Systems and methods for a surface overlay system

Abstract

A surface overlay system comprising a moisture mitigating layer. The moisture mitigating layer comprises a first surface. The first surface comprises a first adhesive material configured to adhere to a base level. The moisture mitigating layer comprises a second surface opposite the first surface. The surface overlay system comprises a first covering layer configured to substantially cover the second surface. The surface overlay system comprises a resin coating configured to cover and further secure the first covering layer to the second surface of the moisture mitigating layer. The first covering layer can include divided solids. The first covering layer can include a self-leveling compound. The second surface of the moisture mitigating layer can include a second adhesive material. The second surface of the moisture mitigating layer can include an aggregate surface of particulates.

Description

SYSTEMS AND METHODS FOR A SURFACE OVERLAY SYSTEMBACKGROUND OF THE INVENTION

[0001] The application of traditional epoxy flake and / or quartz surface overlay system is a timely and costly process. Traditionally, the subsurface onto which the surface overlay system is applied must be profiled (i.e., flattened) through a process of shotblasting and / or grinding in order to receive a mechanical bond between the surface overlay system and the subsurface. Such a process is timely, expensive, and labor intensive, and also leaves excessive debris that must be cleaned before application of a base coat. Once cleaned, the base coat is applied to the subsurface and a decorative flake or quartz is applied with a finish coat. The process comprises concrete preparation and drying and curing of application coats. Not only is the process time intensive, but it can also potentially introduce airborne contamination from grinding the concrete.

[0002] Therefore, there is a need for systems and methods to address the issues described above.SUMMARY OF THE INVENTION

[0003] It is to be understood that this summary is not an extensive overview of the disclosure. This summary provides examples and is not restrictive and it is intended to neither identify key or critical elements of the disclosure nor delineate the scope thereof. The sole purpose of this summary is to explain and provide examples of certain concepts of the disclosure as an introduction to the following complete and extensive detailed description.

[0004] Surface overlay systems and methods of installation are described herein. According to an aspect of the present disclosure, a surface overlay system can be installed by preparing a base level (subsurface, base layer, concrete substrate, flooring substrate, etc.), installing a moisture mitigation layer to the base level, removing a protective film from the moisture mitigation layer, applying a first coating to the moisture mitigation layer, and applying a resin or protective layer to the first coating and / or moisture mitigation layer. The first coating can be divided solids that are broadcasted onto the moisture mitigation layer.

[0005] According to an aspect of the disclosure, preparing the base level may comprise cleaning the base level, leveling (evening, etc.) the base level, patching the base level, skimming coating of the base level, etc. The example installation process may comprise installing a moisture mitigation layer to the base level. According to an aspect of the disclosure, the moisture mitigation layer may comprise tape. The moisture mitigation layer may comprise a first adhesive material on a first surface on the moisture mitigation layerconfigured to bind the moisture mitigation layer to the base level. Installing the moisture mitigation layer may comprise smoothing the moisture mitigation layer to eliminate or substantially eliminate any wrinkles present. Installing the moisture mitigation layer may comprise smoothing the moisture mitigation layer to eliminate or substantially eliminate any bubbles disposed between the moisture mitigation layer and the base level. The moisture mitigation layer may comprise a second adhesive material on a second surface thereof. The example installation process may comprise removing a protective film from the second adhesive material, exposing the second adhesive material and the second surface or the second adhesive material on the second surface. The example installation process may comprise applying a first coating to the second surface. The applying of a first coating can include broadcasting divided solids onto the second surface. According to an aspect of the present disclosure, the divided solids may comprise decorative flakes. The divided solids may comprise quartz. The divided solids may be broadcasted with no rejection. The second adhesive material may bind the divided solids to the second surface of the moisture mitigation layer. An example installation process may comprise removing (scraping, sweeping, vacuuming, etc.) any excess divided solids. The example installation process may comprise applying a resin coating to the second surface and / or the divided solids. The resin coating may be a topcoat. The resin coating may provide protection to the second surface and / or the divided solids. The resin coating can include a receiving coating and a top protective coating, and the divided solids can include a first portion and second portion, in which the first portion is broadcasted onto the second surface, the receiving coating is applied to the second surface and the broadcasted first portion of divided solids, the second portion is broadcasted onto the receiving coat, and then the top protective covering is applied to the second portion of divided solids and the receiving coating.

[0006] The second surface of the moisture mitigation layer may comprise an aggregate surface made up of particulates. The aggregate surface can be configured to have applied a receiving coating of the resin coating, onto which the divided solids can broadcasted, which can then be covered with a topcoat of a resin coating. The aggregate surface may also be configured to receive a first coating made of a self-leveling compound which may or may not receive divided solids, and may also receive a top protective coating of the resin material.

[0007] The systems and methods described herein may remove two steps in a process of application of a resinous system overlay system. More specifically, the systems and methods described herein may eliminate a need to shotblast and / or grind a base level (subsurface, base layer, flooring substrate, concrete, etc.) prior to installation, as well as a base coat removalstep of the system overlay installation process. The systems and methods described herein may reduce time and / or contamination in areas where system overlay is installed. The systems and methods described herein may allow installation of surface overlay system in an area where specific contamination requirements must be maintained. For example, the systems and methods described herein allow for resinous surface overlay systems to be installed in hospitals, clean rooms, and other rooms that require caution with respect to contaminants that other surface overlay systems installation may produce. Further, the systems and methods described herein provide for a resin / epoxy based surface overlay system that is easier to remove as there is no direct bonding between a resin and a subsurface.

[0008] The moisture mitigation layer adds moisture protection to the surface overlay systems described herein. The systems and methods described herein may use double stick (e.g., double-sided) moisture mitigation tape. The tape may be available in widths ranging from 3 feet to 6 feet, inclusive. Decorative flakes and / or quartz may be broadcasted over the tape. A topcoat of a resinous material may be applied to the tape and / or decorative flakes and / or quartz. In some aspects, a finishing coat can be applied to a second resinous coating. Multiple layers of broadcasted divided solids and resin coatings can be applied to the moisture mitigation layer. The systems and methods described herein may provide a cleaner and more efficient method of surface overlay system installation than is currently available. The systems and methods described herein may provide a cheaper method of surface overlay installation than is currently available. By using double stick moisture mitigation tape, the disclosed systems and methods are cleaner than existing systems without the needed expense, time, and skill to shotblast or grind a base level, such as concrete or other flooring subsurface. The systems and methods described herein allow for a more efficient and cleaner process.

[0009] The systems and methods may comprise a moisture mitigation layer, such as moisture mitigation double stick tape. A top surface of the moisture mitigation layer may comprise one or more colors. The one or more colors may be configured to complement (match, comprise variations of, comprise complementary colors of, etc.) colors associated with divided solids (decorative flakes, colored quartz, etc.) applied to the top surface of the moisture mitigation layer. Decorative trim may be applied to the top surface. The decorative trim may create more design elements. The systems and methods may comprise application of a resin coating for protection. In an aspect, an additional finishing coat can be applied to the resin coating. The resin coating may be compatible and / or formulated for compatibility with the moisture mitigation layer and / or the divided solids. The resin coating may comprise polyaspartic,epoxy, urethane, etc. The resin coating may comprise a proprietary formula configured for compatibility with the moisture mitigation layer and / or the divided solids.BRIEF DESCRIPTION OF THE DRAWINGS

[0010] The features and components of the following figures are illustrated to emphasize the general principles of the present disclosure. Corresponding features and components throughout the figures can be designated by matching reference characters for the sake of consistency and clarity.

[0011] FIG. 1 illustrates a representation of a surface overlay system according to an aspect of the present disclosure.

[0012] FIG. 2 illustrates a surface overlay system according to an aspect of the present disclosure.

[0013] FIG. 3 illustrates a component of the surface overlay systems of FIGS. 1-2.

[0014] FIGS. 4A and 4B illustrate a surface overlay system according to an aspect of the present disclosure.

[0015] FIGS. 5A, 5B, and 5C illustrate a surface overlay system according to an aspect of the present disclosure.

[0016] FIG. 6 illustrates a method of surface overlay system installation according to an aspect of the present disclosure

[0017] FIG. 7 illustrates a method of surface overlay system installation according to an aspect of the present disclosure.

[0018] FIG. 8 illustrates a method of surface overlay system installation according to an aspect of the present disclosure.

