Patent Publication Number: US-2006019046-A1

Title: Convex/concave objects formed from co-polymer materials

Description:
TECHNICAL FIELD  
      This invention relates to convex/concave objects made from at least two-layers of co-polymer materials and a decorative third layer that is sandwiched between them. More particularly, it relates to convex/concave vessels of different shapes, sizes and thickness to be used as sinks, bowls, lamp shades, furniture items, vases, etc. and to a method of manufacturing the convex/concave objects.  
     BACKGROUND OF THE INVENTION  
      It is known to make articles of furnitures and other decorative articles by laminating layers of co-polymer and other materials. See for example U.S. Pat. No. 4,293,603, granted Oct. 6, 1981 to Charles R. Hayman-Chaffey and Fredrick W. Hayman-Chaffey; U.S. Pat. No. 5,403,631, granted Apr. 4, 1995 to Yusake Sato and Ryozo Amano, and U.S. Pat. No. 5,643,666, granted Jul. 1, 1997 to Michael Dennis Eckert and Raymond Lynn Goodson. There is a need to extend the creativity evidenced by these patents by using more and different materials and using them for making additional decorative articles. An object of this invention is to provide a new basin structure and a new method of manufacturing such basin structure. The basin structure of the present invention utilizes by layers of co-polymer materials and decorative layers selected from a large variety of materials.  
     BRIEF SUMMARY OF THE INVENTION  
      A convex/concave object of the present invention is basically characterized by a co-polymer first layer; a co-polymer second layer; and a decorative third layer sandwiched between the first and second layers. The first, second, and third layers are bonded together to form an integrated structure.  
      In preferred form, the first and second layers are each selected from the group of materials comprising polymethylmethacrylate, polycarbonate, polyvinyl chloride and polyethylene terephthalate glycol (PETG). The decorative third layer is selected from the group of materials comprising textile fabrics, dry plant leafs, dry grasses, dry flowers, rocks, gems, glitter, crushed glass, metals, meshes, wire, wood veneers, twigs, shells, glass beads, ceramic beads, poly beads, papers, vinyls and combinations thereof.  
      The method of the present invention is basically characterized by providing a mold having a forming surface, e.g., a convex surface and a sandwich of sheet materials comprising a co-polymer first layer, a co-polymer second layer and a decorative third layer between the first and second layer. This sandwich of sheet materials is heated to a plastic state. Then, the heated sandwich of sheet materials and the forming surface are moved relatively together, to cause the forming surface to contact the heated sandwich of sheet materials. Positive pressure and/or a vacuum are used for moving the heated sandwich of sheet materials tight against the forming surface of the mold, causing the sheet materials to bond together and conform to the shape of the forming surface of the mold. After shaping, the bonded sheet materials are separated from the male mold and their edges are trimmed to provide a convex/concave object with a trimmed edge.  
      Other object, advantages and features of the invention will become apparent from the description of the best mode set forth below, from the drawings, from the claims and from the principles that are embodied in the specific structures that are illustrated and described. 
