Floor coverings and films for use therein

A floor covering comprising a thermoplastic solid backing film produced by co-extruding through a die in the following order:

• a first lamina having a first thermnoplastic composition that includes from zero to about 30 percent by weight infusible filler;
• a second larmina having a second thermoplastic composition that includes from about 50 to about 75 percent by weight infusible filler;
• and
• a third lamina having a third thermoplastic composition which includes from zero to about 30 percent by weight infusible filler;
• with the first and third thermoplastic compositions being such that when the first and third laminae were extruded through the die there was substantially no die-lip build-up, and the second thermoplastic composition being such that if the second lamina were to be extruded adjacent a die lip there would be significant die lip build up, the first and the third lamina having prevented the second lamnina from contacting the die during manufacture of the film, wherein the thickness of the coextruded film is in the range of about 100 to 2000 microns.

A floor covering comprising a thermoplastic solid backing film produced by co-extruding through a die in the following order:

• a first lamina having a first thermoplastic composition that includes from zero to about 30 percent by weight-infusible filler;
• a second lamina having a second thermoplastic composition that includes from about 50 to about 75 percent by weight infusible filler;
• and
• a third lamina having a third thermoplastic composition which includes from zero to about 30 percent by weight infusible filler;
• with the first and third thermoplastic compositions being such that when the first and third laminae wire extruded through the die there was substantially no die-lip build-up, and the second thermoplastic composition being such that if the second lamina were to be extruded adjacent a die lip there would be significant die lip build up, the first and the third lamina having prevented the second lamnina from contacting the die during manufacture of the film, wherein the thickness of the second lamina is at least about 45% of the total thickness of the coextruded film.

A floor covering comprising a thermoplastic solid backing layer produced by co-extruding through a die in the following order:

• a first lamina having a first thermoplastic composition that includes from zero to about 30 percent by weight infusible filler;
• a second lamnina having a second thermoplastic composition that includes from about 50 to about 75 percent by weight infusible filler;
• and
• a third lamina having a third thermoplastic composition which includes from zero to about 30 percent by weight infusible filler;
• with the first and third thermoplastic compositions being such that when the first and third laminae were extruded through the die there was substantially no die-lip build-up, and the second thermoplastic composition being such that if the second lamina were to be extruded adjacent a die lip there would be significant die lip build up, the first and the third lamina having prevented the second lamnina from contacting the die during manufacture of the film, wherein the thickness of the first and third laminae is different.

A floor covering comprising a thermoplastic backing layer produced by co-extruding through a die in the following order:

• a first lamnina having a first thermoplastic composition that includes from zero to about 30 percent by weight infusible filler;
• a second lamnina having a second thermoplastic composition that includes from about 50 to about 75 percent by weight invisible filler;
• and
• a third lamina having a third thermoplastic composition which includes from zero to about 30 percent by weight infusible filler;
• with the first and third thermoplastic compositions being such that when the first and third laminae were extruded through the die there was substantially no die-lip build-up, and the second thermoplastic composition being such that if the second lamnina were to be extruded adjacent a die lip there would be significant die lip build up, the first and the third lamnina having prevented the second lamnina from contacting the die during manufacture of the film, wherein the thickness of the first and second laminae is in the range of about 10 to 100 microns.

A method of manufacturing a floor covering, which comprises:

• producing a thermoplastic solid backing film by co-extruding through a die in the following order:
• a first lamina having a first thermoplastic composition that includes from zero to about 30 percent by weight infusible filler;
• a second lamina having a second thermoplastic composition that includes from about 50 to about 75 percent by weight infusible filler;
• and
• a third lamina having a third thermoplastic composition which includes from zero to about 30 percent by weight infusible filler;
• with the first and third thermoplastic composition being such that as the first and third laminae are extruded through the die there is substantially no die-lip build up, and the second thermoplastic composition being such that if the second lamina were to be extruded adjacent a die lip there would be significant die lip build up, the first and the third lamina ensuring that the second lamina does not contact the die lip thereby avoiding any die lip build up of the second thermoplastic polymer composition, wherein the thickness of the first and third laminae is substantially the same.

A floor covering characterised in that it comprises at least one coextruded backing film made by co-extruding through a die in the following order:

• a first lamina having a first thermoplastic composition that includes from zero to about 30 percent by weight infusible filler,
• a second lamina having a second thermoplastic composition that includes from about 50 to about 75 percent by weight infusible filler;
• and
• a third lamina having a third thermoplastic composition which includes from zero to about 30 percent by weight infusible filler;
• with the first and third thermoplastic composition being such that as the first and third laminae are extruded through the die there is substantially no die-lip build up, and the second thermoplastic composition being such that if the second lamina were to be extruded adjacent a die lip there would be significant die lip build up, the first and the third lamina ensuring that the second lamina does not contact the die lip thereby avoiding any die lip build up of the second thermoplastic polymer composition, wherein the thickness of the first and third laminae is substantially the same.

A floor covering characterized in that it comprises at least one coextruded backing film made by co-extruding through a die in the following order:

• a first lamina having a first thermoplastic composition that includes from zero to about 30 percent by weight infusible filler;
• a second lamina having a second thermoplastic composition that includes from about 50 to about 75 percent by weight infusible filler;
• and
• a third lamina having a third thermoplastic composition which includes from zero to about 30 percent by weight infusible filler;
• with the first and third thermoplastic composition being such that as the first and third laminae are extruded through the die there is substantially no die-lip build up, and the second thermoplastic composition being such that if the second lamina were to be extruded adjacent a die lip there would be significant die lip build up, the first and the third lamina ensuring that the second lamina does not contact the die lip thereby avoiding any die lip build up of the second thermoplastic polymer composition, wherein the thickness of the first and third laminae is different.

A method of manufacturing a floor covering, which comprises:

• producing a thermoplastic solid backing film by co-extruding through a die in the following order:
• a first lamina having a first thermoplastic composition that includes from zero to about 30 percent by weight infusible filler;
• a second lamina having a second thermoplastic composition that includes from about 50 to about 75 percent by weight infusible filler;
• and
• a third lamnina having a third thermoplastic composition which includes from zero to about 30 percent by weight infusible filler;
• with the first and third thermoplastic composition being such that as the first and third lamnina are extruded through the die there is substantially no die-lip build up, and the second thermoplastic composition being such that if the second lamina were to be extruded adjacent a die lip there would be significant die lip build up, the first and the third lamina ensuring that the second lamina does not contact the die lip thereby avoiding any die lip build up of the second thermoplastic polymer composition, wherein the thickness of the first and third laminae is different.