ENGINEERED COMPOSITE MATERIALAND PRODUCTS
PRODUCED THEREFROM
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims the benefit of and priority to U.S. Provisional Patent
Application No. 61/718,514, filed October 25, 2012, the entire disclosure of which is
incorporated herein by reference.
BACKGROUND
[0002] The present application relates to a material for use in the production of products
that may benefit from having a hard, non-porous surface appearance and feel, and in
particular may find utility in kitchen and bath products such as kitchen sinks, lavatory sinks,
countertops, bathtubs, shower receptors, and the like. More particularly, the present
disclosure relates to an engineered composite material for use in the production of such
products.
[0003] In many applications, it is desirable to have a hard, generally non-porous surface.
For example, consumers may prefer that kitchen countertops and the like have such a surface
to resist staining and damage due to wear resulting from everyday use. Natural stone (e.g.,
granite, limestone, etc.) is often used in such applications, but is limited by various material
properties. For example, stone may have a number of natural imperfections in the material,
which can result in a brittle material prone to cracking or breaking during the manufacturing
and installation processes. The brittleness of the material can result in chipping or cracking
of the material upon impact (e.g. pans or dishes impacting a stone kitchen counter). Natural
stone also typically has a relatively high porosity and water absorption, which from a
practical standpoint means that such material must be frequently sealed, which results in
significant additional maintenance cost and effort. Additionally, stone is an expensive
material to use given the difficulty to machine the product, as well as its limited availability.
Natural stone also has other limitations, including that the stone cannot be formed into
complicated shapes easily without significant effort. For example, if it were desired to
produce a sink made of a natural stone material, a relatively large amount of material would
be wasted in the machining process, since the manufacture would start with a large piece of
stone and a significant amount of the stone would be removed in the formation process to
create the desired shape.
[0004] Given the numerous disadvantages of using natural stone in household applications,
there exists a need for an engineered composite material that may be used in these
applications and that has enhanced material properties that is intended to resist staining and to
provide increased stain resistance, abrasion resistance, chemical resistance, and decreased
brittleness. Such a material would ideally be relatively simple and efficient to produce and
may incorporate materials that are readily available.
SUMMARY
[0005] An exemplary embodiment relates to a composite material that includes a polymer
matrix material and filler material that includes vitreous china. The composite material has a
water absorption of less than about one percent.
[0006] Another exemplary embodiment relates to an article comprising a composition, the
composition comprising a polymer matrix material and a filler material comprising vitreous
china. The article has a water absorption of less than approximately one percent.
[0007] Another exemplary embodiment relates to a method of making an article that
includes mixing a filler material and a polymer matrix material to produce a composite
material, introducing the composite material produced by the mixing into a mold of a desired
shape, and removing an article having the desired shape from the mold. The resulting article
has a water absorption of less than about one percent and the filler material comprises
vitreous china.
[0008] According to any of the foregoing exemplary embodiments or other embodiments
described in the present application, the filler material may comprise particles with a size in
the range of between 1 and 2000 micrometers.
[0009] According to any of the foregoing exemplary embodiments or other embodiments
described in the present application, the composite material may comprise between 10% and
70% by weight polymer matrix material and between 30% and 90% by weight filler material.
[0010] According to any of the foregoing exemplary embodiments or other embodiments
described in the present application, the filler material may further comprise sand.
[0011] According to any of the foregoing exemplary embodiments or other embodiments
described in the present application, the sand may be recycled core sand.
[0012] According to any of the foregoing exemplary embodiments or other embodiments
described in the present application, the polymer matrix material may comprise a polymer
resin material or a mixture of polymer resin materials.
[0013] According to any of the foregoing exemplary embodiments or other embodiments
described in the present application, the vitreous china may comprise between 50% and 80 %
by weight Si0 2, between 10%> and 30 % by weight AI2O3, between 0%> and 4% by weight
a20 , between 0% and 4% by weight K20 , between 0% and 3% by weight T1O2, and
between 0% and 5% by weight MgO.
[0014] According to any of the foregoing exemplary embodiments or other embodiments
described in the present application, the composite material may have a hardness of between
4 and 9 on the Moh's hardness scale.
[0015] According to any of the foregoing exemplary embodiments or other embodiments
described in the present application, the filler material may have a water absorption of less
than one percent.
[0016] According to any of the foregoing exemplary embodiments or other embodiments
described in the present application, the composite material and any articles produced
therefrom may have a water absorption of less than one percent.
