BR112019009738B1 - LAYER COMPOSITE ARTICLES AND METHODS OF MANUFACTURE THEREOF - Google Patents

Abstract

Disclosed are layered composite articles comprising: a) a rigid support portion comprising a rigid core having a first surface and an opposing second surface, wherein the rigid core comprises at least one densified fiber layer and wherein the at least one densified fiber layer is composed of a first plurality of oriented fibers having a first melting point and a second plurality of oriented fibers having a second melting point different from the first melting point; and b) a decorative portion having a first surface and an opposing second surface, wherein the second surface of the decorative portion is affixed to the first surface of the rigid core. The manufacturing methods thereof are also disclosed in this document.

Description

CROSS REFERENCE TO RELATED ORDERS

[001] This application claims the benefit of priority to the co-pending Provisional Application No. U.S. 62/422,308, filed on November 15, 2016 and to the co-pending Provisional Application No. U.S. 62/553,271, filed at September 1, 2017, both of which are incorporated herein by reference in their entirety.

BACKGROUND OF THE INVENTION

[002] Fiberboards, particularly medium-density fiberboards and high-density fiberboards, and plastic materials (such as PVC resins or other thermoplastic or thermosetting polymers) are commonly used as base materials for floor coverings, wall coverings and ceiling panels. For example, some existing floor panels generally consist of a chipboard core (such as an MDF or HDF core), or a PVC core, which are covered (laminated) with a decoration layer and a wearing surface or a finishing layer.

[003] Laminate flooring has also proven to be a relatively lightweight, economical and visually appealing flooring material that can also be installed by laypeople. Furthermore, they are correspondingly widespread. However, these laminate floors typically have relatively high impact noise, low radiant panel ratings, and high environmental impact. Many attempts have been made to develop composite boards based on alternative materials.

[004] There is still a need, however, to obtain composite plates that do not require a complex layer structure, in order to obtain characteristics suitable for use in heavy-duty applications. Furthermore, there is a need to obtain composite boards with one or more of high impact resistance, heat elongation resistance, heat resistance, dimensional stability, acceptable radiant panel ratings and improved acoustic properties (such as sound propagation) compared to existing fiber panels or composite boards.

[005] Furthermore, there is a need for methods that are capable of manufacturing these composite plates. These needs and other needs to be further described herein may be at least partially satisfied by one or more aspects of the present disclosure.

SUMMARY

[006] The present invention relates to a layered composite article generally comprising a rigid support portion, wherein the rigid support portion comprises a rigid core having a first surface and an opposing second surface, wherein the rigid core comprises at least one densified fiber layer and wherein the at least densified fiber layer is constituted by a first plurality of oriented fibers having a first melting point and a second plurality of oriented fibers having a second melting point different from that first melting point. Furthermore, the layered composite also comprises a decorative portion having an opposing first surface and a second surface, wherein the second surface of the decorative portion is affixed to the first surface of the rigid core.

[007] In additional aspects to be discussed in more detail below, at least one of the first and second pluralities of fibers comprises a multicomponent fiber. In still other aspects, the multicomponent fiber may comprise at least one first component having a first melting point and at least one second component having a second melting point different from the first melting point. In still other aspects, the at least one densified fiber web may further comprise a third plurality of oriented fibers comprising, for example, a natural fiber.

[008] In another aspect, the present disclosure provides a layered composite article generally comprising a rigid support portion wherein the rigid support portion comprises a rigid core having a first surface and an opposing second surface. The rigid core further comprises at least one densified fiber layer wherein the at least one densified fiber layer is comprised of the first plurality of oriented fibers comprising a natural fiber having a decomposition temperature and a second plurality of oriented fibers having a melting point lower than the decomposition temperature of the first plurality of oriented fibers. The layered composite also comprises a decorative portion having an opposing first surface and a second surface, wherein the second surface of the decorative portion is affixed to the first surface of the rigid core.

[009] In still other aspects, disclosed herein is a layered composite article comprising a rigid support portion comprising a rigid core having a first surface and an opposing second surface, wherein the rigid core comprises at least one densified fiber layer and wherein the at least one densified fiber layer is composed of a plurality of oriented multicomponent fibers, wherein each of the plurality of multicomponent fibers comprises at least one first component having a first melting point and at least a second component having a second melting point different from the first melting point. Such a layered composite further comprises a decorative portion having an opposing first surface and a second surface, wherein the second surface of the decorative portion is affixed to the first surface of the rigid core.

[0010] In yet another aspect, the present disclosure provides a method of producing a layered composite article as disclosed herein generally comprising the step of forming a rigid support portion comprising a rigid core having a first surface and a second opposite surface, wherein the rigid core comprises at least one densified fiber layer and wherein the at least densified fiber layer is constituted by a first plurality of oriented fibers having a first melting point and a second plurality of oriented fibers having a second melting point different from the first melting point. The method further comprises forming a decorative portion having a first surface and an opposing second surface and attaching the second surface of the decorative portion to the first surface of the rigid core.

[0011] In yet another aspect, the present disclosure provides a method of making a layered composite article as described herein generally comprising the step of forming a rigid support portion comprising a rigid core having a first surface and an opposing second surface. , wherein the rigid core comprises at least one densified fiber layer and wherein the at least one densified fiber layer is composed of a plurality of oriented multicomponent fibers, wherein each of the plurality of multicomponent fibers comprises at least one first component having a first melting point and at least one second component having a second melting point different from the first melting point. The method further comprises forming a decorative portion having a first surface and an opposing second surface and attaching the second surface of the decorative portion to the first surface of the rigid core.

[0012] In yet another aspect, the present disclosure provides a method of producing a layered composite article as disclosed herein generally comprising the step of forming a rigid support portion comprising a rigid core having a first surface and a second opposite surface, wherein the rigid core comprises at least one densified fiber layer and wherein the at least densified fiber layer is constituted by a first plurality of oriented fibers comprising a natural fiber having a decomposition temperature and a second plurality of fibers oriented having a melting point lower than the decomposition temperature of the first plurality of oriented fibers. The method further comprises forming a decorative portion having a first surface and an opposing second surface and attaching the second surface of the decorative portion to the first surface of the rigid core.

[0013] In yet another additional aspect, the step of forming the rigid support portion may further comprise forming a rigid core through a method comprising overlapping the first plurality of oriented fibers and the second plurality of oriented fibers to form a fibrous matrix ; treating or otherwise subjecting the fibrous matrix to effective conditions or process step to form a fiber layer; and then heat and pressure treating the fiber layer under effective conditions to form the fiber layer.

[0014] Additional aspects of the disclosure will be set forth, in part, in the detailed description, figures and claims below, and in part will be derived from the detailed description or can be learned by practicing the invention. It should be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the invention as disclosed.

BRIEF DESCRIPTION OF FIGURES

[0015] FIG. 1 is a schematic side view illustration of an exemplary layered composite floor covering as disclosed and described herein.

[0016] FIG. 2 shows a schematic illustration of a 3-point bending test that can be used to evaluate the examples of layered composite articles described in this document.

[0017] FIG. 3(a) shows a cross-sectional image of an exemplary conventional floor covering comprising a PVC core and FIG. 3(b) shows a cross-sectional image of an example floor covering an inventive rigid core of the present disclosure.

[0018] FIG. 4 is a schematic illustration of a process and apparatus for forming a high density composite in accordance with various aspects of the present invention.

DETAILED DESCRIPTION

[0019] The present invention can be more readily understood by reference to the following detailed description, examples, drawings and claims and their previous and following description. However, before the present articles, systems and/or methods are disclosed and described in greater detail, it should be understood that this invention is not limited to the specific or exemplary aspects of the disclosed articles, systems and/or methods, unless specified, as such. , obviously, may vary. It should also be understood that the terminology used in this document is intended to describe particular aspects only and is not intended to be limiting.

[0020] The following description of the invention is provided as a facilitating teaching of the invention in its best aspect, currently known. To this end, those skilled in the relevant art will recognize and appreciate that many changes can be made to the various aspects of the invention described herein while still obtaining the beneficial results of the present invention. It will also be apparent that some of the desired benefits of the present invention can be obtained by selecting some of the features of the present disclosure without utilizing other features. Accordingly, those skilled in the pertinent art will recognize that many modifications and adaptations to the present invention are possible and may even be desirable in certain circumstances and are a part of the present invention. Accordingly, the following description is again provided as illustrative of the principles of the present invention and not as a limitation thereof.

DEFINITIONS

[0021] As used herein, the singular forms "a", "an and "the" include the referring plural forms, unless the context clearly indicates otherwise. Thus, for example, reference to a “ fiber” includes aspects that have two or more fibers, unless the context clearly indicates otherwise.

[0022] As used herein, the term "comprising" may include the aspects "consisting of" and "consisting essentially of". The term "comprising" can also mean "including, but not limited to".

[0023] Ranges may be expressed in this document as "about" a specific value and/or "about" another specific value. When such a range is expressed, another aspect includes from a given value and/or to the other given value. Similarly, when values are expressed as approximations, by the use of the antecedent "about", it will be understood that the particular value forms another aspect. It should further be understood that the endpoints of each of the ranges are significantly relative to the other endpoint and independent of the other endpoint. Furthermore, in still further aspects, reference to a parameter that is equal to a specific evaluation criterion or specific value also includes aspects that are characterized as being greater than the declared value or, alternatively, less than the declared value.

[0024] As used herein, the term "optional" or "optionally" means that the event or circumstance described further may or may not occur and that the description includes instances in which said event or circumstance occurs and instances where it does not occur. it happens.

[0025] References in the specification and conclusive claims for parts by weight of a particular element or component in a composition or article denotes the weight relationship between the element or component and any other elements or components in the composition or article for which a part by weight is expressed. Thus, in a composition or a selected portion of a composition consisting of 2 parts by weight of component X and 5 parts by weight component Y, X and Y are present in a weight ratio of 2:5, and are present in such ratio regardless of whether additional components are comprised in the composition.

[0026] A weight percentage of a component, unless specifically indicated otherwise, is based on the total weight of the formulation or composition in which the component is included.

[0027] The term "fiber", as used herein, includes fibers of extreme or indefinite length (i.e., filaments) and fibers of short length (i.e., discontinuous fibers). It is further understood that the fiber described herein can be understood as comprising materials of virgin or recycled origin or a combination of both. In certain aspects of this invention, the fiber comprises recycled materials, wherein the recycled materials include, but are not limited to, post-consumer or post-industrial materials or a combination thereof. In still other aspects, the fiber used in this invention comprises virgin materials.

[0028] The term "oriented fiber", as used herein, is directed to the orientation of fibers in a layer of fibers or in a matrix of fibers.

[0029] The term "rigid core" refers to any composite material that comprises a rigid core and is capable of withstanding heavy-duty applications, such as, for example, heavy pedestrian traffic, without any significant deformation of the plate. Further, in aspects of the disclosure, a rigid composite board may be defined functionally in that it at least substantially prevents the transmission of irregularities in the rigid subfloor structure, such as ripples and waves, to the decorative layer portion when the composite rigid floor covering is contiguous to the subfloor structure in the selected orientation.

[0030] As used here, the term "polyester" refers to a category of polymers that contain the ester functional group in their main chain. The polyesters disclosed herein include naturally occurring chemicals, such as in the cutin of plant cuticles, as well as synthetic ones produced through polycondensation. A non-limiting example of polyesters includes any long-chain synthetic polymer composed of at least 85% by weight of an ester of a substituted aromatic dicarboxylic acid, including, but not restricted to, substituted terephthalic units, p(-R-O-CO-C6H4 -CO- O-)x and parasubstituted hydroxybenzoate units, p(-R-O-CO-C6H4- O)x. In certain examples, the polyesters comprise polyethylene terephthalate (PET) homopolymer and copolymers, polypropylene terephthalate (PPT) homopolymer and polybutylene terephthalate (PBT) homopolymer and copolymers, and the like, including those containing co -monomers such as cyclohexanedimethanol, cyclohexanedicarboxylic acid, isophthalic acid and the like.

