JPH02218743A - Method for forming synthetic surface in imation of stone, marble,etc. - Google Patents

Abstract

PURPOSE: To provide a method for forming a synthetic surface imitated on stone, marble or the like by applying a combination of two or more resin systems contg. a pigment component and a blooming agent and different from each other in specific gravity and thixotropic index to a substrate and curing the applied resin system.

CONSTITUTION: To at least one resin system are added a patterning pigment compsn. comprising 50 to 98 wt.% (hereinafter referred to as '%') pigment component having a larger specific gravity than the resin system and 2 to 50% blooming component having a smaller specific gravity than the resin system. Separately, to at least one resin system is added a thixotropic agent. Thus, at least two resin systems different in each other in specific gravity, thixotropic index, curing rate, and viscosity are separately prepared. The resin systems are combined. The combined resin system is applied on a substrate, and the applied resin system is cured to form a synthetic surface imitated on stone, marble or the like.

COPYRIGHT: (C)1990,JPO

Description

[Detailed Description of the Invention] Field of the Invention The present invention relates to - In terms of boat fishing, marble, stone, agate,
A method for forming synthetic surface materials imitating various natural materials such as agate, jade, stone, etc. More specifically, a method for creating synthetic materials imitating natural materials using unique pigments and resin systems. ,
Relating to a method of manufacturing.

BACKGROUND OF THE INVENTION Various methods of forming synthetic materials and surfaces that have the appearance or imitation of various natural materials, such as stone and marble, currently exist. Such materials are commonly used in the manufacture of flooring and various other types of tiles, countertops, sink materials, architectural surfacing materials, decorative objects, and - in the manufacture of other materials such as marble and stone. used for a purpose.

To give an example, the trade name φFORMICA
) There is a method using a laminated sheet material commercially available.

This sheet material is formed as a large sheet that is cut and applied to the desired surface with an adhesive or the like.

These sheets are solid color or internal color (golidc).
olor) or in various patterns, some of which resemble various stones or textured materials.

Another example is 1 embedded artificial marble (cslt%red
This is a method of manufacturing a material commonly referred to as "ma de baa".

1. Embedded artificial marble" is formed by first making a mold with the desired shape, spraying the inner surface of the mold with a gel coat, and then filling the mold with a conventional casting resin.

Pigments are added to the resin to give it the desired color or pattern. When the mold is removed after the resin has cured, the surface facing the mold becomes the outer surface of the finished product.

(-a x A a Iverso * (E, M, Iverso)
Yet another method is described in U.S. Pat. In the method described in this patent specification, a base support is coated with a resin material, and then colored pigments are sprinkled thereon. The resin material and colored pigment are then covered with a transparent coating, and a tool is moved transversely through the system to dispense the pigment.

Although many of the traditional methods of creating synthetic surfaces that mimic stone, marble, etc. are generally acceptable, new and more desirable or preferable patterns and patterns that more closely resemble various natural materials, e.g. Therefore, there continues to be a need and a desire to improve currently known methods.

SUMMARY OF THE INVENTION According to the method of the present invention, a synthetic surface is prepared by preparing a resin system, i.e., a resin matrix, adding a veining pigment composition containing a blooming agent, i.e., a vehicle, and applying it to a flat surface. Formed by pouring onto a support. According to the present invention, aesthetic properties and surface texture can be improved by using a plurality of resin systems and by varying the specific gravity and thixotropic or flow properties of the resin systems, and by varying the curing rate of the resin systems. It is also possible to create further variations.

Materials made by the method of the present invention exhibit a number of desirable aesthetic and physical properties not previously available.

These materials formed according to the present invention more closely resemble rocks, marble, etc., and at the same time are highly desirable.
and provides a surface that is extremely durable, repairable, and resistant to relatively high heat.

This desirable aesthetic property of the materials formed by the method of the present invention is created by the use of unique striped pigment systems or compositions in conjunction with unique resin systems. The striped pigment composition used in the method of the present invention comprises a pigment component having a specific gravity greater than the specific gravity of the resin system and a blooming agent or the same component having a specific gravity less than the specific gravity of the resin system.

When such pigment compositions are incorporated into resin systems or resin matrices, the blooming agents tend to rise to the surface with small amounts of pigment components. During this migration towards the surface of the blooming agent, a small amount of pigment is dropped and a teal of pigment is created in the resin. This phenomenon in which a portion of the pigment is carried toward the surface is referred to as blooming in the present invention.
The pigment part that is not carried to the surface by the blooming agent tends to sink to the bottom because its specific gravity is greater than that of the resin system.

