Patent ID: 8057626

Claim:
A process for making a noise absorber carpet comprised of a fabric layer portion and a resinous backing layer portion, comprising the substantially concurrent steps of: (a) continuously feeding a softened resinous backing material from a backing resin feeder onto a backing roll to form a continuous resinous backing sheet thereon; and (b) continuously feeding a heated continuous fabric sheet via a fabric roll onto the backing sheet continuously formed on the backing roll; wherein the backing roll is provided with spike depressions and perforation pins on its surface; and wherein the fabric roll is located in close proximity to the backing roll so as to press the fabric sheet against the backing sheet as the fabric sheet and the backing sheet proceed between the fabric roll and the backing roll and mold spikes and perforations on and in the backing sheet with the spike depressions and the perforation pins respectively, the backing roll being cooled at a temperature range between 10 degrees Celsius and 50 degrees Celsius with a cooling medium so as to instantaneously and substantially harden said spikes and said perforations so formed, and also provide bonding between the fabric sheet and the backing sheet, producing a noise absorber carpet having such spikes and perforations.