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: The methods for making a coated thin veneer, plank or wood product in which the coated surface does not crack due to instability of the wood involve applying to a veneer, plank or wood product a composition including a hydrophilic polymer and a reactive monomer or a composition including a reactive (meth)acrylate. In one embodiment, the hydrophilic polymer is a polyalkylene glycol, such as polyethylene glycol. The composition also advantageously includes a thermally activated free radical initiator, a photoinitiator or both. The veneer is further laminated into wood product boards that are cut down to planks. In another aspect of the current invention, several solvent based resins are roll coated onto the loose and/or tight side of the thin veneer or unfinished plank wood, dried to remove solvent, and exposed to UV radiation to cure the resinous material by radical initiation of the photoinitiator that leads to polymerization.

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 composite wear layers, are disclosed. The organic/inorganic top coat layer is formed from a top coat formulation that comprises a coupling agent that includes an organic polymerizable moiety such as epoxy, acrylate and the like, as well as an inorganic polymerizable moiety such as a silanol. 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. An adhesion promoter/binder can be used to better adhere the polyethylene terephthalate wear layer to the organic/inorganic top coat layer.

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.