[0017] According to any of the foregoing exemplary embodiments or other embodiments
described in the present application, the composite material may be used to form a sink,
shower receptor, bathtub, countertop, or integrated top and bowl single structure.
[0018] According to any of the foregoing exemplary embodiments or other embodiments
described in the present application, a method of making an article such as that described
herein may include mixing the filler material and the polymer matrix material to create the
composite material, introducing the composite material into a mold of a desired shape, and
removing the article having the desired shape from the mold.
[0019] According to any of the foregoing exemplary embodiments or other embodiments
described in the present application, a method of producing an article may include at least one
of grinding, pulverizing, or crushing a precursor material to produce the filler material prior
to the mixing.
[0020] According to any of the foregoing exemplary embodiments or other embodiments
described in the present application, a method of producing an article may include heat
treating the article at a temperature between 250°F and 350°F for a period of between 1 and 3
hours.
[0021] According to any of the foregoing exemplary embodiments or other embodiments
described in the present application, a method of producing an article may include coloring
the filler material prior to the mixing.
[0022] According to any of the foregoing exemplary embodiments or other embodiments
described in the present application, a method of producing an article may include mixing
additional fillers or additives with the filler material and polymeric matrix material in an
amount of up to about 20% by weight.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] FIG. 1 is a photograph illustrating a sample of a composite material produced
according to an exemplary embodiment.
[0024] FIGS. 2-8 illustrate various sink designs that may be produced using the composite
material described herein according to various other exemplary embodiments.
[0025] FIGS. 9 and 10 illustrate various shower receptor designs that may be produced
using the composite material described herein according to various other exemplary
embodiments.
[0026] FIGS. 11 and 12 illustrate various bathtub designs that may be produced using the
composite material described herein according to various other exemplary embodiments.
[0027] FIG. 13 is a flow chart detailing the steps of the manufacturing process to make a
composite material according to an exemplary embodiment.
[0028] FIG. 14 is a flow chart detailing the steps of the manufacturing process to make a
composite material according to an exemplary embodiment.
DETAILED DESCRIPTION
[0029] An exemplary embodiment of the invention relates to a composite material
incorporating an inorganic filler material, such as recycled vitreous china or sand, in a
polymer matrix to provide a product that has a generally hard, non-porous surface. The
composite material may be used to make members or structures such as lavatory sinks,
kitchen sinks, countertops, integrated top and bowl sinks, shower receptors, shower
surrounds, bathtubs, or other products for which a hard, non-porous surface characteristic
would be desired.
[0030] Another exemplary embodiment of the invention relates to a method for providing a
composite material incorporating an inorganic filler material, providing an original source of
ceramic material to be used as filler, grinding the original source of material into particles,
mixing the ceramic particles with a polymer resin matrix and molding the mixture into
shapes.
[0031] According to an exemplary embodiment, a member or structure such as a lavatory
sink, kitchen sink, countertop (or, for example, and integrated countertop and sink), shower
receptor or base, bathtub, or the like is manufactured using a composite material comprising a
polymeric substrate or matrix material (e.g., epoxy) and an inorganic filler material (e.g.,
recycled vitreous china or sand from sand cores used in molding processes) in the polymer
matrix to provide a product that has a hard, generally non-porous surface characteristic. In
some, but not all, exemplary embodiments, the material may have the appearance of natural
stone (e.g., the material can be made to resemble a number of different natural stones
traditionally utilized in manufacturing sinks or countertops (such as granite, marble, onyx, or
travertine)).
[0032] According to an exemplary embodiment, the composite material utilizes
reclaimed/recycled vitreous china typically used in sanitary ware such as toilets and
lavatories. One advantageous feature of such materials is that, as compared to traditional
ceramics or china products, vitreous china has a significantly lower porosity and water
absorption level. For example, traditional ceramics may have a porosity level of between
approximately 10 and 20 percent. In comparison, sanitary ware products made with vitreous
china typically have much lower porosity rates, typically on the order of less than 1 percent.
In sanitary ware products, this porosity may advantageously allow for high stain resistance
and lower water absorption; these same properties may advantageously also allow composite
materials made with reclaimed crushed or pulverized vitreous china to exhibit improved
porosity and stain resistance as compared to other composite and natural stone products
available today.