[0031] The term "polyamide", as used herein, is defined as any long-chain polymer in which the linking functional groups are amide bonds (-CO-NH-). The term polyamide is further defined to include copolymers, terpolymers and the like, as well as homopolymers and also includes mixtures of two or more polyamides. In some aspects, the plurality of polyamide fibers comprises one or more of nylon 6, nylon 66, nylon 10, nylon 612, nylon 12, nylon 11 or any combination thereof. In still another aspect, the plurality of polyamide fibers is nylon 6. In yet another aspect, the plurality of polyamide fibers is nylon 66.

[0032] As defined herein, the term "polyolefin" refers to any class of polymers produced from a simple olefin (also called an alkene with the general formula (CnH2n)) as a monomer. In some aspects, polyolefins include, but are not limited to, polyethylene, polypropylene, both homopolymer and copolymers, poly(1-butene), poly(3-methyl-1-butene), poly(4-methyl-1-pentene ) and the like, as well as combinations or mixtures of two or more of the foregoing.

[0033] As defined here, the term "polyurethane" refers to any class of polymers composed of a chain of organic units linked by carbamate bonds (urethane, R1-O-CO-NR2-R3, where R1, R2 and R3 are the same or different).

[0034] As defined here, the term "polystyrene" refers to any class of synthetic polymers produced from simple styrene as a monomer. The term "polystyrene" is understood to include both atactic and syndiotactic polystyrenes. In some specific aspects, co-polystyrenes including a high impact polystyrene (HIPS), acrylonitrile-butadiene-styrene (ABS) or styrene-acrylonitrile copolymer (SAN), or styrene-maleic acid copolymer (SMA) are also described.

[0035] As defined here, the term "acetal" refers to a functional group with the following connectivity of R2C(OR')2, in which both R' groups may comprise hydrogen or organic fragments. The two R'O groups can be equivalent to each other (known as symmetric acetal) or different (known as mixed acetal).

[0036] As used herein, the term "substantially" may in some aspects refer to a quantity or resource that is represented or otherwise quantified as being at least about 80%, at least about 85%, at least about 90%, at least about 91%, at least about 92%, at least about 93%, at least about 94%, at least about 95%, at least about 96%, at least about at least about 97%, at least about 98%, at least about 99% or even about 100% of the stated property, component, composition or other condition for which substantially is used to characterize or otherwise quantify a quantity.

[0037] In other aspects, as used herein, the term "substantially free", when used in the context of a composition or component of a composition that is substantially absent, is intended to refer to an amount that is less than about 1% by weight, for example, less than about 0.5% by weight, less than about 0.1% by weight, less than about 0.05% by weight, or less than about 0.01% by weight of the indicated material, based on the total weight of the composition.

[0038] As used herein, the term or phrase "effective", "effective quantity" or "effective conditions for" refers to the quantity or condition that is capable of performing the function or property for which an effective quantity or condition is expressed. As will be noted below, the exact quantity or specific condition required will vary from one aspect to another, depending on recognized variables such as the materials employed and the processing conditions observed. Therefore, it is not always possible to specify an exact "effective amount" or "effective condition for". However, it should be understood that an appropriate effective amount will be readily determined by one skilled in the art using routine experimentation alone.

[0039] As used herein and unless the context clearly indicates otherwise, the term "carpet" is used to generically include arched carpet, carpet, area rugs and even artificial grass (or tuft). For this purpose, the term "broadloom carpet" refers to a broadloom-type textile flooring product manufactured for and intended to be used in roll form. The term "carpet tile" refers to a modular floor covering, conventionally manufactured in squares measuring 18" x 18" cm (18" x 18", 24" x 24" or 36" x 36"), but other sizes and shapes are also within the scope of the present invention. Any of these example rugs can be woven, non-woven, tufted, or needle punched.

[0040] As used herein, the term “recovered fiber” includes a fiber recovered from a new product, post-industrial product, manufacturing remnants, discarded quality control or rejected material, or a post-consumer product. In some exemplary aspects, such products comprise carpets or carpet tiles.

[0041] As used herein, the term "post-consumer fiber" refers to a fiber that was a component of a product previously used by a consumer. Post-consumer fibers include fibers recovered from products that were used in residential, commercial and industrial applications and were later collected from the site of use or discarded.

[0042] As used herein, the term "post-industrial fiber" refers to a fiber recovered from a product that is a byproduct of manufacturing that has been diverted from the manufacturing waste stream.

[0043] As used herein, the term "acclimatization period" refers to a period of time necessary for one or more components in the layered composite article to adjust or condition the equalization of different stresses that may be present in the various components. In some aspects, the lack of an "acclimatization period" may refer to the lack of an acclimation period associated with the assembly of the various component parts during the manufacture of the layered composite article of the present disclosure. In other aspects, an acclimation period may refer to a period of time or lack thereof required between the arrival of the product at an installation site and the actual installation of the product.

[0044] While aspects of the present invention may be described and claimed in a particular class, such as the system class, this is for convenience only and a person of ordinary knowledge will understand that each aspect of the present invention can be described and claimed in any legal class. Unless expressly stated otherwise, it is in no way intended that any method or aspect set forth in this document be construed as requiring its steps to be performed in a specific order. Thus, if the method claim does not specifically state in the claims or descriptions that the steps are to be limited to a specific order, it is in no way intended that an order be inferred, in any respect. This is true for any possible unexpressed basis for interpretation, including questions of logic regarding the arrangement of steps or operational flow, simple meaning derived from grammatical or punctuation organization, or number or type of features described in the specification.

[0045] The present invention may be more readily understood by reference to the following detailed description of various aspects of the invention and to the examples included herein and to the Figures and their description above and below.

ARTICLE

[0046] In some aspects, and as generally depicted in FIG. 1, described here is a layered composite article 100, comprising: a) a rigid reinforcing portion 110 comprising a rigid core 120 having a first surface 122 and an opposing second surface 124, wherein the rigid core comprises at least one battery of densified fiber 126 and wherein at least one densified fiber web is comprised of a first plurality of oriented fibers having a first melting point and a second plurality of oriented fibers having a second melting point different from the first melting point; and b) a decorative portion 130 having a first surface 132 and an opposing second surface 134, wherein the second surface of the decorative portion is attached to the first surface of the rigid core.

[0047] In some aspects, the densified fiber layer has a density in the range of about 0.08 g/cm3 to about 1.6 g/cm3 (5 lb/ft3 to about 100 lb/ft3), including densities example of 0.16, 0.24, 0.32, 0.4, 0.48, 0.56, 0.64, 0.72, 0.8, 0.88, 0.96, 1.04 , 1.12, 1.2, 1.28, 1.36, 1.44, and 1.52g/cm3 (10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90 and 95 lb/ft3). In still other aspects, the volumetric density may be a value within any range derived from the above values, including, for example, a density of about 0.24 to about 1.2 g/cm3 (15 to about 75 lb /foot3).

[0048] In certain aspects, the densified fiber layer may have a density of at least about 0.16 g/cm3 (10 lb/ft3), including exemplary values of at least about 0.24 g/cm3, about of 0.32g/cm3, about 0.4g/cm3, about 0.48g/cm3, about 0.56g/cm3, about 0.64g/cm3, about 0.72g/cm3 or about 0 .8g/cm3 (15 lb/ft3, about 20 lb/ft3, about 25 lb/ft3, about 30 lb/ft3, about 35 lb/ft3, about 40 lb/ft3, about 45 lb/ ft3 or about 50 lb/ft3). In certain aspects, the densified fiber layer may have a density in a range between any two previous values.

[0049] In still other aspects, the densified fiber layer may have a density of no more than about 0.8g/cm3, about 0.72g/cm3, about 0.64g/cm3, about 0.56g/cm cm3, about 0.48g/cm3, 0.4g/cm3, about 0.32g/cm3, about 0.24g/cm3 or about 0.16 g/cm3 (50 lb/ft3, about 45 lb /ft3, about 40 lb/ft3, about 35 lb/ft3, about 30 lb/ft3, 25 lb/ft3, about 20 lb/ft3, about 15 lb/ft3 or about 10 lb/ft3) In certain aspects, the densified fiber layer may have a density in a range between any two previous values. It is understood that the densified fiber layer may have a density as low as the density of a fiber layer comprising a first plurality of substantially identical oriented fibers and a second plurality of substantially identical oriented fibers that have not undergone any densification processes. , for example, heat treatment or pressure treatment processes.

[0050] In still other aspects, the rigid core of the layered composite article of the invention may have multiple regions or portions of varying or different densities. For example, the rigid core of the layered composite may include a first portion 126(a) having a first density and a second portion 126(b) having a second density different from the first density. In some aspects, the first portion of the rigid core is adjacent to the first surface of the rigid core. In other aspects, the second portion of the rigid core is adjacent to the second surface of the rigid core. In certain respects, the first density is greater than the second density. In still other respects, the first density is lower than the second density. Such portions of varying densities may occur within a single fiber layer or may be provided by the presence of more than one of the fiber layers layered together.

[0051] In still other aspects, the rigid core may comprise at least two densified fiber layers. For example, again as illustrated in FIG. 1, first and second portions 126 (a) and 126 (b) may also represent the presence of two fiber layers. In aspects where two or more densified fiber layers are present, each of the densified fiber layers exhibits a density that may be the same or different from another densified layer. In some aspects, the rigid core may comprise a first densified fiber layer having a third density and a second densified fiber layer having a fourth density. In some respects, third density is greater than fourth density. In still other respects, third density is smaller than fourth density. In certain aspects, the first densified fiber layer is adjacent to the first surface of the rigid core, while the second densified fiber layer is adjacent to the second surface of the rigid core. In aspects where more than two layers of densified fibers are present, each of the layers of densified fibers can be arranged in any configuration determined by one skilled in the art and useful for a final application. In these aspects, each of the densified fiber layers may exhibit the same or different density.

[0052] In still other aspects, the rigid core of the invention may exhibit a density that is lower than a density of a conventional rigid support portion comprising a layer of polyvinyl chloride material or a wood-based material as a core and wherein such conventional rigid support is absent from a densified fiber layer. In still other aspects, the rigid core of the invention exhibits a higher porosity than a comparable conventional rigid support portion comprising a layer of polyvinyl chloride material or a wood material as a core and wherein such conventional rigid support is absent of a layer of densified fiber.

[0053] In still other aspects, the layered composite may optionally comprise a densified layer comprising a non-fibrous composition. For example, the densified layer of non-fibrous composition may be a densified powder layer. The densified powder composition may comprise a polymer powder. In still other aspects, the polymeric powder may comprise a polypropylene, a polyester, a polyethylene or a combination thereof. In still other aspects, such a layer can be formed by dispersing the polymeric powder using a powder dispersion machine. The optional densified non-fibrous layer can be positioned at any desired location within the layered composite structure. For example, the densified non-fibrous layer may be positioned between the upper surface of the rigid central layer and the decorative portion. In this aspect, the densified non-fibrous layer can optionally serve as a substrate for printing an ink layer. This together may form a decorative portion or layer, as described hereinafter. In still other aspects, the densified non-fibrous layer can increase the density of the rigid core to resist recoil during extensive use.

[0054] In certain aspects, the first and second plurality of oriented fibers may have a substantially random orientation, a substantially uniform orientation, or any variation of a predetermined orientation that is between a random and uniform orientation. Furthermore, the plurality of fibers may comprise any desired combination of various orientations. In some aspects, the first plurality of oriented fibers is substantially randomly oriented. In still other aspects, the first plurality of oriented fibers is uniformly oriented. In still other aspects, the first plurality of oriented fibers are arranged in a predetermined orientation.

[0055] In some aspects, the second plurality of oriented fibers is substantially randomly oriented. In still other aspects, the second plurality of oriented fibers is uniformly oriented. In still other aspects, the second plurality of oriented fibers is arranged in a predetermined orientation.

[0056] In still other aspects, the first and second plurality of oriented fibers may have the same or different orientation. In some exemplary aspects, the first plurality of oriented fibers may have a substantially random orientation, while the second plurality of oriented fibers may have a uniform orientation. In still other exemplary aspects, the first plurality of oriented fibers may have a uniform orientation, while the second plurality of oriented fibers is substantially randomly oriented. In still other aspects, both the first and second plurality of oriented fibers may have the same orientation.

