Abstract: Surface covering components that include a topcoat layer with different gloss levels in various regions on the top coat layer, and methods of manufacturing such surface covering components, are disclosed. The surface covering components include a coating layer that includes regions that have a relatively higher gloss, and regions with a relatively lower gloss. The differential gloss is provided by coating a substrate with a UV-curable coating composition, subjecting a first region of the surface coating to polymerization under a first set of conditions, and subjecting a second region of the surface coating to polymerization under a second set of conditions. The UV-curable coating compositions include UV-curable components and one or more flatting agents. The different polymerization conditions involve applying various photoinitiators, thermal initiators and/or cure altering agents to some regions of the coated substrate, and not applying these components to other regions of the substrate.

Abstract: A coated freestanding film, a surface covering and a method of manufacturing such coated freestanding film and surface covering are disclosed. In one embodiment of the present invention, the coated freestanding film and surface covering include a film having a print layer forming a pattern or design disposed on one side of the film. A discontinuous gloss layer is disposed on the other side of the film substantially in-register with at least a portion of the printed pattern or design. Additionally, the gloss layer has at least one portion thereof which has a gloss level different from the side upon which the gloss layer is disposed. The film may be a rigid or semirigid film. In another embodiment, the coated freestanding film and surface covering has a film and a discontinuous gloss layer disposed on one side of the film. The gloss layer forms a pattern or design and at least one portion thereof has a gloss level different from the side upon which the gloss layer is disposed.

Abstract: Disclosed is decorative surface covering that has a substantially non-aqueous absorptive layer and a water retentive layer. The decorative surface covering may be a vinyl-backed floor covering that can be adhered to a substantially non-aqueous absorptive subfloor with a water-based adhesive. The water retentive layer is formed from a polymer matrix and super absorbent water retentive particles. The water retentive layer may also include a hydrophilic additive to facilitate movement of water from the adhesive to the super absorbent water retentive particles. The water retentive layer may also be applied to the substantially non-aqueous absorptive subfloor.

Abstract: A non-directional tile is obtained by surface applying and consolidating a relatively thin, non-porous, multi-colored, resin particulate decorative layer onto a backing layer. The non-directionality is the result of the proper selection of resin particle size distribution and the use of contrasting colors. The result is a tile that an ordinary observer cannot discern the machine direction and a tile floor having seams that are indiscernible by an ordinary observer.

Abstract: Surface covering components that include a topcoat layer with different gloss levels in various regions on the top coat layer, and methods of manufacturing such surface covering components, are disclosed. The surface covering components include a coating layer that includes regions that have a relatively higher gloss, and regions with a relatively lower gloss. The differential gloss is provided by coating a substrate with a UV-curable coating composition, subjecting a first region of the surface coating to polymerization under a first set of conditions, and subjecting a second region of the surface coating to polymerization under a second set of conditions. The UV-curable coating compositions include UV-curable components and one or more flatting agents. The different polymerization conditions involve applying various photoinitiators, thermal initiators and/or cure altering agents to some regions of the coated substrate, and not applying these components to other regions of the substrate.

Abstract: A preglued underlayment assembly comprises a substantially rigid underlayment having an upper and a lower surface, a pressure sensitive adhesive layer disposed on the upper surface, and a release layer disposed on the adhesive layer. Another pressure sensitive adhesive layer and another release layer optionally are provided on the lower surface of the preglued underlayment. One or more performance enhancing layers, such as foam and solid layers, can be disposed between the underlayment and the adhesive layer to modify and/or enhance various properties of the preglued underlayment. Mechanical fasteners, such as staples, penetrate the preglued underlayment assembly and engage a structural support member to attach the preglued underlayment assembly thereto.

Abstract: Surface coverings and surface covering components that include a textured transparent or translucent wear layer and a design layer, where the design layer is printed with an ink that includes collapsible microspheres, are disclosed. Also disclosed are methods of manufacturing such surface coverings and surface covering components. In one embodiment, a pattern is printed on a substrate to be coated with a wear layer. In another embodiment, a clear transparent or translucent layer underlies the design layer. The ink includes collapsible microspheres, and can also include foaming inhibitors. A number of surface covering substrates and surface coverings can be prepared using the methods described herein. The surface coverings include a substrate, for example, a foamable substrate, a design layer printed with an ink composition that includes collapsible microspheres, and a wear layer.

