AU2012202357A1 - Apparatus and method for making a solid object from a fluid material - Google Patents

Abstract

Abstract A method and an apparatus for making a solid object from a solidifiable fluid. The method comprises the steps of: creating an image that is to appear on a surface of the solid object, after the solid object is made; rendering the image, or a reciprocal of the image, in three dimensional form on a generally two-dimensional object; providing an enclosure to co operate with the two-dimensional object so as in use to define a mould for receiving a solidifiable fluid; introducing a solidifiable fluid into the mould; solidifying the solidifiable fluid within the mould; and after the solidifiable fluid has at least substantially solidified, releasing the solid object from the mould. 0 i~ U )II 4, Ar 4,, 3= z 0 1w

Description

P/00/011 Regulation 3.2 Australia Patents Act 1990 ORIGINAL COMPLETE SPECIFICATION STANDARD PATENT Name(s) of Applicant(s): Jaime Guarro Contreras Title of Invention: 'Apparatus and method for making a solid object from a fluid material' The following is a full description of this invention, including the best method known to the Applicant(s) of performing the invention: Apparatus and method for making a solid object from a fluid material Field of the Invention 5 The present invention relates to apparatus and methods for making solid objects from a fluid material. It has particular, although not exclusive application to methods of making solid objects from liquid starting materials, such as liquid soaps, for example. It is especially applicable to methods of making finished or semi-finished solid objects that comprise desired or pre 10 determined features of shape and/or configuration, using liquid starting materials to make the object. The background to the invention will therefore be discussed with particular reference to the example of making a soap from liquid starting materials, being one of the typical applications of the invention. 15 Background to the Invention Many commercial articles that have a solid form are made nowadays using one or more liquid starting materials. Some soaps are a typical example. Many soaps are made from liquids (typically, an oil such as olive oil, 20 palm oil or mixtures of these and/or other oils, as well as including other liquid components, such as colouring agents and/or fragrances, which for example, are often used in making modern soaps). It is often commercially desirable for marketing purposes, or for the purpose of enhancing customer acceptance or appeal, for an article such as a cake or a bar of soap to have a particular 25 appearance. So, for example, a bar of soap might have a particular name or logo imprinted onto or embossed on it, to act either as a trade mark or brand to identify a particular manufacturer's product, or alternatively again, to provide the article with a pleasing appearance that will enhance its appeal to prospective purchasers or users. Alternatively, such a bar of soap might be a 30 custom-made promotional item for a business that itself does not (or which may not) sell soap, but nonetheless, the soap could feature the name or corporate logo of the business, so that the business can provide such articles as promotional gifts to its existing or targeted customers of its actual products or services. Items such as these are frequently manufactured and used for 35 many purposes (including those previously described) in modern commerce.