The extent to which the blooming process occurs and the pigment sinks to the bottom of the resin system depends in large part on the viscosity of the resin system. As part of the present invention, the inventors have discovered that certain desired patterns and effects can be produced by varying the chickentropy of the resin system. Thixotropy is the property of a fluid that causes its viscosity to change as a function of its state of agitation and the history of previous motion within the fluid.

- In conclusion, the viscosity of a thixotropic fluid decreases as its agitation condition and length of agitation time increase;
and increases as the stirring state and length of stirring time decrease. Thixotropic resin systems can be mixed and therefore relatively easily poured. After pouring and in a relatively unstirred state,
Resin systems exhibit fairly high viscosities. This increased viscosity retards or limits pigment migration or dispersion (both blooming, immediate rise and settling) within the resin system, thus controlling pigment migration and dispersion and inhibiting such migration or dispersion. It is possible to stop and fix at a desired point.

This preferred method contemplates the preparation of the resin system, the addition of the pigment for striping and light mixing, followed by pouring the mixture onto the support.

However, the pigment composition can also be added after the resin system has been poured, in which case the pigment will settle and disperse naturally or as a result of mixing by tools or other means, so this aspect also applies. It is also contemplated by the method of the invention that various additional stripes can be added by using highlighting pigments to create a fissured appearance, etc. in the product, which is also contemplated by the invention. It is planned in this way.

Modifications to this preferred method also contemplate the use of multiple resin systems and correspondingly multiple striped compositions to create varying designs and different surface textures.

When using multiple resin systems, it is preferable to mix the second resin system and then add it to the support. Therefore, this method is also included in the present invention.

Another improvement using multiple resin systems is to use multiple resin systems with different specific gravities. Thus, when two resin systems are combined before pouring onto a support, each resin system tends to migrate and move relative to the other under gravity as it cures as they flow onto the support. Because of this, unique patterns and effects can be obtained. When using a plurality of resin systems, a striped pigment containing at least one of the resin systems, a pigment component having a specific gravity greater than the specific gravity of the resin system, and a blooming agent or the same component having a specific gravity smaller than the specific gravity of the resin system. Embodiments in which they are combined with compositions are also included in the present invention.

Yet another modification of multi-resin systems is to vary the cure time of each resin, for example by using different pre-cure or cure catalysts. As each resin cures at different rates, the surface develops wrinkles and pond distortions that lead to a more unique and attractive design and surface texture.

Varying the thixotropic and flow properties of each resin system also makes it possible to create variations in design.

Accordingly, one object of the present invention is to provide a method for forming synthetic surfaces such as simulated stone, marble, etc.

Another object of the present invention is to provide a method for forming synthetic surfaces that results in a more similar and/or unique or more desirable pattern to surfaces such as stone, marble, etc.

Yet another object of the present invention is to imitate stone, marble, etc. using a unique pigment composition comprising a pigment component having a specific gravity greater than the specific gravity of the resin system and a blooming agent component having a specific gravity less than the specific gravity of the resin. The object of the present invention is to provide a method for creating a synthetic surface that has a unique structure.

It is another object of the present invention to provide synthetic surfaces that mimic stone, marble, etc., forming and creating unique patterns by controlling the thixotropic properties of resin systems, either separately or in combination with unique pigment compositions. The present invention is to provide a method for forming.

Yet another object of the present invention is to use a plurality of resin systems, at least one of which is combined with a pigment composition for producing a unique striped pattern as described, to create a synthetic surface that mimics stone, marble, etc. The objective is to provide a method for forming

Yet another object of the present invention is to create a composite surface that further includes design variations and surface textures unique to the plurality of resin systems by varying the specific gravity, cure time, and/or thixotropic or flow properties of each of the plurality of resin systems. There are four ways to help.

These and other objects of the invention will become apparent upon reference to the description of the preferred method and the appended claims.

DESCRIPTION OF THE PREFERRED METHODS The present invention generally relates to a method for forming synthetic surfaces that mimic the appearance of stone, marble, and various other naturally occurring materials.

The methods of the present invention include forming at least a resin system or resin matrix, adding a striped composition to at least one of the resin systems, and applying the mixed system to a support. This includes the step of Throughout the specification and claims of this application, unless indicated otherwise, percentages and ratios are by weight and temperatures are in degrees Fahrenheit.