    
    
     BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING  
      Like reference numerals are used to designate like parts throughout the several views of the drawing, and:  
       FIG. 1  is a pictorial view taken from above and looking towards the top, the front and one side of a sink basin of the present invention and its support structure and a faucet;  
       FIG. 2  is a side elevational view of the basin assembly shown by  FIG. 1 , looking towards the side of the assembly that is in the rear in  FIG. 1 ;  
       FIG. 3  is a sectional view through the basin of  FIGS. 1 and 2 , taken substantially along line  3 - 3  of  FIG. 1 ;  
       FIG. 4  is a view like  FIG. 3 , but of a tilted basin;  
       FIG. 5  is a pictorial flow diagram of the forming apparatus and steps used in the manufacture of the basin;  
       FIG. 6  is a sectional view of a third embodiment of the basin, taken substantially along line  6 - 6  of  FIG. 7 ;  
       FIG. 7  is a top plan view of the basin shown by  FIG. 6 ;  
       FIG. 8  is a pictorial view of a mounting frame for the materials used for forming the basin;  
       FIG. 8A  is a pictorial view of the bottom layer shown in  FIG. 8 ;  
       FIG. 9  is an exploded elevational view, with some parts in section, of forming equipment used in a first process embodiment of the invention;  
       FIG. 10  is a sectional view taken through a wall portion of an embodiment of the invention;  
       FIG. 11  is a view like  FIG. 9 , showing forming equipment used in a second process of the embodiment of the invention;  
       FIG. 12  is an elevational view of a clamp that is used to connect an upper frame structure to an upper housing, such a view showing the clamp in an open position;  
       FIG. 13  is a fragmentary sectional view showing the claim of  FIG. 12  used to connect the upper housing to the upper frame, and showing the upper housing bearing down on the upper frame, such a view further showing the upper frame bearing down on the basin of the invention;  
       FIG. 14  is a sectional view taken through a portion of the upper frame, showing a lower portion of the upper housing and a guide member that is attached to the lower portion of the upper housing;  
       FIG. 15  is a sectional view taken substantially along line  15 - 15  of  FIG. 16 ; and  
       FIG. 16  is top plan view, looking down towards the top of  FIG. 15 . 
    
    
     DETAILED DESCRIPTION OF THE INVENTION  
       FIGS. 1-4 ,  6 ,  7 ,  15  and  16  show four different sink basins that are constructed in accordance with the present invention. In  FIGS. 1 and 2 , a basin  10  is supported on and by a base having a horizontal portion  16  and a vertical portion  18  including a pair of legs  20 ,  22 . The basin  10  has a concave upper surface  24  and a convex lower surface  26 . At its center, it includes a drain opening  28  shown in  FIG. 2  to be connected to a drainpipe  30 . In the embodiment of  FIG. 4 , the basin  12  is titled and the drain opening  30  is provided where the base of the basin  12  contacts the member  16 . The embodiment of  FIGS. 6 and 7  includes a basin  14  having a rim  30  which is formed from the same materials as the basin  14 . The embodiment of  FIGS. 15 and 16  is a four-sided convex/concave basin.  
       FIG. 5  shows a lower housing  34  on which a male form member  36  is mounted. A sandwich structure  38  of layers is positionable above the male form member  36 . An upper housing  40  may be positioned above the sandwich structure  38 .  FIG. 8  shows the sandwich structure  38  positioned above a frame  42  having inner frame members  44 ,  46 ,  48 ,  50  which are fixed in position on the frame  42 . Conventional clamps C are movable towards and away from frame members  44 ,  46 ,  48 ,  50  such as by use of fluid motors  52 . Suitable clamps are obtainable from Brown Machine having a business address at 330 North Frost Street, Post Office Box 434, Beaverton, Mich. 43612. The sandwich structure  38  is placed on the frame  42  and the clamp cylinders  52  are operated to move the clamps C and clamp the edges of the sandwich  38  to the frame member  44 ,  46 ,  48 ,  50 .  
      The sandwich structure  38  comprises but is not limited to an upper layer  54 , a lower layer  56 , and an intermediate layer  58 . As shown by  FIG. 8 , the lower layer  56  may include air escape openings  60 . In preferred form, the layers  54 ,  56  are made from a co-polymer material. The intermediate layer  58  is a layer of decorative material. The upper and lower layers  54 ,  56  are made from materials that are selected from the group of materials comprising polymethylmethacrylate, polycarbonate, polyvinyl chloride and polyethylene terephthalate glycol (PETG). By way of typical and therefore non-limitive example, one of the first and second layers may be a sheet of continuously cast cross-link polymethylmethacrylate. The other may be constructed from extruded polymethylmethacrylate. The decorative third layer is selected from a group of materials comprising textile fabrics, dry plant leafs, dry grasses, dry flowers, rocks, gems, glitter, crushed glass, metals, meshes, wire, wood veneers, twigs, shells, glass beads, ceramic beads, poly beads, papers, vinyls and combinations thereof.  
