Methods of Making a Cushiony Decorative Tile or Cover Product from Extruded Hot Recycled Polyvinyl Chloride Material with Discrete Fibres Randomly Dispersed Therein as the Material Exits the Extruder, and the Products So Formed

摘要

A method of continuously fabricating a cushiony recycled plastic floor tile or wall cover incorporating a decorative printed design wherein a single-ply sheet, made up substantially of recycled membrane and a proportion of discrete fibres sufficient to create a cushion effect in the tile is extruded at an extruding temperature in the range of 300 DEG F.-350 DEG F. in a hot state of semi-solidity in which it can be drawn under tensile load without reducing in thickness. The hot substrate proceeds immediately into the nip between laminating rolls and a transparent cover film, having decorative imprinting on one surface is passed closely alongside one of the laminating rolls to apply radiant preheat to it, before passing on into the nip with the substrate. The cover film utilizes the heat in the substrate and the heat imparted by one of the laminating rolls to bring it to bonding temperature while compressive pressure is applied to autogeneously heat weld the substrate and cover film in surface to surface sealed contact without the imposition of air bubbles or wrinkles between them. The welded product is then cooled and cut into discrete sizes, which are applied as very durable, tough, cushiony floor tile or wall covering.