In a preferred method, the steps of preparing the resin system include selecting a base or principal resin, adding pigments for coloring (if desired), and modifying the properties of the product or resin system during its formation process during curing. sub-steps of adding fillers or other substances to control the next,
Add curing agent or curing catalyst and mix all ingredients thoroughly.

A preferred method of the present invention uses as the primary or base resin an inftal cast resin, which is a conventional transparent or translucent polyester. Resins or resin blends of this type are available from a variety of sources and are generally known in the art. Suitable polyester resins are those made from polymerizable unsaturated polyesters, such as those made from ethylenically unsaturated polycarboxylic acids and polyhydric alcohols. Preferably, the primary resin provides desirable heat, chemical, and moisture resistance when fully cured. A preferred polyester cast resin is a styrenated inphthalic acid cast resin.

Although the preferred resin system consists of inophthalic polyester resins, ortho-7-thalic acid polyester cast resins can be used as well and are therefore also contemplated by the present invention.

Resins of various capacities can also be used and their use is also contemplated by this invention. Other polymeric resins that can be used include methyl methacrylate resin systems and epoxy resin systems. Furthermore, the primary resin can also consist of a blend or mixture of different resin components, provided that the resin components are compatible with each other.

The preparation process of the resin system or resin matrix also involves the use of pigments, fillers, etc. to give the material a background color and to impart certain properties and characteristics to the resin system during its formation and after curing. and/or the possible sub-steps of adding other ingredients. For example, if a certain shade or color is desired, any combination of titanium dioxide or other pigments may be used.
Suitable pigments such as seeds can be added. Certain materials may also be added for such purposes to reduce the coefficient of thermal expansion of the cured system or to provide the cured system with various other desired properties.

In one embodiment of the invention it is contemplated to add a flame retardant filler such as alumina trihydrate to impart flame retardancy to the final product. Although alumina trihydrate is preferred,
Other possible compositions are also effective in achieving the same purpose. If flame retardancy is desired in the final product formed according to the present invention, up to 50% by weight, preferably about 30-50% by weight -
It has been found that it is advantageous to add 50% of alumina trihydrate to the main resin. As will be discussed in more detail below, striped pigment compositions may be prepared by the addition of certain fillers, such as alumina trihydrate, or such pigments may be precipitated according to the present invention and Addition of viscosity reducers or plasticizers for blooming is improved.

In order to further control the dispersion of the striped pigments, the resin system may also contain certain components that control the viscosity and/or thixotropy of the resin system; In this regard, one aspect of the present invention is the use of resin-based tiki/) lobby fumed silica (lsma).
control by the addition of thixotropic agents such as d5ilicα). The addition of such chickentrol agents results in a resin system with thixotropic properties in which the viscosity of the resin system generally varies inversely as a function of its agitation conditions. In other words, the viscosity of the resin system decreases as it is stirred, and the viscosity increases as the stirring condition becomes calmer. These thixotropic properties allow the mixing and pouring of resin systems or resin matrices, and control the initial viscosity to flow to the desired thickness and then the dispersion of the pigment for striping, and finally stop. Provides a resin system or resin matrix with a second viscosity that allows for

In a preferred method of the invention, the resin-based trap object (')?
-+/) A small amount of fumed silica is added to the resin base to provide rope properties. The thixotropic nature of the resin system or matrix can be improved during slight agitation (i.e.
(during mixing and pouring) to provide a sufficiently low viscosity so that the system can be easily mixed and poured, and flowed onto the support to the desired film thickness. It is preferable that The desired film thickness is generally about 1-15 mm, preferably about 2-4 mm.

The viscosity during mixing, pouring and flowing of the matrix is approximately 120
Desirably, it is less than 0 centipoise, or about 800 to 1200 centipoise, preferably less than about 1000 centipoise, or about 8oo to 1000 centipoise.

The favorable thixotropic nature of the resin system also allows the matrix to flow to the desired thickness and, once it has become approximately stationary, to increase the viscosity sufficiently to permit further dispersion of the pigment for striping at the desired time after this state is reached. to stop. Preferably, dispersion of the striped pigment is stopped within about 5 seconds to 5 minutes after the matrix has flowed to the desired film thickness. about 1200 centipoise or more, i.e. about 1200 to 6000 centipoise, preferably about 20
A viscosity of 0.00 centipoise or higher, or about 2000 to 3000 centipoise, is desirable to accomplish this purpose. In a preferred system, about 2-4% by weight fumed silica is added to the base resin to establish the desired degree of chickentropy.

Following the addition of pigments, fillers and other materials for coloring, the base resin is thoroughly mixed.

