FIELD OF INVENTION

[0001] This invention relates to a system and method to manufacture foam underlay.

BACKGROUND

[0002] Underlay is typically arranged under a floor covering to form a protective layer. It provides a cushioning effect and reduces the wear of the floor covering. Underlay can also provide thermal insulation and absorb noise.

[0003] Underlay can be formed from foam. Foam underlay is conventionally formed from chips (fragments) of foam bonded together to form a soft and lightweight foam layer that is easy and flexible to fit.

SUMMARY

[0004] The invention provides a system and method to manufacture foam underlay.

[0005] A first aspect of the invention relates to a system to manufacture foam underlay comprising: a controller to control the system according to a selected manufacturing mode; a mixing container; a foam chips feedline configured to extend from a foam chips container to the mixing container; a foam chips drive selectively controllable by the controller; a binder feedline configured to extend from a binder container to the mixing container; a binder drive selectively controllable by the controller; a scent feedline configured to extend from a scent container to a feedline junction, whereby the scent feedline intersects the binder feedline at the feedline junction; and a scent drive selectively controllable by the controller.

[0006] The selected manufacturing mode may comprise at least a scented manufacturing mode to manufacture scented foam underlay and an unscented manufacturing mode to manufacture unscented foam underlay. [0007] When the manufacturing mode is selected to be the scented manufacturing mode: the foam chips drive may be selectively controllable by the controller to feed foam chips along the foam chips feedline so as to supply foam chips to the mixing container; and the binder drive may be selectively controllable by the controller to feed binder along the binder feedline and the scent drive may be selectively controllable by the controller to feed scent along the scent feedline so as to form a mixture of binder and scent at the feedline junction and to supply the mixture to the mixing container.

[0008] When supplied to the mixing container, the foam chips and the mixture of binder and scent mix within the mixing container wherein the mixture coats the foam chips in the mixing container.

[0009] The foam chips drive may be selectively controllable by the controller to supply foam chips to the mixing container prior to the binder drive and scent drive being selectively controllable to supply of the mixture to the mixing container. Alternatively, the foam chips drive, binder drive and scent drive may be selectively controllable by the controller to supply the foam chips and the mixture of binder and scent simultaneously to the mixing container.

[0010] When the manufacturing mode of the system is selected to be the unscented foam underlay mode: the foam chips drive may be selectively controllable by the controller to feed foam chips along the foam chips feedline so as to supply foam chips to the mixing container; the scent drive may be selectively controllable by the controller to inhibit the feed of scent along the scent feedline; and the binder drive may be selectively controllable by the controller to feed binder along the binder feedline so as to supply binder to the mixing container.

[0011] When supplied to the mixing container, the foam chips and binder mix within the mixing container wherein the binder coats the foam chips in the mixing container.

[0012] The foam chips drive may be selectively controllable by the controller to supply foam chips to the mixing container prior to the binder drive being selectively controllable to supply of binder to the mixing container. Alternatively, the foam chips drive and binder drive may be selectively controllable by the controller to supply the foam chips and binder simultaneously to the mixing container. [0013] The controller may comprise a user interface to allow a user to select the manufacturing mode. For example, the user interface may allow a user to select the scented manufacturing mode and the unscented manufacturing mode, as desired.

[0014] The foam chips drive may be selectively controllable by the controller to regulate the dosage of the foam chips. For example, the foam chips drive may be selectively controllable by the controller to feed a desired dosage of foam chips along the foam chips feedline. The desired dosage of the foam chips to be supplied to the mixing container may be predetermined by the selected manufacturing mode. The controller may comprise a user interface to allow a user to select the desired dosage of foam chips.

[0015] The foam chips drive may comprise a foam chips pump. The foam chips pump may be selectively controllable by the controller to regulate the flow rate of foam chips along the foam chips feedline. For example, the foam chips pump may be selectively controllable by the controller to feed the foam chips are a desired foam chips flow rate along the foam chips feedline.

[0016] The foam chips drive may comprise a foam chips flow monitor to monitor the flow rate of foam chips along the foam chips feedline.

[0017] The binder drive may be selectively controllable by the controller to regulate the dosage of binder. For example, the binder drive may be selectively controllable by the controller to feed a desired dosage of binder along the binder feedline. The desired dosage of the binder may be predetermined by the selected manufacturing mode. The controller may comprise a user interface to allow a user to select the desired dosage of binder according to the manufacturing mode.

[0018] The binder drive may comprise a binder pump. The binder pump may be selectively controllable by the controller to regulate the flow rate of binder along the binder feedline. The binder pump may be selectively controllable by the controller to regulate the pressure of binder along the binder feedline. For example, the controller may be configured to selectively control the binder pump to feed the binder at a desired binder flow rate and/or at a desired binder pressure to enhance the mixing of the binder with the scent during the scented manufacturing mode.

[0019] The binder drive may comprise a binder flow rate monitor to monitor the flow rate of binder along the binder feedline and/or at the feedline junction. The binder drive may comprise a binder pressure monitor to monitor the binder pressure along the binder feedline and/or at the feedline junction.

[0020] The scent drive may be selectively controllable by the controller to regulate the dosage of scent. For example, the scent drive may be selectively controllable by the controller to feed a desired dosage of scent along the scent feedline. The desired dosage of the scent may be predetermined by the selected manufacturing mode. The controller may comprise a user interface to allow a user to select the desired dosage of scent according to the manufacturing mode. For example, the user interface may allow a user to select the dosage of scent in a range up to 10% scent by volume of a foam chips, binder and scent mixture (per foam log) when the foam underlay is to be a scented foam underlay. The user interface may allow a user to select to dosage of 0% scent by volume when the foam underlay is be an unscented foam underlay.

