Method and apparatus for manufacturing molded products

Abstract

The present invention provides apparatuses and methods for producing molded products such as floor mats, including automotive floor mats. In one embodiment, a molding process is provided for producing a molded product using a mold having a lower plate and an upper plate. The molding process includes steps of filling a first cavity of the lower plate with a liquid molding material of a first color, placing the upper plate on top of the lower plate such that a convex portion of the upper plate extends into the first cavity of the lower plate and contacts the molding material in the lower plate, and curing the liquid molding material.

1 - 27 . (canceled)  
     
     
         28 . A floor mat comprising a top surface and a bottom surface and having features provided in both the top surface and the bottom surface, wherein: 
 (a) the floor mat comprises a result of molding and curing a molding material between a lower plate for forming the top surface of the floor mat and an upper plate for forming the bottom surface of the floor mat;    (b) at least a portion of the features in the bottom surface comprise nubs formed as a result of the molding material flowing through a plurality of air holes in the bottom plate.    
     
     
         29 . A floor mat according to  claim 28 , wherein the features in the top surface comprise a pattern of ridges.  
     
     
         30 . A floor mat according to  claim 28 , wherein the features in the top surface comprise a plurality of wells.  
     
     
         31 . A floor mat according to  claim 28 , wherein the features of the bottom surface comprise a plurality of recessed portions and a plurality of non-recessed portions, and the plurality of nubs extend from the non-recessed portions.  
     
     
         32 . A floor mat according to  claim 28 , wherein the top surface includes a plurality of concentric raised ridges.  
     
     
         33 . A floor mat according to  claim 30 , wherein the wells on the top surface are generally octagonal.  
     
     
         34 . A floor mat according to  claim 28 , wherein the nubs are generally cylindrical.  
     
     
         35 . A floor mat according to  claim 31 , wherein the nubs are uniformly spaced around the recessed portions of the bottom surface.  
     
     
         36 . A floor mat according to  claim 31 , wherein the recesses on the bottom surface have a generally pyramid shape including four base edges and four corner points, and wherein nubs are located at the corner points.  
     
     
         37 . A floor mat according to  claim 28 , further comprising a carpet attached to the top surface.  
     
     
         38 . A floor mat according to  claim 28 , wherein the top surface further includes: 
 a front section;    a heel section; and    a rear section.    
     
     
         39 . A floor mat according to  claim 38 , wherein the heel section includes a plurality of raised ribs separated by a plurality of channels.  
     
     
         40 . A floor mat according to  claim 39 , wherein the plurality of raised ribs substantially forms a herringbone pattern.  
     
     
         41 . A floor mat according to  claim 38 , wherein carpet is retained in the front section and the rear section.