Patent ID: 7507362
Filing Date: 2009-03-24
Classification: B29C,B29L,B32B,E04F,Y10T

Abstract:
1. A method of making modular floor panels, comprising: providing a mold, the mold having an injection cavity defined by a first mold half and a second mold half, the first mold half having surface cavities that create a surface pattern for a modular floor panel; opening the mold; inserting a protective sheet into the mold adjacent the first mold half prior to closing the mold, wherein the protective sheet is substantially the same size as the top surface of the modular floor panel volume; closing the mold; injecting a liquid polymer into the mold such that the liquid polymer softens the protective sheet; forming the protective sheet in a pattern of the mold such that the protective sheet conforms to the surface cavities in the first mold half; wherein the liquid polymer bonds to the protective sheet.