US20070087179A1 - Solid surface composite - Google Patents

Solid surface composite Download PDF

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Publication number
US20070087179A1
US20070087179A1 US11/252,030 US25203005A US2007087179A1 US 20070087179 A1 US20070087179 A1 US 20070087179A1 US 25203005 A US25203005 A US 25203005A US 2007087179 A1 US2007087179 A1 US 2007087179A1
Authority
US
United States
Prior art keywords
solid surface
light weight
weight solid
according
surface composite
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
Application number
US11/252,030
Inventor
Donald Horn
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
RAYLYNN SOLID SURFACES Inc
Original Assignee
RAYLYNN SOLID SURFACES Inc
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by RAYLYNN SOLID SURFACES Inc filed Critical RAYLYNN SOLID SURFACES Inc
Priority to US11/252,030 priority Critical patent/US20070087179A1/en
Assigned to RAYLYNN SOLID SURFACES, INC. reassignment RAYLYNN SOLID SURFACES, INC. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: HORN, DONALD R.
Publication of US20070087179A1 publication Critical patent/US20070087179A1/en
Application status is Abandoned legal-status Critical

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Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/06Fibrous reinforcements only
    • B29C70/08Fibrous reinforcements only comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, and with or without non-reinforced layers
    • B29C70/088Fibrous reinforcements only comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, and with or without non-reinforced layers and with one or more layers of non-plastics material or non-specified material, e.g. supports
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29LINDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00Other particular articles
    • B29L2031/769Sanitary equipment
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/249921Web or sheet containing structurally defined element or component
    • Y10T428/249924Noninterengaged fiber-containing paper-free web or sheet which is not of specified porosity

Abstract

A light weight solid surface composite comprises a core member, a resin coat having a first side disposed on and adhered to a first side of the core member and a first layer of fiber reinforced low profile tooling resin disposed on and adhered to a second side of the resin coat. There is a second layer of fiber reinforced low profile tooling resin disposed on and adhered to a second side of the core member and a reinforcing member disposed on at least one preselected area of the second layer, and a surface coat. The surface coat includes a densified resin and methyl methacrylate, and is disposed on and adhered to the second layer of fiber reinforced low profile tooling resin and the reinforcing member.

