Solid surface composites

Abstract

A class of solid surface composite materials has formula parameters that allow for the production of more abrasion resistant surfaces that can be either designed for fabrication of parts with carbide tipped tools, including saw blades and router bits, or to an even more abrasion resistant surface that will not be able to be machined with carbide tipped tools but will require diamond tipped tools or fabrication by other processes such as spraying, casting, injection molding, or press molding. A range of materials are added to a basic solid surface composite composition to yield the desired abrasion resistance. Depending on the amount and type of material added, the composite material can maintain the ability to fabricate parts with carbide tipped tools or it can be made so resistant so that parts cannot be fabricated with carbide tipped tools.

1 - 18 . (canceled)  
   
   
       19 . A method of making an abrasion resistive shaped part, comprising: 
 mixing a thermoset resin with a filler material to create an abrasion resistive mixture; and    applying said abrasion resistive mixture to the part by spraying.    
   
   
       20 . The method of  claim 19 , wherein said applying step comprises spraying said mixture into a mold to surface coat said mold, and filling the mold with a substrate material.  
   
   
       21 . The method of  claim 19 , wherein said applying step comprises spraying said mixture directly onto the shaped part, said shaped party being previously formed.  
   
   
       22 . The method of  claim 19 , wherein said filler material comprises: 
 between about 20% and about 50% by weight abrasion resistant filler; and    between about 5% and about 40% by weight solid surface granules.    
   
   
       23 . The method of  claim 22 , wherein said abrasion resistant filler is selected from ground glass, ceramic, quartz, and calcined alumina.  
   
   
       24 . The method of  claim 22 , wherein said solid surface granules comprise a thermoset resin and alumina trihydrate.  
   
   
       25 . The method of  claim 19 , wherein said filler material comprises: 
 between about 20% and about 50% by weight abrasion resistant filler; and    between about 50% and about 80% by weight solid surface granules.    
   
   
       26 . The method of  claim 25 , wherein said abrasion resistant filler is selected from ground glass, ceramic, quartz, and calcined alumina.  
   
   
       27 . The method of  claim 25 , wherein the granules are crushed quartz.  
   
   
       28 . The method of  claim 25 , wherein the granules are abrasion resistant materials.  
   
   
       29 . The method of  claim 19 , wherein said mixture is sprayed to a thickness of between about 20 and about 50 millimeters.