[0021] The scent drive may comprise a scent pump. The scent pump may be selectively controllable by the controller to regulate the flow rate of scent along the scent feedline. The scent pump may be selectively controllable by the controller to regulate the pressure of scent along the scent feedline. For example, the controller may selectively control the scent pump to feed the scent at a desired scent flow rate and/or at a desired scent pressure to enhance the mixing of the scent with the binder during the scented manufacturing mode.

[0022] The scent drive may comprise a scent flow rate monitor to monitor the flow rate of scent along the scent feedline and/or at the feedline junction. The scent drive may comprise a scent pressure monitor to monitor the pressure of scent along the scent feedline and/or at the feedline junction.

[0023] The scent drive may comprise a scent valve. The scent pump and/or scent valve may be selectively controllable by the controller to inhibit the feed of scent along the scent feedline during the unscented manufacturing mode.

[0024] The scent feedline may be configured to perpendicularly intersect the binder feedline at the feedline junction so as to enhance the mixing of the scent with the binder.

[0025] The mixing container may comprise a moving element to move the foam chips within the mixing container to aid the coating of the foam chips by the mixture of binder and scent or the binder according to the manufacturing mode. [0026] The system may further comprise the foam chips container to store foam chips. The foam chips may have a regular and/or have an irregular shape. The foam chips may have a uniform colour or have a variety of colours. The foam chips may have a generally uniform size or have a variety of sizes. The foam chips may have a uniform density or have a variety of densities. The foam chips may comprise polyurethane and/or any other suitable material. The foam chips may comprise new, off-cuts and/or recycled foam. The foam chips may comprise shredded and granulated fragments of foam.

[0027] The system may comprise the binder container to store binder. The binder comprises a binding agent that is suitable for bonding the foam chips together.

[0028] The system may comprise the scent container to store scent. The scent comprises an aromatic agent to enhance the smell of foam underlay.

[0029] The system may comprise a steamer to steam the foam chips coated in mixture or binder, and thereby activate the binder to bond the foam chips together.

[0030] The system may comprise a mould to form a compacted log of bonded foam chips. The log may have a desired density, and configuration.

[0031] The system may comprise a drier to remove moisture from the compacted log.

[0032] The system may comprise a cutter to cut (peel) a foam layer from the compacted log.

[0033] The system may comprise a laminator to laminate the foam layer with one or more laminating film.

[0034] A second aspect of the invention relates to a use of the system according to the first aspect of the invention to manufacture foam underlay.

[0035] A third aspect of the invention relates to a method to manufacture foam underlay wherein the method comprises: providing a system according to the first aspect of the invention; selecting a manufacturing mode, wherein the manufacturing mode comprises at least a scented manufacturing mode to manufacture scented foam underlay and an unscented manufacturing mode to manufacture unscented foam underlay. [0036] When the scented foam underlay manufacturing mode is selected: feeding foam chips along a foam chips feedline from a foam chips container to a mixing container; feeding binder along a binder feedline from a binder container and feeding scent along a scent feedline from a scent container to cause the mixing of binder and scent at a feedline junction where the binder feedline and the scent feedline intersect and thereby forming a mixture of binder and scent; and feeding the mixture of the binder and scent along the binder feedline from the feedline junction to the mixing container to cause the mixture to coat the foam chips in the mixing container.

[0037] The method of feeding the foam chips may comprise feeding foam chips to the mixing container prior to feeding the mixture to the mixing container. Alternatively, the method of feeding the foam chips may comprise feeding foam chips to the mixing container simultaneously to feeding of the mixture of binder and scent to the mixing container.

[0038] When the unscented foam underlay manufacturing mode is selected, the method may comprise: feeding foam chips along the foam chips feedline from the foam chips container to the mixing container; inhibiting the feed of scent along the scent feedline from the scent container to the feedline junction; feeding binder along the binder feedline from the binder container to the mixing container to cause the binder to coat the foam chips in the mixing container.

[0039] The method of feeding the foam chips may comprise feeding foam chips to the mixing container prior to feeding the binder to the mixing container. Alternatively, the method of feeding the foam chips may comprise feeding the foam chips to the mixing container simultaneously to feeding the binder to the mixing container.

[0040] The method of selecting the manufacturing mode may comprise receiving a user selected manufacturing mode via a user interface.

[0041] The method of feeding the foam chips may comprise selectively controlling a foam chips drive, via a controller, to feed foam chips along the foam chips feedline [0042] Wherein the foam chips drive may comprise a foam chips flow rate monitor selectively controllable by the controller, and the method may comprise monitoring the flow rate of the foam chips along the foam chips feedline using the foam chips flow rate monitor.

[0043] Wherein the foam chips drive may comprise a foam chips pump selectively controllable by the controller, and the method may comprise regulating the flow rate of the foam chips along the foam chips feedline using the foam chips pump. In an example, the method may comprise selectively controlling the foam chips pump, via the controller, to feed foam chips along the foam chips feedline at a desired foam chips flow rate.

[0044] The method of feeding binder may comprise selectively controlling a binder drive, via the controller, to feed binder along the binder feedline.

[0045] Wherein the binder drive may comprise a binder flow rate monitor selectively controllable by the controller, and the method may comprise monitoring the flow rate of the binder along the binder feedline and/or at the feedline junction using the binder flow rate monitor.

[0046] Wherein the binder drive may comprise a binder pump selectively controllable by the controller, and the method may comprise regulating the flow rate of the binder along the binder feedline and/or at the feedline junction using the binder pump. In an example, the method may comprise selectively controlling the binder pump, via the controller, to feed binder along the binder feedline at a desired binder flow rate.

