Abstract: A method of manufacturing an article such as vehicle interior trim component including a decoupler layer is disclosed. The method comprises the conveying of materials into an enclosure to form a preform having a shape of the enclosure, heating the preform to a temperature such that adjacent materials may bond to one another upon cooling and forming the heated preform into a predetermined three-dimensional decoupler configuration via a mold. The enclosure has a perforated portion and at least one panel movable relative to the enclosure so as to selectively expose portions of the perforated portion. The density of the preform may be varied as the at least one panel is moved to expose the perforated portion of the enclosure. A system for manufacturing articles such as a vehicle interior trim component including a decoupler layer is also disclosed.

Abstract: Acoustically absorptive carpeting includes a primary layer of fibrous material with yarn tufts extending outwardly therefrom and a secondary layer of thermoplastic material that forms a carpet backing. The carpet backing is rendered porous. A substrate of porous material is attached to the carpet backing. The substrate includes a layer of fine fibrous material attached to a layer of coarse fibrous material. The layers of fine and coarse fibrous material each have respective different acoustic impedances. The layer of coarse fibrous material has fibers in an open, loose configuration. The carpet backing is bonded to the layer of coarse fibrous material with a thermoplastic adhesive material such that the thermoplastic adhesive material encapsulates individual fibers of the layer of coarse fibrous material without extending therebetween.

Abstract: A method of manufacturing an article having controlled density, such as a decoupler for attenuating sound in a vehicle, is disclosed. The method comprises the conveying of material into a mold to form a preform having a shape of the mold, heating the preform to a temperature such that adjacent materials bond to one another upon cooling, and forming the heated preform in the mold into a predetermined three-dimensional configuration. The mold may have a perforated section and at least one panel movably attached to the mold so as to selectively expose portions of the perforated section. The density of the preform may be varied as the at least one panel is moved to expose the perforated section of the mold. A contoured mold for manufacturing articles such as decouplers is also disclosed.

Abstract: A method of manufacturing an article having controlled density, such as a decoupler for a vehicle interior trim component, is disclosed which uses an indexing, preferably rotary, apparatus. The method comprises the conveying of materials, preferably fibers, into an enclosure to form a preform having a shape of the enclosure, transferring the preform to a mold on an indexing apparatus where the preform is heated to a temperature such that adjacent fibers bond to one another upon cooling, and moving the mold to a press where the heated preform is molded into a predetermined three-dimensional decoupler configuration. The enclosure has a perforated portion and at least one panel movable relative to the enclosure so as to selectively expose portions of the perforated portion. The density of the preform may be varied as the at least one panel is removed to expose the perforated portion of the enclosure.

Abstract: A method of manufacturing an article such as vehicle interior trim component including a decoupler layer is disclosed. The method comprises the conveying of materials into an enclosure to form a preform having a shape of the enclosure, heating the preform to a temperature such that adjacent materials may bond to one another upon cooling and forming the heated preform into a predetermined three-dimensional decoupler configuration via a mold. The enclosure has a perforated portion and at least one panel movable relative to the enclosure so as to selectively expose portions of the perforated portion. The density of the preform may be varied as the at least one panel is moved to expose the perforated portion of the enclosure. A system for manufacturing articles such as a vehicle interior trim component including a decoupler layer is also disclosed.

Abstract: A method of manufacturing an article, such as a decoupler for a vehicle interior trim component, is disclosed. The method comprises the conveying of materials into an enclosure to form a preform having a shape of the enclosure, heating the preform to a temperature such that adjacent materials may bond to one another upon cooling and forming the heated preform into a predetermined three-dimensional configuration via a mold. The enclosure has a perforated portion and at least one panel movable relative to the enclosure so as to selectively expose portions of the perforated portion. The density of the preform may be varied as the at least one panel is moved to expose the perforated portion of the enclosure. A system for manufacturing articles, such as decouplers, of the present invention is also disclosed.