      Referring to  FIG. 9 , the male mold  36  is mountable on the top  68  of the housing  34 . The top  68  includes openings (not shown) which communicate the space below top  68  with the space above top  68 . Lower housing  34  is connected by an angle member  64  to base  66 . When members  64  are connected to base  66 , the housing structure  34  is connected to the angle members  64  and the male mold  36  is connected to the top  68 , a space  70  is defined inside of the structure  34 ,  64 , above the base  66  and below the top  68 . This space  70  is connected to a source of vacuum by a vacuum hose  72 .  
      After the sandwich structure  38  is connected to the frame  42  by the clamps C, the frame  42  is placed in an oven and the temperature is controlled to between 200 to 450 degrees Fahrenheit. When the sandwich structure  38  is hot enough to be soft and plastic, it is removed from the oven and positioned above the male mold  36 . Specifically, the frame  42  is moved into a position which places the sandwich structure  38  above the male mold  36 . Then the frame  42  is anchored so that the sandwich structure  38  is also anchored. Then the male mold  36  is moved upwardly so that its convex upper surface is pressed against the bottom of the sandwich structure  38 . At the same time, a vacuum is pulled into chamber  70 , causing the sandwich structure to move against and take on the shape of the upper forming surface of the male mold  36 . Openings in the member  68  and the mold  36 , and the openings  60  in the lower layer  56  of the sandwich structure  38 , allow sufficient air movement that the sandwich structure  38  can and will be moved against the forming surface of the mold  36 . The openings  60  ( FIG. 8A ) allow air inside the sandwich  38  to escape during the forming process. After the sandwich structure  38  is formed, it is moved away from the male mold  36  and its upper part  39  is cut away from its lower part  41 . The cut edge of the upper part is suitably dressed and the lower part which is excess material is discarded.  
       FIG. 10  is a sectional view showing the upper layer  54 , the lower layer  56  and the decorative layer  58 . The thickness dimension may vary substantially, e.g., from about 0.118-1.00 inches. Each layer  54 ,  56  may be made up of one or plural sheets. More than one decorative layer may be used.  
      According to an aspect of the invention, pressure may be used in addition to or in place of the vacuum to move the sandwich structure against the forming surface. Referring to  FIG. 11 , the upper housing  40  may include an upper frame  80  having angle iron  82  by which it is attached to an enclosure  84  having a high strength silicone diaphragm  86  or the like, secured to its lower end. A rectangular frame  88  has four sides and a top. The wall of the upper enclosure  40  includes a bottom edge  90  which rest down onto the top of the frame  88 . A plurality of spacer lugs  92  are secured to the housing  34 . The housing  34  is positioned generally above frame  88  and it is then moved downwardly, causing the lugs  92  to be positioned laterally outwardly of the outside wall of frame member  88 , all the way around the frame member  88 . The diaphragm  86  contacts the top of the sandwich of materials  38 . It stretches in its middle so that it and the sandwich structure below it will be encouraged to move against the mold  36 . A pressurized fluid, e.g., compressed air, is communicated via passageway  100  to the interior of the housing  40 . This pressure presses against the layer  86  and then against the sandwich structure  38 , moving structure  38  against the convex surface of the mold  36 .  
