Abstract: A laminate sheet for surfacing a dry erase board is provided. The laminate sheet has an upper sheet with a marking surface adapted to receive felt tip marker indicia and has a surface energy of less than 34 dynes per centimeter. A backing layer is provided on opposing surfaces each having a surface energy of more than 36 dynes per centimeter. A tie layer is provided intermediate between the upper layer and the backing layer that includes oblong or prolate particles. A dry erase marker board is formed from such a laminate sheet through applying the sheet to a substrate with an adhesive layer intermediate therebetween. The resulting dry erase marker board lacks a frame bounding the laminate sheet and ideally the laminate sheet wraps around the edges of a substrate.

Abstract: A structurally applicable and thermofoil incorporating article including a body having a substantially thin and planar configuration with a height, width and thickness and with a protective upper layer overlaying at least one interior layer including the thermofoil material. Colorants and additives including veining patterns and stone, glass or metal effecting granules serve to provide additional desired visual effects to the article, and which is capable of being extruded, roll or sheet formed and shipped in bulk. The article is further capable of being applied in a semi-fluidic state upon an uneven, typically male blank or scrim, and so as to anneal thereto without excessive stress accumulations.

Abstract: A material, system for generating and associated method for producing of a composite, resin based and waterproof article exhibiting a faux tile board appearance. The tile board material is produced according to a co-extruding or co-laminating process and in order to include at least a top layer and a backer layer, one or more of which is substantially opaque and includes a decorative component mimicking at least one of a metallic, glass graphic or stone appearance. Either or both of a heat embossing component or a mechanical and numerically controlled router is employed to create a plurality of intersecting grid lines having a roughened, matte finish which mimics that of grout lines separating tile surfaces.

Abstract: The present invention discloses a polymeric resin-based veneer laminating system, associated article and method for producing, for maintaining a mating edge profile of top and edge applied laminates secured to a rigid substrate material, and without compromise to fit and finish in response to temperature and humidity variations existing between the materials. A first (typically PVA) adhesive is applied between the top laminate and associated top surface of the substratum according to a first application, a second adhesive (typically EVA) being applied to the adjoining side surface of the substratum and prior to application of the edgeband according to a further expedited heat and/or pressure application.

Abstract: A flexible and decorative laminate material constructed from an extruded sheet and including a thermoplastic resin base admixed with a volume of a decorative additive, such as compounded granulate. The laminate veneer sheet thus created exhibits at least one substantially transparent viewing surface, combined with an opaque interior and which is capable of being coiled about its least planar dimension to a diameter lesser than the dimension. Typically, the sheet is packaged and shipped to a remote location, prior to being uncoiled, sectioned if necessary, and adhered to a rigid substrate.

Abstract: The plastic material comprises a polymeric base media resin and visually differentiable granules present in situ. The polymeric resin media may be thermoplastic-based or thermoset-based or a combination thereof. The visually differentiable granules are blended from at least two particle color groups having substantially different opaque color hues. The visually differentiable granules are present in an amount sufficient to provide the resulting plastic material with an aesthetic appearance characterized by a depth of color typically imparted by various color hues, The visually differentiable granules may be present in an amount between about 0.25 and 30 percent by weight of the total polymeric composition in which they reside. A color additive system is provided. The additive system contains visually differentiable granules. The visually differentiable granules are composed of planar-shaped, colored material that are surface-pigmented or homogenous material.

Abstract: A method for preparing a polymeric article including the steps of admixing a visually differentiable granule-based coloring system into a fluidic polymeric base material, such as by coextruding, co-laminating, or injection molding. An applied hydraulic force, such as applied along a planar direction and in cooperation with a separate linear directed hydraulic force associated with a sheet article formation step, causes associated and high aspect granules to align in substantially parallel and evenly dispersed fashion. A further step includes “roughening” the surface of the article created, such as by the removal of a selected thickness of material to reveal a top layer of the entrained granules to create a fully exposed stone surface associated with the faux article, this further resulting in a scratch/mar, heat and light resistant article.

Abstract: A process for forming a thermoplastic sheet layer containing granular particulate includes raising the temperature of a thermoplastic to form a melt At least 2% by weight of the particles making up the particulate have a mean x-y-z dimension average linear dimension greater than 0.008 inches. Upon cooling the pigmented melt, pellets are formed. The pellets are then melted and extruded to form a thermoplastic sheet layer. A structural laminate is also provided that has a thickness of from 0.015 to 0.35 inches and an overall composition of at least 60 total weight percent plastic resin. Of the 60 total weight plastic resin, at least 10 weight percent is thermoplastic. The resultant structural laminate has a coefficient of linear thermal expansion of less than 7×10?5 per degrees Celsius, a flexural modulus of between 250,000 and 900,000 pounds per square inch, and a heat distortion temperature of at least 170° F.

Abstract: A structural laminate is provided that has a thickness and includes a thermoplastic layer. A transparent secondary layer is laminated thereto. Opaque granular particulate is loaded within the secondary layer. The layer contains from 7 to 35% by weight inclusive of inorganic granular particulate, wherein the layer has a coefficient of linear thermal expansion that is at least 25% lower than a like layer absent the inorganic granular particulate. A structural laminate is also provided having a translucent or optionally transparent first layer having a uniform coloration. A translucent or optionally transparent secondary layer that is more transmissive to visible light than the thermoplastic layer is viewed through the secondary layer and is bonded to the thermoplastic layer. Opaque granular particulate is embedded such that the coefficient of linear thermal expansion for the first and second layers is within 60%.

