Process for forming a surface covering having decorative effects

Claim 1

A process of forming a surface covering having decorative effects which process comprises: (a) depositing a mechanically frothed foam or forming a chemically blown foam on a backing, said foam comprising at least one polymer or a blend of polymers, said polymer or blend of polymers having at least a first phase region and a second phase region, both phase regions existing at least in the surface region of said foam, (1) flow occurring in said first phase region at a temperature above room temperature and said first phase region serving to hold the compressed shape of the foam in compression step (d) below. (2) said second phase region remaining elastomeric at the temperature at which said first phase region flows; (b) curing or fusing the foam on the backing; (c) compressing the resulting cured or fused foam, at a temperature sufficient to cause flow to occur in said first phase region, in order to form a smooth, printable foam surface and cooling the foam in the compressed shape to a temperature below the temperature at which flow occurs in said first phase region; (d) removing the compressing force whereby the first phase region serves to hold the compression, thus providing a smooth, printable foam surface; (e) applying at least one coating composition to at least a portion of the compressed, smooth, printable foam surface; and, (f) reheating the resulting coated, compressed foam to a temperature at least equal to the temperature at which flow occurs in said first phase region to permit the compressed foam to return to substantially its precompressed shape.