Blow molded load floors

A load floor, comprising:

• a plurality of inserts;
• a top surface at least partially encapsulating said plurality of inserts;
• and
• a bottom surface fused to said top surface and said encapsulated inserts.

A method of forming a load floor of a vehicle comprising the steps of:

• forming a parison;
• feeding said parison between a first mold half and a second mold half, said first and second mold halves shaped like the load floor;
• hanging a carpet having a tuft attached to a first side of a backing and a plurality of inserts attached to a second side of said backing in said first mold half;
• clamping said parison by moving said first and second mold halves together to form a mold;
• and
• pushing said heated parison outward, using blown air, such that said heated parison is adjacent said second side of said backing in said first mold forming a top surface and encapsulating said plurality of inserts, and adjacent said second mold half forming a bottom surface fused to a portion of said parison encapsulating said plurality of inserts.