Method of making cellular plastic articles

Claim 1

THE METHOD OF MAKING A CELLULAR PLASTIC ARTICLE WHICH COMPRISES APPLYING A LIQUID REACTANT MIXTURE OF PHENOL FORMALDEHYDE RESIN CONTAINING A DIVIDED METAL GASSING AGENT, APPROXIMATELY 11% POLYVINYL ALCOHOL AND AN AROMATIC SULFONIC-PHOSPHORIC ACID AQUEOUS SOLUTION CATALYST REACTING WITH SAID AGENT TO RENDER THE MIXTURE CELLULAR, TO THE SURFACE OF A DIE SO THAT THE LAYER HAS AN INNER SURFACE ON THE DIE AND AN UNCONFINED EXTERNAL SURFACE, DISTRIBUTING SAID LIQUID LAYER EVENLY, UNIFORMALLY AND SMOOTHLY ON SAID DIE BY MEANS OF A BLADE, SO THAT THE THICKNESS OF SAID LIQUID LAYER IS SUBSTANTIALLY LESS THAN THE DESIRED THICKNESS OF THE FINISHED PLASTIC ARTICLE, AIR CURING SAID LIQUID LAYER AT ROOM TEMPERATURE FOR FROM 15 TO 30 MINUTES, OVEN CURING AT A TEMPERATURE OF ABOUT 150*F. FROM 1 TO 12 HOURS WHILE SIMULTANEOUSLY PERMITTING SAID CURING LAYER TO EXPAND PERPENDICULARLY FROM SAID DIE SURFACE TO THE DESIRED THICKNESS OF THE FINISHED PLASTIC ARTICLE AQS DETERMINED BY THE THICKNESS OF SAID LIQUID LAYER, WHEREBY THE LAYER SETS TO FORM A PLASTIC ARTICLE HAVING A CONTINUOUS EXTERNAL HARD GLOSSY SURFACE SUBSTANTIALLY PARALLEL TO THE SURFACE OF SAID DIE.

Claim 2

THE METHOD OF MAKING A CELLULAR PLASTIC ARTICLE WHICH COMPRISES APPLYING A LIQUID REACTANT MIXTURE OF PHENOL FORMALDEHYDE RESIN CONTAINING A DIVIDED METAL GASSING AGENT, APPROXIMATELY 11% POLYVINYL ALCOHOL AND AN AROMATIC SULFONIC-PHOSPHORIC ACID AQUEOUS SOLUTION CATALYST REACTING WITH SAID AGENT TO RENDER THE MIXTURE CELLULAR, TO THE SURFACE OF A DIE SO THAT THE LAYER HAS AN INNER SURFACE ON THE DIE AND AN UNCONFINED EXTERNAL SURFACE, DISTRIBUTING SAID LIQUID LAYER EVENLY, UNIFORMALLY AND SMOOTHLY ON SAID DIE BY MEANS OF A BLADE, SO THAT THE THICKNESS OF SAID LIQUID LAYER IS SUBSTANTIALLY LESS THAN THE DESIRED THICKNESS OF THE FINISHED PLASTIC ARTICLE, AIR CURING SAID LIQUID LAYER AT ROOM TEMPERATURE FOR FROM 15 TO 30 MINUTES, OVEN CURING AT A TEMPERATURE OF ABOUT 150*F. FROM 1 TO 12 HOURS WHILE SIMULTANEOUSLY PERMITTING SAID CURING LAYER TO EXPAND PERPENDICULARLY FROM SAID DIE SURFACE TO THE DESIRED THICKNESS OF THE FINISHED PLASTIC ARTICLE AQS DETERMINED BY THE THICKNESS OF SAID LIQUID LAYER, WHEREBY THE LAYER SETS TO FORM A PLASTIC ARTICLE HAVING A CONTINUOUS EXTERNAL HARD GLOSSY SURFACE SUBSTANTIALLY PARALLEL TO THE SURFACE OF SAID DIE.