Abstract:
Items with real natural or organic objects encased in clear, translucent or lightly tinted thermoplastic or thermo-rubber materials, which encapsulate and protect the objects inside from air, water or other environmental factors. A structure can be over-molded with thermoplastic or thermo-rubber material, preferably elastic silicone. Over-molding or encasing real natural objects in such materials aims to merge natural objects with functional kitchen utensils or similar household items. Visible through the encapsulating media, natural objects will keep their stunning looks as they are preserved for long lasting enjoyment. Natural objects can be encapsulated in between two gummy thermo-rubber sheets in airtight overmolding. Also, pre-molded pieces with shaped cavities for the natural objects can be secured together after natural objects are inserted in the cavity. Natural objects may be encased in a cavity of two or more already pre-molded pieces.

Description:
BACKGROUND  
       [0001]     The present disclosure relates to utensils or similar items with real natural or organic objects overmolded or encased in thermoplastic or thermo-rubber materials, which encapsulate and protect the objects inside from air, water or other environmental factors. The disclosure also describes methods of making such items.  
         [0002]     Nature has always been a popular icon for household items. The kitchen remains a popular spot where we use natural ingredients to cook and prepare fine meals. As such, utensils or similar items often seek to integrate such natural objects. However, most reproductions of nature remain two dimensional or synthetic since real natural objects have special considerations making it obviously harder to include such objects into household items. So how does one bring life into a lifeless object? The challenge was to find a way to preserve nature&#39;s preciousness while merging real natural objects with items that withstand the abuses of household use.  
         [0003]     Available household and industrial products have not yet found the way to merge with true nature while remaining suitable for their function. The compromise of synthetic material as replicas of natural objects only results in false impressions of nature&#39;s true beauty.  
         [0004]     Also, many products do not take full advantage of the superb characteristics of thermoplastics or thermo-rubber. Thermoplastic or thermo-rubber materials, such as silicone, are excellent for handles because of their slip-proof nature, gripability, and thermal and chemical characteristics. But these materials can also preserve real natural objects incorporated into functional items.  
         [0005]     U.S. Pat. No. 6,189,540 discloses a hair styling comb with a layer of resilient material overmolded on a core member. It does not disclose encasing natural or organic objects.  
         [0006]     Thus, it is desirable to produce items with real natural objects encased in thermoplastic or thermo-rubber materials.  
       SUMMARY  
       [0007]     The present disclosure describes items having real natural or organic objects encased in thermoplastic or thermo-rubber materials. Overmolding and encasing real natural objects in thermoplastic or thermo-rubber materials aim to merge natural life symbols and objects with functional kitchen utensils or similar household items. The materials can include clear, translucent or lightly tinted thermoplastic or thermo-rubber materials, such as silicone, to encapsulate and protect the objects inside from air, water or other environmental factors, allowing the enjoyment of the encapsulated objects&#39; natural beauty for a long time. Utensils or similar items with real natural or organic objects encased in thermoplastic or thermo-rubber materials may remain functional while capitalizing on the natural beauty of nature.  
         [0008]     The characteristics of silicone are kitchen-friendly and are appropriate for encasing real natural or organic objects: 
        Odorless     Non-toxic     Non-irritating to user&#39;s hands and eyes     Will not scratch surfaces on contact     Provides slip-proof function     Has good grip feel to provide efficient hold     Resistant to a wide range of pH level chemicals around the kitchen i.e. vinegar, pickles, salt, oil and grease     Physiochemical inertness     Resistant to thermal influences from cold or hot     Consistent behavior under heat and thermal shock     Withstands heat up to 600° F./315° C. for reliable safety and function     Moldable as clear, semi-transparent, translucent, tinted or colored     Can provide airtight, leak-proof seal     Long life span and lasting appearance        
 
         [0023]     A variety of real natural objects can be encased in items. Cooking ingredients may include dried spices, peppers, citrus or pasta. Agricultural objects may include coffee beans, corn, wheat, and tea leaves. Landscape objects may include flower blossoms, petals, minerals and crystals.  
