Thermoplastic planks and methods for making the same

Abstract

A thermoplastic laminate plank is described wherein the thermoplastic laminate plank includes a core, a print layer, and optionally an overlay. The core includes at least one thermoplastic material and has a top surface and bottom surface wherein a print layer is affixed to the top surface of the core and an overlay layer is affixed to the top surface of the print layer. An underlay layer can be located and affixed between the bottom surface of the print layer and the top surface of the core. In addition, a method of making the thermoplastic laminate plank is further described which involves extruding at least one thermoplastic material into the shape of the core and affixing a laminate on the core, wherein the laminate comprises an overlay affixed to the top surface of the print layer and optionally an underlay layer affixed to the bottom surface of the print layer.

1 . A thermoplastic laminate plank comprising:
 a core comprising at least one thermoplastic material, wherein said core has a top surface and a bottom surface, and opposing sides;   a print layer affixed to said top surface of said core, wherein said print layer has a top surface and a bottom surface; and   a protective layer affixed to said top surface of said print layer, wherein said at least bottom surface of the core is thermally treated.