Resin panels, methods, and apparatus for making resin panels

Abstract

A process is described for making a resin panel having a grid support backing, comprising (a) applying a layer of liquid gelcoat or first resin to a surface of a mold and allowing the gelcoat or first resin to harden as a surface layer, (b) applying a layer of liquid second resin to a surface of the surface layer, (c) affixing a support grid on top of the layer of liquid second resin, (d) curing the liquid second resin at ambient temperature and pressure, so that the support grid is integral with the cured layer of resin to form a resin panel, and (e) removing the resin panel from the mold. A process is described for making a patterned resin panel, comprising (a) applying a layer of liquid resin to a surface of a mold, (b) applying a medium with the pattern printed on one side to the layer of liquid resin, with a side of the medium having the pattern being in contact with the liquid resin, (c) curing the layer of liquid resin at ambient temperature and pressure, to transfer the pattern from the medium to the layer of liquid resin, and (d) removing the medium from the cured resin.

What is claimed: 
     
         1 . A process for making a sturdy, light-weight resin panel, comprising:
 applying a first resin in liquid form to a surface of a mold and curing the first resin to form a surface resin layer;   applying a second resin in liquid form to a surface of the surface layer to form a second resin layer;   before the second resin has fully cured, applying a support member to a first surface of the second resin layer;   substantially curing the second resin, so that the support member is incorporated within the cured second resin of the second resin layer to form the sturdy, light-weight resin panel, and   removing the sturdy, light-weight resin panel from the mold.   
     
     
         2 . The process of  claim 1 , wherein applying the first resin to the surface of the mold comprises applying the first resin to a generally flat surface of the mold. 
     
     
         3 . The process of  claim 1 , wherein substantially curing the second resin comprises substantially curing the second resin in an environment of ambient temperature and ambient pressure. 
     
     
         4 . The process of  claim 1 , further comprising:
 applying a layer of pigment to a surface of the surface resin layer.   
     
     
         5 . The process of  claim 1 , before the second resin has fully cured, further comprising:
 affixing a support mat between the second resin layer and the support member to form a support layer.   
     
     
         6 . The process of  claim 4 , wherein affixing the support mat comprises affixing a fiberglass mat between the second resin layer and the support member. 
     
     
         7 . The process of  claim 5 , wherein affixing the support mat comprises affixing a support mat comprising biaxials or woven cloth fabrics between the second resin layer and the support member. 
     
     
         8 . The process of  claim 5 , wherein affixing comprises saturating the support mat with the second resin. 
     
     
         9 . The process of  claim 1 , wherein applying the second resin comprises applying a marble-containing resin to the surface of the surface layer. 
     
     
         10 . The process of  claim 1 , wherein applying the support member comprises applying a structured grid to the first surface of the second resin layer. 
     
     
         11 . The process of  claim 10 , wherein applying the structured grid comprises applying a structured grid including a pattern of interconnecting polygons to the first surface of the second resin layer. 
     
     
         12 . The process of  claim 10 , wherein applying the structured grid comprises applying a structured grid including a pattern of interconnecting hexagons to the first surface of the second resin layer. 
     
     
         13 . The process of  claim 10 , wherein applying the structured grid comprises applying a structured grid including a cured resin and a filler to the first surface of the second resin layer. 
     
     
         14 . The process of  claim 1 , wherein applying the support member comprises applying a support member comprising metal to the first surface of the second resin layer. 
     
     
         15 . The process of  claim 1 , wherein applying the support member comprises applying support member comprising wood to the first surface of the second resin layer. 
     
     
         16 . A laminated resin panel, comprising a first resin surface layer, a second resin layer, and a support member. 
     
     
         17 . The laminated resin panel of  claim 16 , wherein the support member is a structured grid. 
     
     
         18 . The laminated resin panel of  claim 17 , wherein the structured grid includes a pattern of interconnecting polygons. 
     
     
         19 . The laminated resin panel of  claim 17 , wherein the structured grid includes a pattern of interconnecting hexagons. 
     
     
         20 . The laminated resin panel of  claim 17 , wherein the structured grid comprises cured resin with a filler. 
     
     
         21 . The laminated resin panel of  claim 16 , further comprising a support layer. 
     
     
         22 . The laminated resin panel of  claim 16 , wherein the support layer comprises a fiberglass mat. 
     
     
         23 . The laminated resin panel of  claim 16 , wherein the support member comprises metal. 
     
     
         24 . The laminated resin panel of  claim 16  wherein the support member comprises wood. 
     
     
         25 . A process for making an image-bearing, sturdy, light-weight resin panel, comprising:
 applying a first layer of resin in liquid form to a surface of a mold,   before the first layer of resin has fully cured, applying a medium with an image printed on one side to the first layer of resin, with a side of the medium carrying the image being in contact with the first layer of resin,   at least partially curing the resin of the first layer to transfer the image from the medium to the first layer of resin,   before the resin of the first layer has fully cured, removing the medium from the first layer of resin,   applying a second layer of resin in liquid form to the first layer of resin,   before the resin of the second layer has fully cured, applying a support member to the second layer of resin,   substantially curing the resin of the second layer, so that the support member is incorporated within the resin of the second layer upon fully curing the resin of the second layer to form the sturdy, light-weight resin panel, and   removing the sturdy, light-weight resin panel from the mold.   
     
     
         26 . The process of  claim 25 , wherein the applying the support member comprises applying a structured grid to the second layer of resin. 
     
     
         27 . The process of  claim 26 , wherein applying the structured grid comprises applying a structured grid comprising cured resin to the second layer of resin. 
     
     
         28 . The process of  claim 25 , wherein applying the support member further comprises applying a support layer to the second layer of resin. 
     
     
         29 . The process of  claim 28 , wherein applying the support layer comprises applying a fiberglass mat to the second layer of resin. 
     
     
         30 . The process of  claim 28 , wherein applying the support layer comprises applying the support layer to the second layer of resin before applying a separate support member to the second layer of resin. 
     
     
         31 . The process of  claim 30 , wherein applying the support layer includes saturating the support layer with the resin of the second layer. 
     
     
         32 . A process for making an image-bearing resin trim piece, comprising:
 applying a layer of liquid resin to a surface of a mold;   applying a strip of a medium having an image carried by one side of the strip to a portion of the layer of liquid resin, with a side of the strip carrying the image being in contact with the liquid resin;   at least partially curing the liquid resin of the layer at ambient temperature and ambient pressure to transfer the image from the strip to the portion of the layer of liquid resin; and   removing the strip from the cured resin to leave a patterned strip.   
     
     
         33 . The process for making an image-bearing resin trim piece of  claim 32 , further comprising:
 applying a white gelcoat to the strip,   applying a marble resin layer to the gelcoat, and   applying a trim piece to the marble resin layer.   
     
     
         34 . The process of making an image-bearing resin trim piece of  claim 33 , further comprising:
 rounding edges of the strip, gelcoat and marble resin layer around edges of the trim piece; and   maintaining the rounded edges until curing of the patterned strip and marble resin layer is finished.   
     
     
         35 . A resin trim pieces having a pattern, design, image or color thereon applied to a partially gelled resin layer at ambient temperature and pressure, and a trim piece affixed to the resin layer, wherein the resin layer is rounded about an edge of the trim piece.