Method of making a floor tile with overmolded pads
AssigneeMacneil IP LLC
InventorsFrederick W. MASANEK, JR., Thomas MALEWIG, David S. IVERSON, Allan R. Thom
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Abstract
A plastic floor tile is formed by molding a body of a first polymer compound and overmolding features onto the body from a second polymer compound. The compounds may be different from each other in hardness and/or color. The overmolded features may include raised pads on the upper surface of the tile. The pads on the upper surface may be injection-molded from the lower surface through through-holes, which are smaller in area than the area of the pads.
Claims5
A method for forming a modular floor tile for use in creating a flooring surface comprising a plurality of such tiles, the method comprising the steps of:
- molding a body of the tile from a first thermoplastic polymer compound to have a general upper surface;
- forming the body of the tile to have at least one through-hole per pad, the through-hole communicating the general upper surface of the body to a lower surface thereof;
- defining each plurality of pads to have an area on the upper surface which is larger than an area on the upper surface of the through hole;
- overmolding, onto the general upper surface, a plurality of pads from a second thermoplastic polymer compound which is different from the first polymer compound, the pads being spaced apart from each other on the general upper surface;
- said step of overmolding including the steps of injecting the second polymer compound into a mold at at least one fill point adjacent the lower surface of the body and flowing the second polymer compound through the through-holes to form a plurality of pads on the general upper surface.
The method of claim 3, and further comprising the steps of
- forming, in the mold, a plurality of runners to be adjacent the lower surface of the body to connect a common fill point to each of the plurality of through-holes;
- and
- during said step of overmolding, flowing the second polymer from the common fill point through the runners to the through-holes.
The method of claim 4, and further comprising the steps of
- forming a second polymer compound gate to extend from the general upper surface of the body to the lower surface thereof, so as to communicate with the runners;
- and
- injecting the second polymer compound through the second polymer compound gate to mold the pads.
A method for forming a modular floor tile for use in creating a flooring surface comprising a plurality of such tiles, the method comprising the steps of:
- molding a body of the tile from a first thermoplastic polymer compound to have a general upper surface;
- forming, around each location at which a pad is to be molded, a smooth crush ring to be elevated above the general upper surface;
- overmolding, onto the general upper surface, a plurality of pads from a second thermoplastic polymer compound which is different from the first polymer compound, the pads being spaced apart from each other on the general upper surface;
- and
- using the crush ring to shut off the second polymer compound in order to substantially prevent flashing of the second polymer compound.
Dependencies are inferred from the claim text.