[0033] Vitreous ceramic media (e.g., vitreous china) is a ceramic material that may in some
cases have been glazed with enamel. Vitreous ceramic media has a compact and uniform
structure which is fired until substantially all of the open cells disappear. During the process
of vitrification, the particles constituting the base material are melted into a glass phase
during firing and the glass phase is fluidized at a high temperature, filing up gaps formed
between unmelted particles. Vitreous china is typically a mixture of clay (e.g. kaolin clay)
and other materials such as silica, zirconia, etc. Vitreous china is typically prepared by
forming different objects from the material and then applying a powdered glass which then is
heated to a temperature sufficient to vitrify the substrate and glass surface. The vitrification
process results in a material having a relatively low water absorption, which in turn provides
the material with relatively high stain resistance.
[0034] According to an exemplary embodiment, the composite material includes a polymer
matrix and an inorganic filler material that is preferably repurposed or recycled from other
applications (e.g., a vitreous china material previously used in sanitary ware manufacture or
sand that has been recycled from spent sand used in molding operations). In such an
embodiment, the filler material is introduced as reinforcement material into a polymer resin
material. According to an exemplary embodiment, the composite material may include
between approximately 10 and 70 percent polymer resin material by weight and between
approximately 30 and 90 percent filler materials (e.g. vitreous china or sand), depending on
the desired characteristics of the resulting composite material. The composite material may
also include other fillers therein, such as fibrous strengthening materials in the form of carbon
fiber, aramid fiber, polypropylene fiber, and the like, as well as other constituent ingredients
at levels of between approximately 0 and 20 percent (e.g. pigment, catalyst, mold release, UV
stabilizer, thickening agent, for controlling material shrinkage, for facilitating cross-linking,
etc.), or other materials consistent with present disclosure as will be recognized by those
skilled in the art. The polymer resin may be a single polymer resin material (e.g., urethane,
epoxy, vinyl esters etc.) or may be a mixture or combination of more than one polymer resin
material.
[0035] According to an exemplary embodiment, the inorganic filler material has a
composition that comprises between approximately 10 and 30 weight percent kaolin clay,
between approximately 20 and 40 weight percent ball clays, and between approximately 35
and 55 weight percent non-plastics. An exemplary embodiment of such a material may
comprise between approximately 50 and 80 weight percent S1O2, between approximately 10
and 30 weight percent AI2O3, between approximately 0 and 4 weight percent a20 , between
approximately 0 and 4 weight percent K2O, between approximately 0 and 3 weight percent
T1O2, and between approximately 0 and 5 weight percent MgO. According to other
exemplary embodiments, the inorganic filler material may have different compositions. Any
vitreous china material may be used according to a variety of other exemplary embodiments.
[0036] According to an exemplary embodiment, the inorganic filler material is a ceramic
material. In one exemplary embodiment, the ceramic is vitreous china. In another exemplary
embodiment, the ceramic is fire clay. The inorganic filler material may be made up of other
materials consistent with the present disclosure as will be recognized by those skilled in the
art. In some exemplary embodiments, the material may be reclaimed or recycled material
that was used to form products such as toilets, bidets, sinks, and other sanitary ware (e.g., it
may be excess material left over from the product manufacturing process and/or crushed or
pulverized material formed by breaking up sanitary ware such as the aforementioned
products). Such materials may have undergone a vitrification process to remove pores
formed in the material.
[0037] In one exemplary embodiment, the inorganic filler material may be provided from
previously processed materials. The previously processed material may be excess from a
current production line (e.g., flash or other unused materials produced in a sanitary ware
production line). The previously-processed material may be defective material that cannot be
used in a different production line (e.g., materials for making toilets, sinks, bidets, etc.). In
another exemplary embodiment, the inorganic filler material may be provided from current
existing products, which are reclaimed and crushed or pulverized to create the inorganic filler
material. These current existing products may have been manufactured using materials with
properties that would be advantageous for use as inorganic filler materials (e.g., low water
absorption, minimal porosity, high hardness). In one exemplary embodiment, the existing
products utilized would be sanitary ware products. These existing products could come from
different manufacturing lines in which excess products or defective products were produced
(e.g., destroyed toilets, destroyed sinks, excess sinks, excess toilets, etc.).
