The tufted surface covering includes a base formed from particles of a
thermosetting polymer compound mixed with a particle binding agent causing
a portion of the particles to bind together to form a self supporting web.
The base is tufted with a tufting material. Thermosetting vulcanized
natural and/or synthetic rubber compounds are employed. The polymer layer
is tufted with a tufting material and heated to a temperature of from
about 110.degree. C. to about 220.degree. C. at an elevated pressure of up
to two tons per square inch, to cause the particles to bind together at
elevated temperature and pressure to anchor and seal the tufts in place.
Cross-linking agents and polar polymer containing compounds may be
employed as particle binding agents. In another aspect of the invention, a
second layer of particles of a thermosetting polymer mixed with a particle
binding agent may be joined together with the particles of the first layer
at elevated temperature and pressure. A series of spaced apertures extends
through the first and second layers to enable free draining of the surface
covering. The lower surface of the covering includes spaced indentations
to reduce the weight of the covering.