Abstract: A flexible and decorative laminate material constructed from an extruded sheet and including a thermoplastic resin base admixed with a volume of a decorative additive, such as compounded granulate. The laminate veneer sheet thus created exhibits at least one substantially transparent viewing surface, combined with an opaque interior and which is capable of being coiled about its least planar dimension to a diameter lesser than the dimension. Typically, the sheet is packaged and shipped to a remote location, prior to being uncoiled, sectioned if necessary, and adhered to a rigid substrate.

Abstract: An additive system for use in a polymeric formulation that includes a plurality of visually differentiable granules, the visually differentiable granules composed of a pigmented material and having a defined size distribution. The visually differentiable granules are composed of at least first and second color groups, each having a pigment shade differing from one another. The visually differentiable granules have an average aspect ratio of at least 2. The visually differentiable granules can be utilized in various polymeric formulations to make useful articles having a pleasing aesthetic appearance.

Abstract: There is disclosed herein a method for manufacturing a solid surface article from a composition of a thermosetting resin, a polymerizable vinyl material, an air release agent and a wetting agent together with sufficient amounts of a thixotropic agent to give the composition a thixotropic index of at least 4.5, as well as a solid, particulate material having a particle size of up to 0.1 inch. The composition is coated into a mold and cured to produce a hardened solid surface article. Also disclosed is a compression molding process for applying a backing material to the article.

Abstract: A mold assembly and method for producing a resin based countertop having an integrally formed sink bowl and a built-up edge. An elongate base is defined by a central surface area which is bounded by a plurality of interconnecting and elevated sides to establish a mold enclosure which is a negative shape of the countertop to be produced. A template is settable upon the elongate base and movable in a selected longitudinal direction so that an opening formed in the template is positioned in overlaying fashion at a desired location along the central area. A first sink bowl pattern is placeable in mating fashion within the opening in the template and upon the central area of the base prior to removal of the template. First applications of selected resinous materials are provided within the mold enclosure and around an exterior circumference of the first sink bowl pattern.

Abstract: A mold assembly for creating a countertop product displaying a built-up edge, the mold assembly having a substantially flat and rectangular planar shaped base which is bounded by first, second, third and fourth interconnected sides to define an interior cavity capable of receiving a pour of a resinous material. A selected number of the interconnected sides, up to all four sides, have inwardly facing surfaces which are configured to produce a countertop product exhibiting a built-up and preferably outwardly bowl-nosed shaped edge. A selectively removable and planar shaped top is arrayed upon the base in overhead fashion relative to the interior cavity and likewise is preferably shaped in a substantially rectangular manner.

Abstract: A cast, composite countertop is prepared by spraying a castable, curable organic resin composition which includes over 20% by weight of an inorganic, particulate material therein, into a mold cavity corresponding to a top surface and side wall of a countertop so as to produce a continuous coating therein. This coating is at least partially cured, and a hardenable, liquid substrate composition introduced into the mold cavity, and the resultant composite is fully cured to produce a countertop. In some instances, an additional casting step may be employed to build up the edge thickness. Also disclosed are dual spray techniques for enhancing the surface quality of the composite, and techniques for enhancing the thermal stability thereof. Also disclosed are countertops made by the disclosed methods.

Abstract: A mold assembly for creating a resin casted countertop exhibiting a built-up edge having a non-constant radius. The mold assembly includes a substantially horizontally planar and upwardly facing mold surface and a plurality of elongated member which are releasably securable upon the planar mold surface to create an outline of a countertop product to be produced. Each of the elongated members include a planar edged top, a likewise planar edged bottom, a rear face and an inwardly contoured front face. The inwardly contoured front face includes a first constant center radius throughout a first degree of angular rotation and at least one additional upper and/or lower constant center radii throughout additional degrees of angular rotation proximate the top and bottom locations of the inwardly contoured front face.

Abstract: An adjustable divider assembly for use with an open-top mold for creating a countertop with a built-up edge, the mold being rectangular in shape with a flat planar surface, first, second and third built-up and inwardly contoured edges and a fourth open edge. A U-shaped divider bar includes a central elongated member and first and second side elongated members which is pivotally attached along the four open edge of the mold using a pin and slot type arrangement and is rotated into the mold so that the elongated members of the divider bar are arranged in a desired spaced apart fashion relative to the opposing contoured mold surfaces. Suspending members extend forwardly from the central elongated member and position the bar at an elevated position above the planar mold surface. A first pour of plasticized resinous material is applied over the planar mold surface according to a predetermined depth, following which the divider bar is attached and rotated into an installed position within the mold.

Abstract: A mold and divider assembly for creating a solid surface countertop having an exterior edge according to different shapes and sizes. The mold includes a planar shaped surface which is bounded by a polygonal shaped body, at least one side of which has a raised and inwardly contoured mold defining edge. A first elongated dividing member equals a length of a first selected side of the mold and is placeable upon the planar surface so as to be movable in directions towards and away from the first selected side. A second elongated dividing member extends between the first dividing member and a second selected side of the mold so that the dividing members define in combination a subset area of the mold for receiving a resinous material pour. The second dividing member may be providing in differing lengths as a kit for producing an assortment of countertops according to differing dimensions. The mold may further be provided in a generally L-shape or rectangular shape.

Abstract: A mold process for producing a finished solid surfaced countertop in which a mold of the product to be produced is placed in a substantially horizontal manner. A series of barriers are constructed atop a flat polished surface of the mold and creates a negative shape of the countertop product to be produced. A release wax surface is applied over the exposed edges of the mold and is followed by the spraying a predetermined layer of a high-quality resin surface coating. The coating is allowed to gel to a point at which a plasticized substrate material is poured into the mold and over the resin surface coating. A catalyst is added to the substrate material prior to pouring and elevates the temperature of the substrate and the surface coating during the hardening and curing process. The surface coating bonds to the substrate and cures without the development of pinholes or other imperfections in the surface coating.