[0019] FIGS. 9-15B illustrate a method of installing a surface overlay system according to an aspect of the present disclosure.

[0020] FIG. 16 illustrates a representation of a surface overlay system according to an aspect of the present disclosure.

[0021] FIGS. 17-22C illustrate a method of installing a surface overlay system according to an aspect of the present disclosure.

[0022] FIG. 23 illustrates a representation of a surface overlay system according to an aspect of the present disclosure.

[0023] FIGS. 24-28C illustrate a method of installing a surface overlay system according to an aspect of the present disclosure.DETAILED DESCRIPTION OF THE INVENTION

[0024] It should be appreciated that this disclosure is not limited to the systems, components, and methods described herein. It is also to be understood that the terminology used herein is for the purpose of describing certain embodiments only, and is not intended to be limiting, since the scope of the present disclosure will be limited only by the appended claims.

[0025] Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure belongs. Any systems, components, and methods similar or equivalent to those described herein can be used in the practice or testing of the present invention. All publications mentioned are incorporated herein by reference in their entirety.

[0026] The use of the terms “a,” “an,” “the,” and similar referents in the context of describing the presently claimed invention (especially in the context of the claims) are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context.

[0027] Recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein.

[0028] Use of the term “about” is intended to describe values either above or below the stated value in a range of approx. + / - 10%; in other embodiments the values may range in value either above or below the stated value in a range of approx. + / - 5%; in other embodiments the values may range in value either above or below the stated value in a range of approx. + / -2%; in other embodiments the values may range in value either above or below the stated value in a range of approx. + / - 1%. The preceding ranges are intended to be made clear by context, and no further limitation is implied. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”) provided herein, is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention unless otherwise claimed. No language in the specification should be constmed as indicating any non-claimed element as essential to the practice of the invention.

[0029] The present disclosure can be understood more readily by reference to the following detailed description, examples, drawings, and claims, and their previous and following description. However, before the present systems, components, and methods are disclosedand described, it is to be understood that this disclosure is not limited to the specific systems, components, and methods disclosed unless otherwise specified, as such can, of course, vary. It is also to be understood that the terminology used herein is for the purpose of describing particular aspects only and is not intended to be limiting.

[0030] It is noted that the term ‘surface overlay system’ as used herein may also be interchangeably used as ‘surface overlay assembly’ without departing from a broader scope of the present disclosure.

[0031] FIGS. 1-28C illustrate representative surface overlay systems and methods of their installation according to aspects of the present disclosure. Upon installation, the surface overlay system 10, as shown in FIG. 1, is installed on a base level / layer / subsurface / flooring substrate 100, and includes a moisture mitigation layer 200 (also interchangeably referred to as a “moisture layer 200” in portions of the present disclosure hereinafter), a first covering layer 300 (which as shown in FIG. 1 comprises a plurality of divided solids 300), and a resin coating 400. Similar to FIG. 1, FIG. 2 shows a flooring system 10 having a moisture layer 200 on a base level / layer 100, and two resin coating layers 400A & B with two applications of divided solids 300A &B (the first application being a first covering layer 300A) according to an aspect of the present invention. While it is shown as separate layers, the divided solids 300A, 300B and resinous material coatings 400A, 400B can mix with one another. In some instances, a finishing coating 500 can be applied over the last layer of resinous material coatings 400 / 400B.

[0032] The base level 100 may comprise a substrate or subsurface. The base level 100 may comprise concrete, wood, terrazzo, self-leveling cementitious, gypsum compounds, and other various materials that are used in forming subsurfaces and the like. One of the advantages of the flooring system 10 is that the base level / layer / flooring substrate 100 does not need to grounded nor profiled before installation, but merely needs to be cleaned to remove debris such as dust and other particulates on the surface of the base layer 100. In addition, the flooring substrate does not need to be primed (i.e., applying a base coat) prior to application of epoxy flake or quartz flooring. The systems and methods discussed below remove at least two steps in the process of application of resinous surface overlay systems. The surface overlay systems of this disclosure can be used in environments in which traditional resinous flooring systems are less likely to be used (e.g., hospitals and clean rooms) given their sensitivity to the contaminants generated by the needed preparation of the subsurface

[0033] The moisture mitigation layer (MML) 200 may comprise double-sided tape, as shown in FIG. 3. Before installation, the moisture mitigation layer / double-sided tape 200 can comeon a roll (on or off a reel) for ease of shipping and storage. Likewise, the MML 200 can vary in length and width on the roll. In some instances, the MML 200 may comprise a width of three feet or more. In other instances, the width of the MML 200 may be six feet or less. In some aspects, the MML can range between 3 to 8 ft in width. Further, the MML 200 is made of a material that can easily cut in order to fit the needs for installation, for example, cutting off sections of the MML 200 from the roll in installation and cutting the MML 200 to fit within the environment or area in which it is installed. In other instances, the MML 200 may be precut at widths or lengths.

[0034] The MML 200 can come in a number of colors which coordinate with the divided solids 300, discussed in more detail below. The MML 200 may comprise two or more heterogeneous sublayers that provide moisture mitigation properties from the substrate. In an aspect, the MML 200 can be made of various materials known in the art that assists in moisture mitigation, including, but not limited to fiberglass layers and other materials.Regardless, it is preferable that the MML 200 has at least a bottom surface 202 having adhesive. In addition, the top surface 204 can also have adhesive applied. In either aspect, a protective layer 250 be applied to prevent the adhesive on the top 204 and bottom 202 surfaces from being exposed prematurely. In other aspects, an aggregate top surface may be utilized, as discussed below.

[0035] The MML 200 may comprise one or more homogeneous sublayers that provide moisture mitigation properties from the substrate. As discussed above ,the MML 200 may be configured to be installed on an ungrounded / profiled base level 100. Further, the MML 200 may be configured to be installed on an unprimed base level 100. The MML 200 may comprise a thickness between 1 to 10 millimeters (mm). In other examples, the MML 200 can have a thickness that ranges between 0.25 mm and 5 mm. The thickness of the moisture mitigation layer 200 may depend on construction of the moisture mitigation layer 200.

[0036] The MML layer 200 comprises a bottom surface 202 and a top surface 204, as shown in FIG. 3. The bottom surface 202 and the top surface 204 can include a first adhesive material and a second adhesive material respectively. The first adhesive material (not shown) may be configured to bind the bottom surface 202 of the MML 200 with a top surface 102 of the base level 100. The top surface 204 of the MML 200 may comprise a second adhesion material, which is configured to bind divided solids 300 (shown in FIG. 1) to the top surface 204 of the MML 200. In an aspect, the first adhesive material may be the same as the second adhesive material. The first adhesive material may be different from the second adhesive material. The first adhesive material may comprise a high moisture adhesive. The secondadhesive material may comprise a chemical compatibility with the divided solids 300 and / or the resin coating 400. Protective films 250 (e.g., liners) be placed and held on the adhesive materials of both surfaces 202, 204 of the MML 200 in order to protect the adhesive materials until installation, at which time the protective films 250 can be removed.

[0037] The first adhesive material of the first / bottom surface 202 of the MML 200 may comprise a moisture resistant material. In some aspects, the first adhesive material of the first / bottom surface 202 of the MML 200 may comprise high moisture adhesive. The first adhesive material of the first / bottom surface 202 can comprise a material to protect from loss of adhesion to the base level 100 due to moisture. The second adhesive material, associated with the top / second surface 204 of the MML 200 may comprise a moisture resistant material. The second adhesive material may comprise a chemical resistant material. The second adhesive material may provide adhesion to the divided solids 300, as discussed below. In most instances, as described above, the first adhesive material and / or the second adhesive material may be pre-applied to the moisture mitigation layer 200 and protected with protective films 250 before installation. While preferred to have the adhesive materials applied at manufacture, in some other aspects, the adhesive materials may be applied to the MML 200 at installation. Alternatively, in some aspects, the MML 200 may not have preapplied adhesive material. In said example aspects, a first adhesive material may be applied to the base level 100 after which the MML 200 is attached to the base level 100, a first surface of the MML 200 being bonded to the base level 100 by the first adhesive material applied on the base level 100. Once the MML 200 is attached or bonded to the base level 100, a second adhesive material may be applied on the second surface of the MML 200 in preparation for the next step / process (e.g., receiving a first covering layer, such as divided solids 300).

