Patent US4877656A successfully refreshed from Google Patents.
US4877656A
Expired / Lapsed
US
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Method of fabricating simulated stone surfaces and improved simulated stone product
Assignee: Academy of Applied Science Inc
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Filing: 1988-08-18
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Granted: 1989-10-31
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Expires: 2008-08-18
Abstract
Abstract Novel artificial or simulated stone facing formed on a substrate with surface-cured finish conformance to the finish of the innerface of a thin flexible film air-sealed to the outer surface of the facing before curing.
Inventors
- 👤 David Baskin
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-07 10:58
CPC Classifications
B; B29; B29C; B29C33/00; B29C33/0011; B29C33/0016; B29C43/00; B29C43/02; B29C43/021; B29C70/00; B29C70/68; B29C70/78; B44; B44F; B44F9/00; B44F9/04; Y; Y10; Y10S; Y10S52/00; Y10S52/07; Y10T; Y10T428/00; Y10T428/24; Y10T428/24355; Y10T428/24446
Claims Analysis
Total Claims: 13
Claim 1
Independent Claim
220 words
A method of fabricating an artificial stone-like facing attached to a substrate, that comprises, preparing a mixture of a wet, soft and uncured synthetic resin binder, color pigment and filler particles and curing agent for the resin; applying the mixture on one side to a substrate with the other side presenting a wet irregular and uneven resin surface; successively and continuously pressing together by rolling pressure successive adjacent portions of the irregular and uneven surface of the wet, soft and uncured resin mixture with corresponding successive portions of a sheet having an inner surface of predetermined smooth finish to compress the resin mixture and force the same into conformance with the successive portions of the said inner surface of the sheet throughout the same and while evacuating air therebetween ,said pressure being used to form either a flat or curved facing; curing the wet resin mixture without heat by action of said curing agent in such compressed and air-sealed condition; the sheet thereafter serving to protect the said facing until the facing is to be used, whereupon the step is performed of separating the sheet and cured mixture to release the facing with a hardened smooth artificial stone-like appearance resulting from the compression of the resin mixture and having the said finish of the said inner surface of the sheet.
Claim 2
Independent Claim
220 words
A method of fabricating an artificial stone-like facing attached to a substrate, that comprises, preparing a mixture of a wet, soft and uncured synthetic resin binder, color pigment and filler particles and curing agent for the resin; applying the mixture on one side to a substrate with the other side presenting a wet irregular and uneven resin surface; successively and continuously pressing together by rolling pressure successive adjacent portions of the irregular and uneven surface of the wet, soft and uncured resin mixture with corresponding successive portions of a sheet having an inner surface of predetermined smooth finish to compress the resin mixture and force the same into conformance with the successive portions of the said inner surface of the sheet throughout the same and while evacuating air therebetween ,said pressure being used to form either a flat or curved facing; curing the wet resin mixture without heat by action of said curing agent in such compressed and air-sealed condition; the sheet thereafter serving to protect the said facing until the facing is to be used, whereupon the step is performed of separating the sheet and cured mixture to release the facing with a hardened smooth artificial stone-like appearance resulting from the compression of the resin mixture and having the said finish of the said inner surface of the sheet.
Claim 3
Independent Claim
199 words
A method of fabricating an artificial stone-like facing as for attachment to a substrate, that comprises, preparing a mixture of a wet, soft and uncured synthetic resin binder, color pigment and filler particles and curing agent for the resin, one side of which is for attachment to a substrate; applying the mixture so that its other side presents a wet surface of irregular and uneven particles; successively and continuously pressing together by rolling pressure successive adjacent portions of the irregular and uneven surface of the wet, soft and uncured resin mixture with corresponding successive portions of a further surface of predetermined smooth finish to compress the resin mixture and force the same into conformance with the successive portions of the further surface througout the same and while evacuating air therebetween , said pressure being used to form either a flat or curved facing; curing the wet resin mixture without heat by action of said curing agent in such compressed and air-sealed condition; and separating the cured mixture and further surface to release the facing with a smooth hardened artificial stone-like appearance resulting from the compression of the resin mixture and having the said finish of the said further surface.
Claim 4
Independent Claim
199 words
A method of fabricating an artificial stone-like facing as for attachment to a substrate, that comprises, preparing a mixture of a wet, soft and uncured synthetic resin binder, color pigment and filler particles and curing agent for the resin, one side of which is for attachment to a substrate; applying the mixture so that its other side presents a wet surface of irregular and uneven particles; successively and continuously pressing together by rolling pressure successive adjacent portions of the irregular and uneven surface of the wet, soft and uncured resin mixture with corresponding successive portions of a further surface of predetermined smooth finish to compress the resin mixture and force the same into conformance with the successive portions of the further surface througout the same and while evacuating air therebetween , said pressure being used to form either a flat or curved facing; curing the wet resin mixture without heat by action of said curing agent in such compressed and air-sealed condition; and separating the cured mixture and further surface to release the facing with a smooth hardened artificial stone-like appearance resulting from the compression of the resin mixture and having the said finish of the said further surface.
