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Thick solid surface laminate product and method of making same

A solid surface and polymer technology, applied in the field of manufacturing thick solid surface materials and solid surface products, can solve the problems of non-uniform surface appearance, incomplete curing of polymer resin, etc.

Inactive Publication Date: 2009-05-20
THE DILLER
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Problems solved by technology

However, such products suffer from a number of disadvantages, including incomplete curing of the polymer resin, residual air bubbles or pores within the cured mass, non-uniform surface appearance, and warping of the finished product after fabrication or after cutting in the working position

Method used

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  • Thick solid surface laminate product and method of making same
  • Thick solid surface laminate product and method of making same
  • Thick solid surface laminate product and method of making same

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Embodiment Construction

[0019] The polymer resin used in the embodiment of the present invention is not particularly limited as long as it can form a solid surface material by curing. Preferred free radical, heat curable resins particularly useful in the practice of the present invention are thermoset unsaturated polyester resins and thermoset polyacrylic resins and mixtures thereof. The term resin or "syrup" generally refers to the uncured liquid state of a polymer in solution with suitable crosslinking monomers. Examples of useful unsaturated polyester resins are unsaturated dicarboxylic acids or the reaction products of unsaturated dicarboxylic acids and saturated dicarboxylic acids with glycols, such as maleic acid, phthalic acid and monohydric acid, respectively. Dipropylene glycol. Typically, styrene acts as a monomeric crosslinker for polyester resins. Examples of useful polyacrylate resins include the different classes of conventional acrylic functional, acrylic functional partial polymers,...

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Abstract

A solid surface product having a thickness of 3 cm or greater is provided which is substantially free from warping, has a homogeneous surface appearance, and is substantially free from entrapped air bubbles or voids. The solid surface material includes from about 25 to about 95 wt%, i.e. weight percent, of a polymer resin and from about 0 to about 70 wt% of a filler. A method for producing the solid surface material is also provided and includes forming a mixture of from about 25 to about 95 wt% of a polymer resin and from about 0 to about 70 wt% of a filler; casting the mixture into an open mold to a thickness of 3 cm or greater; applying a vacuum to the molded mixture to release entrapped gases therein; and curing the molded mixture to produce a thick solid surface material.

Description

Background technique [0001] The present invention relates to decorative solid surface articles made from filled or unfilled polymeric resins, and more particularly to solid surface articles having a thickness equal to or greater than about 3 cm. [0002] Decorative solid surface articles made of particle filled resins have long been known and are commonly used for kitchen and bathroom surfaces. Typically, these materials are made of particle-filled resins, the most common being polyesters and acrylates, while fillers can range widely and often give the product a special visual effect. [0003] These solid surface products typically come in a variety of appearances and colors, and patterns throughout the thickness of the product, giving it its intended aesthetic appearance and use. These materials are also hard, heat-resistant, stain-resistant, abrasion-resistant, and impact-resistant, and are easily repairable if damaged. [0004] Commonly used pigments for these products co...

Claims

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Application Information

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Patent Type & Authority Applications(China)
IPC IPC(8): C08L101/00C08L67/00C08L33/04C08L63/00C08L75/04C08L61/28C08K3/22C08K3/26C08K3/30C08K3/34B29C39/22
CPCB29C39/42B29C70/58B29C39/006
Inventor D·P·赖克温L·R·埃尔邦
Owner THE DILLER