[0038] In an aspect, the MML 200 is configured to receive and secure a first covering layer 300, which may be divided solids 300, as discussed further herein. In an aspect, the divided solids 300 are used to provide a decorative finish to the surface overlay. The divided solids 300 can vary in material, but in most instances the divided solids 300 are made up of a plurality of particulate material of a substantially small size. The divided solids may comprise a diameter of 0.01 inch or greater and of 3 inches or smaller. The diameter of one of the divided solids 300 may refer to a straight line passing from side to side through the center the one of the divided solids 300. In an aspect, enough divided solids 300 are provided that allows application on the MML 200 that ranges between one to twenty pounds per square foot.

[0039] In some aspects, smaller diameters of the divided solids can fall faster during broadcasting, eliminating adhesive surface area for the larger divided solids, which can leave the larger solids to fail to stick and create voids. In such instances, a second coating of a combination of resin and divided solids (disclosed in more detail below) can be applied, or divided solids smaller than .001 inches should be avoided

[0040] The divided solids 300 can be comprised of particulates of a variety of materials. For example, the divided solids 300 may comprise decorative flake chips such as, but not limited to, vinyl or non-vinyl chips, organic flakes or chips like wood flakes, chips, etc.. The divided solids 300 may comprise quartz. The divided solids 300 may comprise decorative rocks. In another example, the divided solids 300 may include, but is not limited to, any appropriate inorganic or organic solids / materials. The divided solids 300 may comprise other decorative elements that may bond to the MML 200. The divided solids 300 may provide a decorative element to the top surface 204 of the moisture mitigating layer 200. The top surface 204 of the MML 200 may comprise a first color, the divided solids 300 may comprise a first color scheme, and the first color and the first color scheme may be configured to correspond to one another. The first color of the MML 200 may match the first color scheme of the divided solids 300. The first color scheme may comprise the first color. The first color scheme may complement the first color. The first color may be a variation of a color in the first color scheme. Once the divided solids 300 are applied, the installer can further distribute them on the MML 200 via sweeping and other means of spreading. After the divided solids 300 have been fully distributed so that they are bonding or sticking with the adhesive material of the top surface 204 of the MML 200, any excess divided solids 300 can be removed via sweeping, scraping, and vacuuming.

[0041] Once the divided solids 300 have been applied to the MML 200, and any non-sticking or excess divided solids 300 removed, a resin coating 400 can be applied to secure the divided solids 300 to the MML 200. The resin coating 400 may comprise polyaspartic. The resin coating 400 may comprise epoxy. The resin coating 400 may comprise urethane. The resin coating 400 may comprise one or more other chemicals relevant to resinous applications. The resin coating 400 (shown in FIG. 1) may be applied to the top surface 204 of the moisture mitigation layer 200 and / or the divided solids 300. The resin coating 400 may provide protection for the moisture mitigation layer 200 and / or the divided solids 300. In an aspect, the resin coating 400 can cover the divided solids 300 while also seeping through the gaps between the divided solids 300 to engage the surface 204 of the MML 200. In an aspect, the resinous coating may range in thickness from 5 to 40 Mils (.127mm to 1.06mm).

[0042] In an aspect, as discussed above, more than one combination layer of divided solids 300 and resin coatings 400 can be applied, as shown in FIG. 2. In such aspects, a first layer of broadcasted divided solids 300A can be covered by a first resinous coating 400A, followed by a second broadcasted divided solids 300B covered by a second resinous coating 400B. In such aspects, the first resinous coating can be called the receiving coating 400A, as a second application of divided solids 300B can be applied to it, and the second resinous coating 400B can be called the top coating. As discussed above, the additional divided solids 300B / resinous coating 400B application can fill in voids, as well as add thickness to the overall system. In some aspects, dependent on the subsurface and the thickness of the MML 200, using a single divided solids 300 / resinous layer 400 combination can lead to imperfections of the subsurface 100 coming through, as well as the seams between the pieces of the MML 200. In such instances, it is preferred to use the additional layers of divided solids and resinous coatings. In some aspects, more than 2 layers of resinous coatings and divided solids can be used. The use of two or more combinations of resinous coatings and divided solids can be employed in environments in which a greater thickness for the floor covering is needed, obtain a fuller coverage of divided solids, as well as to handle substrate undulations that could not be eliminated prior to the installation.

[0043] FIG. 3 illustrates components of the surface overlay system 10 according to an aspect of the present disclosure. The base level 100 may comprise a top surface 102. The top surface 102 of the base level 100 may be cleaned, leveled (evened, etc.), patched, etc. prior to engagement with the moisture mitigation layer 200. A prior coating of the base level 100 may be skimmed prior to engagement with the moisture mitigation layer (MML) 200. Further, prior to engagement, the protective layer 250 associated with the first / bottom surface 202 of the MML 200 can be removed from the MML 200 for installation purposes.

[0044] After placing the MML 200 on the base layer 200, the MML 200 can be rolled and further secured to the base layer 200. Such additional securing can be done by smoothing out the MML 200 to eliminate or substantially eliminate any wrinkles, folds, and / or air bubbles potentially formed between the first surface 202 of the MML 200 and the base layer 100 during the placement step. Rolling or other known techniques can be utilized to further secure and flatten out the MML 200.

[0045] In order to protect the MML 200 during installation, the bottom surface 202 and the top surface 204 of the moisture mitigation layer 200 can include a protective film 250. The protective film 250 may comprise an inner n surface 252 and an outer surface 254. The inner surface 252 may be in communication with the surfaces 202, 204 of the moisture mitigationlayer 200 until installation, as shown in FIGS. 4A and 4B. The outer surface 254 of the protective film 250 may be exposed to elements that would otherwise come in contact with the top surface 204, and more specifically the adhesive material on the top surface 204, of the moisture mitigation layer 200 until the protective film 250 is removed. The protective film 250 may comprise plastic. The protective film 250 may cover the moisture mitigation layer 200 during shipping and may be removed during installation.

[0046] FIGS. 4 A and 4 illustrate a surface overlay system according to an aspect of the present disclosure. As shown in FIG. 4A, the top surface 102 of the base level 100 may be at least partially covered by the moisture mitigation layer 200. The moisture mitigation layer 200 may be initially covered by the protective film 250. The top surface 254 of the protective film 250 may be exposed on a portion of the moisture mitigation layer 200 coupled to the top surface 102 of the base level.

[0047] As shown in FIG. 4B, the protective film may be removed, causing the bottom surface 252 of the protective film 250 to separate from the top surface 204 of the moisture mitigation layer 200. The second adhesive material may be exposed. The second adhesive material may be configured to receive broadcasted divided solids 300 (shown in FIG. 1). After the divided solids 300 are received by the top surface 204 of the moisture mitigation layer 200, the resin coating 400 (shown in FIG. 1) may be applied to the top surface 204 of the moisture mitigation layer 200 and / or the divided solids 300.

[0048] FIGS. 5A, 5B, and 5C illustrate a surface overlay system according to an aspect of the present disclosure. As shown in FIG. 5A, a first covering layer 300 of divided solids 300 may be broadcasted onto the top surface 204 (shown in FIG. 4B) of the moisture mitigation layer 200 (shown in FIG. 4B). The divided solids 300 may cover the top surface 204 of the moisture mitigation layer 200. The second adhesive material of the top surface 204 may bind the divided solids to the moisture mitigation layer 200. The divided solids 300 may comprise decorative flake chips in an example aspect. The divided solids 300 may comprise quartz in an example aspect.

[0049] As shown in FIG. 5B, the resin coating 400 may be applied to the divided solid 300 and / or the top surface 204 of the moisture mitigation layer 200. The resin coating 400 may be transparent. The resin coating 400 may be applied with an applicator 410, such as a roller, brush, etc.

[0050] As shown in FIG. 5C, after application, the resin coating 400 may provide a transparent protective layer over the solid divides 300 and / or the top surface 204 of the moisture mitigation layer 200 after curing (e.g., drying, setting, etc.). A time to cure the resincoating 400 may depend on chemicals in the resin coating 400, application thickness, air flow associated with an application area, temperature associated with the application area, humidity associated with the application area, moisture associated with the base level 100, etc. The resin coating 400 may provide a desired texture over the solid divides 300 and / or the top surface 204 of the moisture mitigation layer 200.

