Abstract:
Resin members that carry images include a topcoat defining a front surface of the resin member and a substrate defining a body of the resin member. An image is carried internally within the resin member, between the front surface and a rear surface of the body. At least portions of the topcoat and the substrate are integral, with no discernible boundaries existing therebetween. The front surface of the resin member may have a texture defined by a surface on which the topcoat is formed.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application is a division of U.S. patent application Ser. No. 13/854,069, filed on Mar. 30, 2013 (hereinafter “the &#39;069 Application”). The &#39;069 Application was a continuation of U.S. patent application Ser. No. 11/726,727, filed on Mar. 21, 2007 and titled “METHODS FOR APPLYING IMAGES TO RESIN MATERIALS.” now U.S. Pat. No. 8,480,939, issued on Jul. 9, 2013 (hereinafter “the &#39;727 Application”). The entire disclosures of the &#39;069 Application and the &#39;727 Application are hereby incorporated in their entireties, by this reference. 
     
    
     TECHNICAL FIELD 
       [0002]    The present invention relates to methods and systems for applying images to materials. More particularly, the present invention provides methods and systems for applying images to polymeric substrates and other resin materials during their curing processes. 
       BACKGROUND 
       [0003]    Numerous processes are currently utilized to apply images to substrates, such as by using masks, etching, photocopying, dye sublimation, dye diffusion thermal transfer, and ink jet, laser, and other printing techniques. The processes are less varied, however, when attempting to apply images to particle-filled resin materials, such as cultured marble. Such composite substrates have become very popular for a variety of home uses, in particular for kitchen and bathroom surfaces, because of their strength, durability, resistance to staining, and ease of cleaning. 
         [0004]    It has been difficult to apply images deeply and permanently in resin materials. Consequently, image fading from wear or exposure to sunlight has been a major problem. Masking and etching have sometimes been used, but the processes have been expensive and time consuming. 
         [0005]    For the most part, the industry has focused on applying images to substrates from a transfer medium, with the images formed from dyes capable of sublimation. In some cases, a substrate of resin material is formed and cured before applying the transfer medium. A gel coating may first be applied to a substrate, and the gel coat may also be allowed to cure. Then the transfer medium having an image formed by sublimable ink is brought into contact with the substrate or coating, and heat and/or pressure are applied to cause the image to sublimate into the substrate or the gel coat. Commonly, a heat press is used to apply substantial heat and pressure to facilitate the image transfer. 
         [0006]    U.S. Pat. No. 7,001,660 (Garitano) discloses an image transfer method using a cured polymeric composite substrate. The substrate is brought into contact with an image transfer medium that carries an image formed by sublimable ink, while applying heat and/or pressure. U.S. Pat. No. 7,108,890 (Home) discloses applying a polymeric coating to a porous natural or synthetic surface. After the coating has cured, an image of sublimation inks is transferred to the coating from a transfer medium, by sublimation facilitated by heat and pressure. U.S. Patent Application Publication No. 2005/0227006 (Segall) discloses applying a gel coat to a substrate of composite material and then transferring an image to the coated composite by sublimation using heat and pressure. 
         [0007]      FIG. 1  shows an example of a prior art image transfer process  10  involving polymeric substrate and images transferred to substrates or coatings by sublimation through heat and pressure. An image  12  is acquired from various means, such as a photograph or painting, and may be scanned by a scanner  14  into a computer  15  for editing. The computer  15  then prints the image on a transfer sheet  20  with a printer  16  employing dye sublimation inks. 
         [0008]    Substrate  23  may be a natural product like stone, masonry, ceramic, marble, or concrete, or synthetic product, such as cultured marble or another polymeric composite material. If substrate  23  is a polymeric composite material, it is produced in a separate molding process (not shown). A liquid resin  26 , such as a polyol resin, may be applied to the substrate  23  by any conventional technique, such as by brush  28  or spray  30 . The resulting coating, referred to as a “receptor coating  24 ,” is allowed to cure by drying, hardening, absorbing, or reacting with a catalyst. 