Claim 5
Dependent Claim
125 words
A method as claimed in claim 2 and in which the uncured synthetic resin binder is selected from the group consisting of polymerizable unsaturated polyester resins, with and without styrene monomers, epoxy resins, and urethane resins; said filler particles are selected from the group consisting of silica, powdered talc, powdered quartz, diatomaceous earth, gypsum, powdered glass, clay minerals, illite, powdered chalk, powdered marble, powdered limestone, aluminum silicate, aluminum stearate, calcium silicate, boracite, borax and alumina trihydrate; said color pigments are selected from the group consisting of inert inorganic powders and pastes, and polyester-dispersed pigments; and said curing agent is selected from the group consisting of polymerzation catalysts including free radical catalysts based on peroxide-type compounds, methyl ethyl ketone peroxide, benezoyl peroxide and tertiary butyl hydroperoxide.
Claim 6
Dependent Claim
45 words
A method as claimed in claim 2 and in which the artificial stone is to simulate smooth marble, and said filler is selected in amount and particle size such that, when homogeneously mixed into the resin binder and after compression thereof, produces a depth-like translucency.
Claim 7
Dependent Claim
39 words
A method as claimed in claim 2 and in which the cured mixture facing is unitarily attached on its said one side to a substrate, covering one or more of the substrate topside, edges and areas of the underside.
Claim 8
Dependent Claim
17 words
An artificial stone-like facing unitarily carried on a substrate and fabricated by the method of claim 2.
Claim 9
Dependent Claim
24 words
A substrate-carrying artificial stone-like facing as claimed in claim 6 and in which the facing surface is one of high gloss and patterned finish.
Claim 10
Dependent Claim
55 words
An artificial stone-like smooth facing that comprises a layer of cured mixture of polyester resin, polyester-dispersed pigment and aluminum trihydrate filler, pressure-applied when wet and uncured against and throughout a predetermined high gloss smooth surface to conform to the high gloss smooth finish thereof and the cured without heat against said surface and released therefrom.
Claim 11
Dependent Claim
55 words
An artificial stone-like smooth facing that comprises a layer of cured mixture of polyester resin, polyester-dispersed pigment and aluminum trihydrate filler, pressure-applied when wet and uncured against and throughout a predetermined high gloss smooth surface to conform to the high gloss smooth finish thereof and the cured without heat against said surface and released therefrom.
Claim 12
Dependent Claim
151 words
An artificial stone-like facing attached to one or more of the topside, edges and areas of the underside of a substrate, and comprising a layer(s) of cured mixture of initially uncured wet and soft synthetic resin binder, color pigment, filler particles and curing agent, said resin being selected from the group consisting of polymerizable unsaturated polyester resins, with and without styrene monomers, epoxy resins and urethane resins; said color pigments being selected from the group consisting of inert inorganic powders and pastes and polyester-dispersed pigments; and said filler particles being selected from the group consisting of powdered silica, silicates, quartz earths and clays and aluminum trihydrate; said layer(s) of cured mixture having been pressure-applied when wet and uncured and compressed against a predetermined smooth surface of high gloss to conform to and the smooth finish of said surface and then cured without heat against and throughout said surface and released therefrom.
Claim 13
Dependent Claim
151 words
An artificial stone-like facing attached to one or more of the topside, edges and areas of the underside of a substrate, and comprising a layer(s) of cured mixture of initially uncured wet and soft synthetic resin binder, color pigment, filler particles and curing agent, said resin being selected from the group consisting of polymerizable unsaturated polyester resins, with and without styrene monomers, epoxy resins and urethane resins; said color pigments being selected from the group consisting of inert inorganic powders and pastes and polyester-dispersed pigments; and said filler particles being selected from the group consisting of powdered silica, silicates, quartz earths and clays and aluminum trihydrate; said layer(s) of cured mixture having been pressure-applied when wet and uncured and compressed against a predetermined smooth surface of high gloss to conform to and the smooth finish of said surface and then cured without heat against and throughout said surface and released therefrom.
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) | 1992-10-30 | 1993-05-01 | 1993-10-31 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1996-10-30 | 1997-05-01 | 1997-10-31 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2000-10-30 | 2001-05-01 | 2001-10-31 | $7700.00 | Window Closed / Lapsed |