Composite Sheet With Visible Filler And Manufacturing Method

Abstract

A solid surface sheet includes visible, elongated, shredded cuttings uniformly distributed throughout a matrix wherein the cuttings and the matrix have substantially the same specific weight and wherein a majority of the cuttings are substantially elongated. Related methods are also disclosed including shredding a first mix while in a gel state, curing the cuttings, sorting by size, and using as a filler in a base material to form a blend having a unique appearance and high internal strength. The preferred material is polyester or acrylic. The solid surface sheet can be used as a countertop, floor or wall panel, furniture, and in similar applications.

What is claimed is: 
     
         1 . A particulate for incorporation into a matrix of material curable into a solid surface material, the particulate comprising: a plurality of cuttings having a shredded and elongated configuration. 
     
     
         2 . The particulate of  claim 1  wherein each cutting of the plurality of cuttings comprises at least one of polyester and acrylic. 
     
     
         3 . The particulate of  claim 1  wherein the matrix and the plurality of cuttings have substantially the same specific weight. 
     
     
         4 . The particulate of  claim 1 , wherein the cuttings are made by cutting a thermoset polymeric material that is partially cured to a gel. 
     
     
         5 . The particulate of  claim 1  wherein a plurality of the plurality of cuttings each have a length that is between ½ and 1 inch. 
     
     
         6 . The particulate of  claim 1  wherein a plurality of the plurality of cuttings each have a length at least three times greater than a width. 
     
     
         7 . A solid surface material comprising:
 a matrix including a resin;   a particulate comprising a plurality of cuttings having a shredded and elongated configuration,   wherein the particulate is added to the matrix and the matrix is properly hardened.   
     
     
         8 . The solid surface material of  claim 7 , wherein the cuttings are distributed throughout the matrix and wherein a significant visible number of the cuttings are elongated on a show surface side of the sheet. 
     
     
         9 . The solid surface material of  claim 7 , wherein the matrix and cuttings include thermoset materials, and wherein the cuttings are substantially uniformly distributed throughout the matrix. 
     
     
         10 . The solid surface material of  claim 7 , wherein:
 the cuttings comprise one of a polyester and acrylic; and   the matrix comprises one of polyester and acrylic.   
     
     
         11 . The solid surface material of  claim 7 , further comprising a plurality of granules distributed within the matrix. 
     
     
         12 . The solid surface material of  claim 7  wherein the matrix further includes a filler mixed with the polymer resin. 
     
     
         13 . The solid surface material of  claim 7  wherein the solid surface material is processed into one of the group consisting of: a countertop, a wall panel, flooring, a table top, furniture, and a fixture. 
     
     
         14 . Cuttings made from a method comprising the steps of:
 providing a matrix in a mold cavity;   removing the matrix from the mold when the matrix has cured to a flexible gel state allowing the matrix to be handled;   feeding the matrix into cutters to make flexible gelled cuttings; and   curing the flexible gelled cuttings in a curing chamber.   
     
     
         15 . The cuttings of  claim 14 , wherein the step of curing includes raising the temperature in the curing chamber to a temperature sufficient to cure the cuttings. 
     
     
         16 . The cuttings of  claim 15 , further comprising the steps of: bringing the cuttings to ambient temperature after curing. 
     
     
         17 . The cuttings of  claim 14 , wherein the matrix comprises a resin and a filler. 
     
     
         18 . The cuttings of  claim 17 , wherein the filler comprises at least one of an aluminatrihydrate particulate and granules.