         [0009]    Next, transfer sheet  20  is applied to a surface of receptor coating  24 , and is subjected to heat and pressure by a heat press  22 . The heat and pressure cause the ink to sublime into receptor coating  24  over a sublimation period. The resulting coated substrate has an image  12  imprinted on receptor coating  24 . 
         [0010]    The entire image transfer process  10  may require several hours of time to cure substrate  23  and receptor coating  24 . In addition, time is required to heat and press image  12  onto receptor coating  24  and then to cool substrate  23  and receptor coating  24 . Furthermore, a large and expensive heat press  22  must be used to apply substantial heat and pressure, typically around 300-500° F. and 20-60 psi. The image transfer process  10  is also labor intensive, requiring a skilled craftsman to operate heat press  22  and another craftsman to mix and pour liquid resin  26  to form substrate  23  and receptor coating  24 . Finally, unless receptor coating  24  has incorporated therein an ultraviolet (UV) radiation-resistant material, the resultant image  12  will exhibit poor light-fastness. 
         [0011]      FIG. 2  shows a cross-section of a product  29  resulting from image transfer process  10  of  FIG. 1 . Substrate  23  has a receptor coating  24  with an image  12 . Product  29  may be a polymeric product, such as a cultured marble surface in a kitchen or bathroom, a decorative stone, a cement or brick surface or wall, a pot or a ceramic container, or tiles in the entryway of a home. 
         [0012]    This type of image transfer process  10  tends to be expensive and time consuming. Substantial cure time is required to cure liquid resin  26  of substrate  23  and of receptor coating  24  before applying image  12 . Typically, a large and expensive heat press  22  is used to apply heat and pressure for the image transfer. Even then, the manufactured article exhibits poor light-fastness, particularly under prolonged exposure to the ultraviolet rays of sunlight, unless a separate UV-protective coating is applied. 
         [0013]    This light-fastness weakness is tied directly to the use of dye sublimation inks. As is well known by those familiar with the art of inkjet printing, dyes inherently exhibit poor light-fastness due to the fact that each dye molecule functions to provide color and is therefore exposed to UV radiation. However, dyes must be used for sublimable inks since the particulate property of pigments cannot be maintained during sublimation. Accordingly, this weakness makes dye sublimation inks particularly unsuitable for applications involving cultured marble and some other resin composites, since the areas in which these materials are used are often exposed to direct sunlight. Therefore, the use of dye sublimation inks requires the application of an additional material to provide UV protection or resistance, which adds time and cost to the production process and reduces the flexibility of the application. 
         [0014]    Moreover, the sublimation process is problematic due to the limitations of the dyes and dye colors and the necessity of special transfer materials having dye-acceptable coatings thereon, which add to the total cost of the process. In addition, since heat and pressure are required to drive the sublimation process, the necessity of using heat-resistant substrates has eliminated the use of some otherwise desirable materials. For example, the heat required for sublimation typically exceeds the heat distortion temperature limits of some composite materials, such as cultured marble. 
         [0015]    In view of the foregoing, it will be appreciated that providing methods for transfer of an image to a resin material without the need for applying heat and/or pressure would be a significant advancement in the art. 
       SUMMARY 
       [0016]    In the present invention, methods of transferring images to a wide range of substrates are provided. In one illustrative embodiment, a transfer medium having an image thereon is placed image-up in a mold for forming polymeric substrates. A polyester resin with filler is poured into the mold over the transfer medium. As the polyester resin is cured, the image is transferred to the adjacent face of the polymeric substrate by chemical absorption. The polymeric substrate, which carries the image, is then removed from the mold and coated with a clear protective coating over the image. 
         [0017]    In another illustrative embodiment, a thin layer of polyester resin is first poured into a mold for forming polymeric substrates to form a thin coating layer. A transfer medium having an image thereon is then placed image-down in the mold, over the thin coating layer. The image is transferred to the thin coating layer by chemical absorption as the polyester resin cures. The transfer medium is removed from the thin coating layer to which the ink is now absorbed. A polyester resin with filler, pigment, and initiator is then poured into the mold over the image and the thin coating layer. The image and the thin coating layer and, optionally, a polymeric substrate are then removed from the mold. 
