Patent GB-1145091-A (GB)
Title: Laminated building or facing materials
IPC: B05D1/36
Filed: 1964-12-15
Abstract: 1,145,091. Metallic surfaced laminates. ADRIAN MARCHANT Ltd., and C. P. C. DURRANT. 11 March, 1966 [15 Dec., 1964], No. 51111/64. Heading B5N. A method of manufacturing a rigid laminated building or facing material having a metallized surface comprises (a) forming in a mould or on a work-surface a substantially horizontal first layer at least 0À008 inch thick, comprising a finely divided metallic material having a particle size in the range of from 50 to 400 B.S. mesh dispersed throughout a gelled thermosetting resin composition containing an unsaturated polyester resin or an epoxy resin, there being from <SP>1</SP>/ 6  to 3 parts by volume of finely divided metallic material for each part by volume of thermosetting resin composition; (b) optionally forming one or more further layers of thermosetting resin composition on said first layer; (c) placing on said first layer, or on said further layer(s) if present, before the thermosetting resin composition has set, a substantially rigid layer of a supporting material; (d) allowing or causing said thermosetting resin composition to set so that the first layer and the layer of supporting material are bonded together, at a rate such that the finely divided metallic material settles to the bottom of said first layer whereby, when the thermosetting resin composition has set and the resulting laminated material has been removed from the mould or work-surface, the particles of metallic material are concentrated at the exposed surface of the first layer; and (e) treating the exposed surface of the first layer with an abrasive to remove the thermoset resin composition until the desired metallized surface is formed. The metallic material may be copper, silver, gold, beryllium, magnesium, zinc, cadmium, aluminium, tin, lead, titanium, vanadium, chromium, manganese, iron, cobalt, nickel, hafnium, zirconium, niobium, tantalum, molybdenum, tungsten, ruthenium, osmium, rhodium, iridium, palladium, platinum, scandium, and the rare earth metals, alloys of such metals, or non-elemental metallic compounds. When an unsaturated polyester resin is used it may be formed from a polyhydric alcohol, e.g. glycol, and an unsaturated dibasic acid or its anhydride, e.g. maleic anhydride, optionally in an admixture with a saturated aliphatic dicarboxylic acid or its anhydride, e.g. succinic acid, or an aromatically unsaturated dicarboxylic acid or its anhydride, e.g. phthalic anhydride. If an epoxy resin is used it may be a glycidyl polyether. When a polyester resin is used a cross-linking agent, e.g. styrene, and a polymerization activator, e.g. methyl ethyl ketone peroxide may be used. The resin may be cured at temperatures in the range 15-150‹ C. in this case, and if temperatures in the range 15-25‹ C. are used an accelerator, e.g. cobalt naphthenate or cobalt octoate or an amine, may be used. When epoxy resin is used, a cross-linking agent, e.g. a polyfunctional compound such as a polyfunctional primary, secondary, or tertiary aliphatic or aromatic amine, e.g. diethylene triamine or benzyldimethylamine, or a dicarboxylic acid anhydride, e.g. dodecylsuccinic anhydride, is also employed. The supporting material may be asbestos board, chipboard, plywood or other forms of wood, or hardboard. To produce the laminate a moulding tray or work-surface is treated with a release agent, e.g. brushed or sprayed with polyvinyl alcohol, which is allowed to dry. The first layer is then applied to the mould or work-surface and before this is set one or more further layers of thermosetting resin composition, which may be metal filled and/or provided with a reinforcement of glass, jute, or nylon fibres, may be applied. The support material is then applied to the first layer, or further layer(s) if present, positioned by a jig, and pressed into place by clamps until the resin has set. The laminate is then removed from the mould, the exposed surface of the first layer treated with abrasive and polished to produce a metallic surface, and the edges of the laminate trimmed with a rotary cutter.