[0047] Wherein the binder drive may comprise a binder pressure monitor selectively controllable by the controller, and the method may comprise regulating the pressure of the binder along the binder feedline and/or at the feedline junction using the binder pump. In an example, the method may comprise selectively controlling the binder pump, via the controller, to feed binder along the binder feedline and/or at the feedline junction at a desired binder pressure.

[0048] In the scented manufacturing mode, the method of feeding scent may comprise selectively controlling a scent drive, via the controller, to feed scent along the scent feedline.

[0049] Wherein the scent drive may comprise a scent flow rate monitor selectively controllable by the controller, and the method may comprise monitoring the flow rate of the scent along the scent feedline and/or at the feedline junction using the scent flow rate monitor. [0050] Wherein the scent drive may comprise a scent pump selectively controllable by the controller, and the method may comprise regulating the flow rate of the scent along the scent feedline and/or at the feedline junction using the binder pump. In an example, the method may comprise selectively controlling the scent pump, via the controller, to feed scent along the scent feedline at a desired scent flow rate.

[0051] Wherein the scent drive may comprise a scent pressure monitor selectively controllable by the controller. The method may comprise regulating the pressure of the scent along the binder feedline and/or at the feedline junction using the binder pump. In an example, the method may comprise selectively controlling the scent pump, via the controller, to feed scent along the scent feedline and/or the feedline junction at a desired scent pressure.

[0052] In the scented manufacturing mode, the method of feeding scent may comprise feeding scent perpendicularly towards the binder at the feedline junction to enhance the mixing of the binder and the scent.

[0053] In the unscented manufacturing mode, the method of inhibiting the feed of scent may comprise selectively controlling the scent drive, via the controller, to prevent (minimise) the feeding of scent along the scent feedline. The scent drive may comprise a scent valve, and the method of selectively controlling the scent drive may comprise selectively controlling the scent valve, via the controller, to prevent (minimise) the feeding of scent along the scent feedline.

[0054] The method of feeding the foam chips may comprise feeding a dosage of foam chips. The method may comprise selectively controlling the foam chips drive, via the controller, to regulate the dosage of foam chips. The method may comprise selectively controlling the foam chips drive, via the controller, to feed a desired dosage (volume or mass) of the foam chips along the foam chips feedline. The desired foam chips dosage may be pre-set by the selected manufacturing mode. The desired foam chips dosage may be a user selected desired foam chips dosage, and the method may comprise receiving a user selected desired foam chips dosage via the user interface.

[0055] The method of feeding the binder may comprise feeding a dosage of binder. The method may comprise selectively controlling the binder drive, via the controller, to regulate the dosage of binder. The method may comprise selectively controlling the binder drive, via the controller, to feed a desired dosage of the binder along the binder feedline. The desired binder dosage may be pre-set by the selected manufacturing mode. The desired binder dosage may be a user selected desired binder dosage, and the method may comprise receiving a user selected desired binder dosage via the user interface.

[0056] In the scented manufacturing mode, the method of feeding the scent may comprise feeding a dosage of scent. The method may comprise selectively controlling the scent drive, via the controller, to regulate the dosage of scent. The method may comprise selectively controlling the scent drive, via the controller, to feed a desired dosage of scent along the scent feedline. The desired scent dosage may be pre-set by the scented manufacturing mode. The desired scent dosage may be a user selected desired scent dosage, and the method may comprise receiving a user selected desired scent dosage via the user interface.

[0057] Wherein the mixing container may comprise a moving element to move foam chips within the mixing container, and the method may comprise activating the moving element to periodically or continuously move the foam chips within the mixing container. The moving of the foam chips may aid the coating of the foam chips by the mixture or the binder according to the manufacturing mode.

[0058] The method may comprise pre-storing the binder in the binder container at a predetermined temperature according to a desired viscosity.

[0059] The method may comprise pre-storing the scent in the scent container at a predetermined temperature according to a desired viscosity.

[0060] The method may comprise steaming the foam chips coated in the mixture or binder to activate the binder and thereby to bond the foam chips together.

[0061] The method may comprise moulding the bonded foam chips to form a compacted log of bonded foam chips.

[0062] The method may comprise drying the compacted log to remove moisture.

[0063] The method may comprise cutting the dried compacted log to peel a foam layer.

[0064] The method may comprise laminating the foam layer to apply one or more laminating film.

DRAWINGS [0065] Embodiments of the invention will now be described by way of example and with reference to the accompanying drawings, in which:

[0066] Figure 1a depicts a cross-sectional view of an embodiment of a scented foam underlay manufactured by a system of the present invention when operating in a scented manufacturing mode;

[0067] Figure 1b depicts a cross-sectional view of an embodiment of an unscented foam underlay manufactured by the system of the present invention when operating in an unscented manufacturing mode;

[0068] Figure 2 depicts a schematic view of an embodiment of a system to manufacture foam underlay according to the present invention;

[0069] Figure 3 depicts a schematic view of a store assembly and a mixing assembly of a first embodiment of a system to manufacture foam underlay according to the present invention;

[0070] Figure 4a depicts a flow diagram of an embodiment of a method to manufacture scented foam underlay according to the present invention;

[0071] Figure 4b depicts a flow diagram of an embodiment of a method to manufacture unscented foam underlay according to the present invention;

[0072] Figure 5 depicts a schematic view of a store assembly and a mixing assembly of a second embodiment of a system to manufacture foam underlay according to the invention;

