Densified coating process and molded articles having densified outer surface
AssigneePyramid Composities Manufacturing Limited Partnership
InventorsJames S. Lapikas, John B. O'Connor
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Abstract
A method of forming a simulated stone and solid color plastic molded article includes a densified surface coating material that is sprayed on the surface of a mold. A glass fiber preform is inserted into the mold and the mold is filled with resin at low pressure. The densified coating material includes a matrix-forming resin and large and small densifier particles in a prescribed size ratio. Articles made in accordance with the method are also described.
Claims16
A method for forming a molded article comprising the steps of preparing a densified coating material which contains a matrix-forming resin and a distribution of densifier particles, said distribution of densifier particles comprising a large densifier particle fraction, said particles of said large densifier particle fraction having an average diameter of about 35 microns to 50 microns, and a small densifier particle fraction, said particles of said small densifier particle fraction having an average diameter of from about 8 microns to about 15 microns;
- wherein the average diameter of the particles of said large densifier particle fraction has a ratio to the average diameter of the particles of said small densifier particle fraction of from about 6 to 1 to about 5.5 to 1;
- coating a surface of a mold cavity with the densified coating material;
- and backfilling the mold such that the densified coating material forms a surface of the molded article.
Dependencies are inferred from the claim text.