U.S. patent application number 10/604972 was filed with the patent office on 2005-03-17 for stones-like laminates.
This patent application is currently assigned to Rochette, Michel. Invention is credited to Rochette, Michel.
Application Number | 20050055931 10/604972 |
Document ID | / |
Family ID | 34273152 |
Filed Date | 2005-03-17 |
United States Patent
Application |
20050055931 |
Kind Code |
A1 |
Rochette, Michel |
March 17, 2005 |
Stones-like laminates
Abstract
The present invention provides a laminate which has a stone-like
appearance comprising a fiber cement board. The cement board layer
can be embossed and/or engraved and/or painted to give the
impression of colors and depths. Organic polymer composition which
includes inorganic filler is included in the laminate.
Inventors: |
Rochette, Michel; (Lac
Beauport, CA) |
Correspondence
Address: |
Larry J Palguta
Honeywell Law Department
3820 Westmoor Street
South Bend
IN
46628
US
|
Assignee: |
Rochette, Michel
24 ch de l'eclaircie
Lac Beauport
CA
|
Family ID: |
34273152 |
Appl. No.: |
10/604972 |
Filed: |
August 28, 2003 |
Current U.S.
Class: |
52/506.01 |
Current CPC
Class: |
A47K 3/40 20130101; B44F
9/04 20130101; B44C 5/04 20130101; E04F 13/185 20130101; E04F 15/10
20130101 |
Class at
Publication: |
052/506.01 |
International
Class: |
E04B 002/00 |
Claims
1. A stones-like laminate comprising: a cement board as a backup
layer; Laminated to at least one surface of said cement board with
a resin comprising polymers selected from the group consisting of
unsaturated polyesters, allyls, aminos, epoxies, phenolics,
silicones, urethanes, siloxanes, silanes, acrylics and combinations
thereof; An inorganic portion comprising particles are at least one
opaque inorganic particles and/or one transparent inorganic
particles.
2. The laminate of claim 1, wherein said the fiber cement board
having embossed and/or engraved portion.
3. The laminate of claim 1, wherein said the cement board having
decorative painted surface.
4. The laminate of claim 1, wherein the polymers resin is a gel
coat base resin.
5. The laminate of claim 1, wherein said the resin having fiber
reinforcement.
6. The laminate of claim 1, in which the resin matrix layer
comprises at least one of the following transparent and/or
translucent particles: calcite, feldspar, glass, marble, mica,
obsidian, quartz, sand, silica, wollastonite and various filled or
unfilled pigmented or dyed, insoluble chips of polymeric materials
such as cellulose, polyethylene, ethylene copolymers, crosslinked
polyacrylic polymers, polyesters, polypropylenes, crosslinked
polyvinyl chlorides and polyacetals.
7. The laminate of claim 1, in which the resin matrix layer
comprises at least one of the following opaque particles: calcined
talc, magnetite, siderite, ilmenite, goethite, galena, coal,
pyrite, hematite, limonite, biotite, natural granite, anhydrite,
chalk, sandstone, peat and chips of various filled or pigmented
insoluble polymers such as polypropylene, crosslinked acrylic
polymers, polyethylene, ethylene copolymers, phenolic resins,
urea/formaldehyde resins, colored chips, hydrated alumina,
crosslinked polyvinyl chloride and polyesters.
8. The laminate of claim 1, in which the resin matrix layer
comprises at least one of the following decorative filler:
pigments, dyes, reflective flakes, metal particles, colored rocks,
colored glass, colored sand, wood products, ceramic particles.
9. A method for making decorative pattern comprising a engraved
and/or embossed cement board as a backup layer, said engraved
and/or embossed served as a stencil, said this stencil-like
technique consist to filled cavity on the cement board layer with
decorative filler with at least one decorative filler with at least
one step, said step consisting to filled and let if is applicable,
the decorative filler dry
10. In the method of claim 9, wherein said decorative filler
comprises at least one of the following filler: pigments, dyes,
paint, colored chips, reflective flakes, metal particles, rocks,
colored glass, colored sand, wood products, ceramic particles and
combinations thereof.