[0073] Figure 6 depicts a schematic view of a store assembly and mixing assembly of a third embodiment of a system to manufacture foam underlay according to the invention;

DETAILED DESCRIPTION

[0074] The system and method of the present invention allow for the manufacture of foam underlay with scent or without scent, according to the manufacturing mode during operation. For example, the system and method may form a scented foam underlay when operating in a scented manufacturing mode. The system and method may further form an unscented foam underlay when operating in an unscented manufacturing mode. [0075] Figures 1a and 1b show cross-sectional views of embodiments of foam underlay Ila, lib manufactured using a system and method according to the present invention. The foam underlay may comprise a foam layer 1a, 1b comprising foam chips bonded together by a binder. As shown, the upper surface of the foam layer may be laminated by an upper laminate film 2a, 2b. The lower surface of the foam layer may be laminated by a lower laminate film 3a, 3b. The one or more laminate film may provide a reinforcing effect to enhance the strength of the foam underlay. The one or more laminate film may provide an aesthetic effect with colour, print, pattern and/or texture that is visible during storage and installation.

[0076] The foam underlay depicted in Figure 1a is an embodiment of a scented foam underlay Ila manufactured by the system and method of the present invention operating in the scented manufacturing mode. In this embodiment, the foam layer 1a comprises a slow releasing scent that enhances its smell over period of time. The foam underlay depicted in Figure 1b is an embodiment of an unscented foam underlay lib manufactured by the system and method operating in the unscented manufacturing mode. As a result, the foam layer 1b is free from scent.

[0077] The foam underlay may be formed as an elongate sheet that is rolled for storage and cut to size as required during installation. Alternatively, the foam underlay may be formed as a discrete element that is fitted with other foam underlay elements during installation.

[0078] Figure 2 shows a schematic view of an embodiment of a system S for manufacturing foam underlay according to the present invention.

[0079] As shown in Figure 2, the system S may comprise a store assembly 10 to separately store foam chips, binder and scent. A mixing assembly 20 may mix the foam chips, binder, and scent according to the manufacturing mode. A moulding and steaming assembly 30 may form a compacted foam log that is subjected to steam under pressure to cure the binder and bond foam chips together. Residual moisture may be removed from the compacted log using a drying assembly 40. A cutting assembly 50 may cut or peel the compacted log into a foam layer. A laminating assembly 60 may apply one or more laminating film onto the foam layer. A laminating film may be applied to the upper surface and/or the lower surface of the foam layer. A controller 70 may be communicatively coupled to the mixing assembly 20 to selectively control the mixing assembly according to the selected manufacturing mode. The controller 70 may be further communicatively coupled to the store assembly 10, the moulding and steaming assembly 30, the drying assembly 40, the cutting assembly 50 and/or the laminating assembly 60 to selectively control the one or more further assemblies during manufacture. In the present invention, the system S may be selected to operate in at least a scented manufacturing mode and an unscented manufacturing mode. As such, the controller 70 may be configured to selectively control at least the mixing assembly 20 according to the scented manufacturing mode to manufacture scented foam underlay Ila. The controller 70 may be further configured to selectively control at least the mixing assembly 20 according to the unscented manufacturing mode as to manufacture unscented foam underlay lib.

[0080] The controller 70 may comprise a wireless communication device configured to wirelessly send and receive communications with at least the mixing assembly 20. The controller 70 may comprise a mobile device. The controller 70 may be arranged local to at least the mixing assembly 20. Alternatively, the controller may be arranged remotely to at least the mixing assembly 20. In an embodiment, the controller 70 is a mobile device that is configured to wirelessly communicate (e.g. via near field communication, Bluetooth connectivity, radio frequency or Wi-Fi connectivity or another wireless connection) with the mixing assembly to control the mixing of foam chips, binder and scent according to the selected manufacturing mode. The controller 70 may comprise a memory for storing data and computer-readable instructions, and a processor for executing the instructions and generating command signals for operating at least the mixing assembly 20 according to the selected manufacturing mode. In an embodiment, the controller 70 may comprise a user interface to allow a user select the manufacturing mode of the system and method so as to manufacture foam underlay with scent, or without scent, as desired.

[0081] Figure 3 shows a schematic view of a store assembly 10 and a mixing assembly 20 for an embodiment of a system S for manufacturing foam underlay according to the invention.

[0082] As shown in Figure 3, the store assembly 10 of the system S may comprise a foam chips container 101 to store foam chips. The foam chips are fragments (pieces) of foam material. The foam chips may have a regular and/or have an irregular shape. The foam chips may have a uniform colour or have a variety of colours. The foam chips may have a generally uniform size or have a variety of sizes. The foam chips may have a uniform density or have a variety of densities. The foam chips may comprise polyurethane and/or any other suitable material. The foam chips may comprise new, off-cuts and/or recycled foam. The foam chips may comprise shredded and granulated fragments of foam.

[0083] As shown in Figure 3, the store assembly 10 of the system S may comprise a binder container 102 to store binder. The binder comprises any suitable binding agent to bond the foam chips together. The binder may be a steam activated binder whereby it is cured in the moulding and steam assembly 30. The binder may be a fluid, and preferably a liquid. [0084] As shown in Figure 3, the store assembly 10 of the system S may comprise a container 103 to store scent. The scent comprises any suitable aromatic agent or fragrance to enhance the smell of the foam underlay. The scent may provide any smell as desired. For example, scent may provide a fresh linen smell, flower smell and/or herb smell to the foam underlay. The scent may be a slow releasing scent. For example, the scent may be released over a period of time and is detectable during storage and after installation of the foam underlay. When added, the scent preferably counteracts or overcomes odours released by other components of the foam underlay. The scent may be a fluid, preferably a liquid. The scent is suitable for mixing with the binder.