[0057] In certain aspects, the first and second plurality of oriented fibers may comprise a staple fiber, a bulk continuous fiber (BCF), or a combination thereof. In some aspects, the first plurality of oriented fibers may comprise a staple fiber. In other aspects, the first plurality of oriented fibers may comprise a continuous bulk fiber. In still other aspects, the first plurality of oriented fibers may comprise both discontinuous and bulk continuous fibers.

[0058] In other aspects, the second plurality of oriented fibers may comprise a discontinuous fiber. In other aspects, the second plurality of oriented fibers may comprise a continuous bulk fiber. In still other aspects, the second plurality of oriented fibers may comprise both discontinuous and bulk continuous fibers.

[0059] In still other aspects, the first plurality of oriented fibers may comprise a staple fiber, while the second plurality of oriented fibers may comprise a continuous bulk fiber. In still other aspects, the first plurality of oriented fibers may comprise a continuous bulk fiber, while the second plurality of oriented fibers may comprise a discontinuous fiber. In still other aspects, both the first and second plurality of oriented fibers may comprise a staple fiber. In still other aspects, both the first and second plurality of oriented fibers may comprise a continuous bulk fiber.

[0060] According to certain aspects, the first and second plurality of oriented fibers may exhibit a substantially uniform size, including substantially uniform coating density measured in denier units and substantially uniform fiber lengths. However, in alternative aspects, the fibers present in the first and second plurality of oriented fibers may have non-uniform linear densities and non-uniform fiber lengths. According to these aspects, the population of the first and second plurality of oriented fibers with non-uniform linear fiber densities may, for example, have individual linear fiber densities in the range of about 1 to about 500 denier, including values of example about 3 denier, about 5 denier, about 10 denier, about 15 denier, about 20 denier, about 25 denier, about 30 denier, about 35 denier, about 40 denier, about 45 denier, about 50 denier, about 60 denier, about 70 denier, about 80 denier, about 90 denier, about 100 denier, about 120 denier, about 150 denier, about 170 denier, about 200 denier, about 250 denier, about 300 denier, about 350 denier, about 400 denier and about 450 denier. It is further understood that the population of the first and second plurality of oriented fibers may have individual linear fiber density in any range between two previous values. For example, in certain aspects, the individual linear fiber density may be from about 1 to about 5 denier, from about 5 denier to about 25 denier, from about 5 denier to about 200 denier, or from about 100 denier to about 500 denier. Furthermore, a population of the first and second plurality of oriented fibers having non-uniform linear density can collectively provide an average linear fiber density that is, for example, greater than 5 denier, greater than 10 denier, greater than 15 denier, greater than 20 denier, greater than 25 denier, greater than 30 denier, greater than 35 denier, greater than 40 denier greater than 45 denier, greater than 50 denier, greater than 100 denier, greater than 200 denier, greater than 300 denier or even greater than 400 denier.

[0061] In other aspects, the first and second plurality of oriented fibers, each independently, may comprise polyester, polypropylene, polyethylene, polyamides, polyurethane, polylactic acid, acetal, co-polyester, co-polyamide, polystyrene or a combination of these.

[0062] Exemplary fibers present in the first and/or second plurality of oriented fibers may include polyamides, polyester, polypropylene, polyethylene, polyurethane, polyethylene terephthalate, polymethylene terephthalate, latex, styrene butadiene rubber or any combination of these.

[0063] In some aspects, the densified fiber may further comprise a third plurality of oriented fibers. In such aspects, the third plurality of oriented fibers has a third melting point different from the first melting point of the first plurality of fibers or the second melting point of the second plurality of fibers. In some aspects, the third plurality of oriented fibers may be natural fibers. In yet another aspect, natural fibers exhibit a point of decomposition. In still other aspects, the third plurality of oriented fibers may comprise a discontinuous fiber, a continuous bulk fiber, or a combination thereof.

[0064] In still other aspects, natural fibers comprise bast fibers, cotton, cellulose, wool, silk, linen, mineral, coconut, glass or any combination thereof.

[0065] In some aspects, the third plurality of oriented fibers may have a substantially random orientation. In still other aspects, the third plurality of oriented fibers may have a substantially uniform orientation. In still other aspects, the third plurality of oriented fibers may have a predetermined orientation.

[0066] In still other aspects, the third plurality of oriented fibers may exhibit a substantially uniform size, including substantially uniform coating density measured in denier units and substantially uniform fiber lengths. However, in alternative aspects, the fibers present in the third plurality of oriented fibers may have non-uniform linear densities and non-uniform fiber lengths. In accordance with these aspects, a population of the third plurality of oriented fibers with non-uniform linear fiber densities may, for example, have individual linear fiber densities in the range of about 1 to about 500 denier, including exemplary values of about 3 denier, about 5 denier, about 10 denier, about 15 denier, about 20 denier, about 25 denier, about 30 denier, about 35 denier, about 40 denier, about 45 denier, about 50 denier, about 60 denier, about 70 denier, about 80 denier, about 90 denier, about 100 denier, about 120 denier, about 150 denier, about 170 denier, about 200 denier, about from 250 denier, about 300 denier, about 350 denier, about 400 denier and about 450 denier. It is further understood that the population of the first and second plurality of oriented fibers may have individual linear fiber density in any range between two previous values. For example, in certain aspects, the individual linear fiber density may be from about 1 to about 5 denier, from about 5 denier to about 25 denier, from about 5 denier to about 200 denier, or from about 100 denier to about 500 denier. Furthermore, a population of the first and second plurality of oriented fibers having non-uniform linear density can collectively provide an average linear fiber density that is, for example, greater than 5 denier, greater than 10 denier, greater than 15 denier, greater than 20 denier, greater than 25 denier, greater than 30 denier, greater than 35 denier, greater than 40 denier greater than 45 denier, greater than 50 denier, greater than 100 denier, greater than 200 denier, greater than 300 denier or even greater than 400 denier.

[0067] In still other aspects, it is understood that the decomposition point of the fibers present in the third plurality of oriented fibers is higher than the first and/or second melting point, so that the heat treatment is effective to result in the Fusion and consolidation of at least one of the first and second plurality of fibers does not result in any substantial decomposition of natural fibers present.

[0068] In still other aspects, the layered composite article may comprise a) a rigid support portion comprising a rigid core having a first surface and an opposing second surface, wherein the rigid core comprises at least one densified fiber layer and wherein the at least one densified fiber layer is composed of a first plurality of oriented fibers comprising a natural fiber having a decomposition temperature and a second plurality of oriented fibers having a melting point lower than the decomposition temperature of the first plurality of fibers oriented; and b) a decorative portion having a first surface and an opposing second surface, wherein the second surface of the decorative portion is affixed to the first surface of the rigid core. It is understood that in these aspects, the first plurality of oriented fibers comprising natural fibers can be any natural fiber listed above. It is further understood that the second plurality of oriented fibers may comprise any preceding fibers, or any fibers described below.

[0069] In still other aspects, where the first plurality of fibers is not a natural fiber, the first plurality of fibers may comprise a multicomponent fiber. In still other aspects, the second plurality of fibers may comprise a multicomponent fiber. It is understood that in some aspects of the present invention, multicomponent fibers can be defined as "extrusion of two polymers from the same spinneret with both polymers contained in the same filament". In some aspects, the multicomponent fibers may have any cross-sectional shape or geometry that can be contemplated by one of skill in the art. In some aspects, the multicomponent fibers may have cross-sectional structures that include, but are not limited to, side-by-side fibers, cladding core fiber, island-in-the-ocean fiber, and segmented pie cross-section types.

[0070] It is understood that in some aspects, the multicomponent fiber may comprise at least the first component having the first melting point and at least the second component having the second melting point different from the first melting point. It is further understood that in some aspects, at least the first component may comprise a polymeric component. In still other aspects, the at least second component may comprise a polymeric component.

[0071] In still other exemplary aspects, multicomponent fibers comprise a core-cladding configuration. In some aspects, the coating comprises the first component. In still other aspects, the core comprises a second component. In still other aspects, the cladding may comprise a second component and the core may comprise the first component. It is understood that both the cladding and the core may comprise any fibers mentioned above as a component. In some aspects, the polymeric core component may have a higher melting point than the polymeric shell component. In some aspects, the polymeric core component may comprise polyester, aliphatic polyamides, polyphenylene oxide and/or copolymers or mixtures thereof. In still other aspects, the polymeric core component may comprise polyester, polypropylene, polyethylene, polyamides, polyurethane, polylactic acid, acetal, co-polyester, co-polyamide, polystyrene or a combination thereof. In still other aspects, the polyester may comprise polyethylene terephthalate, polybutylene terephthalate or polyaparenylene terephthalamide. In still other aspects, the polymeric core comprises polyethylene terephthalate. In further aspects, the coating polymer may comprise a polyamide, polyethylene or polyester. In still other aspects, the coating polymer may comprise polyester, polypropylene, polyethylene, polyamides, polyurethane, polylactic acid, acetal, co-polyester, co-polyamide, polystyrene or a combination thereof. In still other aspects, the coating polymer may comprise a nylon or polypropylene. In still other aspects, the cladding core multicomponent fiber comprises a polyester as the main component and nylon as the cladding component.

[0072] It is further understood that, in some aspects, the cladding and core of the multicomponent fiber may comprise the same polymer with different melting points. In still other aspects, the cladding core multicomponent fiber comprises a polyester as a core component and polyethylene as a cladding component. In still other aspects, the multicomponent cladding sheath fiber comprises a polyester having the first melting point as a core component and a polyester having the second melting point as a cladding component.

[0073] It is understood that, in aspects where multicomponent fiber is used in combination with natural fiber, the melting point of each component in the multicomponent fiber is lower than the decomposition temperature of the natural fiber.

[0074] In some aspects, the at least one densified fiber layer described herein may comprise a first plurality of oriented fibers having a first melting point, wherein the first plurality of oriented fibers comprises a single-component fiber. In still other aspects, the at least one densified fiber web described herein may comprise a second plurality of oriented fibers comprising a multicomponent fiber comprising at least the first component having the first melting point and at least the second component having a second melting point. fusion point.

[0075] In still other aspects, the at least one densified fiber layer described herein comprises a plurality of oriented multicomponent fibers, wherein each of the plurality of oriented multicomponent fibers comprises at least one first component having a first melting point and at least at least one second component has a second melting point different from the first melting point. In these aspects, the plurality of oriented multi-component fibers may comprise any configurations of multi-component fibers described herein. In still other aspects, any polymer disclosed herein can be used as any component of the plurality of oriented multicomponent fibers.

[0076] In still other aspects, the rigid core is substantially free of a PVC material or high density fiber (HDF) derived from a wood based material or medium density fiber (MDF) derived from a wood based material. in wood. In still other aspects, the rigid core is substantially free of a wood-based material.

[0077] In still other aspects, the rigid core may also comprise a filling component. Example and non-limiting fillers that may be incorporated into the rigid core layer may include calcium carbonate, fly ash, recycled calcium carbonate, aluminum trihydrate, talc, nano-clay, barium sulfate, barite, fiberglass barite, glass powder, cullet glass, metal powder, alumina, hydrated alumina, clay, magnesium carbonate, calcium sulfate, silica, glass, fumed silica, carbon black, graphite, cement powder, feldspar, nepheline , magnesium oxide, zinc oxide, aluminum silicate, calcium silicate, titanium dioxide, titanates, glass microspheres, chalk, calcium oxide and any combination of these. In some aspects, the filler content may be virgin. In other aspects, the filler content may be recovered. In certain aspects, filler content may be recovered from post-consumer articles. In still other aspects, the contents of the cargo may be recovered from post-industrial articles.

[0078] In certain aspects, the filler comprises one or more calcium carbonate, aluminum trihydrate, barite, feldspar, cullet, fly ash, kaolin clay, limestone, polyurethane foam, rubber, thermoplastic powder, thermoplastic polyurethane ( TPU), wollastonite or any combination thereof.