Preparation of the resin system also includes the substep of adding a curing agent or curing catalyst that initiates the desired crosslinking and cures the resin.

Of course, a wide variety of catalysts or curing agents or crosslinking agents exist and can be used. Many of these apply quite broadly to various resins or resin blends, while others are more specific.

In a preferred system of the invention, methyl ethyl ketone peroxide (MEKP) is used as the catalyst. The amount of catalyst added to the resin system can vary depending on a number of factors, including the desired rate of cure, the temperature at which cure is to occur, and the like. In a preferred method, about 2-4% by weight of the catalyst MEKP is added to the polyester resin and mixed thoroughly at a temperature of about 21-38°C (below about 70-100°C) for curing. The primary resin can be self-curing and is also included in the present invention. In this case no catalyst is required.

Following IJ sock preparation, the striped coating composition is prepared, added to the matrix, mixed slightly, and then poured onto the flat support. According to a preferred method, such a support is made of plywood, pressed wood.
) etc. consists of 5 flat sheet materials. Side edges of limited height are also provided to stop the flow of the injected matrix. If a sheet of the resulting material is desired, the support can be provided with a release coating and therefore this embodiment is also included in the invention.

During the practice of the preferred method, the IJ socked and slightly mixed striped pigment composition is poured onto the support, allowed to flow to the side edges, where it is retained and cured. In a preferred method, the resin with added striped pigments can be applied in strips or in various other patterns. For striping, pigments may be added and the resins contained may be further mixed following addition, and this is also encompassed by the present invention. Also,
It is also possible to add the resin system first and then add the striped pigment, and this embodiment is also encompassed by the invention. In this case, subsequent mixing may or may not be performed.

The striped pigment composition used in the method of the present invention contains a normal pigment component such as titanium dioxide, which has a specific gravity greater than that of the resin system, and a blooming agent component, that is, a flotation agent, which has a specific gravity less than that of the resin system. (floatattos
agast) components. In a preferred method, the blooming agent is generally immiscible with the pigment component. It is also preferred that the blooming agent be compatible with the particular resin system being used. In other words, it is desirable that the blooming agent not react chemically or physically with the resin in such a way as to degrade or affect the properties of the resin system. Acceptable blooming agents generally include solvents such as styrene and various compatible oils and unsaturated resins for the particular resin system being used. Surfactants such as detergents are also acceptable.

In a preferred system, the particular blooming agent used is a surfactant containing a soybean oil derivative sold by Amwav under the trade name LOC, and the striping is about 10% of the pigment composition. It accounts for 2 to 50% by weight. For the striped pattern, the pigment composition is added to the resin system,
When mixed slightly, poured onto the support, and flowed to the desired thickness, the striped pigments are dispersed within the resin system. Most of the pigment components with specific gravity greater than the specific gravity of the resin tend to settle towards the support due to gravity. The rate at which this settling occurs depends primarily on the viscosity of the resin system.

A small portion of the pigment component is carried towards the top surface, ie, away from the support, by the blooming agent, which has a specific gravity less than that of the resin. As some of the pigment is thus carried upwards towards the surface by the blooming agent, and as the rest of the pigment settles out, a trailing pattern of pigment is left behind and the transparent 8A/translucent resin system, i.e. the same resin matrix, is left behind. A three-dimensional pattern is created inside. This creates the illusion of an inner stripe within the system. Pigment settling tends to cause tonal changes in the background giving the illusion of great depth.

In a preferred method, the striped pigment composition contains from about 50 to 98% by weight of the pigment component, preferably from about 90 to 98% by weight.
Contains in an amount of % by weight. The pigment component has a specific gravity greater than that of the resin. The striped pigment composition also includes a blooming agent component consisting of a substance having a specific gravity less than that of the resin in an amount of about 2 to 50% by weight, preferably about 2 to 10% by weight.

In a preferred method, the pigment component consists of titanium dioxide or other pigments and is dispersed in a polyester base. These pigments are commercially available, as are a variety of other acceptable pigments. The blooming agent consists of methyl ethyl ketone (MEK) or any other solvent for the resin system;
It can also be composed of various surfactants, oils, waxes, paraffins, and unsaturated polyester resins that are compatible with the resin system and have a specific gravity lower than that of the resin system. The striped pigment composition is combined with the resin matrix at a rate of trace amounts of pigment up to about 21 parts pigment per gallon of resin matrix.

