Abstract:
A multi-layered concave basin is formed for mounting in an opening in a wash stand. The basin is made from pliant woven twigs with successive bottom layers of a first clear epoxy, a clear fiber cloth and a second clear epoxy and a top layer of a third clear epoxy to create a basin impervious to water under pressure from a wash basin spigot.

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The invention relates to a lavatory basin. More particularly, it refers to a multi-layered, water-tight wicker lavatory basin suitable for use in a plurality of different basin receptacles. 
     2. Description of the Prior Art 
     It is well known that wicker style articles of manufacture can not withstand the effects of water being introduced thereupon. In other words, they are not typically known for being water-tight. However, many people find them to be aesthetically pleasing and desire their use in their homes and workplaces. Of course, many people employ wicker style furniture on outdoor patios specifically because they will not retain water but instead permit water to flow freely through the piece of furniture. In fact, it is counter intuitive to think that wicker style articles of manufacture could be used in an environment where water is not meant to flow through the article. 
     Some attempts have been made to use wicker style articles of manufacture where water or other fluids are not meant to flow freely through the article. U.S. Pat. No. 4,211,036 describes a planter basket constructed of linear elements in a basket weave pattern with a sealing material coating the linear elements. Although this prior art wicker basket works well as a planter wherein a minimal amount of water flow can be retained, such a basket could not be used as a basin in a wash stand since it could not withstand the pressure from a water filled basin or water pressure emanating from a spigot or faucet. This prior art basket lacks the required sealant layers needed to make it water-tight such that it would be suitable for use as a lavatory basin. Nothing in this prior art basket suggests that it could be employed as a water-tight wash basin having a drain formed in a bottom portion which aligns with a reciprocal drain that leads to a sewer system. 
     A waterproof wicker basin and a met hod to make the same is clearly needed so that a wicker-style basin which is strong enough to withstand water pressure can be employed with a wash stand typically found in homes and work places. 
     SUMMARY OF THE INVENTION 
     We have invented a wicker-style, water-tight lavatory basin suitable for use in a wash stand. The present invention provides for a lavatory basin constructed from a wicker or similar woven structure wherein a top surface is coated with a clear unsaturated polyester resin solution, such as surf board epoxy, and a bottom surface employs multiple bottom layers providing for a leak-proof, water-tight basin. The wicker is formed to present a concave shape with a drain formed at its lowest point. The wicker is strengthened with at least two layers of epoxy clear sealant and a cloth layer sandwiched between the epoxy layers on a bottom surface. Such a strengthened basin can withstand water pressure from a filled water basin or from a wash stand spigot without leaking. The basin of the present invention can be used with a multitude of different counter-tops or wash basins such that it rests within a counter-top opening, sits upon a counter-top surface or mounts upon a pedestal. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The invention can be best understood by those having ordinary skill in the art by reference to the following detailed description when considered in conjunction with the accompanying drawings in which: 
         FIG. 1  is a perspective view of a lavatory wicker basin of the present invention; 
         FIG. 2  is a perspective view of the lavatory wicker basin mounted in a wash stand with an upper annular edge above a top surface of the wash stand; 
         FIG. 3  is a perspective view of the lavatory wicker basin mounted within an opening in a wash basin stand but below the top surface thereof; 
         FIG. 4  is a perspective view of the lavatory wicker basin mounted on top of a wash stand or counter top; 
         FIG. 5  is a cross-sectional view of the preferred lavatory wicker basin illustrating multiple layers employed therein; and 
         FIG. 6  is a cross-sectional view of an alternate lavatory wicker basin illustrating multiple layers employed therein. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     Throughout the following detailed description, the same reference numerals refer to the same elements in all figures. 
     Referring to  FIG. 1 , a wicker style basin  10  of the present invention is shown having a concave configuration with a drain outlet  12  formed at a lowest point  52  and an annular edge circumference  14  disposed along an upper periphery  11 . Edge  14  raises above the concave portion of basin  10 . Drain outlet  12  has a pipe  50  extending downwardly from lowest point  52  which aligns with a drain pipe (not shown) to permit any water entering basin  10  to be disposed of into a sewer system. 
