Abstract: A decorative, nonwoven laminate and a method of forming, including a first side of a first nonwoven affixed to one or both of a) a first side of a polymeric sheet or b) a second nonwoven, wherein the first nonwoven exhibits a basis weight of 15 g/m2 to 2500 g/m2 and the second nonwoven exhibits a basis weight of 15 g/m2 to 1200 g/m2; and a colorant deposited on a second side of the first nonwoven. A topical coating may or may not be applied to improve durability of the printed surface layer. The decorative nonwoven laminate may also amount to a single layer of the first nonwoven, which then includes a layer of colorant and a topical coating over the colorant and single nonwoven layer.

Abstract: A decorative, nonwoven laminate and a method of forming, including a first side of a first nonwoven affixed to one or both of a) a first side of a polymeric sheet or b) a second nonwoven, wherein the first nonwoven exhibits a basis weight of 15 g/m2 to 2500 g/m2 and the second nonwoven exhibits a basis weight of 15 g/m2 to 1200 g/m2; and a colorant deposited on a second side of the first nonwoven. A topical coating may or may not be applied to improve durability of the printed surface layer. The decorative nonwoven laminate may also amount to a single layer of the first nonwoven, which then includes a layer of colorant and a topical coating over the colorant and single nonwoven layer.

Abstract: Porous carpeting for use within vehicles, and methods of making same, are provided. A carpet backing is heated to achieve a fluid or semi-fluid state and then subjected to intense vacuum to draw air through the carpet backing to create a porous structure. A layer of porous thermoformable material may be applied to the porous carpet structure to provide mechanical strength.

Abstract: Sound absorbing/sound blocking products, including trim products formed from a porous fibrous layer backed by a sound absorbing layer and a sound blocking layer for use within vehicles, and methods of making same, are provided. A porous fibrous layer structure including a fibrous layer backing is heated to achieve a fluid or semi-fluid state and then subjected to vacuum to draw air through the fibrous layer backing to create a porous structure. A layer of sound absorbing and a layer of sound blocking material may be applied to the porous fibrous layer backing to provide improved acoustic properties. An underlayment may further be included to provide selected areas of increased thickness and provide tailoring of sound attenuation.

Abstract: Light weight acoustic carpet including porous carpeting backed by a primary sound reducing layer and localized secondary insulators for use within vehicles, and methods of making same, are provided. A porous carpet structure including a carpet backing is heated to achieve a fluid or semi-fluid state and then subjected to intense vacuum to draw air through the carpet backing to create a porous structure. A layer of sound absorbing or insulating material may be applied to the porous carpet structure to provide improved acoustic properties. Secondary sound reducing absorbers/insulators may further be included as part of the molding process to provide selected areas of increased thickness and provide tailoring of sound attenuation.

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: Floor mats that can be removably secured to loop pile carpeting within a vehicle include a surface layer having an aesthetic appearance, a backing layer in face-to-face contacting relationship with the surface layer, and a layer of scrim material integrally disposed within the backing layer, wherein the layer of scrim material comprises a plurality of hooks extending outwardly therefrom and through the backing layer in one or more locations. The hooks are configured to engage loops in floor carpeting within a vehicle when the floor mat is placed on the carpeting. Moreover, the size and density of the hooks are configured such that damage to the carpeting when the floor mat is removed from the carpeting is reduced.

Abstract: Sound absorbing/sound blocking products, including trim products formed from a porous fibrous layer backed by a sound absorbing layer and a sound blocking layer for use within vehicles, and methods of making same, are provided. A porous fibrous layer structure including a fibrous layer backing is heated to achieve a fluid or semi-fluid state and then subjected to vacuum to draw air through the fibrous layer backing to create a porous structure. A layer of sound absorbing and a layer of sound blocking material may be applied to the porous fibrous layer backing to provide improved acoustic properties. An underlayment may further be included to provide selected areas of increased thickness and provide tailoring of sound attenuation.

Abstract: Light weight acoustic carpet including porous carpeting backed by a primary sound reducing layer and localized secondary insulators for use within vehicles, and methods of making same, are provided. A porous carpet structure including a carpet backing is heated to achieve a fluid or semi-fluid state and then subjected to intense vacuum to draw air through the carpet backing to create a porous structure. A layer of sound absorbing or insulating material may be applied to the porous carpet structure to provide improved acoustic properties. Secondary sound reducing absorbers/insulators may further be included as part of the molding process to provide selected areas of increased thickness and provide tailoring of sound attenuation.

Abstract: Apparatus and methods are provided forming a sound attenuating laminate that has a decoupler fiber layer and a mass layer in opposing relationship with each other. The decoupler fiber layer and mass layer of the laminate are heated to the selected temperature in substantially the same amount of time via a hot air source and a heated platen, respectively. The heated laminate is conveyed to a mold and formed into a predetermined three-dimensional configuration via the mold.

Abstract: Porous carpeting for use within vehicles, and methods of making same, are provided. A carpet backing is heated to achieve a fluid or semi-fluid state and then subjected to intense vacuum to draw air through the carpet backing to create a porous structure. A layer of porous thermoformable material may be applied to the porous carpet structure to provide mechanical strength.

Abstract: Sound attenuating composite articles and methods of making same are provided. Sound attenuating composite article include first, second and/or third and/or fourth layers of material. The first layer of material may be either an acoustic fiber batting and/or an acoustic foam material and may be an elastic or inelastic material. The second layer of material is a thermoplastic material that is fused to a surface of the first layer of material. The third layer of material is a thermoplastic material that is fused to a surface of the second layer of material. The fourth layer of material is a woven or non-woven mixture of fibers, such as scrim material, that is attached to a surface of the third layer of material. Selected portions of the sound attenuating composite article are heated and then compressed (referred to as “tuned”) so as to have an acoustic impedance that is greater than an acoustic impedance of adjacent portions.