Process for making noise absorber carpet

Abstract

A process for making a noise absorber carpet including a fabric layer and a resinous backing layer, the process including providing an uncured resinous backing layer within a mold having perforation pins, heating the backing layer to activate the resin, providing a fabric layer, pressing the fabric layer into the backing layer while maintaining the heating process to the backing layer, and providing a cooling medium to cool the mold to fix and cure the perforations within the backing layer thereby forming noise absorber perforations in the resinous backing layer.

1 . A process for making a noise absorber carpet comprised of a fabric layer portion and a resinous backing layer portion, comprising the steps of:
 (a) providing an uncured resinous backing layer within a mold having perforation pins;   (b) heating the resinous backing layer to activate the resin;   (c) providing a fabric layer portion;   (d) pressing the fabric layer portion into the resinous backing layer portion while maintaining the heating process to the resinous backing layer portion; and   (e) providing a cooling medium to cool the mold to fix and cure perforations in the backing layer thereby forming noise absorber perforations in the resinous backing layer.   
     
     
         2 . The process according to  claim 1 , wherein the mold further includes slippage prevention spike forming depressions, and the process further comprises providing the resinous backing layer portion with slippage prevention spikes formed by contact with the spike forming depressions in the mold. 
     
     
         3 . The process according to  claim 1 , wherein the step of pressing the fabric layer portion into the resinous backing layer portion is done on a flat press.