COZEN O'CONNOR BY: Melanie A.

Miller (MM 2992) 457 Haddonfield Road, Suite 300 Cherry Hill, NJ 08002 (856) 910-5000 - Telephone (856) 910-5075 Facsimile mmiller@cozen.com E-Mail Attorneys for Plaintiff Ronald Mark Associates, Inc. UNITED STATES DISTRICT COURT DISTRICT OF NEW JERSEY

Ronald Mark Associates, Inc., Plaintiff, : Case No.

V
.

Stonhard, Inc. Defendant.

COMPLAINT Plaintiff, Ronald Mark Associates, Inc. ("RMA"), by and through its undersigned attorneys for its complaint against Stonhard, Inc. ("Stonhard" or "Defendant"), alleges as follows: Parties 1. RMA is a New Jersey corporation with a principal place of business at 1227

Central Avenue, Hillside, New Jersey. 2. Upon information and belief, Defendant, Stonhard is a New Jersey corporation

with a place of business at 1000 East Park Avenue, Maple Shade, New Jersey.

Jurisdiction and Venue 3. This action arises under the patent laws of the United States, 35 U.S.C. 1 et

seq. This Court has jurisdiction over the subject matter of the claims asserted herein pursuant to 28 U.S.C. 1331 and 1338. 4. This Court has personal jurisdiction over Stonhard as Stonhard is doing business

within this State and Judicial District, transacts business within this State and Judicial District, and maintains its principal place of business within this State and Judicial District. Stonhard has also manufactured, sold, used, offered for sale, and/or aided and abetted others in, making, selling, using, and/or offering for sale resin based floors, flooring materials, and composite materials with bulk decorative features within this jurisdiction. 5. Venue is proper in this judicial district pursuant to Title 28 U.S.C. 1331,

1338(a), 1391, and 1400 (b) because substantial acts of infringement have occurred in this Judicial District, Stonhard resides in this Judicial District, and Stonhard is subject to personal jurisdiction in this Judicial District. BACKGROUND FACTS 6. RMA is in the business of selling and manufacturing thermoplastic raw materials,

including PVC resins, Copolymer PVC resins, plastic sheeting, PVC coated fabrics, PVC sheeting and film, composite materials with bulk decorative features, and decorative particulates with a thermoset or thermoplastic base, among other materials. 7. On August 19, 2003, United States Letters Patent No. 6,607,818 ("the '818

Patent") entitled "Composite Materials with Bulk Decorative Features and Process for Producing Same" was duly and legally issued to Richard Satz and Lawrence E. Wolfe. All rights and interest in the '818 Patent have been assigned to RMA. A true and correct copy of the '818 Patent is attached hereto as Exhibit A.

8.

On November 18, 2003, United States Letters Patent No. 6,649,257 ("the '257

Patent") entitled "Composite Materials With Bulk Decorative Features and Process For Producing Same" was duly and legally issued to Richard Satz. All rights and interest in the '257 Patent have been assigned to RMA. A true and correct copy of the '257 Patent is attached hereto as Exhibit B. 9. One of RMA's products is "KINON." KINON utilizes hand cast resin in

combination with applied decorative effects to produce composite materials with bulk decorative features, including flooring, paneling, and other articles of manufacture that are covered by one or more of the claims of the '818 and '257 Patents. 10. Upon information and belief, Stonhard is in the business of manufacturing,

selling, and installing seamless floors, walls, and lining systems, among other articles of manufacture. 11. Upon information and believe, Liquid Elements is a division of Stonhard that

manufactures, sells, and installs poured resin based floors. The poured resin based floors are composite materials with bulk decorative features. 12. On or about July 1, 2013, Richard Satz, inventor on both the '818 and '257

Patents, noticed floors utilizing the technology in the Patents-in-Suit, that were not installed by RMA. After investigation, it was determined that the floors were installed by Stonhard, and a review of Stonhard's website for its Liquid Elements products (Liquidelements.com ) confirmed the various styles of flooring manufactured by Stonhard. Further detailed at the Liquidelements.com website is a gallery showing 25 different "Liquid Elements installations," each of which are poured resin floors. 13. On or about August 1, 2013, RMA, through its counsel, notified Stonhard of the

'818 and '257 Patents. Stonhard responded on August 6, 2013 and stated that they were

"evaluating" the August 1, 2013 letter. RMA, through its counsel, followed up on August 26, 2013, and in a response dated August 28, 2013, counsel for Stonhard stated that they were "not finished with [their] evaluation." Counsel for RMA sent a further letter on October 17, 2013 inquiring into a response and evaluation of the August 1, 2013 letter. On October 17, 2013, counsel for Stonhard again responded that they "remain in the course of evaluating [RMA's] letter of 1 August 2013." Counsel for RMA again contacted counsel for Stonhard on October 29, 2013 and requested the evaluation of the August 1, 2013 letter by November 1, 2013. To date, Stonhard has not provided any evaluation of the August 1, 2013 letter.

COUNT I INFRINGEMENT OF U.S. PATENT NO. 6,607,818

14.

RIVIA repeats and re-alleges, and incorporates by reference, the foregoing

paragraphs as though they were fully set forth at length herein. 15. Upon information and belief, Stonhard has infringed the '818 Patent either

literally or under the doctrine of equivalents through the manufacture, sale, offer for sale, and/or importation of composite materials with bulk decorative features that infringe on one or more claims of RMA's '818 Patent. Specifically, one or more of the Defendant's products, including, but not limited to the Liquid Elements line of products, infringe one or more claims of the '818 Patent. 16. Upon information and belief, Stonhard and its customers collectively have

infringed and continue to infringe the '818 Patent either literally or under the doctrine of equivalents. In particular, Stonhard has infringed and continues to infringe the '818 Patent by inducing others in the manufacture, use, sale, offer for sale and/or importation of composite materials with bulk decorative features that are covered by one or more claims of the '818 Patent. Specifically, Stonhard is inducing customers to purchase and install decorative flooring of one of at least six different product lines through the Liquid Elements brand, including:

"Smooth," "Reflect," "Crush," "Glitz," "Capture," and "Polished," each of which infringes either directly or through the doctrine of equivalents, one or more claims on the '818 Patent. In particular, Defendant provides a record of at least twenty-five examples of Liquid Elements installations as shown on Defendant's website. 17. RMA has not authorized or granted to Defendant any license to manufacture, sell,

offer for sale, or use any product that falls under any one of the claims of the '818 Patent. 18. Stonhard's acts of infringement have damaged RMA and RMA is entitled to

recover from Stonhard the damages sustained by RMA as a result of Stonhard's wrongful acts in an amount subject to proof at trial. Pursuant to 35 U.S.C. 284, RMA is entitled to damages to adequate to compensate for the infringement of Plaintiff's '818 Patent, including, inter alia, lost profits and/or a reasonable royalty. 19. RMA has been damaged as a result of Stonhard's infringing activities and will

continue to be damaged and will be irreparably harmed unless such activities are enjoined by this Court. 20. Upon information and belief, Stonhard's infringement of the '818 Patent has been

and continues to be willful and deliberate. As a result, RMA is entitled to increased damages under 35 U.S.C. 284 and to attorneys' fees and costs incurred in prosecuting this action under 35 U.S.C. 285.

COUNT II INFRINGEMENT OF U.S. PATENT NO. 6,649,257

21.