The amount of blooming agent in the striped pigment composition depends in part on the desired appearance of the final product. It also depends on the particular resin system used and its properties. For example, in one resin system, about 50 M% alumina trihydrate or other material is added to provide the desired flame retardancy.

Because of the introduction of this substance, the composition of the pigment used for striping must be changed and viscosity reducers or plasticizers added to the resin system to overcome the problems caused by the considerable increase in viscosity. must be added. This involves the addition of about 3-10% by weight of triethylene phosphate as a viscosity reducer or plasticizer to the resin system to reduce the viscosity of the system.It is also sufficient to help push the pigment through the resin system. It involves adding a suitable amount of a surfactant, i.e. a blooming agent. In certain systems where up to 50% by weight alumina trihydrate is added to the resin system, about 3 to 10 f.
ii% triethyl phosphate or viscosity reducing agent should be added to the resin system. The striped pigment should also preferably contain as much as 50% by weight of a suitable surfactant, ie, blooming, such as a soybean oil derivative sold by Amway under the trademark LOCK.

When preparing the striped pigment composition, the pigment component and blooming agent are thoroughly mixed so that the pigment is dispersed in the blooming agent. Therefore, the relative nature of the blooming agent must be such that upon such mixing, dispersion takes place.

Following the application of the blended resin matrix and the striping pigment, further enhancement can be achieved by preparing an amount of the highlighting pigment or the same material and applying a limited amount to the support in the desired pattern. A striped pattern or a striped pattern can be formed. Highlighting pigments, which are primarily composed of pigment and part of a resin matrix, have a higher specific gravity than the resin and therefore tend to settle and give highlighted or crack lines in the final product.

A further refinement of the method of the present invention is the use of multiple resin systems, allowing for a greater variety of designs and surface textures. At least one of the plurality of resin systems preferably comprises a striped coating composition as described above, comprising a pigment component having a specific gravity greater than the specific gravity thereof and a blooming agent component having a specific gravity less than the specific gravity of the resin system. Should. It is also possible to provide such striped compositions in more than one of the resin systems in a multi-resin environment and is within the scope of this invention.

When using multiple resin systems, design variations and different surface textures can be achieved by one or more of the following methods. One such method is to use a plurality of resin systems, at least two of which have different specific gravities. Different ratios! When resin systems with a This tends to cause some of the heavier resin system (resin system with higher specific gravity) to float during the movement. This has the effect of creating raised stripes and more unique design details. The resulting product has a topography-like surface with a unique and aesthetically desirable color pattern when cured. The specific gravity of the resin system can be varied by selection of the resin itself or by using different fillers or different levels of filler in each resin system.

Typical fillers include, but are not limited to, calcium carbonate or alumina trihydrate. The specific gravity of the resin system varies in part between 1.2 and 1.8. To achieve the desired effect, the difference in specific gravity between the two resin systems should be at least 0.
．． 0.01, preferably at least about 0.05.

A second method involves varying the cure rate of at least two of the resin systems in a multi-resin environment. Varying the cure rate produces a textured or patterned surface, depending in part on the particular cure rate of the resin. Since the polymer shrinks (typically about 2%) as the resin system cures, uneven or different curing rates of each resin cause surface distortion. Such distortions are unique to each resin and their specific color because each resin system has its own cure rate. Typical gel times for the resin systems used in the present invention are on the order of about 15 minutes. Mixing a resin system with a gel time of 15 minutes and a resin system with a gel time of 25 minutes results in significant surface distortion.

When the system is fully cured, a material with a texture as large as A inch is obtained. The cure rate of a resin system can be varied in several ways, but the most common method is to vary the cure rate by adjusting the level of catalyst or curing agent in the system. M as a catalyst
For the resin systems of the preferred process using EKP, the amount of catalyst varies between about 1 and 2% based on the resin mixture. Other factors include accelerator levels within the resin itself, filler levels,
There is a return temperature and a resin and mold temperature. When using resin mixtures with different cure rates, it is preferred that the cure times differ by at least about 20% to achieve a significant difference in performance.

A third way to achieve various design variations in a multi-resin system is to vary the chickentropy level between at least two resins. This variation in chickentropy affects the flow characteristics of the individual resin during and after the resin system is poured. This not only affects the general migration or movement of the respective resins, but also tends to hold in place surface distortions formed in other ways, such as variations in cure rate. Resins with a low thixotropic index tend to bleed more (and thus cause less change in surface texture), whereas resins with a higher thixotropic index tend to stay in place and cause more surface change. and provides texture.

