Patent Abstract:
A method of manufacturing a structure by forming an element of the structure using a mold. Resin is poured into the mold to form the element. The element can further incorporate any number of a variety of solids. The element may then be assembled with one or more additional elements to complete the structure.

Full Description:
RELATED APPLICATION  
       [0001]     The current application claims the benefit of co-pending U.S. Provisional Application No. 60/485,214, filed on Jul. 7, 2003, which is hereby incorporated herein by reference. 
     
    
     BACKGROUND OF THE INVENTION  
       [0002]     1. Field of Invention  
         [0003]     The invention relates to furniture and three-dimensional art (“structures”), and more particularly to a method of making these structures.  
         [0004]     2. Related Art  
         [0005]     Conventionally, furniture and three-dimensional art (“structures”) are manufactured using various combinations of well known materials (e.g., wood, polished glass, metal, etc.) that are assembled using well known construction techniques. While these materials and techniques provide a traditional look and/or feel for the resulting structure, many individuals desire structures having a more unique look and/or feel. One way to obtain a unique look and/or texture for a structure is through the use of other nontraditional material. Thus, a need exists for a new method of manufacturing that allows various materials to be used in the creation of a structure to create a unique look and/or a unique texture for the structure.  
       SUMMARY OF THE INVENTION  
       [0006]     The invention provides a method of making structures wherein the materials used and looks achieved can vary widely from the conventional methods and looks. In particular, a mold can be created to create an element of the structure having a desired shape. Resin and/or other materials can be poured into the mold and allowed to harden. Subsequently, the element can be combined with one or more additional elements to form the structure. In one embodiment, an interior of the mold is lined with a sheet that allows the element to be readily removed and easy reuse of the mold for a subsequent element. Further, a release agent can be applied to the sheet and/or mold to further assist in removing the element. As a result, the invention provides a solution for making a non-traditional structure that has a unique look in a manner that allows a shape of one or more elements of the structure to be reused for other elements for the same or numerous structures.  
         [0007]     A first aspect of the invention comprises a method of constructing an element of a structure, the method comprising: creating a mold having a desired shape of the element; lining an interior of the mold with a sheet; and pouring resin into the mold to create the element.  
         [0008]     A second aspect of the invention comprises a method of constructing a structure, the method comprising: creating a mold having a desired shape of at least one element of the structure; lining an interior of the mold with a sheet; applying a release agent to the sheet; pouring resin into the mold to create the at least one element; and removing the at least one element from the mold after the resin has hardened.  
         [0009]     A third aspect of the invention comprises a structure comprising at least one structural support element comprising resin and at least one solid deposited therein.  
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0010]     These and other features of this invention will be more readily understood from the following detailed description of the various aspects of the invention taken in conjunction with the accompanying drawings in which:  
         [0011]      FIG. 1  shows an illustrative mold for creating an element of a structure;  
         [0012]      FIG. 2  shows an illustrative table;  
         [0013]      FIG. 3  shows an illustrative clock; and  
         [0014]      FIG. 4  shows illustrative method steps for creating an element of a structure. 
     
    
       [0015]     It is noted that the drawings of the invention are not to scale. The drawings are intended to depict only typical aspects of the invention, and therefore should not be considered as limiting the scope of the invention. In the drawings, like numbering represents like elements between the drawings.  
       DETAILED DESCRIPTION OF THE INVENTION  
       [0016]     As described above, the invention provides a method of making structures wherein the materials used and looks achieved can vary widely from the conventional methods and looks. In particular, a mold can be created to create an element of the structure having a desired shape. Resin and/or other materials can be poured into the mold and allowed to harden. Subsequently, the element can be combined with one or more additional elements to form the structure. In one embodiment, an interior of the mold is lined with a sheet that allows the element to be readily removed and easy reuse of the mold for a subsequent element. Further, a release agent can be applied to the sheet and/or mold to further assist in removing the element. As a result, the invention provides a solution for making a non-traditional structure that has a unique look in a manner that allows a shape of one or more elements of the structure to be reused for other elements for the same or numerous structures.  