[0038] The inorganic filler material may be processed using a crushing or pulverizing
process to reduce the size of the particle sizes so as to be acceptable for use in the composite
material described herein. For example, according to an exemplary embodiment, the original
source of the inorganic filler material may be in the form of a slab or a block. According to
another exemplary embodiment, the original source of the inorganic filler material may be in
the form of a sanitary ware product such as a toilet, lavatory sink, bathtub or the like. These
embodiments are representative of the sources of the inorganic filler material and are not
intended to limit sources to just these examples provided. The original source of the
inorganic filler material will be ground up to produce particles that can be introduced as a
reinforcement material in a melted polymer resin matrix. The inorganic filler material may
be ground up using milling machines, grinding wheels, or other types of grinding machines.
[0039] The original source of the inorganic filler material can be ground up, crushed, or
pulverized to provide a range of desired particle sizes. The size range of particles can be
controlled during the grinding process. The range of sizes needed, therefore, can be
determined before the original source of material is ground up. The range of particle sizes
could be a small or a large range depending on the type of product for which the filler will be
used. According to an exemplary embodiment, the particle size of the filler ranges from
about 1 to about 2,000 micrometers. In other embodiments the particle size of the filler
ranges from about 1 to about 1,000 micrometers or from about 1 to about 400 micrometers.
In an exemplary embodiment, the range of particle sizes may be varied to achieve different
aesthetic qualities. In another exemplary embodiment, the range of particle sizes can be
determined as to provide consistency in the composite material. In order to provide certain
aesthetic quality or consistency, the range of filler particle sizes may, in an exemplary
embodiment, have different specific ranges of particle size. In an exemplary embodiment,
small particle sizes may be employed to enhance the suspension of the filler material in the
polymer matrix. In another exemplary embodiment, large particle sizes may be employed to
improve the hardness and scratch resistance of the composite material. In an exemplary
embodiment, a mixture of particle sizes (e.g., abimodal or multimodal size distribution) may
be employed to provide increased packing efficiency in addition to improved hardness,
scratch resistance and enhanced suspension of the filler material in the polymer matrix.
[0040] According to an exemplary embodiment, the inorganic filler material may be or
include a sand material. The sand material may be beach sand or core sand recovered from a
sand-casting process. In an exemplary embodiment, an original source of the inorganic filler
material may be core sand that includes a binder material. The original source material may
be treated to remove the binder material. In an exemplary embodiment, the original source
material may be heat treated to burn off the binder material. In another embodiment, the
original source material may be processed with a magnet to remove undesired magnetic
contaminants. The sand particles provided in the original source material may have particle
sizes and water absorption in the range appropriate for introduction to the polymer matrix
material, as described previously.
[0041] According to another exemplary embodiment, the inorganic filler material may be a
mixture of vitreous china and sand. In an exemplary embodiment, the inorganic filler may be
approximately 50% vitreous china and approximately 50% sand by weight. Other mixture
ratios may be employed where appropriate. According to other exemplary embodiments, the
ratio may vary between 100% vitreous china to 100% sand, and anywhere therebetween. As
with the particle distribution sizes, the percentage of vitreous china and sand can be adjusted
to provide a desirable mixture providing a particular performance and/or aesthetic for the
finished product.
[0042] Once the inorganic filler material has been ground into particles, the filler material
can be introduced into a polymer matrix. In an exemplary embodiment, the polymer matrix
will be an epoxy material. After the mixing of the filler material and polymer matrix, the
mixture can be molded into different shapes. In one exemplary embodiment, the mixture can
be molded into a kitchen sink. In another exemplary embodiment, the mixture can be molded
into a lavatory sink. In another exemplary embodiment, the mixture can be molded into a
countertop. In another exemplary embodiment, the mixture can be molded into an integrated
top and bowl single structure (e.g., an assembly that includes both a countertop and a sink
bowl in one integrally formed unit). In yet another exemplary embodiment, the mixture can
be molded into a shower receptor. In another exemplary embodiment, the mixture can be
molded into a bathtub. Molds used in different productions lines (e.g. sink production lines,
countertop production lines, shower receptor production lines, bathtub production lines) can
be used in molding the mixture into shapes.