The thixotropic properties of a particular resin system can be altered in a manner similar to that described above by the addition of thixotropic agents such as fumed silica. Typically, additions of up to about 2% fumed silica are preferred.

A fourth method is to vary the viscosity of the resin without regard to thixotropy by the addition or omission of various styrenes, plasticizers, or other compositions that affect the viscosity of a particular resin system. These viscosity-influencing components have a small effect on the specific gravity of the system, but have a large effect on the flow characteristics of the resin.

By changing the flow characteristics in this way, further variations in design can be obtained.

In multi-resin systems, each of the resin systems and their respective striping compositions, if used, are preferably prepared and combined separately, and then the resin systems are combined with gentle mixing, followed by support. Inject into the body. However, separately prepared resins can also be separately poured onto the support and then physically mixed on the support to create the desired patterns and designs, and this is also contemplated by the present invention. .

Also, in a multi-resin system, at least one of the resin systems preferably includes a striped pigment as described above, which is also contemplated by the present invention. However, many of the advantages of the present invention, and many unique and desirable design variations and surface textures, can be achieved using one or more of the aforementioned methods. This can also be achieved by, and is also contemplated by the present invention.
Certain desirable designs and surface textures may be achieved regardless of whether any of the resin systems contain the previously described striped pigment compositions having the previously described pigment components and blooming agent components. It is thought that this can be done.

The details of the various components and compositions used in the method of the present invention have been explained above, but this method can be further elaborated as follows.
Can be summarized. First, at least one resin system, or resin matrix, is prepared by selecting a primary resin or resin blend and adding various materials to the primary resin if necessary or desired. These substances include color-setting pigments and substances that influence the final properties of the cured resin or the properties of the resin system, ie, the resin matrix, during product formation.

One of these other substances may be added to at least one of the resins to control the viscosity of the resin matrix during mixing and pouring and after the resin matrix has been flowed to the desired thickness. There are thixotropic agents such as fumed silica etc. added.
It has been found that the addition of ˜3% by weight of turmeric and lyca to the main resin provides acceptable thixotropy. This allows the resin to be easily mixed, poured and flowed to the desired thickness, and after this has occurred the resin has a viscosity sufficiently increased that that of the pigment used for the striped patterning. This makes it possible to stop the above dispersion at a desired time.

Another example of these materials is flame retardant components.

Preferably, this involves the addition of up to 50% by weight of alumina trihydrate, since the addition of such a material increases the viscosity considerably and thus helps push the pigment into the resin system. It may be necessary to add viscosity reducing agents to the resin matrix and additional blooming agents and/or surfactants to the striped pigments.

After preparation of the resin system or resin systems, the striped pigment composition is preferably added to at least one of the resin systems. In a preferred method, the striped pigment composition has a specific gravity that is greater than the specific gravity of the resin system and has a specific gravity that is less than the specific gravity of the pigment component and the resin system that constitute about 50 to 98% by weight of the composition; and a blooming agent comprising about 2-50% by weight of the composition. As the matrix is poured onto the support and flows towards its edges, the heavier pigment components settle towards the bottom and some of the pigment is absorbed by the blooming agent. This dispersion of the pigment continues until it ceases as a result of an increase in the viscosity of the matrix due to the thixotropic nature or hardening of the matrix.

The method of the invention is further illustrated in the following examples.

Example 1 A quartz-like stone surface was structured and formed by preparing a resin matrix using a commonly used isophthalic acid*polyester resin as the base resin.

The viscosity of the particular base resin used was approximately 700 centipoise at room temperature. This base resin contains %wt % fumed silica as a thixotropic agent, % titanium dioxide as a color v4v4 cosmetic pigment, and methyl ethyl ketone peroxide (M
EKP) 2% by weight was added. These components were then thoroughly mixed to form a resin matrix.

Next, the metal-coated mica pigment is applied to the base resin 40? A small amount of highlighting pigment or material was prepared by adding 2% by weight of MEKP as catalyst and mixing thoroughly. This mixture was then partially mixed with a resin matrix of 200 yxl to produce a highlighting pigment mixture.

The striped pigment composition is then prepared by thoroughly mixing 95% by weight of titanium dioxide pigment and 5% by weight of a surfactant, a soybean oil derivative sold by Amway under the trade name ROCK. Prepared. The striped pigment composition was blended with a resin matrix in a ratio of approximately 1.2 P-L striped pigment composition/3.78537 (1 gallon) - resin matrix. The resulting blend was poured into a flat support with side edges in strips about 8-18 inches wide and allowed to flow up to the side edges. Following pouring, a limited amount of fore-enhancing pigment was used to form the highlight or crack lines by pouring it onto the support in the desired pattern. The highlighting pigment had a specific gravity greater than that of the resin matrix and therefore tended to settle to the bottom of the poured resin, thus creating the desired crack lines.