Abstract: A preglued underlayment assembly comprises a substantially rigid underlayment having an upper and a lower surface, a pressure sensitive adhesive layer disposed on the upper surface, and a release layer disposed on the adhesive layer. Another pressure sensitive adhesive layer and another release layer optionally are provided on the lower surface of the preglued underlayment. One or more performance enhancing layers, such as foam and solid layers, can be disposed between the underlayment and the adhesive layer to modify and/or enhance various properties of the preglued underlayment. Mechanical fasteners, such as staples, penetrate the preglued underlayment assembly and engage a structural support member to attach the preglued underlayment assembly thereto.

Abstract: A method and composition for providing a colored high performance wear surface for floor coverings is disclosed. Specifically, the floor covering includes a substrate and a high performance layer comprising a radiation cured pigmented composition. The exposed surface of the floor covering has a stain resistance of less than about 150 Delta E units. A pigmented high performance wear layer can be added in register with a printed design on the substrate or in register with an embossed texture of the substrate. Additionally, a high performance topcoat wear layer may be added. The pigmented high performance layer may include a nacreous pigment.

Abstract: Disclosed is a method of manufacturing a mechanically and chemically embossed surface covering having selectively textured surfaces. The method includes forming a web coated with a wear layer. The coated web is heated to a temperature at which the wear layer is cured, the foam layer expands, and the pattern is chemically embossed to form a surface covering having foamed regions and nonfoamed regions. The temperature gradient of the surface covering is adjusted such that there is a temperature gradient difference between the foamed and nonfoamed regions. A surface texture is then mechanically embossed into the wear layer and selectively set onto the wear layer substantially overlying the non-foamed regions.

Abstract: Disclosed is a method of manufacturing a mechanically and chemically embossed surface covering having selectively textured surfaces. The method includes forming a web coated with a wear layer. The coated web is heated to a temperature at which the wear layer is cured, the foam layer expands, and the pattern is chemically embossed to form a surface covering having foamed regions and nonfoamed regions. The temperature gradient of the surface covering is adjusted such that there is a temperature gradient difference between the foamed and nonfoamed regions. A surface texture is then mechanically embossed into the wear layer and selectively set onto the wear layer substantially overlying the non-foamed regions.

Abstract: Composite wear layers that include a polyethylene terephthalate wear layer adhered to an organic/inorganic (O/I) top coat layer, and surface coverings and surface covering components including the wear layers, are disclosed. The organic/inorganic top coat layer is formed from a top coat formulation which comprises a coupling agent. The coupling agent is a molecule which includes an organic polymerizable moiety such as epoxy, acrylate and the like, as well as an inorganic polymerizable moiety such as a silanol. Top coat layers formed from the top coat formulation have both organic and inorganic character. Although not limited to these thickness ranges, the wear layer is typically in the range of about 1-20 mils thickness, and the top coat layer is typically in the range of 2 microns to 0.5 mils thickness. The composite wear layers can be included in surface coverings or surface covering components, such as floor and wall coverings.

Abstract: An underlayment assembly comprising an underlayment with an upper and a lower surface, an adhesive layer disposed on the upper surface, and a release [layer] fastener disposed on the adhesive layer, optionally with an adhesive layer on the lower surface of the underlayment, is disclosed. One or more performance enhancing layers, such as foam and solid layers, can be disposed between the underlayment and the adhesive layer to modify and/or enhance various properties of the underlayment. A primary fastener comprising part of a hook and loop fastener assembly can be attached to the upper surface of the underlayment. Mechanical fasteners, such as staples, penetrate the underlayment assembly and engage a structural support member to attach the underlayment assembly thereto. Methods for installing a surface covering over a structural support member using the underlayment assembly are also disclosed.

