Abstract: A modular interchangeable floor mat includes a mat frame and a mat insert. The mat frame includes a central portion having a plurality of integrally formed upwardly-extending hooked nibs and a peripheral edge. The mat insert includes a hook-retaining material defining a bottom surface. The hook-retaining material may include a nonwoven material or a reticulated foam. The plurality of upwardly-extending hooked nibs of the mat frame is engageable with the hook-retaining material of the mat insert. The mat frame may also include a plurality of integrally formed downwardly-depending nibs or ridges.

Abstract: A floor mat for covering a motor vehicle flooring system having a plurality of fibers is disclosed. The floor mat includes a thermoplastic layer having first and second surfaces and a plurality of projections extending from the second surface. Each of the projections includes an elongated body portion and an enlarged tip for engaging the fibers. A method of making such floor mats is also disclosed.

Abstract: Method for making flexible, noncarpeted thermoplastic articles, including floor mats. The method includes placing a flat slab of thermoplastic material in a cavity between first and second mold sections with each mold section having a mold surface for contacting a respective surface of the slab. The mold cavity is placed under vacuum and the mold sections are heated under compression to cause the thermoplastic material to heat and flow against the mold surfaces. The process further involves cooling the mold sections under compression and removing the floor mat from the mold sections. Vacuum is maintained in the mold cavity by way of a check valve device during transition from the heated compression apparatus to the cooled compression apparatus and during the cooled compression step. In this general manner, a floor mat formed with a Class A, textured finish and with a variable cross sectional thickness may be manufactured in a short cycle time.

Abstract: Methods of making thermoplastic articles having integral projections extending from a surface thereof. The methods utilize a mold plate having a top side, an underside and a cavity extending from the top side to the underside for forming the integral projection. The methods utilize an air escape passage for allowing escape of air from the cavity in the mold plate during the pressing operation. At least a portion of the molding operation is conducted while the temperature of the entrance to the air escape passage is below the molding temperature of the thermoplastic material being molded.

Abstract: A process which combines the technologies of extrusion blow molding to form a shaped article and subsequently forming and attaching a textile to the contoured outer surface of the article.