Description

    CROSS-REFERENCE TO RELATED APPLICATIONS
  • The invention taught in this patent application is closely related to the following co-pending U.S. patent applications, “Process for Making Solid Surface Composites” and “Surface Coat Formula for Solid Surface Composites”. These co-pending applications numbered xx/xxx,xxx and xx/xxx,xxx were filed on July, 2005 and July, 2005. Further, the teachings of the above mentioned applications are incorporated herein by reference hereto.
  • FIELD OF THE INVENTION
  • The present invention relates, in general, to a composite material, and more specifically, the present invention relates to a new formulation for a lightweight composite for use as counter tops, shower surrounds, bath tubs, sinks and various other preselected products for use in such areas as kitchens and bathrooms.
  • BACKGROUND OF THE INVENTION
  • There are many materials that are used to form counter tops that are used in such areas as the kitchens and bathrooms. Different materials have been used for years to form tops that are both attractive and can withstand the use that the tops encounter through the constant usage that such counter top must endure. This is particularly true with the kitchen counter top.
  • Several problems exist with present counter tops. One problem is that corners, back splashes and side splashes are not normally seamless. Further sinks are not integrated into the counter top. Thus, there tends to be unsightly corners and back and side splashes that have to glued onto the counter top providing a point where moisture can compromise the integrity of the top.
  • SUMMARY OF THE INVENTION
  • The present invention provides a light weight solid surface composite. The solid surface composite comprises a core member, a resin coat having a first side disposed on and adhered to a first side of the core member and a first layer of fiber reinforced low profile tooling resin disposed on and adhered to a second side of the resin coat. There is a second layer of fiber reinforced low profile tooling resin disposed on and adhered to a second side of the core member and a reinforcing member disposed on at least one preselected area of the second layer, and a surface coat. The surface coat includes a densified resin and methyl methacrylate, and is disposed on and adhered to the second layer of fiber reinforced low profile tooling resin and the reinforcing member.
  • OBJECTS OF THE INVENTION
  • It is, therefore, one of the primary objects of the present invention to provide a lightweight solid surface composite that can be used for kitchen and bathroom counter tops, shower surrounds, bathtubs, sinks and various other similar applications.
  • Another object of the present invention is to provide a lightweight solid surface composite in which back and side splashes are seamless.
  • Still another object of the present invention is to provide a lightweight solid surface composite in which back and side splashes are integrated into the counter top surface.
  • Yet another object of the present invention is to provide a lightweight solid surface composite in which the corners are seamless.
  • Another object of the present invention is to provide a lightweight solid surface composite in which the surface coat is formed by atomized casting rather than being poured.
  • It is still another object of the present invention to provide a lightweight solid surface composite in which the product contains particle board and corrugated cardboard to increase tensile strength.
  • Yet, it is still another object of the present invention to provide a lightweight solid surface composite in which the product weighs only about 20% of the weight of presently used counter tops.
  • These and various other objects and advantages of this invention will become apparent after a full reading of the following detailed description, particularly, when read in conjunction with the attached drawings as described below and the appended claims.
  • BRIEF DESCRIPTION OF THE PRESENTLY PREFERRED AND ALTERNATE EMBODIMENTS OF THE INVENTION
  • The present invention provides a unique solid surface composite that can be used for kitchen and bathroom counter tops, shower surrounds, bath tubs, sinks and a wide variety of other preselected personal and commercial products.
  • The present invention provides a light weight solid surface composite. The solid surface composite comprises a core member, a resin coat having a first side disposed on and adhered to a first side of the core member and a first layer of fiber reinforced low profile tooling resin disposed on and adhered to a second side of the resin coat. There is a second layer of fiber reinforced low profile tooling resin disposed on and adhered to a second side of the core member. A reinforcing member is disposed on at least one preselected area of the second layer, and a surface coat is disposed on and adhered to the second layer of fiber reinforced low profile tooling resin and to the reinforcing member. The surface coat includes a densified resin and methyl methacrylate. It is presently preferred that such densified resin is a polyester resin. It is further preferred that such surface coat is an atomized casting that is sprayed rather than being a poured product.
  • The reinforcing member is disposed in the corners of the solid composite. Such reinforcing member according to a presently preferred embodiment of the invention includes a putty of cotton flock and a low profile tooling resin. Such low profile tooling resin is selected from a polyester resin. Such reinforcing member provides additional strength for the corners and radius of the surface coat.
  • There is a first layer of fiber reinforcement and a low profile tooling resin that is disposed into said composite. It is preferred that such fiber is fiberglass and that such fiberglass is chopped fiberglass. It is further preferred that this reinforcement is hand laminated onto the cotton flock. The resin coat is disposed on and adhered to into the core member. It is presently preferred that such core member is particle board and corrugated cardboard. Such core member provides significantly increased tensile strength to the composite. The second layer of fiber reinforced, low profile tooling resin is also laminated onto the core. It is presently preferred that such second layer is hand laminated.
  • It is also preferred that such surface coat also includes an air release and wetting agent, a mold release agent and fumed silica.
  • Such a light weight solid surface composite when it is used to form a counter top provides a counter top that is seamless at the corners and which also has back splashes and side splashes that are seamless. It is preferred that such back splashes and side splashes be integrated into the counter top as a single unit.
  • The present invention according to an alternate embodiment also provides a molded in sink that is integrated into the counter top surface.
  • Such composite made according to the present invention provides a counter top that is significantly lighter than the counter tops that are commercially available. The difference in weight is dramatic. The counter top of the present invention is only between about 18% and about 30% of the weight of presently available tops. These light weight counter tops generally are only about 20% of the weight of the present counter tops. Thus, the difference in weight makes the tops of the present invention far easier and less expensive to install. Further, since the counter top is an integrated top the top does not permit moisture to compromise the integrity of the counter top during repeated use over time.
  • While both the presently preferred and a number of alternative embodiments of the present invention have been described in detail above it should be understood that various other adaptations and modifications of the present invention can be envisioned by those persons who are skilled in the relevant art without departing from either the spirit of the invention or the scope of the appended claims.

Claims (20)

