Surface covering backing containing polymeric microspheres and processes of making the same

A textile substrate comprising a primary backing with textile fibers extending upwardly from the backing and forming a surface:

• and a secondary backing affixed to the bottom surface of the primary backing wherein said secondary backing comprises at least one thermoplastic material having polymeric microspheres dispersed therein.

A method of making a textile substrate comprising applying a secondary backing formulation comprising at least one liquid thermoplastic material and polymeric microspheres onto the back of a substrate comprising a primary backing layer;

• gelling the formulation;
• and
• curing the formulation to form the textile substrate comprising the primary backing layer and secondary backing layer.

A surface covering comprising a support surface and overlying and adhered to said support surface is a first layer comprising at least one thermoplastic material and polymeric microspheres dispersed therein.

A surface covering comprising a primary backing and overlying and adhered to said primary backing is a secondary backing comprising at least one thermoplastic material and at least one activated blowing agent, wherein said secondary backing casted on said primary backing.

A method of making a surface covering comprising applying a secondary backing formulation comprising at least one liquid thermoplastic material, at least one blowing agent, and at least one activator onto the back of a substrate comprising a primary backing layer;

• gelling the formulation and activating the blowing agent;
• and
• curing the formulation to form the surface covering comprising the primary backing layer and the secondary backing layer, such that the secondary backing is expanded by about 1 to about 2.5 times.