Processes of applying urethane top coatings to resilient floor coverings

A process for manufacturing a resilient, resinous floor covering having an embossed polyurethane surface coating which comprises:

• forming a foamable, resinous sheet material containing a blowing agent;
• applying a printing ink composition containing an inhibitor for said blowing agent to the surface of said foamable, resinous sheet material in a predetermined pattern;
• applying to said printed, foamable, resinous sheet material a urethane coating composition having a viscosity in the range of from about 10 centipoises to about 100 centipoises, the application of said urethane coating composition being accomplished by a reverse-roll coating procedure wherein the casting ratio is in the range of from about 0.8:1 to about 1.1:1;
• and then, in an in-line manufacturing step, heating said coated, printed, foamable, resinous sheet material to dry and cure and harden said urethane coating composition and subsequently to blow said foamable, resinous sheet material to form a resilient, resinous floor covering having an embossed polyurethane surface coating, the extent of the curing and hardening of said urethane coating composition being controlled so as not to exceed about 80% during the heating and before the beginning of the blowing of said foamable, resinous sheet material by said blowing agent, whereby the curing and hardening of said urethane coating composition does not proceed too far as to interfere with the subsequent blowing and formation of the embossed effects.