Foam cushion and method of making and using the same

a foam cushion and foam technology, applied in the field of foam cushion and method of making and using the same, can solve the problems of many carpet paddings that move so much up and down, and many carpet paddings do not effectively repel liquid and moisture, etc., to achieve suitable shock absorption and thermal insulation properties, and reduce manufacturing costs

Inactive Publication Date: 2005-04-21
PHAT CUSHION LLC
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

[0004] The present invention provides a foam cushion, a method of making the foam cushion, and a method of using the foam cushion. The foam cushion is resilient, sturdy, and tear resistant over an extended period of time (e.g., up to about 20 years, up to about 10 years, or up to about 5 years). The foam cushion is relatively inexpensive to manufacture, especially on a commercial (e.g., kilogram) scale. The foam cushion does not deteriorate with normal use over an extended period of time (e.g., up to about 20 years, up to about 10 years, or up to about 5 years). The foam cushion does not contain any chemicals that are environmentally unfriendly. The foam cushion effectively repels liquids and moisture. Additionally, the foam cushion possesses suitable shock absorbent and thermal insulative properties.

Problems solved by technology

There are several disadvantages with the use of many of these types of carpet padding.
The use of foam padding typically results in the carpet moving up and down so much that the backing soon breaks down.
Many carpet paddings do not effectively repel liquids and moisture and therefore allow the carpets to become stained.
Additionally, many of these carpet paddings are relatively heavy, which increases shipping costs, which are ultimately passed down to the consumer.

Method used

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Examples

Experimental program
Comparison scheme
Effect test

examples

[0118] Following the General Procedure as outlined below, an article of manufacture can be produced.

General Procedure:

[0119] (1) Mix the following substances together: at least one or a resin (colored or colorless) and rubber; a blowing agent (optional), a polymeric adhesion modifier (optional), a decomposition accelerating agent (optional), a cross-linking agent (optional), and one or more auxiliary materials (optional) to form a Concentrated Batch and heat (optional) for a period of time; [0120] (2) Cut the Concentrated Batch into desired Lumps; [0121] (3) Thin the Lumps into thin Sheets of desired thickness; [0122] (4) Cool (to room temperature) Sheets (optional); [0123] (5) Cut Sheets to specific length Pieces (optional); [0124] (6) Spray Non-Stick Substance (optional) to all surfaces of the (optionally textured) Press Mold; [0125] (7) Layer a desired number of Pieces to form a Stack in Press Mold; [0126] (8) Cook Stack in Press; [0127] (9) Remove Cooked Stack from Press Mold...

example # 1

Example #1

[0147] (1) Mix:

[0148] 44.86 Kg Ethylene Vinyl Acetate (White Colored),

[0149] 4.49 Kg Rubber,

[0150] 2.06 Kg Vinyfor AC 7,

[0151] 1.79 Kg Fusabond,

[0152] 0.90 Kg Zinc Oxide, and

[0153] 0.54 Kg Stearic Acid,

[0154] at 100° C.-130° C. for 15 Minutes; and mix

[0155] 0.36 Kg Dicumyl Peroxide at 110° C.-130° C. for 3 minutes;

[0156] mix at 100° C.-130° C. until concentrated to 20 mm thickness. [0157] (2) Cut (1) to 2 Kg Lumps and mix separately at 80° C.-100° C. [0158] (3) Thin Lumps into 1 mm Sheets 6 Ft Width by 7.5 Ft Length. [0159] (4) Cool Sheets slowly to room temperature with non-contact water cooling system. [0160] (5) Cut Sheets to Pieces 6 Width by 7.5 Ft Length. [0161] (6) Apply Silicone Spray to all surfaces of the textured Press Mold. [0162] (7) Layer 50 Pieces in Height in Adjacent Stacks to form an Adjoined Pre-Cooked Stack centered in the Press Mold (with the interior perimeter of the Press Mold exposed up to 50.0% of the surface area). [0163] (8) Cook Stack i...

example # 2

Example #2

[0172] (1) Mix 44.86 Kg Ethylene Vinyl Acetate—White Colored,

[0173] 4.49 Kg Rubber,

[0174] 2.06 Kg Vinyfor AC 7,

[0175] 1.79 Kg Fusabond,

[0176] 0.90 Kg Zinc Oxide, and

[0177] 0.54 Kg Stearic Acid,

[0178] at 110° C.-130° C. for 15 Minutes; and mix

[0179] 0.36 Kg Dicumyl Peroxide at 110° C.-130° C. for 3 Minutes;

[0180] mix at 100° C.-130° C. until concentrated to 20 mm thickness. [0181] (2) Cut (1) to 2 Kg Lumps and mix separately at 80° C.-100° C. [0182] (3) Thin Lumps into 1 mm Sheets 6 Ft Width by 7.5 Ft Length. [0183] (4) Cool Sheets slowly to room temperature with non-contact water cooling system. [0184] (5) Cut Sheets to Pieces 6 Ft Width) by 7.5 Ft Length. [0185] (6) Apply Silicone Spray to all surfaces of the Press Mold. [0186] (7) Layer 50 Pieces in Height in Adjacent Stacks to form an Adjoined Pre-Cooked Stack centered in the Press Mold (with interior perimeter of the Press Mold exposed up to 50.0% of the surface area). [0187] (8) Cook Stack in Press for 28-35 M...

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PUM

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Abstract

The present invention provides a foam cushion, a method of making the foam cushion, and a method of using the foam cushion. The foam cushion is formed from: (a) at least one of rubber and a resin; (b) a blowing agent; (c) a polymeric adhesion modifier; (d) a decomposition accelerating agent, and (e) a cross-linking agent.

Description

CROSS-REFERENCE TO RELATED APPLICATION [0001] This application is a Continuation of U.S. application Ser. No. 10 / 061,672 filed Feb. 1, 2002, which claims benefit under 35 U.S.C. 119(e) of U.S. Provisional Application Ser. No. 60 / 270,688 filed Feb. 23, 2001. These applications are incorporated herein by reference.BACKGROUND OF THE INVENTION [0002] Carpet padding, or carpet cushion, is typically used (i.e., placed below a carpet) to make the carpet feel more comfortable, to act as a shock absorber for the carpet, to extend the life of the carpet, and / or to insulate the floor. There are several types of carpet padding that are currently used, e.g., waffle rubber, foam padding, rebond, slab rubber, fiber, berber pad, and frothed foam. There are several disadvantages with the use of many of these types of carpet padding. For example, the rubber used to make waffle rubber carpet padding is held together with clay type binders that break down with use. The use of foam padding typically res...

Claims

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Application Information

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Patent Type & Authority Applications(United States)
IPC IPC(8): A61G5/02A61F5/14A61G5/04C08J9/00C08J9/04C08J9/06
CPCC08J9/04Y10T156/1059C08J2321/00B32B5/18B32B5/32B32B2266/0221B32B2270/00B32B2437/02C08J9/06
Inventor KOFFLER, ADAM J.HOPWOOD, DONALD W.HOANG, BINH VAN
Owner PHAT CUSHION LLC
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