[0079] In still other aspects, the rigid core may further comprise a pigment, a flame retardant, a surfactant, processing aids or a combination thereof. In certain aspects, the rigid core may comprise one or more flame retardant components. Examples of flame retardants that can be incorporated into the rigid core include, without limitation, organophosphorus flame retardants, magnesium hydroxide, magnesium red phosphorus dihydroxide, hexabromocyclododecane, bromine containing flame retardants, brominated aromatic flame retardants, cyanurate melamine, melamine polyphosphate, melamine borate, methylol and its derivatives, silicon dioxide, calcium carbonate, resourcinol bis-(diphenyl phosphate), brominated latex base, antimony trioxide, strontium borate, strontium phosphate, amine hindered monomeric N-alkoxy (NOR HAS), triazine and its derivatives, high aspect ratio talc, phosphate esters, organically modified nanoclays and nanotubes, non-organically modified nanoarthritis and nanotubes, ammonium polyphosphate, polyphosphoric acid, ammonium salt, triaryl phosphates , isopropylated triphenyl phosphate, phosphate esters, magnesium hydroxide, zinc borate, bentonite nanoclay and nanotubes), organophilic clays, aluminum trihydrate (ATH), azodicarbonamide, diazenodicarboxamide, azodicarbic acid diamide (ADC), triaryl phosphates, isopropylated triphenyl phosphate, triazine derivatives, alkaline activated organophilic clay and aluminum oxide. Any desired amount of flame retardant can be used in the rigid core and the selection of such amount will depend on a required application. Such quantities can be easily determined by no more than routine experimentation.

[0080] In other aspects, any pigments or surfactants known in the art can be used. In still other aspects, any processing aids known in the art may be used. In some aspects, processing aids may include, without limitation, antistatic chemicals, lubricants, oils, or any combination thereof.

[0081] In still other aspects, at least one of the first or second pluralities of fibers, or even third pluralities of fibers, when present, may comprise recovered fibers. In some aspects, the recovered fibers may comprise a post-consumer fiber. In still other aspects, the recovered fibers may comprise a post-industrial fiber. In still further aspects, the recovered fibers may comprise both a post-consumer fiber and a post-industrial fiber. It is understood that both post-consumer and post-industrial fibers may comprise any fibers described above. It is understood that in some aspects, the recovered fiber is recovered from a carpet or carpet tile. In still other aspects, the recovered fiber may be fiber recovered from any material, for example, any material comprising polymeric and/or natural fibers.

[0082] The recovered fibers may be present in the final rigid core in any desired amount, including, for example, an amount in the range greater than 0% to 100% by weight, including exemplary amounts of 5%, 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, 75%, 80%, 85%, 90% and 95%. In still other aspects, the recovered fibers may be present in an amount within any range derived from the above values, including, for example, an amount in the range of more than 0 weight percent to 90 weight percent, of 30 percent by weight. percent by weight to 70 percent by weight, or from 40 percent by weight to 60 percent by weight. In still other aspects, the layered composite article may comprise at least about 10%, at least about 20%, at least about 30%, at least about 40%, or at least about 50% by weight of material. recovered, such as post-consumer material, post-industrial material, post-commercial material or a combination thereof. In another aspect, the layered composite article comprises from about 50% to about 100% by weight of recovered material. It is further understood that the recovered material in the layered composite article may be present as recovered fibers, recovered fillers or a combination thereof.

[0083] It is understood that, by incorporating recovered material into the layered composite articles of the invention, several advantages can be obtained. For example, second-generation products that incorporate recovered material have a smaller environmental footprint compared to traditional composites, comprising only virgin materials. In another aspect, the use of recovered material reduces the amount of traditional, often environmentally harmful materials that were previously sent to landfills, while still providing the same or similar level of composite performance. Additionally, replacing virgin material with reclaimed material can reduce manufacturing costs associated with producing various composite products, such as floor covering products. Additionally, incorporation of recovered material into a second-generation composite can also provide mechanical reinforcement or stability to the second-generation composite, if desired.

[0084] In certain aspects, it is understood that the first plurality of oriented fibers, the second plurality of oriented fibers and the third plurality of oriented fibers described herein may be present in any quantity to provide the rigid core having a desired density. It is understood that the first, second and third pluralities of oriented fibers may be present in any relationship to provide the rigid core having a desired density.

[0085] In some aspects, the plurality of oriented fibers with a lower melting point may be present in the final rigid core (or densified fiber layer) in any desired amount, including, for example, an amount in the range of more from 0% to 100% by weight, including exemplary amounts of 5%, 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, 75%, 80%, 85%, 90%, 95% and 100%. In still other aspects, the plurality of lower melt oriented fibers may be present in an amount within any range derived from the above values, including, for example, an amount in the range of about 0% to about 80% in weight of the total amount of fibers present in the densified fiber layer, alternatively from about 5% to about 60% by weight of the total amount of fibers present in the densified fiber layer, alternatively from about 30% to about 50% by weight weight of the total amount of fibers present in the densified fiber layer or alternatively from about 40% to about 60% by weight of the total amount of fibers present in the densified fiber layer. In aspects where at least a plurality of oriented fibers comprise a multicomponent fiber, the ratio between the various components having different melting points in the multicomponent fiber may be any ratio chosen by one skilled in the art. In some aspects, where two components are present, the weight ratio between two components having different melting points may be about 0.1, about 0.2, about 0.3, about 0.4, about 0.5, about 0.6, about 0.7, about 0.8, about 0.9 or 1.

[0086] In aspects wherein at least the first plurality of oriented fibers comprise a multicomponent fiber, at least one first component of the multicomponent fiber may have a first melting point and at least one second component of the multicomponent fiber may have a second melting point. melting point different from the first melting point of the component. Furthermore, the second plurality of oriented fibers may comprise a plurality of single-component fibers, wherein the single-component fiber may also have approximately the same melting point as the first melting point of the first multi-component fiber. Furthermore, the ratio between the first plurality of fibers and the second plurality of fibers may be any desired value intended to result in a fiber layer having a predetermined desired density. In some exemplary aspects, the multicomponent fiber may be present in an amount greater than 0 to 100% by weight, including exemplary amounts of about 1%, about 5%, about 10%, about 20%, about 30%, about 40%, about 50%, about 60%, about 70%, about 80%, about 90%, about 95%, about 99% and about 99.9% . In some aspects, the multicomponent fiber may be present at 100% by weight.

[0087] In certain aspects, the rigid core may have a thickness in the range of about 0.5 mm to about 12 mm, including exemplary values of about 1 mm, about 2 mm, about 3 mm, about 4mm, about 5mm, about 6mm, about 7mm, about 8mm, about 9mm, about 10mm and about 11mm. In still other aspects, the rigid core may have a thickness in any range between two previous values. In some aspects, the thickness may be in the range of about 0.5 mm to about 12 mm, from about 2 mm to about 12 mm, or from about 5 mm to about 12 mm.

[0088] In some aspects, the inventive rigid core may be permeable to moisture. In still other aspects, the rigid core of the invention is impervious to moisture. In yet other aspects, the innovative rigid core does not accumulate or retain moisture within the densified fiber layer. It is also understood that, in some aspects, the presence of humidity does not alter the rigid core. In some respects, moisture does not alter the mechanical properties of the rigid core. In still other respects, the rigid core exhibits a moisture vapor transmission rate greater than about 1.36 kg/ 93 m2/24h, greater than about 1.58 kg/93 m2/24h, greater than about 1 .8 kg/ 93 m2/ 24h, greater than about 2.04 kg/ 93 m2/ 24h or greater than about 2.27 kg/ 93 m2/ 24h (3 pounds per 1,000 ft2 per 24 hours, greater than about 3.5 pounds per 1,000 ft2 per 24 hours, greater than about 4 pounds per 1,000 ft2 per 24 hours, greater than about 4.5 pounds per 1,000 ft2 per 24 hours, or greater than about 5 pounds per 1,000 ft2) for 24 hours.

[0089] As summarized above and as illustrated again in FIG. 1, the laminated composite article comprises a decorative portion 130 having a first surface 132 and an opposing second surface 134, wherein the second surface of the decorative portion is affixed to the first surface of the rigid core. In certain aspects, the decorative portion of the inventive article comprises a decorative substrate layer or a decorative surface layer 136. As used herein, it is to be understood that the term decorative substrate layer and decorative surface layer may be used interchangeably. In some embodiments, the decorative surface layer comprises polyvinyl chloride (PVC), bleached PVC, opaque PVC, oriented polypropylene (OPP), polyolefin (PO), woven polyethylene (PE), non-woven PE, woven polypropylene (PP) , non-woven PP, woven PET, bleached fiber PET, non-woven PET, woven nylon, non-woven nylon, conventional paper, conventional foil, or sheet-oriented polypropylene. In still other aspects, the decorative surface layer may comprise one or more heat-stable biaxially oriented PET (BoPET), amorphous PET (aPET), recycled PET (rPET), modified polyethylene terephthalate glycol (PETG), polyolefin, cyclic olefin copolymer (COC), cyclic olefin polymer (COP), polyvinylidene fluoride (PVDF), polylactic acid copolymers (PLA), nylon, cellulose acetate, poly(methyl methacrylate) (PMMA), thermoplastic polyurethane (TPU ), thermoplastic elastomers (TPS), polycarbonate, polyethylene (PE) or a copolymer thereof.

[0090] In certain aspects, the decorative surface or substrate layer has a thickness of about 0.5 mil to about 20 mil, including exemplary values of about 2 mil, about 3 mil, about 4 mil, about 5 thousand, about 6 thousand, about 7 thousand, about 8 thousand, about 9 thousand, about 10 thousand, about 11 thousand, about 12 thousand, about 13 thousand, about 14 thousand, about 15 thousand, about 16 thousand, about 17 thousand, about 18 thousand and about 19 thousand. In still other aspects, the decorative surface or substrate layer may have any thickness in a range derived from any two of the exemplary values listed above. For example, the substrate layer may comprise a thickness in a range of about 0.5 mil to about 5 mil, or from about 3 mil to about 7 mil, or from about 7 mil to about 20 mil. . In still further aspects, the substrate layer may be a film.

[0091] In still other aspects, the decorative portion comprises an image layer 138. In certain aspects, the image layer is printed or otherwise transferred onto a surface of the substrate decorative layer or the decorative surface layer. In still other aspects, the image layer is printed or otherwise transferred onto a surface of any visible layer. In some respects, the substrate layer and the visible layer are the same. In other respects, the substrate layer and the visible layer are different.

[0092] In some aspects, the decorative layer is affixed to the first surface of the rigid core with an adhesive. It is understood that the adhesive may be any adhesive known in the art. In some aspects, the adhesive comprises at least one acrylic adhesive, ethylene vinyl acetate (EVA), ethylene acrylic acid (EAA), ethylene acrylic acid-maleic anhydride (EAA-MAH), ethylene methyl acrylate-maleic anhydride ( EMA-MAH), ethylene-vinyl acetate-maleic anhydride (EVA-MAH), low-density polyethylene - maleic anhydride (LDPE-MAH), high-density polyethylene - maleic anhydride (HDPE-MAH), polyurethane (PUR) , polyurethane dispersions (PUD), a polyester thermofusion, a UV-curable adhesive, or a combination thereof. In some aspects, polyurethane dispersions may comprise isocyanate-terminated urethane polymer, methylenebis (phenylisocyanate), methylene bisphenyl isocyanate, and the like. The polyurethane dispersion may further comprise oxazolidine hardeners and various modifiers.

[0093] In some aspects, UV-curable adhesives may comprise polyurethane acrylate-based backbone polymers, polyisoprene acrylate-based backbone polymers, polyisoprene acrylate-based backbone polymers, powder acrylate-based backbone polymers, - libutadiene, monomeric (meth)acrylates and the like. In certain aspects, UV-curable adhesives may comprise any adhesives known in the art that are capable of being cured by exposure to UV light. In other aspects, the UV-curable adhesive may further comprise other additives, such as, for example, and without limitation, photopolymerization initiators, additives that increase the flexibility of the resin, and the like.

[0094] In still other aspects, the adhesive comprises ethylene-vinyl acetate (EVA). In still other aspects, the adhesive comprises ethylene acrylic acid (EAA). In still other aspects, the adhesive comprises polyurethane dispersions (PUD), reactive polyurethane hot melt adhesive (PUR) or a polyester. In still other aspects, the polyester may comprise polyethylene terephthalate (PET), a polylactide (PLA), have modified polyethylene glycol terephthalate, polymethylene terephthalate or any combination thereof.

