Method for producing molded products comprising melamine formaldehyde resin and gypsum

Claim 1

A METHOD FOR PRODUCING MOLDED PRODUCTS COMPRISING LOADING A MOLD SPACE WITH A COMPOSITION CONSISTING ESSENTIALLY OF A WATER SOLUBLE MELAMINE FORMALDEHYDE RESIN IN AN INTERMEDIATE STAGE OF POLYMERIC GROWTH AND CALCINED GYPSUM PRESENT IN THE RATIO OF 1 PART BY WEIGHT RESIN TO 2-8 PARTS BY WEIGHT GYPSUM, WATER IN AMOUNTS GREATER THAN 16 PARTS BY WEIGHT PER 100 PARTS BY WEIGHT OF GYPSUM TO IMPART FLOW OF THE DESIRED CHARACTER BUT NOT MORE THAN THAT THEORETICALLY REQUIRED TO COMBINED WITH THE GYPSUM TO FORM A CURED CEMENT, A WATER SOULBLE ALKALI METAL SALT PRESENT IN AMOUNTS RANGING FROM 0.25-4 PARTS BY WEIGHT PER 100 PARTS BY WEIGHT OF GYPSUM TO SEED THE CEMENT CURE, AN ACIDIC SUBSTANCE TO ADJUST THE PH OF THE COMPOSITION TO BETWEEN 5 AND 7, A RETARDER FOR THE GYPSUM CEMENT, AND GLASS FIBERS OF REINFORCING LENGTHS PRESENT IN AMOUNT RANGING FROM 1-20 PERCENT BY WEIGHT BASED UPON THE SOLIDS IN THE MOLDING COMPOSITION, MOLDING THE COMPOSITION UNDER HEAT AND PRESSURE BETWEEN MOLD SURFACES HEATED TO A TEMPERATURE WITHIN THE RANGE OF 220-300* F. WHEREBY THE COMPOSITION IS CAUSED TO FLOW FOR FILLING THE MOLDING SPACE UNTIL THE MELAMINE FORMALDEHYDE RESIN AND GYPSUM COMPONENTS ARE ADVANCED TO A STAGE CAPABLE OF MAINTAINING MOLD SHAPE, REMOVING THE MOLDED PRODUCT FROM THE MOLD SPACE, AND HYDRATING THE MOLDED PRODUCT WITH A FILM OF WATER IN SURFACE CONTACT WITH THE MOLDED PRODUCT UNTIL SAID COMPONENTS ARE CONVERTED TO A HARD AND CURED STAGE.

Claim 2

A METHOD FOR PRODUCING MOLDED PRODUCTS COMPRISING LOADING A MOLD SPACE WITH A COMPOSITION CONSISTING ESSENTIALLY OF A WATER SOLUBLE MELAMINE FORMALDEHYDE RESIN IN AN INTERMEDIATE STAGE OF POLYMERIC GROWTH AND CALCINED GYPSUM PRESENT IN THE RATIO OF 1 PART BY WEIGHT RESIN TO 2-8 PARTS BY WEIGHT GYPSUM, WATER IN AMOUNTS GREATER THAN 16 PARTS BY WEIGHT PER 100 PARTS BY WEIGHT OF GYPSUM TO IMPART FLOW OF THE DESIRED CHARACTER BUT NOT MORE THAN THAT THEORETICALLY REQUIRED TO COMBINED WITH THE GYPSUM TO FORM A CURED CEMENT, A WATER SOULBLE ALKALI METAL SALT PRESENT IN AMOUNTS RANGING FROM 0.25-4 PARTS BY WEIGHT PER 100 PARTS BY WEIGHT OF GYPSUM TO SEED THE CEMENT CURE, AN ACIDIC SUBSTANCE TO ADJUST THE PH OF THE COMPOSITION TO BETWEEN 5 AND 7, A RETARDER FOR THE GYPSUM CEMENT, AND GLASS FIBERS OF REINFORCING LENGTHS PRESENT IN AMOUNT RANGING FROM 1-20 PERCENT BY WEIGHT BASED UPON THE SOLIDS IN THE MOLDING COMPOSITION, MOLDING THE COMPOSITION UNDER HEAT AND PRESSURE BETWEEN MOLD SURFACES HEATED TO A TEMPERATURE WITHIN THE RANGE OF 220-300* F. WHEREBY THE COMPOSITION IS CAUSED TO FLOW FOR FILLING THE MOLDING SPACE UNTIL THE MELAMINE FORMALDEHYDE RESIN AND GYPSUM COMPONENTS ARE ADVANCED TO A STAGE CAPABLE OF MAINTAINING MOLD SHAPE, REMOVING THE MOLDED PRODUCT FROM THE MOLD SPACE, AND HYDRATING THE MOLDED PRODUCT WITH A FILM OF WATER IN SURFACE CONTACT WITH THE MOLDED PRODUCT UNTIL SAID COMPONENTS ARE CONVERTED TO A HARD AND CURED STAGE.