Decorative signage with portions in relief and method of making same

Abstract

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 “B” 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.

That which is claimed is:  
     
         1 . A method of producing a low stress, decorative article of manufacture having at least one relief portion extending therefrom, the method comprising the steps of: 
 casting a first thermosetting resin having a first color into a recess formed within a mold surface, such that the first resin is not in contact with the mold surface;    partially curing the first resin to provide an air inhibited out-of-mold surface;    applying a coating of second thermosetting resin onto the partially cured first resin and onto the mold surface, wherein the second thermosetting resin comprises an air release agent, and wherein the second thermosetting resin coating has a thickness of up to about 0.10 inch;    placing a substrate face in contacting relationship with the second thermosetting resin;    applying a progressively moving compressive force to the second thermosetting resin via the substrate to prevent air from becoming entrained within the second thermosetting resin;    curing the first and second thermosetting resins such that the second thermosetting resin adheres to the substrate face and such that molecular cross-linking occurs between the first and second thermosetting resins without the second thermosetting resin imparting shear stress on the first thermosetting resin; and    removing the cured article of manufacture from the mold.    
     
     
         2 . A method according to    claim 1    wherein the second thermosetting resin has a second color different from the first color of the first thermosetting resin.  
     
     
         3 . A method according to    claim 1    wherein the second resin cures to a transparent state such that the substrate is visible therethrough.  
     
     
         4 . A method according to    claim 3    wherein the substrate face comprises an image disposed thereon.  
     
     
         5 . A method according to    claim 1    wherein the step of applying a progressively moving compressive force to the second thermosetting resin via the substrate comprises simultaneously applying a first compressive force to the substrate and an opposite second compressive force to the mold while the mold and substrate are moved along a direction substantially orthogonal to the first and second directions.  
     
     
         6 . A method according to    claim 1    wherein the first resin is partially cured to a B-stage.  
     
     
         7 . A method according to    claim 1    wherein the first and second resins are selected from the group consisting of unsaturated polyesters, epoxies, phenolics and polyurethanes, and blends and mixtures thereof.  
     
     
         8 . A method according to    claim 1    wherein the first and second resins are the same.  
     
     
         9 . A method according to    claim 1    wherein the step of curing the first and second thermosetting resins comprises curing the first and second resins at a temperature of between about 15° C. and 100° C.  
     
     
         10 . A method of producing a low stress, decorative article of manufacture having at least one relief portion extending therefrom, the method comprising the steps of: 
 casting a first thermosetting resin having a first color into at least one recess formed within a mold surface, such that the first resin is not in contact with the mold surface, wherein the first thermosetting resin is selected from the group consisting of unsaturated polyesters, epoxies, phenolics and polyurethanes, and blends and mixtures thereof;    partially curing the first resin to provide an air inhibited out-of-mold surface;    applying a coating of second thermosetting resin onto the partially cured first resin and onto the mold surface, wherein the second thermosetting resin coating has a thickness of up to about 0.10 inch, wherein the second thermosetting resin is selected from the group consisting of unsaturated polyesters, epoxies, phenolics and polyurethanes, and blends and mixtures thereof, wherein the second thermosetting resin comprises an air release agent, and wherein the second resin is configured to cure to a transparent state such that the image disposed on the substrate face is visible therethrough;    placing a substrate face in contacting relationship with the second thermosetting resin, wherein the substrate face comprises an image disposed thereon;    applying a progressively moving compressive force to the second thermosetting resin via the substrate to prevent air from becoming entrained within the second thermosetting resin;    curing the first and second thermosetting resins such that the second thermosetting resin adheres to the substrate face and such that molecular cross-linking occurs between the first and second thermosetting resins without the second thermosetting resin imparting shear stress on the first thermosetting resin; and    removing the cured article of manufacture from the mold.    
     
     
         11 . A method according to    claim 1    wherein the step of applying a progressively moving compressive force to the second thermosetting resin via the substrate comprises simultaneously applying a first compressive force to the substrate and an opposite second compressive force to the mold while the mold and substrate are moved along a direction substantially orthogonal to the first and second directions.  
     
     
         12 . A method according to    claim 1    wherein the first resin is partially cured to a B-stage.  
     
     
         13 . A method according to    claim 1    wherein the first and second resins are the same.  
     
     
         14 . A method according to    claim 1    wherein the step of curing the first and second thermosetting resins comprises curing the first and second resins at a temperature of between about 15° C. and 38° C.  
     
     
         15 . A method according to    claim 10    wherein the at least one recess comprises a configuration of a respective alphanumeric character.  
     
     
         16 . A decorative article of manufacture, comprising: 
 a backing member comprising a face;    a thin layer of a first polymer material disposed on the backing member face, wherein the thin layer of first polymer material is devoid of air bubbles and/or voids, and wherein the thin layer of first polymer material has a thickness of between about 0.003 inch and about 0.050 inch; and    a relief portion extending from the thin layer of first polymer material, wherein the relief portion is formed from a second polymer material that is molecularly cross-linked at an interface with the thin layer of first polymer material.    
     
     
         17 . A decorative article of manufacture according to    claim 16    wherein the first and second polymer materials are selected from the group consisting of unsaturated polyesters, epoxies, phenolics and polyurethanes, and blends and mixtures thereof.  
     
     
         18 . A decorative article of manufacture according to    claim 16    wherein the first and second polymer materials are the same.  
     
     
         19 . A decorative article of manufacture according to    claim 16    wherein the first and second polymer materials have different colors.  
     
     
         20 . A decorative article of manufacture according to    claim 16    wherein the first polymer material is transparent such that the backing member face is visible therethrough.  
     
     
         21 . A decorative article of manufacture according to    claim 20    wherein the backing member face comprises an image disposed thereon and wherein the image is visible through the first polymer material.  
     
     
         22 . A decorative article of manufacture, comprising: 
 a backing member comprising a face with an image disposed thereon;    a thin layer of a first polymer material disposed on the backing member face, wherein the first polymer material is transparent such that the image disposed on the backing member face is visible therethrough, wherein the thin layer of first polymer material is devoid of air bubbles and/or voids, and wherein the thin layer of first polymer material has a thickness of between about 0.003 inch and about 0.050 inch; and    a relief portion extending from the thin layer of first polymer material, wherein the relief portion is formed from a second polymer material that is molecularly cross-linked at an interface with the thin layer of first polymer material.    
     
     
         23 . A decorative article of manufacture according to    claim 22    wherein the first and second polymer materials are selected from the group consisting of unsaturated polyesters, epoxies, phenolics and polyurethanes, and blends and mixtures thereof.  
     
     
         24 . A decorative article of manufacture according to    claim 22    wherein the first and second polymer materials are the same.