Abstract:
A composite includes a substrate having a mounting surface and a first substrate side having an irregular profile, and a laminate attached to the mounting surface, a first laminate edge being substantially aligned with the first substrate side and substantially matching the profile thereof. The composite can advantageously be employed in a fountain assembly. A method of making a composite includes substantially aligning an edge of a stone laminate with a side of substrate, and attaching the stone laminate to a mounting surface of the substrate. The edge of the stone laminate substantially matches an irregular profile of the side of the substrate.

Description:
FIELD OF THE INVENTION 
       [0001]    The present invention relates to composites and a related method of making, and, more particularly, to fountain assemblies employing composites. 
       BACKGROUND OF THE INVENTION 
       [0002]    Many natural substances are prized for aesthetic reasons and used in a variety of architectural, art and design applications. However, completely natural substances can be difficult to work with for many reasons. For example, some natural materials may have an extremely high cost or may be very heavy for a particular application. 
         [0003]    For instance, stone, such as slate, is popularly employed in fountain designs. Due to the weight of a stone slab, shipping a fountain employing a stone slab can be extremely costly. Additionally, mounting the fountain often requires costly and time-consuming reinforcement of the wall or other mounting surface. 
         [0004]    In fountain applications, these concerns are addressed to some degree by the use of stone veneers. However, when viewed from the sides, it is clear that real stone is not being employed. The sides of the veneer may be hidden, for example by banding covering the edges of the veneer. This solution, however, does not replicate the appearance of a natural, rough-hewn stone slab. 
       SUMMARY OF THE INVENTION 
       [0005]    In view of the foregoing, it is an object of the present invention to provide an improved composite. According to an embodiment of the present invention, a composite includes a substrate having a mounting surface and a first substrate side having an irregular profile, and a laminate attached to the mounting surface, a first laminate edge being substantially aligned with the first substrate side and substantially matching the profile thereof. 
         [0006]    According to another embodiment of the present invention, a fountain assembly includes a substrate having a mounting surface and a substrate side, the substrate side having an irregular profile, a stone laminate attached to the mounting surface, a laminate edge being substantially aligned with the substrate side and substantially matching the profile thereof, a fluid reservoir arranged to collect fluid passing over the stone laminate, a pump for pumping fluid from the reservoir to a position from which the fluid can pass over the stone laminate, and a fluid conduit for carrying the fluid, the fluid conduit extending at least partially between the fluid reservoir and the position. 
         [0007]    According to a further embodiment of the present invention, a method of making a composite includes substantially aligning an edge of a stone laminate with a side of substrate, and attaching the stone laminate to a mounting surface of the substrate. The edge of the stone laminate substantially matches an irregular profile of the side of the substrate. 
         [0008]    These and other objects, aspects and advantages of the present invention will be better understood in view of the drawings and the following detailed description of preferred embodiments. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS  
         [0009]      FIG. 1  is a perspective view of a composite, according to an embodiment of the present invention; 
           [0010]      FIG. 2  is an exploded view of the composite of  FIG. 1 ; 
           [0011]      FIG. 3  is a detailed view of area  3  of  FIG. 1 ; 
           [0012]      FIG. 4  is a perspective view of a fountain assembly including a composite, with hidden and removed elements shown in broken lines, according to another embodiment of the present invention; and 
           [0013]      FIG. 5  is a flow diagram of a method of making a composite, according to a further embodiment of the present invention. 
       
    
    