RMA repeats and re-alleges, and incorporates by reference, the foregoing

paragraphs as though they were fully set forth at length herein. 22. Upon information and belief, Stonhard has infringed the '257 Patent either

literally or under the doctrine of equivalents through the manufacture, sale, offer for sale, and/or importation of composite materials with bulk decorative features that infringe on one or more

claims of RMA's '257 Patent. Specifically, one or more of the Defendant's products, including, but not limited to the Liquid Elements line of products, infringe one or more claims of the '257 Patent. 23. Upon information and belief, Stonhard and its customers collectively have

infringed and continue to infringe the '257 Patent either literally or under the doctrine of equivalents. In particular, Stonhard has infringed and continues to infringe the '257 Patent by inducing others in the manufacture, use, sale, offer for sale and/or importation of composite materials with bulk decorative features that are covered by one or more claims of the '257 Patent. Specifically, Stonhard is inducing customers to purchase and install decorative flooring of one of at least six different product lines through the Liquid Elements brand, including: "Smooth," "Reflect," "Crush," "Glitz," "Capture," and "Polished," each of which infringes either directly or through the doctrine of equivalents, one or more claims on the '257 Patent. In particular, Defendant provides a record of at least twenty-five examples of Liquid Elements installations as shown on Defendant's website. 24. RMA has not authorized or granted to Defendant any license to manufacture, sell,

offer for sale, or use any product that falls under any one of the claims of the '257 Patent. 25. Stonhard's acts of infringement have damaged RMA and RMA is entitled to

recover from Stonhard the damages sustained by RMA as a result of Stonhard's wrongful acts in an amount subject to proof at trial. Pursuant to 35 U.S.C. 284, RMA is entitled to damages to adequate to compensate for the infringement of Plaintiff's '257 Patent, including, inter alia, lost profits and/or a reasonable royalty. 26. RMA has been damaged as a result of Stonhard's infringing activities and will

continue to be damaged and will be irreparably harmed unless such activities are enjoined by this Court.

27.

Upon information and belief, Stonhard's infringement of the '257 Patent has been

and continues to be willful and deliberate. As a result, RMA is entitled to increased damages under 35 U.S.C. 284 and to attorneys' fees and costs incurred in prosecuting this action under 35 U.S.C. 285. PRAYERS FOR RELIEF WHEREFORE, RMA prays for judgment and seeks relief against Defendant Stonhard as follows: a) For judgment that the claims of the '818 Patent have been and/or continue to be infringed by the Defendant; b) For judgment that the claims of the '257 Patent have been and/or continue to be infringed by the Defendant; c) For an accounting of all damages sustained by RMA as the result of Defendant's acts of infringement; d) For actual damages, together with prejudgment interest, according to proof; e) For a preliminary and permanent injunction, enjoining Defendant from making, using, offering for sale, or selling products that infringe the '818 or '257 Patents; f) For enhanced damages pursuant to 35 U.S.C. 284; g) For an award of attorneys' fees pursuant to 35 U.S.C. 285, or as otherwise permitted by law; h) For all costs of suit; and

i) For such other and further relief as the Court may deem just and proper. DEMAND FOR JURY TRIAL Ronald Mark Associates, Inc. demands a trial by jury on all triable issues of fact. Dated: December 11, 2013 Respectfully submitted by: COZEN O'CONNOR /s/ Melanie A. Miller Melanie A. Miller (MM 2992) Cozen O'Connor 457 Haddonfield Road, Suite 300 Cherry Hill, NJ 08002 (856) 910-5000 - Telephone (856) 910-5075 Facsimile mmiller@cozen.com E-Mail and Camille M. Miller (to be admitted pro hac vice) Kyle Vos Strache (to be admitted pro hac vice) Cozen O'Connor 1900 Market Street Philadelphia, PA 19103 (215) 665-7273 Telephone (215) 701- 2273 Facsimile cmiller@cozen.com E-Mail

Attorneys for Plaintiff Ronald Mark Associates, Inc.

EXHIBIT A

1111111111111111111111111111141111!1 81,1 1 1,1 1 1 1 1 1 1 1 1 1 1 1 1

(12)

United States Patent

Satz et al.

(10) Patent No.: US 6,607,818 Bi (45) Date of Patent: Aug. 19, 2003

(54) COMPOSITE MATERIALS WITH BULK DECORATIVE FEATURES AND PROCESS FOR PRODUCING SAME (75) Inventors: Richard Satz, South Orange, NJ (US); Lawrence E. Wolfe, Wallingford, PA (US) (73) Assignee: Ronald Mark Associates, Inc., Hillside, NJ (US)

(*) Notice:

Subject to any disclaimer, the term of this patent is extended or adjusted under 35 U.S.C. 154(b) by 0 days.
DE DE FR GB

5,178,912 A 1/1993 Piacente et al. 7/1993 Dees et al. 5,230,945 A 5,431,960 A 7/1995 Watts 8/1995 Martiny 5,445,880 A 5,506,030 A 4/1996 Landers et al. 5,536,530 A 7/1996 Landers et al. 5,571,588 A 11/1996 Lussi et al. 5,627,231 A 5/1997 Shalov et al. 5,667,888 A * 9/1997 Yoshida et al. 5,686,507 A 11/1997 Hermele et al. 5,787,655 A 8/1998 Saylor 5,787,667 A * 8/1998 Sheahan et al. 5,789,032 A * 8/1998 Cong et al.

427/278 428/195 427/359 428/323 428/143 427/197 428/46 524/523 428/336 523/153 52/181 52/315 427/346

FOREIGN PATENT DOCUMENTS

1504052 3540078 2310889 1119193 2/1970 11/1986 12/1976 7/1968

(21) Appl. No.: 09/276,996 (22) Filed: (51) hit. CC Mar. 26, 1999 B32B 5/16; B32B 27/38; B32B 27/00; B32B 17/06 (52) U.S. Cl. 428/323; 428/324; 428/325; 428/327; 428/328; 428/331; 428/413; 428/423.1; 428/425.9; 428/426 428/323, 324, (58) Field of Search 428/325, 327, 328, 331, 413, 423.1, 425.9, 426; 65/99.1 (56) References Cited U.S. PATENT DOCUMENTS
3,267,187 A 8/1966 3,527,146 A 9/1970 3,928,706 A 12/1975 3,941,607 A 3/1976 11/1976 3,991,006 A 4,126,727 A 11/1978 4,196,243 A 4/1980 4,239,797 A 12/1980 4,405,657 A 9/1983 4,456,643 A 6/1984 4,501,783 A 2/1985 7/1985 4,530,856 A 4,584,209 A 4/1986 4,599,264 A 7/1986 4,760,103 A 7/1988 4,797,314 A 1/1989 4,816,319 A 3/1989 4,879,143 A 11/1989 4,975,303 A * 12/1990 5/1991 5,017,632 A Slosberg et al. Garling Gibbons Schuhboner Chandler Kaminski Sachs et al. Sachs Miller et al. 264/122 94/5 428/323 106/281 R 260/40 R 428/172 428/147 428/327 428/54.1 428/156 428/147 427/197 427/201 427/264 523/150 428/167 428/167 427/387 427/263 523/400

OTHER PUBLICATIONS Weast, Robert C., CRC Handbook of Chemistry and Physics, 1974, p. B-74.* * cited by examiner
Primary ExaminerHolly Rickman (74) Attorney, Agent, or FirmOstrolenk, Faber, Gerb &

Soffen, LLP (57) ABSTRACT A visually decorative material having bulk decorative effects which may be used as a surface covering or for creating decorative objects, and the method of manufacturing same. The material is formed of a pigmented castable liquid vehicle such as a resinous polymer or glass having dispersed therein a quantity of discrete particles which have a higher specific gravity than the liquid vehicle. The material is formed by pouring the vehicle-particle composite onto a suitable backing. As the liquid flows onto the backing, the particles sink and disturb the uniformity of the pigment distribution. This causes the desired bulk decorative effects in the form of "comet-tails" and other dimensionally extended streaks and curves. The backing may be removed after the castable liquid solidifies or may be left in place to create a laminate. As a floor-covering, the material may be poured in place onto a suitable sub-flooring. A protective surface coating may also be applied to the solidified casting. 37 Claims, No Drawings

Colyer
Hiraggami et al. Kauffman et al. Harrison Kauffman et al. Kraft et al. Davey et al. Dees et al. Rang McKinnon Bredow et al.

