CA2002350A1 - Method of forming a synthetic surface simulating stone, marble or the like - Google Patents
Method of forming a synthetic surface simulating stone, marble or the likeInfo
- Publication number
- CA2002350A1 CA2002350A1 CA 2002350 CA2002350A CA2002350A1 CA 2002350 A1 CA2002350 A1 CA 2002350A1 CA 2002350 CA2002350 CA 2002350 CA 2002350 A CA2002350 A CA 2002350A CA 2002350 A1 CA2002350 A1 CA 2002350A1
- Authority
- CA
- Canada
- Prior art keywords
- resin
- viscosity
- veining
- specific gravity
- pigment
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D5/00—Processes for applying liquids or other fluent materials to surfaces to obtain special surface effects, finishes or structures
- B05D5/06—Processes for applying liquids or other fluent materials to surfaces to obtain special surface effects, finishes or structures to obtain multicolour or other optical effects
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B44—DECORATIVE ARTS
- B44F—SPECIAL DESIGNS OR PICTURES
- B44F9/00—Designs imitating natural patterns
- B44F9/04—Designs imitating natural patterns of stone surfaces, e.g. marble
Abstract
ABSTRACT OF THE DISCLOSURE
A method of preparing a synthetic surface simulating stone, marble and various other naturally occurring substances.
One aspect of the present invention involves utilizing a plurality of resin systems with at least one having a veining pigment composition having a component with a specific gravity greater than that of the one resin system and a component with a specific gravity less than that of the one resin system. A
further aspect of the present invention includes utilizing a plurality of resin systems and varying certain properties of the resin systems to achieve desired variations in design and surface texture of the finished synthetic surface.
A method of preparing a synthetic surface simulating stone, marble and various other naturally occurring substances.
One aspect of the present invention involves utilizing a plurality of resin systems with at least one having a veining pigment composition having a component with a specific gravity greater than that of the one resin system and a component with a specific gravity less than that of the one resin system. A
further aspect of the present invention includes utilizing a plurality of resin systems and varying certain properties of the resin systems to achieve desired variations in design and surface texture of the finished synthetic surface.
Description
--` Z0023~;0 Title: METHOD OF FORMING A SYNTHETXC SURFACE
SIMULATING STONE, MARBLE OR THE LIKE
ThR present invention relates generally eo a method of forming a synthetic surface material simulating various natural `
substances such as marble, stone, onyx, agate, jade, malachite and the like and more particularly, to a method of creating and manufacturing a synthetic material simulating various natural substances which utilizes a unique pigment and resin system.
BACKGROUND OF THE INVENTION
Processes currently exist for forming synthetic ~ ;,. , ~ ,.
materials and surfaces which give the appearance of or simulate various natural substances such as stone, marble and the like.
Such materials are commonly used in the man.ufacture of floor , -and other types of tiles, countertops, sinks, architectural facings, ornamental objects, and generally for any other ~, purpose that marble, stone or the like are used.
One example is a process utilizing a laminated sheet `
of material marketed under the trademark FORMICA. Such ` -material is formed in large sheets and then cut and applied to ~. ~ ` .; .
the desired surface by adhesive or the like. Such sheets can be manufactured in solid colors or in various patterns, some of which simulat~ various stone or other textured material. - `~
Another example is a process for preparlng a material which is commonly referred to as "cultured marble." "Cultured marble" is formed by first creating a mold of a desired shape, - ;-spraying the internal mold surface with a gel coat and then filling the mold with a conventional casting resin. Pigments are added to the resin to giv@ it tha desired color or pattern. After thQ resins have set, the mold is removed with the surface facing the mold forming the outer surface of the ;
finished product.
SIMULATING STONE, MARBLE OR THE LIKE
ThR present invention relates generally eo a method of forming a synthetic surface material simulating various natural `
substances such as marble, stone, onyx, agate, jade, malachite and the like and more particularly, to a method of creating and manufacturing a synthetic material simulating various natural substances which utilizes a unique pigment and resin system.
BACKGROUND OF THE INVENTION
Processes currently exist for forming synthetic ~ ;,. , ~ ,.
materials and surfaces which give the appearance of or simulate various natural substances such as stone, marble and the like.
Such materials are commonly used in the man.ufacture of floor , -and other types of tiles, countertops, sinks, architectural facings, ornamental objects, and generally for any other ~, purpose that marble, stone or the like are used.
One example is a process utilizing a laminated sheet `
of material marketed under the trademark FORMICA. Such ` -material is formed in large sheets and then cut and applied to ~. ~ ` .; .
the desired surface by adhesive or the like. Such sheets can be manufactured in solid colors or in various patterns, some of which simulat~ various stone or other textured material. - `~
Another example is a process for preparlng a material which is commonly referred to as "cultured marble." "Cultured marble" is formed by first creating a mold of a desired shape, - ;-spraying the internal mold surface with a gel coat and then filling the mold with a conventional casting resin. Pigments are added to the resin to giv@ it tha desired color or pattern. After thQ resins have set, the mold is removed with the surface facing the mold forming the outer surface of the ;
finished product.
^`- Z0023S0 . .
A further method is described in Patent No. 3,341,396 issued to E. M. Iverson- In this patent, a base substrate is coated with a resin mate~ial, after which colored pigment is sprinkled onto the resin material- The resin material and colored pigment is then covered with a transparent coating and a tool is passed throu~h the system to distribute the pigment.
Although many of the prior art methods for creating - -synthetic surfaces simulating stone, marble and the like are generally acceptable, there is a continuing effort to develop new and more desirable or pleasing pa~terns as well as patterns which more closely simulate the various natural materials such as stone, marble and the like. Accordinqly, there is a continuing need and desire to improve upon existing methods.
SUMMARY OF THE INVENTION
In accordance with the method of the present invention, a synthetic surface is formed by preparing a resin system or matrix, adding a veining pi~ment composition comprising a "blooming" agent or vehicle, and pouring the same onto a flat substrate. Further variations in aesthetic properties and surface texture can be achieved in accordance with the present inven~ion by using multiple resin systems, varying the specific gravities and thixotropic or flow charac~eristics of the various multiple resins and by varying ;~
the cure rate of the multiple resin systems. The material generated by the present method displays a number of desirable aesthetic and physical properties which have not previously been achieved. These materials formed in accordance with the present invention more closely simulate synthetic rock, marble or the like while at the same time provide a surface which is very pleasing and one which is extremely durable, repairable and capa~le of relatively :~igA heat resistance.
A further method is described in Patent No. 3,341,396 issued to E. M. Iverson- In this patent, a base substrate is coated with a resin mate~ial, after which colored pigment is sprinkled onto the resin material- The resin material and colored pigment is then covered with a transparent coating and a tool is passed throu~h the system to distribute the pigment.
Although many of the prior art methods for creating - -synthetic surfaces simulating stone, marble and the like are generally acceptable, there is a continuing effort to develop new and more desirable or pleasing pa~terns as well as patterns which more closely simulate the various natural materials such as stone, marble and the like. Accordinqly, there is a continuing need and desire to improve upon existing methods.
SUMMARY OF THE INVENTION
In accordance with the method of the present invention, a synthetic surface is formed by preparing a resin system or matrix, adding a veining pi~ment composition comprising a "blooming" agent or vehicle, and pouring the same onto a flat substrate. Further variations in aesthetic properties and surface texture can be achieved in accordance with the present inven~ion by using multiple resin systems, varying the specific gravities and thixotropic or flow charac~eristics of the various multiple resins and by varying ;~
the cure rate of the multiple resin systems. The material generated by the present method displays a number of desirable aesthetic and physical properties which have not previously been achieved. These materials formed in accordance with the present invention more closely simulate synthetic rock, marble or the like while at the same time provide a surface which is very pleasing and one which is extremely durable, repairable and capa~le of relatively :~igA heat resistance.
-3~
., ... `
The desirable aesthetic properties of the material formPd by the method of the present invention are created by -utilizing a unique veining pi5ment system or composition in `~
conjunction with a unique resin system. The veining pigment composition utilized in the method of the present invention includes a pigment component ha~ing a specific gravity greater than the specific gravity of the resin system and a blooming ; ~`
agent or component having a specific gravity less than the specific gravity of the resin system. When such a pigment - ;;
composition is mixed into the resin system or matrix, the - `
blooming agent tends to rise ~oward the surface, carrying small ~ ;
amounts of the pigment component with it. During this migration of the blooming agent toward the surface, small amounts of pigment are dropped to create a ~rail of pigment in the resin. This carrying of a portion of the pigment toward -the surface is what the inventor has referred to as the "blooming" process. The portion of the pigment which is not -~
carried toward the surface by the blooming agent tends to sink ;~
toward the bottom because its specific gravity is greater than that of the resin system.
The extent to which the "blooming" process is allowed to occur as well as the extent to which the piqment is allowed -to sink to the bott~m of the resin system depends, to a great ~`
extent, on the viscosity of th~ resi~ system. As a part of the present invention, the inventor has determined that certain ~-desired patterns and effect can be created by varying the thixotropy of the resin system. Thixotropy is a fluid property ~;-which causes its viscosity to vary as a function of its state ~ `
of agitation and the`previous history of motion within the `
fluid. Generally, the viscosity of a thixotropic fluid decreases and increases as its state of agitation and length of ' . ;~
`` 200Z3S0 agitation increases, and increases as its state of agitation and length of agitation decreases Resin systems which exhibit - -thixotropic properties are able to be mixed and thus poured with relative ease and then, after having been poured and in a relative nonagitated state, exhibit significantly increas~d viscosity. This increased viscosity retards or limits the migration or dispersion (both "blooming" or rising as well as sinking) of the pigments within the resin system and enables one to control the migration and dispersion of the pigment and to stop or fix such migration or dispersion at a desired point in time.
The preferred method contemplates preparation of t:~e resin system, addition and slight mixing of the veining pigmer.t .
composition and then pouring the mixture onto the substrate.
It is contemplated, however, that the pigment composition could also possibly be added after the resin system has been poured, ~;
with the pigment either being allowed to sink and disperse naturally or as a result of mixing with a tool or by some other means. It is also contemplated that various additional veini~g can be added by using accent pigment to create the appearance of fissures and the like in the product.
