Method of making a plastic covered sheet and products made therefrom

Claim 1

A METHOD OF MAKING A LAMINATED STRUCTURE INCLUDING A RIGID FLAT METAL BASE SHEET BY PROVIDING A TRANSPARENT PLASTIC FILM ABOUT .002 IN. THICK, SAID FILM BEING THERMOPLASTIC BUT MAINTAINING ITS ROOM TEMPERATURE CHARACTERISTICS AT LEAST UP TO A TEMPERATURE OF ABOUT 290* F., PRINTING DESIRED INDICIA ON THE BACK SURFACE OF SAID FILM, APPLYING A COATING OF A COLORED SOLUTION OF A THERMOSETTING RUBBER-BASIN ADHESIVE TO THE PRINTED BACH SURFACE OF THE PLASTIC FILM, DRYING SUCH ADHESIVE BY HEATING, APPLYING A LAYER OF THE SAME RUBBER-BASIN ADHESIVE SOLUTION TO THE BASE SHEET, HEATING THE ADHESIVE COATED BASE SHEET TO A LEAST ABOUT 400* F. TO DRY AND PARTIALLY SET THE ADHESIVE HEATING THE PLASTIC FILM TO ABOUT 290* F., FORCING THE ADHESIVE LAYERS ON THE BASE SHEET AND THE PLASTIC FILM TOGETHER UNDER A TEMPORARY ROLLING PRESSURE WHILE HEATED AND MOVING TO SET THE ADHESIVE AND FORM AN INTEGERAL BONDING LAYER THEREFROM, COOLING AFTER THE PRESSURE APPLICATION TO OBTAIN A RIGID FLAT LAMINATED STRUCTURE HAVING A SMOOTH CONTINUOUS UNIFORM PLASTIC FILM SURFACE ON ONE FACE ONLY OF THE METAL BASE SHEET, AND SHAPING THE LAMINATED STRUCTURE UNDER AMBIENT TEMPERATURES TO NON-PLANAR FORM BY STRESSES EXCEEDING THE ELASTIC LIMITS OF THE METAL BASE SHEET, SAID BONDING LAYER RETAING THE LAYERS OF SAID SHAPED LAMINATED STRUCTURE TIGHTLY BONDED TO EACH OTHER WITH SAID PLASTIC FILM FORMING A UNIFORM CONTINUOUS COATING OVER ONLY ONE SAID FACE OF SAID BASE SHEET AND WITH THE PRINTED INDICIA BEING VISIBLE THRERETHROUGH.