         [0018]    In another illustrative embodiment, a transfer medium having an image on one side is placed in contact with a thin layer of polymer resin. The one side of the transfer medium and the image are brought into direct contact with an adjacent surface of the thin layer of polymer resin while it is curing, allowing the image to transfer to the polymer resin during curing, as the polymer resin becomes a solid resin layer. The transfer sheet is then removed from the polymer resin, leaving the image on the adjacent surface of the solid resin layer. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0019]      FIG. 1  is a flow diagram of a prior art process for forming an image on a substrate. 
           [0020]      FIG. 2  is a cross-sectional view of a product formed according to the process shown in  FIG. 1 . 
           [0021]      FIG. 3  is a flow diagram of a process for forming an image on a substrate according to one illustrative embodiment of the present invention. 
           [0022]      FIG. 4  is a cross-sectional view of a product formed according to the process shown in  FIG. 3 . 
           [0023]      FIG. 5  is a flow diagram of another process for forming an image on a substrate according to another illustrative embodiment of the present invention. 
           [0024]      FIG. 6  is a cross-sectional view of a product formed according to the process shown in  FIG. 5 . 
           [0025]      FIG. 7  is a flow diagram of another process for forming an image on a thin coating layer according to another illustrative embodiment of the present invention. 
           [0026]      FIG. 8  is a cross-sectional view of a product formed according to the process shown in  FIG. 7 . 
           [0027]      FIG. 9  is a flow diagram of another process for forming an image on a thin coating layer according to another illustrative embodiment of the present invention. 
           [0028]      FIG. 10  is a cross-sectional view of a product formed according to the process shown in  FIG. 9 . 
           [0029]      FIG. 11  is a perspective view of a mold used in connection with the above illustrative embodiments. 
           [0030]      FIG. 12  is a perspective view of another mold used in connection with the above illustrative embodiments. 
       
    
    
     DETAILED DESCRIPTION 
       [0031]    Before the present methods are disclosed and described, it is to be understood that this invention is not limited to the particular configurations, process steps, and materials disclosed herein, as such configurations, process steps, and materials may vary somewhat. It is also to be understood that the terminology employed herein is used for the purpose of describing particular embodiments only and is not intended to be limiting since the scope of the present invention will be limited only by the appended claims and equivalents thereof. 
         [0032]    The publications and other reference materials referred to herein to describe the background of the invention and to provide additional detail regarding its practice are hereby incorporated by reference. The references discussed herein are provided solely for their disclosure prior to the filing date of the present application. Nothing herein is to be construed as an admission that the inventors are not entitled to antedate such disclosure by virtue of prior invention. 
         [0033]    It must be noted that, as used in this specification and the appended claims, the singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to “a liquid resin” includes a mixture of two or more resins, reference to “an image” includes reference to one or more of such images, and reference to “an ink” includes reference to a mixture of two or more inks. 
         [0034]    Unless defined otherwise, all technical and scientific terms used herein have the same meanings as commonly understood by one of ordinary skill in the art to which this invention belongs. 
         [0035]    In describing and claiming the present invention, the following terminology will be used in accordance with the definitions set out below. 
         [0036]    As used herein, “comprising,” “including,” “containing,” “characterized by,” and grammatical equivalents thereof are inclusive or open-ended terms that do not exclude additional, unrecited elements or method steps. “Comprising” is to be interpreted as including the more restrictive terms “consisting of” and “consisting essentially of.” As used herein, “consisting of” and grammatical equivalents thereof exclude any element, step, or ingredient not specified in the claim. As used herein, “consisting essentially of” and grammatical equivalents thereof limit the scope of a claim to the specified materials or steps and those that do not materially affect the basic and novel characteristic or characteristics of the claimed invention. 