A modification of the preferred method contemplates utilizing multiple resin systems and multiple corresponding vei~ing compositions to create further desi n variations and .
surface textures. When multiple resin systems are utilized, it is desirable to slightly mix the two systems together before ~ .:
pouring the same onto a substrate. ~It is contemplated, ;~
however, that the multiple resin systems could be poured separately onto the substrate and then mixed after such pouring. ~.;; ;
" ;. ~
-5~
`- 2QOZ3SO
A modification of the multiple resin system is to utilize multiple resin systems which have different specific gravities. Thus, when the two resin systems are combined prior ;~
to pouring onto the substrate, or as they are poured onto the `
substrate, unique patterns and effects result as the respective resin systems tend to migrate or move with respect to one another under the force of gravity as the system cures. It is ~ ~`
contemplated that when multiple resin systems are utilized, at least one of the resin systems would be combined with a veining .-~igment composition including a pigment component having a . : .:
specific gravity greater than the specific gravity of such - ~ ~
..i .,.. "., ".. ,~.
resin system and a blooming agent or component having a specific gravity less than the specific gravity of such resin system.
A still further modification of t~e multiple resin ~m system contemplates varying the cure time of the respective resins such as by using different curing agents or catalysts.
When the respective resins cure at different rates, surCace puckering and other distortions result, leading to additionally unique and attracti~e designs and surface textures. Design variations can also be achieved by ~arying the thixotropic and flow characteristics of the respective resin systems.
, Accordingly, it is an object of the present invent.on to provid~ a method of forming a synthetic surface of simulated ;` ;
stone, marble or the like.
Another object of the present invention is to provide a method of forming a synthetic surface which more closely simulates that of stone, marble or the li~e and/or which results in unique or more pleasing patterns. ;
A further object o~ the present inven~ion is to provide a methcd for creatinq a synthatic surface simulatins stone, marble or the like which utilizes a unique pigment composition comprising a pigment component havin~ a specific gravity greater than that of the resin system and a blooming agent component having a specific gravity less than that of the resin system.
Another object of the present invention is to provide a method for forming a synthetic surface simulating stone, marble or the like in which unique patterns are formed and created by controlling the thixotropic properties of the resin `
. ~ ..
system either separately or in combination w~th a unique pigment composition.
A further object of the present invention is to . ~.
provide a method for forming a synthetic surface simulating stone, marble or the like by utilizing mul iple resin syst~ms with at least one of such resin systems being combined with the unique veining pigment compositions as described.
A still further object of the present invention is to ~ `;
provide a method for forming a synthetic s~rface having further unique design variations and surface textures in a multiple !~
` ~ ' ' ;. ,' ~ .
resin system by varying the specific gravities, cure times ~ ~-and/or thixotropic or flow characteristics of the respective resin systems.
These and other objects of the present invention will become apparent with reference to the description of the ~;
preferred method and the appended claims.
-,~, ,; ::, .: ;....
DESCRIPTION OF THE PREFERRED METHOD
In general, the present invention relates to a method .~ "~, t~
of forming a synthetic surface simulating the appearance of ~ ~-stone, marble or varioUs other-naturally occurring materials.
The method steps involve~ in the present invention include preparing at least one resin system or matrix, adding a veining ~,, ,.,;.,. ~, ;, '' ` ~ ~ ' "
'~
"'; ` , _ zooz350 pigment composition to at least one of the resin systems and then applying the same to a substrate. Throughout the ~ -specification and claims, percentages and ratio are by weight and temperatures in degrees Fahrenheit unless otherwise indicated. ` ~ -In the preferred method, the step of preparing the resin system includes the substeps of selecting the base or primary resin, adding a tinting pigment (if desired) and adding :
any fillers or other materials to control the properties of ;he product when cured or the resin system during the forming -~
process. A curing agent or catalyst is then added and all of `
the ingredients are thoroughly mixed. ; ~
The preferred method of the present invention ~ ~;
contemplates the use of a conventional trar.sparent or `
. . . ~
translucent polyester, isophthalic casting resin as the primary ;.:
or base resin. Such resins or resin blends are available through a variety of sources and are generally known in the `
art. Suitable polyester resins are those prepared from polymerizable unsaturated polyesters such as those prepared -~
from ethylenically unsaturated polycarboxcylic acids and polyhydric alcohols. Preferably the primary resin, when fully cured, provides desirable heat, chemical and mois~ure ;
resistance. A preferred polyester casting resin is a styrated isophthalic casting resin.
Although the preferred resin system is comprised of an isophthalic polyester resin, it is contemplated that an orthophthalic polyester casting resin can be utilized as well.
It is also contemplated that ~arious other resins could be utilized. Possible other polymeric resins include methylmethacrylate and epoxy resin systems. Further, it is ~;
possible that the primary resin could be comprised of a blend ~ -' ~
-8~
:
or mixture of different eesin components, provided that the various resin components are compatible with one another.
The resin system or matrix preparation step also includes the possible subste?s of adding tinting pigments, fillers and/or other components for the purpose of providing background colorant to the material and providing certain properties and characteristics to the resin system during . ~ -formation and after it has cured. For example, if a certain tint or color is desired, an appropriate pigment such as titanium dioxide or any one of various other pigments can be .~ .
added. Certain materials may be added for the purpose of reducing the coefficient of thermal expansion of the cured system or providing such system with various other desired .~
properties. . . .`
One embodiment of the present met:~od contemplates the addition of a fire retardant filler such as alumina trihydrate .~
to provide fire retardancy to the end product. Although ` ~ .-alumina trihydrate is preferred, o~her possi~le compositions ~ ~ .
are avaiIab'~e for accomplishing the same Dur?ose. '~hen f~re : .-:`.-retardant properties are desired in the final produc~ formed i~
accordance with the present invention, the in~entor has found `~
that up to 50~ by weight, and preferably between about 30% and 50% by weight, of alumina trihydrate may be added to the primary resin. As will be described in greater detail below, addition of certain fillers such as alumina trihydrate may ~ ;
dictate modifications to the veining pigment composition or the ;~
addition of ~iscos,ty reducing agents or plasticizers in order ,.~ .
for such pigment to sink and "bloom" in accordance wi~h the present invention. ..
It is also contemplated that certain components can .
also be added to the resin system to control the viscosity and~or the thixotropy of the resin system in order to better ~ 5 O OZ 3 ~o control the dispersion of the veining pigments. In this regard, an aspect of the present invention includes controlling the thixotropy of the resin system by addition of a thixotropic agent such as fumed silica or the like. Addition of such an agent provides the resin system with shixotropic proper~ies which results in its viscosity varying generally inversely as a function of its state of agitation. In other words, as the resin system is agitated, its viscosity will decrease, while as ~
its state of agitation is decreased, its viscosity will ~ -increase. These thixotropic properties provide ~he resin system or matrix with a first viscosity to permit the same to be mixed and poured and to flow to a desired thickness, and a ~-second viscosity to thereafter control and ulti.mately stop the dispersion of the veining pigment. ~-In the preferred method of the present inventior., a smali amount of fumed silica or other ;hixotropic agent is added to the resin base to esta~lish the desired thixotropic property of the resin system. Preferably the thixot~opic .
properties of the resin system or matrix results in sufficiently decreased viscosity during slight agi~ation (i.e., mixing and pouring) to permit the system to be easily mixed and poured and to flow to a desired film thickness on the substrate. A desired film thickness is generally about 1 to lSmm, and preferably about 2 to 4mm. A viscosity of less than about 1200 centipoise or about 800 to 1200 centipoise, and preferably less than about 1000 centipoise or about 800 to 1000 centipoise, during the mixing, pouring and flowing of the matrix is desirable.
The preferred thixotropic properties of the resin system also results in sufficiently increased viscosity after the matrix has flowed to a desired film thickness and is ~ `~
genQrally at rest or in a nonagitated state to stop further -10-- '. '"
. . , ~
- 200~3S0 dispersion of the veinin~ pioment within a desired time after reaching this state- Preferably, dispersion of the veining pigment should be stopped within about lS seconds to 5 minutes after the matrix has flowed to the desired film thickness. A
viscosity greater than about 1200 centipoise or between about 1200 to 6000 centipoise, and preferably greater than about 2000 centipoise or between about 2000 to 3000 centipoise, is desirable for accomplishing this objective. In the pre~erred system, approximately l/4% to 3% by weight of fumed silica is added to the base resin to establish the desired degree of thixotropy.
Following addition of the above tinting pigmen~s, ~ ~ .. ,.: .,. -, fillers and other materials, the base resi~ is thoroughly mixed.
Preparation of the resin system a;so includes the substep of adding the curing agent or cata;ys. which initiates the desi~ed crosslinking and causes the resin to cure. There . ., ~-are, of course, a wide variety of cata'ysts or curinq or crosslinking agents that may be uti'ized. .~ar.y of t~.ese have fairly broad application to a variety of resins or resin blends, while others are more specific. In ~he preferred system of the present invention, methylethyl :~etone peroxide (MEXP) is used as the catalyst. The amount of catalyst added to the resin system can vary depending upon a number of factors ` i;
including the speed with which curing is desired, the temperature under which the curing is to occur, etc. In the preferred method, approximately 2% to 4% by ~eight of the catalyst MEKP is added to the polyester resin and thoeoughly ~ -~ `
mixed for curing at a temperature of about 70 to lO0 ~. It is ;; ` -also contemplated that the primary resin could be self curing, . , . , - ~ . ~. .
in which case a catalyst is not needed.
Following the preparation of the resin system or matrix as desoribed above, the veining pigment composition is ` ~ .
~ . ..,:
:. - . -.
- 200Z3~0 .``` '.:`, ~ .
prepared, added to the matrix, mixed slightly, and then poured onto a flat substrate. In accordance with the preferred method, such a substrate comprises a flat sheet of mater al such as plywood, pressed wood or the like. A side edge of limited height for the purpose of restraining the flow of the poured matrix is also provided. It is also contemplated that the substrate can be provided with a release coating or the -like if a sheet of the resulting material is desired.
During the pre~erred method, the veining pigment composition which has been added to the matrix and slightly mixed is poured onto the suSstrate and allowed to flow to the edges where it is retained and allowed to cure. In the preferred method, the resin with added veining pigment can be poured in strips or ~n various other patterns. It is also contemplated that the resin with added ~eining pigment can be poured and subsequently further mixed. It is also contemplated that the resin system can be first poured and then followed by ~ ~
addition of the veining pigment, either with or without ~-subsequent mixing. ~ -The veining pigment composition utilized in the method ;~
of the presen~ invention comprises a conventional pigment . ; ..
component such as titanium dioxide having a specific gravity . ~:
greater than that of the resin system, together with a blooming or floatation agent component ha~ing a specific gravity less than that o~ the resin system. In the preferred method, the .
