Floor mats and method of making same

A method of making a floor mat, the method comprising:

• positioning a thermoplastic layer on a mold having a plurality of cavities for forming projections on the thermoplastic layer;
• positioning the mold between first and second platens of a first press, the first platen having a first surface maintained at a temperature in the range of 40° F. to 120° F., the second platen having a second surface maintained at a temperature in the range of 250° F. to 500° F.;
• applying a compressive force in the range of 10 to 50 psi to the mold and the thermoplastic layer by compressing the mold and the thermoplastic layer between the first and second platens of the first press so as to heat the thermoplastic layer to a first temperature;
• positioning the mold between first and second platens of a second press, the first platen having a first surface maintained at a temperature in the range of 40° F. to 120° F., the second platen having a second surface maintained at a temperature in the range of 250° F. to 500° F.;
• applying a compressive force in the range of 10 to 50 psi to the mold and the thermoplastic layer by compressing the mold and the thermoplastic layer between the first and second platens of the second press so as to heat the thermoplastic layer to a second temperature, which is at least as great as a molding temperature of the thermoplastic layer;
• positioning the mold between first and second platens of a third press, the first platen having a first surface maintained at a temperature in the range of 40° F. to 120° F., the second platen having a second surface maintained at a temperature in the range of 40° F. to 120° F.;
• applying a compressive force in the range of 50 to 180 psi to the mold and the thermoplastic layer by compressing the mold and the thermoplastic layer between the first and second platens of the third press so as to form a plurality of projections on the thermoplastic layer, each of the projections having an elongated body portion;
• removing the thermoplastic layer from the mold;
• positioning the thermoplastic layer between first and second platens of a fourth press, the first platen having a first surface maintained at a temperature in the range of 40° F. to 120° F., the second platen having a second surface maintained at a temperature in the range of 250° F. to 400° F.;
• and
• applying a compressive force in the range of 1 to 10 psi to the thermoplastic layer by compressing the thermoplastic layer between the first and second platens of the fourth press so as form enlarged tips on the projections.

A method of making a removable floor mat for covering a flooring system, the method comprising:

• positioning a thermoplastic layer on a mold having a cavity for forming a projection on the thermoplastic layer, the mold further having an escape passage for allowing air to escape from the cavity;
• heating the mold in a first press including a platen having a surface maintained at a first predefined temperature;
• transferring heat to the thermoplastic layer by contact with the heated mold under conditions sufficient to soften the thermoplastic layer without causing substantial flow thereof;
• causing a portion of the thermoplastic layer to flow into the cavity while maintaining the temperature at about an entrance of the escape passage below the molding temperature of the thermoplastic layer, thereby minimizing flow of thermoplastic material into the escape passage, so as to form a projection on the thermoplastic layer, the projection having an elongated body portion;
• heating the projection to sufficiently soften the projection;
• and
• compressing the thermoplastic layer sufficiently so as to form an enlarged tip on the projection, the enlarged tip being engageable with the flooring system.

A method of making a removable floor mat for covering a flooring system, the method comprising:

• positioning a thermoplastic layer on a mold, the mold having a plurality of cavities for forming projections on the thermoplastic layer, the mold further having a plurality of escape passages extending from the cavities to an edge of the mold for allowing air to escape from the cavities;
• positioning a cover layer over the thermoplastic layer;
• positioning the mold between first and second platens of a first press such that the cover layer is disposed proximate the first platen, the first platen having a first surface maintained at a temperature in the range of 40° F. to 120° F., the second platen having a second surface maintained at a temperature in the range of 250° F. to 500° F.;
• applying a compressive force in the range of 10 to 50 psi to the mold, the thermoplastic layer and the cover layer by compressing the mold, the thermoplastic layer and the cover layer between the first and second platens of the first press so as to heat the thermoplastic layer to a first temperature without causing substantial flow of thermoplastic material into the cavities;
• positioning the mold between first and second platens of a second press such that the cover layer is disposed proximate the first surface, the first platen having a first surface maintained at a temperature in the range of 40° F. to 120° F., the second platen having a second surface maintained at a temperature in the range of 250° F. to 500° F.;
• applying a compressive force in the range of 10 to 50 psi to the mold, the thermoplastic layer and the cover layer by compressing the mold, the thermoplastic layer and the cover layer between the first and second platens of the second press so as to heat the thermoplastic layer to a second temperature without causing substantial flow of thermoplastic material into the cavities, wherein the second temperature is at least as great as a molding temperature of the thermoplastic layer;
• positioning the mold between first and second platens of a third press, the first platen having a first surface maintained at a temperature in the range of 40° F. to 120° F., the second platen having a second surface maintained at a temperature in the range of 40° F. to 120° F.;
• applying a compressive force in the range of 50 to 180 psi to the mold, the thermoplastic layer and the cover layer by compressing the mold, the thermoplastic layer and the cover layer between the first and second platens of the third press, while maintaining the temperature at entrances of the escape passages at least 20° F. below the molding temperature of the thermoplastic layer, thereby minimizing flow of thermoplastic material into the escape passages, so as to form a plurality of projections on the thermoplastic layer;
• removing the thermoplastic layer and the cover layer from the mold;
• positioning the thermoplastic layer between first and second platens of a fourth press such that the cover layer is disposed proximate the first platen and the thermoplastic layer is disposed proximate the second platen, the first platen having a first surface maintained at a temperature in the range of 40° F. to 120° F., the second platen having a second surface maintained at a temperature in the range of 250° F. to 400° F.;
• applying a compressive force in the range of 1 to 10 psi to the thermoplastic layer and the cover layer by compressing the thermoplastic layer and the cover layer between the first and second platens of the fourth press so as form enlarged tips on the projections;
• and
• positioning the thermoplastic layer in heat transfer relationship with a cooling platen having a surface maintained at a temperature in the range of 40° F. to 120° F., so as to sufficiently solidify the projections.