Abstract: A method of continuously fabricating a cushiony recycled plastic floor tile or wall cover wherein a single-ply sheet, made up substantially of recycled membrane and a proportion of discrete fibers sufficient to create a cushion effect in the tile, is extruded. The fibers are reduced in length by cooling the sheet extrudate produced, chopping the sheet extrudate into particles in which the fibers are reduced in length and then passing the chopped extrudate into the extruder to reextrude it. When size reduction is achieved, the hot substrate proceeds immediately into the nip between laminating rolls and a preheated cover film selected from the group comprising transparent sheet, colored sheet, and sheet with decorative imprinting is passed on into the nip with the substrate. Compressive pressure is applied by the laminating rolls 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.

Abstract: 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.degree. F.-350.degree. 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.