1. A light weight solid surface composite, said solid surface composite comprising:
(a) a core member;
(b) a resin coat having a first side disposed on and adhered to a first side of said core member;
(c) a first layer of fiber reinforced low profile tooling resin disposed on and adhered to a second side of said resin coat;
(d) a second layer of fiber reinforced low profile tooling resin disposed on and adhered to a second side of said core member;
(e) a reinforcing member disposed on at least one preselected area of said second layer; and
(f) a surface coat including a densified resin and methyl methacrylate, said surface coat disposed on and adhered to said second layer of fiber reinforced low profile tooling resin and said reinforcing member disposed on said at least one preselected area of said second layer.
2. The light weight solid surface composite, according to claim 1, wherein said reinforcing member includes cotton flock and low profile tooling resin.
3. The light weight solid surface composite, according to claim 1, wherein said surface coat further includes an air release and wetting agent, a mold release agent, and fumed silica.
4. The light weight solid surface composite, according to claim 1, wherein said fiber reinforcing member includes fiberglass.
5. The light weight solid surface composite, according to claim 3, wherein said fiberglass is chopped fiberglass.
6. The light weight solid surface composite, according to claim 1, wherein said core member includes at least one of particle board and corrugated cardboard.
7. The light weight solid surface composite, according to claim 6, wherein said core member significantly increases tensile strength.
8. The light weight solid surface composite, according to claim 1, wherein said composite is a counter top.
9. The light weight solid surface composite, according to claim 8, wherein said counter top is seamless adjacent at least one corner thereof.
10. The light weight solid surface composite, according to claim 8, wherein back splashes and side splashes on said counter top are seamless.
11. The light weight solid surface composite, according to claim 8, wherein back splashes and side splashes on said counter top are integrated into said counter top surface as a single piece unit.
12. The light weight solid surface composite, according to claim 8, wherein said light weight solid surface counter top is significantly lighter than counter tops that are commercially available.
13. The light weight solid surface composite, according to claim 12, wherein said light weight solid surface counter top weighs between about 18 and 30 per cent of the weight of commercially available counter tops.
14. The light weight solid surface composite, according to claim 13, wherein said light weight solid surface counter top weighs about 20 per cent of the weight of commercially available counter tops.
15. The light weight solid surface composite, according to claim 8, wherein said light weight solid surface counter top further includes a molded in sink that is integrated into a surface of said counter top.
16. The light weight solid surface composite, according to claim 1, wherein said at least one preselected area includes at least one corner of said light weight solid surface composite.
17. The light weight solid surface composite, according to claim 16, wherein said at least one preselected area includes a plurality of corners of said light weight solid surface composite.
18. The light weight solid surface composite, according to claim 1, wherein said densified resin is a polyester.
19. The light weight solid surface composite, according to claim 1, wherein said surface coat is an atomized spray.
20. The light weight solid surface composite, according to claim 1, wherein said surface coat has a high gloss finish.
US11/252,030 2005-10-17 2005-10-17 Solid surface composite Abandoned US20070087179A1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
US11/252,030 US20070087179A1 (en) 2005-10-17 2005-10-17 Solid surface composite

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
US11/252,030 US20070087179A1 (en) 2005-10-17 2005-10-17 Solid surface composite

Publications (1)

Publication Number Publication Date
US20070087179A1 true US20070087179A1 (en) 2007-04-19

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20090180957A1 (en) * 2006-08-01 2009-07-16 Eric Olson Identification of a micro-rna that activates expression of beta-myosin heavy chain

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US4070532A (en) * 1975-05-23 1978-01-24 E. I. Du Pont De Nemours And Company Ethylene carbon monoxide copolymers containing epoxy side groups
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US4958888A (en) * 1989-08-04 1990-09-25 E. I. Du Pont De Nemours And Company Low stress concentration cutout countertop
US5098778A (en) * 1990-04-24 1992-03-24 General Electric Company Plastic based laminates comprising outer fiber-reinforced thermoset sheets, lofted fiber-reinforced thermoplastic sheets and a foam core layer
US5102926A (en) * 1990-10-30 1992-04-07 Owens-Corning Fiberglas Corporation Citrate ester compounds and processes for their preparation
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US6030483A (en) * 1996-09-10 2000-02-29 Wilson; Graeme Paul Method of forming laminates using a tessellated core
US6106944A (en) * 1995-06-07 2000-08-22 Andersen Corporation Fiber thermoset reinforced thermoplastic structural member
US20020000290A1 (en) * 2000-06-29 2002-01-03 Crump Larry Scott Curing of a gel coat on a mold
US6399199B1 (en) * 1999-12-28 2002-06-04 Toray Industries Inc. Prepeg and carbon fiber reinforced composite materials
US6429157B1 (en) * 1997-07-11 2002-08-06 Toray Industries, Inc. Prepreg fabric and honeycomb sandwich panel
US6617395B1 (en) * 2002-04-08 2003-09-09 Cook Composites & Polymers Co. Low VOC low tack gel coat resin
US6803110B2 (en) * 2001-01-22 2004-10-12 Formica Corporation Decorative laminate assembly and method for producing same
US7179517B2 (en) * 2000-10-03 2007-02-20 Structural Polymer Systems Ltd. Sheet moulding compound (SMC) with ventilating structure for entrapped gases
US20070088115A1 (en) * 2005-10-17 2007-04-19 Horn Donald R Surface coat formula for solid surface composites
US20070085236A1 (en) * 2005-10-17 2007-04-19 Horn Donald R Process for making solid surface counter tops
US7261930B2 (en) * 2002-02-19 2007-08-28 Hexcel Composites, Ltd. Moulding materials

