Method and apparatus for forming textile pad for laminate floor underlayment

Abstract

A method and apparatus are provided for forming textile pads from a textile batt. The method includes the steps of splitting an incoming single textile batt and forming partial thickness textile batts, applying an adhesive to outer surfaces of the partial thickness textile batts, and adhering vapor barriers to the partial thickness textile batts. The apparatus comprises a pair of feed rollers for receiving a textile batt, a splitting knife downstream of the pair of feed rollers, adhesive appliers positioned downstream of the splitting knife and capable of applying an adhesive to outer surfaces of the partial thickness textile batts, vapor barrier supply positioned downstream of the adhesive appliers and capable of supplying vapor barriers that contact the outer surfaces of the partial thickness textile batts, pressure rollers positioned downstream of the pair of vapor barrier supply rollers.

What is claimed is:  
     
         1 . An apparatus for forming textile pads from a textile batt, comprising: 
 a pair of feed rollers for receiving said textile batt;    a splitting knife downstream of said pair of feed rollers and capable of splitting said textile batt to produce partial thickness textile batts;    adhesive appliers positioned downstream of said splitting knife and capable of applying an adhesive to outer surfaces of said partial thickness textile batts;    a vapor barrier supply positioned downstream of said adhesive appliers and capable of supplying vapor barriers that contact said outer surfaces of said partial thickness textile batts; and    pressure rollers positioned downstream of said pair of vapor barrier supply rollers.    
     
     
         2 . The apparatus of  claim 1 , wherein said pair of feed rollers are positioned about zero to about 2 millimeters from said splitting knife.  
     
     
         3 . The apparatus of  claim 1 , wherein said feed rollers and said splitting knife comprise a splitting machine.  
     
     
         4 . The apparatus of  claim 1 , wherein said feed rollers and said splitting knife comprise a Mercier Turner Scimatic NT 6  splitting machine.  
     
     
         5 . The apparatus of  claim 1 , wherein said apparatus further comprises a pair of tension rollers downstream of said splitting knife and upstream of said adhesive appliers, said tension rollers capable of controlling tension in said two partial thickness textile batts.  
     
     
         6 . The apparatus of  claim 1 , wherein said apparatus further comprises two take-up rollers downstream of said pressure rollers.  
     
     
         7 . The apparatus of  claim 1 , wherein a textile pad of said two textile pads formed according to said method comprises a laminate floor underlayment.  
     
     
         8 . The apparatus of  claim 1 , wherein said textile batt comprises natural fibers.  
     
     
         9 . The apparatus of  claim 1 , wherein said textile batt comprises man-made fibers.  
     
     
         10 . The apparatus of  claim 1 , wherein said textile batt is selected from the group consisting of polyester, nylon, acrylic, and cotton, polypropolene or combinations thereof.  
     
     
         11 . The apparatus of  claim 1 , wherein a partial thickness textile batt is about {fraction (1/16)} to about ⅛ inch in thickness.  
     
     
         12 . The apparatus of  claim 1 , wherein a partial thickness textile batt is about {fraction (1/16)} to about {fraction (7/16)} inch in thickness.  
     
     
         13 . The apparatus of  claim 1 , wherein said two partial thickness textile batts are of unequal thickness.  
     
     
         14 . The apparatus of  claim 1 , wherein said two partial thickness textile batts are of equal thickness.  
     
     
         15 . The apparatus of  claim 1 , wherein a vapor barrier of said two vapor barriers comprises plastic.  
     
     
         16 . The apparatus of  claim 1 , wherein a vapor barrier of said two vapor barriers comprises coextruded polyethylene.  
     
     
         17 . The apparatus of  claim 1 , wherein a vapor barrier of said two vapor barriers is about ½ to about 1 mil in thickness.  
     
     
         18 . The apparatus of  claim 1 , wherein said partially compressing step comprises passing said two partial thickness textile batts and said two plastic vapor barriers through a pair of pressure rollers.  
     
     
         19 . The apparatus of  claim 1 , wherein said partially compressing step further comprises passing said two partial thickness textile batts and said two plastic vapor barriers through a pair of pressure rollers which apply a pressure of about 400 psi.  
     
     
         20 . The apparatus of  claim 1 , wherein said partially compressing step comprises passing said two partial thickness textile batts and said two plastic vapor barriers through a pair of pressure rollers and said pair of pressure rollers are maintained at a temperature of about 200 degrees Fahrenheit.