         [0024]     Nature can be merged with contemporary household products to replace lifeless artificial replicas of nature that disgrace nature&#39;s true beauty. Fake applications with their audacious and boring looks may become obsolete because nature is absolute and timeless. By encasing or overmolding natural objects, like cooking spices (dried out pepper, lime, chilies etc.) or coffee beans, with food grade silicone, these methods preserve natural objects from wear and decay. Clearly visible through the encapsulating media, natural objects will keep their stunning looks as they are preserved for long lasting enjoyment. In addition, silicone provides excellent characteristics for daily use by people like grip comfort, slip-proof and flexibility.  
         [0025]     A first way to successfully merge nature with functional items is airtight overmolding, which is a process where the natural object is directly encapsulated between two gummy thermo-rubber sheets. The object is totally preserved from the outside in a fixed state with no movement.  
         [0026]     Another way to successfully merge nature with functional items is combination molding, which allows a much more advanced assembly of natural or organic objects. It includes a two-step process where one half of the overmold is premolded to shape cavities for the natural objects. This overmold tolerates complex forms of geometric or organic roots and can be applied to thermoplastics as well as thermo-rubbers. Once the first half is done, the prepared cavities are filled with the applicable natural objects and then returned to the machine for the second overmold step, which will seal the natural objects. The second overmold carries the same characteristics as the first overmold. Combination molding may also include the use of other materials, such as ferrous &amp; non-ferrous metals/alloys or ceramics/glass, to form the first mold half. After the second overmold is merged with the first one, the objects encased are safe against any physical battering and kept locked into position without any movement.  
         [0027]     A third way to successfully merge nature with functional products is encasing, which is a manufacturing process where the natural objects may be stored in a cavity of two or more already premolded pieces. The pieces or halves are secured and merged together by ultrasonic means, adhesive, mechanical lock or heat sealing. Products made by this process permit the encased objects either free or restricted movement within the encapsulated space while they are still kept safe from damage from outside the encasement.  
         [0028]     These methods of encasing real natural or organic objects can be used to make functional handles, grips and knobs for kitchen utensils, tools, cookware, tableware, serving containers, mugs, and doors. Other items using these methods include cutting boards, coasters, mousepads, floormats, and placemats. Items with real natural objects encased in durable thermoplastic or thermo-rubber materials will have objects inside protected from outside factors for long lasting enjoyment. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0029]     The features of this disclosure and the manner of obtaining them will become more apparent, and the disclosure itself will be best understood by reference to the following description of embodiments of items including real natural or organic objects encased in thermoplastic or thermo-rubber materials taken in conjunction with the accompanying drawings showing particular embodiments of the items and methods, wherein:  
         [0030]      FIG. 1  shows a perspective view of an item with a natural object encased in the handle;  
         [0031]      FIG. 2  shows a cover, piece or layer that forms half of an encasement;  
         [0032]      FIG. 3  shows a perspective view of an item with a natural object encased in the handle of a mug;  
         [0033]      FIG. 4  shows a perspective view of one utensil with a natural object encased in the handle;  
         [0034]      FIG. 5  shows a handle with one piece clear and another piece as a colored base;  
         [0035]      FIG. 6  shows a handle having numerous natural objects;  
         [0036]      FIG. 7  shows a handle being several pieces;  
         [0037]      FIG. 8  shows an alternative design in a recess near a rim; and  
         [0038]      FIG. 9  shows a handle having the natural object forming a portion to a provide grip for the user&#39;s thumb on the handle. 
     
    
     DETAILED DESCRIPTION  
       [0039]     While the present invention will be fully described hereinafter with reference to the accompanying drawings, in which particular embodiments are shown, it is to be understood at the outset that persons skilled in the art may modify the embodiments disclosed herein while still achieving the desired result. Accordingly, the description that follows is to be understood as a broad informative disclosure directed to persons skilled in the appropriate art and not as limitations of the present disclosure.  
