Method of forming dense smooth surfaced furfuryl alcohol resin compositions

Claim 1

A PROCESS FOR MOLDING FURFURYL ALCOHOL RESIN INTO A DENSE, CHEMICALL AND THERMALLY RESISTANT, OBJECT COMPRISING THE STEPS OF: (A) FORMING A MOLDING COMPOSITION BY MIXING 20 TO 30 PERCENT, BY WEIGHT OF SAID COMPOSITION, OF A FURFURYL ALCOHOL RESIN HAVING A VISCOSITY BETWEEN ABOUT 150 TO ABOUT 350 CENTIPOSED AT 25*C. WITH 70 TO 80 PERCENT BY WEIGHT OF INERT ACID-RESISTANT FILLER AND WITH 0.2 TO 1.2 PERCENT BY WEIGHT OF AN ACID CATALYST; (B) PROVIDING AN OPEN MOLD HAVING A CAVITY WITH THE DESIRED CONFIGURATION FOR SAID OBJECT, SAID CAVITY HAVING A PORTION THEREOF WITH A THICKNESS OF AT LEAST ABOUT 1/2 INCH: (C) FORMING A CONTINOUS FILM OF POLYETHYLENE ON THE PORTIONS OF SAID MOLD DEFINING SAID CAVITY INTO WHICH SAID COMPOSITION IS TO BE INTRODUCED; (D) THEREAFTER INTRODUCING SAID COMPOSITION INTO SAID MOLD CAVITY TO FILL UNTIL AT LEAST ABOUT 1/2 INCH IN THICKNESS OF SAID COMPOSITION IS DEPOSITED IN SAID CAVITY; (E) HEATING SAID COMPOSITION IN SAID MOLD AT A TEMPERATURE BELOW 150*F. AT A RATE OF HEATING INSUFFICIENT TO CAUSE INTERNAL FOAMING OF SAID COMPOSITION. (F) MAINTAINING SAID COMPOSITION AT SAID TEMPERATURE FOR A PERIOD OF TIME SUFFICIENT TO ADVANCE SAID COMPOSITION TO A SOLIDFIED, SET STAGE; (G) SEPARATING THE SOLIDIFIED COMPOSITION TOGETHER WITH SAID FILM OF POLYETHYLENE FROM THE MOLD; (H) STRIPPING SAID FILM FROM THE MOLDED, SOLIDIFIED COMPOSITION; (I) POST CURING THE STRIPPED MOLDED COMPOSITION BY HEATING SAID COMPOSITION TO BETWEEN ABOUT 150*F. AND ABOUT 280*F. FROM A PERIOD OF THE TIME SUFFICIENT TO COMPLETE CURING WITHOUT ALTERATION OF THE CHARACTERISTICS OF THE EXTERIOR MOLDED SURFACE THEREOF.