[0043] According to another exemplary embodiment, a ground or crushed glass material,
such as silicon dioxide (S1O2), based material may be introduced into the polymer matrix in
addition to the inorganic filler material. For example, glass reclaimed from recycled shower
doors, windows, and other sources may be crushed to produce fine particles. One
advantageous feature of using such a glass material in addition to the vitreous china is that the
glass material may assist in keeping the vitreous china particles in suspension. According to
an exemplary embodiment, the composite material may include a filler that is approximately
90 weight percent vitreous china and 10 weight percent glass, although these proportions may
be varied according to other exemplary embodiments depending on the desired characteristics
of the resulting composite material. This vitreous china and glass filler material may be used
in addition to other filler materials as described herein, such as fibrous strengthening
materials in the form of carbon fiber, aramid fiber, polypropylene fiber, and the like, as well
as other constituent ingredients of approximately 0-20 percent (e.g. pigment, catalyst, mold
release, UV stabilizer, thickening agent, for controlling material shrinkage, for facilitating
cross-linking, etc.), or other materials consistent with present disclosure as will be recognized
by those skilled in the art. Again, the polymer resin may be a single polymer resin material
(e.g., urethane, epoxy, vinyl esters etc.) or may be a mixture or combination of more than one
polymer resin material.
[0044] According to an exemplary embodiment, the filler and the overall composite
material each have a water absorption of less than about 1 percent (e.g., calculated by
weighing the composite material before and after submersion in water to determine the
weight percent of water within the composite material after submersion). The water
absorption of the material may depend on the water absorption of the filler material used.
The water absorption can be varied depending on the application for which the product is
intended. The water absorption is varied by using filler materials with different water
absorption values. The water absorption of the material will depend on what preparation
processes the original source material goes through before it is used as a filler material. In
some exemplary embodiments, the inorganic filler material may have undergone the
vitrification process which will significantly reduce the size of the pores in the inorganic filler
material. Kitchen applications such as countertops require material with low water
absorptions. The countertops will likely come into contact with food or liquids which can
permanently stain countertops made from porous materials. Composite material with a very
low water absorption can be used in these kitchen applications to greatly reduce staining that
may occur from day-to-day use. Bathroom applications such as lavatory sinks also require
material with low water absorptions. The sinks will likely come into contact with household
products and chemicals (such as toothpaste, hand soap etc.) which can permanently stain
sinks made from porous materials. Composite materials with very low water absorptions can
be used in bathroom applications to greatly reduce staining that may occur from day-to-day
use.
[0045] According to an exemplary embodiment, the hardness of the composite material will
range from 4 to 9 on the Moh's hardness scale. The hardness of the material may be
comparable to the hardness ratings of natural stone products commonly used in kitchen and
lavatory applications. For example, granite, which is typically used for countertops, has a
hardness of 7 on the Moh's hardness scale, whereas marble, which is typically used for sinks,
has a hardness of 3 on the Moh's hardness scale. The hardness of the composite material can
be varied depending on the application for which the material will be used. Kitchen
applications require material with high abrasion resistance. High abrasion resistance requires
a hard material to be used in manufacturing the kitchen applications. The ceramic material
used as filler is an inherently hard material, making it well suited for kitchen applications.
The hardness of the material can be adjusted by altering the composition of the material (e.g.,
increasing the percentage of the ceramic filler). The hardness of the material can also be
adjusted by the use of additives in the composite. Additives such as alumina may also be
used to increase the hardness of the material.
[0046] According to an exemplary embodiment, the impact resistance and strength of the
composite material and products produced therefrom will exhibit an improvement of at least
about 25% when compared to similar composite materials. In an exemplary embodiment, the
composite material such that it will survive an impact from a five pound dart dropped from a
height of at least approximately 36 inches.
[0047] According to an exemplary embodiment, the resulting product may be any of a
variety of colors. For example, the composite material may have a matte black or matte
brown appearance, or may have other colors or combinations of colors according to other
exemplary embodiments.
[0048] According to an exemplary embodiment, the particles of the inorganic filler material
in the substrate material can subjected to a coloring process prior to introduction into the
polymer matrix. One advantageous feature of coloring the particles is that ceramic material
from a variety of sources may be used in the composite material despite their initial variations
in colors. For example, sinks in a variety of colors or shades may be broken down to form
the particles, and all of the particles may be colored using the same colorant to obtain a
consistent color for the particles. According to other exemplary embodiments, particles
having a variety of colors may be used to provide the composite materials with a desired
color aesthetic (e.g., the composite may use white, green, and blue particles within a matrix to
provide a multi-colored surface appearance).
[0049] The colorants can be applied to the ceramic particles so that a chemical bond is
formed, which may advantageously reduce or prevent the color from fading or leaching, and
may also allow a more consistent look for the particles included in the composite.
