Method of manufacturing carpet for automobiles having a three-dimensional shape

A method for manufacturing a three dimensional shaped carpet used for an automobile, comprising steps of providing a preheated liquid foamable mixture:

• coating a preheated liquid foamable mixture directly on a back surface of a surface material of said carpet by a spray system;
• placing said surface material in a molding die comprising an upper portion and a lower portion, said upper and said lower portions defining a space inside said molding die corresponding to a three dimensional shape of said carpet;
• pressing and clamping) said liquid foamable mixture with said surface material between said upper portion and said lower portion, when said liquid foamable mixture coated on said back surface of said surface material has completed a gas reaction thereof but is still in a visco-elastic flowing condition;
• and
• changing said liquid foamable mixture into a solid condition, thereby a foamed body layer made of said liquid foamable mixture is molded in three dimension and is molded and connected in one with said surface material through said back surface thereof,
• wherein droplets of said liquid foamable mixture coated on said surface material by said spray system are entered into a fiber structure of said surface material and are attached on a surface of each fiber of said fiber structure while said liquid foamable mixture attached on said fiber of said fiber structure is immediately foamed and expanded by said gas reaction, so that said liquid foamable mixture remains at a shallow part inside of said surface material and is foamed without said liquid foamable mixture being impregnated into a deeper part thereof, and thereby said foamed body layer is in one with said carpet.