      The circled portion of  FIG. 11  is shown by  FIG. 14 . Frame  40  is provided with a plurality of clamps  100  spaced around its peripheral. These clamps are conventional per say. By way of typical and therefore non-limitive example, they may be a Southco clamp comprising a base  102  that is connected to the frame  40  ( FIG. 13 ) and mounts a hook assembly  104 . Hook assembly  104  includes a hook  106  that is movable up and down relative to a mounting member  108 . The mounting member  108  is swingable above axis  110  towards and away from the mount  102 . In use, the hook assembly is swung into the position shown by  FIG. 13 , placing the hook element  106  below a catch  112  that is a part of the frame  88 . Then, a control lever  114  is operated to draw the hook element  104  upwardly into contact with the catch  112 . When all of the clamps  100 , spaced around the housing  40  are secured, the lower edge  116  of the housing sidewall is moved tight against the upper surface  118  of the frame  88  so that when pressure is applied it will not leak between the surfaces  116 ,  118 .  
      The heated sandwich structure  38  is positioned above the male mold  36  and the assembly of frame  88 , diaphragm  86  in housing  40  are lowered, causing the diaphragm  86  to be move against the sandwich structure  38 . Pressure is then introduced then into the interior of the housing  40 . This pressure acting on the diaphragm  86  will further move the heated sandwich structure  38  until it is tight against the forming surface of the male mold  36 .  
      As an option, a texture, e.g., embossing, can be created on one or both sides of the sandwich structure  38 . This is done by the use of silicone texture pads which are preembossed. The desired texture is transferred from a texture plate to the silicone pads. The textured or embossed silicone pads may be made as follows: a sheet of uncured silicone (0.108-0.118 inches thick) is placed on top of a Teflon coated film sheet that has been laid on top of a metal sheet plate. The texture sheet plates are set down on top of the uncured silicone sheet. Preferably, the textured plates are coated with Teflon or some other substance such as soap, to avoid sticking of the silicon to the plate. A metal sheet is then positioned on top of the textured plate to complete a sandwich structure which is referred to as a “book.” This “book” is put into autoclave oven and is heated between 200 to 300 degrees Fahrenheit, and the autoclave is operated at a pressure of between 60 psi to 120 psi. The “book” is held within the auto clave from between 60-80 minutes, depending on the texture. Then, the “book” is removed and the layers of the sandwich are separated. The cured silicone sheet which has been texturized or embossed by this process is then used to create a texture and emboss patterns on the basin formed by use of the equipments shown on  FIGS. 9 and 11 .  
      The following is an example of how to use the textured silicone pads to texture or emboss the surfaces of the basins  10 . The textured silicone pad is mounted with its textured side out within a metal frame by use of mechanical fasteners or an adhesive so that the pad is airtight on the frame. The frame is then fastened to the rim of the pressure chamber  40  as has been described above. Firstly, the vacuum process may be used to pull the sandwich structure  38  against the forming surface of the male mold  36 . Then, the pressure chamber and the silicone texture pad are lowered against the formed sandwich structure  38 . Pressure is introduced into the housing  40 , causing fluid pressure above the diaphragm  86  to push the sandwich structure  38  into the mold corners. This moves the texture silicone pad against the sandwich structure  38 , causing it to emboss a complementary texture onto the molded sandwich structure  38 . At the same time, the layers  54 ,  56 , 58  and the sandwich structure are caused to bond and form together an integral structure.  
       FIGS. 15 and 16  show a basin  130  that has four sides and a bottom. In the illustrated embodiment, the four sides  132 ,  134 ,  136 ,  138  converge from their tops to their bottoms. The bottom  140  is shown to be flat. Other embodiment of the invention can be created that have shapes somewhere between the rounded shapes shown by  FIGS. 3 and 4  and the substantially straight walled shape shown by  FIGS. 15 and 16 . Although its sides and bottom are not curved, the basin  130  shown by  FIGS. 15 and 16  has a convex-concave form.  
      The illustrated embodiments are only examples of the present invention and, therefore, are non-limitive. It is to be understood that many changes in the particular structure, materials and features of the invention may be made without departing from the spirit and scope of the invention. It is my intention that my patent rights not be limited by the particular embodiments illustrated and described herein, but rather are to be determined by the following claims, interpreted according to accepted doctrines of patent claim interpretation, including use of the doctrine of equivalents and reversal of parts.