Method of bonding a thermoplastic component to a carpeted component and the carpeted component to a cellulose-based core in a single pressing step

A method of bonding a thermoplastic component to a carpeted component and the carpeted component to a cellulose-based core in a single pressing step, the method comprising:

• providing a stack of materials comprising a base component of a reinforced thermoplastic material, a solid one-piece thermoplastic component, a fibrous carpet between the components, a sheet of thermoplastic adhesive and a core of cellulose-based material, the carpet having a plurality of cavities, the carpet overlying and in contact with the base component and the thermoplastic component overlying and in contact with the carpet, the carpet being made of a polypropylene thermoplastic material whose fibers become softened and bond to the thermoplastic component in response to heat at the interface between the thermoplastic component and the carpet;
• heating the carpet at the interface between the thermoplastic component and the carpet in a range of 160° C. to 200° C. for a period of time to soften the carpet fibers;
• and
• pressing the components, the sheet, the core and the softened carpet together under a pressure to cause the softened carpet fibers to flow into the cavities wherein the fibrous carpet at the interface is transformed into a solid bonding layer to bond the components together and the sheet bonds the base component and the core together to create a finished structure.