Synthetic resins or natural rubbers -- part of the class 520 ser – Synthetic resins – At least one aryl ring which is part of a fused or bridged...
Reexamination Certificate
1998-12-28
2001-06-19
Cain, Edward J. (Department: 1714)
Synthetic resins or natural rubbers -- part of the class 520 ser
Synthetic resins
At least one aryl ring which is part of a fused or bridged...
C524S446000, C524S449000, C523S206000
Reexamination Certificate
active
06248822
ABSTRACT:
BACKGROUND OF THE INVENTION
This invention relates to a method of making a composite product from particles of an exfoliated vermiculite impregnated with a suitable impregnating composition containing a thermosetting resin, and to the composite product so produced.
Examples of decorative resinous composites in common use include “cultured” marble made from filled and pigmented polyester resin systems where colour blending is incomplete and which are cast using, vibration.
Granitic composites are made by dyeing or pre-pigmenting a polyester resin system, polymerising the resin, milling it to acceptable particle size and then using this to fill a liquid unsaturated polyester resin system which is either clear or which has been dyed, and in which the pre-coloured set polyester resin particles do not either float or drop out during the subsequent casting or spraying of the product.
A further composite is produced when pre-pigmented resin systems are applied through a multi-head gun onto substrates in such a way that a variegated finish results, due to the incomplete mixing or blending of the different colour streams on the surface.
All three composites described above are characterised by high cost because the resin proportion of the final composite generally exceeds 80% by weight. Another disadvantage of most composites is that a slurry or a paste or a composition containing hard particles such as stone or marble chip cannot be press formed. In addition, resinous compositions heavily filled with inorganic extenders such as calcium carbonate cannot be easily cut or worked after casting and may often be dimensionally unstable.
SUMMARY OF THE INVENTION
According to a first aspect of the invention there is provided a method of making a composite product which method includes the steps of:
(1) impregnating particles of an exfoliated vermiculite with an impregnating composition comprising a first thermosetting resin, an extending liquid for the first thermosetting resin, if necessary a catalyst for the first thermosetting resin, and a colouring agent for the particles;
(2) removing the extending liquid;
(3) subjecting the impregnated particles to suitable conditions to polymerise or cross-link the first thermosetting resin;
(4) coating the particles of step (3) with a binder composition comprising a second thermosetting resin and if necessary a catalyst for the second thermosetting resin;
(5) forming the particles of step (4) into a desired shape; and
(6) subjecting the particles of step (5) to suitable conditions to polymerise or cross-link the second thermosetting resin to bind the particles together to form the composite product.
In step (1) the colouring agent may be a pigment dispersed in the impregnating composition or may be a dye dissolved in the impregnating composition.
In step (1) the particles may be impregnated with the impregnating composition by immersion in the impregnating composition, or by mixing with the impregnating composition, or by spraying the impregnating composition onto the particles.
In step (2), the extending liquid may be recovered for reuse.
In step (3), suitable conditions to polymerise or cross-link may be elevated temperature, irradiation, and exposure to ultra violet light, or a combination of two or more thereof, optionally also with elevated pressure.
In step (4), the particles of step (3) may be coated with the binder composition by mixing or the like.
The first and second thermosetting resins may be the same or may be different.
The coating composition may also include a colouring agent, or may be colourless.
In step (5) the particles of step (4) may be, for example:
placed in a mould, or
placed on a substrate to which the particles are to be adhered, or
placed on a plate of a suitable press.
In step (6) the most usual conditions used are elevated temperature and pressure.
After step (6), the composite product may be post-treated by buffing, sanding, cutting or machining or the like, or by application of a suitable coating thereto.
According to a second aspect of the invention there is provided a composite product comprising:
(a) particles of an exfoliated vermiculite impregnated with a first thermosetting resin and a colouring agent for the particles, the first thermosetting resin having been polymerised or cross-linked; and
(b) a binder comprising a second thermosetting resin, the second thermosetting resin having been polymerised or cross-linked to bind the particles together to form the composite product.
REFERENCES:
patent: 2135554 (1938-11-01), Babor
patent: 4485203 (1984-11-01), Hutchinson
patent: 5145627 (1992-09-01), Berion et al.
patent: 5174818 (1992-12-01), Symons
patent: 5552469 (1996-09-01), Beall et al.
patent: 5879600 (1999-03-01), Symons
patent: 564 137 (1975-07-01), None
patent: 921 051 (1954-12-01), None
patent: WO 96/13468 (1996-05-01), None
Cain Edward J.
Pillsbury & Winthrop LLP
Windsor Technologies Limited
Wyrozebski Kat Lee
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