         [0037]    In contrast to the prior art process described in the Background, the embodiments of the present invention disclose a much faster, simpler, and less expensive process that is also capable of providing an image with much improved UV resistance. Images are transferred to substrates or coatings for substrates while the substrates or coatings are being formed and/or cured. The chemical absorption process that occurs while a substrate or coating that has not fully cured, or that is in a viscous or gel state, and is curing is sufficient to facilitate image transfer at room temperatures without the application of further heat or pressure. 
         [0038]    The reasons that image transfer to resin in the viscous or gel state works well at room temperatures are not fully understood. However, it is thought that an image on a transfer sheet transfers readily to polymer molecules in a viscous or gel state because the smaller molecules, including polymer molecules, that are present in a material that has not fully cured are more mobile than the larger polymer molecules present in a fully cured, or solid state, material, and chemical bonding can be more readily effected. This mobility provides a high degree of bonding between ink and molecules that cannot be achieved with molecules in cured materials, unless sublimation ink designs are used, accompanied by substantial heat and pressure. This process is referred to herein as “chemical absorption.” Other theories that could come into play in this invention are the likelihood of diffusion and/or solvation. There could be some diffusion of an image into the resin because of a relatively high solvent content of resin that has not fully cured. In addition, the solvent content of the resin gel may cause a dissolving or swelling of an ink-receptive coating on the transfer sheet, thus weakening the coating and facilitating image transfer to the resin. The foregoing theories are conjecture and have no effect on the scope of this patent application. As used herein, the term “liquid resin” refers to a resin in various stages of curing from a pure liquid to a viscous or gel form, and may include filler and/or reinforcement. 
         [0039]    Image transfer is accomplished without sublimation, opening up the use of less expensive inks also providing improved light-fastness (such as solvent- or aqueous-based pigment inkjet inks) for the images. Thus, images are transferred quickly and inexpensively to substrates and coatings at room temperature using relatively inexpensive materials and yielding a higher quality product. Images are transferred to resin layers that can be easily applied to any structure or surface. 
         [0040]    Transferring Images to Substrate. Referring now to  FIG. 3 , one embodiment of the present invention is shown. An image transfer process  50  involves acquiring an image  52  from various means such as a camera  54 , and inputting the image  52  into a computer  56  directly or through a scanner. Computer  56  may be used to process and edit image  52  before printing a reverse image (or minor image) to a transfer sheet  60  using a wide-format inkjet type printer  58  employing any suitable type of ink, including pigmented inkjet inks. 
         [0041]    Transfer sheet  60  is then laid face up in a mold  62 . Various means, such as vacuum or taping, may be used to secure transfer sheet  60 . A matrix  80  may be formed, for example, by combining a polyester resin  70  in liquid form, an inorganic filler  72 , a pigment  74 , and an initiator  76 , which is then poured over transfer sheet  60  in mold  62 . Matrix  80  cures through chemical cross-linking, and the pigmented ink of image  52  in transfer sheet  60  is absorbed during curing of polyester resin  70  of matrix  80  onto a surface  82  of matrix  80 , apparently using a process of chemical absorption. 
         [0042]    The cured or curing matrix  80  is removed from mold  62  at any selected time, and transfer sheet  60  is removed from surface  82 . Further curing may be carried out, as needed. Image  52  and surface  82  are then covered with a top coat  84  to provide protection from scratching and wearing. Note that top coat  84  does not need to provide UV resistance for pigmented inks, as would be the case if dye-based inks were used to form image  52  on transfer sheet  60 . 
         [0043]      FIG. 4  shows a cross-section of a product  90  resulting from image transfer process  50  of  FIG. 3 . Matrix  80  has an image  52  on its surface  82 , with a top coat  84  coating image  52  and surface  82  and protecting image  52 . Product  90  may have a variety of uses and applications, including for trims, jambs, curbs, and sills. 