..
blooming agent is generally immiscible with respect to the -pigment component. It is also preferable for the blooming agent to be compatible with the particular resin system being ;~
utilized. In other words, it is desirable for the ~looming agent to not chemically or physically react with the resin `
system so as to reduce or affect the properties of that .- .
-12~
~.~ , ,.
- Z002350 ~ ~ ~
system. Acceptable blooming agents generally include solvents of the particular resin system being utilized, such as styrene, as well as various compatible oils and unsaturated resins.
: ~:
Surfactants such as detergents are also acceptable.
In the preferred system, the specific blooming agent utilized is a surfactant comprising a soybean oil derivative ; ~ ~ ~
sold by Amway under the trademark LOC and comprises ~ :
approximately 2% to 50% by weight of the veining pigment ;~
composition. When the veining pigment composition is added to the resin system, slightly mixed, poured onto the substrate and allowed to flow to the desired thickness, the veining pigment will disperse within the resin system. The majority of ~he pigment component, which has a specific gravity greater than that of the resin, tends to sink as a resllt of gravity toward the supporting substrate. The rate at which this sinking occurs is primarily dependent upon the viscosity of the resin system. ~''!'':`'~"'~
A minority portion of the pigment componen~ is carr~ed ; , by the blooming agent, which has a spec Cic gravity less ~:~an that of the resin, toward the top surface or away from the ;~
substrate. As some of the pigment is carried upwardly toward the surface by the blooming agent, and as the remainder of the pigment sinks, trails of pigment are left behind, therèby creating three-dimensional patterns in the transparent/ - ~ -u translucent resin system or matrix. This creates the illusion of internal veining within the system. The sinking portion of , th,e pigment tends to form tonal variations in the background : . . . ~ : ,: .
giving the illusion of great depth.
In tha preferred method, the veining pigment ^` i``~ `
composition includes a pigment component in the amount of about ;,~ ,:
50% to 98% by weight, and preferably about 90% to 98% by '`~
: ~ . ,. .: .
-13~
:: ~: .
~`` 2002350 ." . : ::
weight. The piqment component has a specific gravity greater -than that of the resin. T~e veining pigment composition also ~;
includes a blooming agent component in an amount of about 2% to 50% by weiqht, and referably about 2% and 10% by weight, of a material with a specific gravity less than that of the resin.
In the preferred method, the pigment component is comprised of titanium dioxide or various other pigmenes dispersed in a polyester base. These are commercially available as are various other acceptable pigments. The blooming agen~ is comprised o : ;
methylethyl ketone (ME~) or any other resin system solvent, as well as various sur.actants, oils, waxes, paraf~ins and ~ `
unsaturated polyester resi~s ~hich are compa~ible with the -~ `
resin system and have a specific gravity less than tha~ o~ t~.e resin system. The veining pigment composi~:on is combined with the resin matrix at the rate of from trace amounts of pigment :
up to about two grams of pigment per galion of matrix.
: . ~
The amount of blooming agent in the veining pigment composition depends, to some extent, on the desired look of t~.e final product. It aiso depends on the par~icular resin system being utilized and the proper~ies of such resin system. For example, in one resin system, approximately 50% by weight of ~ ~
alumi~a trihydrate or other similar material is added in order ~ .
to induce desired ire retardant properties. Because of the ; -~
introduction of this material, the composition of the veining pigment must be altered and a viscosity reducing agent or plasticizer must be added to the resin sys;em to overcome the --, problems arising from the significantly insreased viscosity. ~ .
This involves addition to the resin system of approximately 3%
to 10% triethylphosphate by weight as a viscosity reducing agent or plasticizer for the purpose of decreasing the viscosity of the system. rt also involves the addition of a sufficient amount of a surfactant or bloc~ing aqent foc the -purpose of assisting in driving the pigments through the resi~
system~ In the particular system in which up to 50~ by weight of alumina trihydrate is added to the resin system, about 3% .o 10% by weight of triethylphosphate or a viscosity reducing agent should be added to the resin system. The veining pigment should also preferably include as much as 50% by weight of a suitable surfactant or blooming agent such as the soybean oil derivative sold by Amway under the trademark LOC. -~
In preparing the veining pigment composition, the pigment component and the blooming agent are thoroughly mixed so that the pigment is dispersed in the blooming agent. Th~s, the relative properties of the blooming agent must be such tha~ `~
a dispersion will result upon such mixing.
Following the pouring of the bler.ced resin matrix and veining pigment, additional accent or vein.ng can be forme~ by preparing a quantity of accent pigment or material and pouring limited amounts in a desired pattern onto the subs.rate.
8ecause the accent pigment, which is compr sed ~rincipally of pigment and a portion of the resin matrix, has a specific gravity greater than that of the resin, it tends to sink and .
.., , . ~ . ~
provides accent or fissure lines in the final product.
I A further modification of the method of the present .
invention involves the utilization of multiple resin systems ~o achieve further design variations and surface textures. At least one of these multiple resin systems should preferably ; ~: --.; .;:
include a veining piqment composition as described above having -a pigment component with a specific gravity greater than that of the such one resin system and a blooming agent component with a specific gravity less than that of said one resin :~
system. It is also contemplated that more than one of the ' '' .` ,~'',' ' ~.
-l5-resin systems in a multiple resin system environment could ~e provided with such a veining composition.
When a multiple resin system is utilized, design variations and different surface textures can ~e achieved by one or more of the ~ollowing techniques. One such technique is to utilize multiple resin sys~ems in which at least two of such resin systems ~.ave different specific gravities. When the resin systems with different specific gravities are partially mixed and poured oneo the substrate, the light resin system (that with the lower speciÇic gravity) tends to move as a result of gravity toward the surface and while doing so, tends to float some of the heavier eesin system (that with a greater specific gravity). This has the effect of creating raised veining and further unique design detail. rhe resulting :
product, when cured, has a terrain-like su.face with a unique ~`
and aesthetically desirable color pattern. The specific .-gravity of the resin systems can be varied by selection of ehe .
resin itself or by using different fillers or different levels of fillers in the respective resin systems. ~ypical fillers , could include, but would not be limited to, calcium carbonate or aluminum trihydrate. Specific gravities of resin systems will typically vary between 1.2 and 1.8. To achieve a desirable effect, the differences in specific gravity between two resin systems should be at least .01 and preferably at least about.05.
A second technique includes varying ~he cure rate of at least two of the resin systems in a multiple resin environment. This varying of the cure rate results in a textured surface which is dependent, to some extent, on the specific cur~ rates of the resins. Since polymers shrink when they cure (typically about 2%), the uneven or different cure rates in the re~pective resins will caus~ distortions in the ;
,. ~. , :
.,....... , ,~ ,... ,, ~' "
z o OZ 3tjO
surface. Such distortions will generally be in registration with the resin systems and their particular color since each resin system has its own cure rate. Typical gel time for a ~ ;~
resin system utilized in the present in~ention is on the order ;~
of about 15 minutes. By mixing a resin system with a lS-minute ~ -gel time with a second resin system having a 25-minute gel ~ ~
time, significant distortion of the surface will occur. When : ~ :
the system is fully cured, a material with a surface texture of a magnitude of as much as 3/32 inch will result. The cure rate of a resin system can be varied in several ways; however, the most common way is to vary the cure rate by adjusting the level ~;
of the catalyst or curing agent in the system. In resin systems of the 2referred method using the catalyst MEK~, the .-amount of catalyst will vary between about 3/4~ and 2% of the resin mixture. Other factors include the ievel of promoter in the resin itself, the level of filler, the ambient temperature and the resin and mold temperature. When resin mixtures of different cu e times are utilized, it is preferable that the cure times be at least a~out 20% different tO achieve a meaningful difference in effect. ' Y:.
,i . :, ~
A third technique for achieving design variations in a .. ;, . , .. ,.:
multiple resin system is to vary the level of thixotropy . . : . -. -between at least two resin systems. This variance of thixotropy affects the flow characteristics of the individual . . . ~ . .
resins while, and after, they are poured. This will not only affect the general migration or movement of the respective ; --resin systems, but will also tend to hold surface distortion in place which has been formed by other techniques such as the variance of curing rates. Resins which have a low thixotropic index will tend to flow out more, thus tending to reduce surface texture variation, while resin systems with a high thixotropic index will tend to stay in place, resulting in .: .
-17 -~
., "
.
` Z002350 enhanced surface variations and textures. The thixotropic properties of a particular resin system can be altered in a manner similar to that described above by the addition of a thixotropic agent agent such as f~1med s lica. Normally, addition of fumed silica up to an amount of about 2% is preferred.
A fourth technique is to vary the viscosity of the resin, independent of the thixotropic properties, through the addition or deletion of various styrenes, plasticizers or other compositions affecting the viscosity of a particular resin system. These viscosity affecting components generally have a ~
small effect on the specific gravity of the system, but can :
have a major effect on the flow c.~aracteristics of the resin. .~ -Such varying flow characteris~ics results in further design variations.
In the multiple resin system, each of the resin systems and its respective veining composition if utilized, is preferably prepared and combined separately, after which the resin systems are combined with slight mixing and subse~ent'y pou~ed onto the substrate. ~; is contemplated, however, .hat the separately prepared resin systems can be separately ~oured onto the substrate and then physically mixed on the substrate itself to create the desired patterns and designs.
It is also contemplated that in a multiple resin system, at least one of the resin systems would preferably include a veining piqment as described above; however, it is -further contemplated that many of the benefits of the present invention and many unique and desirable design variations and surface textures can be achieved by eliminating the described ~ ~
~eining pigment composition, but utilizing one or more of the ~ ~-above described techniques. Thus, it is believed that certain , . .