     Referring to  FIG. 2 , basin  10  is mounted in an opening  16  in a wash stand  18 . Basin  10  can be attached to opening  16  by caulk, glue or by clips. In the preferred embodiment, edge  14  rests upon top surface  20  of wash stand  18 . However, as shown in  FIG. 3 , edge  14  can be disposed with respect to vertical wall  22  of opening  16  such that edge  14  is slightly below wash stand top surface  20 . The basin  10  rests on a horizontal support below opening  16 . Still further, as shown in  FIG. 4 , basin  10  can be positioned completely above wash stand top surface  20  such that the entire concave shape of basin  10  rests outside of wash stand  18 . Of course, in this alternate embodiment (FIG.  4 ), opening  16  is not needed. Although not shown in  FIG. 4 , pipe  50  fits within a small aperture which again aligns with a drain pipe permitting any water that enters basin  10  to be expelled into the sewer system. 
     Another alternate embodiment, although not shown, employs a pedestal type wash stand which can receive basin  10  in any of the same manners as described above for a traditional style wash stand as shown in  FIGS. 2-4 . Regardless of the style of wash stand employed (counter-top or pedestal) and regardless of how basin  10  is mounted, each configuration employs a hot  24  and cold  26  water handle and a spigot  28  for delivery of water to basin  10 , as shown in  FIGS. 2-4 . 
     Wicker is a slender pliant twig  32  that is woven together and shaped to form the basin  10  as seen in  FIG. 5  for the preferred embodiment. It is understood however that basin  10  is not limited to being constructed from wicker. Other pliant type twigs or slivers of wood, such as osier or withe, can be employed to achieve the same result. Further, nothing herein limits the use of synthetically made material that has the same pliability of wicker. Even further, a non pliable synthetically made material could be employed through injected molding which would give the same appearance of wicker. 
     Referring again to  FIG. 5 , in a preferred embodiment for basin  10 , a first layer of clear surf board epoxy  38  is applied over a bottom surface  40  of the woven twigs  32 . The surf board epoxy  38  is allowed to become tacky. A fabric cloth  42  (having been pre-soaked in surf board epoxy before being applied) is then applied over the first layer of clear epoxy  38 . The fabric cloth is allowed to set. Next, a second layer of clear surf board epoxy  44  is applied over the hardened cloth  42 . Other layers of epoxy can be added as desired. Lastly, one or more layers of clear epoxy  34  is applied to a top surface  36  of the woven twigs  32 . These layers are 1.8 to 2.6 mm thick. It is understood that each clear epoxy layer described can actually represent the application of multiple layers being applied. For instance, as one example, the application of layer  34  to the inside portion (top surface  36 ) of basin  10  can actually represent eight to ten coats being applied to form layer  34 . Further, different configurations can be employed wherein fiber cloth  42  is only used on bottom surface  40 , only on top surface  36  or used on both top and bottom surface  36  and  40 , respectively. In a preferred embodiment, fiber cloth  42  is six to 8 ounce fiberglass. Further, the layers can be painted on with a brush, or basin  10  be dipped repeatedly to apply each layer. Of course, fiber cloth  42 , acting as a reinforcement layer, is most accurately applied by hand. As an example of an alternative embodiment,  FIG. 6  is shown wherein additional layers of epoxy; namely, layer  46  and layer  48  are applied. 
     The clear epoxy employed in this invention can be clear coat two-part epoxy. It is preferably applied in layers to achieve a thickness of 0.5 to 3.0 mm thick such that all openings in between the pliant twigs are completely filled. The clear fiber cloth  42  is fiberglass preferably applied saturated with the two part epoxy. 
     The description of basin  10 , as shown in  FIGS. 5 and 6 , discloses that the various layers are applied on the top and bottom surfaces,  36  and  40 , respectively. The present invention also includes a method of making basin  10 . The preferred method employs the following steps. First, a concave-shaped wicker basin is provided. Next, a first layer of epoxy is applied to basin bottom surface  40 . The epoxy is allowed to become tacky. Thereafter, a pre-soaked in epoxy fiber cloth layer is applied over the first set layer of epoxy. Next, additional layers of epoxy are applied over the hardened fiber cloth layer to a thickness of 0.5 to 3.0 mm. Then, multiple layers of epoxy, to a thickness of 0.5 to 3.0 mm, are applied to the basin top surface  36  (or inner surface). An opening is then cut through the wicker and epoxy layers at the lowest point within the basin inner surface (top surface  36 ) so that a drain pipe and collar can be inserted therethrough. Finally, the basin is attached to a wash stand and its associated plumbing. 
     The preferred clear epoxy sealant layer employed is a two component mix at a ratio of one pint of unsaturated polyester resin solution to 5 cc of a methyl ethyl ketone peroxide activator. It is commonly called surf board epoxy. 
     Equivalent elements can be substituted for the ones set forth above such that they perform in the same manner in the same way for achieving the same result. Further, equivalent steps can be substituted for the ones set forth above such that they perform in the same manner in the same way for achieving the same result.