Cushioned rubber floor mat article and method

A method of a forming a cushioned dust control mat comprising the steps of

• (a) placing a die having at least a first and second side over at least a portion of at least one layer of unvulcanized rubber and of at least one layer of unvulcanized rubber further comprising at least one blowing agent to form a closed-cell foam rubber structure upon vulcanization, wherein said die has a plurality of portions thereof removed to allow for the entry of molten rubber, and wherein said die is comprised of a material which can withstand vulcanization temperatures and pressures;
• (b) subjecting the resultant composite comprising at least two layers of unvulcanized rubber and the die to vulcanization temperatures and pressures to vulcanize the at least two layers of rubber, and to form a plurality of rubber protrusions through the removed portions of the die, wherein at least one of said protrusions has a cross section shape selected from the group consisting of oval, octagonal, circular, letters, numbers, and combinations thereof.