Floor covering with viscoelastic dampening properties

This application claims benefit to German applications No. DE 10 2007 049 506.6, filed on Oct. 15, 2007 and DE 10 2008 046 667.0, filed on Sep. 10, 2008 which are incorporated by reference in their entirety for all useful purposes.

1. Field of the Invention

The present invention concerns a floor covering, comprising a first textile planar element and a first layer which is at least partially connected to the first textile planar element over their surfaces, wherein the first layer comprises viscoelastic polymer foam. Such floor coverings may be, for example, carpets. The present invention further concerns a method for manufacturing such a floor covering.

2. Description of the Prior Art

Carpets may be employed in a variety of uses. In private or commercial housing spaces they can be used for heat and acoustical insulation besides being used for decorative purposes. One possibility to manufacture carpets is to anchor fibers in a carpet backing and then to subsequently back-foam the carpet backing on its rear side.

It is generally known to back-foam carpet backings with a viscoelastic foam. In this respect, DE 33 13 624 A1 discloses a flexible polyurethane foam for acoustical insulation purposes, a method for its manufacture and the use thereof. The described flexible polyurethane foam for acoustical insulation purposes with a density of less than 90 kg/m³ and a modulus of elasticity of less than 106 N/m² has a loss factor of at least 0.3 and viscoelastic properties in a temperature range of −20° C. to +80° C.

The flexible foam can be obtained by reacting an isocyanate with a polyol, wherein the polyol has at least one component with an OH number of 180 to 400. The foam is especially suitable for the absorption and dampening of airborne sound and for the dampening of solid-borne sound. According to this disclosure, the flexible polyurethane foam can be used for back-foaming the cowl or floor carpet of automobiles. In an embodiment, a specially prepared carpet, optionally with acoustical insulation sheets, was added to the foaming mould in order to reach a sufficient foam density. After application of the usual separating agent the reaction mixture was added with the mould covering closed. 2.5 to 3 minutes thereafter the formed article could be removed.

DE 39 42 330 A1 discloses a method for manufacturing flexible polyurethane soft foams with viscoelastic and solid-borne sound dampening properties in a temperature range of −20° C. to +80° C. by reacting a) a polyoxyalkylene polyol mixture comprising ai) special block polyoxypropylene-polyoxyethylene polyol mixtures with a hydroxyl number from 14 to 65 and a content of terminally bound ethylene oxide units from 2 to 9 weight-%, which can themselves be obtained by using a starter mixture with an average functionality of 2.2 to 2.8, consisting of water and glycerine or trimethylol propane or of water and glycerine and trimethylol propane and aii) at least one di- or trifunctional polyoxypropylene polyoxyethylene polyol with a content of oxyethylene units from 60 to 85 weight-% relative to the total weight of polymerizable alkylene oxide units, and a hydroxyl number from 20 to 80; b) optionally low molecular weight chain extenders with c) organic and/or modified organic polyisocyanates in the presence of d) catalysts, e) blowing agents, f) adjuvants and/or additives as well as the polyoxyalkylene polyol mixtures (a).

The flexible polyurethane foams obtained by this method can be used in the household sector, for example in back-foaming of carpets for the dampening of foot fall sound, as interior linings and in the automotive industry for the dampening of solid-borne sound, for example for the encapsulation of the motor compartment or for preventing interior noise by using layers back-foamed with these foams.

Carpet backings for the carpets used in the automotive sector for noise dampening are generally of a stiff structure because a stepping through or sinking into the carpet is found to be undesirable.

When actually using carpets with tangible and therefore comfort improving dampening properties which comprise a carpet backing that has been back-foamed with a viscoelastic foam there are several issues to be taken into consideration. If these carpets are to be used as floor coverings where persons walk over them and not only rest their feet as in automobiles, the carpet must be suitable for bearing the pressure and the shear stress. In particular, the composite of carpet backing, carpet fibers and back foam should not disintegrate.

Finally, it can be observed that walking over a pure layer of viscoelastic foam which is thick enough to achieve a sufficient dampening effect is not very comfortable. This can be attributed to the insecurity that arises when the foot sinks into the foam after hitting the foam.

From the preceding it is apparent that the need still exists for a viscoelastically dampened carpet which displays a high comfort when one is walking over it, but at the same time stands up to the stress of use.

The present invention has the object of overcoming at least one of the mentioned drawbacks in the art. In particular, the invention has the object of providing such a carpet.

According to the invention this object is achieved by a floor covering, comprising a first textile planar element and a first layer which is at least partially connected to the first textile planar element over their surfaces, wherein the first layer comprises viscoelastic polymer foam.

The floor covering according to the invention is characterized in that the first textile planar element has a modulus of elasticity of ≧0.5 N/mm² to ≦2.5 N/mm², that in the first layer the viscoelastic polymer foam has a compression load deflection at 40% compression of ≧1 kPa to ≦10 kPa and that in the first layer the viscoelastic polymer foam has a hysteresis when determining the compression load deflection at 40% compression of ≧20% to ≦70%.

A BRIEF DESCRIPTION OF THE INVENTION

Continue reading about Floor covering with viscoelastic dampening properties...
Full patent description for Floor covering with viscoelastic dampening properties

Brief Patent Description - Full Patent Description - Patent Application Claims

Click on the above for other options relating to this Floor covering with viscoelastic dampening properties patent application.
###


How KEYWORD MONITOR works... a FREE service from FreshPatents
1. Sign up (takes 30 seconds). 2. Fill in the keywords to be monitored.
3. Each week you receive an email with patent applications related to your keywords.  
Start now! - Receive info on patent apps like Floor covering with viscoelastic dampening properties or other areas of interest.
###


Previous Patent Application:
Hydrophilic coating of polymeric substrates
Next Patent Application:
Composite structures and methods of making same
Industry Class:
Stock material or miscellaneous articles

###

Design/code © 2009 FreshContext LLC/Freshpatents.com. Website Terms and Conditions - Also read: About this Page
Patent data source: patents published by the United States Patent and Trademark Office (USPTO)
Information published here is for research/educational purposes only (and in conjunction with our Keyword Monitor) and is not meant to be used in place of the full USPTO patent document/images or a comprehensive patent archive search. Complete official applications are on file at the USPTO and often contain additional data/images (Freshpatents is currently text-only). FreshPatents.com is not affiliated with or endorsed by the USPTO or firms/individuals or products/designs/ideas related to listed patents.

FreshPatents.com Support
Thank you for viewing the Floor covering with viscoelastic dampening properties patent info.
IP-related news and info


Results in 2.0769 seconds


Other interesting Feshpatents.com categories:
Tyco , Unilever , Warner-lambert , 3m paws