Process for forming decorative surface coverings

Abstract

A process for producing a decorative surface covering wherein granular dryblend is deposited on a releasable carrier and heated to form a porous cohesive layer. Settable resinous inks are then applied to selected surface portions of the dryblend to form design areas which may overlap at the points of application. The inked areas extend partially or completely through the layer so that they are visible from the bottom surface of the sheet which ultimately becomes the face of the surface covering, after final fusion of all of the resinous materials. The ink may optionally be set by heat prior to or simultaneously with the subsequent application and gelling of a resinous back coating, if one is used. The back coating may be reinforced by included or attached material to form a permanent carrier. Depending on the backing used, heat may be applied to fuse the composite structure before or after the release carrier is removed. Clearly defined, in-register, design areas are obtained which extend from the back of the wear layer up to or toward the wear surface of the sheet without the need for printing in register.