" 20~2350 desirable designs and surface textures can be achieved whether ~:
or not any of the resin systems includes the specifically -described veining ~igment ccmposition with the described ~ -piqment component and ~loo~ing agent component. `
Having described the ~etails regarding the various -components and compositions utilized in the method of the present invention, the method can be further summarized as follows. First, at least one resin system or matrix is prepared ~ , .. - .
by selecting a primary resin or resin blend and, if needed or `
desired, adding various materials to the primary resin. These ` ~
materials may include a tinting pigment as well as materials - -which affect the ultimate ~roperties of the cured resin or t~.e properties of the resin system or matrix during formation of ::
the product. . ,,~
One of these other materials may nclude a thixotropic .. - . ... .
agent such as ~lmed silica or the like to a~ least one of the ~ -.. . .
resins ~or the ~urpose of controlling the viscosity of the ;~ ~ .
matrix while t~e same ~s bein~ mixed and poured and after it has been allowed to flow to its desired ~hickness. It has been -found that addi-ion of approximately l/4% ~o 3~ by ~eight of fumed silica to the primary resin provides acceptable thixotropic properties. This permits the resin to be easily . . - - :,::
mixed and poured and to flow to a desired thickness, and after ;; ;
~his has occurred, to have a sufficiently increased viscosity to stop the further dispersion of the veining pigment at a . . ~. . - .~
desired point in time.
Another of these materials is a fire retardant;~
component. Preferably, this invol~es addin~ up to 50% by weight of alumina ~rihydrate. When such material is added, the viscosity is signi~lcantly increased to the point where it may be necessary to add viscosity reducing agents or plasticizers .. ,: -, ,: .
-19- ~.:,', ,.
': "' ' .. . .
to the matrix and additional bloominy a~ent and/or surfactants to the veining pigment in order to help drive the pigments through the resin system.
After preparation of the resin system or systems, a veining pigment composition is preferably added to at least one ;- -of the resin systems. In the preferred method, the veining pigment composition includes a pigment component naving a specific gravity less than that of the resin system and comprising about 50~ to 98~ by weight of the composition and a blooming agent having a specific gravity less than that of t~e resin system and comprising about 2% to 50% by weight of the composition. As the ma~rix is poured onto the substrate and allowed to flow to its edges, the ~eining pigment disperses within~the resin system as a result of the heavier pigment component sinking toward the bottom and a ~art of the pigment being carried upwardly toward the surface of the matrix as a result of the blooming agent. This dispersion of the pigment continues until it is stopped as a result of thé increase in viscosity of the matrix due to its thixotropic ~r~perties or curing.
The method of the present invention is further illustrated by the following examples:
Example 1 Simulation of a quartz-like stone surface was formed by preparing a resin matrix utilizing a conventional styrated isophthalic polyester resin as the base resin. T~e particular ;~
base resin utilized had a viscosity at room temperature of -~
about 700 centipoise. To this base resin were added lJ2% by weight of fumed silica as a thixotropic agent, 1/4 gram per ;~
gallon of titanium dioxide as a tinting pigment and 2% by ' .
weight of methylethyl ketone peroxide (MREP) as the catalyst. ~ :~
.' ;''~ ", '~' ';', ~
- 200Z350 ~ , These ingredients were then thorouqhly mixed to produce the .. . :
resin matrix.
A small quan~ity of accent piqment or material was then prepared by adding 20 grams of metal coated mica pigment with 40 grams of the base resin along with 2~ by weight of the ~ ~
catalyst MEKP and thoroughly mixing the same. This mixture was ~ `
.. .. ..
then partially mixed with 200 ml, of the resin matrix, to produce the accent pigment mixture. ` `
The veining pigment composition was then prepared by ;~
thoroughly mixing 95% b~ weight titanium dioxide pigment and 5% -by weight of a surfactant, namely, the soybean oil derivative sold by ~mway Corpora~ion under the trademark LOC This vei~.-r.g pigment composition was partially blended with the resin matrix at the rate of about 1/2 gram of veining F~gment co~position -~
per gallon of resin matrix. The resulting blend was poured .n strips approximately 8 inches to 18 inches wide and allowed eo `~
flow to the side edges of a flat substrate provided with side ~ -edges. Following the pour, limited amounts of the accent .
pigment were used to form accen~ or fissure lines by ?ouring ;~
the same in desired patterns onto the subs~ra.e. The accent ~ i~
pigment, having a greater specific gravity than that of the resin matrix tended to sink to the bottom of the poured resin thereby creating desirable fissure lines. ~
The poured resin mixture was cured at 110F for four ; - ~ `
hours. The final film thickness was 1/8 inch and exhibited highly desirable aesthetic properties. ;A, ". , ~. ' ExamPle 2 `
A simulation of a marble surface was prepared by utilizing a base resin similar to that in Example 1 above and ad~ing 1/2% by w0ight of fumed silica. This resin/fumed silica mixture was divided in two equal parts. Titanium dioxide 21- ~ -: .:
2()02350 .-- , .
pigment ~as added to one part at the rate of 1/4 gram of ~-pigment per gallon of resin and was added to the second part a~
the rate of 2 grams of pigment per ga}lon of resin. Both parts were catalyzed with 2~ by wei~ht MEKP and thoroughly mixed to produce a first and second resin matrix respectively.
An accent piqment material was prepared as in Example 1 above.
A veining pigment composition comprising 95% titanium dioxide and 5% of the surfactant utilized in Example 1 was prepared and added to the first resin matrix at thè rate of 1/2 gram of veining pigment composition per gallon of resin solution and slightly mixed. Equal ~ortions of the fi!st resin ~ -matrix (with added veining pigment composition) and the second ;~
resin matrix were combined, mixed slightly and poured onto a substrate as in Example 1 above. Accent ve ning was also ~ -conducted as in Example 1 above. The resulting poured material was cured at 100 for four hours. The thickness of the resulting product was 1/8 inch and provided an aesthe~ically pleasing, marble-llke surface.
Example 3 A black marble simulation with raised white veining and detailing was prepared by utilizing a combination of two resin systems. A first resin system was prepared by maxing one -part (by weight) transluscent isopthalic polyester resin (SG
1.1) with one part (by weight) alumina trihydrate filler (SG
2.2), resulting in a specific gravity of 1.65. To this resin /;~
mixture was added 1/2% ~lack pigment, 1~4% fumed silica ;
(cabosil), 1% MEXP catalyst and 1~ triethylphosphate (to reduce viscosity). The le~el of catalyzation in the resin as it comes - ;
from the supplier is dependent, to some extent; on the level of ;-;
promoter (~obalt napthalate) in the resin. In the present ,.. ., ~. . , ,~
case, this level is .1%. The level of catalyst, ths ambient --2 2 ! ' ~
:~'' ,,`,' '~"""' " .'''~,',"'' - ZOOX350 :`` ;-temperature, the resin temperature and the temperature of the -~
mold also affect the catalyzation and ultimate cure time. In -~-the present example, ;he above identified mixture had a gel .--~
time of approximately 25 minutes. The gel time for purposes Oc the present invention s the point at which the material is sufficiently cured so that it achieves the consistency of jelly.
A second resin mixture was prepared in a similar fashion by mixing one part (by weight) of transiuscent isopthalic polyester resin with .8 parts alumina trihydrate -~
filler, thus resulting in a specific gravity of about 1.58. To this mixture was added 1/4% titanium dioxide (white piqment), 1~2% fumed silica (cabosil) and 2~ MEKP as the catalyst. This - -~
combina~ion was mixed .n accordance with standard procedure ;
known in the cultured marble industry. T~.e gel time of this second resin mixture was determi~ed to be approximately 15 minutes.
Nine parts (by volume? of the first resin mixture were then combined wit;~ one part (by volume) of t~e second resin mixture, blended ligh:;y and poured onto a level surface or ;~
substrate and allowed to sel~ level to a thickness of ~:
approximately 3/16 of an inch. During the curing process, the white resin mixture tended to rise through the black resin mixture because of its lower specific gravity leaving , "contrails" in the transluscent bl~ck resin. The white veinin~
also tended to draw to~ether on the surface of the poured . . ~ " . .
mixture as a result of a tendency to "kick out of solution"
much like any two liquids with different densities. After ;~
three to four minu~es the white veining tended to diffuse into the black background. This tendency was controlled by the level of ~hixotropy of the white resin which was achieved by addition of the 1/2% fumed silica. In general, a high level of ~:~
thixotropy will ~ive more distinct veïning, while a lower level of thixotropy will give a more diffused and less distinct veining. The raised or textured nature of the white veining could be observed within the first minute after pouring. Aftee 12 to 15 minutes, the white portion reached its gel stage and -began to shrink and float more dramatically on the surface of the black background. At 25 minutes, the black resin mixture ~; ~
reached its gel point. Thereafter, the mold was moved to a ~ -curing oven to be further cured at 110 F for four hours. The resulting material developed an attractive pattern o white veining partially superimposed on and partially dispersed in a black background.
Although .he description of the present invention has been quite specific, it is contemplated that various modifications could be made ~ithout deviat ng from the spirit ;~
thereof. Accordingly, it is intended that -he scope of the pr~sent invention be dictated by the appended claims rather than by the description of the preferred embodiment.
,' '''''`''''`'"''.'''',~ ."'''`' ''''~''~"
' ~' " " ' ' . ~.:".' . ~ '.',',' ''~ `~
-24- , ~
., ... `
The desirable aesthetic properties of the material formPd by the method of the present invention are created by -utilizing a unique veining pi5ment system or composition in `~
conjunction with a unique resin system. The veining pigment composition utilized in the method of the present invention includes a pigment component ha~ing a specific gravity greater than the specific gravity of the resin system and a blooming ; ~`
agent or component having a specific gravity less than the specific gravity of the resin system. When such a pigment - ;;
composition is mixed into the resin system or matrix, the - `
blooming agent tends to rise ~oward the surface, carrying small ~ ;
amounts of the pigment component with it. During this migration of the blooming agent toward the surface, small amounts of pigment are dropped to create a ~rail of pigment in the resin. This carrying of a portion of the pigment toward -the surface is what the inventor has referred to as the "blooming" process. The portion of the pigment which is not -~
carried toward the surface by the blooming agent tends to sink ;~
toward the bottom because its specific gravity is greater than that of the resin system.