[0095] The adhesive may comprise substantially linear ethylene polymers and homogeneously branched linear ethylene polymers (i.e., homogeneously branched ethylene polymers). Homogeneously branched ethylene polymers (including substantially linear ethylene polymers in particular) have low solidification temperatures, good adhesion to polypropylene, and low modulus relative to conventional ethylene polymers such as low-density polyethylene (LDPE), linear low-density polyethylene. heterogeneously branched density polyethylene (LLDPE), high density polyethylene (HDPE), and heterogeneously branched ultra-low density polyethylene (ULDPE).

[0096] In certain aspects, the adhesive has a thickness of about 0.1 mil to about 5 mil, including exemplary values of about 0.5 mil, about 1 mil, about 1.5 mil, about 2 thousand, about 2.5 thousand, about 3 thousand, about 3.5 thousand, about 4 thousand and about 4.5 thousand. In still other aspects, the adhesive may be any thickness in a range derived from any two of the exemplary values listed above. For example, the adhesive may comprise a thickness in the range of about 0.5 mil to about 4 mil, or from about 0.1 mil to about 3 mil.

[0097] In still other aspects, the decorative portion may be affixed to the first surface of the rigid core by any other method known in the art. In some exemplary aspects, the decorative portion may be attached to the first surface of the rigid core by stitching. For example, the decorative portion comprising a plurality of bleached PET fibers as a substrate can be fixed to the first surface of the rigid core by means of stitching. In other aspects, the seam-attached decorative portion may be further heat pressed to the first surface of the rigid core. In these aspects, the image layer may be formed by direct printing onto the substrate after the decorative portion is affixed to the first surface of the rigid core. In such aspects, randomly oriented fibers with a base tone of white or off-white may be affixed to the first surface of the rigid core. The fibers used to form this substrate may comprise at least about 10%, at least about 20%, at least about 30%, at least about 40%, at least about 50%, at least about 60% , at least about 70%, at least about 80%, at least about 90%, or at least about 95% by weight of a low melting point fiber that can create a bond to the rigid core when heated to a temperature of about 110 to about 250°C, including example values of about 120°C, about 130°C, about 140°C, about 150°C, about 160°C, about 170°C, about 180°C, about 190°C, about 200°C, about 210°C, about 220°C, about 230°C and about 240°C. In still other aspects, the resulting surface may be further flattened to maintain a level of smoothness allowing the transferred image to have sufficient detail by a belt or the use of a release film or paper.

[0098] In still other aspects, the decorative portion can be affixed to the first surface of the rigid core by first dispersing a polymer powder. In such aspects, the spread powder comprises a polymer comprising a polypropylene, a polyester, a polyethylene or a combination thereof. In still other aspects, the decorative portion placed on the spread powder is further compressed to the first surface of the rigid core.

[0099] In some aspects, the image layer may comprise any conventional ink, dye, pigment or other marking substance that can be applied in a desired pattern. For example and without limitation, the imaging layer may comprise water-based inks, soy-based inks, UV-cured inks and/or solvent-based pigments. In yet another aspect, the image layer is a UV-cured ink.

[00100] It is understood that UV-cured inks may comprise photo-initiators, pigments, additives, monomers and oligomers of various polymers, and the like. In some exemplary aspects, UV-cured inks may comprise, without limitation, (5-ethyl-1,3-dioxan-5-yl)methyl acrylate, 2-phenoxyethyl acrylate; 1-vinylhexa-hydro-2H-azepin-2-one, substituted phosphine oxide, trimethylolpropane triacrylate, phenyl bis(2,46-trimethylbenzoyl) phosphine oxide, epoxy acrylate oligomer, diacrylate monomer, multifunctional monomers, amine-modified acrylate oligomer, 1-vinylhexahydro-2H- asepin-2-one, diacrylate oligomers, benzophenone, triacrylate monomer, 1-hydroxy-cyclohexylphenyl-ketone, 2-hydroxy- 2- methylpropiophenone and the like.

[00101] It is further understood that the image layer may be applied to the decorative substrate layer or decorative surface layer or any other visible layer by any conventional printing means, which may include, without limitation, direct printing, gravure printing , digital printing, screen printing, flexographic printing, lithographic printing, offset lithographic printing, relief printing, thermographic printing, thermal sublimation printing, dye sublimation printing, heat transfer printing, digital printing and the like. In still other aspects, the image layer may be applied by reverse printing. In exemplary aspects, the image is printed on a lower portion of the transparent film rather than the upper side of the film. In this regard, layers 136 and 138 in FIG. 1 would be reversed.

[00102] In still further aspects, the image layer can be applied by a digital print. In some aspects, the image layer is applied before attaching the decorative part to the rigid core. In other aspects, the image layer is applied after the decorative part is affixed to the rigid core. In an exemplary aspect, the image layer may comprise inks and pigments manufactured by INX Inks, Durst, HP, EFI, Sun Chemical, DyStar, Sensient Inks Technologies, Kao Collins, Mankiewicz, Marabu, Borbeaux or Tiger. In still other aspects, the image layer can be digitally printed using digital printers manufactured by Cefla, Durst, Hymmen, EFI, Barbaran, Zimmer Austria, HP, Fujifilm, Mi maki, AGFA, Kodak, Canon, Epson, KBA, OKI, Ricoh, Heidelberg, Mutoh or Inca.

[00103] In certain aspects, the image layer formed may be a continuous layer that substantially covers the entire upper surface of the substrate. In still other aspects, the image layer formed may be a discontinuous layer that covers only a portion of the upper surface of the substrate. In still other respects, the image layer can have any desired aesthetic appearance. In some exemplary aspects, the image layer may have the appearance of simulated wood, concrete, slate, or tile flooring.

[00104] In some aspects, the decorative layer portion may be of any suitable weight and thickness. In some embodiments, the decorative layer portion has a weight of about 0.2 ounces per square yard to about 1.0 ounces per square meter, including, without limitation, decorative layer portions having a weight of about 0. 3, 0.4, 0.5, 0.6, 0.7, 0.8 and 0.9 ounces per square yard. In a further aspect, a decorative layer portion may have a total thickness of about 1 mil to about 20 mil, including exemplary values of about 2 mil, about 3 mil, about 4 mil, about 5 mil, about 6 thousand, about 7 thousand, about 8 thousand, about 9 thousand, about 10 thousand, about 11 thousand, about 12 thousand, about 13 thousand, about 14 thousand, about 15 thousand, around 16 thousand, around 17 thousand, around 18 thousand and around 19 thousand; although virtually any thickness can be used.

[00105] In still other aspects, the decorative layer may further comprise an aesthetic layer, such as a thin veneer of slate, ceramic, stone, wood, cork, film, fabric or non-woven material.

[00106] In yet another aspect, the decorative layer may further comprise a layer made of a dispersed coated powder. In some aspects, the dispersed powder may comprise a polypropylene, a polyester, a polyethylene, or a combination thereof.

[00107] In still other aspects, the decorative layer may comprise woven fibers, stone, ceramics, glass, perforated materials, leather, animal skins, veneers or any combination thereof.

[00108] In a further aspect, any of the aesthetic layers described above can be adhered to any previous substrate.

[00109] In still other aspects, the decorative portion further comprises an optional wear layer 140 adherent to the upper surface 132 of the decorative layer. In still other aspects, the wear layer is not present. In aspects where the wear layer is present, the wear layer may comprise, for example and without limitation, conventional ionomers, polyethylene terephthalate (PET), polyurethane, polyurethane reactive hot-melt adhesive polypropylene (PUR), terephthalate polymethylene (PTT), polyamide, polyvinyl chloride (PVC) and the like. In another aspect, the wear layer may comprise surlyn resin, such as, for example and without limitation, Surlyn® 1706 resin, manufactured by E.I. du Pont de Nemours and Company, Inc, or Incor PUR supplied by Kleiberit. or Henkel.

[00110] In still other aspects, the wear layer may comprise heat-stable biaxially oriented PET (BoPET), amorphous PET (aPET), recycled PET (rPET), modified polyethylene terephthalate glycol (PETG), polyolefin, cyclic olefin copolymer (COC), cyclic olefin polymer (COP), polyvinylidene fluoride (PVDF), polylactic acid (PLA) copolymers, nylon, cellulose acetate, poly(methyl methacrylate) (PMMA), thermoplastic polyurethane ( TPU), thermoplastic elastomers (TPE), polycarbonate, polyethylene (PE), high-density polyethylene (HDPE), low-density polyethylene (LDPE) or a copolymer thereof.

[00111] In some aspects, the wear layer is substantially transparent. In other aspects, the wear layer is substantially opaque.

[00112] In yet a further aspect, the wear layer may have a thickness in the range of more than 0 mil to about 30 mil, including example thickness ranges of about 0.5 mil, about 1 mil, about 1.5 thousand, about 2 thousand, about 2.5 thousand, about 3 thousand, about 3.5 thousand, about 4 thousand, about 5 thousand, about 6 thousand, about 7 thousand, about 8 thousand, about 9, about 10 thousand, about 12 thousand, about 15 thousand, about 17 thousand, about 20 thousand, about 22 thousand, about 25 thousand and about 27 thousand. In yet another aspect, the thickness of the wear layer may be in a range derived from any of the exemplary values listed above. For example, the thickness can vary up to 4 mil, or between 4 mil and 9 mil, or between 4 mil and 16 mil.

[00113] In some aspects, the wear layer is laminated to the decorative part. In still other aspects, the wear layer is UV cured for the decorative portion. In some aspects, where the wear layer is not present, a spray material may be applied to the upper surface of the decorative portion. In such aspects, the pulverized material may serve as a scratch layer.

[00114] In certain aspects, the decorative portion has a top layer. In still other aspects, an upper surface of the decorative portion is engraved or embossed into the register. In aspects where the wear layer is present, the top layer of the decorative portion is the wear layer. In aspects where the wear layer is absent, but the decorative portion comprises a substrate layer, the surface of the substrate may also be the top layer of the decorative portion. In aspects where any additional aesthetic layers are present and the wear layer is absent, an upper surface of the additional aesthetic layer is also the upper surface of the decorative portion. In still additional aspects, a layer of risk 142 may be present. The scratch layer may be applied to the top surface of the wear layer 140. Alternatively, in aspects where the optional wear layer is not present, the scratch layer may be applied directly to the top surface of the decorative layer. It is understood that the scratch layer may be applied by any method known in the art. In some aspects, the draft layer may comprise any materials suitable for the purpose. In still other aspects, the scratch layer may comprise transparent polyurethane-based materials or transparent acrylic-based materials. In still other aspects, the scratch layer can be UV cured.

[00115] When desired, embossing can be done to provide visuals and textures intended to duplicate or imitate the appearance of wood grain, slate and other visual characteristics. Laser engraving can also be used instead of embossing to achieve the desired aesthetic. Some other potential methods for texturing the surface of cladding materials, wall plates, ceilings, or roofing products include drag spinning while the temperature of an extruded product is still above the glass transition temperature or dragging probes across the surface while the product or probe is moving. Additionally, a texture can be incorporated into the surface of an injection mold, compression mold, or vacuum form mold. A texture can also be hot or cold stamped with pressure to create the desired look. It is understood that recording can be done by any techniques known in the art. In some aspects, embossing roll, film or UV “freeze” embossing may be used. In still further aspects, recording can be done using heat or inert UV curing under film or tape. In some exemplary aspects, engraving can be done by applying a viscous liquid that can be cured and crosslinked. In some additional aspects, a film with a texture may be applied to the viscous liquid which is then cured through the film to form a textured surface mirroring the texture that was present in the textured film. In still other aspects, the uncured UV polymer may be pressed with a belt or film having a negative embossing structure and then cured by UV energy to cause the UV varnish materials to harden into the shape of the embossing film or structure. , band or paper.

[00116] In certain aspects, the engraving may be pressed or cured into the scratch or wear layer. In other aspects, the image layer comprising embossing may be compressed or cured into the scribe or wear layer by various means, for example, and without limitation by a UV curing molding method.

[00117] In still other aspects, the entire decorative portion, for example, a composite portion comprising an image layer, a wear layer and a scratch layer, can be made prefabricated and then applied to the rigid core using any method known in the art. In some exemplary aspects, this fixation can be done with any known adhesive material.

