Method and apparatus for making composite solid surface article and composite solid surface article containing large particles

Abstract

A method and apparatus for producing a composite solid surface article are disclosed. The method includes feeding a first composition toward a mixing point and feeding solid particles toward the mixing point. The method further includes mixing at the mixing point the first composition and the solid particles fed to the mixing point to form a second composition, and transferring the second composition away from the mixing point. The method further comprises polymerizing the polymerizable compound in the second compound so as to form a curable composition comprising the solid particles. The apparatus includes a solid particle feeder, a slurry feeder and a blender configured to blend and transfer a mixture of the solid surface forming slurry and solid particles away from the blending area. The composite solid surface article produced using the method and apparatus contain particles with a size greater than 5 mm.

1 . A method of producing a composite solid surface article, comprising: 
 feeding a first composition toward a mixing point, the first composition comprising a polymerizable compound;    feeding solid particles toward the mixing point;    mixing the first composition and the solid particles fed to the mixing point to form a second composition comprising the polymerizable compound and solid particles;    transferring the second composition away from the mixing point; and    polymerizing the polymerizable compound in the second compound so as to form a curable composition comprising the solid particles.    
   
   
       2 . The method of  claim 1 , further comprising controlling at least one of a feeding rate of the first composition and a feeding rate of the solid particles.  
   
   
       3 . The method of  claim 2 , wherein controlling comprises maintaining at least one of the feeding rates of the first composition and the solid particles substantially close to a predetermined value over a period of time.  
   
   
       4 . The method of  claim 2 , wherein controlling comprises varying at least one of the feeding rates of the first composition and the solid particles substantially constant.  
   
   
       5 . The method of  claim 1 , further comprising mixing the second composition while transferring.  
   
   
       6 . The method of  claim 1 , wherein the first composition is not a curable form.  
   
   
       7 . The method of  claim 1 , wherein the solid particles are generally homogeneously dispersed in the curable composition.  
   
   
       8 . The method of  claim 1 , wherein the solid particles have irregular shapes.  
   
   
       9 . The method of  claim 1 , wherein the solid particles have one or more colors that are substantially different from that of the first composition.  
   
   
       10 . The method of  claim 1 , wherein the solid particles have a diameter with a longest length from about 3 mm to about 100 mm.  
   
   
       11 . The method of  claim 1 , wherein the solid particles have an average diameter from about 7 mm to about 15 mm.  
   
   
       12 . The method of  claim 11 , wherein the first composition comprises solid particles having a diameter from about 0.1 mm to about 5 mm.  
   
   
       13 . The method of  claim 1 , wherein the first composition further comprises a polymerization initiator and an inorganic filler.  
   
   
       14 . The method of  claim 13 , wherein the first composition comprises 100 parts by weight of an acrylic resin syrup comprising the polymerizable compound, about 100 to about 200 parts by weight of the inorganic filler, and about 0.1 to about 10 parts by weight of the polymerization initiator.  
   
   
       15 . The method of  claim 1 , wherein at least one of feeding the first composition, feeding solid particles and transferring is performed continuously or repetitively for a period of time.  
   
   
       16 . The method of  claim 1 , further comprising curing the curable composition to provide a composite solid surface article.  
   
   
       17 . A composite solid surface article produced by the method of  claim 16 .  
   
   
       18 . A method of producing a composite solid surface article, comprising: 
 conveying solid particles along a passage;    adding a solid surface forming slurry to the solid particles that are being conveyed when the solid particles are passing a location in the passage;    blending the solid surface forming slurry and the solid particles; and    thickening the solid surface forming slurry while blending, thereby forming a fluidable solid composition comprising the solid particles dispersed therein generally homogeneously.    
   
   
       19 . The method of  claim 18 , wherein the solid particles have irregular shapes.  
   
   
       20 . The method of  claim 18 , wherein the solid particles have a diameter from about 5 mm to about 70 mm.  
   
   
       21 . The method of  claim 18 , wherein the solid particles have an average diameter from about 7 mm to about 50 mm.  
   
   
       22 . The method of  claim 21 , wherein the solid surface forming slurry comprises solid particles having a diameter from about 0.1 mm to about 5 mm.  
   
   
       23 . The method of  claim 18 , wherein the solid particles comprises pieces of a natural or synthetic solid surface material.  
   
   
       24 . The method of  claim 18 , wherein the solid particles are produced by crushing rocks, granite or a synthetic solid surface material.  
   
   
       25 . The method of  claim 18 , wherein the solid surface forming slurry comprises a polymerizable compound and an inorganic filler.  
   
   
       26 . The method of  claim 25 , wherein thickening comprises polymerizing the polymerizable compound.  
   
   
       27 . The method of  claim 18 , wherein at least one of conveying and adding is performed continuously or repetitively for a period of time.  
   
   
       28 . The method of  claim 18 , further comprising solidifying the fluidable solid composition into a shape to provide a composite solid surface article  
   
   
       29 . A composite solid surface article produced by the method of  claim 28 .  
   
   
       30 . A composite solid surface article, comprising: 
 a matrix of at least one polymer resin;    a filler dispersed in the matrix; and    solid particles dispersed in the matrix having a size from about 7 to about 100 mm.    
   
   
       31 . The article of  claim 30 , wherein the solid particles are generally homogeneously dispersed throughout the matrix of the article  1 .  
   
   
       32 . The article of  claim 30 , wherein the solid particles have a diameter from about 12 mm to about 50 mm.  
   
   
       33 . The article of  claim 30 , wherein the solid particles have a diameter from about 7 mm to about 15 mm.  
   
   
       34 . The article of  claim 30 , wherein the at least one polymer resin comprises an acrylic resin.  
   
   
       35 . The article of  claim 30 , wherein at least some of the solid particles have one or more colors, which are substantially different from a color surrounding the at least some of the solid particles in the article.  
   
   
       36 - 45 . (canceled)