Formaldehyde-free highly water and abrasion resistant overlay for building products

A method for producing an overlay, comprising steps of:

• a. impregnating paper with an acrylic resin composition comprising an acrylic resin having a glass transition temperature in a range of from about −20° C. to about 40° C. to an acrylic resin content in a range of from about 15 wt. % to about 35 wt. % based on the weight of the impregnated paper;
• b. curing the impregnated paper at ambient pressure and at a temperature in a range of from 100° C. to about 200° C.;
• c. melting the solid adhesive at a temperature from about 100° C. to about 300° C. in a heated drum or tank melter;
• d. applying the molten adhesive through an extruder to the back of a substrate;
• and
• e. cooling the molten adhesive at room temperature prior to rewinding the substrate.