         [0044]    Transferring Images to Substrate Coating. Looking next at  FIG. 5 , another embodiment of the present invention is shown. As in  FIG. 3 , an image transfer process  100  involves acquiring an image  102  from various means, such as a camera  104 , and inputting image  102  into a computer  106  directly or through a scanner. Computer  106  may be used to process and edit image  102  before printing image  102  onto a transfer sheet  110  using a wide-format inkjet type printer  108  employing any suitable kind of ink, including pigmented inkjet inks. 
         [0045]    Next, a mold  112  is covered with a thin, clear layer of resin  116  in liquid form, which thin, clear layer may be called a “coat  114 ,” by spraying, pouring or brushing resin  116  therein. At any desired point, while coat  114  is still curing, transfer sheet  110  is laid face down in mold  112  so that image  102  is in contact with coat  114  as resin  116  cures. Again, image  102  is transferred to coat  114 , apparently by a process of chemical absorption. Transfer sheet  110  is then removed from mold  112 . 
         [0046]    A matrix  130  is formed by combining, for example, a polyester resin  120  in liquid form, an inorganic filler  122 , a pigment  124 , and an initiator  126 . Matrix  130  is then poured over coat  114  in mold  112 . Matrix  130  solidifies through chemical cross-linking, and becomes integral with coat  114 . 
         [0047]    In contrast to the image transfer process  50  shown in  FIG. 3 , the current image transfer process  100  forms a coat  114 , which may also be referred to as a “top coat,” in mold  112  before matrix  130  is formed. Accordingly, matrix  130  is removed from mold  112  with coat  114  already covering matrix  130 . Since image  102  is on a backside of coat  114 , image  102  is also protected by coat  114  from scratching and wearing. Moreover, in the event that image  102  was formed from pigmented inks, coat  114  does not need to provide UV resistance. 
         [0048]      FIG. 6  shows a cross-section of a product  140  resulting from the image transfer process  100  of  FIG. 5 . Matrix  130  is integral with coat  114 . Image  102  is on the backside of coat  114 , which serves as a protective coating over image  102  and matrix  130 , which may now be fully cured. As with the product  90  in  FIG. 4 , product  140  may be a polymeric product with a variety of uses and applications, including as panels for tub surrounds, shower enclosures, and wainscoting. 
         [0049]    Transferring Images to Resin Layer. Looking now at  FIG. 7 , another embodiment of the present invention is shown, using a process  200  in which a design  208  or another image is applied to a layer of resin  204  in a liquid or other not fully cured state on a film  202 , which serves as a mold. As in  FIGS. 3 and 5 , a design  208  or another image is obtained, edited, and printed on a transfer sheet  206 . In this case, the mold is only a sheet of film  202 , possibly having a thin framework (not shown) around film  202 . 
         [0050]    Film  202  is first partitioned in some manner, such as by using tape or strips of plastic. Film  202  is then covered with a thin layer of resin  204  in liquid form, such as by pouring from a container, or by spraying, brushing or other means. At some point in the curing process, when resin  204  reaches an appropriate viscosity, a transfer sheet  206  is applied to resin  204  with a design  208  being laid face down in contact with resin  204 . 
         [0051]    As resin  204  cures, design  208  is transferred to resin  204 , apparently by a process of chemical absorption. Transfer sheet  206  is then carefully removed from resin  204 , revealing design  208  on resin  204 . Resin  204 , which now carries design  208 , will remain pliable for some period of time, making it easy to trim or cut with a simple knife  210  for various applications. 
         [0052]      FIG. 8  shows a cross-section of a cured resin product  220  resulting from the process  200  of  FIG. 7 . Film  202  has a layer of resin  204  thereon with design  208  integral with the layer of resin  204 . Resin  204  may be applied, while still in a viscous or gel state, directly to a substrate (not shown). Alternatively, resin  204  may be applied to a substrate later with various adhesives. Film  202  may then be stripped from the layer of resin  204 . The result is a thin, durable, cured layer of resin  204  having a design  208  ( FIG. 7 ) thereon and mounted on a substrate. The layer of resin  204  serves as a protective coating over design  208 , protecting it from surface abrasion and, if necessary, UV damage. 