[00118] The layered composite article can generally have any desired shape. In one aspect, the layered composite article is substantially flat. Flat composite articles may be useful for floor coverings, or decking material, wall boards and the like. Flat composite articles can be manufactured to any desired size, which will generally depend on the targeted application. In one aspect, the flat composite article may have a length dimension greater than a width dimension. For example, the planar composite article may be sized as a sheet, e.g., a 5' x 12' sheet. Such sheet can be cut into smaller sizes as required. In other aspects, the composite articles may be sized at a 4' x 8' cm composite, or a 4' x 10' cm composite, or a 5' x 12' among other elongated sizes. In other aspects, composite articles can be sized to fit a final product. Elongated composite articles may be useful, for example, as decking materials. Composite articles can also be of any desired thickness. In one aspect, the composite has a thickness of about 0.635cm to about 7.62cm or from 1.27cm to 2.54cm or from about 0.635cm to about 1.095cm or from about 1.524cm to about 1.095cm. cm (about 0.25 to about 3 inches, or from 0.5 inches to 1.0 inches, or from about 0.25 to about 0.75 inches, or from about 0.6 to about 0.75 inches). In a further aspect, the composite articles may have a suitable shape and dimension, typically used in floor tiles, wall tiles, ceiling tiles, including, but not limited to, dimensions such as 1' x 1', 2' x 2', 3' x 3', 3' x 5' and similar. In some aspects, the covering article may be configured as a panel, plank, sheet, plate or tile. In other aspects, the layered composite article is a wall plate. In yet another aspect, the layered composite is a ceiling article. Other shapes include diamond, rectangles, triangles, circles and other shapes.

[00119] In some aspects, the layered composite article comprises a first pair of opposing side edges and a second pair of opposing side edges. In certain aspects, the plurality of side edges is not profiled to define any form of an interlocking mechanism or other fastening mechanism by which adjacent articles can be secured to each other. In still other aspects, the plurality of side edges may be profiled to form an interlocking mechanism.

[00120] As used herein, the terms “interlocking mechanism” or “interlocking structure” refer to a mechanism that allows the connection of various parts of the floor covering plate so that the operation of one part automatically trigger or prevent the operation of another party. The interlocking mechanisms contain locking means that lock adjacent skin plates in at least a horizontal manner, or at least in a vertical manner, or may include features that lock in both a horizontal and vertical direction. Some exemplary interlocking mechanisms contain a tongue-type projection and a groove-type profile within the same floor covering plate. For example, the tongue profile may be machined on one side and one end of the board with the groove being machined on the opposite side and end of the same panel. Such joints can be made by machining the edges of the plates. Such joints can be made by machining the edges of the plates. It is understood that the term "interlocking mechanism" is not considered to be limited to the tongue and groove profiles of floor covering boards only. Other example interlocking mechanisms include snap connections incorporated into the plate edges, tilt plate with interlocking edges, plates with overlapping edges, plates with puzzle locking edges, plates with slanted edges, etc. It is understood that the term "interlocking mechanism" allows a plurality of panels to be readily joined together in an interlocking relationship so that when assembled, there is no need for separate structures. In other aspects, the interlocking mechanism may comprise a fastener. In still other respects, the articles are free or mechanically fixed.

[00121] In addition to, or as an alternative to, the integrated interlocking mechanisms described herein, the disclosed layered composite may further include or be installed using additional locking elements. In some examples, such locking elements may include strips with protruding features that engage the locking element with two adjacent articles. Such locking devices may be made of the same material as a layered composite article, aluminum, wood fiber, etc.

[00122] In additional aspects, the layered composite article of the invention can be glued directly to a subsurface. In still other aspects, the layered composite article can be freely placed on a subsurface. In still other aspects, the layered composite article may be adhered to the surface with locking points, adhesive strips and the like. In such aspects, glues that may be used include, but are not limited to, Dupont VHB Gorilla glue, liquid nails or any other commercially available glue. In still other aspects, the layered composite article can be magnetically attached to a subsurface. In some exemplary aspects, the subsurface may, for example, be coated with any substance that has magnetic properties or that contains material otherwise attracted to a magnetic material. For example, the subfloor may be coated with iron oxide or iron. In such aspects, the layered composite article may further comprise any substance that exhibits magnetic properties and be connected to the subfloor with the magnetic field present once the floor is installed.

[00123] In still other aspects, the layered composite article of the invention can be bonded to an additional support material. It is understood that attachment of the layered composite article of the invention to the additional support material may be accomplished by any methods known in the art. For example, and without limitation, the accessory may be made by applying an adhesive material or loosely layering the composite article onto the additional support. It is understood that such adhesives may comprise any adhesive known in the art, for example, and without limitation, PUR hot-melt adhesives. In still other exemplary aspects, the additional support material may be a backing film, a foam, a glue or adhesive layer, or other padded or cushioned backings, such as cork. In certain aspects, the additional support may comprise a non-slip backing, a cushion, an embossed backing, a foam, a carpet backing, or any combination thereof.

[00124] It is understood that the non-slippery backing, cushion, embossed backing, foam or mat base may be comprised of any backing materials known in the art. In some aspects, they may include polyurethane foams. In other aspects it may comprise polyethylene-based plastomeric base foams or bases, such as HBEP or SLEP-based foams. Description of example bases can be found, for example, in U.S. Patent Application No. 11/915,553, U.S. Patent Application No. 12/786,036, U.S. Patent Application No. 12/619,059, or Patent Application No. U.S. 9,410,026, which are incorporated herein by reference in their entirety.

[00125] In certain aspects, the layered composite article described herein may exhibit a Class I radiant flux test rating in accordance with ASTM E-648.

[00126] In still other aspects, the layered composite article has a residential indentation of less than 0.0127mm (0.0005 inches), when measured in accordance with ASTM F1914-07 (2011). In still other aspects, the layered composite article exhibits a residual indentation of less than 8% of the total thickness when measured in accordance with ASTM F1914-07 (2011). In still other respects, the layered composite article has a commercial indentation of less than 0.127 mm (0.005 inches) when measured in accordance with ASTM F970. In still other aspects, the layered composite article exhibits a static load indentation of less than 0.127 mm (0.005 inches) when measured in accordance with ASTM F970.

[00127] In still other aspects, the layered composite article passes a Mandrel bending radius test measured in accordance with ASTM F137 (2013). In certain aspects, the test is considered passed if no cracks or breaks are observed when the sample of the inventive article is bent around the 2.54cm (1”) mandrel. In still other aspects, the layered composite article passes a Mandrel bend radius test of less than 2.54 cm 1 (inch) measured in accordance with ASTM F137 (2013).

[00128] It is understood that the rigidity of the product can be determined by measuring a flexural modulus and a flexural strength of the article.

[00129] In some aspects, flexural modulus and flexural strength can be measured by the three-point bending flexural test. In some aspects, flexural modulus (also known as modulus of elasticity) is calculated as the ratio of stress to strain in flexural deformation, or the tendency of a material to bend. In certain aspects, this value is measured in units of force per area and may be determined from the slope of a stress-strain curve produced by a bending test, for example, when tested in accordance with ASTM D790. The schematic of the conditions used in a 3-point test is shown in FIG. 2. The rectangular beam (200) behaving as an isotropic linear material, having a width w (202) and a height h (204) is used for a test. The values used in the test, in addition to the width w (202) and height h (204) of the beam, are a distance L (206) which is measured between the two external supports (208), a second moment of area of the cross section of beam I (not shown) and a deflection d (210) that exists due to the load F (212) applied in the middle of the beam. Flexural modulus calculations can be done according to formula (1)

[00130] From elastic beam theory, d can be found according to formula (2)

[00131] where, again, I is the moment of inertia of the cross section, and E is a modulus of elasticity. For a rectangular beam I can be found according to formula (3)

[00132] Thus, Ef=E, that is, Ef is equal to Young's modulus or modulus of elasticity.

[00133] Without being linked to a theory, ideally, the flexural or bending modulus of elasticity is equivalent to the tension modulus (Young's modulus) or comprehensive modulus of elasticity. However, as a person of ordinary knowledge would readily appreciate, polymers are an unpredictable part of the art and thus flexural modulus values can vary greatly.

[00134] Building codes determine the maximum deflection, generally as a fraction of the range, for example, 1/400 or 1/600. Thus, the allowable stress (or strength limit state) or serviceability limit state (various deflection considerations) may affect the minimum member dimensions required for testing.

[00135] In some aspects, the layered composite article exhibits a flexural modulus of about 0.1 to about 15.0 GPa, including exemplary values of about 0.5 GPa, about 1 GPa, about 1 .5 GPa, about 2 GPa, about 2.5 GPa, about 3 GPa, about 3.5 GPa, about 4 GPa, about 4.5 GPa, about 5 GPa, about 5.5 GPa, about 6 GPa, about 6.5 GPa, about 7 GPa, about 7.5 GPa, about 8 GPa, about 8.5 GPa, about 9 GPa, about 9.5 GPa, about 10 GPa, about 10.5 GPa, about 11 GPa, about 11.5 GPa, about 12 GPa, about 12.5 GPa, about 13 GPa, about 13.5 GPa, about 14 GPa and about 14.5 GPa.

[00136] In still other aspects, the layered composite article has a flexural strength of about 20 to about 400 MPa, including example values of about 30 MPa, about 50 MPa, about 70 MPa, about 100 MPa, about 130 MPa, about 150 MPa 170 MPa, about 200 MPa, about 230 MPa, about 250 MPa, about 270 MPa, about 300 MPa, about 330 MPa, about 350 MPa and about 370 MPa.

[00137] In still other aspects, the layered composite article presents substantially equalized component stress. In certain aspects of the present invention, the layered composite article exhibits substantially uniform stability throughout the article and therefore does not require acclimation periods to allow stresses to equalize prior to any installation. In still other aspects, dimensional stability and the lack of need for an acclimation period can be measured according to ISO 23999 (Heat Curl Dimensional Stability) dimensional stability standards. In certain aspects, dimensional stability can be measured by analyzing the dimensional variations of the article when the article is heated to a temperature of about 80°C or 180°F (80°C/180°F) and then cooled back to the temperature environment. The maximum variation shown in such aspects may be no more than about 0.05%, no more than about 0.1%, no more than about 0.11%, no more than about 0.12%, no more than about 0.13%, no more than about 0.14%, no more than about 0.15%, no more than about 0.16%, no more than about 0.17%, no more than about 0.18%, no more than about 0.19%, no more than about 0.20%, no more than about 0.25%, no more than about 0.30%, no more than about 0.35%, no more than about 0.40%, or no more than about 0.5%. In still other respects, the maximum observed variation may be any range of values derived by any two preceding values. In some respects, the maximum variation is about 0.1% to about 0.2%, or about 0.15% to about 0.5%. In still other respects, the maximum variation is not more than about 0.17% when the article is heated to 80°C or 180°F (80°C/180°F) and then cooled to room temperature. In still other aspects, dimensional stability can be measured in accordance with ASTM F2199 and exhibits shrinkage of less than 0.166cm/m, less than 0.125cm/m, less than 0.083cm/m, or less than 0.041cm/m (0.020”/m). foot, less than 0.015”/foot, less than 0.010”/foot or less than 0.005”/foot). In still other aspects, dimensional stability can be measured in accordance with ASTM F2199 and exhibits a maximum shrinkage of about 0.200%, maximum of about 0.167%, maximum of about 0.170%, maximum of about 0.160%, maximum of about 0.155%, maximum about 0.150, or maximum about 0.145%.

[00138] FIG. 3 (a) shows a cross-sectional image of an exemplary layered composite article comprising a layer of polyvinyl chloride material as a rigid support portion. This is shown in comparison to FIG. 3(b) illustrating an exemplary layered composite comprising a rigid core densified fiber layer of the invention. Specifically, FIG. 3(a) shows a cross-sectional image of a conventional rigid article having a PVC core or support portion layer (310a) and a decorative portion 330a affixed thereto. The decorative portion 330a consists of a printed image layer (336/338a). The printed image layer is itself constituted by a substrate 336 that has a printed image layer 338 printed thereon and a wear layer (340a). FIG. 3(b) shows a cross-sectional image of an exemplary inventive layered composite comprising an inventive rigid core support portion (310b) comprising an inventive fiber layer and a decorative portion 330b attached thereto. The decorative portion 330b consists of a printed image layer (336/338a). The printed image layer is itself constituted by a substrate 336 that has a printed image layer 338 printed thereon and a wear layer (340b).