US 6,607,818 B1
1 COMPOSITE MATERIALS WITH BULK DECORATIVE FEATURES AND PROCESS FOR PRODUCING SAME

2
pigmented liquid vehicle of suitable viscosity as detailed below, and a quantity of dispersable particles having a high specific gravity relative to the liquid vehicle. The manufacturing process itself can be quite simple: after the constitus ents are thoroughly blended, the material is poured onto a suitable surface and allowed to set. The thickness of the casting can be adjusted mechanically and the surface textured or smoothed as desired. The liquid can be poured onto a backing material if desired to produce a laminate, and a to protective coating can be added after the composite has set and/or hardened. As the liquid is poured or cast, the included particles tend to float then sink due to the relationship of specific gravity to viscosity. The flow of the liquid is thus interrupted both 15 vertically and horizontally by the movement of the particles, and the resulting non-uniformity of the dispersal of the pigment produces characteristic streaks, whirls, comet-tails and other extended bulk decorative effects. Among the liquids which may be used are resinous 20 polymers such as epoxy, PVC plastisols, acrylics, urethanes and the like, or other castable liquids such as glass. Any compatible colorant materials which have suitable light refracting properties may be used. A wide range of particle materials may be used, subject to the various requirements 25 discussed in detail below. Such materials include chips or flakes formed of PVC, acrylic, urea or polyester etc., or natural materials such as mica, quartz, sand or metal. The process according to this invention makes available a new class of decorative materials for use as floor and wall 30 coverings, laminated surfaces for furniture and even artists materials. Additionally, these materials can be produced easily and inexpensively in continuous sheet form or as discrete blocks or other desired shapes. It is accordingly a general object of this invention to 35 provide a new class of decorative materials and methods of manufacturing such materials. More particularly, it is an object of this invention to provide materials having dimensionally extended bulk decorative effects which may be as floor and wall coverings, as surfaces for furniture and for a variety of other decorative purposes. A related object of the invention is to provide a convenient and cost effective process for manufacturing the materials of 45 this invention. Another object of the invention is to provide decorative materials having bulk decorative effects in the form of extended streaks, comet-tails, waves or other curves and the like. 50 A further object of the invention is to provide decorative materials comprised of a castable pigmented liquid vehicle and a quantity of dispersable particles having a high specific gravity relative to the liquid vehicle, as well as a method of manufacturing such materials. SS A related object is provide decorative materials having bulk decorative effects which are achieved by mechanical interaction between a pigmented castable liquid vehicle and dispersed particles contained therein as the liquid is cast and 60 cures and/or hardens. A further related object is to provide such materials and the process for manufacturing same in which the decorative effects are in the form of extended streaks, comet-tails, waves or other curves and the like. Yet another object of the invention is to provide decora65 tive materials and methods for manufacturing the same in which the materials are comprised of a castable pigmented

FIELD OF THE INVENTION The present invention relates to composite materials with visible bulk decorative features within the body of the material, and to methods for producing such materials in sheet or block form. Such materials are useful as surface coverings for walls, floors, furniture etc. and as materials for making jewelry or other decorative objects. Broadly speaking, such materials are formed of castable pigmented liquids and solid particles specifically chosen to interact mechanically with the pigments to produce bulk decorative effects in extended forms such as streaks, comet-tails, waves, curves, etc. DESCRIPTION OF THE PRIOR ART Various methods for producing decorative materials which can be formed as laminates and used as surface coverings or from which decorative objects can be produced are well-known. For example, decorative laminates formed of sheet material of a resinous polymer composition, e.g. polyvinyl chloride, on a suitable substrate, e.g. a fibrous backing sheet, have been used for many years as sheet flooring. Similarly, laminates with simulated wood-grain or marbleized surfaces are used to produce furniture which is attractive and durable but inexpensive compared to natural materials. Methods for producing such materials include mechanical embossing, chemical embossing or inlaying to provide contrasting surface finishes and other decorative effects. Another type of decorative composite material consists of a transparent binder with embedded particles of various types. In these, the particles themselves provide decorative bulk effects and/or other functionality. Patents covering such materials include U.S. Pat. No. 3,941,607 to Schuhbauer which discloses a high traffic surface layer having chip grains, bituminous binder, and a high viscosity mortar; U.S. Pat. No. 3,950,581 to Maurin which shows a prefabricated tile panel having asbestos coated PVC chips; U.S. Pat. No. 4,126,727 to Kaminski covering a resinous polymer sheet containing mica, and transparent or translucent PVC chips; U.S. Pat. No. 4,257,834 to Iida which teaches a process for producing floor or wall sheet having a "chip like" pattern wherein the chips can be resin (PVC), inorganic, ceramic, metallic, stone, and wooden together with an epoxy or urethane resin; U.S. Pat. No 4,530,856 to Kauffman which is directed to a floor covering laminate having a textured and glossy finish, wherein various types of PVC resin particles are used. To the extent these patents are concerned with decorative effects, however, such effects are achieved from the appearance of the embedded particles themselves. So far as applicants have been able to determine, the prior art does not disclose materials or processes for manufacturing materials in which bulk decorative effects are achieved in continuous or extended form such as streaks, waves, curves, etc. through mechanical interaction between the constituents. SUMMARY AND OBJECTS OF THE INVENTION Broadly stated, decorative materials produced in accordance with this invention are comprised of a castable,

US 6,607,818 B1

3
liquid vehicle and included particulate material, and in which the decorative effects are achieved by proper selection of the properties of the liquid vehicle and the particulate material relative to each other. Other objects, advantages and novel features of the invention will become readily apparent to those skilled in the art from the following drawings and detailed description of a preferred embodiment of the invention.

