Patent ID: 6296076
Filing Date: 2001-10-02
Classification: B60R,G10K,Y10T

Abstract:
A molded assembly of an automotive carpet or felt and a composite acoustical barrier, comprising:(a) a carpet or felt (12);(b) a composite acoustical barrier (10) bonded at a top surface (22) thereof to an underside (12a) of the carpet or felt (12) to form an assembly of the carpet or felt (12) and composite acoustical barrier (10), said assembly having a molded configuration which generally corresponds to the configuration of at least a portion of an automobile floor, trunk or headliner;and wherein said composite acoustical barrier (10), comprises:(1) a non-woven first layer (13) of needleable textile first fibers (13a), said first layer (13) having a thickness of between about 0.01 inch and 0.5 inch and a density of between about 1.0 and 10 lbs. per cubic foot;(2) a non-woven, low density second layer (15) of textile second fibers (15a), said second layer (15) having a thickness of between about 0.2 inch and 5 inches and a density of between about 0.1 and 4.0 lbs. per cubic foot;(3) a high-density intermediate acoustical barrier layer (14) disposed between the first and second layers (13, 15), said intermediate barrier layer (14) having a thickness of between about 0.01 inch and 0.5 inch, a density of at least about 50 lbs. per cubic foot, and said barrier layer comprising a substantially continuous film of high-density needleable polymeric material; and(4) a plurality of needled stitches (19) formed from the first fibers (13a) and extending from the first layer (13), through the intermediate barrier layer (14) and at least into the second layer (15).