Abstract: A throw-in mat for a vehicle floor includes a primary backing layer having first and second sides with a carpet pile tufted into the first side of the primary backing layer. A thermoplastic back is secured to the second side of the primary backing layer. The thermoplastic back has a base thickness and a contiguous diamond-shaped pattern of grooves formed therein such that the thermoplastic back has a residual thickness adjacent each groove which is less than approximately 50% of the base thickness, thereby preventing curling and bowing problems at extreme temperatures.

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: 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.