Method for making simulated marble and product of the method

Claim 2

A process for making a reinforced simulated marble or onyx product comprising the step of: (a) providing a mold; (b) applying a thin and substantially clear, hardenable resin coating on said mold; (c) applying a first layer of a mixture of thermosetting polyester resin and filler over said hardenable resin coating, said polyester resin and filler selected such that said first layer is essentially translucent; (d) permitting said first layer to partially cure; (e) forming at least one groove in said partially cured first layer; (f) depositing visible veins of a mixture of finely divided filler and binder in said groove; (g) applying a layer of fibers over said first polyester resin/filler layer and said veins; (h) applying a second layer of polyester resin and filler over said fibers; and (i) permitting said various layers to cure thereby forming said product.

Claim 3

A process according to claim 1 wherein said mold is a single cavity mold in the shape of a bathtub.

Claim 4

A process according to claim 1 wherein said veins are made from a composition comprising from 50-80 wt.% of an inorganic filler and a resinous binder.

Claim 5

A process according to claim 1 wherein the mixture in step (c) includes a solvent and is applied by means of spraying said polyester resin/filler/solvent mixture.

Claim 6

A product produced by the process of claim 1 or 2.

Claim 7

A process according to claim 1 wherein each layer formed in steps (b) and (c) is permitted to cure at least to a tacky state prior to the application of a subsequent layer.

Claim 8

A process according to claim 1 wherein in step (e), each said groove is formed by cutting into said first layer.

Claim 9

A process according to claim 1 wherein said layers formed in steps (c) and (h) have approximately the same thickness.

Claim 10

A process according to claim 1 wherein, in step (f), each said groove is formed by cutting into said first layer.

Claim 11

A process according to claim 1 wherein said layers formed in steps (d), (i) and (j) have approximately the same thickness.

Claim 12

A process according to claim 1 wherein said filler used in said polyester resin/filler mixture is selected from the group consisting of glass frit, aluminum trihydrate and mixtures thereof.

Claim 13

A product produced by the process of claim 11.

Claim 14

A process for making a reinforced simulated marble or onyx product comprising the steps of: (a) providing a mold; (b) spraying a composition comprising (i) an unsaturated polyester resin; (ii) a compatible liquid polymerizerable monomer which crosslinks said polyester resin; (iii) a filler; and (iv) from 2-20 wt.% of a solvent for said unsaturated polyester resin and said monomer on said mold so as to form a first layer, and wherein said crosslinked polyester resin and said filler are selected such that said first layer is essentially translucent; (c) permitting said first layer to partially cure; (d) forming at least one groove in said partially cured first layer; (e) depositing visible veins of a composition comprising a finely divided inorganic filler and binder in said groove; (f) applying a layer of a mixture of glass fibers and hardenable resin over said first layer and said veins so as to form a backing; and (g) permitting said various layers to completely cure whereby a reinforced simulated marble or onyx product is produced.

Claim 15

A process for making a reinforced simulated marble or onyx product comprising the steps of: (a) providing a mold; (b) spraying a composition comprising (i) an unsaturated polyester resin; (ii) a compatible liquid polymerizerable monomer which crosslinks said polyester resin; (iii) a filler; and (iv) from 2-20 wt.% of a solvent for said unsaturated polyester resin and said monomer on said mold so as to form a first layer, and wherein said crosslinked polyester resin and said filler are selected such that said first layer is essentially translucent; (c) permitting said first layer to partially cure; (d) forming at least one groove in said partially cured first layer; (e) depositing visible veins of a composition comprising a finely divided inorganic filler and binder in said groove; (f) applying a layer of a mixture of glass fibers and hardenable resin over said first layer and said veins so as to form a backing; and (g) permitting said various layers to completely cure whereby a reinforced simulated marble or onyx product is produced.

Claim 16

A process according to claim 13 wherein said fibers in step (f) are glass fibers.

Claim 17

A process according to claim 13 wherein prior to step (b), the mold is coated with a clear, thin coating.

Claim 18

The product produced by the process of claims 13 or 14.

Claim 19

A process for making a reinforced simulated marble or onyx product comprising the steps of: (a) providing a mold; (b) applying a thin and substantially clear, hardenable resin coating on said mold; (c) permitting said clear, hardenable resin coating to at least partially cure; (d) spraying a first layer of a polyester resin/filler composition over said mold, said composition comprising: (i) a thermosetting polyester matrix resin formed from an ethylenically unsaturated polyester resin and a compatible liquid polymerizable monomer for crosslinking said unsaturated polyester resin; (ii) a finely divided filler, said filler and said matrix resin having substantially the same index of refraction such that said first layer is essentially translucent; and (iii) a low boiling point solvent; (e) permitting said first layer to partially cure; (f) forming a plurality of grooves in said partially cured first layer; (g) depositing readily visible veins of a composition comprising a finely divided filler and binder in said grooves; (h) permitting said first layer to further cure; (i) applying a layer of a mixture of fibers and hardenable binder over said first layer and said veins; (j) applying a second layer of thermosetting polyester resin and filler mixture over said fiber layer; and (k) permitting said various layers to cure thereby forming said product.

Claim 20

A process for making a reinforced simulated marble or onyx product comprising the steps of: (a) providing a mold; (b) applying a thin and substantially clear, hardenable resin coating on said mold; (c) permitting said clear, hardenable resin coating to at least partially cure; (d) spraying a first layer of a polyester resin/filler composition over said mold, said composition comprising: (i) a thermosetting polyester matrix resin formed from an ethylenically unsaturated polyester resin and a compatible liquid polymerizable monomer for crosslinking said unsaturated polyester resin; (ii) a finely divided filler, said filler and said matrix resin having substantially the same index of refraction such that said first layer is essentially translucent; and (iii) a low boiling point solvent; (e) permitting said first layer to partially cure; (f) forming a plurality of grooves in said partially cured first layer; (g) depositing readily visible veins of a composition comprising a finely divided filler and binder in said grooves; (h) permitting said first layer to further cure; (i) applying a layer of a mixture of fibers and hardenable binder over said first layer and said veins; (j) applying a second layer of thermosetting polyester resin and filler mixture over said fiber layer; and (k) permitting said various layers to cure thereby forming said product.

Claim 21

A process according to claim 17 wherein said clear, hardenable resin coating applied in step (b) is a thermoseting polyester resin.

Claim 22

The product produced by the process of claim 17 or 18.

Claim 23

A process according to claim 17 wherein the fibers in step (i) are glass fibers and said hardenable binder is a polyester resin.

Claim 24

A process according to claim 17 wherein the composition applied in steps (d) and (j) each comprise from about 50 to 85% wt.% of a filler selected from the group consisting of glass frit, silica, aluminum trihydrate and mixtures thereof.

Claim 25

A process according to claim 21 wherein said finely divided filler will pass through a 60 mesh sieve.

Claim 26

The product produced by the process of claim 21 or 22.

Claim 27

A process according to claim 17 wherein said veins formed in step (g) are formed from a highly pigmented polyester resin composition.

Claim 28

A process according to claim 21 wherein said solvent is present in an amount of from about 5 to 16 wt.% based on the total weight of (i) and (ii).

Claim 29

The product produced by the process of claim 25 or 24.