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS  
       [0014]    Referring to  FIGS. 1 and 2 , according to an embodiment of the present invention, a composite  10  includes a substrate  12  and a laminate  14 . The laminate  14  is attached to a mounting surface  16  of the substrate  12 . The substrate  12  includes first and second sides  20 ,  22 . The sides  20 ,  22  have respective irregular profiles  24 ,  26 . The laminate  14  has first and second edges  30 ,  32  with respective irregular profiles  34 ,  36 . The irregular profiles  34 ,  36  of the edges  30 ,  32  substantially match the irregular profiles  24 ,  26  of the sides  20 ,  22 . 
         [0015]    The present invention is not necessarily limited to particular materials for the substrate  12  and laminate  14 . However, according to one advantageous aspect of the invention, the substrate  12  is a relatively lightweight synthetic material, such as a resin or plastic and the laminate is stone, such as a thin ply of slate. The matched irregular edge profiles  24 ,  26  and  24 ,  36  create the appearance of a solid, rough-hewn stone slab but at a fraction of the weight. 
         [0016]    Referring to  FIGS. 1 and 3 , sides  20 ,  22  (only side  20  is shown in the detailed view of  FIG. 3 ) of the substrate  12  include a plurality of layers  40 . The corresponding edges  30 ,  32  (only edge  30  is shown in the detailed view of  FIG. 3 ) of the laminate  14  match the profile of the layer  40  most proximate to the mounting surface  16 . Advantageously, this allows the composite  10  to closely replicate the appearance of foliated stone, like slate. 
         [0017]    The composite of the present invention can be advantageously employed in many applications. For example, referring to  FIG. 4 , according to another embodiment of the present invention, a fountain assembly  100  includes a composite  110 . The composite  110  includes a substrate  112  and a laminate  114 . A fluid reservoir  150  is arranged along the bottom of the composite  110  to collect fluid (fluid flow represented generally by arrows  152 ) passing over the laminate  114 . 
         [0018]    A pump  156  is arranged within the fluid reservoir  150  for pumping the collected fluid to the top of the laminate  114 , where the fluid can again pass over the laminate. The fluid is pumped through a fluid conduit  158 , such as a tube or pipe. 
         [0019]    A collection volume  162  is defined between corresponding portions of the substrate  112  and laminate  114 . To facilitate even flow of water over the laminate  114 , an upper edge  164  of the laminate  114  is crenellated in the area of the collection volume  162 . A blocking plate  166  is arranged over the upper end of the fluid conduit  158  to help channel fluid leaving the conduit  158  into the collection volume  162 . A decorative top cap  168  can be added to conceal the top of the composite  110 . Mounting brackets, lights, and other structures can also be added. 
         [0020]    It will appreciated that use of the composite  110  with a stone laminate  114  can replicate the appearance of a rough-hewn slab at a fraction of the weight, greatly facilitating the transportation and hanging of the fountain assembly  100 . Use of a molded substrate  112  also advantageously facilitates assembly of the fountain assembly  100 . For instance, the fluid conduit  158  can be arranged within the substrate  112 . The fluid conduit  158  and other structures, such as reinforcing strips, can be molded within the substrate. The collection volume  162  can be readily defined between corresponding portions of the substrate  112  and laminate  114 , for example, by forming a recess into the substrate  112  during molding. 
         [0021]    Referring to  FIG. 5 , a method of making a composite will be explained, according to a further aspect of the present invention. The method begins at block  200 . At block  202 , a substrate mold is formed. For replicating the appearance of stone, such as slate, a stone slab can be used to form the mold. Various methods of forming molds are known to those skilled the art, and the present invention is not necessarily limited to a particular method. 
         [0022]    At block  204 , internal components are placed in the mold. For example, components such as a fluid conduit or reinforcement strips could be placed in the mold prior to molding. At block  206 , a substrate is molded. Any components placed in the mold are thereby molded in place. 
         [0023]    At block  208 , it is determined whether substrate side profiles were captured within a predetermined number (N) of substrate moldings, for instance, within the last fifty moldings. If the profiles were not captured within the predetermined number of moldings, then an image is captured, for example a digital picture, of the substrate side profiles at block  210 . 
         [0024]    At block  212 , computer cutting commands are generated. For instance, a plurality of points could be manually or automatically plotted along the image of the side profiles and used to generate computer numerical control (CNC) commands. At block  214 , the edges of a laminate are cut to match the side profiles using the computer cutting commands. 
         [0025]    Referring again to block  208 , if the substrate side profiles were captured within the predetermined number of molds, then blocks  210  and  212  are omitted and the laminate is cut based on the existing set of computer cutting commands. Under some circumstances, the side profiles of a later-molded substrate may not closely match the side profiles of an earlier-molded substrate used to generate an earlier set of computer cutting commands; for example, due to degradation or deformation of the mold over time. The determination of block  208  can advantageously compensate for this effect. 
         [0026]    At block  216 , the laminate is attached to a mounting surface of the substrate, for example, using an adhesive. At block  218 , additional structures are added. For instance, for the composite  110  used in the fountain assembly  100 , the additional structures could include other components of the fountain assembly  100 . Additional composites are formed by repeating blocks  204 - 218 , if desired (see block  220 ). Otherwise, the method ends at block  222 . 
         [0027]    The above embodiments are described for exemplary and illustrative purposes; the present invention is not necessarily limited to such embodiments. Instead, those skilled in the art will appreciate that numerous modifications, as well as adaptations for particular circumstances, are possible within the scope of the present invention. 
         [0028]    Although particularly advantageous to replicate the appearance of stone, and most particularly, slate, the present invention is not necessarily limited to such composites. 
         [0029]    Also, the present invention is not necessarily limited to particular dimensions or designs. The contact area of the mounting surface need not necessarily be coextensive with the laminate. For instance, the mounting surface and laminate could contact only along respective edges thereof. 
         [0030]    Additionally, although the present invention is particularly advantageous for use in connection with fountain applications, the present invention is not necessarily limited to such applications. 
         [0031]    The term “crenellated” as used herein generally refers to a plurality of notches formed along an edge, and does not necessarily require a particular geometry, regular interval or periodicity for the notches. 
         [0032]    The term “cutting” as used herein refers generically to altering the laminate edge profiles, and is not necessarily limited to a particular process. For example, cutting could also include boring, milling and water and laser cutting operations. 
         [0033]    The present invention does not necessarily include a determination like that of block  208 . For example, the determination could be omitted or another determination could be used to compensate for any mold degradation or deformation. For instance, an image could be captured of each molded substrate and compared to the image used to generate the computer cutting commands. If the image of a given substrate differs from the image used to generate the computer cutting commands outside of a given tolerance, computer cutting commands could be regenerated at that time. 
         [0034]    The foregoing is not an exhaustive list of possible modifications and adaptations. Rather, those skilled in the art will appreciate that these modifications and adaptations fall within the scope of the invention as herein shown and described.