Hot melt calendered or extruded wear layer for embossed substrates and method of manufacture

A method of manufacturing a textured surface covering having a wear layer bonded thereto comprising the steps of:

• a) heating a melt processable polymer resin composition to melt or soften the polymer resin composition;
• b) applying the melted or softened melt processable polymer resin composition to a pre-textured surface of a substrate, the pre-textured surface. having an area with a difference in height of at least about 1 mil vertical distance over no more than about 20 mils horizontal distance;
• and
• c) cooling the melt processable polymer resin composition after it is applied to the pre-textured surface to form a textured surface covering for floor or walls comprising a wear layer bonded well on the pre-textured substrate, the wear layer having an average thickness of between about 2 mils to about 50 mils, wherein the melt processable polymer resin composition is applied to the pre-textured substrate between a heated roll or drum and a conformable pressure roll, and
• wherein the melt processable polymer resin composition is heated on the roll or drum, prior to being applied to the textured substrate. and
• wherein the exposed surface of the wear layer closely follows the textured surface of the substrate wherein the wear layer is of substantially uniform thickness.

A method of manufacturing a textured surface covering having a wear layer bonded thereto comprising the steps of:

• a) heating a melt processable polymer resin composition to melt or soften the polymer resin composition;
• b) applying the melted or softened melt processable polymer resin composition to a pre-textured surface of a substrate, the pre-textured surface having an area with a difference in height of at least about 1 mil vertical distance over no more than about 20 mils horizontal distance;
• and
• c) cooling the melt processable polymer resin composition after it is applied to the pre-textured surface to form a textured surface covering for floor or walls comprising a wear layer bonded well on the pre-textured substrate, the wear layer having an average thickness of between about 2 mils to about 50 mils,
• wherein the melt processable polymer resin composition comprises a PVC resin and
• wherein the exposed surface of the wear layer closely follows the textured surface of the substrate, wherein the wear layer is of substantially uniform thickness.