. The poured resin mixture was cured at 43°G (below 110) for 4 hours. The final film had a thickness of 3.21 inches and exhibited very desirable aesthetic properties.

Example 2゜Using the same base resin as the base resin of Example 10,
A marble surface replica was then prepared by adding % by weight of humid silica.

That is, this resin/fumed silica mixture was divided into two equal parts. Titanium dioxide in one part - grams of pigment/3.7
851/(1 gallon)-resin and to a second portion the same pigment was added at a ratio of 2f-pigment/3.7853 J (I gallon)-resin.

The two parts were catalyzed with 2% by weight MEKP and mixed thoroughly to produce the first and second resin polymers.

The highlighting pigment was prepared as in Example 10 above.

A striped pigment consisting of 95% titanium dioxide and 5% of the surfactant used in Example 1 was prepared, and a 3A t -L striped pigment composition/3. 78531 (1 gallon) - resin solution and mixed gently. The first resin matrix (containing the striped pigment composition) and the second resin matrix are combined in equal parts, light (mixed) and
was added to the same support. Emphasizing striped patterning was also carried out in the same manner as in Example 1. The obtained pouring material was heated to 38°C (100°C
"F) for 4 hours. The thickness of the obtained product was 3.
zmm (K inch) gives an aesthetically pleasing thick buried stone-like second surface.

Example 3 A black marble replica with raised white stripes and dgtailing was made using a combination of two resin systems. The first resin system consists of 1 part (by weight) of a translucent isophthalic acid polyester resin (SG 1.1) and 1 part (by weight) of alumina trihydrate (SG 2.2) as a filler.
parts (by weight). The specific gravity of the mixture was 1.65. This resin mixture contains %% black pigment, %% fumed silica (carbonyl), and %% MEKP.
1% catalyst and 1% triethyl phosphate (for viscosity reduction) were added. The level of catalysis in the resin depends in part on the promoter (cobalt naphthalate) level in the resin as it comes from the supplier. In this example, this level is 0.1%. Catalyst level, reflux temperature, resin temperature, and mold temperature also affect catalytic and final cure times. In this example, the gelation time of the above mixture was approximately 2
It was 5 minutes. Gelation time for the purposes of the present invention is
Refers to the point at which the material has sufficiently hardened to achieve a jelly consistency.

A second resin mixture was similarly prepared by mixing 1 part (by weight) of a translucent inphthalic polyester resin and 0.8 parts of alumina trihydrate filler. The specific gravity of the mixture was approximately 1.58. This mixture contains 3A% titanium dioxide (white pigment) and 3A% fumed silica (carbosyl).
and 2% MEKP as a catalyst were added. This combination was mixed according to standard methods known in the embedded marble industry.

The gelation time of this second resin mixture was measured to be approximately 15
It was a minute.

Next, 9 parts (by volume) of the first resin mixture was added to 1 part (by volume) of the second resin mixture.
(by volume), lightly blended, poured onto the horizontal surface of the support, and allowed to self-level to a thickness of approximately 4.811 (Xs inches). During this curing process, the white resin mixture tends to rise through the black resin mixture due to its low specific gravity, resulting in intermediate pressure “travel marks” of the translucent black resin.
left behind. The white stripes also tended to cluster at the surface of the poured mixture as a result of the "solution kick-ost" tendency, much like any two liquids with different densities. After 3-4 minutes, the white stripes tended to diffuse into the black background. This trend was controlled by the thixotropic level of the white resin achieved with the addition of % fumed silica. in general,
Higher thixotrope levels give more distinct stripes, while lower thixotrope levels give more diffuse, less distinct stripes. A raised or textured appearance with white stripes could be observed within the first minute after pouring. After 12-15 minutes, the white part reached the gel stage and began to shrink and float more dramatically onto the surface of the black background. In 25 minutes the black resin mixture reached its gel point. The mold was then transferred to a curing oven and further cured at 43°C (below 110°C) for 4 hours.

The resulting material exhibited an attractive white striped pattern partially overlapping and partially dispersed within the black background.

Although the description of the invention is quite specific, various modifications may be made without departing from the spirit of the invention. Accordingly, the scope of the invention is defined by the appended claims rather than by any description of the preferred embodiments.