[0051] One or more of the components of the surface overlay system 10 may be sold together in a kit. For example, an example kit may comprise the moisture mitigating layer 200, the divided solids 300, and / or the resin coating 400. The moisture mitigating layer 200 in the example kit may comprise a first color. The divided solids 300 in the example kit may comprise colors complementary to the first color. The kits can include components in a ratio, dependent on the square feet of the MML such that enough divided solids are supplied for an application of one to twenty pounds per square foot, and enough resinous material 400 to form a thickness of 5 to 40 Mils when applied to the divided solids 300 and MML 200 respectively.

[0052] FIG. 6 illustrates a method 500 of floor installation according to an aspect of the present disclosure. At step 502, a top surface of a base layer may be prepared. Preparing the top surface of the base layer can include cleaning the base layer 100. As discussed above, the system and method does not require grinding or priming the top surface of the base layer.

[0053] At step 504, a moisture mitigation layer may be applied to the base layer. A bottom surface of the moisture mitigating layer may be in communication with the top surface of the base layer. A first adhesive material may bind the base layer with the moisture mitigating layer. A protective film may be removed to expose the first adhesive material. A first panel of the moisture mitigating layer may be applied directly to the base layer. A second panel of the moisture mitigating layer may be applied such that a first portion of the second panel is in direct communication with the base layer and a second portion of the second panel is in communication with the first panel, resulting in the second panel partially overlapping with the first panel. A second portion of the second panel may be removed (e.g., cutting overlapping pieces), resulting in the first panel and the first portion of the second panel forming adjacent and flush line. The moisture mitigating layer may comprise a protective film over the second adhesive material. The protective film may be maintained over the second adhesive material until the applying the moisture mitigating layer to the base layer is complete.

[0054] At step 506, divided solids may be broadcast to (i.e., broadcasted onto) a top surface of the moisture mitigating layer. A second adhesive material may bind at least a portion of thedivided solids to the top surface of the moisture mitigating layer. A protective film may be removed to expose the second adhesive material before broadcasting the divided solids. The applying the moisture mitigating layer to the base layer may be ensured to be complete before the broadcasting the divided solids to the top surface of the moisture mitigating layer. A plurality of sections on the top surface of the moisture mitigating layer may be created. The protective film over the second adhesive material may be removed from the moisture mitigating layer associated with a first section of the plurality of sections of the top surface of the moisture mitigating layer. The divided solids may be broadcast to the first section. The protective film over the second adhesive material may be removed from the moisture mitigating layer associated with a second section of the plurality of sections of the top surface of the moisture mitigating layer. The divided solids may be broadcast to the second section.

[0055] At step 508, a resin coating may be applied over the divided solids. The resin coating may cover and further secure the divided solids to the top surface of the moisture mitigating layer. A first coat of the resin coating may be applied. A second coat of the resin coating may be applied.

[0056] In some aspects of the different embodiments described herein (i.e., FIGs. 1-28), the divided solids 300 and / or the resin coating 400 may be applied manually, whereas in other aspects, the divided solids 300 and / or the resin coating 400 may be applied using automated systems that can be configured to adjust the rate of application as desired without departing from a broader scope of the present disclosure.

[0057] FIG. 7 illustrates a method 600 of floor installation according to an aspect of the present disclosure. At step 602, a base layer may be prepared for application of a moisture mitigating layer by cleaning a top surface of the base layer. The top surface of the base layer may not be grinded. The top surface of the base layer may not be primed.

[0058] At step 604, the moisture mitigating layer may be applied to the base layer. A bottom surface of the moisture mitigating layer may be in communication with the top surface of the base layer. A first adhesive material may bind the base layer with the moisture mitigating layer. A first panel of the moisture mitigating layer may be applied directly to the base layer. A second panel of the moisture mitigating layer may be applied such that a first portion of the second panel is in direct communication with the base layer and a second portion of the second panel is in communication with the first panel, resulting in the second panel partially overlapping with the first panel. A second portion of the second panel may be removed, resulting in the first panel and the first portion of the second panel forming adjacent and flush lines. A protective film may be removed to expose the first adhesive material. The moisturemitigating layer may comprise a protective film over the second adhesive material. The protective film over the second adhesive material may be maintained until the applying the moisture mitigating layer to the base layer is complete.

[0059] At step 606, divided solids may be broadcast to a top surface of the moisture mitigating layer. A second adhesive material may bind at least a portion of the divided solids to the top surface of the moisture mitigating layer. A protective film may be removed to expose the second adhesive material. The applying the moisture mitigating layer to the base layer may be ensured to be complete before the broadcasting the divided solids to the top surface of the moisture mitigating layer. A plurality of sections on the top surface of the moisture mitigating layer may be created. The protective film over the second adhesive material may be removed from the moisture mitigating layer associated with a first section of the plurality of sections of the top surface of the moisture mitigating layer. The divided solids may be broadcast to the first section. The protective film over the second adhesive material may be removed from the moisture mitigating layer associated with a second section of the plurality of sections of the top surface of the moisture mitigating layer. The divided solids may be broadcast to the second section.

[0060] At step 608, a resin coating may be applied over the divided solids. The resin coating may cover and further secure the divided solids to the top surface of the moisture mitigating layer. A first coat of the resin coating may be applied. A second coat of the resin coating may be applied.

[0061] FIG. 8 illustrates a method 700 of floor installation according to an aspect of the present disclosure. At step 702, a moisture mitigating layer may be applied to an unprimed base layer. A bottom surface of the moisture mitigating layer may be in communication with a top surface of the base layer. A first adhesive material may bind the base layer with the moisture mitigating layer. At step 704, a plurality of decorative flakes may be applied to a top surface of the moisture mitigating layer. A second adhesive material may bind at least a portion of the decorative flakes to the top surface of the moisture mitigating layer. At step 706, a resin coating may be applied to a top surface of the at least the portion of the decorative flakes.

[0062] FIGS. 9-15 illustrate a method of installation of a surface overlay system 10 according to an aspect of the disclosure. As discussed above, the base layer / substrate / subsurface 100 is first prepared to receive the surface overlay system, as shown in FIGS. 9A-9B. As shown, the concrete subsurface 100 is prepared by cleaning and completed and substrate preparation. Ifself-leveling, patching, or skim coating of concrete is needed it would be completed during this step.

[0063] After the subsurface 100 is prepared, the MML 200 can be applied, as shown in FIGS.10A-B. To apply, the MML 200 is sized according to the need of the space or environment. The bottom protective layer 250 is removed and then the MML 200 is secured to the substrate. In an aspect, this process may include installing the MML 200 such that it is securely adhered to the substrate 100 with all or substantially all wrinkles or bubbles eliminated. This can be done through the application of squeegee or straight-edge tool that pushes out any bubbles and straighten outs any wrinkles. This ensures a more level layer for additional applications discussed below. The top protective layer 250 is left on until the first covering layer 300 is ready to be applied.

[0064] The next step is now to apply the covering layer 300, which takes the form of divided solids 300A, as shown in FIGS. 11A-D. Before applying the divided solids 300A, the protective layer 250 of the MML 200 is removed to expose the upper surface 204 of the MML 200, and its adhesive. In such aspects, it is suggested that the protective layers 250 are left on sections of the MML 200 until right before application of the divided solid 300A, as shown in FIGS. 11B-C. The divided solid 300A is then broadcasted. Brooms and other spreading tools can be used to broadcasted the divided solids 300A evenly after the initial distribution. It is also suggested that the user wear spiked shoes for application purposes so that the shoes do not stick to the adhesive surface. The broadcasting of the divided solids 300A is done until all the surface 204 of the MML 200 is completely covered and there is no rejection - i.e., a full broadcast of the divided solids 300A onto the adhesive surface 204 until no more divided solids 300A are accepted.

[0065] After broadcasting is completed, excess broadcasted divided solids 300A are removed, as shown in FIGS. 12A-B. This can be done through sweeping, scraping, vacuuming, or other similar means. It is desirable to make sure that no loose divided solids 300A remain, i.e., the divided solids 300A need to be adhered to the MML 200 before applying the resinous material. After removing the loose divided solids 300A, a resinous material 400A is applied, as shown in FIGS. 13A-B. Rollers and other known tools can be used to spread the resinous material / coating 400A across the divided solids 300A and MML 200. As discussed above, this application of resinous coating can be considered the receiving coating 400A. This resinous coating 400A should not be allowed to dry before a second broadcasting of divided solids 300B is applied, as shown in FIG. 14A. The divided solids 300B is applied until there is no clear area and until no rejection. Following that, the surfaceis cleaned (see FIG. 14B) to remove excessive or loose divided solids 300B, similar to that done after the first broadcasting of divided solids 300A. Then, an additional layer of resinous material 400B is applied, as shown in FIG. 15A-B. The top layer of resinous material 400B can be applied in the same manner as that of the receiving layer 400A and can be referred to as the top coating 400B. In some aspects, a finishing coating (not shown) can be applied to the top resinous material layer 400B.

