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.

Abstract: An aqueous frothed and filled vinyl chloride and/or vinylidene chloride polymer latex containing an emulsified plasticizer is used to coat and impregnate the back of a carpet. The carpet containing the froth is heated to drive off or evaporate the water and gel the vinyl polymer. While still hot or soft, the froth on the carpet is densified to obtain uniform dimensions or thickness. The resulting laminate is then cooled and cut to the required shape and size for carpet tiles.

Abstract: An aqueous frothed and filled vinyl chloride and/or vinylidene chloride polymer latex containing an emulsified plasticizer is used to coat and impregnate the back of a carpet. The carpet containing the froth is heated to drive off or evaporate the water and gel the vinyl polymer. While still hot or soft, the froth on the carpet is densified to obtain uniform dimensions or thickness. The resulting laminate is then cooled and cut to the required shape and size for carpet tiles.

Abstract: A pattern is produced on the polymeric frothed coating on a substrate by reciprocating a rake through the froth on the substrate as the froth carried by the substrate moves under the rake. After curing and drying there is provided a substrate having an adherent resilient sponge or cellular pattern.

Abstract: Corn syrup is used to extend and stiffen carpet backing adhesive containing a carboxylated styrene butadiene copolymer latex.