2 Where, for example, a business wishes to have an article of this kind made, often, a mould must be custom made for the particular article to be manufactured. While commercial forms and moulds are widely available, they must often be made to order for a particular customer (especially if, as 5 previously discussed, the form or mould is to be used to make an article that is intended to feature a particular customer's corporate logo or name: in such circumstances it is not always possible simply to "adapt" an existing mould for this purpose). The need for a custom made mould usually introduces a not insignificant element of expense into the overall cost to the customer, of 10 having the soap manufactured. Commercial moulds must typically be made to very precise tolerances, in order for products to be made by using them to have a professional and commercially acceptable appearance. Apart from the cost of having a mould custom made, the process of designing the mould, ensuring that it conforms with acceptable manufacturing practices/standards 15 and that it meets the customer's requirements for the intended end product, also tend, of necessity, to retard or delay the manufacturing process. It would therefore be desirable to have alternative or improved methods for making solid objects from liquid materials, being alternative or improved methods of a kind that overcome, or at least lessen these problems. The 20 present invention attempts to provide a solution to one or more of these problems. Summary of the Invention The present invention generally provides a method of making a solid 25 object from a fluid material, comprising the steps of: (a) creating an image that is to appear on a surface of the solid object; (b) rendering the image in three-dimensional form on a generally two dimensional object; (c) providing an enclosure to co-operate with the two-dimensional object 30 so as in use to define a mould for receiving a solidifiable fluid; (d) introducing a solidifiable fluid into the mould; (e) solidifying the solidifiable fluid within the mould; and 3 (f) after the solidifiable fluid has at least substantially solidified, releasing the solid object from the mould. In some embodiments, the image may be designed manually. 5 Preferably however, the image is created using a computerized means, either as an alternative to creating the image manually, or in combination with manual design. In some preferred embodiments of the invention, the computerized means comprise using computer aided design or graphic design software. Examples of suitable computer software include CoreDrawTM (the 10 trade mark registration for which is owned in Australia by Corel Corporation), Adobe IllustratorTM and Adobe Photoshop T M (the trade mark registration for ADOBR for computer software being owned in Australia by Adobe Systems, Inc). In particular embodiments, the image could be scanned in from a hard copy image or line drawing. As desired or necessary in particular 15 embodiments, the scanned image could be digitally processed or manipulated using appropriate software, in order to give rise to the image to appear on the solid object. In yet other embodiments, the design of the image could take the form of the combination of manual and computerized processes. So, for example, the desired image could result from manually prepared drawings in 20 the first instance, which are scanned into or otherwise reproduced on a computer, and then digitally processed or manipulated so as to give rise to the final desired image. Preferably further, where computerized means are used (either as the sole means of generating the desired image, or as part of the design process), 25 such computerized means co-operate, or work in association with, suitable hardware and peripheral equipment, to enable the image to be realized in a hard copy or tangible format. In some preferred embodiments, the image would be printed or engraved or etched onto another medium constituting the generally two-dimensional object, as the output of the computerized design 30 software. In some preferred embodiments, the generally two-dimensional object would take the form of a sheet of a solid material, and preferably further, the sheet of the solid material could be worked either by: 4 (a) etching, engraving or carving one or more recesses on a two dimensional (planar) surface of the object, so as generally to define one or more recessed features in the sheet material below the planar surface of the object; or 5 (b) so as to deposit one or more materials on a two-dimensional (planar) surface of the object, so as to define one or more features upstanding from the plane defined by that two dimensional surface on the object. 10 In embodiments of the invention comprehended by feature (a) discussed in the preceding paragraph, either manual and/or computerised means may result in the formation of one or more recesses in the two dimensional planar surface of the object. This could be achieved by any of the following means: 15 (i) cutting means; (ii) engraving means; (iii) etching means; 20 or the like. In one particularly preferred embodiment, the means for forming one or more recesses on a planar surface of the general two-dimensional object take the form of laser means to etch the surface of the two-dimensional object so 25 as to cut one or more recesses or holes in it below the planar surface. In that particularly preferred version of this embodiment, the laser means co-operate with the computerised means, so as to achieve that outcome. In such an embodiment, the computerised means control the laser means in order to cut one or more holes or recesses on the planar surface (which would typically be 30 a sheet of a material having a shallow depth) so as to create an image on that sheet that corresponds to the image stored or depicted on the computerised means.

