Method of molding composite polymerized articles

Claim 1

THE METHOD OF FORMING A MOLDED COMPOSITE ARTICLE OF POLYMERIZED METHACRYLATE ESTER RESIN COMPRISING SHAPING A FIRST PORTION FROM A DOUGH OF MIXED FINELY DIVIDED SOLID METHACRYLATE ESTER POLYMER AND LIQUID METHACRYLATE MONOMER ESTER WITH UP TO 20% OF A CROSS-LINKING AGENT SELECTED FROM THE GROUP CONSISTING OF ALLYL METHANCRYLATE, ETHYLENE GLYCOL DIMETHACRYLATE AND POLYETHYLENE GLYCOL DIMETHACRYLATE, SIMULTANEOUSLY CONTACTING ONE SURFACE OF SAID SHAPED DOUGH WITH A HEAT-RESISTANT NON-ADHERENT LINER SHEET MADE OF SYNTHETIC RESIN SELECTED FROM THE GROUP CONSISTING OF LINEAR POLYETHYLENE, TETRAFLUORETHYLENE POLYMER, POLYVINYL ALCOHOL AND HEAT RESISTANT NYLON, SAID LINER HAVING A THICKNESS OF BETWEEN ABOUT 1 TO ABOUT 10 MILS, POLYMERIZING SAID FIRST PORTION BY MOLDING SAID DOUGH FACED WITH SAID LINER AT A TEMPERATURE BETWEEN ABOUT 180* F. TO ABOUT 210*F. AND PRESSURE OF ABOUT 800 TO ABOUT 5000 POUNDS PER SQUARE INCH FOR 2 TO 5 MINUTES TO PROVIDE A LATENT ADHESIVE PREFORM HAVING SUBSTANTIALLY THE SAME SHAPE AS IN THE MOLDED COMPOSITE ARTICLE BUT ALSO HAVING AN INCOMPLETELY POLYMERIZED LATENT ADHESIVE SURFACE UNDER SAID LINER, REMOVING SAID LINER SHEET, ASSEMBLING AGAINST SAID LATENT ADHESIVE SURFACE OF SAID FIRST PREFORM PORTION SECOND PREFORM PORTION CONSISTING OF AN UNPOLYMERIZED MASS OF FINELY DIVIDED SOLID METHACRYLATE ESTER POLYMER IN INTIMATE ADMIXTURE WITH LIQUID METHYL METHACRYLATE IN DOUGH CONSISTENCY AND MOLDING SAID FIRST LATENT ADHESIVE PREFORM AND SAID SECOND UNPOLYMERIZED MASS AT A TEMPERATURE OF ABOUT 190*-300*F. AND PRESSURE OF ABOUT 1500-5000 POUNDS PER SQUARE INCH FOR ABOUT 11/2 TO ABOUT 10 MINUTES TO POLYMERIZE SAID SECOND PORTION WHILE BONDING AND POLYMERIZING SAID INCOMPLETELY POLYMERIZED SURFACE OF SAID FIRST PREFORM WITH THE CONTACTING SURFACE OF SAID SECOND PORTION.

Claim 2

THE METHOD OF FORMING A MOLDED COMPOSITE ARTICLE OF POLYMERIZED METHACRYLATE ESTER RESIN COMPRISING SHAPING A FIRST PORTION FROM A DOUGH OF MIXED FINELY DIVIDED SOLID METHACRYLATE ESTER POLYMER AND LIQUID METHACRYLATE MONOMER ESTER WITH UP TO 20% OF A CROSS-LINKING AGENT SELECTED FROM THE GROUP CONSISTING OF ALLYL METHANCRYLATE, ETHYLENE GLYCOL DIMETHACRYLATE AND POLYETHYLENE GLYCOL DIMETHACRYLATE, SIMULTANEOUSLY CONTACTING ONE SURFACE OF SAID SHAPED DOUGH WITH A HEAT-RESISTANT NON-ADHERENT LINER SHEET MADE OF SYNTHETIC RESIN SELECTED FROM THE GROUP CONSISTING OF LINEAR POLYETHYLENE, TETRAFLUORETHYLENE POLYMER, POLYVINYL ALCOHOL AND HEAT RESISTANT NYLON, SAID LINER HAVING A THICKNESS OF BETWEEN ABOUT 1 TO ABOUT 10 MILS, POLYMERIZING SAID FIRST PORTION BY MOLDING SAID DOUGH FACED WITH SAID LINER AT A TEMPERATURE BETWEEN ABOUT 180* F. TO ABOUT 210*F. AND PRESSURE OF ABOUT 800 TO ABOUT 5000 POUNDS PER SQUARE INCH FOR 2 TO 5 MINUTES TO PROVIDE A LATENT ADHESIVE PREFORM HAVING SUBSTANTIALLY THE SAME SHAPE AS IN THE MOLDED COMPOSITE ARTICLE BUT ALSO HAVING AN INCOMPLETELY POLYMERIZED LATENT ADHESIVE SURFACE UNDER SAID LINER, REMOVING SAID LINER SHEET, ASSEMBLING AGAINST SAID LATENT ADHESIVE SURFACE OF SAID FIRST PREFORM PORTION SECOND PREFORM PORTION CONSISTING OF AN UNPOLYMERIZED MASS OF FINELY DIVIDED SOLID METHACRYLATE ESTER POLYMER IN INTIMATE ADMIXTURE WITH LIQUID METHYL METHACRYLATE IN DOUGH CONSISTENCY AND MOLDING SAID FIRST LATENT ADHESIVE PREFORM AND SAID SECOND UNPOLYMERIZED MASS AT A TEMPERATURE OF ABOUT 190*-300*F. AND PRESSURE OF ABOUT 1500-5000 POUNDS PER SQUARE INCH FOR ABOUT 11/2 TO ABOUT 10 MINUTES TO POLYMERIZE SAID SECOND PORTION WHILE BONDING AND POLYMERIZING SAID INCOMPLETELY POLYMERIZED SURFACE OF SAID FIRST PREFORM WITH THE CONTACTING SURFACE OF SAID SECOND PORTION.