Process to form a tile using low temperature heat lamination

Abstract

A method to produce a tile comprising at least the following layered sections: a wear layered section, a decor layered section and a base layered section; and wherein the wear layered section comprises the following: A) a compositional layer A formed from a composition A comprising at least one olefin-based polymer; wherein the decor layered section comprises the following: B1) a compositional layer B1 formed from a composition B1 comprising a propylene-based polymer; B2) a compositional layer B2 formed from a composition B2 comprising an olefin-based polymer; wherein the base layered section comprises the following: C) a compositional layer C formed from a composition C comprising an olefin-based polymer; wherein the method comprises the following step(s): i) heat laminating compositional layer A to compositional layer B1, at a temperature T1≤140° C.; and wherein, for a continuous production of the tile, T1 is the temperature at the surface of the compositional layer with the highest, or equivalent, surface temperature; and for a batch production of the tile, T1 is the interfacial temperature between the two compositional layers; ii) heat laminating compositional layer B2 to compositional layer C, at a interfacial temperature T2≤140° C.; and wherein, for a continuous production of the tile, T2 is the temperature at the surface of the compositional layer with the highest, or equivalent, surface temperature; and for a batch production of the tile, T2 is the interfacial temperature between the two compositional layers.

Dependencies are inferred from the claim text.