Abstract: The present invention relates to a composite shoddy for use in a vehicle interior. To this end, the composite shoddy of the present invention includes an organic material having a predetermined density defining a shoddy bottom layer and a scrim material having a predetermined density defining a scrim top layer. The scrim top layer is adapted to operatively engage a surface material and accommodate movement of a surface material in the shear direction. The composite shoddy further includes a bituminous mastic material having a predetermined density defining a mastic middle layer. The mastic middle layer is disposed between the organic bottom layer and the scrim top layer.

Abstract: The present invention provides for an improved method of making non-carpeted floor coverings for vehicles. The method includes providing a non-carpeted floor covering blank having a precut non-carpeted flooring, precut under-pad, and precut adhesive layer. The adhesive layer is situated intermediate the non-carpeted flooring and under-pad. The blank is heated to join the non-carpeted flooring and under-pad to the adhesive layer to form an integrated blank. The integrated blank is molded into a desired shape then trimmed for use as a non-carpeted floor covering in a vehicle.

Abstract: A method of making an acoustic insulator includes depositing thermoplastic particulate on a first surface of a base layer. The method further includes heating the particulate such that the particulate at least partially melts and penetrates the first surface of the base layer, thereby increasing density and airflow resistance of the base layer proximate the first surface such that the base layer has an areal mass in the range of 0.1 to 1.0 kg/m2 and an airflow resistance in the range of 300 to 5,000 Nsm?3 proximate the first surface.

Abstract: Methods for reducing surface gloss of a vehicle interior trim component, such as non-carpeted floor coverings. Gloss is reduced by treating a surface of the interior trim component with an energy beam, such as a gas plasma, a flame plasma, or a corona discharge, emitted from a treatment device. A positioning device supports the treatment device in a spaced relationship to the surface. The positioning device causes the treatment device and the interior trim component to be moved relative to each other during the course of the gloss reduction treatment.

Abstract: The present invention relates to a composite shoddy for use in a vehicle interior. To this end, the composite shoddy of the present invention includes an organic material having a predetermined density defining an organic bottom layer and a scrim material having a predetermined density defining a scrim top layer. The scrim top layer is adapted to operatively engage a surface material and accommodate movement of a surface material in the shear direction. The composite shoddy further includes a mastic material having a predetermined density defining a mastic middle layer. The mastic middle layer is disposed between the organic bottom layer and the scrim top layer.

Abstract: A non-pile carpet vehicle floor covering having a mass filled layer of variable thickness sprayed onto a polyurethane top surface. The method of making the vehicle floor covering comprises spraying a polyurethane layer over a mold release layer. A mass filled layer is then sprayed onto the polyurethane top layer before the polyurethane layer fully solidifies. A decoupler may be poured onto or adhesively attached to the mass filled layer. The mass filled layer may have thick areas and thin areas to provide varying levels of noise and vibration control as required by a particular vehicle application.