Solid surface composite

Abstract

A light weight solid surface composite comprises a core member, a resin coat having a first side disposed on and adhered to a first side of the core member and a first layer of fiber reinforced low profile tooling resin disposed on and adhered to a second side of the resin coat. There is a second layer of fiber reinforced low profile tooling resin disposed on and adhered to a second side of the core member and a reinforcing member disposed on at least one preselected area of the second layer, and a surface coat. The surface coat includes a densified resin and methyl methacrylate, and is disposed on and adhered to the second layer of fiber reinforced low profile tooling resin and the reinforcing member.

1 . A light weight solid surface composite, said solid surface composite comprising: 
 (a) a core member;    (b) a resin coat having a first side disposed on and adhered to a first side of said core member;    (c) a first layer of fiber reinforced low profile tooling resin disposed on and adhered to a second side of said resin coat;    (d) a second layer of fiber reinforced low profile tooling resin disposed on and adhered to a second side of said core member;    (e) a reinforcing member disposed on at least one preselected area of said second layer; and    (f) a surface coat including a densified resin and methyl methacrylate, said surface coat disposed on and adhered to said second layer of fiber reinforced low profile tooling resin and said reinforcing member disposed on said at least one preselected area of said second layer.    
   
   
       2 . The light weight solid surface composite, according to  claim 1 , wherein said reinforcing member includes cotton flock and low profile tooling resin.  
   
   
       3 . The light weight solid surface composite, according to  claim 1 , wherein said surface coat further includes an air release and wetting agent, a mold release agent, and fumed silica.  
   
   
       4 . The light weight solid surface composite, according to  claim 1 , wherein said fiber reinforcing member includes fiberglass.  
   
   
       5 . The light weight solid surface composite, according to  claim 3 , wherein said fiberglass is chopped fiberglass.  
   
   
       6 . The light weight solid surface composite, according to  claim 1 , wherein said core member includes at least one of particle board and corrugated cardboard.  
   
   
       7 . The light weight solid surface composite, according to  claim 6 , wherein said core member significantly increases tensile strength.  
   
   
       8 . The light weight solid surface composite, according to  claim 1 , wherein said composite is a counter top.  
   
   
       9 . The light weight solid surface composite, according to  claim 8 , wherein said counter top is seamless adjacent at least one corner thereof.  
   
   
       10 . The light weight solid surface composite, according to  claim 8 , wherein back splashes and side splashes on said counter top are seamless.  
   
   
       11 . The light weight solid surface composite, according to  claim 8 , wherein back splashes and side splashes on said counter top are integrated into said counter top surface as a single piece unit.  
   
   
       12 . The light weight solid surface composite, according to  claim 8 , wherein said light weight solid surface counter top is significantly lighter than counter tops that are commercially available.  
   
   
       13 . The light weight solid surface composite, according to  claim 12 , wherein said light weight solid surface counter top weighs between about 18 and 30 per cent of the weight of commercially available counter tops.  
   
   
       14 . The light weight solid surface composite, according to  claim 13 , wherein said light weight solid surface counter top weighs about 20 per cent of the weight of commercially available counter tops.  
   
   
       15 . The light weight solid surface composite, according to  claim 8 , wherein said light weight solid surface counter top further includes a molded in sink that is integrated into a surface of said counter top.  
   
   
       16 . The light weight solid surface composite, according to  claim 1 , wherein said at least one preselected area includes at least one corner of said light weight solid surface composite.  
   
   
       17 . The light weight solid surface composite, according to  claim 16 , wherein said at least one preselected area includes a plurality of corners of said light weight solid surface composite.  
   
   
       18 . The light weight solid surface composite, according to  claim 1 , wherein said densified resin is a polyester.  
   
   
       19 . The light weight solid surface composite, according to  claim 1 , wherein said surface coat is an atomized spray.  
   
   
       20 . The light weight solid surface composite, according to  claim 1 , wherein said surface coat has a high gloss finish.