Synthetic resins or natural rubbers -- part of the class 520 ser – Synthetic resins – Processes of preparing a desired or intentional composition...
Reexamination Certificate
2001-10-15
2002-10-08
Yoon, Tae H. (Department: 1714)
Synthetic resins or natural rubbers -- part of the class 520 ser
Synthetic resins
Processes of preparing a desired or intentional composition...
C264S073000, C264S650000, C524S423000, C524S425000, C524S444000
Reexamination Certificate
active
06462103
ABSTRACT:
BACKGROUND OF INVENTION
The present invention is directed to formation of three-dimensional burls in a solid surface material comprising a filled acrylic composition exhibiting a series of burls present on the surface of the material.
The formation of different surface appearances in a solid surface material such as used for countertops and sinks is well known in the prior art.
Iverson, U.S. Pat. No. 3,816,155, discloses a method for producing protective coatings in simulation of wood graining. The method comprises preparing a plurality of portions of thixotropic viscous settable resins colored with metallic pigments in different colors. These separate portions of vehicle are combined with a minimum of admixing, either in a common container from which the mixture is applied to a base surface, or by spreading the several vehicle portions onto a base. The applied coating mixture is allowed to level or is leveled into a relatively uniform layer. While liquid and viscous, the leveled coating is furrowed to develop a lined pattern therein in simulation of wood graining. The coating is permitted to set up and harden and may be formed on a non-adhering surface from which it is stripped as a self-sustaining film.
Iverson, U.S. Pat. No. 3,904,791 also discloses a method for producing protective coatings in simulation of wood graining, leather, and like effects such as sandblasted graining, distressed wood graining, burled graining, elephant hide leather may be obtained by variations of the basic method. The resin may be cast in slabs or blocks of substantial thickness from which veneer layers may be removed.
Murakami, et al., U.S. Pat. No. 4,710,333 provide teachings for a continuous process in formation of synthetic resin plates having an irregular flow pattern of different colors.
Stecker, U.S. Pat. No. 5,055,324 prepares synthetic surfaces having a pattern simulating stone, marble and other natural substances by combining a resin matrix with a veining pigment composition with a specific gravity heavier than the resin system. In addition, a blooming agent component is employed with a specific gravity less than the resin system.
Barnett, U.S. Pat. No. 6,011,101, discloses a process for making a marble casting material by partial intermingling of two or more partially incompatible marble casting resins that are not intended to be normally used in combination.
A need is present in solid surface materials for varying surface appearances which extend into the interior of such materials.
SUMMARY OF INVENTION
The present invention is directed to a method of incorporating a burl appearance into solid surface material comprising the steps of: a)forming two separate acrylic resin suspensions with a first suspension having i)a viscosity in a range from 500 to 3,000 centipoise, ii) a density in a range from 1.5 to 1.7 grams per milliliter and iii) a surface tension in a range from 35 to 45 dyne per centimeter and a second suspension having i) a viscosity in a range from 500 to 3,000 centipoise and ii) a density in a range from 1.6 to 1.8 gram per milliliter with the proviso that the second suspension has a density of at least 0.05 gram per milliliter more than the first suspension and the second suspension has a surface tension of at least 0.5 dyne per centimeter greater than the first suspension and b)combining and partially mixing the two suspensions and c) curing the two suspensions whereby a series of three-dimensional burls are formed.
DETAILED DESCRIPTION
In the present invention, it is required that a series of burls are formed in a solid surface material comprising a cured, mineral-filled acrylic composition.
As employed herein, a “burl” is employed in its normal meaning but is applied to a material other than wood. Thus, the solid surface material will have a burl appearance. As set forth in The Random House Dictionary of the English Language (Unabridged Dictionary) Copyright 1967, a burl means “a dome-shaped growth on the trunk of a tree. In accordance with this definition a series of burls are in a three dimensional configuration in the solid surface material and, ignoring coloration, have a tree-like growth appearance. However, since a surface of the material is two-dimensional (ignoring edge portions), the surface will comprise a series of burl cross-sections.
However, it is understood that the burls may be in any color, or series of colors, and in many instances will not resemble wood solely due to coloration. In similar fashion as burls on a tree with different shadings of color, the burls in the solid surface material will have different shades of the same color, or entirely different colorations. For purposes of illustration, different shades of white can be employed which present a unique appearance compared to coloration of a tree. Of course, a wood-like product such as with different shades of brown can be formed in the solid surface material to mimic or resemble a wood product.
As employed herein, a solid surface material is employed in its normal meaning and represents a three dimensional material such as a material particularly useful in the building trades for kitchen countertops, sinks and wall coverings wherein both functionality and an attractive appearance are necessary.
This invention is directed to a thermoset casting composition which is comprised of two or more individual casting compositions which are partially mixed prior to cure. In general, the casting compositions described are composed of a liquid polymerizable fraction, an optional noncrosslinked polymer fraction, and a solid fraction. Also included are cure agents, pigments and additives.
Liquid polymerizable fraction: The liquid polymerizable fraction is a liquid starting material. By liquid is meant that the material is fluid at room temperature. The liquid polymerizable material may include one or more of the following: (a) at least one monofunctional monomer reactive material; (b) at least one polyfunctional monomer reactive material, and (c) at least one oligomeric reactive material.
Monofunctional monomer reactive material: A “monofunctional monomer reactive material” refers to a compound having one unit of unsaturation capable of taking part in a free radical initiated polymerization reaction, thus becoming incorporated into a polymeric chain. Suitable monofunctional monomer reactive materials can include, for example, monomers having one acrylic group, monomers having one vinyl group, monomers having one allyl group, substituted butadienes or combinations thereof.
A preferred type of monofunctional monomer reactive material is an ester of acrylic or methacrylic acid. The ester is generally derived from an alcohol having 1 atoms. The alcohols can be aliphatic, cycloaliphatic or aromatic. The ester may also be substituted with groups including, but not limited to, hydroxyl, halogen, and nitro. Representative (meth)acrylate esters include methyl (meth)acrylate, ethyl (meth)acrylate, butyl (meth) acrylate, 2(meth)acrylate, glycidyl (meth)acrylate, cyclohexo(meth)acrylate, isobornyl (meth)acrylate, siloxane (meth)acrylates, and the like. Acrylic and methacrylic acid can also be used. Most preferred is methylmethacrylate and copolymers thereof.
Examples of monofunctional monomer materials including one vinyl group include acrylonitrile, methacrylonitrile, and vinyl acetate.
Polyfunctional monomer reactive material: A “polyfunctional monomer reactive material” refers to a monomeric compound having multiple units of unsaturation which can take part in free radical initiated polymerization reactions, thus becoming incorporated into two or more polymeric chains. By the nature of the resulting structure, such a reaction is referred to as “crosslinking” in which two or more polymeric chains are joined by the polyfunctional monomer reactive material. As such, polyfunctional monomer reactive materials are often referred to as crosslinking agents.
The reactive group can be one that copolymerizes with the liquid polymerizable material, such as a polymerizable ethylenically unsaturated group. The reactive group ca
Beitelshees Carl P.
Walter Elizabeth R.
Weberg Rolf T.
Zhu Shitong S.
E. I. du Pont de Nemours and Company
Yoon Tae H.
LandOfFree
Formation of three dimensional burls in a filled acrylic... does not yet have a rating. At this time, there are no reviews or comments for this patent.
If you have personal experience with Formation of three dimensional burls in a filled acrylic..., we encourage you to share that experience with our LandOfFree.com community. Your opinion is very important and Formation of three dimensional burls in a filled acrylic... will most certainly appreciate the feedback.
Profile ID: LFUS-PAI-O-2949777