Kenneth B Garner

US Patent:

6576577, Jun 10, 2003

Filed:

Jun 4, 1999

Appl. No.:

09/326383

Inventors:

Kenneth B. Garner - Ringgold GA

Assignee:

Foam Products Corporation - Calhoun GA

International Classification:

B32B 518

US Classification:

442374, 442370, 442401, 4283044, 524031

Abstract:

An underlayment material is disclosed for use as an underlayment in a non-textile flooring system. The underlayment material comprises a thin, flexible layer of polyurethane foam and a thin, flexible substrate layer bonded to one side of the layer of polyurethane foam. In a preferred embodiment, the underlayment material is a mechanically frothed polyurethane foam. In another preferred embodiment, the substrate layer is a layer of non-woven spun bonded polyester fibers. In another preferred embodiment, the underlayment material has a thickness of between about 0. 05 and 0. 125 inches, and most preferably, about 0. 085 inches. In still another preferred embodiment, the foam has a fine cell structure and a density of between 10 and 30 pounds per cubic foot, and most preferably about 20 pounds per cubic foot. In still another preferred embodiment, the foam has a compression set of between about 5% and 25%, and most preferably about 10%.