A mat of one or more tiles of desired shape is provided. The mat is produced from a production mat manufactured as an integral unit with multiple tiles connected together according to various embodiments of this invention. The production mat may be divided into one or more mats of desired shape and size by severing the production mat between adjacent tiles. As such, the production mat may be cut into discrete mats, each having one or more tiles according to this invention. The entirety of the production mat is used as one or more mats according to aspects of this invention thereby avoiding waste and/or recycling of any portion of the production mat while utilizing each of the tiles in the production mat as part of the resulting mat(s). This avoids the need for any supplemental or auxiliary connecting means for joining two adjacent tiles to form a mat.

Mats and panels of mats and methods of making the same are described. The panels include a first portion defined by a first material and a second portion defined by a second material. The first material and the second material have at least one of different compositions and different material properties. The methods include depositing a first material into a mold of a panel, depositing a second material into the mold of the panel after deposition of the first material, and applying at least one of pressure and heat to the mold of the panel to form a panel having the first material and the second material having at least one different compositions and different material properties.

Mats and methods of making the same are described. The mats include a main body defined by a plurality of sidewalls and two exterior surface walls opposing each other, a lip structure extending outwardly from the plurality of sidewalk around a portion of a periphery of the main body, and at least one fiber-reinforcement layer arranged between the two exterior surface walls of the mat. The methods include depositing a first deposition layer of material within a mold, positioning at least one fiber-reinforcement layer on the first deposition layer, depositing a second deposition layer of material within the mold over the at least one fiber-reinforcement layer and the first deposition layer, and treating the first deposition layer, the at least one fiber-reinforcement layer, and the second deposition layer to form a mat.

Mats and panels of mats and methods of making the same are described. The panels include a first portion defined by a first material and a second portion defined by a second material. The first material and the second material have at least one of different compositions and different material properties. The methods include depositing a first material into a mold of a panel, depositing a second material into the mold of the panel after deposition of the first material, and applying at least one of pressure and heat to the mold of the panel to form a panel having the first material and the second material having at least one different compositions and different material properties.

A method of forming aligned patterns on a mat contains steps of: (1). providing a main die configured to mold a body on a substrate; (2). forming multiple patterns on the body so as to produce a decoration portion; (3). forming a toothed cutting line on the body by ways of the alignment mark line so as to form multiple connection units on which multiple patterns are formed respectively, thus producing the mat; and (4). aligning the multiple patterns on the mat so as to provide or design the decoration portion on the multiple patterns, wherein the mat is disassembled to multiple coupling parts, and the multiple coupling parts of the mat are connected with another mat, thus producing an expandable mat.

A method of manufacturing a mat is provided. The method involves securing a first layer formed of a polymer within a base die, positioning an intermediate cushion layer on top of the first layer, securing a second layer formed of the polymer to the base die, and securing a perimeter of the first layer to a perimeter of the second layer by radio-frequency welding, so as to envelop the intermediate cushion layer within the first and second layers and thereby form the mat. The first layer has a first surface and an opposing second surface in contact with the base die. The intermediate cushion layer has a first surface and an opposing second surface in contact with the first surface of the first layer. The second layer has a first surface and an opposing second surface in contact with the first surface of the intermediate cushion layer.

A multi-layer exercise mat including a first layer including an outer surface and an opposing inner surface, the opposing inner surface of the first layer including a first array of three-dimensional features integral with the first layer; and a second layer including an outer surface and an opposing inner surface, the opposing inner surface of the second layer including a second array of three-dimensional features integral with the second layer. The first and second arrays of three-dimensional features are configured to grip each other to removably secure the inner surface of the first layer to the inner surface of the second layer.

Mats and panels of mats and methods of making the same are described. The panels include a first portion defined by a first material and a second portion defined by a second material. The first material and the second material have at least one of different compositions and different material properties. The methods include depositing a first material into a mold of a panel, depositing a second material into the mold of the panel after deposition of the first material, and applying at least one of pressure and heat to the mold of the panel to form a panel having the first material and the second material having at least one different compositions and different material properties.

The mat of the present invention includes a main body integrally formed by a plastic material. The main body at least has a first surface and a second surface adjacent to the first face. The first face and the second face have different surface physical characteristics. The first surface and the second surface are shaped into a third surface and a fourth surface respectively. The third surface and the fourth surface have a substantially same surface physical characteristic. An angle between the third surface and the fourth surface outside the main body is a specific value.

Apparatus and methods are provided for providing an artificial turf system having an array of integrated fibers and base arrangement. The fibers can be integrally formed with a substrate, for example, by using a molding process. The fibers can be formed to be bonded directly to the base using molecular bonds of the material that formed the base and the fibers at the same time.