4
done using a hand mixer, but a power mixer may also be used if it is of a type which does not cause introduction of a significant volume of air into the mixture. The mixture is then pre-cured if necessary and poured onto the desired substrate. To create floor tiles, wall covering panels or laminates for use in furniture manufacture, backing materials such as wood, fiberboard, or the like are preferred. For other applications, ceramics, metal or other materials may also be used. A suitable mold may be used to achieve the desired shape or the mixture may be poured without a mold to and the edges finished after the resin has hardened. Alternatively, as a floor covering, the mixture may be poured in place directly on a concrete or plywood sub-flooring. The desired product thickness and surface appearance may be achieved using a roller or other suitable tool. To produce a starting material for use in making jewelry or other deco15 rative objects, the pigmented vehicle-particulate mixture can be cast onto a glass substrate or onto a non-stick backing such a polyethylene, which may be removed after the resin has hardened. Once the mixture has cured or hardened, a surface layer 20 may be added to provide a smoother or more lustrous finish. The surface layer may be formed of any suitable material such as a urethane or polyester, if a harder, more protective surface is desired. This may be done using any suitable or conventional technique. Urethane coatings having a thick25 nesses in the range of about 1.0 to about 15.0 mils, or polyester coatings having a thicknesses in the range of about 1.0 to about 20.0 mils are preferred. Further details concerning typical and preferred manufacturing processes, constituents and material characteristics 30 may be found in the following illustrative examples, but it should be appreciated that these are intended to be illustrative only, and that the scope of the invention is to be measured by the appended claims. EXAMPLE 1 35 For an epoxy based product, a composite material was created as follows:

DETAILED DESCRIPTION OF THE INVENTION As noted above, the materials according to this invention are comprised of castable pigmented liquids and solid particles which interact mechanically with the pigmented liquid to produce the desired decorative effects. In accordance with several preferred embodiments of the invention, suitable liquids include resinous polymers such as epoxies, PVC plastisols, acrylics, urethanes and the like. Other nonresinous castable liquids such as glass may also be used. As previously noted, any colorant materials which are compatible with the liquid vehicle and have suitable light refracting properties may be used. For resinous vehicles, preferred colorants include mica-based pigments such as Mearle Hilite Pearl manufactured by Engelhard Corp oration of Iselin, N.J. or metallic pigments such as manufactured by Silberline Manufacturing Co., Inc. of Tamaqua, Pa. Awide range of particulate materials may be used, subject to several specific requirements. A first of these is that the particles not be reactive or soluble in the liquid vehicle so that the particles maintain their discrete shape during the pouring and setting stages of the process. Similarly for a liquid vehicle such as glass which is cast at an elevated temperature, the particles must not be affected by the heat. Further, because the particles must briefly remain suspended in the liquid and then sink as the liquid flows, the specific gravity of the particles is an important factor. Related to this is the viscosity of the liquid vehicle. Particle size is also important in achieving the desired visual effects. Suitable materials include chips or flakes formed of PVC, 40 QUANTITY acrylic, urea or polyester etc., or natural materials such as (Per Square Foot of Product) CONSTITUENT mica, quartz, sand or metal, the latter being especially 89.2 gm. Resin (Dow 325) preferred when the liquid vehicle is molten glass. Good 44.0 gm. Hardener (Eastech Agent M) results have been achieved using particles having specific 1.0 gm. Pigment (Silberline 554YG) gravities in the range of about 0.80 to about 3.0. Particle 45 PVC Chips (18 mesh, sp. gray. 1.3) 2.4 gm. sizes in the range of about two inches to about 400 mesh size may be employed, with a preferred range of about 40 gp to The resin, pigment and chips were thoroughly blended about 16 mesh size. Generally, the volume of particulates with a hand mixer, and then the hardener is added. After should not exceed about 75% of the composite material. further blending, the mixture is allowed to cure briefly to Liquid vehicle viscosities ranging from about 10 to about so achieve a viscosity of between 700 and 1000 centipoises, as 148,000 centipoises are suitable, with best results being measured by using a Brookfield LV type viscometer, no. 3 achieved with viscosities in the range of about 700 to about spindle at 12 RPM (about two minutes). The material was 1000 centipoises. poured onto a wood panel as a substrate, and nap rolled to a thickness of 50 to 55 mils per sq. foot. As the liquid flowed When a vehicle having relatively high viscosity is used, the specific gravity of the particles should be also be 55 relative to the sinking particles, the uniformity of the pigment was disturbed, and marbleized "comet-tails" and other correspondingly higher for a given particle size to achieve extended decorative effects were created. The effects were more pronounced decorative effects. Particle size may also three dimensional due to the refractive properties of the be increased to compensate for higher liquid viscosity but pigment, and the apparent texture of the design varied with the corresponding patterns and the surface texture of the the angle at which the surface was viewed. After the resin product will appear to be coarser. 60 was completely cured, the material was cut to produce The manufacturing process itself can be a simple, manual finished straight edges. process, or can be automated in various ways which will be EXAMPLE 2 obvious to one skilled in the art from the present description. For example, the components of the resin system, the The process of Example 1 was repeated, but after the colorant and the particles are mixed together, with the order 65 mixture had cured, a urethane coating having a thickness of in which the constituents are added to the mixture depending 10 mils was added. A smoother, more lustrous surface resulted. on the particular resin system used. Blending is preferably

US 6,607,818 B1

5
EXAMPLE 3 The process of Example 1 was again repeated, but using PVC chips of 40 mesh size. The result was essentially similar except that the visual effects were smaller and the surface was smoother.

6
7. A decorative composite material as described in claim 6 in which the particles are of substantially uniform size in

the range of about 16 to about 40 mesh. 8. A decorative composite material as described in claim 5 7 in which the amount of particulates does not exceed 75% of the volume of the solidified casting. 9. A decorative composite material as described in claim EXAMPLE 4 8 further including a surface coating comprised of a resinous polymer. For a PVC plastisol based product, composite materials 10. A decorative composite material as described in claim were created as follows: 10 9 in which the surface coating is formed of a material selected from the group consisting of urethanes and polyesters. 11. A decorative composite material as described in claim QUANTITY CONSTITUENT (Per Square Foot of Product) 10 further including a backing material permanently affixed 15 to the solidified casting. Dispersion Resin (Borden 1071) 100 parts 12. A decorative composite material as described in claim Plasticizer (Butyl Benzyl Phthalate) 50 parts Epoxidized Soybean Oil 5 parts 1 on which the liquid vehicle is glass. Stabilizer (Therm Check SP-1363) 3.5 parts 13. A decorative composite material as described in claim Stabilizer (Therm Check 5526) 1 part 1 in which the particles are selected to have a specific gravity Diluent (Aromatic 150) 5.5 to 50 parts 20 in the range of about 0.80 and about 3.0. Pigment (Mearle Hilite Pearl No. 9120C) 5-10 parts PVC Chips (18 mesh, sp. gray 1.3) 10-20 parts 14. A decorative composite material as described in claim 13 in which the particles are of substantially uniform size in the range of about 16 to about 40 mesh. The constituents were blended using a hand mixer, and the 15. A decorative composite material as described in claim viscosity was adjusted to between 700 and 1000 centipoises, 25 13 in which the particles are of substantially uniform size in as measured by using a Brookfield LV type viscometer, no. the range of about two inches to about 400 mesh. 3 spindle at 12 RPM, by adding diluent. The mixture was 16. A decorative composite material as described in claim poured and rolled to a thickness of 50 to 55 mils per sq. foot 13 in which the amount of particulates does not exceed 75% as in Example 1. Similar results were achieved, with the of the volume of the solidified casting. visual effects being more closely spaced for higher chip 30 17. A decorative composite material as described in claim concentrations. 1 in which the particles are of substantially uniform size in the range of about two inches to about 400 mesh. EXAMPLE 5 18. A decorative composite material as described in claim The process of Example 4 was repeated using PVC 17 in which the particles are of substantially uniform size in 35 particles of 40 mesh size and various chip concentrations. the range of about 16 to about 40 mesh. The results were similar to those in Examples 3 and 4. 19. A decorative composite material as described in claim What is claimed is: 1 in which the particles are of substantially uniform size in 1. A decorative composite material having bulk decorative the range of about 16 to about 40 mesh. effects, the material comprising: 20. A decorative composite material as described in claim 40 a substantially transparent body of solidified castable 19 in which the amount of particulates does not exceed 75% of the volume of the solidified casting. liquid; 21. A decorative composite material as described in claim a colorant substantially uniformly dispersed therein; and 1 in which the amount of particulates does not exceed 75% a quantity of dispersed particles, the specific gravity of the dispersed particles relative to 45 of the volume of the solidified casting. 22. A decorative composite material as described in claim the viscosity of the castable liquid being such that the 1 further including a surface coating comprised of a resinous dispersed particles sink as the liquid flows before polymer. becoming solidified, to form three dimensional 23. A decorative composite material as described in claim extended non-uniformities in the dispersion of colorant so 22 in which the surface coating is formed of a material visible in the body of the material. selected from the group consisting of urethanes and poly2. A decorative composite material as described in claim esters. 1 in which the solidified castable liquid is selected from the 24. A decorative composite material as described in claim group consisting of an epoxy, an acrylic, a PVC plastisol, a 23 including a backing material permanently affixed to the polyester, and a urethane. 3. A decorative composite material as described in claim 55 solidified casting. 25. A decorative composite material as described in claim 2 further including a surface coating comprised of a resinous including a backing material permanently affixed to the 1 polymer. solidified casting. 4. A decorative composite material as described in claim 26. A decorative composite material having bulk decora3 in which the surface coating is formed of a material tive effects, the material comprising: selected from the group consisting of urethanes and poly- 60 a solidified castable liquid; esters. a colorant substantially uniformly dispersed therein; and 5. A decorative composite material as described in claim a quantity of dispersed particles, 2 in which the particles are selected to have a specific gravity a specific gravity of the dispersed particles relative to the in the range of about 0.80 and about 3.0. viscosity of the castable liquid being such that the 6. A decorative composite material as described in claim 65 dispersed particles sink as the liquid flows before 5 in which the particles are of substantially uniform size in becoming solidified, the range of about two inches to about 400 mesh.