Additionally, the chemical bonding of the colorant to the ceramic particles allows the
composite material to maintain color on its surface. In other exemplary embodiments, the
particles can be colored using one or more of dry temper colors, dry mortar, dyes, pigments,
paint, or other materials consistent with present disclosure as will be recognized by those
skilled in the art. In an exemplary embodiment, the particles can be substantially coated
using the colorant to provide consistency. According to other exemplary embodiments, the
particles can be substantially coated using the colorant to provide a desired aesthetic effect.
Different colorants can be applied to different positions of the particles to achieve varying
colors or effects. Colorants can be applied to the ceramic particles to provide a material that
resembles natural stone. In other exemplary embodiments, different colorants can be applied
to the particles so that it matches the exterior color of the member or structure (e.g., lavatory
sink, kitchen sink). The colorant matching the exterior of the member or structure can greatly
decrease the perception of any scratches or imperfections of the member or structure.
[0050] According to an exemplary embodiment, the ceramic particles can be mixed with
additives. The additives can include one or more of wood ash, mica, stone particles, glass
particles, or other materials consistent with the present disclosure as will be recognized by
those skilled in the art. In one exemplary embodiment, the additives can be mixed with the
particles to provide consistency. In another exemplary embodiment, the additives can be
mixed with the particles to provide a desired aesthetic effect. A combination of additives can
be mixed with the particles to provide a desired aesthetic effect. Different additives can be
mixed with different portions of the particles to achieve varying colors or effects.
[0051] Turning now to the accompanying drawing figures, FIG. 1 illustrates a sample made
of a composite material comprising an epoxy matrix and a vitreous china filler according to
an exemplary embodiment. As illustrated, the sample has a dark stone-like appearance. The
color of the sample may differ depending to various other exemplary embodiments depending
on the type of colorant used with the particles and/or polymer matrix material.
[0052] FIGS. 2-8 illustrate a number of possible sink designs that may be formed using the
composite materials described herein. These sink designs are intended as illustrative and are
in no way intended to be limiting. According to other exemplary embodiments, any of a
variety of different sink designs may be created using such composite materials. According
to still other exemplary embodiments, the composite material may be used to form
countertops, integrated sink and countertop products, bathtubs, shower stalls and surrounds,
and any of a variety of other types of products for which an engineered stone-like surface
may be desired.
[0053] FIGS. 9 and 10 illustrate a pair of possible shower receptor designs that may be
formed using the composite materials described herein. These shower receptor designs are
intended as illustrative and are in no way intended to be limiting. According to other
exemplary embodiments, any of a variety of different shower receptor designs may be created
using such composite materials.
[0054] FIGS. 11 and 12 illustrate a pair of possible bathtub designs that may be formed
using the composite materials described herein. These bathtub designs are intended as
illustrative and are in no way intended to be limiting. According to other exemplary
embodiments, any of a variety of different bathtub designs may be created using such
composite materials.
[0055] FIG. 13 is a flowchart illustrating a process 100 for producing a composite material
and a product therefrom according to an exemplary embodiment.
[0056] In a step 110, a source of the ceramic filler material is obtained. For example, the
source may be existing sanitary ware products such as sinks, toilets, and the like. In another
example, the source may be excess material from the production of sanitary ware or other
types of products. The source material is preferably a vitrified china material that has a
composition and water absorption as described herein.
[0057] In a step 120, the source material is processed to produce particles having the
desired size and/or shape characteristics for use in the composite material. According to
various other exemplary embodiments, the source material may be subjected to crushing,
pulverizing, and/or grinding operations to reduce the size of the particles and to obtain a
desired particle size distribution. Such operations may be performed using any suitable
equipment, whether now known or later developed. It should be noted that while the process
100 contemplates that this processing step may be performed in conjunction with the
manufacturing process, according to other exemplary embodiments, pre-processed particles
may be obtained from a third-party source such as a materials supplier (i.e., the end producer
of the product need not crush the source material for the filler, but may instead obtain that
material from a supplier; the supplier may also color the particles prior to delivering them if
desired).
[0058] In an optional step 130, the processed particles may be colored as described herein.
According to one exemplary embodiment, all particles used in the product may have the same
color, while according to other exemplary embodiments, a variety of colors may be utilized.