[0066] In another aspect, another system 1010 can be utilized to cover subsurface 1100 with a MME 1200, divided solids 1300, and resinous coatings 1400, as shown in FIG. 16. The MML 1200 may range in thickness from 1-10 mm. In such aspects, the MML 1200 includes many of the same features of the MML 200 as described above, but has an upper surface 1204 that is an aggregate surface 1204, and not just merely adhesive. The top side 1204 can include a range of aggregate particulates, including, but not limited to, quartz, ceramic, granite, limestone, Polyolefin, PVC, hard plastics, metals, etc. The aggregate surface 1204 increases the mechanical bond between the surface of the MML 1200, divided solids 1300, and resinous materials 1400. In an aspect, the aggregate surface 1204 has a gritty surface that ranges between 80 to 100 grit. The bottom side 1202 of the MML 1200 comprises an adhesion layer that will bond to the surface of the substrate 1100 when installed.

[0067] FIGS. 17-22 illustrate a method of installation of a system 1010 that utilizes an MML 1200 with an aggregate surface 1204. First, the base layer / subsurface 1100 is first prepared to receive the surface overlay system (e.g., cleaning, repair, and leveling, etc.), as shown in FIG. 17. If self-leveling, patching, or skim coating of the subsurface is needed it would be completed during this step. After the subsurface 1100 is prepared, the MML 1200 can be applied, as shown in FIGS. 18A-B. To apply, the MML 1200 is sized according to the need of the space / environment, a bottom protective layer 1250 is removed and then the MML 1200 is secured to the substrate, having preferably eliminated or substantially eliminated any wrinkles or bubbles. This is done to ensure a more level layer for additional applications discussed below.

[0068] After secured, a first covering layer is applied, which can be a resinous coating 1400 A, is applied to the upper aggregate surface 1204, as shown in FIGS. 19A-B. The application of resinous coating 1400A may range in thickness from 5-40 mils thickness. As discussed above, the resinous coating 1400A forms a direct mechanical bond to the particulates of the aggregate surface 1204. In some aspects, this resinous material is referred to as a receiving coating 1400A, distributed to receive an application of broadcasted divided solids 1300, as shown in FIG. 20. This requires the resinous material 1400A not to fully set.The divided solids 1300 can include the same types of divided solids 1300 as discussed above. In an aspect, the application of the divided solids 1300 may range from 1-20 lbs per square feet of divided solids. The divided solids 1300 are applied until full rejection. After application, the surface is cleaned / swept / vacuumed to remove excess divided solids 1300 which did not adhere to the receiving coating 1400A, as shown in FIG. 21.

[0069] The next step is to apply a topcoat 1400B of the resinous material for protection, as shown in FIGS. 22A-C. The topcoat 1400B is compatible and / or formulated for compatibility with the aggregate surface 1204 and divided solids 1300. This can be comprised of apolyaspartic, epoxy, urethane, and the like. There may be additional topcoat formulations created for compatibility. The application of resinous coating may range in thickness from 5-40 mils thickness per coating. In some aspects, an additional finishing coat (not shown) can be applied over the last resinous layer 1400B.

[0070] In another aspect, a system 2010 utilizing a combination of an MML 2200 with an aggregate particulate surface 2204 and a self-leveling compound 2500 can be used as a floor covering system, as shown in FIGS. 23-28C. The system 2010 is used to cover a substrate 2100 with a MML 2200, covered by a self-leveling compound 2500, with divided solids 2300 and a resinous material 2400 to follow, as shown in FIG. 23. The MML 2200, like the other MMLs discussed above, can come in different widths ranging from 3ft -8ft in width. The bottom side 2202 comprises an adhesion layer that will bond to the surface 2102 of the substrate. The top side 2204 of the MML 2200 can be of assorted different aggregate particulates, including, but not limited to, quartz, ceramic, granite, limestone, Polyolefin, PVC, hard plastics, metals, and the like. The MML 2200 may range in thickness from 1-10 mm. The self-leveling compound 2500 may comprise a cementitious or gypsum self-leveling compound. The thickness of the compound 2500 range may range from 1 / 8 inches -10 inches. The divided solids 2300 can be applied to provide various visuals and textures to the leveling compound 2500, if applied. The application may range from l-201bs per sqft. of divided solids 2300. In some aspects, a smaller amount of divided solids 2300 (e..g, .5 to 10 lbs per sqft) may be applied as the divided solids 2300 in such an application are for aesthetic purposes, and not necessary for thickness or protection for the MML 2200, or for the majority of color, as the self-leveling compound 2500 provides the majority of this function for the overall surface overlay system 2010. The resinous material 2400 is compatible and / or formulated for compatibility with the MML 2200, self-leveling compound 2500, and divided solids 2300. This may comprise apolyaspartic, epoxy, urethane, and the like. There may beadditional topcoat formulations created for compatibility. Application of resinous coating to the applied divided solids 2300 may range in thickness from 5-40 mils thickness.

[0071] FIGS. 24-28 illustrate a method of installation of a system 2010 that utilizes an MML 2200 with an aggregate surface 2204 and a self-leveling compound 2500. First, the base layer / substrate 2102 is first prepared to receive the surface overlay system, as shown in FIG.24. As shown, the concrete substrate is prepared by cleaning and completed and substrate preparation. If self-leveling, patching, or skim coating of concrete is needed it would be completed during this step. After the substrate 2100 is prepared, the MML 2200 can be applied, as shown in FIGS. 25A-B. To apply, the MML 2200 is sized according to the need of the space for installation. A bottom protective layer 2250 is removed and then the MML 2200 is secured to the substrate 2100.

[0072] After secured, a self-leveling compound 2500 is applied to the upper aggregate surface 2204, as shown in FIG. 26. The thickness of the compound 2500 range may range from 1 / 8 inches -10 inches. The self-leveling compound 2500 forms a direct mechanical bond to the particulates of the aggregate surface 2204. Once the self-leveling compound 2500 is applied, the divided solids 2300 can be added, as shown in FIG. 27. The divided solids 1300 can include the same types of divided solids 2300 as discussed above. In an aspect, the application of the divided solids 2300 may range from .5 to 10 lbs per square feet, and may range from 1-20 lbs per square feet in other aspects. The divided solids 2300 are applied until completely covering the compound 2500. After application, the surface is cleaned / swept / vacuumed to remove excess divided solids 2300 which did not adhere.

[0073] The next step is to apply a topcoat 2400 of the resinous material for protection, as shown in FIGS. 28A-C. The topcoat 2400 is compatible and / or formulated for compatibility with the aggregate surface 2204 and divided solids 2300. This can be comprised of apolyaspartic, epoxy, urethane, and the like. There may be additional topcoat formulations created for compatibility. The application of resinous coating may range in thickness from 5-40 mils thickness per coating.

[0074] In an aspect, the topcoat 2400 can be applied directly to the self-leveling compound 2500, without any divided solids 2300 being applied.

[0075] In some aspects, a surface overlay system may exist in one or more intermediate, partially completed installation states prior to full curing or final acceptance / finished state. In these intermediate states, the system may comprise a moisture-mitigation layer positioned on a base level (subsurface), with at least a portion of the protective film removed to expose an adhesive or aggregate-bearing upper surface (MML with aggregate-bearing upper surfacemay not have a protective film). Divided solids may be distributed over the exposed upper surface such that at least some of the solids physically engage or adhere to the moisture-mitigation layer, while other solids may remain unbonded and removable. A curable resin may be applied over the divided solids in an uncured or partially cured state, wherein the resin is flowable, ungelled, or otherwise not in a final hardened condition. In some examples, additional layers of divided solids and resin may be applied over the first layer of resin and divided solids, wherein all the layers of resin coatings or one or more layers (e.g., top-most layer) may be in an uncured or partially cured state. In some other example aspects, as described above, a self-leveling compound may be applied to the aggregate surface of the MML followed by addition of divided solids and / or the resin coating, where the resin coating is flowable, ungelled, or otherwise not in a final hardened condition. The intermediate-state system may include partially completed sections, and distinct installation stages, and may exhibit functional relationships between the components — such as, but not limited to, adhesion, mechanical engagement and / or bonding, or resin wet-out — while still remaining short of a completed, fully cured surface overlay assembly installation.

