Patent ID: 7105069

Claim:
A method of forming a sound absorbing/sound blocking product, comprising: providing a first composite; wherein said first composite is formed by providing a primary layer of fibrous material having opposite first and second sides and a thickness and yarn tufts that extend from the first side, providing a secondary layer of thermoplastic material, applying the secondary layer of thermoplastic material at a temperature such that the secondary layer penetrates the primary layer and forms a fibrous layer backing, subjecting the carpet backing to conditions sufficient to cause the carpet backing to achieve a fluid state, and subjecting the carpet backing to air flow sufficient to create a porous carpet backing, providing a thermoformable porous layer, and applying said thermoformable porous layer to said fibrous layer backing; providing a second composite; wherein said second composite is formed by providing a sound absorbing layer and a sound blocking layer, and heating said first composite and said second composite and bonding said first composite to said second composite.