# US 10,766,172 B2 · Method of bonding a thermoplastic component to a carpeted component > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 10,766,172 B2 - Document ID: US10766172B2 - Status: Granted - Kind: B2 - Application number: 15/163,797 - Filed: 2016-05-25 - Published: 2016-09-15 - Granted: 2020-09-08 - Earliest claimed: 2012-06-14 - Assignees: Global IP Holdings, LLC - Applicants: Global IP Holdings, LLC - Inventors: Darius J. Preisler; Christopher A. Heikkila - Web page: https://patentgrep.com/patent/US10766172B2 ## CPC - B29C 43/18: incorporating preformed parts or layers, e.g. compression moulding around inserts or for coating articles {(B29C43/206 takes precedence)} - B29B 13/022: {Melting the material to be shaped} - B29C 43/203: {Making multilayered articles} - B29C 43/52: Heating or cooling - B29C 65/70: by moulding (using a particular moulding technique, see the relevant technique {, e.g. by injection B29C45/14467}) - B29C 70/68: by incorporating or moulding on preformed parts, e.g. inserts or layers {, e.g. foam blocks (mould constructions therefor B29C33/12; joining preformed parts by moulding B29C65/70)} - B32B 37/182: {one or more of the layers being plastic} - B29C 2043/189: {the parts being joined} - B29C 2043/525: {at predetermined points for local melting, curing or bonding} - B29K 2623/12: {PP, i.e. polypropylene} - B29K 2667/00: Use of polyesters {or derivatives thereof} for preformed parts, e.g. for inserts - B29K 2713/00: Use of textile products or fabrics for preformed parts, e.g. for inserts (B29K2105/06 takes precedence) - B29L 2031/7322: {Carpets} - B32B 37/06: characterised by the heating method - B32B 2309/02: Temperature - B32B 2309/12: Pressure - B32B 2398/20: Thermoplastics - B32B 2471/02: Carpets - B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00) - B29B: PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS - B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM - B29K: INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR {MOULDS, } REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS - B29L: INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES ## Abstract A method of bonding a thermoplastic component to a carpeted component is provided. The method includes providing a base component, a thermoplastic component and a fibrous carpet or mat between the components. The carpet has a large number of cavities. The carpet is made of a thermoplastic material adapted to bond to the thermoplastic component in response to heat at the interface between the thermoplastic component and the carpet. The method also includes heating the thermoplastic component and the carpet at the interface between the thermoplastic component and the carpet for a period of time to soften the carpet. The method finally includes pressing the components and the softened carpet together under a pressure to cause the softened carpet to flow and at least partially fill the cavities. The carpet at the interface is transformed into a solid bonding layer to bond the components together to create a finished structure. ## Claims ### Claim 1 A method of bonding thermoplastic components to a carpeted component to form a sandwich-type article, the method comprising: providing a set of article components, the set of article components including a thermoplastic component, a first thermoplastic carpet, a first reinforced thermoplastic skin, a cellulose-based core, a second reinforced thermoplastic skin, a second thermoplastic carpet, and a covering layer, the first thermoplastic carpet being adapted to bond to the thermoplastic component and the first reinforced thermoplastic skin upon becoming fluent under application of heat, the second thermoplastic carpet being adapted to bond to the covering layer and the second reinforced thermoplastic skin upon becoming fluent under application of the heat; heating the set of article components sufficiently to cause the first thermoplastic carpet to become fluent in the area where the first thermoplastic carpet is to be bonded to the thermoplastic component and the first reinforced thermoplastic skin and to cause the second thermoplastic carpet to become fluent in the area where the second thermoplastic carpet is to be bonded to the covering layer and the second reinforced thermoplastic skin; placing, in a compression mold, the covering layer, the second thermoplastic caret overlying and in contact with the covering layer, the second reinforced thermoplastic skin overlying and in contact with the second thermoplastic carpet, the cellulose-based core overlying and in contact with the second reinforced thermoplastic skin, the first reinforced thermoplastic skin overlying and in contact with the cellulose-based core, the first thermoplastic carpet overlying and in contact with the first reinforced thermoplastic skin, the thermoplastic component overlying and in contact with the first thermoplastic carpet; closing the compression mold and applying substantially uniform pressure over the surface area of the set of article components to cause the set of article components to bond into a sandwich-type article in a single pressing operation, the bonding including to cause the fluent thermoplastic of the first thermoplastic carpet to form a solid bonding layer at its interfaces with the thermoplastic component and the first reinforced thermoplastic skin, as well as to cause the fluent thermoplastic of the second thermoplastic carpet to form a solid bonding layer at its interfaces with the covering layer and the second reinforced thermoplastic skin; and removing the bonded components from the mold as a sandwich-type article. ### Claim 2 (depends on 1) The method as claimed in claim 1, wherein the step of heating the set of article components occurs prior to the placing step. ### Claim 3 (depends on 1) The method as claimed in claim 1, wherein the step of heating the set of article components occurs after the placing step. ### Claim 4 (depends on 1) The method as claimed in claim 1, wherein the thermoplastic of the first thermoplastic carpet and the second thermoplastic carpet is polypropylene. ### Claim 5 (depends on 1) The method as claimed in claim 1, wherein the thermoplastic of the thermoplastic carpet and the thermoplastic of the second thermoplastic carpet is polyester. ### Claim 6 (depends on 1) The method as claimed in claim 1, wherein the first thermoplastic carpet has a surface area greater than a surface area of the thermoplastic component and wherein a portion of the first thermoplastic carpet spaced away from the interface forms an outer exterior surface of a finished structure. ### Claim 7 (depends on 1) The method as claimed in claim 1, wherein the heating step occur during the application of substantially uniform pressure over the surface area of the set of article components and wherein the set of article components including the fluent first and second thermoplastic carpets are thereby welded to each other at their interfaces. ### Claim 8 (depends on 1) The method as claimed in claim 1, wherein the temperatures of the set of article components in the heating step lie in a range of 160° C. to 200° C. ### Claim 9 (depends on 1) The method as claimed in claim 1, wherein the pressure lies in a range of 1×106 Pa to 3×106 Pa.