Imprinting Film for a Building Material and System and Method for Use of Same

Abstract

An imprinting film for a building material, and a system and method for use of the same are disclosed. In one embodiment of the imprinting film, a transparent film has first and second imprinting states. In the first imprinting state, a first side of the transparent film includes a pigment photomask defining an image and a second side includes a mold receiving surface. In the second imprinting state, the second side includes a relief of the image on the mold receiving surface. The mold receiving surface is configured to receive a molding material and the molding material hardening into the building material. The transparent film transitions from the first imprinting state to the second imprinting state in response to the second side being coated with a light-sensitive, non-laminate adhesive layer and a light source irradiating the first side.

What is claimed is: 
     
         1 . An imprinting film for a building material, the imprinting film comprising:
 a transparent film having a first side and a second side, the transparent film having a first imprinting state and a second imprinting state;   the first imprinting state including the first side having a pigment photomask and the second side having a mold receiving surface, the pigment photomask defining an image, the mold receiving surface being clear of pigmentation;   the second imprinting state including the second side having a relief of the image on the mold receiving surface, the mold receiving surface configured to receive a molding material, the molding material hardening into the building material; and   the transparent film transitioning from the first imprinting state to the second imprinting state in response to the second side being coated with a light-sensitive, non-laminate adhesive layer and a light source irradiating the first side.   
     
     
         2 . The imprinting film as recited in  claim 1 , wherein the transparent film further comprises a sheet of plastic. 
     
     
         3 . The imprinting film as recited in  claim 1 , wherein the light-sensitive, non-laminate adhesive layer further comprises an adhesive selected from the group consisting of UV-catalyzed epoxies and acryl-based adhesives. 
     
     
         4 . The imprinting film as recited in  claim 1 , further comprising a backing layer that provides the light-sensitive, non-laminate adhesive layer by releasable bonding, wherein the backing layer further comprises a non-reflective, hard and flat, non-porous material. 
     
     
         5 . The imprinting film as recited in  claim 1 , wherein the light source further comprises a source selected from the group consisting of tubular fluorescent black lights and incandescent mercury bulbs. 
     
     
         6 . The imprinting film as recited in  claim 1 , wherein the molding material further comprises a material selected from the group consisting of low-viscosity cementitious mixes, rubber mold-making mixes, and blended two-part epoxy applications. 
     
     
         7 . The imprinting film as recited in  claim 1 , wherein the second side being releasably bonded with the light-sensitive, non-laminate adhesive layer to the backing layer at room temperature. 
     
     
         8 . The imprinting film as recited in  claim 1 , wherein the second side being releasably bonded with the light-sensitive, non-laminate adhesive layer to the backing layer with an absence of air pockets between the second side and the backing layer. 
     
     
         9 . An imprinting film system for manufacturing an engraved plate made of a building material, the system comprising:
 an imprinting film comprising:
 a transparent film having a first side and a second side, the transparent film having a first imprinting state and a second imprinting state, 
 the first imprinting state including the first side having a pigment photomask and the second side having a mold receiving surface, the pigment photomask defining an image, the mold receiving surface being clear of pigmentation, 
 the second imprinting state including the second side having a relief of the image on the mold receiving surface, the mold receiving surface configured to receive a molding material, and 
 the transparent film transitioning from the first imprinting state to the second imprinting state in response to the second side being coated with a light-sensitive, non-laminate adhesive layer and a light source irradiating the first side; and 
   a building material in the shape of the engraved plate having an engraving, the building material being hardened from the molding material, the engraving being a negative impression of the relief.   
     
     
         10 . The system as recited in  claim 9 , wherein the negative impression of the relief is filled by a cementitious material. 
     
     
         11 . The system as recited in  claim 10 , wherein the cementitious material further comprises a grout. 
     
     
         12 . The system as recited in  claim 9 , wherein the transparent film further comprises a sheet of plastic. 
     
     
         13 . The system as recited in  claim 9 , wherein the light-sensitive, non-laminate adhesive layer further comprises an adhesive selected from the group consisting of UV-catalyzed epoxies and acryl-based adhesives. 
     
     
         14 . The system as recited in  claim 9 , wherein the molding material further comprises a material selected from the group consisting of low-viscosity cementitious mixes, rubber mold-making mixes, and blended two-part epoxy applications. 
     
     
         15 . An imprinting film system for manufacturing a mold for use with a building material, the system comprising:
 an imprinting film comprising:
 a transparent film having a first side and a second side, the transparent film having a first imprinting state and a second imprinting state, 
 the first imprinting state including the first side having a pigment photomask and the second side having a mold receiving surface, the pigment photomask defining an image, the mold receiving surface being clear of pigmentation, 
 the second imprinting state including the second side having a relief of the image on the mold receiving surface, the mold receiving surface configured to receive a first molding material, and 
 the transparent film transitioning from the first imprinting state to the second imprinting state in response to the second side being coated with a light-sensitive, non-laminate adhesive layer and a light source irradiating the first side; 
   a building material in the shape of an engraved plate having an engraving, the building material being hardened from the first molding material, the engraving being a negative impression of the relief, the engraving configured to receive a second molding material; and   a mold form in the shape of the mold, the mold form being hardened from the second molding material, the mold form being a positive impression of the relief.   
     
     
         16 . The system as recited in  claim 15 , wherein the transparent film further comprises a sheet of plastic. 
     
     
         17 . The system as recited in  claim 15 , wherein the light-sensitive, non-laminate adhesive layer further comprises an adhesive selected from the group consisting of UV-catalyzed epoxies and acryl-based adhesives. 
     
     
         18 . The system as recited in  claim 15 , wherein the light source further comprises a source selected from the group consisting of tubular fluorescent black lights and incandescent mercury bulbs. 
     
     
         19 . The system as recited in  claim 15 , wherein the first molding material further comprises a material selected from the group consisting of low-viscosity cementitious mixes, rubber mold-making mixes, and blended two-part epoxy applications. 
     
     
         20 . The system as recited in  claim 15 , wherein the second molding material further comprises a rubber.