[0076] In further aspects, methods are provided for forming a surface overlay using commercially available surface overlay materials while employing an improved, rapid, or contamination-reduced installation sequence. The method may include preparing a subsurface without grinding or priming, positioning a moisture-mitigation layer on the subsurface, and removing a protective film only from a selected portion of the moisture-mitigation layer to create a workable installation section. Divided solids or self-leveling compounds (in some examples) may then be broadcasted across (or applied across) the exposed adhesive or aggregate surface until the surface exhibits full coverage or until no additional solids are accepted. The method may further include applying a curable resin over the adhered solids to form a receiving layer or a protective layer. These steps may be performed by an installer or installation contractor prior to the surface overlay being placed into service, and may be carried out using appropriate installation tools (manual or automated tools / devices). The described methods enable improved efficiency, reduced airborne contamination, and reduced subsurface-preparation requirements while maintaining compatibility with common resinous surface overlay system materials.

[0077] In some aspects, a kit may be provided to facilitate the installation of a surface overlay system using components arranged or selected for compatibility with the installation sequence described herein. The kit may include a roll or panel of moisture-mitigation material having a defined width and thickness, a quantity of divided solids sized to achieve atarget coverage density across the moisture-mitigation layer as described herein, and a resin or resin system packaged or sized to achieve a desired coating thickness when applied over the solids. The components of the kit may be provided with instructions, markings, or specifications that correlate the relative quantities of the materials with intended installation coverage, sectioning procedures, broadcasting procedures or parameters, protective-film removal procedures, or resin application parameters. The kit may also include optional tools, such as spiked shoes, spreading implements, edge-trimming guides, or other accessories, selected to support the installer in performing the sequencing and section-based installation operations described herein. In some examples, the kit may include a self- leveling compound along with instructions on application procedures and parameters for the self-leveling compound. In some examples, the kit may further include a finishing coating to be applied above the resin coating and / or directions associated with the application of the finishing coating.

[0078] In yet other aspects, the disclosure includes a workflow architecture defining the order, timing, and manner in which the components of a surface overlay system are manipulated during installation. The workflow may involve dividing the installation area into sections, removing protective films sequentially rather than in one operation, broadcasting divided solids or applying self-leveling compounds to each section (or over all sections for self- leveling compounds) immediately or within a threshold time period upon exposure of its adhesive surface, and applying resin over the solids while the underlying adhesive or receiving layer (first resin layer in examples having multiple layers of solids and resins) remains active or uncured. The workflow may further specify that the moisture-mitigation layer is smoothed or rolled to eliminate / alleviate the presences of wrinkles or bubbles prior to section activation, that solids are broadcasted until no further acceptance occurs, or that seams are created by overlapping and trimming adjacent moisture-mitigation sections to achieve a flush boundary. This sequencing may be designed to optimize installation speed, minimize environmental contamination, allow installation in sensitive environments, and ensure compatibility between the adhesive surface, divided solids, and curable resin without requiring specialized substrate preparation.

[0079] As used herein, the term “surface overlay system” or “surface overlay assembly” may refer to any system or assembly configured to provide a surface covering on a supporting structure. In one or more examples, a surface overlay system comprises or is a decorative flooring system, including but not limited to a resinous decorative flooring system or assembly and can be interchangeably used as such in place of surface overlay system orassembly without departing from the broader scope of the present disclosure. In other examples, the term may refer to decorative countertops, work surfaces, or any other appropriate surfaces that receive an applied covering or overlay. Similarly, the term “subsurface” as used herein may refer to a floor subsurface and may be used interchangeably with the term “substrate,” unless otherwise indicated or contradicted by context.

[0080] It is further noted that, in the various methods described herein, one or more of the individual steps may be optional, may be omitted, and / or may be performed in a different order than expressly illustrated. The sequence of operations may be rearranged, combined, subdivided, or otherwise modified in order to optimize installation workflow, improve efficiency, or accelerate installation time, while still forming a surface overlay system or assembly consistent with the broader teachings of the present disclosure. Any such variations in step order or inclusion / exclusion of steps remain within the scope of the disclosed concepts unless expressly stated otherwise or clearly contradicted by context.

[0081] Although several aspects have been disclosed in the foregoing specification, it is understood by those skilled in the art that many modifications and other aspects will come to mind to which this disclosure pertains, having the benefit of the teaching presented in the foregoing description and associated drawings. It is thus understood that the disclosure is not limited to the specific aspects disclosed hereinabove, and that many modifications and other aspects are intended to be included within the scope of any claims that can recite the disclosed subject matter.

[0082] It should be emphasized that the above-described aspects are merely possible examples of implementations, merely set forth for a clear understanding of the principles of the present disclosure. Many variations and modifications can be made to the abovedescribed aspect(s) without departing substantially from the spirit and principles of the present disclosure. Further, the scope of the present disclosure is intended to cover any and all combinations and sub-combinations of all elements, features, and aspects discussed above. All such modifications and variations are intended to be included herein within the scope of the present disclosure, and all possible claims to individual aspects or combinations of elements or steps are intended to be supported by the present disclosure.EXAMPLE CLAUSES

[0083] Example Clause 1 : A surface overlay system may include: a moisture mitigating layer, where the moisture mitigating layer may include a first surface, where the first surface may include a first adhesive material configured to adhere to a base level, and a second surfaceopposite the first surface, and where the second surface may include a second adhesive material; divided solids configured to be broadcasted onto and substantially cover the second adhesive material; and a resin coating configured to cover and further secure the divided solids to the second surface of the moisture mitigating layer.

[0084] Example Clause 2: The surface overlay system as Example Clause 1 describes, where the moisture mitigating layer may include a width of three feet or more.

[0085] Example Clause 3: The surface overlay system as either of Example Clauses 1 or 2 describe, where the width of the moisture mitigating layer is six feet or less.

[0086] Example Clause 4: The surface overlay system as any of Example Clauses 1 -3 describe, where the moisture mitigating layer may include two or more heterogeneous sublayers.

[0087] Example Clause 5: The surface overlay system as any of Example Clauses 1-4 describe, where the moisture mitigating layer may include one or more homogeneous sublayers.

[0088] Example Clause 6: The surface overlay system as any of Example Clauses 1-5 describe, where the second adhesive material is covered with a protective film prior to installation.

[0089] Example Clause 7 : The surface overlay system as any of Example Clauses 1 -6 describe, where the first adhesive material is the same adhesive material as the second adhesive material.

[0090] Example Clause 8: The surface overlay system as any of Example Clauses 1-7 describe, where the first adhesive material may include a moisture resistant material.

[0091] Example Clause 9: The surface overlay system as any of Example Clauses 1-8 describe, where the first adhesive material may include high moisture adhesive.

[0092] Example Clause 10: The surface overlay system as any of Example Clauses 1-9 describe, where the second adhesive material may include a moisture resistant material.

[0093] Example Clause 11: The surface overlay system as any of Example Clauses 1-10 describe, where the second adhesive material may include a chemical resistant material.

[0094] Example Clause 12: The surface overlay system as any of Example Clauses 1-11 describe, where at least one of the first adhesive material or the second adhesive material may include a temporary layer, where the temporary layer prevents the first adhesive material and / or the second adhesive material from inadvertently securing to an object during shipping, and where the temporary layer is configured to be removed prior to installation.

[0095] Example Clause 13: The surface overlay system as any of Example Clauses 1-12 describe, where the divided solids may include decorative flake chips.

[0096] Example Clause 14: The surface overlay system as any of Example Clauses 1-13 describe, where the divided solids may include quartz.

[0097] Example Clause 15: The surface overlay system as any of Example Clauses 1-14 describe, where the divided solids may include decorative rocks.

[0098] Example Clause 16: The surface overlay system as any of Example Clauses 1-15 describe, where the moisture mitigating layer is configured to be installed on the base level without grinding the base level.