In an exemplary embodiment, particles of substantially similar color (e.g., white, almond,
biscuit, etc.) may be utilized. As will be understood by those reviewing this disclosure, the
polymer used for the matrix (e.g., an epoxy) may also be colored either to match or to
contrast or complement the particles to be used in the product. In an exemplary embodiment,
the polymer used for the matrix may be opaque and coat the particles such that the particles
appear to have a uniform color.
[0059] In a step 140, the particles and any additives are added to a polymeric resin material
using any acceptable method. The particles may be added concurrently with the other
additives or the constituents to be added may be added in a staged fashion according to any
desired processing order. Optional coloring of the polymeric matrix material may be
accomplished in this step or may be performed prior to or after the addition of the particles
and/or additive materials.
[0060] The composite material formed in step 140 may then be added into a mold having a
desired shape to produce the end product in a step 150. The introduction into the mold may
be accomplished by any desired method, and any of a variety of mold designs, shapes, and/or
sizes may be used according to various exemplary embodiments.
[0061] After introducing the composite material into the mold, the composite material is
allowed to harden in a step 160 to form the product. After the product is removed from the
mold, optional post-molding finishing processes may be performed in a step 170, and may
include, for example, applying protective coatings to the resultant product, polishing,
removing flash or other undesirable components of the product, and the like. In an
exemplary embodiment, post-molding finishing step 170 may be a heat treatment step
including holding the molded product at a temperature of between approximately 250°F and
350°F for a time period of between approximately 1 and 3 hours. In another exemplary
embodiment, post- molding finishing step 170 may be a heat treatment step including holding
the molded product at a temperature of approximately 300°F for a time period of
approximately 2 hours. Post-molding heat treatment may beneficially allow cross-linking of
the polymer chains and complete hardening of the product.
[0062] FIG. 14 is a flowchart illustrating a process 200 for producing a composite material
and a product therefrom according to another exemplary embodiment.
[0063] In a step 210, a source of the inorganic filler material is obtained. For example, the
source may be beach sand, core sand recovered from a sand-casting process, and the like.
The source material is preferably a core sand material that has a composition and water
absorption as described herein.
[0064] In an optional step 220, the source material may be processed to remove
contaminants. In an exemplary embodiment, a binder may be removed from the source
material, such as by heat treatment, to produce a binder free filler material. In another
embodiment, magnetic contaminants may be removed, such as by magnetic separation. Such
operations may be performed using any suitable equipment, whether now known or later
developed. It should be noted that while the process 200 contemplates that this processing
step may be performed in conjunction with the manufacturing process, according to other
exemplary embodiments, pre-processed particles may be obtained from a third-party source
such as a materials supplier (i.e., the end producer of the product need not remove the binder
from the source material, but may instead obtain that material from a supplier; the supplier
may also color the particles prior to delivering them if desired).
[0065] In an optional step 230, the processed particles may be colored as described herein.
According to one exemplary embodiment, all particles used in the product may have the same
color, while according to other exemplary embodiments, a variety of colors may be utilized.
In an exemplary embodiment, particles of substantially similar color (e.g., white, almond,
biscuit, etc.) may be utilized. As will be understood by those reviewing this disclosure, the
polymer used for the matrix (e.g., an epoxy) may also be colored either to match or to
contrast or complement the particles to be used in the product. In an exemplary embodiment,
the polymer used for the matrix may be opaque and coat the particles such that the particles
appear to have a uniform color.
[0066] In a step 240, the particles and any additives are added to a polymeric resin material
using any acceptable method. The particles may be added concurrently with the other
additives or the constituents to be added may be added in a staged fashion according to any
desired processing order. Optional coloring of the polymeric matrix material may be
accomplished in this step or may be performed prior to or after the addition of the particles
and/or additive materials.
[0067] The composite material formed in step 240 may then be added into a mold having a
desired shape to produce the end product in a step 250. The introduction into the mold may
be accomplished by any desired method, and any of a variety of mold designs, shapes, and/or
sizes may be used according to various exemplary embodiments.
[0068] After introducing the composite material into the mold, the composite material is
allowed to harden in a step 260 to form the product. After the product is removed from the
mold, optional post-molding finishing processes may be performed in a step 270, and may
include, for example, applying protective coatings to the resultant product, polishing,
removing flash or other undesirable components of the product, and the like. In an exemplary
embodiment, post-molding finishing step 270 may be a heat treatment step including holding
the molded product at a temperature of between approximately 250°F and 350°F for a time
period of between approximately 1 and 3 hours. In another exemplary embodiment, postmolding
finishing step 270 may be a heat treatment step including holding the molded
product at a temperature of approximately 300°F for a time period of approximately 2 hours.