         [0017]     Turning to the Figures,  FIG. 1  shows an illustrative mold  10  for creating an element of a structure according to one embodiment of the invention. As used herein, the term “structure” is used to refer to any three-dimensional work, including a sculpture, furniture such as a table, shelf, chair, etc., and accent furniture such as a clock, frame, light, etc. Further, the term “element” is used to refer to any part that forms the structure. For example, a table would typically include elements comprising four legs and a top.  
         [0018]     In general, mold  10  can comprise any combination of various traditional manufacturing elements such as cardboard, wood, clay, plaster, tape, etc. Further, mold  10  can be created to form an element having any desired shape. To this extent, mold  10  can be used to form an element having a substantially longer length than width/depth (e.g., a leg for a table), an element having a small depth but relatively large width/length (e.g., a side for a mantel clock), etc. In the latter case, one side of the element can be uncovered by mold  10 . As will be discussed further below, this configuration can generate an element having one side with that is uniquely textured.  
         [0019]     Additional details of  FIG. 1  are discussed in conjunction with  FIG. 4 , which shows illustrative method steps for creating an element using mold  10 . In step S 1  of  FIG. 4 , mold  10  is created, which has a desired shape of the element to be constructed using mold  10 . In step S 2 , an interior of mold  10  can be lined with a sheet  12 . Sheet  12  can be used to ease in the removal of the element from mold  10 . To this extent, sheet  12  can comprise any type of flexible sheet that can substantially conform to the shape of the element (interior of mold  10 ). For example, sheet  12  can comprise a thin sheet of plastic (e.g., plastic wrap) or a thin flexible sheet of metal (e.g., aluminum foil).  
         [0020]     In step S 3 , a release agent  14  can be applied to sheet  12 . Release agent  14  can assist in removing a finished element from mold  10  and sheet  12 . To this extent, it is understood that release agent  14  should be present on a side of sheet  12  facing toward the interior of mold  10 . In one embodiment, release agent  14  can be applied to sheet  12  prior to step S 2 , and sheet  12  is placed in the interior of mold  10  so that release agent  14  is appropriately located. Alternatively, release agent  14  can be applied directly to mold  10 . Further, release agent  14  could be used instead of sheet  12 . Still further, sheet  12  could be permanently or temporarily attached to mold  10 . In any event, release agent  14  can comprise any type of compound that will assist in removing the finished element from mold  10  and/or sheet  12 . For example, release agent  14  could comprise a mold release typically used in candle making.  
         [0021]     In step S 4 , resin  16  is poured into mold  10 . Resin  16  can comprise any type of resin that comprises a liquid form when obtained, but will harden once exposed to air and/or heat. To this extent, resin is typically used as a general surface coating for a table top or the like. In one embodiment, resin  16  comprises a two-part epoxy resin substantially comprising of a resin and a hardener. Further, resin  16  can comprise a dye resin or the like. In any event, resin  16  is poured into mold  10  and allowed to harden to form the element. As a result, resin is used to create the element, rather than merely coating a surface of the element.  
         [0022]     In step S 5 , one or more solids  18  can be deposited into mold  10 . Solid(s)  18  can be deposited after pouring resin  16  and prior to its hardening and/or prior to pouring resin  16  into mold  10 . In either case, resin  16  hardens around all or a portion of solids  18  to create the element. Each solid  18  can comprise any material, size and/or shape to obtain a desired appearance of the element. However, in one embodiment of the invention no solid  18  individually provides support and/or shape for the element without the hardened resin  16 . For example, solid(s)  18  can comprise broken glass, pottery, stone, plastic, sand, a mirror, wire, porcelain, etc. Further, solid(s)  18  can comprise plant and/or animal materials such as wood, leaves, fruit, vegetables, etc.  
         [0023]     Once resin  16  has hardened, the element can be removed from mold  10 . For example, sheet  12  and resin  16  can be removed, and sheet  12  can be removed from resin  16 . As noted above, release agent  14  can further assist in the removal of the element so that mold  10  is not damaged and can be used to create another element. One or more additional steps also may be required. For example, due to the way resin  16  hardens, it may be necessary to remove excess resin from the element. In any event, the element can then be used to construct a structure that includes a plurality of elements.  
