Resilient foam-backed carpet and method of preparation

A carpet-tile floor covering which comprises:

• a) a primary backing sheet having a fibrous face wear surface and a back surface;
• b) a first, solid, bitumen backing layer;
• c) a second, solid, bitumen backing layer;
• d) a polymeric foal layer which comprises an olefinic, thermoset, substantially closed-cell, foam material having a foam density of 4 to 12 pcf, and characterized by high compression set and bonded between the first and second backing layers;
• e) a protective sheet material on the top surface of the polymeric foam layer;
• and
• f) the polymeric foam layer having a thickness of from about 4 to 16 mm, and the first and second backing layers each having a thickness of from about 0.5 mm to 4 mm.

A method of preparing a floor covering, which method comprises:

• a) providing a primary backing layer having a fibrous face wear surface and a back surface;
• b) bonding a first solid thermoplastic layer to the back surface of the primary backing layer;
• c) bonding one surface of a polymeric foam layer to the first thermoplastic backing layer, the polymeric foam layer characterized by a high compression set and a substantially closed-cell structure;
• and
• d) bonding a second solid thermoplastic layer to the other surface of the polymeric foam layer, the first and second backing layers of sufficient thickness to disperse the mechanical force on the foam layer, and to provide a floor covering, with the first and second thermoplastic backing layers providing protection of the polymeric foam layer from excessive compressive set.