5 In the embodiment in paragraph (b) discussed earlier, the computerised (or for that matter, manual) means reproduce the desired image by depositing a material on the two-dimensional surface of the object. By way of example, this could be achieved by depositing a carbon-containing 5 material, or a substance which solidifies once deposited on the planar surface of the two-dimensional object, so as to define one or more bosses or protrusions on the two-dimensional object that are generally upstanding from the planar surface thereof, and which correspond to the desired image. 10 In either the case of embodiment (a) (in which recesses are formed on the two-dimensional object) or in (b) (in which case, protrusions or bosses upstanding from the planar surface of the object are formed), the recesses or bosses/protrusions (as the case may be, according to the embodiment concerned) correspond to the desired image. 15 The desired image itself may be any of the following: (a) one or more characters from any language and/or numerals, either represented in a simple font or in any font or combination of two or more fonts or typefaces; 20 (b) a graphic or pictorial image; and/or (c) combinations of two or more of any of the features described in paragraphs (a) or (b). The desired image may be either: 25 (a) a two-dimensional; or (b) a three-dimensional image. In most commercially preferred embodiments, the image would be a 30 three-dimensional image however. This is especially true of the reproduction of the image on the finished solid object, where the image could comprise either: (a) one or more recesses on a surface of the solid object; or 6 (b) one or more bosses or protrusions upstanding from the surface of the object; or (c) one or more of (a) or (b). 5 In some embodiments, the reproduction of the desired image could include at least one recess, and at least one boss/protrusion on a surface of the solid object. In some solid objects made in accordance with the invention, the object 10 may comprise for than one desire image. In particularly preferred embodiments, the desired image may take the form of one or more characters that define the name of a business or of one or more individuals, or a graphic pictorial image. In some preferred 15 embodiments, the desired image could be a combination of such characters (defining the name of a business or an individual), in association with a pictorial image. A pictorial image for this purpose may be of any desired kind, and can include corporate logos or graphics, trade marks, likenesses of real or fictional individuals, cartoon characters, or any other desired image 20 whatsoever. Preferably, the enclosure to co-operate with the two-dimensional object is a structure, in use, that co-operates with the two-dimensional object so as to define a three-dimensional mould assembly capable of receiving a 25 solidifiable fluid within the enclosure defined by the combination of: (a) the two-dimensional object; and (b) the enclosure. In preferred embodiments, the two-dimensional object may take the 30 form of an acetate sheet or the like. In such embodiments, the acetate sheet may be etched readily by known means, such as by the use of a laser. Alternatively, in other embodiments, the acetate sheet or other two dimensional object used may have one or more materials deposited on it by means known to those of skill in the art, so as to define one or more three- 7 dimensional protrusions or bosses upstanding from the general plane of the two-dimensional (acetate) sheet. As indicated earlier, in some embodiments, the two-dimensional object may be worked so as to create at least one recess and at least one boss or protrusion on its planar surface. 5 Preferably further, the enclosure which co-operates with the two dimensional object defines a three-dimensional article which in use, will when filled with the solidifiable fluid - ultimately result in a three-dimensional object after the solidifiable fluid has been solidified within the overall mould 10 assembly. So for example, in the case of a soap, the two-dimensional object could take the form of an acetate sheet with laser-etched engravings in it to define an image on a surface of the solidified object (once formed), and the enclosure could be a generally rectilinear open enclosure which is placed against or over the acetate sheet, and which in turn, defines a generally 15 rectilinear mould which can be filled with a solidifiable fluid. The solidifiable fluid may comprise any number of different fluid materials. These include (but are not limited to) the following: (a) oils or fats; 20 (b) sugars (including those used for making confectionery); (c) fragrances; (d) flavourings; (e) plastics; (f) colouring or colourant materials; 25 (g) chocolate in liquid or powdered form; (h) liquids comprising water or aqueous or organic solvents; or (i) one or more basic compounds selected from the group consisting of sodium hydroxide, potassium hydroxide and lithium hydroxide. 30 A 'fluid' for the purpose of the invention may take any one or more of the following forms: (i) one or more liquids; 8 (ii) one or more powdered flowable materials; and/or (iv) combinations of two or more of the aforegoing. A 'fluid' for the purposes of the present invention must however be 5 capable of forming a solid during the solidification procedure forming part of the method aspect of the present invention. For this purpose, solidification may be achieved by any of the following means (amongst others): (a) by cooling or freezing the solidifiable fluid once within the mould; 10 (b) by heating or heat-curing the solidifiable fluid within the mould; (c) by the application of pressure once the solidifiable fluid is within the mould; (d) by introducing a setting or curing agent or substance (or one or more such substances) to the solidifiable fluid once it is within 15 the mould; or (e) by any combination of two or more of the aforegoing. Persons of skill in the art would readily apprehend which one or more of these methods would be applicable to any particular solidifiable fluid. 20 In some embodiments of the invention, a first solidifiable fluid would be applied to the generally two-dimensional object, so as to form a first solidified structure on it. So for example, in the manufacture of a soap in accordance with the method aspect of the present invention, after the three-dimensional 25 image is rendered on the two-dimensional object (eg, by engraving or etching recesses on it), a first solidifiable fluid might be applied to the recesses, and then allowed generally to solidify in them, before being presented to the mould for further processing. In the example of the manufacture of a soap, in one embodiment of the invention, a first soap-forming solidifiable fluid might be 30 introduced at this stage, and allowed to solidify within the etchings or recesses in the acetate sheet. In some preferred embodiments, the first solidifiable fluid used in that stage of the manufacturing process might have (for example) a different colour to the solidifiable fluid introduced at method step (d) of the present invention. In other embodiments, the solidifiable fluid used at step (b)

