Abstract: A carpet underlay cushion structure is provided having a carrier layer of open-cell resilient foam material having an initial thickness, said resilient foam material being substantially completely and uniformly impregnated with an impregnant composition containing a polymer which is cured after said impregnation, wherein the open cells of said carpet underlay cushion structure partially comprise said foam material of said carrier layer, and wherein said cured polymer impregnant retains said carpet underlay cushion structure comprising said carrier layer and said cured polymer impregnant at a finished thickness less than said initial thickness of said carrier layer, and wherein the carpet underlay cushion structure possesses substantially the mechanical and physical properties of the polymer impregnant and wherein said carpet underlay cushion structure retains an open cell configuration at said finished thickness.

Abstract: A carpet underlay cushion structure is provided having a carrier layer of an open-cell, resilient polyurethane foam naterial substantially completely impregnated with a latex such as a non-carboxylated styrene-butadiene rubber or natural rubber, the foam material further having a woven substrate adhered thereto, the impregnated foam material being dried and cured to form a foamed, open-cell, resilient composite cushion structure wherein the open cells thereof partially comprise the carrier layer of polyurethane foam material.