         [0024]      FIGS. 2 and 3  show illustrative structures  120 ,  220 , respectively. Structures  120 ,  220  are formed by assembling elements  110 A-C,  210  to one or more additional elements. For example, as shown in  FIG. 2 , elements  110 A-B can provide structural support for structure  120 . In this case, elements  110 A-B comprise legs for structure  120 . To this extent, it is understood that one or more traditional structural support elements can be included in elements  110 A-B to provide additional support for structure  120 . For example, one or more of elements  110 A-B could have a metallic rod or the like disposed within resin  16  ( FIG. 1 ) and along the length of element  11 A-B to provide support for structure  120  when disposed in an upright position. However, it is understood that element  110 A-B will comprise a large portion of resin  16  ( FIG. 1 ) and/or solids  18  ( FIG. 1 ) that substantially define the overall look and/or shape of element  110 A-B.  
         [0025]     Structure  120  can also include one or more elements that comprise traditional building materials such as wood, marble, polished glass, and the like that are formed using traditional building techniques. For example, a top  122  and/or a lower support/shelf  124  of structure  120  can comprise glass. Further, other materials can be incorporated into structure  120  to add support. For example, top surface  122  could comprise a thermoplastic acrylic resin, a light weather resistant thermoplastic, a polycarbonate, or the like, alone or in combination with resin  16  ( FIG. 1 ). Still further, top  122  and shelf  124  could both comprise resin  16  and be constructed as described above. To this extent, structure  110  can comprise a plurality of resin  16  and/or solid  18  ( FIG. 1 ) elements joined to other resin  16  and/or solid  18  elements.  
         [0026]     Additionally, a structure can include other functional elements. For example, structure  120  is shown including a drawer  126 . Drawer  126  comprises an element  110 C for a facing side of drawer  126 . In one embodiment, drawer  126  can comprise a bottom  128  and one or more sides  130 A-B comprising a smooth material such as a thermoplastic acrylic resin, a light weather resistant thermoplastic, a polycarbonate, polished glass, wood, etc. To construct element  110 C, mold  10  ( FIG. 1 ) can comprise a relatively narrow depth compared to the width and length. Further, a top of mold  10  can remain exposed. As a result, when one or more solids  18  ( FIG. 1 ) are used in element  110 C, portions of the solids  18  may protrude from the hardened resin  16  ( FIG. 1 ).  
         [0027]     Further, other solids can be disposed in mold  10  to provide functionality desired for element  110 C. For example, a handle  132  can be placed in a desired position in element  110 C. Various other functional solids, such as mechanical elements, can be incorporated into an element. For example,  FIG. 3  shows an illustrative structure  220  that comprises a clock  240 . Element  210  comprises a facing side of structure  220  and can comprise a structural support for structure  220 . Clock  240  can be placed in resin  16  ( FIG. 1 ) or be attached to element  210  after resin  16  has hardened using a traditional assembling technique as is known. It is understood that drawer  126  ( FIG. 2 ) and clock  240  are only illustrative. To this extent, structures  120 ,  220  can include various other functional elements. For example, a door can be disposed on a back side of structure  220  to allow access to a back of clock  240 . In this case, hinges and the like can be used to attach the door to structure  220 . Further, felt or the like can be applied to the bottom of the structure to prevent scratching.  
         [0028]     A top  242  and/or a bottom  244  of structure  220  can comprise elements made as described herein or made of traditional building material using a traditional manufacturing technique. In the former case, mold  10  ( FIG. 1 ) can comprise a shape that forms a groove or the like in order to assist in attaching the elements to form structure  220 . Alternatively, the required shape can be removed from and/or added to the element after resin  16  ( FIG. 1 ) has hardened. Still further, traditional attaching approaches such as nails, screws, glue, etc., can be used to attach the elements.  
         [0029]     The foregoing description of various embodiments of the invention has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed, and obviously, many modifications and variations are possible. Such modifications and variations that may be apparent to a person skilled in the art are intended to be included within the scope of the invention as defined by the accompanying claims.

Technology Classification (CPC): 0