Surface Technologies, Inc.

Other

William M Stecker

A decorative article of manufacture includes a substrate having a surface of thermoplastic material and one or more relief portions extending from the substrate surface. The one or more relief portions are formed from a blend of powdered thermoplastic material and powdered non-thermoplastic material, wherein the powdered non-thermoplastic material is selected from the group consisting of metals, glass, minerals, and combinations thereof, wherein the powdered thermoplastic material is fused together and to the substrate thermoplastic material.

Decorative articles with portions in relief and methods of making same

A process for producing a decorative article having a face layer of multiple laminae is disclosed. A first curable resin is formed into a first lamina having a face layer with a relief and a substantially planar back layer. The first resin is cured and then a second curable resin is-applied to the face layer of the first lamina. The second resin is cured to produce a second lamina and the first and second laminae are then sanded to provide a decorative article of manufacture having a substantially planar face layer.

Process for making a multi-layered solid surface article

A method of producing a low stress, decorative article of manufacture having at least one relief portion extending therefrom includes casting a first thermosetting resin into recesses formed within a mold surface such that the first resin is not in contact with the mold surface. The first resin is partially cured to a &ldquo;B&rdquo; stage to provide an air inhibited out-of-mold surface. A coating of second thermosetting resin, such as unsaturated polyester, is then applied onto the partially cured first resin and onto the mold surface. A substrate having a face is placed in contacting relationship with the second thermosetting resin film and a progressively moving compressive force is applied to the second thermosetting resin via the substrate to prevent air from becoming entrained within the second thermosetting resin. The first and second thermosetting resins cure without the second thermosetting resin imparting shear stress on the first thermosetting resin.

Decorative signage with portions in relief and method of making same

Decorative structural panels have a release material of wax, silicone, or oil applied to portions of a substrate surface. One or more curable thermosetting resins are applied on top of the release material and substrate surface and allowed to commingle. The surface tension of each resin is greater than that of the release material such that the resin or resins are pulled away from the release material prior to curing to produce a fish-eye appearance having a strong and durable finish.

Decorative structural panel

Non-corrosive concrete reinforcing members are formed by pultruding reinforcing fibers through resin to produce an elongated core and a plurality of elongated flanges extending radially outward from the core. A slot is formed through a portion of the elongated core such that each flange has a free inner edge adjacent the slot. The reinforcing member is thereby bendable along the slot in a direction transverse to the elongated core.

Non-corrosive reinforcing member having bendable flanges

A decorative, multi-layered article of manufacture is described having a surface with portions of the underlying layers exposed. Multiple layers of curable thermosetting resin are cast into a mold having relief portions therein, wherein each layer has a different color. The resins are cured to form a first laminate with a substantially planar out-of-mold surface and an opposing in-mold surface having relief portions therein. Multiple layers of thermosetting resin are then cast onto the first laminate in-mold surface to follow the relief portions. Each layer has a color different from the other layers. The plurality of resins are then cured to form a second laminate, and such that the first and second laminates form an integral article having a face surface with relief portions therein and an opposing substantially planar back surface. The face surface of the article is then subjected to conditions sufficient to expose portions of the layers of the first and second laminates.

Process for making a multi-layered decorative article

A method of producing a substantially finished surface on the outmold side of a thermosetting casting. The method entails preparing a first laminae having a curable thermosetting resin material as a first outmold surface, and providing a second laminae having an imprinted surface thereon. The first surface and second laminae having an imprinted surface are then positioned in face-to-face registration with one another. Substantial vacuum conditions are generated in the area between the first surface and the imprint surface, and the surfaces are pressed together under substantial vacuum conditions. The vacuum and pressure conditions maintain the surfaces in face-to-face registration and contain any volatile components of the curable thermosetting resin material of the first laminae while the curable thermosetting resin material cures. After the curable thermosetting resin material cures, the second laminae having an imprinted surface is separated from the first laminae to form the substrate having the imprint of the second laminae.

Method for forming a laminated substrate

A method for producing synthetic shaped articles simulating marble, granite or the like is provided by the present invention. A thermosetting resin is subjected to first reaction conditions effective to partially polymerize the resin to form a semi-solid mass. The partially polymerized semi-solid mass of resin is comminuted to form a plurality of discrete partially polymerized resin particles. An article of the desired shape is formed from a mass of the partially polymerized resin particles. The thus formed shaped article is then subjected to second chemical reaction conditions effective to polymerize the resin to provide a synthetic shaped article simulating marble, granite and the like.

Method for producing a synthetic shaped article simulating marble,

A method of preparing a synthetic surface having a pattern simulating stone, marble and various other naturally occurring substances. The method involves preparing a resin matrix and combining such with a matrix veining pigment composition having a pigment component with a specific gravity heavier than that of the resin system and a blooming agent component with a specific gravity less than that of the resin system. The pigment component is allowed to disperse under the influence of the blooming agent to form the pattern. A further aspect of the present invention includes controlling the dispersement of the veining pigment within the resin matrix by controlling its thixotropic properties.

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Chapel Hill, NC, United States of America

William M Stecker