Abstract: A novel polyurethane foam is shown which uses ground vehicle tires as a filler material. A method of manufacturing a carpet pad using the novel polyurethane composition is also shown. A frame is provided to which is mounted a conveyor belt. The conveyor belt feeds a first liner having an exposed surface of the polyurethane foam along a conveyor path from a forward end to a rearward end. A foam spray assembly is connected to a conventional uncured polymeric foam supply having a spray nozzle mounted adjacent to the forward end of the conveyor path. The spray nozzle dispenses uncured, resilient polymeric foam as a generally uniform layer on a surface of the first liner of previously cured polyurethane. A second conveyor belt, parallel to the first conveyor belt, feeds a second liner sheet along the conveyor path so that the second liner sheet is positioned over the layers of foam laminate.

Abstract: A laminated carpet pad is manufactured by utilizing liner sheets which are fed along a conveyor path. Uncured, polymeric foam material is sandwiched between the liner sheets and is compressed between opposite facing parallel conveyor belts which are spaced apart so that the sandwiched layer of polymeric foam is compressed to a uniform thickness while curing. Additionally, an inner layer of padding material may be sandwiched between the liner sheets with the polymeric foam material bonding the padding material to the liner sheets as it cures.