The extent to which the "blooming" process is allowed to occur as well as the extent to which the piqment is allowed -to sink to the bott~m of the resin system depends, to a great ~`
extent, on the viscosity of th~ resi~ system. As a part of the present invention, the inventor has determined that certain ~-desired patterns and effect can be created by varying the thixotropy of the resin system. Thixotropy is a fluid property ~;-which causes its viscosity to vary as a function of its state ~ `
of agitation and the`previous history of motion within the `
fluid. Generally, the viscosity of a thixotropic fluid decreases and increases as its state of agitation and length of ' . ;~
`` 200Z3S0 agitation increases, and increases as its state of agitation and length of agitation decreases Resin systems which exhibit - -thixotropic properties are able to be mixed and thus poured with relative ease and then, after having been poured and in a relative nonagitated state, exhibit significantly increas~d viscosity. This increased viscosity retards or limits the migration or dispersion (both "blooming" or rising as well as sinking) of the pigments within the resin system and enables one to control the migration and dispersion of the pigment and to stop or fix such migration or dispersion at a desired point in time.
The preferred method contemplates preparation of t:~e resin system, addition and slight mixing of the veining pigmer.t .
composition and then pouring the mixture onto the substrate.
It is contemplated, however, that the pigment composition could also possibly be added after the resin system has been poured, ~;
with the pigment either being allowed to sink and disperse naturally or as a result of mixing with a tool or by some other means. It is also contemplated that various additional veini~g can be added by using accent pigment to create the appearance of fissures and the like in the product.
A modification of the preferred method contemplates utilizing multiple resin systems and multiple corresponding vei~ing compositions to create further desi n variations and .
surface textures. When multiple resin systems are utilized, it is desirable to slightly mix the two systems together before ~ .:
pouring the same onto a substrate. ~It is contemplated, ;~
however, that the multiple resin systems could be poured separately onto the substrate and then mixed after such pouring. ~.;; ;
" ;. ~
-5~
`- 2QOZ3SO
A modification of the multiple resin system is to utilize multiple resin systems which have different specific gravities. Thus, when the two resin systems are combined prior ;~
to pouring onto the substrate, or as they are poured onto the `
substrate, unique patterns and effects result as the respective resin systems tend to migrate or move with respect to one another under the force of gravity as the system cures. It is ~ ~`
contemplated that when multiple resin systems are utilized, at least one of the resin systems would be combined with a veining .-~igment composition including a pigment component having a . : .:
specific gravity greater than the specific gravity of such - ~ ~
..i .,.. "., ".. ,~.
resin system and a blooming agent or component having a specific gravity less than the specific gravity of such resin system.
A still further modification of t~e multiple resin ~m system contemplates varying the cure time of the respective resins such as by using different curing agents or catalysts.
When the respective resins cure at different rates, surCace puckering and other distortions result, leading to additionally unique and attracti~e designs and surface textures. Design variations can also be achieved by ~arying the thixotropic and flow characteristics of the respective resin systems.
, Accordingly, it is an object of the present invent.on to provid~ a method of forming a synthetic surface of simulated ;` ;
stone, marble or the like.
Another object of the present invention is to provide a method of forming a synthetic surface which more closely simulates that of stone, marble or the li~e and/or which results in unique or more pleasing patterns. ;
A further object o~ the present inven~ion is to provide a methcd for creatinq a synthatic surface simulatins stone, marble or the like which utilizes a unique pigment composition comprising a pigment component havin~ a specific gravity greater than that of the resin system and a blooming agent component having a specific gravity less than that of the resin system.
Another object of the present invention is to provide a method for forming a synthetic surface simulating stone, marble or the like in which unique patterns are formed and created by controlling the thixotropic properties of the resin `
. ~ ..
system either separately or in combination w~th a unique pigment composition.
A further object of the present invention is to . ~.
provide a method for forming a synthetic surface simulating stone, marble or the like by utilizing mul iple resin syst~ms with at least one of such resin systems being combined with the unique veining pigment compositions as described.
A still further object of the present invention is to ~ `;
provide a method for forming a synthetic s~rface having further unique design variations and surface textures in a multiple !~
` ~ ' ' ;. ,' ~ .
resin system by varying the specific gravities, cure times ~ ~-and/or thixotropic or flow characteristics of the respective resin systems.
These and other objects of the present invention will become apparent with reference to the description of the ~;
preferred method and the appended claims.
-,~, ,; ::, .: ;....
DESCRIPTION OF THE PREFERRED METHOD
In general, the present invention relates to a method .~ "~, t~
of forming a synthetic surface simulating the appearance of ~ ~-stone, marble or varioUs other-naturally occurring materials.
The method steps involve~ in the present invention include preparing at least one resin system or matrix, adding a veining ~,, ,.,;.,. ~, ;, '' ` ~ ~ ' "
'~
"'; ` , _ zooz350 pigment composition to at least one of the resin systems and then applying the same to a substrate. Throughout the ~ -specification and claims, percentages and ratio are by weight and temperatures in degrees Fahrenheit unless otherwise indicated. ` ~ -In the preferred method, the step of preparing the resin system includes the substeps of selecting the base or primary resin, adding a tinting pigment (if desired) and adding :
any fillers or other materials to control the properties of ;he product when cured or the resin system during the forming -~
process. A curing agent or catalyst is then added and all of `
the ingredients are thoroughly mixed. ; ~
The preferred method of the present invention ~ ~;
contemplates the use of a conventional trar.sparent or `
. . . ~
translucent polyester, isophthalic casting resin as the primary ;.:
or base resin. Such resins or resin blends are available through a variety of sources and are generally known in the `
art. Suitable polyester resins are those prepared from polymerizable unsaturated polyesters such as those prepared -~
from ethylenically unsaturated polycarboxcylic acids and polyhydric alcohols. Preferably the primary resin, when fully cured, provides desirable heat, chemical and mois~ure ;
resistance. A preferred polyester casting resin is a styrated isophthalic casting resin.
Although the preferred resin system is comprised of an isophthalic polyester resin, it is contemplated that an orthophthalic polyester casting resin can be utilized as well.
It is also contemplated that ~arious other resins could be utilized. Possible other polymeric resins include methylmethacrylate and epoxy resin systems. Further, it is ~;
possible that the primary resin could be comprised of a blend ~ -' ~
-8~
:
or mixture of different eesin components, provided that the various resin components are compatible with one another.
The resin system or matrix preparation step also includes the possible subste?s of adding tinting pigments, fillers and/or other components for the purpose of providing background colorant to the material and providing certain properties and characteristics to the resin system during . ~ -formation and after it has cured. For example, if a certain tint or color is desired, an appropriate pigment such as titanium dioxide or any one of various other pigments can be .~ .
added. Certain materials may be added for the purpose of reducing the coefficient of thermal expansion of the cured system or providing such system with various other desired .~
properties. . . .`
One embodiment of the present met:~od contemplates the addition of a fire retardant filler such as alumina trihydrate .~
to provide fire retardancy to the end product. Although ` ~ .-alumina trihydrate is preferred, o~her possi~le compositions ~ ~ .
are avaiIab'~e for accomplishing the same Dur?ose. '~hen f~re : .-:`.-retardant properties are desired in the final produc~ formed i~
accordance with the present invention, the in~entor has found `~
that up to 50~ by weight, and preferably between about 30% and 50% by weight, of alumina trihydrate may be added to the primary resin. As will be described in greater detail below, addition of certain fillers such as alumina trihydrate may ~ ;
dictate modifications to the veining pigment composition or the ;~
addition of ~iscos,ty reducing agents or plasticizers in order ,.~ .
for such pigment to sink and "bloom" in accordance wi~h the present invention. ..
It is also contemplated that certain components can .
also be added to the resin system to control the viscosity and~or the thixotropy of the resin system in order to better ~ 5 O OZ 3 ~o control the dispersion of the veining pigments. In this regard, an aspect of the present invention includes controlling the thixotropy of the resin system by addition of a thixotropic agent such as fumed silica or the like. Addition of such an agent provides the resin system with shixotropic proper~ies which results in its viscosity varying generally inversely as a function of its state of agitation. In other words, as the resin system is agitated, its viscosity will decrease, while as ~
its state of agitation is decreased, its viscosity will ~ -increase. These thixotropic properties provide ~he resin system or matrix with a first viscosity to permit the same to be mixed and poured and to flow to a desired thickness, and a ~-second viscosity to thereafter control and ulti.mately stop the dispersion of the veining pigment. ~-In the preferred method of the present inventior., a smali amount of fumed silica or other ;hixotropic agent is added to the resin base to esta~lish the desired thixotropic property of the resin system. Preferably the thixot~opic .
properties of the resin system or matrix results in sufficiently decreased viscosity during slight agi~ation (i.e., mixing and pouring) to permit the system to be easily mixed and poured and to flow to a desired film thickness on the substrate. A desired film thickness is generally about 1 to lSmm, and preferably about 2 to 4mm. A viscosity of less than about 1200 centipoise or about 800 to 1200 centipoise, and preferably less than about 1000 centipoise or about 800 to 1000 centipoise, during the mixing, pouring and flowing of the matrix is desirable.
The preferred thixotropic properties of the resin system also results in sufficiently increased viscosity after the matrix has flowed to a desired film thickness and is ~ `~
genQrally at rest or in a nonagitated state to stop further -10-- '. '"
. . , ~
- 200~3S0 dispersion of the veinin~ pioment within a desired time after reaching this state- Preferably, dispersion of the veining pigment should be stopped within about lS seconds to 5 minutes after the matrix has flowed to the desired film thickness. A
viscosity greater than about 1200 centipoise or between about 1200 to 6000 centipoise, and preferably greater than about 2000 centipoise or between about 2000 to 3000 centipoise, is desirable for accomplishing this objective. In the pre~erred system, approximately l/4% to 3% by weight of fumed silica is added to the base resin to establish the desired degree of thixotropy.
Following addition of the above tinting pigmen~s, ~ ~ .. ,.: .,. -, fillers and other materials, the base resi~ is thoroughly mixed.
Preparation of the resin system a;so includes the substep of adding the curing agent or cata;ys. which initiates the desi~ed crosslinking and causes the resin to cure. There . ., ~-are, of course, a wide variety of cata'ysts or curinq or crosslinking agents that may be uti'ized. .~ar.y of t~.ese have fairly broad application to a variety of resins or resin blends, while others are more specific. In ~he preferred system of the present invention, methylethyl :~etone peroxide (MEXP) is used as the catalyst. The amount of catalyst added to the resin system can vary depending upon a number of factors ` i;
including the speed with which curing is desired, the temperature under which the curing is to occur, etc. In the preferred method, approximately 2% to 4% by ~eight of the catalyst MEKP is added to the polyester resin and thoeoughly ~ -~ `
mixed for curing at a temperature of about 70 to lO0 ~. It is ;; ` -also contemplated that the primary resin could be self curing, . , . , - ~ . ~. .
in which case a catalyst is not needed.
