Synthetic resin solid surface material and method of making...

Details Synthetic resin solid surface material and method of making... Synthetic resin solid surface material and method of making...

B - Operations, Transporting

29

C

B29C 39/12 (2006.01) B29C 39/02 (2006.01) B29C 39/10 (2006.01) B29C 70/70 (2006.01) B32B 37/00 (2006.01) B44F 9/04 (2006.01)

Patent

CA 2083474

- 13 - SYNTHETIC RESIN SOLID SURFACE MATERIAL AND METHOD OF MAKING SAME ABSTRACT OF THE DISCLOSURE A synthetic resin solid surface material (10), such as cultured marble or onyx, and which is cast as a unitary structure, comprises a front or working surface formed by a first layer (16) of a synthetic resin, a rear surface formed by a second layer (18) of a synthetic resin and a layer of a core material (14) sandwiched between the first and second layers. A fibrous reinforcing material (22) is provided between the first layer (16) and the core (14). In one embodiment of the invention, the core material comprises plywood. In another embodiment, the core material comprises balsa wood with its grain arranged to extend between the first and second layers and including a further fibrous reinforcing layer (26) between the core (14) and the second layer (18). A two-step method for manufacturing the synthetic resin solid surface material comprises the steps of pouring a hardenable synthetic resin mixture into a mold (30) to form the first layer (16), allowing the first layer (16) at least partially to cure, proving a layer of fibrous reinforcing material (22) on top of the first layer (16), locating a layer of core material (14) on top of the layer of reinforcing material (22), pouring a hardenable synthetic resin mixture into the mold to form the second layer (18) on top of the core material (14) and allowing the resin to cure.

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