Patent ID: 6755997
Filing Date: 2004-06-29
Classification: B29C,B29K,B29L,B60R

Abstract:
A method of producing a vehicle interior floor covering, comprising:ascertaining acoustic properties of a vehicle floor on which the floor covering is to be placed to identify the one or more portions of the floor covering requiring enhanced sound attenuation, comprising identifying areas of the vehicle floor through which sound within a predetermined frequency range passes at an intensity level that exceeds a threshold intensity level; applying a first layer of polymeric barrier material onto a mold surface, wherein the mold surface is configured to impart a desired appearance on a surface of the first layer of polymeric barrier material; applying a second layer of polymeric barrier material onto one or more portions of the first layer of polymeric material, wherein the one or more portions of the first layer of polymeric material correspond to areas of a vehicle floor identified as requiring enhanced sound attenuation; applying a sound absorbing thermoformable foam material onto the second layer of polymeric barrier material and onto exposed portions of the first layer of polymeric barrier material such that the second layer of polymeric barrier material is completely encapsulated by the sound absorbing thermoformable foam material; subjecting the first and second layers of polymeric barrier material and the sound absorbing foam material to conditions within the mold to produce a contoured floor covering having a desired shape; and removing the floor covering from the mold.