Following the preparation of the resin system or matrix as desoribed above, the veining pigment composition is ` ~ .
~ . ..,:
:. - . -.
- 200Z3~0 .``` '.:`, ~ .
prepared, added to the matrix, mixed slightly, and then poured onto a flat substrate. In accordance with the preferred method, such a substrate comprises a flat sheet of mater al such as plywood, pressed wood or the like. A side edge of limited height for the purpose of restraining the flow of the poured matrix is also provided. It is also contemplated that the substrate can be provided with a release coating or the -like if a sheet of the resulting material is desired.
During the pre~erred method, the veining pigment composition which has been added to the matrix and slightly mixed is poured onto the suSstrate and allowed to flow to the edges where it is retained and allowed to cure. In the preferred method, the resin with added veining pigment can be poured in strips or ~n various other patterns. It is also contemplated that the resin with added ~eining pigment can be poured and subsequently further mixed. It is also contemplated that the resin system can be first poured and then followed by ~ ~
addition of the veining pigment, either with or without ~-subsequent mixing. ~ -The veining pigment composition utilized in the method ;~
of the presen~ invention comprises a conventional pigment . ; ..
component such as titanium dioxide having a specific gravity . ~:
greater than that of the resin system, together with a blooming or floatation agent component ha~ing a specific gravity less than that o~ the resin system. In the preferred method, the .
..
blooming agent is generally immiscible with respect to the -pigment component. It is also preferable for the blooming agent to be compatible with the particular resin system being ;~
utilized. In other words, it is desirable for the ~looming agent to not chemically or physically react with the resin `
system so as to reduce or affect the properties of that .- .
-12~
~.~ , ,.
- Z002350 ~ ~ ~
system. Acceptable blooming agents generally include solvents of the particular resin system being utilized, such as styrene, as well as various compatible oils and unsaturated resins.
: ~:
Surfactants such as detergents are also acceptable.
In the preferred system, the specific blooming agent utilized is a surfactant comprising a soybean oil derivative ; ~ ~ ~
sold by Amway under the trademark LOC and comprises ~ :
approximately 2% to 50% by weight of the veining pigment ;~
composition. When the veining pigment composition is added to the resin system, slightly mixed, poured onto the substrate and allowed to flow to the desired thickness, the veining pigment will disperse within the resin system. The majority of ~he pigment component, which has a specific gravity greater than that of the resin, tends to sink as a resllt of gravity toward the supporting substrate. The rate at which this sinking occurs is primarily dependent upon the viscosity of the resin system. ~''!'':`'~"'~
A minority portion of the pigment componen~ is carr~ed ; , by the blooming agent, which has a spec Cic gravity less ~:~an that of the resin, toward the top surface or away from the ;~
substrate. As some of the pigment is carried upwardly toward the surface by the blooming agent, and as the remainder of the pigment sinks, trails of pigment are left behind, therèby creating three-dimensional patterns in the transparent/ - ~ -u translucent resin system or matrix. This creates the illusion of internal veining within the system. The sinking portion of , th,e pigment tends to form tonal variations in the background : . . . ~ : ,: .
giving the illusion of great depth.
In tha preferred method, the veining pigment ^` i``~ `
composition includes a pigment component in the amount of about ;,~ ,:
50% to 98% by weight, and preferably about 90% to 98% by '`~
: ~ . ,. .: .
-13~
:: ~: .
~`` 2002350 ." . : ::
weight. The piqment component has a specific gravity greater -than that of the resin. T~e veining pigment composition also ~;
includes a blooming agent component in an amount of about 2% to 50% by weiqht, and referably about 2% and 10% by weight, of a material with a specific gravity less than that of the resin.
In the preferred method, the pigment component is comprised of titanium dioxide or various other pigmenes dispersed in a polyester base. These are commercially available as are various other acceptable pigments. The blooming agen~ is comprised o : ;
methylethyl ketone (ME~) or any other resin system solvent, as well as various sur.actants, oils, waxes, paraf~ins and ~ `
unsaturated polyester resi~s ~hich are compa~ible with the -~ `
resin system and have a specific gravity less than tha~ o~ t~.e resin system. The veining pigment composi~:on is combined with the resin matrix at the rate of from trace amounts of pigment :
up to about two grams of pigment per galion of matrix.
: . ~
The amount of blooming agent in the veining pigment composition depends, to some extent, on the desired look of t~.e final product. It aiso depends on the par~icular resin system being utilized and the proper~ies of such resin system. For example, in one resin system, approximately 50% by weight of ~ ~
alumi~a trihydrate or other similar material is added in order ~ .
to induce desired ire retardant properties. Because of the ; -~
introduction of this material, the composition of the veining pigment must be altered and a viscosity reducing agent or plasticizer must be added to the resin sys;em to overcome the --, problems arising from the significantly insreased viscosity. ~ .
This involves addition to the resin system of approximately 3%
to 10% triethylphosphate by weight as a viscosity reducing agent or plasticizer for the purpose of decreasing the viscosity of the system. rt also involves the addition of a sufficient amount of a surfactant or bloc~ing aqent foc the -purpose of assisting in driving the pigments through the resi~
system~ In the particular system in which up to 50~ by weight of alumina trihydrate is added to the resin system, about 3% .o 10% by weight of triethylphosphate or a viscosity reducing agent should be added to the resin system. The veining pigment should also preferably include as much as 50% by weight of a suitable surfactant or blooming agent such as the soybean oil derivative sold by Amway under the trademark LOC. -~
In preparing the veining pigment composition, the pigment component and the blooming agent are thoroughly mixed so that the pigment is dispersed in the blooming agent. Th~s, the relative properties of the blooming agent must be such tha~ `~
a dispersion will result upon such mixing.
Following the pouring of the bler.ced resin matrix and veining pigment, additional accent or vein.ng can be forme~ by preparing a quantity of accent pigment or material and pouring limited amounts in a desired pattern onto the subs.rate.
8ecause the accent pigment, which is compr sed ~rincipally of pigment and a portion of the resin matrix, has a specific gravity greater than that of the resin, it tends to sink and .
.., , . ~ . ~
provides accent or fissure lines in the final product.
I A further modification of the method of the present .
invention involves the utilization of multiple resin systems ~o achieve further design variations and surface textures. At least one of these multiple resin systems should preferably ; ~: --.; .;:
include a veining piqment composition as described above having -a pigment component with a specific gravity greater than that of the such one resin system and a blooming agent component with a specific gravity less than that of said one resin :~
system. It is also contemplated that more than one of the ' '' .` ,~'',' ' ~.
-l5-resin systems in a multiple resin system environment could ~e provided with such a veining composition.
When a multiple resin system is utilized, design variations and different surface textures can ~e achieved by one or more of the ~ollowing techniques. One such technique is to utilize multiple resin sys~ems in which at least two of such resin systems ~.ave different specific gravities. When the resin systems with different specific gravities are partially mixed and poured oneo the substrate, the light resin system (that with the lower speciÇic gravity) tends to move as a result of gravity toward the surface and while doing so, tends to float some of the heavier eesin system (that with a greater specific gravity). This has the effect of creating raised veining and further unique design detail. rhe resulting :
product, when cured, has a terrain-like su.face with a unique ~`
and aesthetically desirable color pattern. The specific .-gravity of the resin systems can be varied by selection of ehe .
resin itself or by using different fillers or different levels of fillers in the respective resin systems. ~ypical fillers , could include, but would not be limited to, calcium carbonate or aluminum trihydrate. Specific gravities of resin systems will typically vary between 1.2 and 1.8. To achieve a desirable effect, the differences in specific gravity between two resin systems should be at least .01 and preferably at least about.05.
A second technique includes varying ~he cure rate of at least two of the resin systems in a multiple resin environment. This varying of the cure rate results in a textured surface which is dependent, to some extent, on the specific cur~ rates of the resins. Since polymers shrink when they cure (typically about 2%), the uneven or different cure rates in the re~pective resins will caus~ distortions in the ;
,. ~. , :
.,....... , ,~ ,... ,, ~' "
z o OZ 3tjO
surface. Such distortions will generally be in registration with the resin systems and their particular color since each resin system has its own cure rate. Typical gel time for a ~ ;~
resin system utilized in the present in~ention is on the order ;~
of about 15 minutes. By mixing a resin system with a lS-minute ~ -gel time with a second resin system having a 25-minute gel ~ ~
time, significant distortion of the surface will occur. When : ~ :
the system is fully cured, a material with a surface texture of a magnitude of as much as 3/32 inch will result. The cure rate of a resin system can be varied in several ways; however, the most common way is to vary the cure rate by adjusting the level ~;
of the catalyst or curing agent in the system. In resin systems of the 2referred method using the catalyst MEK~, the .-amount of catalyst will vary between about 3/4~ and 2% of the resin mixture. Other factors include the ievel of promoter in the resin itself, the level of filler, the ambient temperature and the resin and mold temperature. When resin mixtures of different cu e times are utilized, it is preferable that the cure times be at least a~out 20% different tO achieve a meaningful difference in effect. ' Y:.
,i . :, ~
A third technique for achieving design variations in a .. ;, . , .. ,.:
multiple resin system is to vary the level of thixotropy . . : . -. -between at least two resin systems. This variance of thixotropy affects the flow characteristics of the individual . . . ~ . .
resins while, and after, they are poured. This will not only affect the general migration or movement of the respective ; --resin systems, but will also tend to hold surface distortion in place which has been formed by other techniques such as the variance of curing rates. Resins which have a low thixotropic index will tend to flow out more, thus tending to reduce surface texture variation, while resin systems with a high thixotropic index will tend to stay in place, resulting in .: .
-17 -~
., "
.
` Z002350 enhanced surface variations and textures. The thixotropic properties of a particular resin system can be altered in a manner similar to that described above by the addition of a thixotropic agent agent such as f~1med s lica. Normally, addition of fumed silica up to an amount of about 2% is preferred.
A fourth technique is to vary the viscosity of the resin, independent of the thixotropic properties, through the addition or deletion of various styrenes, plasticizers or other compositions affecting the viscosity of a particular resin system. These viscosity affecting components generally have a ~
small effect on the specific gravity of the system, but can :
have a major effect on the flow c.~aracteristics of the resin. .~ -Such varying flow characteris~ics results in further design variations.