[0085] The separate storage of the foam chips, binder and scent in the respective containers 101 , 102, 103 allows the system S to store the foam chips, binder and scent according to their optimum characteristics. For example, the binder container may be configured to store the binder at its optimum pressure, temperature, humidity and/or volume for use. The scent container may be configured to store scent at its optimum pressure, temperature, humidity and/or volume for use. In an example, the binder container may store the binder at a temperature to optimise the viscosity of the binder, which in turn optimises the flow of binder, the mixing of the binder with the scent and the coating of the foam chips by the binder.

[0086] The foam chips container 101 , binder container 102 and/or scent container 103 may be removably attachable to the mixing assembly 20 to allow for removal and replacement of containers to provide a continuing supply of foam chips, binder and/or scent during manufacturing.

[0087] The foam chips container 101 , binder container 102 and/or sent container 103 may be removably attachable to the mixing assembly 20 to allow for the removal and replacement of containers to provide different types of foam chips, binder and/or scent as desired during manufacturing. As such the system and method can manufacture foam underlay with different types of foam chips, binder and/or scent.

[0088] As shown in Figure 3, the mixing assembly 20 of the system S may comprise a mixing container 201 to receive and mix the foam chips, binder and scent according to the manufacturing mode.

[0089] As shown in Figure 3, the mixing assembly 20 of the system S may further comprise a foam chips feedline 211 and a foam chips drive 212. The foam chips feedline 211 defines a flow path between the foam chips container 101 and the mixing container 201 . The foam chips feedline 211 may comprise a pipe, conveyor or any other suitable feed means along which the foam chips can flow. The foam chips drive 212 is operable to feed foam chips along the foam chips feedline 211 to the mixing container 201. The operation of the foam chips drive 212 is controllable by the controller (not shown) to regulate the feeding of the foam chips to the mixing container during both the scented manufacturing mode and the unscented manufacturing mode.

[0090] As shown in Figure 3, the mixing assembly 20 of the system S may further comprise a binder feedline 221 and a binder drive 222. The binder feedline 221 defines a flow path between the binder container 102 and the mixing container 201. The binder feedline 221 may comprise a pipe, conveyor or any other suitable feed means along which the binder can flow. The binder drive 222 is operable to feed binder along the binder feedline. The operation of the binder drive 222 is controllable by the controller (not shown) to regulate the feeding of the binder along the binder feedline 221 according to the selected manufacturing mode.

[0091] As shown in Figure 3, the mixing assembly 20 of the system S may further comprise a scent feedline 231 and a scent drive 232. The scent feedline 231 defines a flow path between the scent container 103 and a feedline junction 233, where the scent feedline 231 intersects (interconnects with) the binder feedline 221. The scent feedline 231 intersects the binder feedline at an angle. In the embodiment shown in Figure 3, the scent feedline intersects the binder feedline 221 at an approximately 45 degree angle. In an alternative embodiment, the scent feedline 231 may perpendicularly intersect the binder feedline 221 . Feeding scent in a perpendicular direction to the binder may enhance turbulence at the feedline junction 233, which can augment the mixing effect of the binder and scent. The feedline junction 233 is arranged in the binder feedline 221 between the binder container 102 and the mixing container 101 (downstream from the binder container 102 and upstream from the mixing container 101).

[0092] The scent feedline 231 may comprise a pipe, conveyor or any other suitable feed means along which the scent can flow. The operation of the scent drive 232 is selectively controllable by the controller (not shown) according to the selected manufacturing mode. The scent drive 232 is selectively controllable by the controller (not shown) to regulate the feeding of the scent during the scented manufacturing mode. The scent drive 232 is also selectively controllable by the controller to regulate the inhibition of scent during the unscented manufacturing mode.

[0093] When the system is operating in the scented manufacturing mode, the scent drive 232 is operable to feed scent along the scent feedline 231 to cause the mixing of the binder and scent at the feedline junction 233. When the system is operating in the unscented manufacturing mode, the scent drive 232 is operable to inhibit (prevent, impair) the feeding (flow) of scent along the sent feedline 231 to avoid the mixing of the binder and scent at the feedline junction 233.

[0094] Figure 4a depicts a flow diagram of an embodiment of the manufacturing method Ma where the system S is selected to operate in the scented manufacturing mode to manufacture scented foam underlay Ila (step 1a). The foam chips drive 212, under the control of the controller 70, feeds foam chips along the foam chips feedline 211 so that they collect in the mixing container 201 (step 2a). The binder drive 222 and scent drive 232, under the control of the controller, simultaneously feed binder and scent along the respective feedlines to the feedline junction 233, whereby the binder and scent mix and form a mixture (step 3a). Due to the direction of flow of the binder feedline 221 and/or the scent feedline 231 towards the mixing container 201 , the mixture subsequently flows to the mixing container 201 (step 4a). Within the mixing container 201 , the mixture mixes with the foam chips and forms a coating on the foam chips. In an embodiment, the controller may control the foam chips drive 212, binder drive 222 and scent drive 232 such that the foam chips drive 212 is configured to initially feed the foam chips to the mixing container 201 , and the binder drive 222 and scent drive 232 are configured to subsequently feed the respective binder and scent to form the mixture as desired. As such, the foam chips are pre-received in the mixing container 201 prior to feeding the mixture into the mixing container 201. In an alternative embodiment, the controller may control the foam chips drive 212, binder drive 222 and scent drive 232 to simultaneously feed the foam chips and mixture to the mixing container 201 .

