Patent ID: 6464812
Filing Date: 2002-10-15
Classification: A44C,B29C,B29K,B29L,B44C,B44F,Y10T

Abstract:
A process for manufacturing a decorative laminate for use in making trophies, medals, plates, or panels, said process comprising the steps of(a) providing, cleaning, and drying a smooth base, (b) applying 4 or 5 layers of a polyvinyl alcohol thereto, (c) drying the polyvinyl alcohol layers to form a release layer on top of the base, (d) applying a catalyzed resin layer comprising a polyester, vinyl ester, or epoxy resin onto said release layer, (e) allowing the catalyzed organic resin layer to dry to a state of tackiness which is a touch point, (f) applying 2 further layers of catalyzed organic resin on the tacky layer formed in step (e), (g) placing fiberglass in the form of chopped strand mat, woven roving, or fabric onto the layers of catalyzed organic resin applied in step (f) and rolling the fiberglass chopped strand mat, woven roving, or fabric into the resin layers until the fiberglass is totally absorbed by the resin and there are no air bubbles in the fiberglass-containing resin layer formed by this procedure, (h) placing a decorative design face down onto the fiberglass-containing resin layer, (i) applying a further layer of catalyzed organic resin on top of the layer formed in step (h), (j) placing a cloth on top of the layer formed in step (i), (k) applying a further layer of catalyzed organic resin on top of the layer formed in step (j), (l) placing fiberglass in the form of chopped strand mat, woven roving, or fabric onto the layer of catalyzed organic resin applied in step (k) and rolling the fiberglass fabric into the resin layer, (m) placing a plastic film on top of the layer formed in step (l) to form a laminate, (n) rolling the thus-formed laminate with a cylinder or pipe until all air bubbles are expelled, (o) allowing the catalyzed organic resin layers to polymerize for at least 24 hours, and (p) releasing the laminate consisting of all of the materials applied subsequent to step (c), trimming said laminate to frame the decorative design of step (h), and finishing the trimmed piece encompassing the decorative design.