         [0040]      FIG. 1  shows an item  10  having a handle  12  with a real natural object  14  encased in a thermoplastic or thermo-rubber material  16 . The material  16  may be two layers or pieces  18  and  20  that encapsulate and protect the encased object  14  from air, water or other environmental factors.  
         [0041]     Thermoplastic or thermo-rubber materials, such as silicone, are excellent for handles because of their slip-proof nature, gripability, and thermal and chemical characteristics. The materials can be clear, translucent or lightly tinted thermoplastic or thermo-rubber material, such as silicone, to encapsulate and protect the objects  14  inside from air, water or other environmental factors. Pure silicone has excellent thermal and chemical properties. The preferred material  16  is a high grade elastic silicone that withstands heat up to at least 600° F./315° C. Ideally, the material  16  is clear food grade silicone.  
         [0042]     As shown in the  FIG. 1 , a coffee bean is the object  14  sealed in the handle  12  of an item  10 , shown as a coffee scoop, but it is also suitable that such a natural object  14  can be hermetically molded between layers  18  and  20 . In either case, the natural object  14  is completely encased in thermoplastic or thermo-rubber materials  16 . In  FIG. 1 , specifically, the natural object  14  is a coffee bean sealed in the handle  12  of the coffee scoop. The handle  12  of the coffee scoop as shown has a looped wire core  23  that is encased in the material  16 , wherein the object  14  is surrounded by the looped wire core  23 , but the looped wire core  23  does not penetrate the cavity  22 .  
         [0043]      FIG. 2  shows a layer or overmold piece  18  of material  16  having an optional cavity  22  for holding the natural object  14  and a preformed channel  24  to accept the looped wire core  23  of the handle  12 . Layer  18  may be secured to a complementary layer  20 , possibly as a flat piece or possibly also having a cavity and/or a channel (as a mirror image of  FIG. 2 ), that encases the object  14  and covers the handle  12 .  
         [0044]      FIG. 3  shows a handle  12  having a natural object  14 , such as a leaves, encased between the handle  12  and a layer  18  of thermoplastic or thermo-rubber material  16 .  FIG. 4  shows a utensil  10  having a handle  12  with a natural object  14  as part of the handle  12  wherein the natural object  14  is completely encased in a material. The thicker handle  12  can be formed of two overmolds merged together. A core  30  that is a shaft extends into and is encased by the material  16 .  FIG. 5  shows a handle having a dried bean as the natural object  14  with piece  18  being clear, and piece  20  as a colored base.  FIG. 6  shows a handle having numerous beans as the natural object  14  with piece  18  being clear, and piece  20  being translucent but tinted. As apparent, the pieces can be any combination of clear, tinted or colored.  FIG. 7  shows a handle having a coffee bean as the natural object  14  with piece  18  being clear, and piece  20  being several pieces. In  FIG. 7 , the coffee bean as the natural object  14  forms a raised portion to provide finger grips on the handle.  FIG. 8  shows an alternative design where the two layers or pieces  18  and  20  that encapsulate the object  14  are laid in a recess near the rim of a cup or container.  FIG. 9  shows a handle having a coffee bean as the natural object  14  forming a portion to provide a grip for the user&#39;s thumb on the handle.  
         [0045]     In various embodiments, the layer or piece  18  may be considered the top as closest to the viewer&#39;s eye and may be clear, and the layer or piece  20  may be translucent and lightly tinted to complement the natural object  14 . For example, for a coffee bean as the natural object  14 , layer or piece  20 , if farthest from the viewer&#39;s eye, could be tinted light brown.  
         [0046]     Several methods of encasing real natural objects  14  in thermoplastic or thermo-rubber materials  16  can be used to make functional handles, grips and knobs or other items.  