[0095] Figure 4b depicts a flow diagram of an embodiment of the manufacturing method Mb when the system S is selected to operate in the unscented manufacturing mode to manufacture unscented foam underlay lib (step 1b). Foam chips are fed along the foam chips feedline 211 by the foam chips drive 212, under the control of the controller, and collect in the mixing container 201 (step 2b). So as to manufacture a scent-free foam underlay, the scent drive 232 under the control of the controller inhibits the flow of scent along the scent feedline 231 (step 3b). Meanwhile, the binder drive 222, under the control of the controller, feeds binder along the binder feedline 221 to the mixing container 201 (step 4b). The binder mixes with the foam chips within the mixing container 201 and forms a coating on the foam chips. In an embodiment, the controller may control the foam chips drive 212, binder drive 222 and scent drive 232 such that the foam chips drive 212 is configured to initially feed the foam chips to the mixing container 201 and binder drive 222 is configured to subsequently feeds the binder to the mixing container 201 so that the foam chips are pre-received in the mixing container 201 prior to feeding the binder into the mixing container 201. In an alternative embodiment, the controller may control the foam chips drive 212, binder drive 222 and scent drive 222 to simultaneously feed the foam chips and binder to the mixing container 201.

[0096] In an embodiment, the foam chips drive 212 may comprise one or more foam chips pump, one or more foam chips sensor, one or more foam chips valve, and/or any other suitable foam chips drive means to drive the foam chips from the foam chips container 101 and along the foam chips feedline and to the mixing container 201. The foam chips pump may be controllable by the controller to regulate the flow rate of the foam chips along the foam chips feedline 211. For example, the foam chips may have a flow rate of approximately 40,000kg/hr. The foam chips sensor may comprise a foam chips flow rate monitor. The controller may regulate the foam chips pump according to a desired manufacture cycle rate, desired flow rate, desired dosage (volume or mass) of foam chips during manufacture. In an embodiment, the desired dosage of the foam chips may be dosage predetermined by the selected manufacturing mode. For example, the desired foam chip dosage may fall within the range of approximately 350kg to 830kg of foam chips by mass. For example, the desired foam chips dosage may fall within the range of approximately 75% to 94% by volume of the mixture of foam chips, binder and scent in the mixing container. In an embodiment, the controller may comprise a user interface to allow a user to select the dosage of foam chips as desired. In an embodiment, the foam chips pump may comprise a screw pump extending between the foam chips container 101 and the mixing container 201 , and the foam chips feedline 211 is defined by the flow path of the screw pump.

[0097] In an embodiment, the binder drive 222 may comprise one or more binder pump, one or more binder sensor, one or more binder valve and/or any other suitable binder drive means to drive the flow of binder from the binder container 102 and along the binder feedline 221 in the direction towards the mixing container 201. The binder pump may be controllable by the controller to regulate the flow rate of the binder along the binder feedline 221. For example, the binder may have a flow rate of approximately 3500kg/hr. The binder sensor may comprise a binder flow rate monitor. The binder pump may be controllable by the controller to regulate the pressure of the binder flow. In the scented manufacturing mode, the controller may control the binder pump to regulate the flow rate and/or the pressure of the binder relative to the scent to enhance the mixing of the binder with the scent at the feedline junction 233, and preferably form a substantially uniform mixture.

[0098] The controller may control the binder pump to regulate the dosage (volume or mass) of the binder along the binder feedline. The controller may control the binder pump to feed a desired dosage of binder along the binder feedline. In an embodiment, the desired dosage of binder may be a predetermined binder dosage according to the manufacturing mode. For example, the desired binder dosage may fall within the range of approximately 20kg to 100kg of binder by mass. For example, the desired binder dosage may fall within the range of approximately 5% to 15% by volume of the mixture of foam chips, binder and scent in the mixing container. In an embodiment, the controller may comprise a user interface to allow a user to select the dosage of binder according to the manufacturing mode as desired. The desired binder dosage may optimise the binding of the foam chips.

[0099] In an embodiment, the scent drive 232 may comprise one or more scent pump, one or more scent sensor, one or more scent valve and/or any other suitable scent drive means to drive or inhibit the flow of scent from the scent container and along the scent feedline towards the feedline junction. The scent pump may be controllable by the controller to regulate the flow rate of scent along the scent feedline 231. For example, the scent may have a flow rate of approximately 70kg/hr. The scent sensor may comprise a scent flow rate monitor. The scent pump may be controllable by the controller to regulate the pressure of the scent flow. The scent sensor may comprise a scent pressure monitor. In the scented manufacturing mode, the controller may control the scent pump to regulate the flow rate and/or the pressure of the scent relative to the binder to enhance the mixing of the scent with the binder at the feedline junction 233, and preferably form a substantially uniform mixture. In the unscented manufacturing mode, the controller may control the scent pump and/or the valve to impair the flow of scent and thereby avoid (minimise) the mixing of scent and binder at the feedline junction 233.

[0100] The controller may control the scent pump to regulate the dosage (volume or mass) of the scent along the scent feedline. The controller may control the scent pump to feed a desired dosage (volume or mass) of scent along the scent feedline. In an embodiment, the desired scent dosage may be a predetermined scent dosage according to the scented manufacturing mode. For example, the desired scent dosage may fall within the range of approximately Okg to 10kg of scent by mass. For example, the desired scent dosage may fall within the range of approximately 0% to 10% by volume of the mixture of foam chips, binder and scent in the mixing container. In an embodiment, the controller may comprise a user interface to allow a user to select the dosage of scent according to the manufacturing mode as desired. For example, the user interface may allow a user to select a scent dosage in a range between 0% and 10% by volume of the mixture of foam chips, binder and scent (per foam log). The manufacturing mode of the system may be determined by the user selected scent dosage. For example, when selecting a scent dosage greater than 0% volume, the user is selecting the system operates in a scented manufacturing mode. When selecting a scent dosage of 0% volume, the user is selecting the system operates in the unscented manufacturing mode. The desired scent dosage may optimise the scenting effect of the scented foam underlay.