(4 other people)

Claims (1)

[Claims] 1. a. At least two resin systems are prepared separately; b.
combining said resin systems; c. applying said combined resin systems to a support; and d. curing said combined resin mixture. Method of manufacturing synthetic surfacing materials. 2. Adding to at least one of the resin systems a striped patterning pigment composition containing a pigment component having a specific gravity greater than the specific gravity of the resin system and a blooming agent component having a specific gravity smaller than the specific gravity of the resin system. 2. The method of claim 1, comprising: 3. For applying a second striped pattern, the second resin system includes a second pigment component having a specific gravity greater than the specific gravity of the resin system, and a second blooming agent component having a specific gravity smaller than the specific gravity of the resin system. Claim 2 comprising the step of adding a pigment composition.
Method described. 4. The method according to claim 1, wherein at least two of the resin systems prepared have different specific gravities. 5. The method of claim 4, wherein the specific gravity differs by at least about 0.01. 6. The method of claim 5, wherein the specific gravity differs by at least about 0.05. 7. The method of claim 1, wherein at least two of the resin systems prepared have different thixotropic indices. 8. The method of claim 7 including the step of adding a thixotropic agent to at least one of said resin systems. 9. The method of claim 7, wherein the two resin systems have different curing rates. 10. The method of claim 1, wherein at least two of the resin systems have different curing rates. 11. The method of claim 9, wherein the cure rates differ from each other by at least about 20%. 12. The method of claim 1, wherein at least two of the resin systems have different viscosities. 13. The method of claim 2, wherein at least two of the resin systems prepared have different specific gravities. 14. The method of claim 2, wherein at least two of the resin systems prepared have different thixotropic indices. 15. The method of claim 2, wherein at least two of the resin systems have different curing rates. 16. a. preparing at least one resin system; b. said 1
Adding a striped patterning pigment composition comprising a pigment component having a specific gravity greater than the specific gravity and a blooming agent component having a specific gravity less than the specific gravity to the seed resin system; c. applying the patterning pigment composition to a support; and d curing the combined resin system and the striped patterning pigment composition to imitate stone, marble, etc. Method of manufacturing synthetic surfacing materials. 17. The pigment composition for forming a striped pattern contains about 50 to 98% by weight of the pigment component and about 2 to 50% by weight of the blooming agent component, and the pigment component and the blooming agent component are different from each other. 17. The method of claim 16, wherein the method is immiscible. 18. The method of claim 16, wherein the step of preparing the resin system includes the step of adding a thixotropic agent to control dispersion of the striped pigment composition. 19. The resin matrix in which the thixotropic agent has a first viscosity when the resin matrix is mixed and poured and has a second viscosity when the resin matrix is substantially stationary. wherein the first viscosity is low enough to allow the resin matrix to be easily mixed and poured;
19. The method of claim 18, wherein the second viscosity is sufficiently high to stop dispersing the striped pigment within about 15 seconds to about 5 minutes after the resin matrix becomes substantially stationary. 20. The method of claim 19, wherein the addition of the thixotropic agent is sufficient to provide the resin matrix having a first viscosity of less than about 1200 centipoise and a second viscosity of greater than or equal to about 1200 centipoise. 21. The method of claim 20, wherein the first viscosity is about 1000 centipoise or less and the second viscosity is about 2000 centipoise or more. 22.a. A step of preparing a resin matrix including a step of adding a thixotropic agent to control the dispersion of the pigment composition for striped patterning: Here, the thixotropic agent is mixed and poured into the resin matrix. the first viscosity is effective to provide the resin matrix having a first viscosity when the resin is at rest and a second viscosity when the resin matrix is substantially stationary; The second viscosity is sufficiently low to allow the matrix to be easily mixed and poured, and the second viscosity is such that the second viscosity is such that the striped pigment is dissolved within about 15 seconds to about 5 minutes after the resin matrix becomes substantially stationary. b. adding another striping pigment composition to the resin matrix; and c. adding a mixture of the resin matrix and the striping pigment composition. 1. A method for producing a synthetic surface material imitating stone, marble, etc., comprising the step of applying it to a support. 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 an amount of about 1/4 to 3% by weight. 25. The method of claim 24, wherein the addition of the thixotropic agent is sufficient to provide the resin matrix having a first viscosity less than about 1200 centipoise and a second viscosity greater than or equal to about 1200 centipoise. 26. The method of claim 25, wherein the first viscosity is about 1000 centipoise or less and the second viscosity is about 2000 centipoise or more.