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Methods of making sound insulation moldable carpets
| Details |
Inventors: Pole, Ernest G.; Graham, Everett S.;
Assignee: Polysar Limited (Sarnia, CA)
Primary Examiner: McCamish; Marion E.
Assistant Examiner:
Attorney, Agent or Firm: Stevens, Davis, Miller & Mosher
A method of making sound insulating floor or wall covering in which carpet is backed with a layer of sound insulating material and a layer of contour retaining material for holding the covering in a desired contoured shape. The latter material, which is conveniently a carpet precoat, is made formable for instance by heating, the carpet and its backing is shaped to desired form, and the retaining material is allowed to set thus holding the carpet and sound insulating layer to that shape. Desirably, the insulating material is a curable rubbery polymer which is cured before carpet shaping takes place. For improved sound insulating properties, deaerated insulating material is used. |
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DETAILED DESCRIPTION What is claimed is: 1.
A method of making profiled sound insulating floor or wall covering comprising a carpet, a layer of formable material attached to the underside of the carpet, the layer of formable material being capable of setting after it is formed to make a carpet contour retaining layer, and an unfoamed sound insulating backing which includes a curable rubbery polymer made by preparing a latex composition which includes at least 200 dry parts by weight of filler per 100 dry parts by weight of solids in the latex, the method comprising conditioning said layer of material to make it formable, and with the sound insulating backing in a flexible condition, contouring the covering to a desired configuration, and setting the material so as to form the contour retaining layer, the contour retaining layer in its set condition having a stiffness sufficient to retain the covering in its desired configuration.
2.
A method of making profiled sound insulating floor or wall covering comprising attaching to the underside of a carpet length, a layer of formable material which is capable of setting after it is formed to make a carpet contour retaining layer, and an unfoamed sound insulating backing to form a backed carpet length, the backing including a curable rubbery polymer made by preparing a latex composition which includes at least 200 dry parts by weight of filler per 100 dry parts by weight of solids in the latex, cutting backed individual coverings from the carpet length, conditioning said material on each individual covering to make it formable, and with the sound insulating backing in a flexible condition, contouring the individual covering to a desired configuration, and setting the material so as to form the contour retaining layer, the contour retaining layer in its set condition having a stiffness sufficient to retain the covering in its desired configuration.
3.
A method according to claim 2 wherein the carpet length is treated with the layer of formable material and then with the sound insulating backing
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