A pearlized plastics mosaic article having a ceramic glaze thereover is made in a mold having a deep etched pattern of engravings to provide a relief casting having a pattern of grooves simulating the look of mosaic tiles. An ornamental mosaic finish is obtained by casting mosaic and background layers of thermoset materials. For contrast and definition of the mosaic ornamentation, the thermoset layers are cast of materials having different color pigmentations and material textures. In the molding process, the first thermoset layer is cast to a depth which is less than the height of mold engravings. After curing the first layer to a gel consistency, the second background layer of thermoset material is cast in overlying relation to the first thermoset layer and mold engravings. The thermoset materials are then cured and demolded to provide an integral mosaic casting.
The present invention provides methods for producing a detailed mosaic decoration with a planar top surface. Specifically, this invention provides a multi-level supporting surface or substrate such that a less detailed portion of the mosaic, made up of relatively thicker mosaic materials, is formed atop a base portion of the support substrate, while a more detailed portion of the mosaic, made up of the relatively thinner mosaic materials, is formed atop a raised portion of the support substrate. Thus, both the highly detailed portion of the mosaic, being formed of relatively thinner mosaic materials, and the less detailed portion of the mosaic, being formed of relatively thicker mosaic materials, appear as though they are formed from relatively thicker mosaic materials.
A method for manufacturing decorative features in situ in a base layer of cast plastic material includes the steps of providing a heated mold tool with a selectively heated surface in the form of a desired decorative feature; depositing a covering of thermoplastic material in the recessed surface and heating the recessed surface to partially fuse the thermoplastic material on the recessed surface to form segments of plastic corresponding to the desired decorative feature; dumping excess thermoplastic material from the heated mold tool; thereafter spray coating the mold at the recessed surface to stabilize the location of the partially fused material in the recessed surface; reheating the mold tool to partially remelt the retained stabilized segments and thereafter depositing a base layer of thermoplastic material across the full surface of the mold and reheating the mold to bond the retained stabilized segments to the base layer and cooling and stripping the mold to form a finished plastic shell having a decorative feature formed in situ therein.
A thin glaze layer (2) is formed on a relief surface (1R) to a thickness which leaves recess on the relief surface (1R). A glaze-repellent layer (4) capable of repelling the glaze slurry is then formed on the surface of the thin glaze layer (2) to form a coated substrate. The glaze slurry is affixed to the coated substrate for forming a glaze slurry layer (5) for completing the glazing.
A thin glaze layer 2 is formed on a relief surface 1R to a thickness which leaves recesses on the relief surface 1R. A glaze-repellent layer 4 capable of repelling the glaze slurry is then formed on the surface of the thin glaze layer 2 to form a coated substrate. The glaze slurry is affixed to the coated substrate for forming a glaze slurry layer 5 for completing the glazing. With the conventional method for producing a ceramic article or for glazing, it has been extremely difficult to produce a ceramic article having a relief pattern of beautiful appearance, that is a ceramic article glazed to a sufficient thickness and presenting clearly defined crests and valleys of the relief pattern.
A process for producing a decorative article having a face layer of multiple laminae is disclosed. A first curable resin is formed into a first lamina having a face layer with a relief and a substantially planar back layer. The first resin is cured and then a second curable resin is-applied to the face layer of the first lamina. The second resin is cured to produce a second lamina and the first and second laminae are then sanded to provide a decorative article of manufacture having a substantially planar face layer.
