Patent ID: 6899927

Claim:
A method for manufacturing a decorative floor covering which is comprised of a backing layer, a substrate layer, and a surface layer, in which the backing layer is comprised of at least one of a foaming sub-layer, a mechanical foaming sub-layer, and a sizing sub-layer, and wherein the surface layer is comprised of at least one of a foaming sub-layer, a non-foaming sub-layer, a printing sub-layer, and a skin sub-layer, comprising the processes of: (A) air-knife coating a surface treatment composition comprising: urethaneacrylate oligomer comprised of 10 to 20 weight parts of soft type urethaneacrylate oligomer, and 25 to 35 weight parts of hard type urethaneacrylate oligomer; acrylate based monomer comprised of 5 to 10 weight parts of single functional group monomer, 15 to 25 weight parts of bi-functional group monomer, and 10 to 25 weight parts of tri-functional group monomer; photoinitiator comprised of 1 to 5 weight parts of acetophenone, and 0.1 to 2 weight parts of benzophenone; 0.5 to 3 weight parts of reactive or non-reactive silicon additive; 3 to 10 weight parts of silica or wax coated silica matting agent; and 0.1 to 2 weight parts of amine reaction promoter, wherein the air-knife coating applies the surface treatment composition to a thickness of 10 to 40 μm on the surface layer; and (B) curing the coated surface treatment composition at a line speed of 5 to 30 m/min using 4 to 8 middle pressure mercury lamps having an output of 200 to 300 watt/in 2 with the strongest wavelength at 365 nm.