9 of the general manufacturing method according to the invention, and the one used at step (d) could be of the same colour. The choice of whether the same or different coloured fluids is used in any instance will be a matter of preference for the user of the method. 5 In some embodiments of the invention, the computerised means discussed previously could be such as to control the deposition of a first solidifiable fluid on the generally two-dimensional object, and first fluid could then undergo solidification on the two-dimensional object. 10 The solidifiable fluid used at step (b) might also differ with respect to some other physical or chemical characteristic, compared to the solidifiable fluid used at step (d) of the method aspect of the present invention. Such a difference might be with respect to: 15 (a) texture; (b) density; (c) fragrance; (d) melting point; or 20 (e) the solidification method required in order to solidify the fluid used at step (b) of the method, relative to the one used at step (d). The two fluids might also differ with respect to any two or more of these 25 or other physical or chemical characteristics. After the solidifiable fluid has (or at least one of the solidifiable fluids have [in those embodiments where two different fluids are used at method steps (b) and (d)]) solidified (or at least substantially solidified), the object 30 formed by solidification within the mould would be released from the confines of the mould assembly itself. This could be achieved by any number of desired means, such as by (for example): 10 (a) lining either the two-dimensional object and/or the mould enclosure with a material (for example, a lubricant) which facilitates the release of the solidified object from the mould; or (b) either cooling and/or heating, or otherwise physically treating the 5 mould assembly, so as to encourage the release of the solid object from the mould. Where the object is a material such as a soap, cooling would normally be a preferred means used. Again, the choice of which method would be 10 adopted to release the solid object from the mould in any given instance, would generally be apparent to persons of skill in the field. A 'solid' object, for the purposes of the present invention, is one characterized as having structural rigidity and which generally resists changes 15 to its shape or volume. A 'solid' object for present purposes is to be distinguished from a fluid in that it does not flow so as to assume the shape of its container. Nor does such an object expand to fill its surrounding volume, as does a gas. It should be noted however that some deformable and resilient objects (such as those made of resilient or otherwise deformable 20 materials) are 'solid' objects for the purposes of the present invention. Examples include rubber, foam rubber and some plastics materials. The present invention further generally provides an apparatus for making a solid object from a fluid material, comprising: 25 (a) means for creating an image that is to appear on a surface of the solid object; (b) means for rendering the image in three-dimensional form on a generally two-dimensional object; and 30 (c) an enclosure to co-operate with the two-dimensional object so as in use to define a mould for receiving a solidifiable fluid, to be solidified and thereby to form the solid object.

11 Preferably, the apparatus additionally comprises one or more means for solidifying the solidifiable fluid. Preferably further, the apparatus additionally comprises means 5 for introducing the solidifiable fluid to (or into) the mould. Such means could comprise, for example, providing the mould with one or more inlets for introducing the solidifiable fluid into the mould. Preferably further, the apparatus would additionally comprise 10 means for removing the object from the mould, once it has solidified. Such means could comprise, for example, a mechanism for disassembling the mould and/or a mechanism for ejecting or dislodging the solid object from the mould. 15 The Accompanying Drawing Preferred embodiments of the Invention will now be described by way of example only, with reference to the accompanying drawing, in which: Drawing Number Description Fig 1 Represents a schematic depiction of an apparatus and method for making a solid object (in the example discussed hereafter, the object being a soap) from one or more fluid starting materials, in accordance with the invention. ...... ..... 20 Detailed description of preferred embodiments of the Invention Many solid objects may be made from a fluid predecessor material, and 25 soap is one such product. There are some important differences however between the physico-chemical properties soaps on the one hand, and those of other solid products (eg, chocolate) on the other, that are made from a fluid predecessor ingredient (or ingredients, as the case may be). These differences also influence the way in which a solid soap product (as opposed 30 to a solid chocolate product, for example) might be made in accordance with the present invention. In the discussion of the exemplary soap products made 12 in accordance with the invention, these important differences should be borne in mind. The differences are explained in the comments that follow. The process of making a soap is called "saponification". This term 5 refers to a chemical reaction between fats and lye (a base compound) that results in the formation of soap (containing the sodium salt of a carboxylate) or glyecerol. The fats used to make soap are typically of animal or vegetable origin. 10 A base compound (usually sodium hydroxide, also known as caustic soda or lye) is used as the reagent with the fat, because in the saponification reaction, sodium hydroxide is known to produce typical "hard" soaps. Other basic compounds (eg, Potassium hydroxide and lithium hydroxide) may be used in place of sodium hydroxide. 15 Soaps are made from starting materials according to either of two traditional saponification reactions, namely (1) the "cold process" method, or (2) the "hot process". 20 The hot process begins by adding lye to water. This seemingly simple step is actually somewhat dangerous, since people who accidentally add water to lye will inadvertently cause a minor explosion: lye must be added to the water, not the other way around. Next, the lye mixture is added to heated fat. The mixture is then stirred (for example, with an electric blender) for a 25 while before any desired additional ingredients, such as herbs, scents, colourants and/or oatmeal (for example) are added. The mixture is then stirred a little more to make sure that everything is evenly distributed before the mixture thickens further and is poured into moulds and allowed to cool, set and cure. 30 The cold process is very similar to the hot process, except that the mixture is not heated throughout the entire stirring process; the fat is heated, but the lye, water, and fat mixture is not heated.

