Method of forming three-dimensional pattern

Claim 1

A method of forming a three-dimensional pattern from an acrylic resin concrete composition which comprises: attaching a pattern forming mold to a work surface where a three-dimensional pattern is to be formed, said pattern forming mold being formed from an expanded polyethylene to thus prevent adherence of said acrylic resin concrete composition to said pattern forming mold while avoiding attack of said pattern forming mold by said acrylic resin concrete composition; casting onto said work surface a surfacing material of said acrylic resin concrete composition comprising: (A) at least one monomer compound selected from the group consisting of acrylic acid, methacrylic acid and esters thereof, in an amount of 45-85 parts by weight, (B) a polymer that dissolves in said monomer component (A) or that is swollen by said monomer component (A), in an amount of 5-20 parts by weight, and (C) an aggregate in a proportion of 1-6 times the amount of (A)+(B) by volume as said surfacing material; allowing said acrylic resin concrete composition of said surfacing material to harden to thus prevent dripping of unhardened surfacing material during removal of said pattern forming mold from said surfacing material; and then detaching and removing said pattern forming mold from said work surface and said hardened surfacing material to form said three-dimensional pattern of said hardened acrylic resin concrete composition such that said three-dimensional pattern of said hardened acrylic resin concrete composition is not fouled or disfigured by said dripping of said unhardened surfacing material.

Claim 2

A method of forming a three-dimensional pattern from an acrylic resin concrete composition which comprises: attaching a pattern forming mold to a work surface where a three-dimensional pattern is to be formed, said pattern forming mold being formed from an expanded polyethylene to thus prevent adherence of said acrylic resin concrete composition to said pattern forming mold while avoiding attack of said pattern forming mold by said acrylic resin concrete composition; casting onto said work surface a surfacing material of said acrylic resin concrete composition comprising: (A) at least one monomer compound selected from the group consisting of acrylic acid, methacrylic acid and esters thereof, in an amount of 45-85 parts by weight, (B) a polymer that dissolves in said monomer component (A) or that is swollen by said monomer component (A), in an amount of 5-20 parts by weight, and (C) an aggregate in a proportion of 1-6 times the amount of (A)+(B) by volume as said surfacing material; allowing said acrylic resin concrete composition of said surfacing material to harden to thus prevent dripping of unhardened surfacing material during removal of said pattern forming mold from said surfacing material; and then detaching and removing said pattern forming mold from said work surface and said hardened surfacing material to form said three-dimensional pattern of said hardened acrylic resin concrete composition such that said three-dimensional pattern of said hardened acrylic resin concrete composition is not fouled or disfigured by said dripping of said unhardened surfacing material.

Claim 3

A method of forming a three-dimensional pattern from an acrylic resin concrete composition which comprises: attaching to a work surface where a desired three-dimensional pattern is to be formed a pattern forming mold comprising a substrate layer and having at least one release layer formed thereon as a topmost layer on a surface of said substrate layer, said substrate layer being formed from an expanded polyethylene to thus prevent adherence of said acrylic resin concrete composition to said pattern forming mold while avoiding attack of said pattern forming mold by said acrylic resin concrete composition; casting onto said work surface a surfacing material of said acrylic resin concrete composition comprising: (A) at least one monomer component selected from the group consisting of acrylic acid, methacrylic acid and esters thereof, in an amount of 45-85 parts by weight, (B) a polymer that dissolves in said monomer component (A) or that is swollen by said monomer component (A), in an amount of 5-20 parts by weight, and (C) an aggregate in a proportion of 1-6 times the amount of (A)+(B) by volume as said surfacing material; allowing said acrylic resin concrete composition of said surfacing material to harden to thus prevent dripping of unhardened surfacing material during removal of said pattern forming mold from said hardened surfacing material; and then detaching and removing said pattern forming mold from said work surface and said hardened surfacing material to form said three-dimensional pattern of said hardened acrylic resin concrete composition such that said three-dimensional pattern of said hardened acrylic resin concrete composition is not fouled or disfigured by said dripping of said unhardened surfacing material.

Claim 4

A method of forming a three-dimensional pattern from an acrylic resin concrete composition which comprises: attaching to a work surface where a desired three-dimensional pattern is to be formed a pattern forming mold comprising a substrate layer and having at least one release layer formed thereon as a topmost layer on a surface of said substrate layer, said substrate layer being formed from an expanded polyethylene to thus prevent adherence of said acrylic resin concrete composition to said pattern forming mold while avoiding attack of said pattern forming mold by said acrylic resin concrete composition; casting onto said work surface a surfacing material of said acrylic resin concrete composition comprising: (A) at least one monomer component selected from the group consisting of acrylic acid, methacrylic acid and esters thereof, in an amount of 45-85 parts by weight, (B) a polymer that dissolves in said monomer component (A) or that is swollen by said monomer component (A), in an amount of 5-20 parts by weight, and (C) an aggregate in a proportion of 1-6 times the amount of (A)+(B) by volume as said surfacing material; allowing said acrylic resin concrete composition of said surfacing material to harden to thus prevent dripping of unhardened surfacing material during removal of said pattern forming mold from said hardened surfacing material; and then detaching and removing said pattern forming mold from said work surface and said hardened surfacing material to form said three-dimensional pattern of said hardened acrylic resin concrete composition such that said three-dimensional pattern of said hardened acrylic resin concrete composition is not fouled or disfigured by said dripping of said unhardened surfacing material.