In the multiple resin system, each of the resin systems and its respective veining composition if utilized, is preferably prepared and combined separately, after which the resin systems are combined with slight mixing and subse~ent'y pou~ed onto the substrate. ~; is contemplated, however, .hat the separately prepared resin systems can be separately ~oured onto the substrate and then physically mixed on the substrate itself to create the desired patterns and designs.
It is also contemplated that in a multiple resin system, at least one of the resin systems would preferably include a veining piqment as described above; however, it is -further contemplated that many of the benefits of the present invention and many unique and desirable design variations and surface textures can be achieved by eliminating the described ~ ~
~eining pigment composition, but utilizing one or more of the ~ ~-above described techniques. Thus, it is believed that certain , . .
" 20~2350 desirable designs and surface textures can be achieved whether ~:
or not any of the resin systems includes the specifically -described veining ~igment ccmposition with the described ~ -piqment component and ~loo~ing agent component. `
Having described the ~etails regarding the various -components and compositions utilized in the method of the present invention, the method can be further summarized as follows. First, at least one resin system or matrix is prepared ~ , .. - .
by selecting a primary resin or resin blend and, if needed or `
desired, adding various materials to the primary resin. These ` ~
materials may include a tinting pigment as well as materials - -which affect the ultimate ~roperties of the cured resin or t~.e properties of the resin system or matrix during formation of ::
the product. . ,,~
One of these other materials may nclude a thixotropic .. - . ... .
agent such as ~lmed silica or the like to a~ least one of the ~ -.. . .
resins ~or the ~urpose of controlling the viscosity of the ;~ ~ .
matrix while t~e same ~s bein~ mixed and poured and after it has been allowed to flow to its desired ~hickness. It has been -found that addi-ion of approximately l/4% ~o 3~ by ~eight of fumed silica to the primary resin provides acceptable thixotropic properties. This permits the resin to be easily . . - - :,::
mixed and poured and to flow to a desired thickness, and after ;; ;
~his has occurred, to have a sufficiently increased viscosity to stop the further dispersion of the veining pigment at a . . ~. . - .~
desired point in time.
Another of these materials is a fire retardant;~
component. Preferably, this invol~es addin~ up to 50% by weight of alumina ~rihydrate. When such material is added, the viscosity is signi~lcantly increased to the point where it may be necessary to add viscosity reducing agents or plasticizers .. ,: -, ,: .
-19- ~.:,', ,.
': "' ' .. . .
to the matrix and additional bloominy a~ent and/or surfactants to the veining pigment in order to help drive the pigments through the resin system.
After preparation of the resin system or systems, a veining pigment composition is preferably added to at least one ;- -of the resin systems. In the preferred method, the veining pigment composition includes a pigment component naving a specific gravity less than that of the resin system and comprising about 50~ to 98~ by weight of the composition and a blooming agent having a specific gravity less than that of t~e resin system and comprising about 2% to 50% by weight of the composition. As the ma~rix is poured onto the substrate and allowed to flow to its edges, the ~eining pigment disperses within~the resin system as a result of the heavier pigment component sinking toward the bottom and a ~art of the pigment being carried upwardly toward the surface of the matrix as a result of the blooming agent. This dispersion of the pigment continues until it is stopped as a result of thé increase in viscosity of the matrix due to its thixotropic ~r~perties or curing.
The method of the present invention is further illustrated by the following examples:
Example 1 Simulation of a quartz-like stone surface was formed by preparing a resin matrix utilizing a conventional styrated isophthalic polyester resin as the base resin. T~e particular ;~
base resin utilized had a viscosity at room temperature of -~
about 700 centipoise. To this base resin were added lJ2% by weight of fumed silica as a thixotropic agent, 1/4 gram per ;~
gallon of titanium dioxide as a tinting pigment and 2% by ' .
weight of methylethyl ketone peroxide (MREP) as the catalyst. ~ :~
.' ;''~ ", '~' ';', ~
- 200Z350 ~ , These ingredients were then thorouqhly mixed to produce the .. . :
resin matrix.
A small quan~ity of accent piqment or material was then prepared by adding 20 grams of metal coated mica pigment with 40 grams of the base resin along with 2~ by weight of the ~ ~
catalyst MEKP and thoroughly mixing the same. This mixture was ~ `
.. .. ..
then partially mixed with 200 ml, of the resin matrix, to produce the accent pigment mixture. ` `
The veining pigment composition was then prepared by ;~
thoroughly mixing 95% b~ weight titanium dioxide pigment and 5% -by weight of a surfactant, namely, the soybean oil derivative sold by ~mway Corpora~ion under the trademark LOC This vei~.-r.g pigment composition was partially blended with the resin matrix at the rate of about 1/2 gram of veining F~gment co~position -~
per gallon of resin matrix. The resulting blend was poured .n strips approximately 8 inches to 18 inches wide and allowed eo `~
flow to the side edges of a flat substrate provided with side ~ -edges. Following the pour, limited amounts of the accent .
pigment were used to form accen~ or fissure lines by ?ouring ;~
the same in desired patterns onto the subs~ra.e. The accent ~ i~
pigment, having a greater specific gravity than that of the resin matrix tended to sink to the bottom of the poured resin thereby creating desirable fissure lines. ~
The poured resin mixture was cured at 110F for four ; - ~ `
hours. The final film thickness was 1/8 inch and exhibited highly desirable aesthetic properties. ;A, ". , ~. ' ExamPle 2 `
A simulation of a marble surface was prepared by utilizing a base resin similar to that in Example 1 above and ad~ing 1/2% by w0ight of fumed silica. This resin/fumed silica mixture was divided in two equal parts. Titanium dioxide 21- ~ -: .:
2()02350 .-- , .
pigment ~as added to one part at the rate of 1/4 gram of ~-pigment per gallon of resin and was added to the second part a~
the rate of 2 grams of pigment per ga}lon of resin. Both parts were catalyzed with 2~ by wei~ht MEKP and thoroughly mixed to produce a first and second resin matrix respectively.
An accent piqment material was prepared as in Example 1 above.
A veining pigment composition comprising 95% titanium dioxide and 5% of the surfactant utilized in Example 1 was prepared and added to the first resin matrix at thè rate of 1/2 gram of veining pigment composition per gallon of resin solution and slightly mixed. Equal ~ortions of the fi!st resin ~ -matrix (with added veining pigment composition) and the second ;~
resin matrix were combined, mixed slightly and poured onto a substrate as in Example 1 above. Accent ve ning was also ~ -conducted as in Example 1 above. The resulting poured material was cured at 100 for four hours. The thickness of the resulting product was 1/8 inch and provided an aesthe~ically pleasing, marble-llke surface.
Example 3 A black marble simulation with raised white veining and detailing was prepared by utilizing a combination of two resin systems. A first resin system was prepared by maxing one -part (by weight) transluscent isopthalic polyester resin (SG
1.1) with one part (by weight) alumina trihydrate filler (SG
2.2), resulting in a specific gravity of 1.65. To this resin /;~
mixture was added 1/2% ~lack pigment, 1~4% fumed silica ;
(cabosil), 1% MEXP catalyst and 1~ triethylphosphate (to reduce viscosity). The le~el of catalyzation in the resin as it comes - ;
from the supplier is dependent, to some extent; on the level of ;-;
promoter (~obalt napthalate) in the resin. In the present ,.. ., ~. . , ,~
case, this level is .1%. The level of catalyst, ths ambient --2 2 ! ' ~
:~'' ,,`,' '~"""' " .'''~,',"'' - ZOOX350 :`` ;-temperature, the resin temperature and the temperature of the -~
mold also affect the catalyzation and ultimate cure time. In -~-the present example, ;he above identified mixture had a gel .--~
time of approximately 25 minutes. The gel time for purposes Oc the present invention s the point at which the material is sufficiently cured so that it achieves the consistency of jelly.
A second resin mixture was prepared in a similar fashion by mixing one part (by weight) of transiuscent isopthalic polyester resin with .8 parts alumina trihydrate -~
filler, thus resulting in a specific gravity of about 1.58. To this mixture was added 1/4% titanium dioxide (white piqment), 1~2% fumed silica (cabosil) and 2~ MEKP as the catalyst. This - -~
combina~ion was mixed .n accordance with standard procedure ;
known in the cultured marble industry. T~.e gel time of this second resin mixture was determi~ed to be approximately 15 minutes.
Nine parts (by volume? of the first resin mixture were then combined wit;~ one part (by volume) of t~e second resin mixture, blended ligh:;y and poured onto a level surface or ;~
substrate and allowed to sel~ level to a thickness of ~:
approximately 3/16 of an inch. During the curing process, the white resin mixture tended to rise through the black resin mixture because of its lower specific gravity leaving , "contrails" in the transluscent bl~ck resin. The white veinin~
also tended to draw to~ether on the surface of the poured . . ~ " . .
mixture as a result of a tendency to "kick out of solution"
much like any two liquids with different densities. After ;~
three to four minu~es the white veining tended to diffuse into the black background. This tendency was controlled by the level of ~hixotropy of the white resin which was achieved by addition of the 1/2% fumed silica. In general, a high level of ~:~
thixotropy will ~ive more distinct veïning, while a lower level of thixotropy will give a more diffused and less distinct veining. The raised or textured nature of the white veining could be observed within the first minute after pouring. Aftee 12 to 15 minutes, the white portion reached its gel stage and -began to shrink and float more dramatically on the surface of the black background. At 25 minutes, the black resin mixture ~; ~
reached its gel point. Thereafter, the mold was moved to a ~ -curing oven to be further cured at 110 F for four hours. The resulting material developed an attractive pattern o white veining partially superimposed on and partially dispersed in a black background.
Although .he description of the present invention has been quite specific, it is contemplated that various modifications could be made ~ithout deviat ng from the spirit ;~
thereof. Accordingly, it is intended that -he scope of the pr~sent invention be dictated by the appended claims rather than by the description of the preferred embodiment.
,' '''''`''''`'"''.'''',~ ."'''`' ''''~''~"
' ~' " " ' ' . ~.:".' . ~ '.',',' ''~ `~
-24- , ~
Claims (26)
1. A method of preparing a synthetic surface material simulating stone, marble or the like comprising the steps of:
a. separately preparing at least two resin systems;
b. combining said prepared resin systems;
c. applying the combined resin systems to a substrate; and d. curing the combined resin mixtures.
a. separately preparing at least two resin systems;
b. combining said prepared resin systems;
c. applying the combined resin systems to a substrate; and d. curing the combined resin mixtures.