11. An article selected from the class consisting of wall panels,
vanities, kitchen counters, shower cabinets, sinks table tops and
furniture parts made from the laminates of claim 1.
12. The laminate of claim 1, which further includes forming a
tongue and groove structure in the sides of said laminate.
Description
BACKGROUND OF INVENTION
[0001] The present invention relates to sheets and slabs of acrylic
solid surface now commonly used as kitchen countertops, interior
and exterior decorative coverings and architectural panel. Since
the early 1980's, several major manufacturers have developed their
own brand of solid surface products. For the most part, these
products are expensive because acrylic panel need a lot of polymer.
The present invention can create the appearance of granite, marble
or other types of stone surfaces. The present invention show
superior hardness, high structural toughness at a low cost when
compared to other acrylic solid surfaces or other stone-like
laminates products.
[0002] Other processes have attempted to reduced the cost of
acrylic panel. Several such prior art teachings are shown in U.S.
Pat. No. 3,963,846 proposes a backing sheet consisting of a
multicellular resin-impregnated paper core. This layer is made
partially of polymer and the cost of this products is for the same
toughness, superior of the present invention
[0003] U.S. Pat. No. 4,446,177 disclosed simulated stone product
formed of a reinforced plastic including a gelcoat layer, a
thermoplastic or thermoset resin matrix and a backup layer. The
backup layer is comprised of a fibrous polyester sheet impregnated
with thermoplastic or thermoset resin and plasticizer. This layer
is made partially of polymer and show similar problems as U.S. Pat.
No. 3,963,846.
SUMMARY OF INVENTION
[0004] The object of the present invention is to provide a
composite lamina which is relatively inexpensive to manufacture and
provide a simulated natural stone-like appearance.
[0005] The main advantage of the present invention is the backer
layer, more specifically a cement board panel who gives over other
solutions offered today a very good adhesion for the organic
portion, better strength for the same thickness, and a very
economical way to make stone-like panels. For example, at an equal
strength, it is more economical to put a cement board backing with
a thinner layer of polymer than no backing and a greater amount of
polymers.
[0006] By utilizing the process of the present invention, various
solid surface decorative articles can be provided having a myriad
of aesthetic designs. Moreover such process is economical and
capable of mass production. Also, highly detailed inlays may be
produced from engraved cement board backing with one or more color
as inlays. Final product may have embossed surface made by the
embossed and/or engraved cement board.
DETAILED DESCRIPTION
[0007] The present invention proposes a cement board as a backup
layer. Hard surface of cement board provide a very good substrate
for engraved and/or embossed high precision pattern. Cement board
are corrosion resistant and maintenance cost is minimal. Cement
board provides high rigidity and stiffness at low cost.
[0008] The present invention is impact resistant, termite and
vermin resistant highly fire-resistant, moisture resistant and it
provides to the final product very good and economical structural
qualities and it is perfect for interior/exterior application such
as wall panels, balconies and decks.
[0009] The present invention decrease the needs of polymer material
without affecting the strength of the product, therefore the
present invention gives a low cost versus strength ratio.
[0010] The present invention provides a high strength-to-weight
ratio which enables the resin layer to be thinner without
sacrificing mechanical strength characteristics.
[0011] The present invention is easily cut and installed using
standard carpentry tools. The back layer is composed of a flat or
engraved cement board painted or not. Such cement board is marketed
under brand names such as, but not limited to Sheetrock, Durock,
HardiBacker, PermaBase, PRO_Backerboard, ProRoc, WonderBoard,
Plycem and RhinoBoard. The engraved cement board layer improved the
adhesion surface with the resin. The transparency of the resin or
other transparent material used for the inorganic portion creates a
depth effect that simulates the granite or marble appearance.
