Decorative surface materials having a decorative pattern and process for preparing the same

Abstract

Decorative surface material having a decorative pattern in which a combination of domains of varying sizes and colors are defined by shading variations at the interfaces of adjoining domains, the decorative pattern being provided by a process in which a flowable thermosettable molding formulation having orientable particles mixed therein is divided into fragments which are mixed together, the mixture is fed into a hot mold and pressure is applied to form the solid surface material.

1 - 14 . (canceled)  
     
     
         15 . A decorative surfacing material comprised of a multiplicity of domains of a thermoset molding formulation, said domains having an interface between adjacent domains, at least some of said domains containing oriented particles having an aspect ratio of at least three and oriented along lines formed by interfaces of the adjacent domains, said surfacing material exhibiting a decorative pattern with shading variations in the domains along the interfaces, with the proviso that interfaces between adjacent domains are fused.  
     
     
         16 . The material of  claim 15  wherein said particles are in the form of plates and are selected from the group consisting of mica, synthetic mica, glass, metal flake, alumina, silica, polymer flake, ceramics, and combinations thereof.  
     
     
         17 . The material of  claim 15  wherein said particles are in the form of fibers and are selected from the group consisting of glass, metal, carbon, ceramic, polymer, natural fibers and combinations thereof.  
     
     
         18 . The material of  claim 15  wherein said particles are in the form of ribbons and are selected from the group consisting of glass, metal, carbon, ceramic, polymer ribbons and combinations thereof.  
     
     
         19 . The material of  claim 15  wherein said thermoset molding formulation is comprised of a thermosettable acrylic component and the anisotropic pigment is of mica.  
     
     
         20 . The material of  claim 15  wherein said thermoset molding formulation contains a thermoset resin selected from the group consisting of acrylic, polyester, epoxy, urethane, acrylo-urethane and melamine resins and combinations thereof.  
     
     
         21 . The material of  claim 15  wherein a finely divided filler having an aspect ratio of less than three is present with said thermoset molding formulation.  
     
     
         22 . The material of  claim 21  wherein said finely divided filler is selected from the group consisting of alumina trihydrate, calcium carbonate, silica, alumina, barium sulfate, alumina monohydrate, aluminum hydroxide, aluminum oxide, aluminum sulfate, aluminum phosphate, aluminum silicate, Bayer hydrate, borosilicates, calcium sulfate, calcium silicate, calcium phosphate, calcium carbonate, calcium hydroxide, calcium oxide, apatite, glass bubbles, glass microspheres, glass fibers, glass beads, glass flakes, glass powder, glass spheres, barium carbonate, barium hydroxide, barium oxide, barium sulfate, barium phosphate, barium silicate, magnesium sulfate, magnesium silicate, magnesium phosphate, magnesium hydroxide, magnesium oxide, kaolin, montmorillonite, bentonite, pyrophyllite, mica, gypsum, silica, ceramic microspheres, ceramic particles, and ceramic whiskers, powder talc, titanium dioxide, diatomaceous earth, wood flour, borax, and combinations thereof.  
     
     
         23 . The material of  claim 21  wherein the finely divided filler is alumina trihydrate.  
     
     
         24 . The material of  claim 15  wherein one or more additional molding formulations containing the same, different or no orientable particles are blended with said thermoset molding formulation.  
     
     
         25 . The material of  claim 15  wherein said domains are coated with a colorant.