Abstract: Sound-deadening composites of metallocene copolymers having superior properties are used in automotive applications. Flexible composites having low temperature performance properties with improved elongation and impact strength are provided.

Abstract: A recyclable, thermoplastic backing material having the feel and weight of a rubber backing for use on a throw in mat. As compared with conventional rubber backed throw-in mats, the new thermoplastic material does not require a latex backing to adhere the rubber backing material to the primary backing layer. This may lead to decreased manufacturing costs associated with purchasing and applying the latex backing material. Further, because the material is recyclable, decreased costs associated with waste may be achieved.

Abstract: A vehicle carpet module consisting of a piece of tufted carpet that is attached to a piece of thermoplastic material, the module being contoured to the shape of a motor vehicle floor. The carpet module being vacuum formed over a single hollow mold element. The mold element having a molding surface shaped to correspond to the shape of the vehicle floor and having a plurality of vacuum ports formed through the contoured surface. A vacuum pulling the air from the interior of the mold element and causes the vacuum ports to draw a heated carpet segment against the contoured surface and thereby shape the segment into a carpet module. The carpet segment is heated sufficiently soften the thermoplastic material which, upon subsequent cooling, hardens to retain the shape of the molding surface.

Abstract: Sound-deadening composites of metallocene copolymers having superior properties are used in automotive applications. Flexible composites having low temperature performance properties with improved elongation and impact strength are provided.

Abstract: A grommet assembly for providing a location for a fastener to attach a cover member to a support structure includes first and second flange members. The flange members are sonically weldable to each other and are adapted to sandwich the cover member therebetween. Each of the flange members defines a passageway portion and has a recess portion. At least one of the flange members has a plurality of protrusions. The first and second flange members, upon being sonically welded together, cooperate to define a passageway with the passageway portions, and further cooperate to define a recess with the recess portion. The passageway is adapted to receive the fastener, and the recess is adapted to receive the cover member. The protrusions extend into the passageway and are engageable with the fastener.

Abstract: A material comprising a thermoplastic sheet is bonded ultrasonically to another thermoplastic textile or non-thermoplastic fibrous textile surface. The fibrous textile surface has an equivalent or higher melt temperature than thermoplastic sheet.