US 6,607,818 B1 7 8
whereby dimensionally extended non-uniformities in the 30. A decorative composite material as described in claim shape of comet tails are present in the dispersion of 29, in which the solidified castable liquid is selected from colorant in the vicinity of the dispersed particles. the group consisting of an epoxy, an acrylic, a PVC plastisol, 27. A decorative composite material having bulk decoraa polyester, and a urethane. tive effects, the material comprising: 5 31. A decorative composite material as described in claim a substantially transparent body of solidified castable 29, further including a surface coating comprised of a liquid; resinous polymer. a colorant substantially uniformly dispersed therein; and 32. A decorative composite material as described in claim a quantity of dispersed particles, 10 31, in which the surface coating is formed of a material selected from the group consisting of urethanes and polythe specific gravity of the dispersed particles relative to esters. the viscosity of the castable liquid being such that relative movement of the dispersed particles and the 33. A decorative composite material as described in claim liquid as it flows before becoming solidified, forms 29, in which the particles are selected to have a specific three dimensional extended non-uniformities in the is gravity in the range of about 0.80 and about 3.0. dispersion of colorant visible in the body of the mate34. A decorative composite material as described in claim rial. 29, in which the particles are of substantially uniform size in 28.A decorative composite material as described in claim the range of about 16 to about 40 mesh. 1, in which the particles comprise between about 5% and 35. A decorative composite material as described in claim about 20% of the weight of the cast material. 20 29, in which the amount of particulates does not exceed 40% 29. A decorative composite material having bulk decoraof the volume of the solidified casting. tive effects, the material comprising: 36. A decorative composite material as described in claim a substantially transparent body of solidified castable 29, including a backing material permanently affixed to the liquid; solidified casting. a colorant substantially uniformly dispersed therein; and 25 37. A decorative composite material as described in claim a quantity of dispersed particles, 29, in which the particles comprise between about 5% and about 20% of the weight of the cast material. wherein three dimensional extended non-uniformities in the dispersion of colorant are visible in the body of the material.

EXHIBIT B

1 1111111111111111111111111111111161111111t111111111111111111111111111
(12)

United States Patent

Satz

(10) Patent No.: US 6,649,257 Bi (45) Date of Patent: Nov. 18, 2003

(54) COMPOSITE MATERIALS WITH BULK DECORATIVE FEATURES AND PROCESS FOR PRODUCING SAME (75) Inventor: Richard Satz, South Orange, NJ (US)

(73) Assignee: Ronald Mark Associates, Inc., Hillside, NJ (US) * ) Notice: Subject to any disclaimer, the term of this patent is extended or adjusted under 35 U.S.C. 154(6) by 0 days.
DE DE FR GB

4,879,143 A 5,017,632 A 5,178,912 A 5,230,945 A 5,431,960 A 5,445,880 A 5,506,030 A 5,536,530 A 5,571,588 A 5,627,231 A 5,686,507 A 5,787,655 A 5,789,032 A *

11/1989 5/1991 1/1993 7/1993 7/1995 8/1995 4/1996 7/1996 11/1996 5/1997 11/1997 8/1998 8/1998

Raua Bredow et aL Piacente et al. Dees et al. Wattc Martiny Lauders et al. Lauders et al. Luss et al. Shalov et al. Hermile et al. Saylor Le Cong et al.

427/387 523/400 427/278 428/195 427/359 428/323 428/143 427/197 428/46 524/523 523/153 52/181 427/346

(21) Appl. No.: 09/644,883 (22) Filed: Aug. 23, 2000 Related U.S. Application Data (63) Continuation-in-part of application No. 09/276,996, filed on
Mar. 26, 1999, now abandoned.

FOREIGN PATENT DOCUMENTS

1504052 3540078 2310889 1119193 2/1970 11/1986 12/1976 7/1968

* cited by examiner
Primary ExaminerDeborah Jones Assistant ExaminerAbraham Bahta (74) Attorney, Agent, or FinnOstrolenk, Faber, Gerb &

Cl.7 (51) (52) U.S. CL

B32B 5/16 428/323; 428/206; 428/320.2; 428/327; 428/363; 428/339 (58) Field of Search 428/172, 323, 428/159, 208, 320.2, 206, 324, 363, 327, 403, 339, 346, 328, 331; 52/445 (56)
3,267,187 A 3,527,146 A 3,928,706 A 3,941,607 A 3,991,006 A 4,126,727 A 4,196,243 A 4,239,797 A 4,405,657 A 4,456,643 A 4,501,783 A 4,530,856 A 4,584,209 A 4,599,264 A 4,760,103 A 4,797,314 A 4,816,319 A

Soffen, LLP (57) ABSTRACT A visually decorative material having bulk decorative effects which may be used as a surface covering or for creating decorative objects, and the method of manufacturing same. The material is formed of a pigmented castable liquid vehicle having dispersed therein a quantity of discrete particles of higher specific gravity than the liquid vehicle. The material is formed by pouring the vehicle-particle composite onto a suitable backing. As the liquid flows onto the backing, the particles sink and disturb the uniformity of the pigment distribution. This causes the desired bulk decorative effects in the form of "comet-tails" and other dimensionally extended streaks and curves. Thereafter, a second casting is applied using a formulation which is at an earlier stage of curing. The backing may be removed after the castable liquids solidify or may be left in place to create a laminate. As a floor-covering, the material may be poured in place onto a suitable sub-flooring. A protective surface coating may also be applied to the solidified casting. 22 Claims, No Drawings