Post-molding heat treatment may beneficially allow cross-linking of the polymer chains and
complete hardening of the product.
[0069] As utilized herein, the terms "approximately," "about," "substantially", and similar
terms are intended to have a broad meaning in harmony with the common and accepted usage
by those of ordinary skill in the art to which the subject matter of this disclosure pertains. It
should be understood by those of skill in the art who review this disclosure that these terms
are intended to allow a description of certain features described and claimed without
restricting the scope of these features to the precise numerical ranges provided. Accordingly,
these terms should be interpreted as indicating that insubstantial or inconsequential
modifications or alterations of the subject matter described and claimed are considered to be
within the scope of the invention as recited in the appended claims.
[0070] It should be noted that the term "exemplary" as used herein to describe various
embodiments is intended to indicate that such embodiments are possible examples,
representations, and/or illustrations of possible embodiments (and such term is not intended
to connote that such embodiments are necessarily extraordinary or superlative examples).
[0071] It is important to note that the construction and arrangement of the various
exemplary embodiments are illustrative only. Although only a few embodiments have been
described in detail in this disclosure, those skilled in the art who review this disclosure will
readily appreciate that many modifications are possible (e.g., variations in sizes, dimensions,
structures, shapes and proportions of the various elements, values of parameters, mounting
arrangements, use of materials, colors, orientations, etc.) without materially departing from
the novel teachings and advantages of the subject matter described herein. For example,
elements shown as integrally formed may be constructed of multiple parts or elements, the
position of elements may be reversed or otherwise varied, and the nature or number of
discrete elements or positions may be altered or varied. The order or sequence of any process
or method steps may be varied or re-sequenced according to alternative embodiments. Other
substitutions, modifications, changes and omissions may also be made in the design,
operating conditions and arrangement of the various exemplary embodiments without
departing from the scope of the present invention.

WHAT IS CLAIMED IS:
1. A composite material comprising:
a polymer matrix material; and
a filler material comprising vitreous china;
wherein the composite material has a water absorption of less than about one
percent.
2. The composite material as recited in claim 1, wherein the filler material
comprises particles with a size in the range of between 1 and 2000 micrometers.
3. The composite material as recited in claim 1 or 2, wherein the composite
material comprises between 10% and 70% by weight polymer matrix material and between
30% and 90% by weight filler material.
4. The composite material as recited in any of the preceding claims, wherein the
filler material further comprises sand.
5. The composite material as recited in claim 4, wherein the sand is recycled core
sand.
6. The composite material as recited in any of the preceding claims, wherein the
polymer matrix material comprises a polymer resin material or a mixture of polymer resin
materials.
7. The composite material as recited in any of the preceding claims, wherein the
vitreous china comprises:
between 50% and 80 % by weight Si0 2,
between 10%> and 30 % by weight AI2O3,
between 0% and 4% by weight a20 ,
between 0% and 4% by weight K2O,
between 0% and 3% by weight T1O2, and
between 0% and 5% by weight MgO.
8. The composite material as recited in any of the preceding claims, wherein the
composite material has a hardness of between 4 and 9 on the Moh's hardness scale.
9. The composite material as recited in any of the preceding claims, wherein the
filler material has a water absorption of less than one percent.
10. An article comprising the composite material as recited in any of the preceding
claims, wherein the article has a water absorption of less than one percent.
11. The article of claim 10, wherein the article is a sink.
12. The article of claim 10, wherein the article is a shower receptor, bathtub,
countertop, or integrated top and bowl single structure.
13. A method of making an article as recited in any one of Claims 10-12, the
method comprising:
mixing the filler material and the polymer matrix material to create the
composite material;
introducing the composite material into a mold of a desired shape; and
removing the article having the desired shape from the mold.
14. The method of claim 13, further comprising at least one of grinding,
pulverizing, or crushing a precursor material to produce the filler material prior to the mixing.
15. The method of claim 13 or 14, further comprising heat treating the article at a
temperature between 250°F and 350°F for a period of between 1 and 3 hours.
16. The method of any one of claims 13-15, further comprising coloring the filler
material prior to the mixing.
17. The method of any one of claims 13-16, further comprising mixing additional
fillers or additives with the filler material and polymeric matrix material in an amount of up
to about 20% by weight.