Abstract: Sound attenuating laminates, and methods of making the same, are provided. Heat is applied to a surface of a non-woven, fibrous layer of material to form a stratum of melted fibers having a density greater than that of the remainder of the fibrous layer. The density of the melted fibers is effective in attenuating noise traversing the fibrous layer of material. Upholstery material, such as carpeting, is attached to the surface of the heated fibrous layer. The fibrous layer and upholstery material are then subjected to compressive molding pressure to obtain a desired shape. The compressive molding pressure may further tune the sound attenuating properties of the fibrous layer by selectively changing the densities of portions of the fibrous layer.

Abstract: Sound attenuating laminates, and methods of making the same, are provided. Heat is applied to a surface of a non-woven, fibrous layer of material to form a stratum of melted fibers having a density greater than that of the remainder of the fibrous layer. The density of the melted fibers is effective in attenuating noise traversing the fibrous layer of material. Upholstery material, such as carpeting, is attached to the surface of the heated fibrous layer. The fibrous layer and upholstery material are then subjected to compressive molding pressure to obtain a desired shape. The compressive molding pressure may further tune the sound attenuating properties of the fibrous layer by selectively changing the densities of portions of the fibrous layer.

Abstract: Sound attenuating laminates, and methods of making the same, are provided. Heat is applied to a surface of a non-woven, fibrous layer of material to form a stratum of melted fibers having a density greater than that of the remainder of the fibrous layer. The density of the melted fibers is effective in attenuating noise traversing the fibrous layer of material. Upholstery material, such as carpeting, is attached to the surface of the heated fibrous layer. The fibrous layer and upholstery material are then subjected to compressive molding pressure to obtain a desired shape. The compressive molding pressure may further tune the sound attenuating properties of the fibrous layer by selectively changing the densities of portions of the fibrous layer.

Abstract: Sound attenuating composite articles for use within vehicles as floor coverings and other interior trim components are provided. A sound attenuating composite article includes a damping layer, decoupler layer, scrim/web layer, and a porous upholstery material sandwiched together. The damping layer has a thickness of less than about 5 mm and is configured to be attached to a surface of a panel of a vehicle (e.g., a sheet metal or polymeric component of a vehicle, such as a floor panel, door panel, etc.) in face-to-face contacting relationship therewith. The decoupler layer has a thickness of less than about 70 mm and is attached to a surface of the damping layer in face-to-face contacting relationship. The scrim/web layer has a thickness of less than or equal to about two millimeters (2 mm). The porous upholstery material (e.g., carpeting) is attached to a surface of the scrim/web layer of material in face-to-face contacting relationship therewith.

Abstract: Sound attenuating composite articles for use within vehicles as floor coverings and other interior trim components are provided. A sound attenuating composite article includes a damping layer, decoupler layer, scrim/web layer, and a porous upholstery material sandwiched together. The damping layer has a thickness of less than about 5 mm and is configured to be attached to a surface of a panel of a vehicle (e.g., a sheet metal or polymeric component of a vehicle, such as a floor panel, door panel, etc.) in face-to-face contacting relationship therewith. The decoupler layer has a thickness of less than about 70 mm and is attached to a surface of the damping layer in face-to-face contacting relationship. The scrim/web layer has a thickness of less than or equal to about two millimeters (2 mm). The porous upholstery material (e.g., carpeting) is attached to a surface of the scrim/web layer of material in face-to-face contacting relationship therewith.

Abstract: Sound attenuating laminates, and methods of making the same, are provided. Heat is applied to a surface of a non-woven, fibrous layer of material to form a stratum of melted fibers having a density greater than that of the remainder of the fibrous layer. The density of the melted fibers is effective in attenuating noise traversing the fibrous layer of material. Upholstery material, such as carpeting, is attached to the surface of the heated fibrous layer. The fibrous layer and upholstery material are then subjected to compressive molding pressure to obtain a desired shape. The compressive molding pressure may further tune the sound attenuating properties of the fibrous layer by selectively changing the densities of portions of the fibrous layer.