Method for making seamless flooring and the like

Claim 1

A METHOD FOR PROVIDING AN ADHERENT WEAR-RESISTANT, DECORATIVE LAYER ON A SUBSTRATE HAVING A SUBSTANTIALLY HARDENED SEALANT LAYER OF LIQUID EPOXY RESIN, SAID METHOD COMPRISING (1) APPLYING ON SAID SEALANT LAYER A POLYURETHANE BASE CHIP COAT, SAID CHIP COAT COMPRISING A SOLUTION IN ORGANIC SOLVENT OF (A) AN -NCO TERMINATED PREPOLYMER OF A DIISOCYNATE CONTAINING UNEQUALLY REACTIVE ISOCYNATE GROUPS AND A BRANCHED CHAIN POLYOL HAVING AN AVERAGE EQUIVALENT WEIGHT OF FROM 1000 TO 2000, SAID PREPOLYMER HAVING FREE -NCO CONTENT OF FROM 1,5 TO 6% AND AS A CROSS LINKING AGENT (B) A SOLID RESIN HAVING AT LEAST 4 HDYROXYL GROUPS PER MOLECULE, (2) INCORPORATING COLORED PAINT CHIP INTO THE SURFACE REGIONS OF SAID CHIP COAT AFTER ITS APPLICATION OVER SAID SEALANT COAT ON SAID SEALANT LAYER, BUT BEFORE IT IS PERMITED TO HARDERN, (3) PERMITTING SAID CHIP COAT WITH CHIPS THEREIN TO SOLIDIFY, (4) APPLYING OVER THE SOLIFIED CHIP COAT AN INTERMEDIATE COATING OF A SOLUTION OF POLYURETHANE COMPRISING: (A) AN -NCO TERMINATED PREPOLYMER OF A DIISOCYANATE CONTAINING UNEQUALLY REACTIVE ISOCYANATE GROUPS AND A BRANCHED CHAIN POLYOL HAVING AN AVERAGE EQUIVALENT WEGHT OF FROM 180 TO 400, WHEREIN SAID PREPOLYMER HAS A FREE -NCO CONTENT OF FROM 1,5 TO 6% AND (B) A SOLID, SOLUBLE HYDROXYL CONTAINING RESIN HAVING AT LEAST 4 HYDROXYL GROUPS PER MOLECULE TO REACT WITH SAID -NCO GROUPS OF SAID PREPOLYMER, (5) AFTER PERMITTING SAID INTERMEDIATE COAT TO HARDEN APPLYING OVER THE HARDENED SURFACE A GLAZE COAT WHICH COMPRISES A SOLUTION OF: (I) AN -NCO TERMINATED PREPOLYMER OF A DIISOCYNATE CONTAINING UNEQUALLY REACTIVE ISOCYANATE GROUPS AND A BRANCH CHAIN POLYOL HAVING AN EQUIVALENT WEIGHT OF BETWEEN 160 AND 400 AND A FREE -NCO CONTENT OF 5 TO 10% AND (II) A CHAIN EXTENDER COMPRISING A POLYCAPROLACTONE TROIL, A POLYESTER HAVING AN EQUIVALENT WEIGHT OF ABOUT 200 TO 600 AND ABOUT 3 HYDROXYLS PER MOLECULE OR MIXTURE THEREOF, TO REACT WITH SAID FREE -NCO.

Claim 2

A METHOD FOR PROVIDING AN ADHERENT WEAR-RESISTANT, DECORATIVE LAYER ON A SUBSTRATE HAVING A SUBSTANTIALLY HARDENED SEALANT LAYER OF LIQUID EPOXY RESIN, SAID METHOD COMPRISING (1) APPLYING ON SAID SEALANT LAYER A POLYURETHANE BASE CHIP COAT, SAID CHIP COAT COMPRISING A SOLUTION IN ORGANIC SOLVENT OF (A) AN -NCO TERMINATED PREPOLYMER OF A DIISOCYNATE CONTAINING UNEQUALLY REACTIVE ISOCYNATE GROUPS AND A BRANCHED CHAIN POLYOL HAVING AN AVERAGE EQUIVALENT WEIGHT OF FROM 1000 TO 2000, SAID PREPOLYMER HAVING FREE -NCO CONTENT OF FROM 1,5 TO 6% AND AS A CROSS LINKING AGENT (B) A SOLID RESIN HAVING AT LEAST 4 HDYROXYL GROUPS PER MOLECULE, (2) INCORPORATING COLORED PAINT CHIP INTO THE SURFACE REGIONS OF SAID CHIP COAT AFTER ITS APPLICATION OVER SAID SEALANT COAT ON SAID SEALANT LAYER, BUT BEFORE IT IS PERMITED TO HARDERN, (3) PERMITTING SAID CHIP COAT WITH CHIPS THEREIN TO SOLIDIFY, (4) APPLYING OVER THE SOLIFIED CHIP COAT AN INTERMEDIATE COATING OF A SOLUTION OF POLYURETHANE COMPRISING: (A) AN -NCO TERMINATED PREPOLYMER OF A DIISOCYANATE CONTAINING UNEQUALLY REACTIVE ISOCYANATE GROUPS AND A BRANCHED CHAIN POLYOL HAVING AN AVERAGE EQUIVALENT WEGHT OF FROM 180 TO 400, WHEREIN SAID PREPOLYMER HAS A FREE -NCO CONTENT OF FROM 1,5 TO 6% AND (B) A SOLID, SOLUBLE HYDROXYL CONTAINING RESIN HAVING AT LEAST 4 HYDROXYL GROUPS PER MOLECULE TO REACT WITH SAID -NCO GROUPS OF SAID PREPOLYMER, (5) AFTER PERMITTING SAID INTERMEDIATE COAT TO HARDEN APPLYING OVER THE HARDENED SURFACE A GLAZE COAT WHICH COMPRISES A SOLUTION OF: (I) AN -NCO TERMINATED PREPOLYMER OF A DIISOCYNATE CONTAINING UNEQUALLY REACTIVE ISOCYANATE GROUPS AND A BRANCH CHAIN POLYOL HAVING AN EQUIVALENT WEIGHT OF BETWEEN 160 AND 400 AND A FREE -NCO CONTENT OF 5 TO 10% AND (II) A CHAIN EXTENDER COMPRISING A POLYCAPROLACTONE TROIL, A POLYESTER HAVING AN EQUIVALENT WEIGHT OF ABOUT 200 TO 600 AND ABOUT 3 HYDROXYLS PER MOLECULE OR MIXTURE THEREOF, TO REACT WITH SAID FREE -NCO.