METHOD

[00139] The present disclosure also provides methods for making each of the layered composite articles described above. In one aspect, a method is provided which generally comprises the steps of: a) forming a rigid support portion comprising a rigid core having a first surface and an opposing second surface, wherein the rigid core comprises at least one densified fiber layer and wherein the at least one densified fiber layer is composed of a first plurality of oriented fibers having a first melting point and a second plurality of oriented fibers having a second melting point different from the first melting point; b) forming a decorative portion having a first surface and an opposing second surface; and c) affixing the second surface of the decorative portion to the surface of the rigid core.

[00140] In another aspect, disclosed herein is a method comprising: a) forming a rigid support portion comprising a rigid core having a first surface and an opposing second surface, wherein the rigid core comprises at least one densified fiber layer and wherein the at least one densified fiber layer is composed of a plurality of multicomponent fibers, wherein each of the plurality of oriented multicomponent fibers comprises at least one first component having a first melting point and at least one second component having a second melting point different from the first melting point; b) forming a decorative portion having a first surface and an opposing second surface; and c) affixing the second surface of the decorative portion to the first surface of the rigid core.

[00141] In still other aspects, described herein is a method of producing the layered composite article comprising: a) forming a rigid support portion comprising a rigid core having a first surface and an opposing second surface, wherein the rigid core comprises at least one densified fiber layer and wherein the at least one densified fiber layer is composed of a first plurality of oriented fibers comprising a natural fiber having a decomposition temperature and a second plurality of oriented fibers having a decomposition point melting lower than the decomposition temperature of the first plurality of oriented fibers; b) forming a decorative portion having a first surface and an opposing second surface; and c) affixing the second surface of the decorative portion is affixed to the first surface of the rigid core.

[00142] The step of forming the rigid support portion may further comprise forming a rigid core comprising: a) overlapping the first plurality of oriented fibers and the second plurality of oriented fibers to form a fibrous matrix; b) treating the fibrous matrix to form a fiber layer; and c) heat and pressure treating the fiber layer under conditions effective to form the densified fiber layer.

[00143] In other aspects, a third plurality of oriented fibers may be present. In these aspects, the step of forming the rigid core may comprise: a) overlapping the first plurality of oriented fibers, the second plurality of oriented fibers and the third plurality of oriented fibers to form a fibrous matrix; b) treating the fibrous matrix to form a fiber layer; and c) heat and pressure treating the fiber layer under conditions effective to form the densified fiber layer. It is to be understood that the first, second and third plurality of oriented fibers may comprise any of the fibers described herein.

[00144] It is further understood that any method known in the art that provides intertwining of fibers can be used to form the fiber layer. In some aspects, the treating step may comprise a needle piercing step. In other aspects, the treatment step may comprise a powder dispersion process. In still other aspects, the treating step may comprise any known process capable of forming a fiber layer. In some aspects, the needle piercing step is optional. In still other aspects, the needle punching step may be replaced by a water interlacing step, pneumatic interlacing or any other method capable of holding the fibers together, for example, a thermal bonding method or the use of additional adhesives.

[00145] In aspects where the treatment step comprises a powder dispersion, the powder may first be spread on the belt and the fibers may be superimposed on top of the powder. In other aspects, the components may be hot pressed to form a fiber layer. In such aspects, the dispersed powder may comprise a polypropylene, a polyester, a polyethylene or a combination thereof.

[00146] The methods described herein can, again, provide a densified fiber layer having a density of about 0.08 g/cm3 to about 1.6 g/cm3 (5 lb/ft3 to about 100 lb/ft3 ), including example densities of 0.16, 0.24, 0.32, 0.4, 0.48, 0.56, 0.64, 0.72, 0.8, 0.88, 0.96 , 1.04, 1.12, 1.2, 1.28, 1.36, 1.44, and 1.52g/cm3 (10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90 and 95 lb/ft3). In still other aspects, the volumetric density may be a value within any range derived from the above values, including, for example, a density of about 0.24 to about 1.2 g/cm3 (15 to about 75 pounds per cubic foot).

[00147] In certain aspects, the methods described herein provide a densified fiber layer that has a density of at least about 0.16 g/cm3, including exemplary values of at least about 0.24 g/cm3, about 0.32 g/cm3, about 0.4 g/cm3, about 0.48 g/cm3, about 0.56 g/cm3, about 0.64 g/cm3, or about 0.8 g/cm3 (10 lb/ft3, including exemplary values of at least about 15 lb/ft3, about 20 lb/ft3, about 25 lb/ft3, about 30 lb/ft3, about 35 lb/ft3, about 40 lb/ft3 ft3, about 45 lb/ft3 or about 50 lb/ft3). In certain aspects, the densified fiber layer may have a density in a range between any two previous values.

[00148] In other aspects, the methods described herein provide a densified fiber layer having a density greater than about 0.8 g/cm3, about 0.72 g/cm3, about 0.64 g/cm3, about 0 .56g/cm3, about 0.48g/cm3, 0.4g/cm3, about 0.32g/cm3, about 0.24g/cm3 or about 0.16 g/cm3 (50 lb/ft3, about of 45 lb/ft3, about 40 lb/ft3, about 35 lb/ft3, about 30 lb/ft3, 25 lb/ft3, about 20 lb/ft3, about 15 lb/ft3 or about 10 lb /foot3). In certain aspects, the densified fiber layer may have a density in a range between any two previous values. It is understood that the densified fiber layer may have a density as low as the density of a fiber layer comprising a first plurality of substantially identical oriented fibers and a second plurality of substantially identical oriented fibers that have not undergone any densification processes. , for example, heating and pressurization.

[00149] The methods described herein can provide a densified fiber layer having a density as low as a density of a fiber layer comprising a first substantially identical plurality of oriented fibers, a second substantially identical plurality of oriented fibers, and a substantially identical third plurality of oriented fibers that have not undergone any densification process, for example, heating or pressurization.

[00150] In some aspects, described here are methods that provide a rigid core as described herein, wherein the rigid core has a variable density across portions of the rigid core. For example, described herein are methods that can provide a rigid core comprising a first portion having a first density and a second portion having a second density different from the first density. To form such a rigid core with different densities, in some aspects, the ratio between the first and second plurality of fibers can be manipulated to achieve a desired result. In other aspects, the proportion between the first, second and third plurality of fibers can be manipulated to achieve a desirable result.

[00151] In still other aspects, the article may comprise a densified layer comprising non-fibrous composition. In such aspects, the densified layer may be disposed between the rigid core and the decorative portion.

[00152] It is understood that the first, second and third plurality of fibers can be present in any previous quantity or proportion.

[00153] In still other aspects, described herein are methods for providing a rigid support portion of the layered composite article of the invention that has a variable density across the rigid core. Such methods may comprise forming at least two layers of separate densified fibers which are then layered adjacent to each other. In these aspects, each of the densified sleeves may be formed by any method described herein and exhibits a density that may be the same or different from another densified fiber layer.

[00154] In certain aspects, the step of overlapping the pluralities of oriented fibers can be carried out using a carding and crossing overlap system, an airlay system or a combination thereof. It is understood that in some aspects, after the overlapping step, the rigid core forming step may further comprise needle piercing. In other aspects, after the overlay step, the rigid core forming step may further comprise any methods known in the art, for example, and without limitation, a powder dispersion step. In still other aspects, the rigid core forming step further comprises treating with heat and pressure under conditions effective to form the densified fiber layer.

[00155] Depending on the temperature at which the composite layer is heated, the use of heat-resistant conveyor belts may be desired. Generally, the composite layer is heated to a temperature sufficient to at least partially fuse the plurality of fibers having the lowest melting point. In some aspects, heat treatment conditions effective for forming the densified fiber layer may comprise heating to a temperature of about 82.2°C to about 426.7°C, including exemplary temperatures of about 93.3°C. C, 121.1°C, 149°C, 176.7°C, 204.4°C, 232.02°C, 260°C, 287.8°C, 315.5°C, 371.1° C and about 398.9°C (180°F to about 800°F, including exemplary temperatures of about 200°F, 250°F, 300°F, 350°F, 400°F, 450° F, 500°F, 550°F, 600°F, 700°F and about 750°F). In still other aspects, heat treatment conditions effective for forming the densified fiber layer may comprise heating to a temperature of about 82.2°C to about 176.7°C, about 232.02°C, or about from 121.1°C to about 176.7°C or about 176.7°C to about 315.5°C (180°F to about 350°F, about 250°F to about 450°C °F or about 250°F to about 350°F or about 350°F to about 600°F).

[00156] In certain aspects, a furnace can be used for heat treatment. In still other aspects, it is understood that any heating means known in the art may be used. For example, in some aspects, the fiber layer may be calendared hot oil. In still other aspects, heat and pressure may come from continuous double-belt presses, for example, commercially available from TPS, Sandvik, Meyer, HELD, Schott & Meissner, Meyer, HELD or Hymmen. In still other aspects, heat and pressure can come from single- and multiple-opening static presses. In still other aspects, the fiber layer can be heated in an air oven and then scheduled.

[00157] During or after the heating step, the fiber layer may optionally be subjected to effective pressure treatment conditions to form the densified fiber layer. In these aspects, the fiber layer is subjected to a pressure in excess of 0 to about 8273.7 kilopascals, including for example, from about 68.9 kilopascals to about 3447.4 kilopascals, from about 689.5 kilopascals to 6894.7 kilopascals, from about 1723.7 kilopascals to 6894.7 kilopascals, from about 2757.9 kilopascals to about 6550 kilopascals, from about 3447.4 kilopascals to 5171 kilopascals or from about 4136.8 kilopascals to 4826.3 kilopascals.

[00158] An example apparatus suitable for making layered composite articles is shown in FIG. 4. In a predetermined relationship, the first plurality of fibers and a second plurality of fibers are removed from the bundles 424, 426 and placed manually or mechanically on a feed conveyor 430 as a mixture of loose oriented fibers. The loose fiber mixture is initially moved through a textile carding 432 which orients the fibers to form a fibrous matrix. Once carded, the fibrous matrix is moved to a crossover overlapping equipment 434 where the web is overlapped for a predetermined number of layers. The crossover overlay fibrous matrix moves through a crossover overlay device 434 through a tacker loom 438. The tacker loom 438 operates to loosely interconnect the matrix layers by means of barbed needle penetration to form a layer of fiber. After initial stitching by the tacker loom 438, the fabric layer may be optionally stretched through the tension rollers 440. After drafting, the optionally stretched fabric layer may be further moved through an additional main loom 442. The main loom 442 is operable to provide additional barbed needle penetration. Following processing by the main loom 442, the fabric layer is moved through a calendar 444, where hot oil is calendared between about 121.1°C and 204.4°C and 8273.7 kilopascals (250 and 400° F and 50 to 1,200 psi). After calendar lamination, the fabric may optionally pass through an additional heating station 448. At the optional heating station 448, the fabric layer may be exposed to infrared heat between about 65.5°C and 176.7°C. C (150°F and 350°F). Once the fabric layer is heated and optionally subjected to pressure, the formed densified fabric layer can then be cooled. It is understood that other steps can be performed during the process, as desired.

[00159] In some aspects, the step of attaching the decorative portion to the first surface of the rigid core may comprise applying an adhesive. In some aspects, it is understood that the adhesive material can be applied by any method known in the art. In some aspects, the adhesive may be applied as a hot-melt. In other aspects, the adhesive may be extruded into the densified fiber layer. In still other aspects, the adhesive material may be applied as an aqueous dispersion.

[00160] In still other aspects, the method further comprises applying a substrate layer as described above. The image substrate layer may be applied by any known methods, for example, by the pinch roller method or any lamination method known in the art.

