Method for making a decorative plate used in a building

A process for making a decorative plate used in a building consisting essentially of the steps of:

• (a) preparing a transfer sheet by applying a primer layer comprising a water-soluble binder in an amount of 1-10 grams/m.sup.2 (dry) on the surface of a synthetic resin sheet less than 0.5 mm thick, and printing a pattern layer comprising a coloring agent and a binder, at least one of which is water-soluble, on said primer layer;
• (b) forming a protective film of a water-soluble binder on the surface of said transfer sheet having the pattern layer thereon;
• (c) forming a mold from said transfer sheet for a slip casting wherein the pattern layer is on the inside surface of said mold by shaping the transfer sheet such that the surface of said pattern layer faces upward;
• (d) pouring a mixture comprising a hydraulic material and water into said mold for slip casting;
• (e) hardening said mixture;
• and
• (f) stripping said synthetic resin sheet from the resulting hardened configuration to produce said decorative plate.

A process for making a decorative plate used in a building, consisting essentially of the steps of:

• (a) preparing a transfer sheet by primer treating a film of opal polyvinyl chloride having a thickness of 0.2 mm with a solution of 15 parts of hydroxypropyl cellulose and 85 parts of ethyl alcohol and printing the film with a marble pattern by a gravure printing technique using inks A, B and C having the following composition:
• ______________________________________ A ink Permanent Yellow HR (C.I.Pigment Yellow 83) 10 parts Polyvinyl alcohol 5 parts Polyvinyl pyrrolidone 3 parts Ethyl alcohol 42 parts Water 40 parts B ink PV Carmine HF4C (C.I.Pigment Red 185) 10 parts Polyvinyl alcohol 5 parts Polyvinyl pyrrolidone 3 parts Ethyl alcohol 42 parts Water 40 parts C ink Mikethrene Blue RSN(C.I.69800) 10 parts Polyvinyl alcohol 5 parts Polyvinyl pyrrolidone 3 parts Ethyl alcohol 42 parts Water 40 parts ______________________________________
• (b) preparing a mold for a slip casting wherein the pattern layer is on the inside surface of said mold by laying the above said transfer sheet on a heating plate so as to contact the pattern layer of said transfer sheet with said heating plate, said plate being heated at a temperature of 100.degree. C. for 4 seconds, shaping said transfer sheet such that the surface of said pattern layer faces upward by pressure forming said transfer sheet on a forming die under air pressure of 5 kg/cm.sup.2, cooling the resulting formed transfer sheet and removing said formed transfer sheet from the forming die to provide the mold for slip casting having the size of 9 mm thickness.times.200 mm length.times.200 mm width,
• (c) pouring a slurry consisting of 100 parts of gypsum, 40 parts of water, 0.3 parts of glass fiber and 2 parts of urea resin into the mold,
• (d) hardening said slurry and
• (e) stripping said transfer sheet from the resulting hardened configuration to produce a decorative gypsum tile plate.