[0101] In an embodiment of the system operating in the scented manufacturing mode, the controller may be configured to control the foam chips drive, binder drive and scent drive to form a predetermined mixture in the mixing container 201 comprising 662kg of foam chips, 50kg of binder and 2kg of scent.

[0102] The foam chips feedline 211, foam chips drive 212, binder feedline 221, binder drive 222, scent feedline 231 and scent drive 232 provide the system and method of the present invention with separate and selective control of the foam chips, binder and scent when manufacturing foam underlay.

[0103] The separate and selective control of the foam chips, binder and scent allow the system and method of the present invention to operate in at least a scented manufacturing mode and an unscented manufacturing mode as desired. Hence, the system and method of the present invention can form foam underlay with or without scent according to the selected manufacturing mode.

[0104] The separate and selective control of the feedlines and drives allows the system and method to use multiple different types of foam chips, binders and scents in the manufacture of foam underlay.

[0105] The separate and selective control of the feedlines and drives allow the system and method of the present invention to mix different combinations of foam chips, binder and scent in the mixing container.

[0106] The separate and selective control of the feedlines and drives allow the system and method of the present invention to form different dosage mixtures of binder and scent at the feedline junction 233 as desired.

[0107] The separate and selective control of the feedlines and drives allows the system and method to mix binder and scent during manufacture in real-time as desired, and avoids the pre-mixing of binder and scent, and avoid the pre-storage of a mixture of binder and scent.

[0108] The separate and selective control of the foam chips, binder, and scent enhance the manufacturing efficiency of the system and method of the present invention, being cost and time efficient. [0109] In an embodiment, the mixing container 201 may comprise a moving element (not shown) to move the foam chips within the mixing container. The moving element may move the foam chips continuously or periodically. By moving the foam chips, the coating of the foam chips by the mixture or binder is improved and becomes substantially uniform. The moving element may comprise a screw drive to rotate the foam chips within the mixing container.

[0110] Embodiments of the system and method according to the present invention may have a store assembly comprising one or more foam chips container 101 , one or more binder container 102, and/or one or more scent container 103 as described above.

[0111] Embodiments of the system and method according to the present invention may have a mixing assembly comprising one or more foam chips feedline 211 , one or more binder feedline 221 , one or more scent feedline 231 and/or one or more mixing container 201 as described above.

[0112] Figure 5 depicts an embodiment of the system S’ according to the present invention to allow for the mixing of multiple combinations of foam chips, binders and scents as desired in a single mixing container 201.

[0113] In this embodiment of the system S’, a first foam chips feedline 211a defines a first flow path between a first foam chips container 101a and the mixing container 201. A second foam chips feedline 211 b defines a second flow path between a second foam chips container 101b and the mixing container 201. A first foam chips drive 212a is selectively controllable by the controller (not shown) to feed first foam chips along the first foam chips feedline 211a to the mixing container 201. A second foam chips drive 212b is selectively controllable by the controller to feed second foam chips along the second foam chips feedline 211 b to the mixing container 201. The controller may comprise a user interface to allow the user to select the foam chips, and optionally the dosage of foam chips. The first foam chips may be different foam chips to the second foam chips.

[0114] A first binder feedline 221a defines a first flow path between a first binder container 102a and the mixing container 201 , and a first binder drive 222a is selectively controllable by the controller (not shown) to feed first binder along the first binder feedline 221a. A second binder feedline 221b defines a second flow path between a second binder container 102b and the mixing container 201 , and a second binder drive 222b is selectively controllable by the controller to feed second binder along the second binder feedline 221 b. The controller may comprise a user interface to allow the user to select the binder, and optionally the dosage of binder. The first binder may be a different binder to the second binder. [0115] A first scent feedline 231a defines a first flow path between a first scent container 103a and a first feedline junction 233a, where the first scent feedline 231 intersects the first binder feedline 221a. A first scent drive 232a is selectively controllable by the controller (not shown) to feed or prohibit a flow of first scent to the first feedline junction 233a according to the selected manufacturing mode. Likewise, a second scent feedline 231 b defines a second flow path between a second scent container 103b and a second feedline junction 233b, where the second scent feedline intersects the second binder feedline 221b. A second scent drive 232b is selectively controllable by the controller to feed or prohibit a flow of second scent to the second feedline junction 233b according to the manufacturing mode. The controller may comprise a user interface to allow the user to select the scent, optionally the dosage of scent. The first scent may be a different scent to the second scent.

[0116] When the system S’ is operating in the scented manufacturing mode, the first binder drive 222a and the first scent drive 232a are selectively controllable to feed first binder and first scent to form a first mixture at the first feedline junction 233a, wherein the first mixture subsequently flows from the first feedline junction 233a to the mixing container 201. Additionally or alternatively, the second binder drive 222b and the second scent drive 232b are selectively controllable to feed second binder and second scent to form a second mixture at the second feedline junction 233b, wherein the second mixture subsequently flows from the second feedline junction 233b to the mixing container 201 . The first mixture may be a different mixture to the second mixture, for example having a different type of binder, a different type of scent and/or different dosage ratio of binder and scent.