         [0053]    Accordingly, product  220  has a wide variety of uses and applications and may be affixed to many different materials, including stone, wood, composites, metal, cement, brick, and glass, for many decorative purposes. Resin strips may also be used for covering exposed strip surfaces after cutouts are made in various substrates. The resin strips may be cured in a hardened form or may remain flexible until final application. Alternately, a sheet of resin  204  made according to this method may be used to overlay any type of surface. 
         [0054]    Looking now at  FIGS. 9 and 10 , a further alternative embodiment is shown. This process  230  is similar to process  200  described with respect to  FIG. 7 , except that the same or different designs  236 ,  244  or other images may be transferred to both sides of a layer of resin  240 , so that a product  246  ( FIG. 10 ) may be affixed to selected clear surfaces, such as glass or plastic, such as acrylic sheeting. As in  FIGS. 3 and 5 , a design  236 ,  244  is obtained, edited, and printed on a transfer sheet  234 . In this case, a film  232  may serve as a mold, possibly with a thin framework (not shown) around film  232 . 
         [0055]    As shown in  FIG. 9 , transfer sheet  234  having design  236  thereon is placed on film  232  with design  236  facing up, away from film  232 . Next, resin  240  in liquid form is poured from a container  238  onto transfer sheet  234 , covering design  236 . The resin  240  is allowed to partially cure while in contact with the design  236 . Then, at a selected time, another transfer sheet  242  may be applied to a top side  241  of the layer of resin  240  with another design  244  face down and in contact with top side  241 . Design  244  may be the same as design  236  on transfer sheet  234 , or it may be a different design. 
         [0056]    At a selected time, transfer sheet  242  is peeled off the layer of resin  240  leaving design  244  on top side  241  of the layer of resin  240 . Likewise, as shown in  FIG. 10 , film  232  and transfer sheet  234  are peeled off an underside  239  of the layer of resin  240 , exposing design  236  at underside  239  of the layer of resin  240 . 
         [0057]    A product  246  of process  230  is best seen in  FIG. 10 , as a layer of resin  240  having a design  244  embedded in the top side  241  of the layer of resin  240  and another design  236  embedded in underside  239  of the layer of resin  240 . Product  246  may remain flexible in order to adhere to various surfaces, in numerous different applications, including as a two-sided design strip or layer to cover part or all of a glass or acrylic window or wall, so that designs  236  and  244  on underside  239  and top side  241 , respectively, of the layer of resin  240  are displayed. 
         [0058]    As used herein, a “mold” may take many shapes and forms. The term “mold” includes, without limitation, a table with sides, a deeper mold for various specialty items, and a flat surface or film that may or may not be framed in some manner to define a mold area. 
         [0059]    Referring now to  FIGS. 11-12 , examples are shown of various types of molds that can be used in the above processes according to the present invention.  FIG. 11  shows a panel mold  250  having aluminum bars  252  and four glass tables  254 . Panel mold  250  is relatively shallow since the thickness of each aluminum bar  252  is small compared to the other dimensions. Glass tables  254  provide a smooth, glossy, finished surface. Resin (not shown) in liquid form is poured on glass tables  254 , before or after a transfer sheet (not shown) with a design or other image (not shown) thereon is positioned on glass tables  254 , depending on the process being used.  FIG. 12  shows a mold  260  for a shower floor. Textured black slate PIONITE® tables  262  are provided with aluminum bars  264  on the sides. Mold  260  provides shape and texture for the shower floors. 
       Materials 
       [0060]    There are many materials that may be used as substrates in connection with the present invention. Natural materials, such as wood and stone, may be used only with the embodiments shown in  FIGS. 7-8 , which involve creating an imaged resin layer that may then be affixed to objects. In the embodiments shown and described in  FIGS. 3-6 , the processes involve preparing a substrate by pouring a liquid matrix into a mold. 