[0099] Example Clause 17: The surface overlay system as any of Example Clauses 1-16 describe, where the moisture mitigating layer is configured to be installed on the base level without priming the base level.

[0100] Example Clause 18: The surface overlay system as any of Example Clauses 1-17 describe, where the divided solids provide a decorative clement to the second surface of the moisture mitigating layer.

[0101] Example Clause 19: The surface overlay system as any of Example Clauses 1-18 describe, where the second surface may include a first color, and where the divided solids may include a first color scheme, where the first color and the first color scheme are configured to correspond to one another.

[0102] Example Clause 20: The surface overlay system as any of Example Clauses 1-19 describe, where the first color matches the first color scheme.

[0103] Example Clause 21: The surface overlay system as any of Example Clauses 1-20 describe, where the first color scheme may include the first color.

[0104] Example Clause 22: The surface overlay system as any of Example Clauses 1-21 describe, where the first color is a variation of a color in the first color scheme.

[0105] Example Clause 23: The surface overlay system as any of Example Clauses 1-22 describe, where the resin coating may include epoxy.

[0106] Example Clause 24: The surface overlay system as any of Example Clauses 1-23 describe, where the resin coating may include urethane.

[0107] Example Clause 25: The surface overlay system as any of Example Clauses 1-24 describe, where the resin coating may include polyaspartic.

[0108] Example Clause 26: The surface overlay system as any of Example Clauses 1-25 describe, where the moisture mitigating layer may include a thickness between 0_prd_25 millimeters (mm) and 5 mm.

[0109] Example Clause 27: The surface overlay system as any of Example Clauses 1-26 describe, where the moisture mitigating layer is rolled for shipping.

[0110] Example Clause 28: The surface overlay system as any of Example Clauses 1-27 describe, where the moisture mitigating layer is rolled into a reel for the shipping.

[0111] Example Clause 29: The surface overlay system as any of Example Clauses 1-28 describe, where the moisture mitigating layer is precut at widths of three feet or more to six feet or less.

[0112] Example Clause 30: The surface overlay system as any of Example Clauses 1-29 describe, where the divided solids may include a diameter of 0_prd_01 inch or greater and of 3 inches or smaller.

[0113] Example Clause 31 : The surface overlay system as any of Example Clauses 1-30 describe, where, once installed, removal of the surface overlay system is easier than a surface overlay system installed without the moisture mitigating layer.

[0114] Example Clause 32: The surface overlay system as any of Example Clauses 1-31 describe, where, once installed, removal of the surface overlay system happens without destroying a previously created mechanical bond between the resin coating and the base level.

[0115] Example Clause 33: A method of a surface overlay system installation may include: preparing a top surface of a base layer; applying a moisture mitigating layer to the base layer, where a bottom surface of the moisture mitigating layer is in communication with the top surface of the base layer, and where a first adhesive material binds the base layer with the moisture mitigating layer; broadcasting divided solids to a top surface of the moisture mitigating layer, where a second adhesive material binds at least a portion of the divided solids to the top surface of the moisture mitigating layer; and applying a resin coating over the divided solids, where the resin coating covers and further secures the divided solids to the top surface of the moisture mitigating layer.

[0116] Example Clause 34: The method of surface overlay system installation as Example Clause 33 describes, where the applying the resin coating over the divided solids may include applying a first coat of the resin coating, and where the applying the resin coating over the divided solids may include applying a second coat of the resin coating.

[0117] Example Clause 35: The method of surface overlay system installation as either of Example Clauses 33 or 34 describe, where the applying the moisture mitigating layer to the base layer may include removing a protective film to expose the first adhesive material.

[0118] Example Clause 36: The method of surface overlay system installation as any of Example Clauses 33-35 describe, where the applying the moisture mitigating layer to the base layer further may include: applying a first panel of the moisture mitigating layer directly to the base layer; applying a second panel of the moisture mitigating layer such that a first portion of the second panel is in direct communication with the base layer and a second portion of the second panel is in communication with the first panel, resulting in the second panel partially overlapping with the first panel; and removing a second portion of the second panel, resulting in the first panel and the first portion of the second panel forming adjacent and flush lines.

[0119] Example Clause 37: The method as any of Example Clauses 33-36 describe, where the preparing the top surface of the base layer does not include grinding the top surface of the base layer nor priming the top surface of the base layer.

[0120] Example Clause 38: The method as any of Example Clauses 33-37 describe, where the preparing the top surface may include cleaning the top surface of the base layer.

[0121] Example Clause 39: The method as any of Example Clauses 33-38 describe, where the broadcasting the divided solids to the top surface of the moisture mitigating layer may include removing a protective film to expose the second adhesive material before broadcasting the divided solids.

[0122] Example Clause 40: The method as any of Example Clauses 33-39 describe, where the broadcasting the divided solids to the top surface of the moisture mitigating layer may include ensuring the applying the moisture mitigating layer to the base layer is complete before broadcasting the divided solids to the top surface of the moisture mitigating layer.

[0123] Example Clause 41: The method as any of Example Clauses 33-40 describe, where the moisture mitigating layer may include a protective film over the second adhesive material, and where the applying the moisture mitigating layer to the base layer may include maintaining the protective film over the second adhesive material until the applying the moisture mitigating layer to the base layer is complete.

[0124] Example Clause 42: The method as any of Example Clauses 33-41 describe, where the broadcasting the divided solids to the top surface of the moisture mitigating layer further may include: creating a plurality of sections on the top surface of the moisture mitigating layer; removing the protective film over the second adhesive material from the moisture mitigating layer associated with a first section of the plurality of sections of the top surface of the moisture mitigating layer; broadcasting the divided solids to the first section; removing the protective film over the second adhesive material from the moisture mitigating layerassociated with a second section of the plurality of sections of the top surface of the moisture mitigating layer; and broadcasting the divided solids to the second section.

[0125] Example Clause 43: A method of surface overlay system installation having of: preparing a base layer for application of a moisture mitigating layer by cleaning a top surface of the base layer; applying the moisture mitigating layer to the base layer, where a bottom surface of the moisture mitigating layer is in communication with the top surface of the base layer, and where a first adhesive material binds the base layer with the moisture mitigating layer; broadcasting divided solids to atop surface of the moisture mitigating layer, where a second adhesive material binds at least a portion of the divided solids to the top surface of the moisture mitigating layer; and applying a resin coating over the divided solids, where the resin coating covers and further secures the divided solids to the top surface of the moisture mitigating layer.

[0126] Example Clause 44: The method of surface overlay system installation as Example Clause 43 describes, where the applying the moisture mitigating layer to the base layer further may include: applying a first panel of the moisture mitigating layer directly to the base layer; applying a second panel of the moisture mitigating layer such that a first portion of the second panel is in direct communication with the base layer and a second portion of the second panel is in communication with the first panel, resulting in the second panel partially overlapping with the first panel; and removing a second portion of the second panel, resulting in the first panel and the first portion of the second panel forming adjacent and flush lines.

[0127] Example Clause 45: The method of surface overlay system installation as either of Example Clauses 43 or 44 describe, where the applying the resin coating over the divided solids may include applying a first coat of the resin coating, and where the applying the resin coating over the divided solids may include applying a second coat of the resin coating.

[0128] Example Clause 46: The method of surface overlay system installation as any of Example Clauses 43-45 describe, where the applying the moisture mitigating layer to the base layer may include removing a protective film to expose the first adhesive material.

[0129] Example Clause 47 : The method of surface overlay system installation as any of Example Clauses 43-46 describe, where the preparing the base layer for application of the moisture mitigating layer does not include grinding the top surface of the base layer.

[0130] Example Clause 48: The method of surface overlay system installation as any of Example Clauses 43-47 describe, where the preparing the base layer for application of a moisture mitigating layer does not include priming the top surface of the base layer.

[0131] Example Clause 49: The method of surface overlay system installation as any of Example Clauses 43-48 describe, where the broadcasting the divided solids to the top surface of the moisture mitigating layer may include removing a protective film to expose the second adhesive material.

[0132] Example Clause 50: The method of surface overlay system installation as any of Example Clauses 43-49 describe, where the broadcasting the divided solids to the top surface of the moisture mitigating layer may include ensuring the applying the moisture mitigating layer to the base layer is complete before broadcasting the divided solids to the top surface of the moisture mitigating layer.

