Method for manufacturing a sound insulating structure and the structure produced thereby

A laminated vehicle sound insulating carpet panel comprising:

• a backing layer having a plurality of textile tufts embedded therein to establish interior and exterior faces of the backing layer;
• and
• a layer of a permeable polymeric material disposed on the exterior face of the backing material, wherein the polymeric material is disposed in the plurality of textile tufts and defines a plurality of voids;
• wherein the shape of the panel corresponds to a predetermined shape of an interior surface of a motor vehicle;
• and
• wherein the plurality of voids are formed in the panel, which is preheated, and subsequently closed within a forming mold with controlled pressure sufficient for expanding the panel to conform it to the mold.

A laminar textile assembly for use in a motor vehicle comprising:

• a backing layer having a plurality of textile tufts embedded therein to establish interior and exterior faces of the backing layer;
• and
• a layer of a polymeric material disposed on the exterior face of the backing material, wherein the polymeric material defines a plurality of voids between the plurality of textile tufts with portions of the polymeric material being disposed in textile tufts;
• wherein the plurality of voids are formed in the assembly, which is preheated, and subsequently closed within a forming mold with controlled pressure sufficient for expanding the assembly to conform it to the mold.

A three dimensional laminar assembly for use in a motor vehicle comprised of:

• a backing;
• a plurality of textile tufts embedded in the backing to define face and exterior surfaces and a plurality of voids between the tufts;
• and
• a polymeric material overlying the exterior surface and disposed in the textile tufts and the voids between the textile tufts;
• wherein the plurality of voids are formed in the assembly, which is preheated, and subsequently closed within a forming mold with controlled pressure sufficient for expanding the assembly to conform it to the mold.

A three dimensional sound insulating carpet panel for use in a motor vehicle comprising:

• a backing layer having a plurality of textile tufts embedded therein to establish interior and exterior faces of the backing layer and a plurality of voids among the plurality of textile tufts;
• and
• a layer of a polymeric material disposed on the exterior face of the backing material and in the plurality of textile tufts to define a plurality of voids between tufts;
• wherein the plurality of voids are formed in the panel, which is preheated, and subsequently closed within a forming mold with controlled pressure sufficient for expanding the panel to conform it to the mold.