Patent ID: 6861024

Claim:
A method of manufacturing a release sheet for use in replicative casting of curable systems comprising: a) applying an acrylic functional coating layer to a substrate constructed to function as a temporary mold during casting of a curable material; b) pressing the coated side of the substrate against a replicative surface including a desired surface effect to cause the acrylic functional coating layer to conform with the replicative surface; c) curing the acrylic functional coating layer so that the acrylic functional coating layer includes a mirror image of the desired surface effect to be replicated during casting; d) stripping the cured coated substrate from the replicative surface; e) applying a silicone release coating layer on an exposed surface of the acrylic functional coating layer wherein the silicone release coating layer is adapted to receive the curable material, to provide acceptable release of a cast film of the curable material, and to allow the surface effect to be substantially replicated in the cast film; and f) curing the silicone release coating layer.