Engraved a cement board causes no problem and can be done by
various type of machines. The painted part of the process can be
realized on the entire surface or partially with one or many
colors. The cement board may be painted with various art
techniques. Cement board can be impregnated with acrylic and/or any
dyes that may be desirable for color control. Cement board backing
show that unsaturated polyester resin can't change dimensional
stability and rigidity of this layer.
[0012] The present invention have the advantage of a molded
composition marketed under brand names such as Corian, Hi-Macs,
Staron and Earthstone but with lightness, strength and low cost.
Like other molded products, the present invention has the advantage
of being easily removable of the mold, without using detaching
substances.
[0013] Particle board or fiber board, at an equal thickness, are
not strength enough and do not have water proof quality of cement
board. Particle board or fiber board need to be treating at there
four face to be waterproof and that kind of operation increase the
cost of the final product. Particle board or fiber board also have
adhesion problems with some polymers.
[0014] Plywood, at an equal thickness, will deteriorate under
long-term exposure to humidity. The thin parts of polymers of the
present invention provide a low cost advantage. The thin polymers
layer of the present invention has little tensile strength and need
rigid and stiff substrate. Cement board are harder than plywood.
The plywood substrate also have adhesion problems with some
polymers.
[0015] Metal or polymeric materials as a back layer are definitely
more expensive than cement board substrate.
[0016] One problem with actual cast acrylic sheet is that they are
extremely heavy and thus difficult to fabricate and transport.
Further, large quantities of resin required to make such a
structure substantially increase the price. The advantage of the
present invention is the high strength-to-weight ratio and
strength-to-thick ratio, cost effective, easy to handle and
install. The ideal thickness for the present invention is 3/8 (10
mm); 1/4 (6 mm) engraved cement board with a {fraction (5/32)} (4
mm) polymer/inorganic portion. The strength-to-weight ratio and
strength-to-thick ratio of molded products such as Corian are not
as good as the present invention. The 3/4" (19 mm) thickness sheet
can only reach 12" (304 mm) open spacing.
[0017] Thickness and/or expansive price of actual products bring a
major disadvantage of the kitchen design; the back-splash of the
countertops must be made with other material such as ceramic.
Finding ceramic who will fit with the countertops colors may be a
difficult task. With the thickness of the present invention, less
than 3/8 (10 mm) and the affordable price of the product, Kitchen
design will be easier and esthetical.pleasing.
[0018] While a wide variety of substantially clear or transparent
thermosetting resins such as acrylic resins, vinyl ester resins,
epoxy resins and other resins which are resistant to hot water are
available as gelcoats. For the present composition, unsaturated
polyester resins are preferred for reasons of cost, availability,
clarity and ease of handling. Depending on the choice of raw
materials and on how the resin is manufactured, polyesters can be
formulated to meet any one of a wide range of special needs.
[0019] The polyester resin gelcoat may contain other promoters,
anti-oxidants and the like. Preferably a flexible agent is added
such as an alkyd resin dissolved in styrene and other vinyl
monomers. Such agents are marketed under brand names such as
Polylite Polyester Flex Resin by Reichold Chemicals, White Plains,
N.Y. Other flexibilizing agents are suitable and may be used. The
purpose of the gelcoat is to provide a clear stain resistant film
on the surface of the laminate. Many types of gelcoats are
available under such brand names as Ferro NPG Gelcoat VT12044,
manufactured by the Ferro Corporation, Cleveland, Ohio.
[0020] A wide variety of generally clear, transparent or
translucent thermosetting polyester resins are available and are
within the scope of the present invention. In the preferred
embodiment such resins are formed by the copolymerization of
styrene and unsaturated polyester formed by reacting an alpha,
beta-unsaturated dicarboxylic acid with glycol . . . Other
unsaturated polyester resins within the scope of the present
invention are those discussed in the Modern Plastics Encyclopedia
as being the polycondensation product of a dicarboxylic acid with a
dihydric alcohol. Examples of diacids include phthalic acid and
isophthalic acid. Examples of the dihydric alcohol include ethylene
glycol and propylene glycol. These types of unsaturated polyester
resins are usually catalyzed with peroxide.
