Method of bonding a thermoplastic component to a carpeted component

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.

1 . A method of bonding a thermoplastic component to a carpeted component, the method comprising:
 providing a base component, a thermoplastic component and a fibrous carpet having thermoplastic fibers between the components, the carpet having a large number of cavities between the fibers, 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 thermoplastic material adapted to bond to the thermoplastic component in response to heat at the interface between the thermoplastic component and the carpet;   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 including the fibers; and   pressing the components and the softened carpet together under a pressure to cause the softened carpet including the fibers to flow and at least partially fill the cavities wherein the carpet including the fibers at the interface are transformed into a solid bonding layer to bond the components together to create a finished structure and wherein the individual fibers at the interface are transformed to lose their definition.   
     
     
         2 . The method as claimed in  claim 1 , wherein the carpet is a decorative carpet. 
     
     
         3 . The method as claimed in  claim 1 , wherein the carpet is made of non-woven fibers. 
     
     
         4 . The method as claimed in  claim 1 , wherein the carpet is made of woven fibers. 
     
     
         5 . The method as claimed in  claim 1 , wherein the carpet has an upper thermoplastic fiber layer and a lower thermoplastic backing layer. 
     
     
         6 . The method as claimed in  claim 1 , wherein at least a portion of the carpet bonds the components together. 
     
     
         7 . The method as claimed in  claim 1 , wherein the entire carpet bonds the components together. 
     
     
         8 . The method as claimed in  claim 1 , wherein the thermoplastic of the carpet and the thermoplastic of the thermoplastic component are polypropylene. 
     
     
         9 . The method as claimed in  claim 1 , wherein the thermoplastic of the carpet and the thermoplastic of the thermoplastic component are polyester. 
     
     
         10 . The method as claimed in  claim 1 , wherein the step of heating occurs before the step of pressing and wherein the components and the fabric are cold-pressed during the step of pressing. 
     
     
         11 . The method as claimed in  claim 1 , wherein the base component is a skin or layer made of a reinforced thermoplastic material. 
     
     
         12 . The method as claimed in  claim 1 , wherein the carpet has a surface area greater than a surface area of the thermoplastic component and wherein a portion of the carpet spaced away from the interface is not transformed and forms an outer exterior surface of the finished structure. 
     
     
         13 . The method as claimed in  claim 12 , wherein the carpet is a decorative carpet and wherein the portion of the outer exterior surface is a decorative surface. 
     
     
         14 . The method as claimed in  claim 1 , wherein the step of heating occurs during the step of pressing and wherein the thermoplastic component and the carpet are welded to each other at the interface. 
     
     
         15 . The method as claimed in  claim 1 , wherein a temperature at the interface lies in a range of 160° C. to 200° C. during the step of heating. 
     
     
         16 . The method as claimed in  claim 1 , wherein the pressure lies in a range of 1×106 Pa to 3×106 Pa. 
     
     
         17 . The method as claimed in  claim 1 , wherein both of the components are heated to a temperature above a softening temperature of the carpet during the step of heating. 
     
     
         18 . The method as claimed in  claim 1 , wherein the step of pressing includes the step of press molding in a compression mold. 
     
     
         19 . A method of bonding thermoplastic components together, the method comprising:
 providing first and second thermoplastic components and a fibrous carpet having a large number of cavities between the components, the carpet overlying and in contact with the first component and the second component overlying and in contact with the carpet, the carpet being made of a thermoplastic material adapted to bond to the first and second thermoplastic components in response to heat at the interfaces between the components and the carpet;   heating the components to a temperature above a softening temperature of the carpet, heat from the heated components heating the carpet at the interfaces between the components and the carpet for a period of time to soften the carpet; and   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 in the carpet wherein the carpet at the interfaces is transformed into a solid bonding layer to bond the components together to create a finished structure.   
     
     
         20 . A method of bonding thermoplastic components together, the method comprising:
 providing first and second thermoplastic components and a fibrous mat having thermoplastic fibers and having a large number of cavities between the components and between the fibers, the mat overlying and in contact with the first component and the second component overlying and in contact with the mat, the mat being made of a thermoplastic material adapted to bond to the first and second thermoplastic components in response to heat at the interfaces between the components and the mat;   heating the components to a temperature above a softening temperature of the mat, heat from the heated components heating the mat at the interfaces between the components and the mat for a period of time to soften the mat including the fibers; and   pressing the components and the softened mat together under a pressure to cause the softened mat including the fibers to flow and at least partially fill the cavities in the mat wherein the mat including the fibers at the interfaces are transformed into a solid bonding layer to bond the components together to create a finished structure and wherein the individual fibers at the interfaces are transformed to lose their definition.