2. The method of claim 1 including adding a veining pigment composition to at least one of said resin systems in which said veining pigment composition includes a pigment component having a specific gravity greater than the specific gravity of said one resin system and a blocking agent component having a specific gravity less than the specific gravity of said one resin system.
3. The method of claim 2 including adding a second veining pigment composition to a second resin system in which said second veining pigment composition includes a second pigment component having a specific gravity greater than the specific gravity of said second resin system and a second blooming agent component having a specific gravity less than the specific gravity of said second resin system.
4. The method of claim 1 wherein the specific gravities of at least two of said prepared resin systems are different.
5. The method of claim 4 wherein said specific gravities are different by at least about .01.
6. The method of claim 5 wherein said specific gravities are different by at least about .05.
7. The method of claim 1 wherein the thixotropic indices of at least two of said prepared resin systems are different.
8. The method of claim 7 including adding a thixotropic agent to at least one of said resin systems.
9. The method of claim 1 wherein the cure rates of said two of said resin systems are different.
10. The method of claim 1 wherein the cure rates of at least two of said resin systems are different.
11. The method of claim 9 wherein said cure rates are at least about 20% different from one another.
12. The method of claim 1 wherein the viscosity of at least two of said resin systems is different.
13. The method of claim 2 wherein the specific gravities of at least two of said prepared resin systems are different.
14. The method of claim 2 wherein the thixotropic indices of at least two of said prepared resin systems are different.
15. The method of claim 2 wherein the cure rates of at least two of said resin systems are different.
16. A method of preparing a synthetic surface material simulating stone, marble or the like comprising the steps of:
a. preparing at least one resin system;
b. adding a veining pigment composition to said one resin system in which said veining pigment composition includes a pigment component having a specific gravity greater than the specific gravity of said one resin system and a blooming agent component having a specific gravity less than the specific gravity of said one resin system;
c. applying the combined resin system and veining pigment composition to a substrate; and d. curing the combined resin system and veining pigment composition.
a. preparing at least one resin system;
b. adding a veining pigment composition to said one resin system in which said veining pigment composition includes a pigment component having a specific gravity greater than the specific gravity of said one resin system and a blooming agent component having a specific gravity less than the specific gravity of said one resin system;
c. applying the combined resin system and veining pigment composition to a substrate; and d. curing the combined resin system and veining pigment composition.
17. The method of claim 16 wherein said veining pigment composition includes about 50% to 98% by weight of said pigment component and about 2% to 50% by weight of said blooming agent component and wherein said pigment component and said blooming agent component are immiscible with respect to the other.
18. The method of claim 16 wherein said step of preparing said resin system includes the addition of a thixotropic agent for the purpose of controlling the dispersion of the veining pigment composition.
19. The method of claim 18 wherein the addition of said thoxotropic agent is effective to provide said resin matrix with a first viscosity when said resin matrix is being mixed and poured and a second viscosity when said resin matrix is substantially at rest, said first viscosity being sufficiently low to permit said resin matrix to be easily mixed and poured and said second viscosity being sufficiently high to stop the dispersion of veining pigment within about 15 seconds to S
minutes after said resin matrix is substantially at rest.
minutes after said resin matrix is substantially at rest.
20. The method of claim 19 wherein the addition of said thixotropic agent is sufficient to provide said resin matrix with a first viscosity of less than about 1200 centipoise and a second viscosity greater than about 1200 centipoise.
21. The method of claim 20 wherein said first viscosity is less than about 1000 centipoise and said second viscosity is greater than about 2000 centipoise.
22. A method of preparing a synthetic surface material simulating stone, marble or the like comprising the steps of:
a. preparing a resin matrix which includes adding a thixotropic agent for the purpose of controlling the dispersion of veining pigment composition, said thixotropic agent being effective to provide said resin matrix with a first viscosity when said resin matrix is being mixed and poured and a second viscosity when said resin matrix is substantially at rest, said first viscosity being sufficiently low to permit said resin matrix to be veining pigment within about 15 seconds to 5 minutes after said resin matrix is substantially at rest;
b. adding a veining pigment composition to said resin matrix; and c. applying the mixture of said resin matrix and veining pigment composition to a substrate.
a. preparing a resin matrix which includes adding a thixotropic agent for the purpose of controlling the dispersion of veining pigment composition, said thixotropic agent being effective to provide said resin matrix with a first viscosity when said resin matrix is being mixed and poured and a second viscosity when said resin matrix is substantially at rest, said first viscosity being sufficiently low to permit said resin matrix to be veining pigment within about 15 seconds to 5 minutes after said resin matrix is substantially at rest;
b. adding a veining pigment composition to said resin matrix; and c. applying the mixture of said resin matrix and veining pigment composition to a substrate.
23. The method of claim 22 wherein said thixotropic agent comprises fumed silica.
24. The method of claim 23 wherein said fumed silica is present in said resin matrix in the amount of between about 1/4% to 3% by weight.
25. The method of claim 24 wherein the addition of said thixotropic agent is sufficient to provide said resin matrix with a first viscosity of less than about 1200 centipoise and a second viscosity greater than about 1200 centipoise.
26. The method of claim 25 wherein said first viscosity is less than about 1000 centipoise and said second viscosity is greater than about 2000 centipoise.
Applications Claiming Priority (4)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US268,555 | 1981-06-01 | ||
| US07/268,555 US5055324A (en) | 1988-11-08 | 1988-11-08 | Method of forming a synthetic surface simulating stone, marble or the like |
| US42729189A | 1989-10-26 | 1989-10-26 | |
| US427,291 | 1989-10-26 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2002350A1 true CA2002350A1 (en) | 1990-05-08 |
Family
ID=26953171
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA 2002350 Abandoned CA2002350A1 (en) | 1988-11-08 | 1989-11-02 | Method of forming a synthetic surface simulating stone, marble or the like |
Country Status (3)
| Country | Link |
|---|---|
| EP (1) | EP0368294A3 (en) |
| JP (1) | JPH02218743A (en) |
| CA (1) | CA2002350A1 (en) |
Families Citing this family (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| FR2670158A1 (en) * | 1990-12-11 | 1992-06-12 | Euro Creation | Process for decorating substrates of any kind or shape |
| JPH0818377B2 (en) * | 1991-09-13 | 1996-02-28 | 株式会社ホリカワ | Synthetic resin decorative component for eyeglass frame and method for manufacturing the same |
| US5166230A (en) * | 1991-09-16 | 1992-11-24 | Stecker William M | Method for producing a synthetic shaped article simulating marble, granite or the like |
| DE29500706U1 (en) * | 1995-01-18 | 1995-03-30 | Coelan Chemie Produktionsgesel | Coating material with embedded particles |
| FR2866601B1 (en) * | 2004-02-24 | 2006-10-27 | Dominique Bardoul | PROCESS FOR COATING A SURFACE OF ANY FORM, OF ONE OR MORE LAYERS OF SYNTHETIC MATERIALS FOR PERMITTING THE REPRESENTATION OF OBJECTS MIMITATING A MATERIAL SUCH AS STONE, METAL |
Family Cites Families (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US3071487A (en) * | 1959-06-10 | 1963-01-01 | John G Jenne | Method for producing decorative surface coverings |
| GB1076167A (en) * | 1963-05-21 | 1967-07-19 | Mecmax Ltd | Improvements in and relating to the manufacture of artificial materials |
| FR2124711A5 (en) * | 1972-01-06 | 1972-09-22 | Cazenave Andre | Translucent artificial stone coating - formed from eg resin bonded marble chippings |
| JPS5721448B2 (en) * | 1974-03-13 | 1982-05-07 | ||
| JPS5843246B2 (en) * | 1976-05-04 | 1983-09-26 | 株式会社日本触媒 | Manufacturing method of artificial marble products |
-
1989
- 1989-11-02 CA CA 2002350 patent/CA2002350A1/en not_active Abandoned
- 1989-11-08 JP JP29095689A patent/JPH02218743A/en active Pending
- 1989-11-08 EP EP19890120728 patent/EP0368294A3/en not_active Withdrawn
Also Published As
| Publication number | Publication date |
|---|---|
| EP0368294A2 (en) | 1990-05-16 |
| JPH02218743A (en) | 1990-08-31 |
| EP0368294A3 (en) | 1991-01-23 |
Similar Documents
| Publication | Publication Date | Title |
|---|---|---|
| US5055324A (en) | Method of forming a synthetic surface simulating stone, marble or the like | |
| EP0616620B1 (en) | Granite-like coating | |
| CA1198256A (en) | Reinforced plastic product | |
| US5476895A (en) | Granite-like coating | |
| US7544317B2 (en) | Synthetic solid surface material and method | |
| US3230284A (en) | One-coat marbleizing process | |
| EP0578829B1 (en) | Laminated body | |
| JPH06509035A (en) | Cosmetic surface layer composition | |
| CA2002350A1 (en) | Method of forming a synthetic surface simulating stone, marble or the like | |
| JP2020163854A (en) | Face material | |
| KR102130349B1 (en) | Method for manufacturing building interior material and building interior material | |
| KR100414676B1 (en) | Method for preparing artificial marble having crack pattern | |
| GB2233640A (en) | Mineral composition | |
| CA2567946A1 (en) | Building material for forming an architectural surface covering and method for producing the same | |
| AU672755C (en) | Granite-like coating | |
| US11753539B2 (en) | Simulated marble slab and process | |
| US20020137411A1 (en) | Method for forming coating with embedded particles | |
| US6011101A (en) | Cast marble objects having superior depth characteristics and color separation and methods for making the same | |
| CA2420294A1 (en) | Composite materials with bulk decorative features and process for producing same | |
| JP3361888B2 (en) | Manufacturing method of uneven decorative board | |
| JPS6220894B2 (en) | ||
| KR950006069B1 (en) | Process for the preparation of vinyl floor sheet | |
| JP2999628B2 (en) | Plastic decorative sheet | |
| JPH09131801A (en) | Colored gel coat for molding of grain and artificial stone with grain tone | |
| JP2020163853A (en) | Face material |
Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| FZDE | Dead |