13 Irrespective of whether the hot or the cold process is used, the mixture is stirred in each instance until it reaches what is called "trace". "Trace" is often referred to in the soap making process as the "point of no return", in that when the mixture reaches trace, it will not separate back into the precursor fat, 5 water-lye components. A soap making mixture is said to have reached "trace" when a utensil (eg, spatula or spoon) is immersed into the mixture and then removed, and a little residue of the mixture on the utensil is allowed to fall back into the mixture after making a pattern on its surface. If the residue takes only a brief period (typically a second or two) to disappear into the mixture, 10 then it leaves a temporary "trace" on the surface before doing so. Alternatively, the point at which trace has been reached can be tested by removing the spatula or spoon from the mixture and running it across a hard surface. If very little of the mixture is left on the surface, then the mixture has reached trace. At trace, a soap mixture often has a consistency similar to cake 15 batter. After trace has been reached, the saponification process often progresses rapidly to the point where the former cake-batter consistency of the mixture ceases to exist, and the mixture becomes very dense. At this point, the mixture is said to have reached "seize". 20 After a soap mixture has reached trace, it is typically poured into moulds, and allowed to cool, set and cure. In the 12 to 48 hours after a recently made soap mixture has been poured into moulds, the mixture is covered to allow the saponification process 25 to progress further. This prevents separation of the precursor reagents, and controls the amount of residue that forms on the surface of the soap. This period (known as the "insulation" period) also keep the batch from cooling too rapidly, and allows heat to be created within the soap. Within about 24 hours, the soap will have hardened sufficiently to enable it to be removed from the 30 mould and sliced into bars (if desired). Fresh bars of cold process soap in particular must be dried on cooling racks for four to six weeks, to allow the lye within the soap to continue react with the fat and oil components so that saponification is completed.

