Simulated marble slab and process

Abstract

Disclosed herein is a process for making a marble appearing casting having superior depth characteristics by placing a low-density polymerizable resin into a mold to at least partially cover the bottom thereof placing a high-density polymerizable resin on top of the low-density resin to completely cover the low-density resin, allowing the low-density resin to float up through the high-density resin as both resins polymerize and solidify.

What is claimed is: 
     
         1 . A process for preparing a simulated marble slab comprising the steps of:
 preparing, in a mold, a polymerizable resin blend comprising a first polymerizable resin comprising aluminum hydroxide dispersed therein with a particle size of less than 20 microns and a second polymerizable resin comprising aluminum hydroxide therein with a particle size of between 20 and 40 microns;   catalyzing the first polymerizable resin; and   catalyzing the second polymerizable resin.   
     
     
         2 . The process according to  claim 1 , wherein the first polymerizable resin has a lower viscosity than the second polymerizable resin. 
     
     
         3 . The process according to  claim 1 , wherein the first polymerizable resin further comprises a white pigment and the second polymerizable resin further comprises a gray pigment. 
     
     
         4 . The process according to  claim 1 , wherein the first polymerizable resin is placed in the mold as ribbons and the second polymerizable resin is poured over said ribbons. 
     
     
         5 . The process according to  claim 1 , wherein the first polymerizable resin and the second polymerizable resin are catalyzed before the polymerizable resin blend is prepared in the mold. 
     
     
         6 . The process according to  claim 1 , further comprising placing a polymerizable clear gel coat into the mold. 
     
     
         7 . The process according to  claim 1 , wherein the polymerizable resin blend comprises marble dust. 
     
     
         8 . The process according to  claim 1 , wherein the first polymerizable resin and the second polymerizable resin are polyester. 
     
     
         9 . The process according to  claim 1 , wherein the second polymerizable resin has a lower viscosity than the first polymerizable resin. 
     
     
         10 . The process according to  claim 1 , wherein the second polymerizable resin further comprises a white pigment and the first polymerizable resin further comprises a gray pigment. 
     
     
         11 . The process according to  claim 1 , wherein the second polymerizable resin is placed in the mold as ribbons and the first polymerizable resin is poured over said ribbons. 
     
     
         12 . A process for preparing a simulated marble slab comprising the steps of:
 preparing, in a mold, a polymerizable resin blend comprising a first polymerizable resin comprising aluminum hydroxide dispersed therein with a particle size of less than 20 microns, a second polymerizable resin comprising aluminum hydroxide therein with a particle size of between 20 and 40 microns, and a third polymerizable resin comprising aluminum hydroxide therein with a particle size of between 40 to 100 microns;   catalyzing the first polymerizable resin;   catalyzing the second polymerizable resin; and   catalyzing the third polymerizable resin.   
     
     
         13 . The process according to  claim 12 , further comprising placing a polymerizable clear gel coat into the mold. 
     
     
         14 . The process according to  claim 12 , wherein the polymerizable resin blend comprises marble dust. 
     
     
         15 . The process according to  claim 12 , wherein the first polymerizable resin, the second polymerizable resin, and the third polymerizable resin are polyester. 
     
     
         16 . The process according to  claim 12 , wherein the first polymerizable resin, the second polymerizable resin, and the third polymerizable resin are catalyzed before the polymerizable resin blend is prepared in the mold.