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: 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 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 shoddy bottom layer and the scrim top layer.

Abstract: A method for adhesively bonding a covering to a support using a dry heat-sensitive adhesive to produce an assembly for an automotive interior. The method positions the layers to form an assembly of material layers in tooling that concentrates microwave radiation energy conversion to the adhesive layer above its melting temperature. The method for fabricating an assembly in accordance with the subject invention, particularly when the tooling is transparent to the radiation, controls the radiation reflection, which is generated at a frequency exceeding 30 GHz.

Abstract: A method of making a composite part including an insert and an elastomer layer that is bonded to the insert. The insert is placed in a mold and an uncured elastomer is sprayed into the mold to form a composite part. The inherent adhesive properties of the uncured elastomer is the sole mechanism for bonding the elastomer to the insert.

Abstract: An interior component for a motor vehicle has a first front surface region made from a first polyurethane, and a second front surface region integrated with the first region and made from a material different from the first polyurethane. For example, the second region may be carpeting or a region of polyurethane having a different color from the first region. In one embodiment, the interior component is a floor for a motor vehicle.

Abstract: A method of making a composite part including an insert and an elastomer layer that is bonded to the insert. The insert is placed in a mold and an uncured elastomer is sprayed into the mold to form a composite part. The inherent adhesive properties of the uncured elastomer is the sole mechanism for bonding the elastomer to the insert.

Abstract: A method for adhesively bonding a covering to a support using a dry heat-sensitive adhesive to produce an assembly for an automotive interior. The method positions the layers to form an assembly of material layers in tooling that concentrates microwave radiation energy conversion to the adhesive layer above its melting temperature. The method for fabricating an assembly in accordance with the subject invention, particularly when the tooling is transparent to the radiation, controls the radiation reflection, which is generated at a frequency exceeding 30 GHz.

Abstract: A method of making a vehicle floor covering by a spray forming process wherein areas of different thickness are provided. The thickness of the non-carpeted floor covering is varied to selectively improve durability, vibration absorption and noise reduction. Thickness may be selectively reduced to minimize material costs and weight reduction requirements. The floor covering is installed on the compartment pan of a vehicle over a decoupler.

Abstract: A method of forming an interior trim part having an insert and a spray formed layer. The insert has a rib that is received in a groove formed in a surface of the mold. The groove is provided with a vacuum port that may be used to draw the insert into the groove while the spray polymer layer is applied over at least a portion of the back of the insert. The bead receiving groove may be partially formed by a tool insert to which the vacuum is ported. The insert may be formed as a multi-layer film including a backing layer, decoration layer and clear coat layer. The multi-layer film may be vacuum formed to create a bead or rib on the insert. The method and tool may be used to form an interior trim part such as a floor covering with integral floor mats.

Abstract: An interior component for a motor vehicle has a first front surface region made from a first polyurethane, and a second front surface region integrated with the first region and made from a material different from the first polyurethane. For example, the second region may be carpeting or a region of polyurethane having a different color from the first region. In one embodiment, the interior component is a floor for a motor vehicle.

Abstract: A seat assembly includes a seat structural member and a clip having first and second hook portions. The first hook portion of the clip is attached to the structural member. The seat assembly also includes a first trim material having an edge attached to the clip. Preferably, the first trim material is an elastomeric material. The seat assembly further includes a second trim material having a first edge attached to the first trim material and a second edge attached to the second hook portion.

Abstract: A method and apparatus for bonding a cover (22) over an undulating surface of a foam cushion (10) by placing the cover, an adhesive layer (82) and the cushion on a tool (18), compressing the cushion with a compression plate (58) to force ambient temperature air from an interior thereof, piercing the cushion with a plurality of needles (44) extending through holes (60) in the compression plate, releasing the compression, heating compressed air and ejecting the heated air from the needles into the interior of the cushion to elevate the temperature of the cushion. The heat is transferred from the cushion (10) to melt the adhesive (82). The cushion (10) is again compressed by the compression plate (58) to force the heated air from the interior of the cushion and the compression is released to allow ambient temperature air to flow into the interior of the cushion to cure the adhesive (82) and bond the cover (22) to the cushion (10).

Abstract: The method of producing a cushion assembly includes bonding a foam pad to a cover material with a heat-activatable adhesive layer and an electrically conductive layer therebetween. The cover material is placed in a contoured mold with the adhesive layer and the electrically conductive layer placed thereover and in heat transfer relationship to each other. The foam pad is placed thereover and the electrically conductive layer is energized to heat and activate the heat-activatable adhesive layer to allow bonding between the foam pad, the cover material and the electrically conductive layer.

Abstract: A method and apparatus for bonding a cover (22) over the undulating surface of a foam cushion (10) by placing the foam cushion (10) on a tool (18), piercing the cushion (10) with a plurality of needles (44), lifting the needles (44) to lift the cushion (10) as the cushion is frictionally retained on the needles (44), heating ambient air and ejecting the hot air from the needles (44) and into the cushion to elevate the temperature of the cushion. A compression plate (58) with holes (60) extending therethrough is disposed against the backside of the cushion (10) with the needles (44) extending through the holes (60). The needles (44) with the cushion (10) thereon are lowered to place the undulating surface of the cushion against an adhesive film (82) on the backside of the cover (22) so that heat is transferred from the cushion (10) to melt the adhesive.

Abstract: A method and apparatus for bonding a cover (22) over the undulating surface of a foam cushion (10) includes placing the foam cushion (10) on a tool (18), piercing the cushion (10) with a plurality of needles (44), lifting the needles (44) to lift the cushion (10) as the cushion is frictionally retained on the needles (44), heating ambient air and ejecting the hot air from the needles (44) and into the cushion to elevate the temperature of the cushion. A compression plate (58) with holes (60) extending therethrough is disposed against the backside of the cushion (10) with the needles (44) extending through the holes (60). The needles (44) with the cushion (10) thereon are lowered to place the undulating surface of the cushion against an adhesive film (82) on the backside of the cover (22) so that heat is transferred from the cushion (10) to melt the adhesive.