         [0047]     Overmolding includes a process where the natural object  14  can be directly encapsulated between two gummy thermo-rubber sheets, such as  18  and  20 . The natural object  14  is totally preserved from the outside in a fixed state with no movement of the object  14 . The method includes situating an item  10  or a portion of an item, such as a handle  12 , along with natural objects  14 . A method of making a utensil  10  with a natural object  14  encased in a handle  12  of the utensil  10  includes obtaining the natural object  14  and obtaining the handle  12  with a core, such as loop  23  or shaft  30 . Heat is applied to a first and a second thermo-rubber sheet  18  and  20  so the sheets  18  and  20  become gummy. The first and the second gummy thermo-rubber sheets  18  and  20  can be secured together to completely encapsulate in an airtight manner the natural object  14  between the first and second gummy thermo-rubber sheets  18  and  20  and to encase a portion of the shaft  23  or  30  of the handle  12  to preserve the natural object  14  in a fixed state from outside exposure. The natural object  14  can be initially adhered to the first gummy thermo-rubber sheet  18  before the first gummy thermo-rubber sheet  18  is secured together with the second gummy thermo-rubber sheet  20 .  
         [0048]     Combination molding allows a more advanced assembly of natural objects  14 . It includes a two-step process where one half of the overmold piece  18  is premolded to shaped cavities (i.e.  22 ) for the natural objects  14 . This overmold tolerates complex forms of geometric or organic roots, and can be applied to thermoplastics as well as thermo-rubbers. Once the first portion is done, the prepared cavities  22  are filled with the applicable natural objects  14  and then returned to the machine for the second overmold step, which will seal the natural objects  14 . The second overmold piece  20  carries the same characteristics as the first overmold piece  18  and preferably is the same material. Combination molding may also include the use of other materials, such as ferrous &amp; non-ferrous metals/alloys or ceramics/glass, to form the first mold half. After the second overmold piece  20  is merged with the first piece  18 , the objects  14  encased are safe against any physical battering and kept secured into position without any movement.  
         [0049]     A method of making a utensil  10  with a natural object  14  encased in the utensil  10  may include premolding a first thermoplastic overmold piece  18  with a shaped cavity  22  that is compatible with the natural object  14 . The natural object  14  is inserted into the shaped cavity  22 . The second thermoplastic piece  20  is secured to the first thermoplastic overmold piece  18  to completely encase the natural object  14  within the first and second pieces  18  and  20 . The second piece  20  can be flat or it can be premolded with a shaped cavity  22  (mirror image of  FIG. 2 ) that forms an encapsulated space with the shaped cavity  22  of the first thermoplastic overmold piece  18  so that the natural object  14  has free movement within the encapsulated space formed by the cavities  22 .  
         [0050]     Encasing objects  14  in a cavity  22  is a manufacturing process where the natural objects  14  may be stored in a cavity  22  of two or more already premolded pieces  18  and  20 . The pieces or halves (i.e.  18  and  20 ) can be secured and merged together by ultrasonic means, adhesive, mechanical lock or heat sealing. Items  10  made by this process permit the encased objects  14  free or restricted movement within the encapsulated space while they are still kept safe from outside harm.  
         [0051]     The natural objects can correspond to the product. For example, coffee beans can be used with coffee mugs, coffee cups, coffee carafes, coffee servers, coffee sets, coffee scoops, and coffee presses. Similarly, tea leaves can be used with tea services sets and handles on tea kettles. Grass, leaves and petals can be used with garden tools and other theme items, such as door knobs, coasters and mouse pads.  
         [0052]     Although preferred methods and embodiments are illustrated and described in connection with particular steps and features, they can be adapted for use with a wide variety of items and methods. Other embodiments and equivalents of the items and related methods of making those items are envisioned within the scope of the claims. Various features of the disclosure have been particularly shown and described in connection with illustrated embodiments. However, it must be understood that the particular examples merely illustrate and that the invention is to be given its fullest interpretation within the terms of the claims.