         [0061]    For substrates, various types of polymeric materials are available—typically utilizing various types of resin matrices and fillers. The resin may be a polyester-type resin, and the filler may be of calcium carbonate, alumina tri-hydrate (ATH), similar inorganics, or fiberglass. In the construction industry, cultured marble is used in many applications, particularly in kitchens, baths, and entryways, to achieve a marbled look. Cultured marble is made by combining a matrix of specially formulated resin, ground calcium carbonate (limestone), powder pigments for color, and a hardening agent, such as methyl ethyl ketone peroxide (MEKP), acetyl acetone peroxide (AAP), or similar curing agent. 
         [0062]    Other resins that may be used to form substrates and/or coatings include phenolic mixtures, melamine formaldehyde, unsaturated polyesters, vinyl esters, epoxies, cross-linkable acrylics, and polyurethanes. In addition, other thermo-set resins may be used, depending upon their properties, in addition to thermoplastic resins, which are applied as melts or solutions. These thermoplastic resins may include, but are not limited to, polyethylene, polyethylene terephthalate (PET), polypropylene, nylon, polystyrene, poly methyl methacrylate (PMMA or acrylics), and polycarbonates. Clear coat materials may be various types of resins having the capability to provide protection from sunlight fading, water resistance, color-fastness, stain resistance, wear and cleanability, and chemical resistance. 
         [0063]    Transfer sheets or other transfer media for use in the present invention include paper, vinyl, fabric, and polymeric film. For forming an image on a transfer sheet, sublimation dyes of all types may be used, which vaporize when heated. However, in the present invention, image transfer is accomplished without elevated temperatures. Accordingly, any ordinary ink may also be used, such as solvent-based pigment inkjet inks, solvent-based dye inkjet inks, aqueous-based pigment inkjet inks, aqueous-based dye inkjet inks, dye diffusion thermal transfer inks, chemical toner, thermal wax transfer inks, and the like. 
       EXAMPLE 1 
       [0064]    In this example, image transfer process  100  described above with respect to  FIG. 5  was used. All activities were conducted at room temperature, between 65-75° F. Mold  112 , which was a table surface, was cleaned and prepared. The table surface was framed off to the dimensions of the selected part, using layers of tape or adhesive strips to achieve a height of 35-40 mils. A resin  116  comprising a solid surface polyester resin in liquid form was mixed with MEKP initiator, 3% by weight. Resin  116  was poured into the framed area of the table surface and vibrated to release trapped air. Resin  116  was allowed to set for 11-15 minutes until it began to gel. 
         [0065]    A transfer sheet  110  having an image  102  printed thereon in a pigment ink was laid face down on resin  116 , and the air bubbles were pushed out with a smoothing bar as transfer sheet  110  and image  102  made contact with resin  116 . Transfer sheet  110  was allowed to remain on resin  116  for 20-40 minutes. Separate test strips were used to determine when transfer of image  102  to resin  116  was complete. Transfer sheet  110  was carefully peeled off of resin  116 . 
         [0066]    Resin  116  was then ready to serve as a coat  114  for a matrix  130 , or substrate. A matrix  130  of cultured marble was mixed, comprising resin, inert calcium carbonate filler, pigment, and initiator. Matrix  130  was allowed to gel for 20-28 minutes. The finished product  140  ( FIG. 6 ) was removed from the table surface and post-cured for an hour at 180° F. to enhance hardness and stain resistance of coat  114 . 
       EXAMPLE 2 
       [0067]    In this example, process  200  described above with respect to  FIG. 7  was used. All activities were conducted at room temperature, between 65-75° F. An uncoated gloss finish film  202  was placed on a flat surface. The selected size of the layer of resin  204  was framed up with tape or thin strips until it achieved a thickness of 35-40 mils. Resin  204  was mixed with an initiator and poured onto the framed area. The initiator was about 3% by weight, which caused resin  204  to begin to gel in about 11 to 15 minutes. 
