeable to moisture vapor at a moisture vapor transmission rate of at least 14.6 grams per square meter per twenty-four hours (14.6 g/m 2 /24 hours),
the pad being sufficiently durable to maintain liquid impermeability after a Vetterman Drum Wear Test-Staining/Stain Cleaning Test of at least ten thousand cycles,
whereby the carpet pad does not absorb liquid deposited onto the pad from above the upper surface of the barrier film and allows moisture from below the lower surface of the cushion to pass through the pad.
29. The carpet pad of claim 28 wherein the cushion is formed of a synthetic, non-cellulosic material.
30. The carpet pad of claim 28 wherein the barrier film has a thickness in the range from 0.5 to 1.5 mils.
31. The carpet pad of claim 28 wherein the barrier film is formed from a resilient polymeric material.
32. The carpet pad of claim 28 wherein the barrier film is formed from an elastomeric polymeric material.
33. The carpet pad of claim 32 wherein the barrier film is formed from a material selected from the group consisting of vulcanized silicone rubber, silicone polymer, polyurethanes, polyether/polyester, polyether/amides, polyvinyl alcohol, and copolymers and blends thereof.
34. The carpet pad of claim 28 wherein the barrier film is formed from a perfluoroalkyl polymer material.
35. The carpet pad of claim 28 wherein the barrier film has a first predetermined melting temperature, and
wherein the adhesive is formed of a second polymeric material having a second, lower melting temperature, thereby to bond thermally the film to the upper surface of the cushion.
36. The carpet pad of claim 35 wherein the adhesive is a solid adhesive introduced between the film and the upper surface of the cushion.
37. The carpet pad of claim 28 wherein the adhesive is a liquid adhesive introduced between the film and the upper surface of the cushion. the upper surface of the cushion.
38. The carpet pad of claim 28 wherein the barrier film is formed of butylene/poly(alkylene ether) phthalate.
39. A carpet pad comprising:
a cushion having an upper and lower surface thereon, and,
a barrier film formed of a synthetic polymeric material bonded to the upper surface of the cushion, the barrier film being free of any fibrous substrate laminated thereto,
the carpet pad being simultaneously
impermeable to liquid deposited onto the pad from above the barrier film, and
permeable to moisture vapor transmission at a rate of at least 14.6 grams per square meter per twenty-four hours (14.6 g/m 2 /24 hours),
the pad being sufficiently durable to maintain liquid impermeability under a pressure of at least eight pounds per square inch (0.56 kg/m 2 ) as measured by a Modified Mullen Bursting Strength Test,
whereby the carpet pad does not absorb liquid deposited onto the pad from above the upper surface of the barrier film and allows moisture from below the lower surface of the cushion to pass through the pad.
40. The carpet pad of claim 39 wherein the unsupported barrier film is directly bonded to the upper surface of the cushion.
41. The carpet pad of claim 39 further comprising a layer of adhesive material bonding the barrier film to the upper surface of the cushion.
42. The carpet pad of claim 39 or wherein the barrier film is formed from a resilient polymeric material.
43. The carpet pad of claim 39 wherein the barrier film is formed from an elastomeric polymeric material.
44. The carpet pad of claim 43 wherein the barrier film is formed from a material selected from the group consisting of vulcanized silicone rubber, silicone polymer, polyurethanes, polyether/polyester, polyether/amides, polyvinyl alcohol, and copolymers and blends thereof.
45. The carpet pad of claim 39 wherein the barrier film is formed from a perfluoroalkyl polymeric material.
46. A carpet pad comprising:
a cushion having an upper and lower surface thereon, and,
a barrier film formed of a synthetic polymeric material bonded to the upper surface of the cushion, the barrier film being free of any fibrous substrate laminated thereto,
the carpet pad being simultaneously
impermeable to liquid deposited onto the pad from above the barrier film, and
permeable to moisture vapor transmission at a rate of at least 14.6 grams per square meter per twenty-four hours (14.6 g/m 2 /24 hours),
the pad being sufficiently durable to maintain liquid impermeability after a Vetterman Drum Wear Test/Staining/Stain Cleaning Test of at least ten thousand cycles,
whereby the carpet pad does not absorb liquid deposited onto the pad from above the upper surface of the barrier film and allows moisture from below the lower surface of the cushion to pass through the pad.
47. The carpet pad of claim 46 wherein the unsupported barrier film is directly bonded to the upper surface of the cushion.
48. The carpet pad of claim 46 further comprising a layer of adhesive material bonding the barrier film to the upper surface of the cushion.
49. The carpet pad of claim 46 wherein the barrier film is formed from a resilient polymeric material.
50. The carpet pad of claim 46 wherein the barrier film is formed from an elastomeric polymeric material.
51. The carpet pad of claim 50 wherein the barrier film is formed from a material selected from the group consisting of vulcanized silicone rubber, silicone polymer, polyurethanes, polyether/polyester, polyether/amides, polyvinyl alcohol, and copolymers and blends thereof.
52. The carpet pad of claim 46 wherein the barrier film is formed from a perfluoroalkyl polymeric material.