References Cited U.S. PATENT DOCUMENTS

8/1966 Slosberg et aL 9/1970 Garling 12/1975 Gibbons 3/1976 Schuhbauer 11/1976 Chandler 11/1978 Kaminski 4/1980 Sachs et al. 12/1980 Sachs 9/1983 Miller et al. 6/1984 Colyer 2/1985 Hiragami et al. 7/1985 Kauffman et al. 4/1986 Harrison 7/1986 Kauffman et al. 7/1988 Kraft et aL 1/1989 Dovey et al. 3/1989 Dees et al. 264/122 94/5 428/323 106/281 R 260/40 R 428/172 428/147 428/327 428/54.1 428/156 428/147 427/197 427/201 427/264 523/150 428/167 428/167

US 6,649,257 B1 1
COMPOSITE MATERIALS WITH BULK DECORATIVE FEATURES AND PROCESS FOR PRODUCING SAME

2
pigmented liquid vehicle and a quantity of dispersable particles having a high specific gravity relative to the liquid vehicle, and a second castable liquid vehicle. The manufacturing process itself can be quite simple: after the first liquid 5 and particles are thoroughly blended, the material is poured onto a suitable surface and allowed to begin to set. Then the second vehicle is applied in a desired pattern and the two vehicles allowed to set. The thickness of the casting can be adjusted mechanically and the surface textured or smoothed to as desired. The first liquid can be poured onto a backing material if desired to produce a laminate, and a protective coating can be added after the composite has set and/or hardened. As the first liquid is poured or cast, the included particles 15 tend to float then sink due to the difference in specific gravity. The flow of the liquid is thus interrupted both vertically and horizontally by the movement of the particles, and the resulting non-uniformity of the dispersal of the pigment produces characteristic streaks, whirls, comet-tails 20 and other extended bulk decorative effects. Among the liquids which may be used are resinous polymers such as epoxy, PVC plastisols, acrylics, urethanes and the like, or other castable liquids such as glass. Any compatible colorant materials which have suitable light 25 refracting properties may be used. A wide range of particle materials may be used, subject the various requirements discussed in detail below. Such materials include chips or flakes formed of PVC, acrylic, urea or polyester etc., or natural materials such as mica, quartz, sand or metal. 30 The process according to this invention makes available a new class of decorative materials for use as floor and wall coverings, laminated surfaces for furniture and even artists materials. Additionally, these materials can be produced easily and inexpensively in continuous sheet form or as 35 discrete blocks or other desired shapes. It is accordingly a general object of this invention to provide a new class of decorative materials and methods of manufacturing such materials. More particularly, it is an object of this invention to 40 provide materials having dimensionally extended bulk decorative effects which may be as floor and wall coverings, as surfaces for furniture and for a variety of other decorative purposes. A related object of the invention is to provide a convenient 45 and cost effective process for manufacturing the materials of this invention. Another object of the invention is to provide decorative materials having bulk decorative effects in the form of extended streaks, comet-tails, waves or other curves and the 50 like. A further object of the invention is to provide decorative materials comprised of a castable pigmented liquid vehicle and a quantity of dispersable particles having a high specific 55 gravity relative to the liquid vehicle, and a second vehicle, as well as a method of manufacturing such materials. A related object is provide decorative materials having bulk decorative effects which are achieved by mechanical interaction between a pigmented castable liquid vehicle and 60 dispersed particles contained therein as the liquid is cast and cures and/or hardens. A further related object is to provide such materials and the process for manufacturing same in which the decorative effects are in the form of extended streaks, comet-tails, 65 waves or other curves and the like. Yet another object of the invention is to provide decorative materials and methods for manufacturing the same in

This application is a continuation-in-part of U.S. application Ser. No. 09/276,996, filed Mar. 26, 1999 abandoned. FIELD OF THE INVENTION The present invention relates to composite materials with visible bulk decorative features within the body of the material, and to methods for producing such materials in sheet or block form. Such materials are useful as surface coverings for walls, floors, furniture etc. and as materials for making jewelry or other decorative objects. Broadly speaking, such materials are formed of castable pigmented liquids and solid particles specifically chosen to interact mechanically with the pigments to produce bulk decorative effects in extended forms such as streaks, comet-tails, waves, curves, etc. DESCRIPTION OF THE PRIOR ART Various methods for producing decorative materials which can be formed as laminates and used as surface coverings or from which decorative objects can be produced are well-known. For example, decorative laminates formed of sheet material of a resinous polymer composition, e.g. polyvinyl chloride, on a suitable substrate, e.g. a fibrous backing sheet, have been used for many years as sheet flooring. Similarly, laminates with simulated wood-grain or marbleized surfaces are used to produce furniture which is attractive and durable but inexpensive compared to natural materials. Methods for producing such materials include mechanical embossing, chemical embossing or inlaying to provide contrasting surface finishes and other decorative effects. Another type of decorative composite material consists of a transparent binder with embedded particles of various types. In these, the particles themselves provide decorative bulk effects and/or other functionality. Patents covering such materials include U.S. Pat. No. 3,941,607 to Schuhbauer which discloses a high traffic surface layer having chip grains, bituminous binder, and a high viscosity mortar; U.S. Pat. No. 3,950,581 to Maurin which shows a prefabricated tile panel having asbestos coated PVC chips; U.S. Pat. No. 4,126,727 to Kaminski covering a resinous polymer sheet containing mica, and transparent or translucent PVC chips; U.S. Pat. No. 4,257,834 to Iida which teaches a process for producing floor or wall sheet having a "chip like" pattern wherein the chips can be resin (PVC), inorganic, ceramic, metallic, stone, and wooden together with an epoxy or urethane resin; U.S. Pat. No. 4,530,856 to Kauffman which is directed to a floor covering laminate having a textured and glossy finish, wherein various types of PVC resin particles are used. To the extent these patents are concerned with decorative effects, however, such effects are achieved from the appearance of the embedded particles themselves. So far as applicants have been able to determine, the prior art does not disclose materials or processes for manufacturing materials in which bulk decorative effects are achieved in continuous or extended form such as streaks, waves, curves, etc. through mechanical interaction between the constituents. SUMMARY AND OBJECTS OF THE INVENTION Broadly stated, decorative materials produced in accordance with this invention are comprised of a castable,