[00161] In still other aspects, the decorative portion may be affixed to the first surface of the rigid core by any other method known in the art. In some methods, the attachment step comprises sewing the second surface of the decorative portion to the first surface of the rigid core. In certain aspects, after the decorative portion is adhered to the rigid core, the heat press may be applied at a temperature of about 110 ° C to about 250 ° C and under sufficient pressure to adhere the decorative portion to the rigid core. In still further aspects, the decorative portion may be attached to the first surface of the rigid core by means of stitching. For example, the decorative portion comprising a plurality of bleached PET fibers as a decorative substrate or a decorative surface layer can be affixed to the first surface of the rigid core by stitching. In other aspects, the seam-attached decorative portion may be further heat pressed to the first surface of the rigid core. It is understood that the image layer can be transferred to any visible surface of the article by any method known in the art. In some aspects, the image layer may be formed by direct printing onto the substrate after the decorative portion is affixed to the first surface of the rigid core. In still other aspects, the image layer may be transferred by other methods including, but not limited to, rotogravure, digital and direct printing, screen printing or sublimation after the decorative portion is affixed to the first surface of the rigid core.

[00162] In still other aspects, the decorative portion can be affixed to the rigid core using a polymer powder dispersion. In such aspects, the powder may be spread on the first surface of the rigid core before attaching the second surface of the decorative portion. In still other aspects, the decorative portion affixed by powder dispersion may be further heat compressed to the first surface of the rigid layer.

[00163] In still other aspects, the method further comprises a step of applying a wear layer having a first surface and an opposing surface. In still other aspects, the wear layer overlaps the decorative portion so that a second surface of the wear layer is in contact with the first surface of the decorative portion. It is understood that the wear layer may be applied by any method known in the art. In some aspects, the wear layer is applied by a pinch roller method. In these aspects, the wear layer is applied to the decorative layer and is laminated by passing through an additional clamp roller. In other aspects, the wear layer may be UV cured.

[00164] For example, the top surface of the decorative layer may optionally be post-pressed, smoothed, embossed or contoured to obtain various functional or aesthetic effects. Additionally, other optional materials can be applied to the composite layer or composite formed during the manufacturing process.

[00165] In connection with any of the inventive aspects described here, the methods may optionally comprise a sanitization step. As one skilled in the art will appreciate, the presence of impurities in the recovered carpet material may necessitate the need to sanitize the recovered materials for health and safety purposes. To this end, the plurality of fibers may be subjected to a sanitization step at any point during manufacturing: sanitizing the plurality of fibers prior to their use in the methods described herein or alternatively sanitizing the plurality of fibers during or after formation. of the compound.

[00166] In several aspects, the layered composite articles of the present invention advantageously exhibit higher radiant panel ratings, less squeaking, improved noise reduction properties and less embodied energy.

EXAMPLES

[00167] The following examples are presented in order to provide those skilled in the art with a complete disclosure and description of how the compounds, compositions, articles, devices and/or methods claimed herein are made and evaluated, and whether They are intended to be simply exemplary and are not intended to limit dissemination. Efforts have been made to ensure accuracy regarding numbers (e.g. quantities, temperature, etc.), but some errors and deviations must be accounted for.

[00168] Unless otherwise indicated, parts are pieces by weight, temperature is in °C or room temperature, and pressure is atmospheric or near-atmospheric or near-vacuum.

Example 1

[00169] Example articles were prepared according to the methods described above. The plurality of oriented multicomponent fibers and the plurality of single-component fibers were used to form the densified fiber layer of the invention. Exemplary multi-component fibers had a core-cladding configuration, wherein the core was polyester having the first melting point and a cladding was polyester having the second melting point lower than the first melting point. Exemplary single-component fibers comprised polyester with the first melting point. The example densified fiber layer comprised 60 wt% multicomponent fiber and 40 wt% monocomponent fiber.

[00170] Exemplary samples weighing 2.03 kg/m2 and 2.133 kg/m2 (60 oz/square yard and 90 oz/square yard) were placed on a lower platen of a static press; a frame with a thickness of 2.032 mm or 3.175 mm (0.080 or 0.125 inch) was placed around the sample and a top plate of a static press was lowered to contact the frame. The upper and lower plates were heated to a temperature of 132.2°C or 162.8°C (270°F or 325°F). The resulting density of the densified fiber layer was measured and is shown in Table 1.

[00171] The example articles were also tested for static load stability. To measure a static charge, samples measuring 5.08cm x 5.08cm (2” x 2”) were prepared. The top of the clean sample was marked diagonally to make an "X". The initial thickness (T1) of the sample in the center of the “X” was measured. The specimen was placed face up on a bottom plate of the indenter and an intermediate plate was placed on top of the specimen with the 3.175 cm (1.25") diameter circle facing down. The desired weight of 340. 2Kg or 680.4 Kg (750 pounds or 1,500 pounds) is applied for 24 hours. After removing the weight, the compressed thickness (T2) was measured and recorded at the center of the "X". in the center of the “X” was measured after an additional 24 hours when the sample was not exposed to any external load. The residual compression was calculated as: n = T1 - T3. The results are presented in Table 2. The sample does not pass the test. if the static load is >0.127 mm (>0.005 inches). All inventive samples have passed the test.

[00172] To measure residual indentation, 5.08cm x 5.08cm (2" x 2") specimens were prepared. The top of the clean sample was marked diagonally to make an "X". The sample was placed under the 4.52mm (0.178”) diameter presser foot with the center of the “X” directly under the presser foot. The initial sample thickness (T1) was measured using the digimatic indicator on the induction tester. To measure residual recoil, the digimatic indicator with the presser foot resting on the sample was zeroed. A weight of 63.5 kg (140 pounds) was applied to the sample for 10 min and the T2 thickness was measured. Then the sample was removed and left undisturbed for 1 hour and the final thickness of the sample (T3) was measured using the digimatic indenter with the p foot with the previous mark. The % residual indentation was measured as: % residual indentation = ((T1-T3)/T1) x 100. The sample fails if the residual indentation is % > 8%. The results are presented in Tables 3-6. All inventive samples passed the test.

[00173] To measure dimensional stability, 15.2cm x 15.2cm (6” x 6”) samples were prepared and measured in accordance with ISO 23999. The dimensional stability of the samples was measured in both machine directions and transverse machine direction. Specimens were subjected to 80°C (176°F) for 6 hours and then allowed to rest for 24 hours. Then the specimen was measured again at the same location to calculate the % change in dimension. A test pass is 0.17% or less. The results are presented in Table 7. Table 1. Density of Example Fiber Layers. Table 2. Static Load Measurements for Example Fiber Layers. Table 3. Residual Indentation for Example Fiber Layers. Table 4. Residual Indentation for Example Fiber Layers. Table 5. Residual Indentation for Example Fiber Layers. Table 6. Residual Indentation for Example Fiber Layers. Table 7. Dimensional Stability of Example Fiber Layers.

[00174] To measure the flexural modulus and flexural strength, the test is performed in accordance with the ASTM D790 standard. For this test, a 0.3175cm x 1.27cm x 12.7cm (1/8" x 1/2" x 5") sample is placed on two supports and a load is applied to the center. The yield load is The flexural strength of the sample material. The flexural strength can also be measured according to the ISO-178 standard. It is understood that the values reported in the ASTM D-790 and ISO-178 tests rarely differ significantly. material is also measured in accordance with ASTM D-790 or ISO-178 and is expressed as a ratio of stress to bending strain. Typical flexural strength and flexural modulus of various polymers are listed in Table 8 below. It is clear that flexible materials such as elastomers have lower values than fiber-reinforced engineering polymers used as metal substitutes such as polyimides or acetals. Table 8. Typical Flexural Strength and Flexural Modulus of Polymers.

[00175] Although various embodiments of the invention are disclosed in the preceding specification, it is understood by those skilled in the art that many modifications and other embodiments of the invention will concern themselves, to which the invention belongs, having the benefit of the teaching presented in the preceding description and the associated designs. It is understood that the inventions are not limited to the specific embodiments disclosed above and that many modifications and other embodiments are intended to be included within the scope of the added claims. Furthermore, although specific terms are used herein, as well as in the claims that follow, they are used only in a generic and descriptive sense and not for the purposes of limiting the described invention, nor the claims that follow.

Claims (19)

1. Layered composite article, characterized in that it comprises: (a) a rigid support portion comprising a rigid core having a first surface and an opposing second surface, wherein the rigid core comprises at least one densified fiber layer and wherein the at least one densified fiber layer is composed of a first plurality of single-component polyester fibers having a first melting point and a second plurality of fibers, wherein the multi-component fibers have a core-cladding configuration, wherein the core is polyester and has a first melting point, and a coating is polyester and has a second melting point lower than the first melting point, wherein the first plurality of fibers and the second plurality of fibers each has a substantially random orientation, a substantially uniform orientation, or any variation from a predetermined orientation that is between random and uniform, wherein the at least one densified fiber layer comprises between 30% and 60% by weight of the multicomponent fibers and 40% by weight. weight of the single-component fibers, where the densified fiber layer has a density of at least 641 kg/m3 (40 lbft3); and (b) a decorative portion having an opposing first surface and a second surface, wherein the second surface of the decorative portion is affixed to the first surface of the rigid core, wherein the rigid core is needle-pierced. 2. The layered composite article of claim 1, wherein the densified fiber layer has a density of at least 721 kg/m3 (45 lb/ft3). 3. Layered composite article according to claim 1 or 2, characterized in that the rigid core has a first portion having a first density, and a second portion having a second density different from the first density. 4. Layered composite article according to claims 1 to 3, characterized in that the rigid core comprises at least two densified fiber layers. 5. Layered composite article according to any one of claims 1 to 4, characterized in that the rigid core is free of a PVC material. 6. Layered composite article according to any one of claims 1 to 5, characterized in that the rigid core is free of a wood-based material. 7. Layered composite article according to any one of claims 1 to 6, characterized in that at least one of the first and second pluralities of fibers comprises regenerated fibers. 8. Layered composite article according to any one of claims 1 to 7, characterized in that the rigid core has a thickness in the range of 0.5 mm to 12 mm. 9. Layered composite article according to any one of claims 1 to 8, characterized in that the rigid core is permeable to moisture. 10. The layered composite article of claim 9, wherein a moisture vapor transmission rate is greater than 3 pounds per 1,000 ft2 per 24 hours. 11. Layered composite article according to any one of claims 1 to 10, characterized in that the layered composite has a Class I radiant flux test rating in accordance with ASTM E-648. 12. Layered composite article according to any one of claims 1 to 11, characterized by the fact that the layered composite article has a residual indentation of less than 8% of the total thickness of the product, when measured in accordance with ASTM F1914- 07(2011). 13. Layered composite article according to any one of claims 1 to 12, characterized by the fact that the layered composite article has a static load indentation of less than or equal to 0.005 inch when measured in accordance with ASTM F970. 14. Layered composite article according to any one of claims 1 to 13, characterized by the fact that the layered composite article passes a Mandrel bend radius test of less than 1 inch, measured in accordance with ASTM F137 (2013 ). 15. Layered composite article according to any one of claims 1 to 14, characterized by the fact that the layered composite article has a flexural modulus of 0.1 to 15.0 GPa, as measured in accordance with ASTM D790 . 16. Layered composite article according to any one of claims 1 to 15, characterized by the fact that the layered composite article has a flexural strength of 20 to 400 MPa, as measured in accordance with ASTM D790. 17. Layered composite article according to any one of claims 1 to 16, characterized by the fact that the layered composite article has an equivalent component stress characterized by having a maximum dimensional variance not exceeding 0.17% when heated at 80oC/180oF and cooled to room temperature. 18. A method of manufacturing a layered composite article as defined in claim 1, characterized in that it comprises: (a) forming a rigid support portion comprising a rigid core having a first surface and an opposing second surface, in wherein the rigid core comprises at least one densified fiber layer and wherein the at least one densified fiber layer is composed of a first plurality of single-component polyester fibers having a first melting point and a second plurality of fibers, in that multi-component fibers have a core-cladding configuration, wherein the core is polyester and has a first melting point, and a cladding is polyester and has a second melting point lower than the first melting point, wherein the at least one densified fiber layer comprising between 30% and 60% by weight of multicomponent fibers and 40% by weight of monocomponent fibers, (b) forming a decorative portion having a first surface and an opposing second surface; and (c) attaching the second surface of the decorative portion to the first surface of the rigid core. 19. Method according to claim 18, characterized by the fact that the step of forming the rigid support portion further comprises forming the rigid core, which comprises: (a) superimposing the first plurality of fibers and the second plurality of fibers to form a fibrous matrix; (b) treating the fibrous matrix to form a fiber layer; and (c) heat and pressure treating the fiber layer under conditions effective to form the densified fiber layer.