Polyurethane coated resilient surface covering having improved fidelity of texture and process of manufacture

Abstract

Mechanically embossed resilient surface coverings having superior textural fidelity are prepared by mechanically embossing a polyurethane coated floorcovering before the polyurethane is cured. The mechanical embossing is conducted when the polyurethane is dry and the underlying plastic layer and the polyurethane are softened by heating. After the mechanical embossing step, the polyurethane is cured using ultraviolet (UV) light. The product can be cooled before or after UV curing. The invention is applicable to a variety of resilient surface covering products including floor and wall coverings which otherwise have a wearlayer which can be softened by heating. This includes surface coverings having the full range of decorative effects available in the art, including surface coverings which also have been, for example, chemically embossed, mechanically embossed, chemically and mechanically embossed or not embossed at all prior to application of the process of the invention.