Composite sheet with visible filler and manufacturing method

Abstract

A solid surface sheet includes visible, elongated, shredded cuttings uniformly distributed throughout a matrix wherein the cuttings and the matrix have substantially the same specific weight and wherein a majority of the cuttings are substantially elongated. Related methods are also disclosed including shredding a first mix while in a gel state, curing the cuttings, sorting by size, and using as a filler in a base material to form a blend having a unique appearance and high internal strength. The preferred material is polyester or acrylic. The solid surface sheet can be used as a countertop, floor or wall panel, furniture, and in similar applications.

Claims

1. A particulate for incorporation into a matrix of material that is independently curable into a solid surface material, the particulate comprising: a plurality of separate, cured cuttings, having a shredded and elongated configuration, and a plurality of surfaces, defining a cutting surface area, substantially all of the cutting surface area having a shredded surface configuration, with the cured cuttings having a hardness above that which allows formation of a shredded surface configuration after curing.

2. The particulate of claim 1 wherein each cutting of the plurality of cuttings comprises at least one of polyester or acrylic.

3. The particulate of claim 2 wherein each cutting of the plurality of cuttings further comprises at least one filler.

4. The particulate of claim 1 wherein the matrix and the plurality of cuttings have substantially the same specific weight.

5. The particulate of claim 1, wherein the cuttings are cut from a thermoset polymeric material when it is partially cured to a gel.

6. The particulate of claim 1 wherein a plurality of the plurality of cuttings each have a length that is between and 1 inch.

7. The particulate of claim 1 wherein a plurality of the plurality of cuttings each have a length at least three times greater than a width.

8. A solid surface material comprising: a matrix including a resin; and a particulate comprising a plurality of separate, cured cuttings, having a shredded and elongated configuration, and a plurality of surfaces, defining a cutting surface area, substantially all of the cutting surface area having a shredded surface configuration, with the cured cuttings having a hardness above that which allows formation of a shredded surface configuration after curing; wherein the particulate is added to the matrix and the matrix is then cured to form the solid surface material.

9. The solid surface material of claim 8, wherein the cuttings are distributed throughout the matrix such that at least some of the cuttings are elongated on a show surface side of the sheet.

10. The solid surface material of claim 8, wherein the matrix and cuttings comprise thermoset materials.

11. The solid surface material of claim 8, wherein: the cuttings comprise one of a polyester or acrylic; and the matrix comprises one of a polyester or acrylic.

12. The solid surface material of claim 8, further comprising a plurality of granules distributed within the matrix.

13. The solid surface material of claim 8 wherein the matrix further includes a filler mixed with the resin.

14. The solid surface material of claim 8 wherein the solid surface material is processed into one of the group consisting of: a countertop, a wall panel, flooring, a table top, furniture, and a fixture.

Description

BRIEF DESCRIPTION OF DRAWINGS

(1) FIG. 1 shows the prior art including polyester granules in the matrix of the solid surface material;

(2) FIG. 2 shows cuttings of the present invention;

(3) FIG. 3 is an illustration of one embodiment of the present invention;

(4) FIG. 4 is an illustration of another embodiment of the present invention;

(5) FIG. 5 is a top perspective view of FIG. 4.

(6) FIGS. 1A-5A are line drawings replicating the photographs of FIGS. 1-5, respectively.

PRIOR ART

(7) The reference numeral 5 (FIG. 1) generally designates a block of prior art solid surface material. The illustrated block 5 includes a resin made of unsaturated polyester 7, and filler in the form of aluminatrihydrate, a catalyst, a pigment, and a colorant. To add texture to the appearance of the solid surface material, small polyester granules 9 have been added to the matrix. The polyester granules 9 are obtained through recycling of polyester slabs. Polyester slabs are fed into a grinding mill that breaks them down, resulting in the formation of polyester granules 9. Notably, the granules tend to be chunks or chips of material that are not elongated, but instead are more ball-shaped. The filler and particulates are added to a base resin and cured to make a solid surface material, with at least one side processed to form a show surface, such as for a countertop.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

(8) For purpose of description herein the terms upper, lower, right, left, rear, front, vertical, horizontal and derivatives thereof shall relate to the invention as oriented in FIG. 5. However, it is to be understood that the invention may assume various alternative orientations and step sequences, except where expressly specified to the contrary. It is also to be understood that the specific devices and processes illustrated in the attached drawings, and described in the following specification are exemplary embodiments of the inventive concepts defined in the appended claims. Hence, specific dimensions and other physical characteristics relating to the embodiments disclosed herein are not to be considered as limiting, unless the claims expressly state otherwise.

