US4235948A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Simulated stone article and method for making same
Assignee: ROYAL BATHS MANUFACTURING Co
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Filing: 1979-04-02
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Granted: 1980-11-25
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Expires: 1999-04-02
Abstract
Abstract In one exemplar embodiment a simulated stone article having a pre-formed acrylic sheet "skin" is integrally bonded to a simulated stone matrix layer. The surface of the acrylic "skin" is cleaned with an inert organic solvent to make the surface more receptive to molecular bonding. A coat of urethane is applied to the acrylic "skin" surface and permitted to cure. The simulated stone matrix is a composition including a catalyzed polyester bonding resin, a simulated stone aggregate mix, coloring, veining and pigmentation agents and an exothermic reducing agent for slowing the setting time and lowering the temperature of the bonding resin for permitting greater flexing of the composition during shrinkage of the resin while curing for improving the bond between the acrylic "skin" and cured urethane, and the bonding resin of the simulated stone matrix.
Inventors
- 👤 Donald F. Holmes
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-26 22:21
CPC Classifications
B; B32; B32B; B32B27/00; B32B27/06; B32B27/08; B32B27/18; B32B38/00; B32B38/16; B32B38/162; B32B7/00; B32B7/04; B32B9/00; B32B9/04; B32B9/045; B44; B44C; B44C3/00; B44C3/04; B44C5/00; B44C5/06; B44F; B44F9/00; B44F9/04; C; C08; C08J; C08J5/00; C08J5/12; C08J5/121; B32B2318/00; B32B2318/04; Y; Y10; Y10T; Y10T428/00; Y10T428/13; Y10T428/131; Y10T428/1314; Y10T428/1352; Y10T428/25; Y10T428/252; Y10T428/31504; Y10T428/31551; Y10T428/31616; Y10T428/3162
Claims Analysis
Total Claims: 18
Claim 1
Independent Claim
132 words
The method of forming a simulated stone product having an integral acrylic resin surface, comprising the steps of applying to the surface of a sheet of the acrylic resin an organic solvent for cleaning said surface and rendering said surface more receptive to bonding, applying to said surface a coating of liquid urethane, allowing said urethane to set for a preselected time period, applying to said urethane coating a composition including a catalyzed polyester bonding resin, a simulated stone aggregate, pigmenting agents, and an exothermic reducing agent, and curing said polyester bonding resin for bonding said resin to said urethane coating, said exothermic reducing agent causing a slowing of the setting rate and a lowering of the temperature of said resin for permitting greater flexing during shrinkage of said resin while curing.
Claim 2
Independent Claim
132 words
The method of forming a simulated stone product having an integral acrylic resin surface, comprising the steps of applying to the surface of a sheet of the acrylic resin an organic solvent for cleaning said surface and rendering said surface more receptive to bonding, applying to said surface a coating of liquid urethane, allowing said urethane to set for a preselected time period, applying to said urethane coating a composition including a catalyzed polyester bonding resin, a simulated stone aggregate, pigmenting agents, and an exothermic reducing agent, and curing said polyester bonding resin for bonding said resin to said urethane coating, said exothermic reducing agent causing a slowing of the setting rate and a lowering of the temperature of said resin for permitting greater flexing during shrinkage of said resin while curing.
Claim 3
Dependent Claim
101 words
The method as described in claim 1 wherein said curing step proceeds for a predetermined time period and further includes the additional steps of applying to the outer surface of said partially cured polyester bonding resin-simulated stone matrix composition a mixture of glass fibers and a curable polyester bonding resin for said fibers, continuing curing of said polyester bonding resin-simulated stone matrix composition for securely bonding said composition and the acrylic resin to said urethane coating, and curing said curable polyester bonding resin to securely bond said resin and glass fiber mixture to said composition for reinforcing said simulated stone product.
Claim 4
Dependent Claim
14 words
The method as described in claim 1, wherein said organic solvent is methylene chloride.
Claim 5
Dependent Claim
43 words
The method as described in claim 1, wherein said composition includes about 18 to 20% by weight polyester bonding resin, 80 to 78% by weight calcium carbonate, and other mineral fillers, and 2% by weight catalyst, pigmenting agents and said exothermic reducing agents.
Claim 6
Dependent Claim
41 words
The method as described in claim 1, wherein said composition includes about 19 to 20% by weight polyester bonding resin, 80 to 79% by weight aluminum tri-hydrate and other mineral fillers, 1% by weight catalyst, pigmenting agents, and exothermic reducing agent.
Claim 7
Dependent Claim
15 words
The method as described in claim 1, wherein said exothermic reducing agent is alpha-methyl styrene.
