Resilient floor covering and method of making same

A method of providing a resilient surface covering comprising the steps of:

• (a) providing a resilient support surface;
• (b) applying to the top of and adhering to said resilient support surface, a wear surface,
• (b1) said wear surface being applied by applying a wear layer base coat comprising a flexible, thermosettable, polymeric composition having a flexibility, such that the wear layer base coat passes a 1 inch mandrel diameter face out mandrel bend test when applied at a nominal dry film thickness of 1.0 mil over a flexible 80 mil underlying substrate;
• (b2) partially curing said wear layer base coat;
• (b3) applying to the top of said wear layer base coat, a wear layer top coat comprising a thermosettable, UV-curable blend of acrylic or acrylate monomers, said wear layer top coat having a glass transition temperature of greater than 50.degree. C.;
• and
• (b4) completely curing said wear layer base coat and said wear layer top coat.

A method of providing a resilient surface covering comprising the steps of:

• (a) providing a resilient support surface comprising curing an unfoamed strengthening layer comprising a vinyl resin and a polymerizable, cross-linkable monomer, with the proviso that, said strengthening layer is not disposed between two foam layers;
• and
• (b) applying to the top of and adhering to said resilient support surface, a wear surface,
• (b1) said wear surface being applied by applying a wear layer base coat comprising a flexible, thermosettable, polymeric composition having a flexibility, such that the wear layer base coat passes a 1 inch mandrel diameter face out mandrel bend test when applied at a nominal dry film thickness of 1.0 mil over a flexible 80 mil underlying substrate;
• (b2) curing said wear layer base coat;
• (b3) applying to the top of and adhered to said wear layer base coat, a wear layer top coat comprising a thermosettable, UV-curable blend of acrylic or acrylate monomers, said wear layer top coat having a glass transition temperature of greater than 50.degree. C.;
• and
• (b4) curing said wear layer top coat.

A method of providing a resilient surface covering comprising the steps of:

• (a) providing a resilient support surface comprising providing a substrate layer comprising an uncross-linked vinyl composition or a fibrous sheet, adhering to the substrate layer and curing an unfoamed strengthening layer comprising a vinyl resin and a polymerizable, cross-linkable monomer, with the proviso that, said strengthening layer is not disposed between two foam layers, and providing a foam layer adhered to the strengthening layer;
• and
• (b) providing a wear surface comprising applying to the top of and adhered to said foam layer an initial wear layer comprising poly(vinyl chloride);
• applying to the top of and adhered to said initial wear layer a wear layer base coat comprising a flexible, thermosettable, polymeric composition having a flexibility, such that the wear layer base coat passes a 1 inch mandrel diameter face out mandrel bend test when applied at a nominal dry film thickness of 1.0 mil over a flexible 80 mil underlying substrate;
• curing said wear layer base coat;
• applying to the top of and adhered to said wear layer base coat, a wear layer top coat comprising a thermosettable, UV-curable blend of acrylic or acrylate monomers, said wear layer top coat having a glass transition temperature of greater than 50.degree. C.;
• and
• curing said wear layer top coat.

A method of providing a resilient surface covering comprising the steps of:

• (a) providing a resilient support surface comprising curing an unfoamed strengthening layer comprising a vinyl resin and a polymerizable, cross-linkable monomer, with the proviso that, said strengthening layer is not disposed between two foam layers;
• and
• (b) applying to the top of and adhering to said resilient support surface, a wear surface,
• (b1) said wear surface being applied by applying a wear layer base coat comprising a flexible, thermosettable, polymeric composition having a flexibility, such that the wear layer base coat passes a 1 inch mandrel diameter face out mandrel bend test when applied at a nominal dry film thickness of 1.0 mil over a flexible 80 mil underlying substrate;
• (b2) partially curing said wear layer base coat;
• (b3) applying to the top of said wear layer base coat, a wear layer top coat comprising a thermosettable, UV-curable blend of acrylic or acrylate monomers, said wear layer top coat having a glass transition temperature of greater than 50.degree. C.;
• and
• (b4) completely curing said wear layer base coat and said wear layer top coat.

A method of providing a resilient surface covering comprising the steps of:

• (a) providing a resilient support surface comprising providing a substrate layer comprising an uncross-linked vinyl composition or a fibrous sheet, adhering to the substrate layer and curing an unfoamed strengthening layer comprising a vinyl resin and a polymerizable, cross-linkable monomer, with the proviso that, said strengthening layer is not disposed between two foam layers, and providing a foam layer adhered to the strengthening layer;
• and
• (b) providing a wear surface comprising applying to the top of and adhered to said resilient support surface an initial wear layer comprising poly(vinyl chloride);
• applying to the top of and adhered to said initial wear layer a wear layer base coat comprising a flexible, thermosettable, polymeric composition having a flexibility, such that the wear layer base coat passes a 1 inch mandrel diameter face out mandrel bend test when applied at a nominal dry film thickness of 1.0 mil over a flexible 80 mil underlying substrate
• partially curing said wear layer base coat;
• applying to the top of and adhered to said wear layer base coat, a wear layer top coat comprising a thermosettable, UV-curable blend of acryliz or acrylate monomers, said wear layer top coat having a glass transition temperature of greater than 50.degree. C.;
• and
• completely curing said wear layer base coat and said wear layer top coat.