Abstract: A connector includes, an elongate web member, a pair of first and second elongate members extending outward from an end of the web member at a first angle relative to each other to form a V-shape, and a pair of third and fourth elongate members extending outward from an opposite end of the web member at a second angle relative to each other to form a V-shape. The first and second elongate members each have a respective longitudinal free end, and the third and fourth elongate members each have a respective longitudinal free end. The first and second elongate members are slidably engaged with respective receiving slots in a first element, and the third and fourth elongate members are slidably engaged with receiving slots in a second element to join the first and second elements together.

Abstract: A method of making a decorative article, such as, a sign or plaque. with raised elements/graphics, includes cutting at least one character from a multi-layered sheet, positioning the at least one character on a mold surface, placing a substrate in contacting relationship with the at least one character, wherein the substrate comprises clear or colored thermoplastic material, and applying a compressive force to the substrate and mold such that the at least one character fuses to the substrate. The multi-layered sheet includes a clear first thermoplastic layer, a second thermoplastic layer, and a printed color layer sandwiched between the first and second thermoplastic layers. The at least one character may be an alpha-numeric character an image, or a portion of an image.

Abstract: A method of making a bas relief from a two-dimensional image includes converting a two-dimensional image to a grey-scale image that comprises a plurality of shades of grey. Each shade of grey corresponds to a respective elevation of a three dimensional representation of the two-dimensional image. Ink is deposited on a substrate via a printer to form a three-dimensional topography that corresponds to the three-dimensional representation of the two-dimensional image. The two-dimensional image is then printed, in accurate registration, onto the three-dimensional pattern to produce the bas relief. A protective coating and/or film may be applied to the three-dimensional pattern and image printed thereon.

Abstract: A method of making a bas relief from a two-dimensional image includes converting a two-dimensional image to a gray-scale image that comprises a plurality of shades of gray. Each shade of gray corresponds to a respective elevation of a three dimensional representation of the two-dimensional image. The gray-scale image is then converted to a half-tone bitmap image that is etched onto a print screen stencil. Meltable powder is forced through the open mesh areas of the print screen stencil to form a three-dimensional pattern of powder on a substrate positioned beneath the print screen stencil in spaced-apart relationship therewith. The three-dimensional pattern of the powder corresponds to the three-dimensional representation of the two-dimensional image. The three-dimensional pattern of powder is then heated to fuse the powder together to form a bas relief.

Abstract: A method of making a bas relief from a two-dimensional image includes converting a two-dimensional image to a gray-scale image that comprises a plurality of shades of gray. Each shade of gray corresponds to a respective elevation of a three dimensional representation of the two-dimensional image. The gray-scale image is then converted to a half-tone bitmap image that is etched onto a print screen stencil. Meltable powder is forced through the open mesh areas of the print screen stencil to form a three-dimensional pattern of powder on a substrate positioned beneath the print screen stencil in spaced-apart relationship therewith. The three-dimensional pattern of the powder corresponds to the three-dimensional representation of the two-dimensional image. The three-dimensional pattern of powder is then heated to fuse the powder together to form a bas relief.

Abstract: A method of coating an object includes applying a heterogeneous mixture of polymeric powder and metal powder to a surface of an object and heating the surface for a period of time sufficient to cause the polymeric powder to cure and form a coating on the surface. The cured polymeric coating may then be subjected to one or more finishing operations. The resulting coating contains a substantially equal distribution of metal powder throughout a thickness thereof. The powder mixture may adhere to adhesive material applied to one or more surfaces of an object. The powder mixture may adhere to one or more heated surfaces of an object.

Abstract: A method of coating an object includes applying a heterogeneous mixture of polymeric powder and metal powder to a surface of an object and heating the surface for a period of time sufficient to cause the polymeric powder to cure and form a coating on the surface. The cured polymeric coating may then be subjected to one or more finishing operations. The resulting coating contains a substantially equal distribution of metal powder throughout a thickness thereof. The powder mixture may adhere to adhesive material applied to one or more surfaces of an object. The powder mixture may adhere to one or more heated surfaces of an object.

Abstract: A decorative article of manufacture includes a substrate having a surface of thermoplastic material and one or more relief portions extending from the substrate surface. The one or more relief portions are formed from a blend of powdered thermoplastic material and powdered non-thermoplastic material, wherein the powdered non-thermoplastic material is selected from the group consisting of metals, glass, minerals, and combinations thereof, wherein the powdered thermoplastic material is fused together and to the substrate thermoplastic material.

Abstract: 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.