Claim 8
Independent Claim
214 words
The method of forming a reinforced simulated stone product having an integral acrylic resin surface, comprising the steps of applying to the surface of a sheet of the acrylic resin an organic solvent for cleaning said surface and rendering said surface more receptive to bonding, applying to said surface a coating of liquid urethane, allowing said urethane to set for a preselected time period, applying to said urethane coating a composition including a catalyzed polyester bonding resin-simulated stone aggregate, pigmenting agents and an exothermic reducing agent, curing said polyester bonding resin for a predetermined time period for initially bonding said resin to said urethane coating, said exothermic reducing agent causing a slowing of the setting rate and a lowering of the temperature of said resin for permitting greater flexing during shrinkage of said resin while curing, applying to the outer surface of said catalyzed polyester bonding resin-simulated stone matrix composition a mixture of glass fibers and a curable polyester bonding resin for said fibers, continuing curing of said catalyzed polyester bonding resin-simulated stone matrix composition for securely bonding said composition and the acrylic resin surface to said urethane coating, and curing said curable polyester bonding resin to securely bond said resin and glass fiber mixture to said composition for reinforcing said simulated stone product.
Claim 9
Independent Claim
214 words
The method of forming a reinforced simulated stone product having an integral acrylic resin surface, comprising the steps of applying to the surface of a sheet of the acrylic resin an organic solvent for cleaning said surface and rendering said surface more receptive to bonding, applying to said surface a coating of liquid urethane, allowing said urethane to set for a preselected time period, applying to said urethane coating a composition including a catalyzed polyester bonding resin-simulated stone aggregate, pigmenting agents and an exothermic reducing agent, curing said polyester bonding resin for a predetermined time period for initially bonding said resin to said urethane coating, said exothermic reducing agent causing a slowing of the setting rate and a lowering of the temperature of said resin for permitting greater flexing during shrinkage of said resin while curing, applying to the outer surface of said catalyzed polyester bonding resin-simulated stone matrix composition a mixture of glass fibers and a curable polyester bonding resin for said fibers, continuing curing of said catalyzed polyester bonding resin-simulated stone matrix composition for securely bonding said composition and the acrylic resin surface to said urethane coating, and curing said curable polyester bonding resin to securely bond said resin and glass fiber mixture to said composition for reinforcing said simulated stone product.
Claim 10
Dependent Claim
14 words
The method as described in claim 7, wherein said organic solvent is methylene chloride.
Claim 11
Dependent Claim
48 words
The method as described in claim 7, wherein said catalyzed polyester bonding resin-simulated stone matrix includes about 18 to 20% by weight polyester bonding resin, 80 to 78% by weight calcium carbonate and other mineral fillers, and 2% by weight catalyst, pigmenting agents and said exothermic reducing agent.
Claim 12
Dependent Claim
48 words
The method as described in claim 7, wherein said catalyzed polyester bonding resin-simulated stone matrix includes about 19 to 20% by weight polyester bonding resin, 80 to 79% by weight aluminum tri-hydrate and other mineral fillers, and 1% by weight catalyst, pigmenting agents and said exothermic reducing agents.
Claim 13
Dependent Claim
15 words
The method as described in claim 7, wherein said exothermic reducing agent is alpha-methyl styrene.
Claim 14
Dependent Claim
111 words
A simulated stone article having an integral acrylic resin surface, comprising a formed sheet of an acrylic resin in the configuration of the article, a layer of partially set liquid urethane coating a surface of the acrylic sheet and molecularly bonded thereto, a cured composition of catalyzed polyester bonding resin and simulated stone aggregate molecularly bonded to the surface of the layer of urethane, said composition further including an exothermic reducing agent causing a slowing of the setting rate and a lowering of the temperature of said resin during curing for permitting greater flexing during shrinkage of said resin while curing to improve the bond between said resin and said urethane.
Claim 15
Dependent Claim
111 words
A simulated stone article having an integral acrylic resin surface, comprising a formed sheet of an acrylic resin in the configuration of the article, a layer of partially set liquid urethane coating a surface of the acrylic sheet and molecularly bonded thereto, a cured composition of catalyzed polyester bonding resin and simulated stone aggregate molecularly bonded to the surface of the layer of urethane, said composition further including an exothermic reducing agent causing a slowing of the setting rate and a lowering of the temperature of said resin during curing for permitting greater flexing during shrinkage of said resin while curing to improve the bond between said resin and said urethane.
Claim 16
Dependent Claim
33 words
The article described in claim 12, further comprising glass fibers, and a cured polyester bonding resin molecularly bonded to said polyester bonding resin-simulated stone matrix composition for securely bonding said glass fibers thereto.
Claim 17
Dependent Claim
47 words
The article described in claim 12, wherein said composition when applied to said sheet includes about 18% to 20% by weight polyester bonding resin, 80% to 78% by weight calcium carbonate and other mineral fillers, and 2% by weight catalyst, pigmenting agents and said exothermic reducing agent.
Claim 18
Dependent Claim
53 words
The article as described in claim 12, wherein said catalyzed polyester bondng resin-simulated stone matrix when applied to said sheet includes about 19% to 20% by weight polyester bonding resin, 80% to 78% by weight aluminum tri-hydrate and other mineral fillers, and 1% by weight catalyst pigmenting agents and said exothermic reducing agent.
References Cited (Backward Citations)
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1983-11-25 | 1984-05-26 | 1984-11-25 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1987-11-25 | 1988-05-26 | 1988-11-25 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1991-11-25 | 1992-05-26 | 1992-11-25 | $7700.00 | Window Closed / Lapsed |