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4070532A (en) * 1975-05-23 1978-01-24 E. I. Du Pont De Nemours And Company Ethylene carbon monoxide copolymers containing epoxy side groups
US4061812A (en) * 1976-06-22 1977-12-06 The United States Of America As Represented By The Administrator Of The National Aeronautics And Space Administration Honeycomb-laminate composite structure
US4135019A (en) * 1977-03-16 1979-01-16 The United States Of America As Represented By The Administrator Of The National Aeronautics And Space Administration Low density bismaleimide-carbon microballoon composites
US4316934A (en) * 1979-07-05 1982-02-23 Rohm Gmbh Method for making laminates comprising a hard foam layer and a fiber-reinforced synthetic resin layer
US4402778A (en) * 1981-08-05 1983-09-06 Goldsworthy Engineering, Inc. Method for producing fiber-reinforced plastic sheet structures
US4446177A (en) * 1982-03-12 1984-05-01 Munoz George L Reinforced plastic product
US4752415A (en) * 1982-03-16 1988-06-21 American Cyanamid Co. Compositions convertible to reinforced conductive components and articles incorporating same
US4608300A (en) * 1983-06-21 1986-08-26 Ciba-Geigy Corporation Fibre composite materials impregnated with a curable epoxide resin matrix
US4774121A (en) * 1986-06-16 1988-09-27 Vollenweider Ii Edward E Core for composite structures
US4871596A (en) * 1986-12-11 1989-10-03 Aica Kogyo Co., Ltd. Artificial marble
US4801483A (en) * 1987-02-13 1989-01-31 Power-Tel Products Group, Inc. High strength, light weight structural composite and method of preparing same
US4868038A (en) * 1987-10-23 1989-09-19 The Dow Chemical Company Carbonaceous fiber reinforced composites
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US5162414A (en) * 1989-01-17 1992-11-10 Industrial Technology Research Institute Preparation of interpenetrating polymer network composition
US5262230A (en) * 1989-06-13 1993-11-16 Bayer Aktiengesellschaft Lightweight composite material with a thermoset matrix
US4958888A (en) * 1989-08-04 1990-09-25 E. I. Du Pont De Nemours And Company Low stress concentration cutout countertop
US5098778A (en) * 1990-04-24 1992-03-24 General Electric Company Plastic based laminates comprising outer fiber-reinforced thermoset sheets, lofted fiber-reinforced thermoplastic sheets and a foam core layer
US5102926A (en) * 1990-10-30 1992-04-07 Owens-Corning Fiberglas Corporation Citrate ester compounds and processes for their preparation
US5688602A (en) * 1991-11-07 1997-11-18 Ghahary; Akbar Method for producing laminated articles
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US5547735A (en) * 1994-10-26 1996-08-20 Structural Laminates Company Impact resistant laminate
US6106944A (en) * 1995-06-07 2000-08-22 Andersen Corporation Fiber thermoset reinforced thermoplastic structural member
US5683638A (en) * 1996-06-20 1997-11-04 Excelstone International, Inc. Seamless flush mounted countertop sink
US6030483A (en) * 1996-09-10 2000-02-29 Wilson; Graeme Paul Method of forming laminates using a tessellated core
US6429157B1 (en) * 1997-07-11 2002-08-06 Toray Industries, Inc. Prepreg fabric and honeycomb sandwich panel
US5976670A (en) * 1998-05-08 1999-11-02 Architectural Precast, Inc. Solid surface composite and method of production
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US7261930B2 (en) * 2002-02-19 2007-08-28 Hexcel Composites, Ltd. Moulding materials
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US20070085236A1 (en) * 2005-10-17 2007-04-19 Horn Donald R Process for making solid surface counter tops

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20090180957A1 (en) * 2006-08-01 2009-07-16 Eric Olson Identification of a micro-rna that activates expression of beta-myosin heavy chain

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Date Code Title Description
AS Assignment

Owner name: RAYLYNN SOLID SURFACES, INC., ARIZONA

Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNOR:HORN, DONALD R.;REEL/FRAME:017568/0168

Effective date: 20051117

STCB Information on status: application discontinuation

Free format text: ABANDONED -- FAILURE TO RESPOND TO AN OFFICE ACTION