[0117] When the system S’ is operating in the unscented manufacturing mode, the first scent drive 232a and second scent drive 232b are selectively controllable to prohibit the feed of first scent and second scent along the respective feedlines. The first binder drive 222a is selectively controllable to feed first binder to the mixing container 201 and/or the second binder drive 222b is selectively controllable to feed second binder to the mixing container as desired.

[0118] The drives may be selectively controllable to regulate the dosage, flow rate and/or pressure of the foam chips, binders and scents as desired.

[0119] As such, during a manufacturing cycle in any selected manufacturing mode, the mixing container 201 can receive first foam chips and/or second foam chips as desired. When operating in a scented manufacturing mode, the mixing container 201 can also receive a first mixture of first binder and first scent as desired to mix with the first foam chips and/or a second mixture of second binder and second scent as desired to mix with the second foam chips. When operating in an unscented manufacturing mode, the flow of first scent and second scent is inhibited, and the mixing container 201 can receive a first binder and/or a second binder as desired to mix with the respective foam chips. The configuration of the system S’ also allows for the mixing of different combinations of foam chips, binder and scent in the single mixing container 201 during different manufacturing cycles to form different types of foam underlays.

[0120] Figure 6 depicts an embodiment of the system S” according to the present invention to allow for the mixing of multiple combinations of foam chips, binder and scent as desired in two mixing containers 201.

[0121] In this embodiment, a first foam chips feedline 211a defines a first flow path between a foam chips container 101 and a first mixing container 201a. A second foam chips feedline 211 b defines a second flow path between the foam chips container 101 and a second mixing container 201b. A first foam chips drive 212a is selectively controllable by the controller (not shown) to feed foam chips along the first foam chips feedline 211a to the first mixing container 201a. A second foam chips drive 212b is selectively controllable by the controller to feed foam chips along the second foam chips feedline 211b to the second mixing container 201b. The controller may comprise a user interface to allow the user to select the dosage of foam chips supplied to the first mixing container 201a and/or the second mixing container 201 b.

[0122] A first binder feedline 221a defines a first flow path between a binder container 102 and the first mixing container 201a, and a first binder drive 222a is selectively controllable by the controller (not shown) to feed binder along the first binder feedline 221a. A second binder feedline 221b defines a second flow path between the binder container 102 and the second mixing container 201 b, and a second binder drive 222b is selectively controllable by the controller to feed binder along the second binder feedline 221 b. The controller may comprise a user interface to allow the user to select the dosage of binder fed along the first binder feedline 221a and/or the second binder feedline 221 b.

[0123] A first scent feedline 231a defines a first flow path between a scent container 103 and a first feedline junction 233a, where the first scent feedline 231a intersects the first binder feedline 221a. A first scent drive 232a is selectively controllable by the controller (not shown) to feed or prohibit a flow of scent to the first feedline junction 233a according to the manufacturing mode. Likewise, a second scent feedline 231b defines a second flow path between the scent container 103 and a second feedline junction 233b, where the second scent feedline 231b intersects the second binder feedline 221 b. A second scent drive 232b is selectively controllable by the controller to feed or prohibit a flow of second scent to the second feedline junction 233b according to the manufacturing mode. The controller may comprise a user interface to allow the user to select the dosage of scent feed along the first scent feedline 231 a and/or the second scent feedline 231b.

[0124] When the system S” is operating in the scented manufacturing mode, the first binder drive 222a and the first scent drive 232a are selectively controllable to feed binder and scent to form a first mixture at the first feedline junction 233a, wherein the first mixture subsequently flows from first feedline junction 233a to the first mixing container 201a. Additionally or alternatively, the second binder drive 222b and the second scent drive 232b are selectively controllable to feed second binder and second scent to form a second mixture at the second feedline junction 233b, wherein the second mixture subsequently flows from the second feedline junction 233b to the second mixing container 201b. The first mixture may be same mixture or a different mixture to the second mixture, for example having a different dosage ratio of binder and scent.

[0125] When the system S” is operating in the unscented manufacturing mode, the first scent drive 232a and second scent drive 232b are selectively controllable to prohibit the feed of scent along the respective feedlines. The first binder drive 222a is selectively controllable to feed binder to the first mixing container 201 a and/or the second binder drive 222b is selectively controllable to feed binder to the second mixing container 201 b as desired.

[0126] The drives may be selectively controllable to regulate the dosage, flow rate and/or pressure of the foam chips, binder and scent as desired.

[0127] As such, during a manufacturing cycle in any selected manufacturing mode, the first mixing container 201a can receive foam chips and/or the second mixing container 201b can receive foam chips as desired. When operating in a scented manufacturing mode, the first mixing container 201a can also receive a first mixture of binder and scent as desired to mix with foam chips and/or the second mixing container 201b can receive a second mixture of binder and scent as desired to mix with foam chips. When operating in an unscented manufacturing mode, the flow of scent is inhibited, and so the first mixing container 201 a can receive a binder as desired to mix with foam chips and/or the second mixing container 201b can receive binder as desired to mix with foam chips. The configuration of the system S” allows for the mixing of different combinations of foam chips, binder and scent in the mixing containers 201a, 201b. The system S” allows for the mixing of foam chips, binder and scent in one or both the mixing containers 201a, 201b during a manufacturing cycle. The system S” allows for the mixing of foam chips, binder and scent in the mixing containers 201a, 201 b simultaneously or sequentially during a manufacturing cycle. The system allows for the mixing containers 201a, 201b to operate under the same manufacturing mode or different manufacturing modes during a manufacturing cycle.

[0128] Although the invention has been described with reference to one or more embodiments, it will be appreciated that various changes or modifications may be made without departing from the scope of the invention as defined in the appended claims.