Abstract: A preglued underlayment assembly comprising a substantially rigid underlayment having an upper and a lower surface, a pressure sensitive adhesive layer disposed on the upper surface, and a release layer disposed on the adhesive layer. A second pressure sensitive adhesive layer and another release layer are optionally provided on the lower surface of the preglued underlayment. One or more performance enhancing layers, such as foam and solid layers, can be disposed between the underlayment and the adhesive layer to modify and/or enhance various properties of the preglued underlayment. Mechanical fasteners, such as staples, penetrate the preglued underlayment assembly and engage a structural support member to attach the preglued underlayment assembly thereto. A method of installing a surface covering over a structural support member utilizing the preglued underlayment assembly is also disclosed.

Abstract: A surface covering and a method of manufacturing such surface covering is disclosed. In one embodiment of the present invention, the surface covering includes a film having a print layer forming a pattern or design disposed on one side of the film. A discontinuous gloss layer is disposed on the other side of the film substantially in-register with at least a portion of the printed pattern or design. Additionally, the gloss layer has at least one portion thereof which has a gloss level different from the side upon which the gloss layer is disposed. In another embodiment, the surface covering has a film and a discontinuous gloss layer disposed on one side of the film. The gloss layer forms a pattern or design and at least one portion thereof has a gloss level different from the side upon which the gloss layer is disposed. A surface texture is mechanically embossed into the film substantially in-register with the pattern or design of the gloss layer. Optionally, a web may be laminated to the surface covering.

Abstract: Surface covering components that include a topcoat layer with different gloss levels in various regions on the top coat layer, and methods of manufacturing such surface covering components, are disclosed. The surface covering components include a coating layer that includes regions that have a relatively higher gloss, and regions with a relatively lower gloss. The differential gloss is provided by coating a substrate with a UV-curable coating composition, subjecting a first region of the surface coating to polymerization under a first set of conditions, and subjecting a second region of the surface coating to polymerization under a second set of conditions. The UV-curable coating compositions include UV-curable components and one or more flatting agents. The different polymerization conditions involve applying various photoinitiators, thermal initiators and/or cure altering agents to some regions of the coated substrate, and not applying these components to other regions of the substrate.

Abstract: Disclosed is a method of manufacturing a mechanically and chemically embossed surface covering having selectively textured surfaces. The method includes forming a web coated with a wear layer. The coated web is heated to a temperature at which the wear layer is cured, the foam layer expands, and the pattern is chemically embossed to form a surface covering having foamed regions and nonfoamed regions. The temperature gradient of the surface covering is adjusted such that there is a temperature gradient difference between the foamed and nonfoamed regions. A surface texture is then mechanically embossed into the wear layer and selectively set onto the wear layer substantially overlying the non-foamed regions.

Abstract: A sheet flooring product, including a homogeneous melt processable resin layer formed of a melt processable, non-plastisol layer, and an adjacent felt layer produced by a beater saturated method and having a substantially uniform thickness of between about 5 mils and about 40 mils. The melt processable resin layer is preferably applied by a hot melt calender (“HMC”) process to achieve enhanced can drop, refrigerator drag and indentation values.

Abstract: Surface covering components that include a topcoat layer with different gloss levels in various regions on the top coat layer, and methods of manufacturing such surface covering components, are disclosed. The surface covering components include a coating layer that includes regions that have a relatively higher gloss, and regions with a relatively lower gloss. The differential gloss is provided by coating a substrate with a UV-curable coating composition, subjecting a first region of the surface coating to polymerization under a first set of conditions, and subjecting a second region of the surface coating to polymerization under a second set of conditions. The UV-curable coating compositions include UV-curable components and one or more flatting agents. The different polymerization conditions involve applying various photoinitiators, thermal initiators and/or cure altering agents to some regions of the coated substrate, and not applying these components to other regions of the substrate.

Abstract: A flooring resistant to bottom-up staining is provided which includes a substrate; a polyethylene terephthalate (PET) barrier layer contacting the substrate; and a flooring structure in contact with the PET barrier layer. A method for manufacturing the flooring utilizing lamination processes is also provided.