(9) FIG. 2 illustrates elongated shredded polyester cuttings 11 sliced/cut from an unsaturated polyester in a gel state prior to the polyester curing. To make such cuttings 11, a predetermined amount of resin is poured into a mixer. A filler is added, if desired, such as by adding aluminatrihydrate particulate or granules 13 to the mixer. The blend (also called a matrix herein) is mixed with the resin until the filler is satisfactorily completely wet-out and there are no lumps or powder remaining. Colorant and pigment are added, if required, while the mixture of resin and filler continues to be mixed. The mixer is then closed and vacuum is pulled from the mixer for a predetermined duration of time. Upon completion of that duration of time, the lid is opened and the catalyst is added (i.e., methylethylketone peroxide). After the catalyst has been added, the lid is again closed and vacuum is again pulled from the mixer. After vacuum has been pulled from the mixer for a predetermined second amount of time, a matrix is formed in the mixer.

(10) The matrix is then poured into mold cavities and the temperature and time is monitored to determine when the blend is cured enough to form a flexible gel that can be handled. The flexible gel preferably has a consistency similar to refrigerated Colby cheese, such that it can be handled and cut with a cheese shredder. Once a complete gel set has been reached, the matrix is removed from the mold and fed into cutters. The cutters act similarly to a cheese slicer in that they shred the matrix forming elongated shaped cuttings 11 of unsaturated polyester 7. The cuttings 11 are not allowed to cool, and are immediately spread into a curing chamber and cured at the correct temperature for the required amount of time. The temperature is then raised during the post-curing time, and afterwards, the cuttings 11 are brought back to ambient temperature. Typically the cuttings 11 are then screened or air-qualified into required sizes. The new cuttings 11 can be advantageously used as filler in the production of a new solid surface material, or more specifically, a solid surface sheet, providing a highly novel and new appearance (examples of which are shown in FIGS. 3-5). It is noted that the present fillers can be virtually any shape, size, length, profile, color, and/or appearance. Yet, the present fillers provide excellent bonding, do not tend to lead to surface defects (since the material of the filler is the same as the base material of the countertop). Preferably, the cuttings 11 are the same specific weight as the matrix material 12, and are of the same polymeric chemistry for optimal bonding.

(11) FIG. 3 illustrates a solid surface material incorporating the cuttings 11 of the aforementioned process into the matrix of the solid surface material 12. A majority of the cuttings 11 are substantially linear and about to 1 inch long, although some smaller cuttings 11 or longer cuttings 11 may be present. It is contemplated that the length, curvature and shape of the cuttings 11 can be varied as desired. Preferably they are long enough (such as at least twice as long as wide, or more preferably at least 3-4 times their width . . . or up to an inch long or longer) so that their appearance is distinctive and appealing.

(12) FIG. 4 illustrates a second embodiment of the present invention wherein solid surface material has both granules 13 and elongated cuttings 11 present in the matrix of the solid surface material 12. In this instance, the granules 13 are added at the same time as the elongated cuttings 11, prior to molding the matrix into a sheet of solid surface material. Once the sheet has been formed, cured, and properly hardened, the sheet can then be processed into a countertop, wall panels (such as may be used in luxurious lobbies or bathrooms), flooring, table tops, furniture, and many types of commercial fixtures/surfaces.

(13) FIG. 5 depicts a slab 14 of the solid surface material of the second embodiment of the present invention. It may be of varying dimensions with varying amounts of resin, cuttings 11, and/or granules 13.

(14) The present inventive concepts can be used on other materials. For example, where a solid surface might be made of a different curable thermoset resin other than polyester, that particular curable resin can be cured to a gel state sufficient for handling, shredded/cut to desired elongated shapes, cured, and then added as filler to a base mix to make a blend with a novel desired appearance. For example, this present inventive method can be done with acrylic materials. It is also contemplated that the present novel filler might be used with other materials to provide a unique appearance and set of properties.

(15) It is to be understood that variations and modifications can be made on the aforementioned structure and process without departing from the concepts of the present invention, and further it is to be understood that such concepts are intended to be covered by the following claims unless these claims by their language expressly state otherwise.