         [0068]    A transfer sheet  206  with a design  208  defined by pigment ink thereon was placed face down on resin  204 . Transfer sheet  206  was left on resin  204  for about 20 to 40 minutes. Test strips were used on extra resin  204  to determine the optimal point of design  208  transfer. When transfer of design  208  was complete, film  202  was carefully pulled back from the surface of resin  204 . 
         [0069]    Resin  204  bearing design  208  on one side and film  202  as a backing on the opposite side was cut into strips of varying sizes (e.g., using knife  210 , etc.). The pliable strips were applied to a substrate, and film  202  was released, leaving a glossy, finished surface with design  208  embedded about 35-49 mils beneath the surface of the layer of resin  204 , protecting design  208  from abrasion. 
       Advantages and Applications 
       [0070]    From the foregoing description, the advantages of the various embodiments of the present invention can be seen. By applying a transfer sheet carrying a design or another image to substrates or coatings formed from resin, one can cause the transfer of designs or other images directly to substrates and coatings using chemical absorption characteristics that are evident while curing the resin. Accordingly, expensive and cumbersome heat presses and other means of applying heat and pressure to the transfer sheets are not needed. 
         [0071]    Moreover, expensive sublimation inks and their associated specialty coated ink-receptive materials are not needed. Instead, inexpensive solvent- or aqueous-based inks may be used to apply images to generic, inexpensive transfer sheets. If pigmented inks are chosen, the need for UV-resistant coatings is mitigated, thus reducing the number of requirements placed on the resin that will be used to form a protective overcoat, or top coat, for the design or other image. If dye-based inks are chosen, UV-resistant materials may be incorporated into the resin, as the application allows. In either case, the protective overcoat provides oxidation protection to the image, along with improved aesthetics. 
         [0072]    The number of manufacturing steps and the time required for making prior art imaged structures are substantially reduced, since the image transfer and curing processes may be simultaneously carried out. In addition, the manufacture of thin imaged resin layers opens up many additional applications to many natural and man-made materials. 
         [0073]    Because the transfer of the image is by chemical absorption, a larger variety of printing substrates is possible than in other methods for transferring printed images. Hence, printing need not be restricted to the often expensive, limited set of printing substrates that is required in other printing-transfer methods. 
         [0074]    The ability to use chemical transfer broadens the variety of inks available for use. This reduces cost and allows for changes in ink and printing technology which are likely to give even further improvements in the print quality available. 
         [0075]    Many applications are available for the present invention. In homes, the products may be used for kitchen and bathroom surfaces, such as countertops, vanity tops, sinks, bathtubs, showers, tub splashes, window sills, architectural surfaces, picture substrates and frames, bathroom implements, soap dishes, shower seats, shampoo shelves, and the like. In addition, the products of the present invention may be applied to entryway structures, walls and other surfaces, table and desk tops, and visual display surfaces such as signage, artwork, murals, and award and recognition items. 
         [0076]    Furthermore, since a design or other image can be transferred with a variety of resins and is independent of the materials that might be used to back the resin, this technology can be used for fiber reinforced products, such as, to name only a few, wall panels, boats, tubs and showers, architectural forms (such as columns, facades, etc.), sporting goods to which a design or a logo might be attached, and even aerospace products wherein a design or other printed coating would be desirable. 
         [0077]    This method of transferring designs or other images also provides a means of enhancing or replacing normal painting processes. Instead of painting a polymeric surface, the desired finish for that surface can be achieved by transferring a design or image of the color (which could include a pattern) onto the polymeric surface and therefore avoid the need for additional painting. This process has the advantage of protecting the colored/printed surface by a layer of resin. Thus, for example, with airplanes, the use of a polymeric surface prepared according to the present invention may eliminate the need for paint, resulting in a weight reduction and lower maintenance. 
         [0078]    Although the above embodiments are representative of the present invention, other embodiments will be apparent to those skilled in the art from a consideration of this specification and the appended claims, or from a practice of the embodiments of the disclosed invention. It is intended that the specification and embodiments therein be considered as exemplary only, with the present invention being defined by the claims and their equivalents.