US 6,649,257 B1 3
which the materials are comprised of a castable pigmented liquid vehicle and included particulate material, and in which the decorative effects are achieved by proper selection of the properties of the liquid vehicle and the particulate material relative to each other. Other objects, advantages and novel features of the invention will become readily apparent to those skilled in the art from the following drawings and detailed description of a preferred embodiment of the invention. DETAILED DESCRIPTION OF THE INVENTION The first material according to this invention is comprised of a castable pigmented liquid and solid particles which interact mechanically with the pigmented liquid to produce the desired decorative effects. This is described in application Ser. No. 09/276,996, filed Mar. 26, 1999, which is hereby incorporated herein by reference. In accordance with several preferred embodiments of the invention, suitable liquids include resinous polymers such as epoxies, PVC plastisols, acrylics, urethanes and the like. Other non-resinous castable liquids such as glass may also be used. Any colorant materials which are compatible with the liquid vehicle and have suitable light refracting properties may be used. For resinous vehicles, preferred colorants include mica-based pigments such as Mearl Hllite Pearl manufactured by Engelhard Corporation of Iselin, N.J. or metallic pigments such as manufactured by Silberline Manufacturing Co., Inc. of Tamaqua, Pa. Awide range of particulate materials may be used, subject to several specific requirements. A first of these is that the particles not be reactive or soluble in the liquid vehicle so that the particles maintain their discrete shape during the pouring and setting stages of the process. Similarly for a liquid vehicle such as glass which is cast at an elevated temperature, the particles must not be affected by the heat. Further, because the particles must briefly remain suspended in the liquid and then sink as the liquid flows, the specific gravity of the particles is an important factor. Related to this is the viscosity of the liquid vehicle. Particle size is also important in achieving the desired visual effects. Suitable materials include chips or flakes formed of PVC, acrylic, urea or polyester etc., or natural materials such as mica, quartz, sand or metal, the latter being especially preferred when the liquid vehicle is molten glass. Good results have been achieved using particles having specific gravities in the range of about 0.8 to about 3. Particle sizes in the range of about 5 cm to about 400 mesh size may be employed, with a preferred range of about 40 up to about 16 mesh size. Generally, the volume of particulates should not exceed about 75% of the composite material. Liquid vehicle viscosities ranging from about 10 to about 148,000 centipoises are suitable, with best results being achieved with viscosities in the range of about 700 to about 1000 centipoises. When a vehicle having a relatively high viscosity is used, the specific gravity of the particles should also be correspondingly higher for a given particle size to achieve more pronounced decorative effects. Particle size may also be increased to compensate for higher liquid viscosity but the corresponding patterns and the surface texture of the product will appear to be coarser. The manufacturing process itself can be a simple, manual process, or can be automated in various ways which will be obvious to one skilled in the art from the present description.

4
For example, the components of the resin system, the colorant and the particles are mixed together, with the order in which the constituents are added to the mixture depending on the particular resin system used. Blending is preferably 5 done using a hand mixer, but a power mixer may also be used if it is of a type which does not cause introduction of a significant volume of air into the mixture. The mixture is then pre-cured if necessary and poured onto the desired substrate. To create floor tiles, wall covering panels or laminates for use in furniture manufacture, backing materi10 als such as wood, is fiberboard, or the like are preferred. For other applications, ceramics, metal or other materials may also be used. A suitable mold may be used to achieve the desired shape or the mixture may be poured without a mold and the edges finished after the resin has hardened. 15 Alternatively, as a floor covering, the mixture may be poured in place directly on a concrete or plywood sub-flooring. The desired product thickness and surface appearance may be achieved using a roller or other suitable tool. To produce a starting material for use in making jewelry or other deco20 rative objects, the pigmented vehicle-particulate mixture can be cast onto a glass substrate or onto a non-stick backing such a polyethylene, which may be removed after the resin has hardened. When the first layer is partially cured, a second layer is 25 applied thereto in a desired pattern. The second layer is composed of a castable liquid vehicle which may or may not be pigmented, depending on the desired appearance, and may or may not contain dispersable particles. Thus, the second vehicle may be a quantity of the first vehicle which 30 is at a different stage of curing. Preferable, the second vehicle is pigmented but does not contain the particles. As the first layer cures, there is a period of time during which there will be resistance to substantial mixing and/or substantial spreading of the second vehicle such that the 3 5 second vehicle will essentially remain at the position it is applied. During this period of time, the first liquid vehicle will still be sufficiently uncured such that it will allow the second liquid to both sink into its depth and spread out somewhat laterally while at the same time allowing the two 40 liquids to form a single level layer, all the while remaining substantially distinct entities. In other words, the two formulations interact to self-level the resulting coating. This state or period of time is hereinafter referred to as the semi-cured self-leveling cure state or time. The semi-cured 45 self-leveling cure time differs for each particular combination of liquids, pigments, particles and curing conditions but can readily be ascertained by a few routine test preparations. One manner of operating is to prepare the two casing compositions at different points in time and allow both to so cure under the same conditions. For example, one composition is prepared by mixing the vehicle, pigment and particles and then cast. After about an hour, preparation of the second vehicle is begun and 15 minutes later, it is applied to the surface of the first layer. Since the two materials are 55 at a different points in their curing process, there is incomplete mixing. The curing of both then proceeds until complete. Alternatively, the two formulations can be prepared simultaneously. The first is cast and the curing of the resulting layer is accelerated by application of heat while the 60 other formulation is maintained under ambient conditions. As a result, the extent of cure at any given time of one formulation is different from that of the other formulation. When the first layer is at the semi-cured self-leveling cure stage, the second formulation is applied and the resulting 65 composite cured. Once the composite has cured or hardened, a surface layer may be added to provide a smoother or more lustrous finish.

US 6,649,257 B1
5
The surface layer may be formed of any suitable material such as a urethane or polyester, if a harder, more protective surface is desired. This may be done using any suitable or conventional technique. Urethane coatings having a thicknesses in the range of about 1 to about 15 mils, or polyester coatings having a thicknesses in the range of about 1 to about 20 mils are preferred. Further details concerning typical and preferred manufacturing processes, constituents and material characteristics may be found in the following illustrative examples, but it should be appreciated that these are intended to be illustrative only, and that the scope of the invention is to be measured by the appended claims. EXAMPLE 1 For an epoxy based product, a composite material was created as follows:

6
EXAMPLE 4 The process of Example 1 is again repeated, but substituting a contrasting pigment, namely specify, in the second formulation. The result is similar except that the symmetrical pattern has a different color. EXAMPLE 5 For a PVC plastisol based product, composite materials were created as follows:

10

15

CONSTITUENT

QUANTITY (Per Square Foot of Product) 100 parts 50 parts 5 parts 3.5 parts 1 part 5.5 to 50 parts 5-10 parts 10-20 parts

CONSTITUENT Resin (Dow 325) Hardener (Eastech Agent M) Pigment (Silberline 554YG) PVC Chips (18 mesh, sp. gray. 1.3)

QUANTITY (Per Square Foot of Product) 89.2 gm. 44.0 gm. 1.0 gm. 2.4 gm.

Dispersion Resin (Borden 1071) Plasticizer (Butyl Benzyl Phthalate) Epoitdized Soybean Oil Stabilizer (Therm Check SP-1363) Stabilizer (Therm Check 5526) 20 Diluent (Aromatic 150) Pigment (Mearl Hilite Pearl No. 9120C) PVC Chips (18 mesh, sp. gray. 1.3)

The resin, pigment and chips were thoroughly blended with a hand mixer, and then the hardener is added. After further blending, the mixture is allowed to cure briefly to achieve a viscosity of between 700 and 1000 centipoises, as measured by using a Brookfield LV type viscometer, no. 3 spindle at 12 RPM (about two minutes). The material was poured onto a wood panel as a substrate, and nap rolled to a thickness of 50 to 55 mils per sq. foot. As the liquid flowed relative to the sinking particles, the uniformity of the pigment was disturbed, and marbleized "comet-tails" and other extended decorative effects were created. The effects were three dimensional due to the refractive properties of the pigment, and the apparent texture of the design varied with the angle at which the surface was viewed. One hour later, the same resin and pigment are thoroughly blended with a hand mixer, and then the same hardener is added. After further blending, the mixture is allowed to cure briefly to achieve a viscosity of between 700 and 1000 centipoises, as measured by using a Brookfield LV type viscometer, no. 3 spindle at 12 RPM (about two minutes). Then the second formulation is applied to the surface of the first layer in a symmetrical pattern and the resulting composite is allowed to cure. It is observed that the edges of the second formulation diffuse laterally somewhat and the two formulations rearrange themselves to form a single level surface. After the resins are completely cured, the material is cut to produce finished straight edges. EXAMPLE 2 The process of Example 1 is repeated, but after the composite has cured, a urethane coating having a thickness of 10 mils is added. A smoother, more lustrous surface results. EXAMPLE 3 The process of Example 1 is again repeated, but using PVC chips of 40 mesh size in the first formulation. The result is essentially similar except that the visual effects are smaller and the surface is smoother.