Abstract: A method of producing a low stress, decorative article of manufacture having at least one relief portion extending therefrom includes casting a first thermosetting resin into recesses formed within a mold surface such that the first resin is not in contact with the mold surface. The first resin is partially cured to a “B” stage to provide an air inhibited out-of-mold surface. A coating of second thermosetting resin, such as unsaturated polyester, is then applied onto the partially cured first resin and onto the mold surface. A substrate having a face is placed in contacting relationship with the second thermosetting resin film and a progressively moving compressive force is applied to the second thermosetting resin via the substrate to prevent air from becoming entrained within the second thermosetting resin. The first and second thermosetting resins cure without the second thermosetting resin imparting shear stress on the first thermosetting resin.

Abstract: A method of producing a low stress, decorative article of manufacture having at least one relief portion extending therefrom includes casting a first thermosetting resin into recesses formed within a mold surface such that the first resin is not in contact with the mold surface. The first resin is partially cured to a “B” stage to provide an air inhibited out-of-mold surface. A coating of second thermosetting resin, such as unsaturated polyester, is then applied onto the partially cured first resin and onto the mold surface. A substrate having a face is placed in contacting relationship with the second thermosetting resin film and a progressively moving compressive force is applied to the second thermosetting resin via the substrate to prevent air from becoming entrained within the second thermosetting resin. The first and second thermosetting resins cure without the second thermosetting resin imparting shear stress on the first thermosetting resin.

Abstract: Decorative structural panels have a release material of wax, silicone, or oil applied to portions of a substrate surface. One or more curable thermosetting resins are applied on top of the release material and substrate surface and allowed to commingle. The surface tension of each resin is greater than that of the release material such that the resin or resins are pulled away from the release material prior to curing to produce a fish-eye appearance having a strong and durable finish.

Abstract: Non-corrosive concrete reinforcing members are formed by pultruding reinforcing fibers through resin to produce an elongated core and a plurality of elongated flanges extending radially outward from the core. A slot is formed through a portion of the elongated core such that each flange has a free inner edge adjacent the slot. The reinforcing member is thereby bendable along the slot in a direction transverse to the elongated core.

Abstract: Non-corrosive concrete reinforcing members are formed by pultruding reinforcing fibers through resin to produce an elongated core and a plurality of elongated flanges extending radially outward from the core. A slot is formed through a portion of the elongated core such that each flange has a free inner edge adjacent the slot. The reinforcing member is thereby bendable along the slot in a direction transverse to the elongated core.

Abstract: Non-corrosive concrete reinforcing members are formed by pultruding reinforcing fibers through resin to produce an elongated core and a plurality of elongated flanges extending radially outward from the core. A slot is formed through a portion of the elongated core such that each flange has a free inner edge adjacent the slot. The reinforcing member is thereby bendable along the slot in a direction transverse to the elongated core.

Abstract: A decorative, multi-layered article of manufacture is described having a surface with portions of the underlying layers exposed. Multiple layers of curable thermosetting resin are cast into a mold having relief portions therein, wherein each layer has a different color. The resins are cured to form a first laminate with a substantially planar out-of-mold surface and an opposing in-mold surface having relief portions therein. Multiple layers of thermosetting resin are then cast onto the first laminate in-mold surface to follow the relief portions. Each layer has a color different from the other layers. The plurality of resins are then cured to form a second laminate, and such that the first and second laminates form an integral article having a face surface with relief portions therein and an opposing substantially planar back surface. The face surface of the article is then subjected to conditions sufficient to expose portions of the layers of the first and second laminates.

Abstract: A method of producing a substantially finished surface on the outmold side of a thermosetting casting. The method entails preparing a first laminae having a curable thermosetting resin material as a first outmold surface, and providing a second laminae having an imprinted surface thereon. The first surface and second laminae having an imprinted surface are then positioned in face-to-face registration with one another. Substantial vacuum conditions are generated in the area between the first surface and the imprint surface, and the surfaces are pressed together under substantial vacuum conditions. The vacuum and pressure conditions maintain the surfaces in face-to-face registration and contain any volatile components of the curable thermosetting resin material of the first laminae while the curable thermosetting resin material cures.

Abstract: A method for producing synthetic shaped articles simulating marble, granite or the like is provided by the present invention. A thermosetting resin is subjected to first reaction conditions effective to partially polymerize the resin to form a semi-solid mass. The partially polymerized semi-solid mass of resin is comminuted to form a plurality of discrete partially polymerized resin particles. An article of the desired shape is formed from a mass of the partially polymerized resin particles. The thus formed shaped article is then subjected to second chemical reaction conditions effective to polymerize the resin to provide a synthetic shaped article simulating marble, granite and the like.

Abstract: A method of preparing a synthetic surface having a pattern simulating stone, marble and various other naturally occurring substances. The method involves preparing a resin matrix and combining such with a matrix veining pigment composition having a pigment component with a specific gravity heavier than that of the resin system and a blooming agent component with a specific gravity less than that of the resin system. The pigment component is allowed to disperse under the influence of the blooming agent to form the pattern. A further aspect of the present invention includes controlling the dispersement of the veining pigment within the resin matrix by controlling its thixotropic properties.