14 It might be thought that, for example, chocolate making would follow essentially the same method. The soap making process however has some unique characteristics that can be distinguished from the procedure for making a solid chocolate from a fluid precursor, in the following ways 5 (amongst others). (a) a cold process can be used to make a solid soap from a fluid precursor, but a solid chocolate cannot be made by a cold process, as the chocolate must be melted first into a mould; 10 (b) a liquid soap mixture must form trace before it can be poured into a mould in order eventually to form a solid soap: there is no equivalent or analogous concept in the process of making a solid chocolate from a liquid precursor; 15 (c) chocolate must be in liquid form in order to be poured into a mould. This generally requires the chocolate to be at a temperature between 40 and 50 degrees Celsius. Below this temperature , the chocolate will not be molten, and thus, it will not be fluid. At temperatures above the 20 higher end of this range, the chocolate will burn, rendering it useless. If chocolate is heated to within this range, but later falls below the lower temperature limit, it can be re-heated to bring it back within the desired range; 25 (d) in contrast to the characteristics of chocolate described at (c), in a method for making a cold process soap: (1) the oils or fats need not be at a temperature of 40 degrees Celsius or greater (and typically, they are at between 30 to 40 degrees 30 Celsius); (2) the lye solution component is typically at 20 - 30 degrees (ie, at room temperatures); 15 (3) when the soap mixture reaches trace, it intrinsically creates heat due tyo the saponification reaction: there is no equivalent reaction in the manufacture of chocolate from a fluid precursor (and if anything, the chocolate simply cools down). 5 Referring now to the accompanying drawing, Fig 1 depicts schematically, an example of a method of making a solid object (in the example shown in accompanying Fig 1, the solid object is a soap) in accordance with the invention. Fig 1 also depicts an apparatus for use in 10 making a solid object from one or more fluid starting materials, in accordance with the invention. In the accompanying drawing, the feature E is a computer (and in the example shown, it is represented schematically as a personal computer, 15 although any kind of computer that is capable of generating a desired image may be used). As shown in the accompanying drawing, the desired image shown on the computer is a graphic representation of the letters 'E' and 'A' in a stylised form, with an ampersand symbol displayed over the letters, and in between them. As will be appreciated, the desired image is displayed on the 20 computer monitor in the reverse to the way in which it would appear on the finished solid object produced by the method (as will further become apparent from the following discussion). The computer E is connected by a suitable connection means (which 25 might be via one or more communication cables, or wirelessly, or a combination of these or other means) to a laser engraver, depicted schematically as 'F'. The computer E is able to control the output of the laser engraver, by means of suitable software . Examples of suitable computer software include CorelDrawTM (the trade mark registration for which is owned 30 in Australia by Corel Corporation), Adobe IllustratorM and Adobe PhotoshopTM (the trade mark registration for ADOBE for computer software being owned in Australia by Adobe Systems, Inc). Such computer programs might work in co-operation with other s 16 The computer is therefore able to reproduce the desired image shown on the monitor of computer E onto a generally two-dimensional object (which is depicted schematically as 'A' in the accompanying drawing). The general two-dimensional object depicted as 'A' in the accompanying drawing would, in 5 the example shown, typically take the form of an acetate sheet or another similar material. Examples of other materials that could constitute or take the form of the generally two-dimensional object include plastic sheets of the kind that can be laser-etched, acrylic sheets, rubber sheets of the kind that can be laser-etched, glass and wood. Once driven by commands from computer E 10 (including commands from the software used to drive the laser engraver F), an image may be etched on the surface of the acetate sheet A, which corresponds to the image shown on the display or monitor of computer E, as depicted at step Al shown in the accompanying drawing. Suitable laser engravers for this purpose would for example, include C02 laser engravers, 15 such as those known as Trotec Laser Engravers, Epilog Laser Engravers, and Universal Laser Engravers. As the feature Al (which is the acetate sheet 'A', but which has been worked by the laser engraver so as to create an image on.its surface which 20 corresponds to the desired image shown on the monitor of computer E). Those of skill in the art would appreciate that the dark areas shown in the feature Al in the accompanying drawing would represent areas in which the laser engraver has etched out a recess in the surface of the acetate sheet A, such that those recesses generally extend below the two-dimensional planar 25 surface of the acetate sheet. The areas shown in feature Al as not being darkened are those parts of the acetate sheet which the laser has not etched, and which therefore - after the etching process has concluded - remain untouched (and thus, which are contiguous with the plane defined by the two dimensional planar surface of the acetate sheet A). 30 As discussed previously, instead of using a laser engraver or another form of engraving apparatus (as is depicted in the drawing accompanying this specification), alternatively, a computer (such as computer E) could be connected to a means for depositing a material (such as a carbon-containing 17 material or a first solidifiable fluid) on the two-dimensional planar surface of the acetate sheet, so that rather than etching out recesses in the planar surface of the two-dimensional sheet, one or more three-dimensional protrusions or bosses could be defined on the sheet. As also previously 5 discussed in this specification, in an alternative embodiment (or in alternative embodiments), a means for depositing a material on the planar surface of the two-dimensional sheet material could also be used in conjunction with an engraving or etching means, so that the sheet could have: (a) one or more recesses formed on it; and/or 10 (b) one or more protrusions or bosses generally upstanding from the planar surface defined by the two-dimensional plane of the sheet material, as desired in any given instance. 15 As shown in step A2 of the accompanying drawing, in the present instance however, the example shows a two-dimensional planar sheet which has had a number of recesses (predominantly representing the letters 'A' and 'E' in stylised form, albeit in reverse orientation to normal) formed on the 20 sheet. In this step of the exemplary manufacturing method depicted in the accompanying drawing, a first fluid material (shown as being poured from the vessel denoted 'B') is being introduced onto the planar surface of the etched acetate sheet shown at A2. The recesses formed by the etchings or engravings on the acetate sheet thus are capable of receiving a liquid material 25 into them. In the example shown in the accompanying drawing, the fluid material could (for example) be a liquid soap material. In particular, the first fluid material introduced at that stage of the manufacturing process could be a liquid soap material having a particular colour (being a colour which is intended either to be the same as that of a second fluid material introduced 30 later in the procedure, or alternatively, a colour that is different to the second fluid material). If first and second fluid materials of different colours are used, then the manufacturing process may result in the formation of an end product which has a body portion having one appearance or colour, and a second 18 portion (typically the portion which features the desired image) which has a different colour or appearance. Optionally at this stage, excess amounts of the first solidifiable fluid 5 could be removed from the acetate sheet, by using a scraper blade or spatula, before the acetate sheet is used in the subsequent steps of the manufacturing method. As shown at step D of the exemplary manufacturing process, an 10 enclosure (denoted 'Dl') is superimposed over the acetate sheet A2. As will be evident from step D of the exemplary manufacturing process, the mould D2 has a profile which: (a) in this embodiment, corresponds to the peripheral shape of the 15 acetate sheet A2; but (b) has a central circular portion which borders the desired image etched onto the acetate sheet A2 (although at this stage, the desired image has now been filled with a first solidifiable fluid material in the form of a liquid soap, as previously discussed). 20 As shown at step G in the accompanying exemplary manufacturing method, at this stage, a second fluid (albeit solidifiable) material is introduced into the cavity of the mould. In the example shown, it is intended that the second fluid (although solidifiable) material would comprise a liquid soap 25 (which, as discussed earlier, may be the same as, or different to the first liquid soap). The liquid soap is introduced into the cavity of the mould, so as to fill or substantially fill it. In the next stage of the manufacturing process, the second fluid (albeit 30 solidifiable) material is allowed to solidify within the cavity of the mould. As discussed earlier, such solidification could be achieved by any desired means (such as, for example, by cooling or chilling the solidifiable liquid: for this purpose, the mould assembly could comprise or co-operate with another means (such as a cooling apparatus) to bring about the desired solidification).

