Production of three-dimensional designs

Method of producing a resin sheet having a three-dimensional pattern or design thereon which comprises applying a heat-foamable plastic material in the form of a two-dimensional pattern on a flexible sheet or web, then heating said heat-foamable plastic material to cause said heat-foamable plastic material to unite with said sheet or web and to expand forming a three-dimensional pattern on said sheet or web and thus form a master mold form, applying a release coating to the three-dimensional surface of said sheet or web, depositing a layer of fluid non-foaming resin upon the surface of said three-dimensional pattern, curing said layer while said layer is in contact with said three-dimensional surface to form a solid resin article and removing said sheet or web from said fused resin article to expose the three-dimensional pattern thereon.

Method of continuously producing a resin sheet having a three-dimensional pttern or design thereon which comprises applying a heat-foamable plastic material in the form of a two-dimensional pattern to a cylinder, heating said heat-foamable plastic material to cause said heat-foamable plastic to unite with the cylinder and to expand forming a three-dimensional pattern on said cylinder and thus form a master mold form applying a release material to the three-dimensional surface of said cylinder, continuously contacting a fluid non-foaming resin with said release-coated three-dimensional surface of said cylinder and causing said fluid resin to cure while in contact with said three-dimensional surface to form a solid resin article.

Method of continuously producing a resin sheet having a three-dimensional pattern or design thereon which comprises applying a heat-foamable plastic material in the form of a two-dimensional pattern to a flexible sheet or web, attaching said sheet or web to a cylinder, heating said heat-foamable plastic material to cause said material to expand forming a three-dimensional pattern on sheet or web and thus form a master mold form, applying a release material to the three-dimensional surface of said sheet or web, continuously contacting a fluid resin with said release-coated three-dimensional surface of said sheet or web by rotating said cylinder, and causing said fluid resin to cure or gel and fuse while in contact with said three-dimensional surface to form a solid resin article.

Method of continuously producing a resin sheet having a three-dimensional pattern or design thereon which comprises applying a heat-foamable plastic material in the form of a two-dimensional pattern to a cylinder, heating said heat-foamable plastic material to cause said heat-foamable plastic to unite with the cylinder and to expand forming a three-dimensional pattern on said cylinder and thus form a master mold form, applying a release material to the three-dimensional surface of said cylinder, continuously contacting a fluid foaming resin with said release-coated three-dimensional surface of said cylinder and causing said fluid resin to fuse while in contact with said three-dimensional surface to form a solid resin article.