Carpet with integrated ventilation duct and footrest and method for making same

摘要

A carpet assembly for a motor vehicle is provided. The carpet assembly includes a carpet fitted to cover the floor pan of the motor vehicle. A plastic ventilation duct is disposed below the carpet and extends from the heating and air conditioning system in the instrument panel to beneath the front row of seats. A hard foam blocked footrest is also disposed below said carpet. Polyurethane foam is provided below the carpet not only to provide cushion for the carpet but also to attach the ventilation duct and footrest to the carpet, thereby providing a unitary carpet assembly. The foam is formed substantially about the ventilation duct to reduce the heat transfer between the conditioned air and the surroundings.