[0021] The laminate composition of the present invention optionally
includes at least one filler. The laminate structures ideally have
transparent and opaque filler, so that the product corresponds to
the natural rock material with respect to its reflective properties
and its impression of color and depth.
[0022] The filler included transparent and/or opaque portion such
as calcite, feldspar, glass, marble, mica, obsidian, quartz, sand,
silica, wollastonite and various filled or unfilled pigmented or
dyed, insoluble chips of polymeric materials such as cellulose,
polyethylene, ethylene copolymers, cross linked polyacrylic
polymers, polyesters, polypropylenes, cross linked polyvinyl
chlorides and polyacetals can be add to increase the esthetical
aspect of the panel. Since room temperature curing is too
time-consuming it is generally preferred to employ elevated
temperatures and catalysts which allow for faster curing of the
polyester layer. Mold temperatures up to 100.degree. F. can be
employed with cement board backing. Additionally catalysts may be
added to the unsaturated polyester matrix to accelerate the
curing.
[0023] In terms of the fillers which are used, the filler is
preferably finely divided and can be any one of the well recognized
fillers used in the prior art including calcium carbonates, silica,
glass frit, alumina trihydrate, glass flour, antimony oxide, quartz
flour, onyx flour, talc, titanium dioxide and the like.
[0024] The veins in marble may have a wide range of color. These
veins in marble slabs are preferably painted on the cement board
layer but can be add to the resin from colorants of varying
viscosity. Such colorants are commercially available. Coloring
matter which is insoluble or slightly soluble in the polymerizable
mixture is used to produce veining. The terms "pigment" as applied
herein is used in the broad sense to include inorganic pigments
which may be opaque, translucent and transparent and may be natural
or synthetic. The term "dye" includes lakes, toners and organic and
inorganic pigments.
[0025] According to the invention a composite surface element
comprises visible side and a rear side that find utility in home
and office construction in such applications as countertops, shower
pan and wall panels, balconies and decks, office tables and
furniture. The sheets or slab includes an engraved and painted
fiber cement board, who give the impressions of colors and depths,
an acrylic resin and inorganic fragments. Reinforcing material may
be included on the cement board The cement board layer is
commercially available in sheet form of various thicknesses. The
cement board surface can be partially or totally painted with one
or more colors with one or many steps. Stencil-like technique with
the engraved portion can be utilized with latex and/or dye of one
or many colors for a specific drawing. The acrylic resin is
commercially available. The acrylic resin, preferably unsaturated
polyesters are poured on the cement board surface. Acrylic resin
may contain transparent or translucent particles and/or opaque
particles.
[0026] Since room temperature curing is too time-consuming it is
generally preferred to employ elevated temperatures and catalysts
which allow for faster curing of the polyester layer. Mold
temperatures up to 100.degree. F. can be employed with cement board
backing. Additionally catalysts may be added to the unsaturated
polyester matrix to accelerate the curing. Such catalysts are
well-recognized and usually free radical catalysts based on a
peroxidetype compound such as for example benzoyl peroxide, methyl
ethyl ketone peroxide, tertiary butyl perbenzoate and cumene
hydroperoxide are usually added to the polyester resin to effect
curing. A number of other peroxide catalysts such as cyclohexanone
peroxide, 2,4-dichlorobenzoyl peroxide, bis-(para-bromobenzoyl)
peroxide, and acetyl peroxide, and the like. Typically, the
catalyst may be present in amounts ranging from about 0.1 to 6% by
weight of the polyester resin.
[0027] Sanding and polishing can be made at different step of the
method. Different Polymer commercially available can be utilized as
a finish coating for the desirable gloss.
* * * * *