19 In order to facilitate the eventual removal of the solid object forming within the mould, the interior lining of the mould could be treated so as to encourage the eventual removal of the finished solid object. This could be achieved by any of a number of ways, the nature of which would be apparent to persons of skill 5 in the art. One example of such a method would however, be to line the interior casing of the enclosure (mould) so as to provide a lubricant to discourage or prevent the second solidifiable fluid from adhering to the inner lining or casing of the mould enclosure. As persons of skill in the art would appreciate however, other methods could also be used in order to facilitate 10 the removal of the finished solidified object from the mould. Such means would include (but are not limited to) cooling and/or heating the mould assembly, by way of example. Where the solid object is a soap, cooling would normally be a preferred means for this purpose. 15 As shown at steps H1 and H2 of the accompanying drawing, after the fluids in the mould assembly have solidified, the finished (now solid) object (in the example shown, a squat cylindrical cake of soap featuring the desired image on one of its faces) has been released from the mould, and is ready for use as intended. 20 The present invention therefore provides a convenient method and apparatus for forming a solid object from one or more fluid starting materials. Persons of skill in the art will readily appreciate that the method and apparatus previously described could be used to make many different products 25 (including soaps, chocolates, various forms of confectionery, as well as many plastic, rubber and other articles). Interpretation of this specification 30 It will therefore be understood that the invention could take many forms and be put to many different uses. All such forms and uses are embodied within the spirit and scope of the invention, which is to be understood as not being limited to the particular constructional details of the embodiments 35 discussed above, but which extends to each novel feature and combination of 20 features disclosed in or evident from this specification and the accompanying claims and drawings. All of these different combinations constitute various alternative aspects of the invention. It will also be understood that the term "comprises" (or its grammatical 5 variants), as used in this specification, is equivalent in meaning to the term "includes" and should not be taken as excluding the presence of other elements or features. Further, wherever used in this specification, the term "includes" is not a term of limitation, and is not be taken as excluding the presence of other elements or features. 10 It is further to be understood that any discussion in this specification of background or prior art documents, devices, acts, information, knowledge or use ('Background Information') is included solely to explain the context of the invention. Any discussions of such Background Information is not be taken as an admission in any jurisdiction that any such Background 15 Information constitutes prior art, part of the prior art base or the common general knowledge in the field of the invention on or before the priority date of the appended claims or any amended claims later introduced into this specification.

Claims (26)

1. A method of making a solid object from a solidifiable fluid, comprising the steps of: 5 (a) creating an image that is to appear on a surface of the solid object, after the solid object is made; (b) rendering the image, or a reciprocal of the image, in three dimensional form on a generally two-dimensional object; (c) providing an enclosure to co-operate with the two-dimensional 10 object so as in use to define a mould for receiving a solidifiable fluid; (d) introducing a solidifiable fluid into the mould; (e) solidifying the solidifiable fluid within the mould; and (f) after the solidifiable fluid has at least substantially solidified, 15 releasing the solid object from the mould.

2. A method as claimed in claim 1, in which the image or the reciprocal of the image is created manually.

3. A method as claimed in claim 1, in which the image or the reciprocal of 20 the image is created: (a) solely by using a computerised means; or (b) by using a combination of manual and computerised means. 25

4. A method as claimed in any one of claims 1 to 3, in which the image or the reciprocal of the image is created, for use in steps (b) to (f) of the method, in hard copy form. 30

5. A method as claimed in claim 4 in which after creation, the image or the reciprocal of the image is reproduced for use in steps (b) to (f) of the method, in an electronic form.