[0133] Example Clause 51 : The method of surface overlay system installation as any of Example Clauses 43-50 describe, where the moisture mitigating layer may include a protective film over the second adhesive material, and where the applying the moisture mitigating layer to the base layer may include maintaining the protective film over the second adhesive material until the applying the moisture mitigating layer to the base layer is complete.

[0134] Example Clause 52: The method of surface overlay system installation as any of Example Clauses 43-51 describe, where the broadcasting the divided solids to the top surface of the moisture mitigating layer further may include: creating a plurality of sections on the top surface of the moisture mitigating layer; removing the protective film over the second adhesive material from the moisture mitigating layer associated with a first section of the plurality of sections of the top surface of the moisture mitigating layer; broadcasting the divided solids to the first section; removing the protective film over the second adhesive material from the moisture mitigating layer associated with a second section of the plurality of sections of the top surface of the moisture mitigating layer; and broadcasting the divided solids to the second section.

[0135] Example Clause 53: A method of surface overlay system installation may include: applying a moisture mitigating layer to an unprimed base layer, where a bottom surface of the moisture mitigating layer is in communication with a top surface of the base layer, and where a first adhesive material binds the base layer with the moisture mitigating layer; applying a plurality of decorative flakes to a top surface of the moisture mitigating layer, where a second adhesive material binds at least a portion of the decorative flakes to the top surface of the moisture mitigating layer; and applying a resin coating to a top surface of the at least the portion of the decorative flakes.

[0136] Example Clause 54: A kit for surface overlay system installation may include: a moisture mitigating surface overlay layer may include a first color, where the moisture mitigating surface overlay layer may include a first surface, where the first surface may include first adhesive material configured to adhere to a base level, where the moisture mitigating surface overlay layer may include a second surface, and where the second surface may include second adhesive material; divided solids configured to adhere to the second adhesive material, where the divided solids may include colors complementary of the first color; and a resin coating.

[0137] Example Clause 55: A surface overlay system may include: moisture mitigating layer, where the moisture mitigating layer may include a first surface, where the first surface may include a first adhesive material configured to adhere to a base level, and a second surface opposite the first surface; a first coating configured to substantially cover the second surface of the moisture mitigating layer; and a resin coating configured to cover and further secure the first coating to the second surface of the moisture mitigating layer.

[0138] Example Clause 56: The surface overlay system as Example Clause 54 describes, where the moisture mitigating layer may include two or more heterogeneous sublayers.

[0139] Example Clause 57: The surface overlay system as either of Example Clauses 55 or 56 describe, where the second surface may include a second adhesive material.

[0140] Example Clause 58: The surface overlay system as any of Example Clauses 55-57 describe, where at least one of the first adhesive material or the second adhesive material may include a temporary layer, where the temporary layer prevents the first adhesive material and / or the second adhesive material from inadvertently securing to an object during shipping, and where the temporary layer is configured to be removed prior to installation.

[0141] Example Clause 59: The surface overlay system as any of Example Clauses 55-58 describe, where the moisture mitigating layer is configured to be installed on the base level without grinding or priming the base level.

[0142] Example Clause 60: The surface overlay system as any of Example Clauses 55-59 describe, where the moisture mitigating layer may include a thickness between 0_prd_25 millimeters (mm) and 5 mm.

[0143] Example Clause 61 : The surface overlay system as any of Example Clauses 55-60 describe, where the first coating may include divided solids.

[0144] Example Clause 62: The surface overlay system as any of Example Clauses 55-61 describe, where the divided solids may include a diameter of 0.01 inch or greater and of 3 inches or smaller.

[0145] Example Clause 63: The surface overlay system as any of Example Clauses 55-62 describe, where the divided solids may include a first portion and a second portion, and the resin coating may include a receiving coating and a top coating, where the first portion of divided solids is configured to be applied to substantially cover the second adhesive material, the receiving coating is configured to be applied to the first portion of divided solids, the second portion of divided solids is configured to mix with and substantially cover the receiving coating, and the top coating is configured to be is applied over the first and second portion of divided solids and the receiving coating.

[0146] Example Clause 64: The surface overlay system as any of Example Clauses 55-63 describe, where the second surface of the moisture mitigating layer may include a first color, and where the divided solids may include a first color scheme, where the first color and the first color scheme are configured to correspond to one another.

[0147] Example Clause 65: The surface overlay system as any of Example Clauses 55-64 describe, where the second surface may include an aggregate surface, the aggregate surface may include particulates.

[0148] Example Clause 66: The surface overlay system as any of Example Clauses 55-65 describe, where the first coating may include divided solids, and where the resin coating may include a receiving coating and a top coating, where the receiving coating is configured to be applied to the aggregate surface and to receive a broadcasting of the divided solids, and the top coating is configured to be applied to cover the receiving coating and the broadcasted divided solids.

[0149] Example Clause 67: The surface overlay system as any of Example Clauses 55-66 describe, where the first coating may include a self-leveling compound, the self-leveling compound configured to coat and bond the aggregate surface, and where the resin coating is configured to coat the self-leveling compound.

[0150] Example Clause 68: The surface overlay system as any of Example Clauses 55-67 describe, further may include divided solids, where the divided solids are configured to be broadcasted over the self-leveling compound, and where the resin coating is configured to coat the broadcasted divided solids and self-leveling compound.

[0151] Example Clause 69: The surface overlay system as any of Example Clauses 55-68 describe, where the resin coating may include epoxy, urethane, or polyaspartic.

Claims

CLAIMSWhat is claimed is:

1. A surface overlay system comprising:a moisture mitigating layer, wherein the moisture mitigating layer comprises a first surface, wherein the first surface comprises a first adhesive material configured to adhere to a base level, and a second surface opposite the first surface;a first covering layer configured to substantially cover the second surface of the moisture mitigating layer; anda resin coating configured to cover and further secure the first coating to the second surface of the moisture mitigating layer.

2. The surface overlay system of claim 1, wherein the moisture mitigating layer comprises two or more heterogeneous sublayers.

3. The surface overlay system of claim 1, wherein the second surface comprises a second adhesive material.

4. The surface overlay system of claim 3, wherein at least one of the first adhesive material or the second adhesive material comprises a temporary layer, wherein the temporary layer prevents the first adhesive material and / or the second adhesive material from inadvertently securing to an object during shipping, and wherein the temporary layer is configured to be removed prior to installation.

5. The surface overlay system of claim 1, wherein the moisture mitigating layer is configured to be installed on the base level without grinding or priming the base level.

6. The surface overlay system of claim 1, wherein the moisture mitigating layer comprises a thickness between 0.25 millimeters (mm) and 5 mm.

7. The surface overlay system of claim 1, wherein the first covering layer comprises divided solids.

8. The surface overlay system of claim 7, wherein the divided solids comprise a diameter of 0.01 inch or greater and of 3 inches or smaller.

9. The surface overlay system of claim 7, wherein the divided solids comprise a first portion and a second portion, and the resin coating comprises a receiving coating and a top coating, wherein the first portion of divided solids is configured to be applied to substantially cover the second adhesive material, the receiving coating is configured to be applied to the first portion of divided solids, the second portion of divided solids is configured to mix with and substantially cover the receiving coating, and the top coating is configured to be is applied over the first and second portion of divided solids and the receiving coating.

10. The surface overlay system of claim 7, wherein the second surface of the moisture mitigating layer comprises a first color, and wherein the divided solids comprise a first color scheme, wherein the first color and the first color scheme are configured to correspond to one another.

11. The surface overlay system of claim 1 , wherein the second surface comprises an aggregate surface, the aggregate surface comprising particulates.

12. The surface overlay system of claim 11, wherein the first covering layer comprises divided solids, and wherein the resin coating comprises a receiving coating and a top coating, wherein the receiving coating is configured to be applied to the aggregate surface and to receive a broadcasting of the divided solids, and the top coating is configured to be applied to cover the receiving coating and the broadcasted divided solids.

13. The surface overlay system of claim 11, wherein the first covering layer comprises a selfleveling compound, the self-leveling compound configured to coat and bond the aggregate surface, and wherein the resin coating is configured to coat the self-leveling compound.

14. The surface overlay system of claim 13, further comprising divided solids, wherein the divided solids are configured to be broadcasted over the self-leveling compound, andwherein the resin coating is configured to coat the broadcasted divided solids and selfleveling compound.

15. The surface overlay system of claim 1, wherein the resin coating comprises epoxy, urethane, or poly aspartic.

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