PVC-FREE FLOORING AND METHOD OF MANUFACTURE

1 . A polyvinyl chloride free flooring, comprising: an upper decorative nonwoven fabric layer bonded without the use of adhesive to an intermediate extruded polymeric layer, and a extruded lower base layer bonded without the use of adhesive to the intermediate polymeric layer to provide a composite flooring that is free of polyvinyl chloride.

2 . The flooring of claim 1 , wherein the polymeric layer comprises an ionomer.

3 . The flooring of claim 2 , wherein the ionomer comprises a sodium ionomer.

4 . The flooring of claim 1 , wherein the polymeric layer comprises a thermoplastic polyurethane.

5 . The flooring of claim 1 , wherein the base layer comprises a PVC-free thermoplastic elastomer.

6 . The flooring of claim 5 , wherein the PVC-free thermoplastic elastomer comprises a polyolefin-based thermoplastic elastomer.

7 . The flooring of claim 5 , wherein the PVC-free thermoplastic elastomer comprises a styrenic block copolymer.

8 . The flooring of claim 1 , wherein the flooring is provided in a roll.

9 . A polyvinyl chloride free flooring, comprising: an upper decorative nonwoven fabric layer bonded without the use of adhesive to an intermediate extruded polymeric layer comprising an ionomer, and a extruded lower base layer bonded without the use of adhesive to the intermediate polymeric layer to provide a composite flooring that is free of polyvinyl chloride.

10 . A method of making a polyvinyl chloride free flooring, comprising the steps of:

providing an upper decorative nonwoven fabric layer;

extruding an intermediate polymeric layer using a first sheet die and joining the upper decorative nonwoven fabric layer to the extruded polymeric layer by passing the extruded polymeric layer and the nonwoven fabric layer through a first nip to provide a first composite; and

extruding a lower base layer using a second sheet die having a die temperature and joining the polymeric layer of the first composite to a surface of the base layer by passing the extruded base layer and the first composite through a second nip comprising a first roller having a roller temperature of from about 30 to about 35 percent of the die temperature, and a second roller having a roller temperature greater than the temperature of the first roller, but less than about 50 percent of the temperature of the die temperature.

11 . The method of claim 10 , wherein the first roller directly contacts the extruded base layer.