The constituents were blended using a hand mixer, and the viscosity was adjusted to between 700 and 1000 centipoises, as measured by using a Brookfield LV type viscometer, no. 3 spindle at 12 RPM, by adding diluent. The mixture was poured and rolled to a thickness of 50 to 55 mils per sq. foot as in Example 1. 30 One hour later, another preparation of the same formulation but without the particulate is prepared and allowed to cure briefly to achieve a viscosity of between 700 and 1000 centipoises, as measured by using a Brookfield LV type viscometer, no. 3 spindle at 12 RPM (about two minutes). 35 Then the second formulation is applied to the surface of the first layer in a symmetrical pattern and the resulting composite is allowed to cure. It is observed that the edges of the second formulation diffuse laterally somewhat and the two formulations rearrange themselves to form a level surface. 40 After the resin is completely cured, the material is cut to produce finished straight edges. Similar results to that in the other examples are achieved, with the visual effects being more closely spaced because of the higher chip concentration.
25 45

50

EXAMPLE 6 The process of Example 5 is repeated using PVC particles of 40 mesh size and various chip concentrations. The results are similar to those in Example 5. EXAMPLE 7 The process of Example 5 is repeated except that the particles were not omitted from the second formulation when the second preparation is made. Various changes and modifications can be made to the foregoing invention without departing from the spirit and scope there. The embodiments set forth above were for the purpose of illustration only and were not intended to limit the invention. What is claimed is: 1. A decorative composite material having bulk decorative effects and formed as a casting, the material comprising: a substantially transparent solidified first castable liquid having a first colorant and a quantity of dispersed particles therein, wherein a specific gravity of the dispersed particles relative to the viscosity of the first

55

60

65

US 6,649,257 B1
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castable liquid is such that the dispersed particles sink as the liquid flows before becoming solidified, to form three dimensional extended non-uniformities in the dispersion of the first colorant visible in the body of the material; and a second solidified castable liquid disposed in a pattern on the first castable liquid, whereby a first surface of the casting is substantially level. 2. A decorative composite material as claimed in claim 1, in which the second solidified castable liquid comprises a colorant. 3. A decorative composite material as claimed in claim 2, in which the particles have a specific gravity in the range of about 0.8 and about 3 and have a size in the range of about 5 cm to about 400 mesh, and in which each of the first and second solidified castable liquids are individually selected from the group consisting of glass, an epoxy, an acrylic, a PVC plastisol, a polyester and a urethane. 4. A decorative composite material as claimed in claim 3, further including a surface coating comprised of a resinous polymer. 5. A decorative composite material as claimed in claim 1, wherein the casting has a second surface affixed to a substrate, and wherein the second surface is opposite the first surface. 6. A decorative composite material as claimed in claim 1, in which the particles have a specific gravity in the range of about 0.8 and about 3 and have a size in the range of about 5 cm to about 400 mesh, and in which each of the first and second solidified castable liquid is individually selected from the group consisting of glass, an epoxy, an acrylic, a PVC plastisol, a polyester and a urethane. 7. A decorative composite material as claimed in claim 1, further including a surface coating comprised of a resinous polymer. 8. A decorative composite material as claimed in claim 7, wherein the casting has a second surface affixed to a substrate, and wherein the second surface is opposite the first surface. 9. A decorative composite material as claimed in claim 1, wherein the casting has a second surface affixed to a substrate, and wherein the second surface is opposite the first surface. 10. A decorative composite material as claimed in claim 1, in which the non-uniformities in the dispersion of colorant are in the shape of comet tails. 11.A decorative composite material as claimed in claim 1, in which the particles have a specific gravity in the range of about 0.8 and about 3. 12. A decorative composite material as claimed in claim 1, in which the particles have a size in the range of about 5 cm to about 400 mesh. 13. A decorative composite material as claimed in claim 1, in which each of the first and second solidified castable

8
liquid is individually selected from the group consisting of glass, an epoxy, an acrylic, a PVC plastisol, a polyester and a urethane. 14. A decorative composite material as claimed in claim 5 1, in which the particles comprise between about 5% and about 20% of the material by weight. 15. A decorative composite material having bulk decorative effects and formed as a casting, the material comprising: a substantially transparent solidified first castable liquid 10 having a first colorant and a quantity of dispersed particles therein, wherein a specific gravity of the dispersed particles relative to the viscosity of the first castable liquid is such that the relative movement of the dispersed particles and the liquid as it flows before 15 becoming solidified, forms three dimensional extended non-uniformities in the dispersion of the first colorant visible in the body of the material; and a second solidified castable liquid disposed in a pattern on the first castable liquid, whereby a first surface of the 20 casting is substantially level. 16. A decorative composite material having bulk decorative effects and formed as a casting, the material comprising: a substantially transparent solidified first castable liquid having a first colorant and a quantity of dispersed 25 particles therein, wherein three dimensional extended non-uniformities in the dispersion of the first colorant are visible in the body of the material; and a second solidified castable liquid disposed in a pattern on 30 the first castable liquid, whereby a first surface of the casting is substantially level. 17. A decorative composite material as claimed in claim 16, further including a surface coating comprised of a resinous polymer. 35 18. A decorative composite material as claimed in claim 16, wherein the casting has a second surface affixed to a substrate, and wherein the second surface is opposite the first surface. 19. A decorative composite material as claimed in claim 4 16, in which the particles have a specific gravity in the range of about 0.8 and about 3. 20. A decorative composite material as claimed in claim 16, in which the particles have a size in the range of about 5 cm to about 400 mesh. 45 21. A decorative composite material as claimed in claim 16, in which each of the first and second solidified castable liquid is individually selected from the group consisting of glass, an epoxy, an acrylic, a PVC plastisol, a polyester and a urethane. 50 22. A decorative composite material as claimed in claim 16 in which the particles comprise between about 5% and about 20% of the material by weight.

UNITED STATES PATENT AND TRADEMARK OFFICE

CERTIFICATE OF CORRECTION
PATENT NO. : 6,649,257 B1 DATED : November 18, 2003 INVENTOR(S) : Richard Satz Page 1 of 1

It is certified that error appears in the above-identified patent and that said Letters Patent is hereby corrected as shown below:

Title page,
Item [63], Related U.S. Application Data, should read: -- Continuation-in-part of application No. 09/276,996, filed on Mar. 26, 1999, now U.S. Patent No. 6,607,818 B1 --.

Signed and Sealed this Twentieth Day of April, 2004

JON W. DUDAS Acting Director of the United States Patent and Trademark Office