6. A method as claimed in claim 5, in which the image or the reciprocal of 35 the image is reproduced in electronic form by scanning the hard copy form of the image. 22

7. A method as claimed in any one of claims 1 to 3, in which the image or the reciprocal of the image is created in electronic form.

8. A method as claimed in any one of the preceding claims, in which the 5 step of rendering the image or the reciprocal of the image in three dimensional form on a generally two-dimensional object comprises cutting, etching, engraving or depositing the image onto a sheet of a solid material. 10

9. A method as claimed in claim 8, in which the step of etching, engraving or depositing the image or the reciprocal of the image onto the sheet of the solid material is performed: (a) manually; 15 (b) by computer-controlled means; or (c) by a combination of manual and computer-controlled means. 20

10. A method as claimed in claim 9, in which: (a) the sheet of the solid material is an acetate sheet; and (b) the image or the reciprocal of the image is cut, etched or 25 engraved onto the acetate sheet by a computer-controlled laser means.

11. A method as claimed in any one of the preceding claims, in which the image or the reciprocal of the image is: 30 (a) a two-dimensional image; or (b) a three-dimensional image. 35

12. A method as claimed in any one of the preceding claims, in which the image or the comprises: (a) one or more characters from any language, either represented in a simple font or in any font or combination of two or more fonts or typefaces; 40 (b) one or more numerals, either represented in a simple font or in any font or combination of two or more fonts or typefaces; 23 (c) a graphic or pictorial image; (d) combinations of two or more of any of the features described in paragraphs (a), (b) and (c); or (e) the reciprocal of any of (a) to (d). 5

13. A method as claimed in any one of the preceding claims, in which the image or the reciprocal of the image is a three-dimensional image which is defined by: (a) one or more recesses on a surface of the solid object; and/or 10 (b) one or more bosses or protrusions upstanding from the surface of the solid object; or (c) combinations of (a) and (b).

14. A method as claimed in any one of the preceding claims, in which the solidifiable fluid comprises one or a combination of any two or more of: 15 (a) an oil or fat; (b) a sugar; (c) a fragrance; (d) a flavouring; 20 (e) a plastic; (f) a colouring; (g) a colourant material; (h) chocolate in liquid or powdered form; (i) a fluid comprising water or an organic solvent; and 25 (j) a basic compound selected from the group consisting of sodium hydroxide, potassium hydroxide and lithium hydroxide.

15. A method as claimed in claim 14, in which the solidifiable fluid comprises: (a) one or more liquids; 24 (b) one or more powdered flowable materials; or (c) combinations of two or more of the fluids listed in (a) and (b).

16. A method as claimed in either of claims 14 or 15, in which, the method additionally comprises the step of: 5 (a) heating the solidifiable fluid; or (b) cooling the solidifiable fluid so as to solidify the solidifiable fluid.

17. A method as claimed in any one of claims 14 to 16, in which the solidifiable fluid is used to make a solid object which is a: 10 (a) soap; or (b) a foodstuff.

18. A solid object made in accordance with a method as claimed in any one of claims 1 to 17. 15

19. A solid object as claimed in claim 18, in which the object is a soap.

20. A soap as claimed in claim 19, made in accordance with a cold process.

21. A soap as claimed in claim 19, made in accordance with a hot process.

22. An apparatus for making a solid object from a solidifiable fluid 20 according to a method as claimed in any one of claims 1 to 17, comprising: (a) means for creating an image that is to appear on a surface of the solid object; (b) means for rendering the image or a reciprocal of the image in 25 three-dimensional form on a generally two-dimensional object; and (c) an enclosure to co-operate with the two-dimensional object so as in use to define a mould for receiving a solidifiable fluid to be solidified, and so as thereby to form the solid object. 25

23. An apparatus as claimed in claim 20, in which the apparatus additionally comprises one or more means for solidifying the solidifiable fluid. 5

24. A method as claimed in any one of claims 1 to 17, substantially as described in this specification, and with reference to the examples of the invention given and the accompanying drawings.

25. A solid object as claimed in claim 18, substantially as as described in this specification, and with reference to the examples of the invention 10 given and the accompanying drawings.

26. An apparatus as claimed in either of claims 19 or 20 for making a solid object from a solidifiable fluid, the apparatus being substantially as described in this specification, and with reference to the examples of the invention given and the accompanying drawings. 15 Dated: 23 April 2012 JAIME GUARRO-CONTRERAS By his Patent Attorneys KNIGHTSBRIDGE PATENT ATTORNEYS 20