IL181029A - Decorated articles - Google Patents

Description

DECORATED ARTICLES 131-lAP.DOC 28.1.2007 DECORATED ARTICLES FIELD OF THE INVENTION The present invention relates to decorated articles, in general and, in particular, to aesthetically pleasing articles for use in bathrooms and humid locations.

BACKGROUND OF THE INVENTION Bathroom fittings and useful articles for humid locations require certain characteristics, such as water resistance, heat resistance, resistance to cleaning materials, and effective sealing. Providing an aesthetic product having these characteristics, which also fulfils its plumbing or other function, has been problematic in the past.

There are known products, such as the handles or holders of toilet bowl brushes, which are formed of plastic with flowers or decorative objects inside the plastic. These products need not fulfill the same standards required of shower wall fixtures, etc., which are constantly exposed to hot water and steam, and are mounted in a wall or floor.

In addition, plastic is problematic as it is brittle and the articles can break, and during the heat forming process, objects inside can be damaged.

Accordingly, there is a long felt need for a method of forming decorated articles that can withstand the conditions of bathrooms, saunas, etc., and it would be very desirable to have useful articles having a wide range of decorative finishes.

SUMMARY OF THE INVENTION The present invention relates to decorated articles and appliances, particularly for use in bathrooms, saunas, pools, and other humid locations. These functional articles are given a special, aesthetic finish, which is heat and chemical resistant and waterproof, and which can be chosen to match the decor in the room where they will be used. In particular, a selected object or objects, whether stones, shells, feathers, l toys, or whatever suitable object, is embedded in the article, and the surface of the article (at least) is formed of a transparent material to permit viewing of the objects inserted in the transparent material during molding.

There is provided according to the present invention a method for forming a decorated article, the method including providing a mold in a form of the desired article, mixing a curable material with a hardening agent to provide a transparent material, pouring the transparent material into the mold, placing at least one object in the transparent material, and curing the curable material to hold the object, in order to provide at least a surface through which objects held inside the curable material can be viewed.

The mold can be formed by shaping the mold to the desired shape, such as that of a sink, a shower pan or a toilet tank, or the mold can be a pre-formed article having hollow areas serving as the mold, such as the cover of a clean-out, or the mold can be a frame which will become an integral part of the article.

Thus, there is also provided according to the invention, an article with a metal or wood frame, and epoxy, or another transparent polymerizable filling, holding at least one, and preferably a plurality of selected objects arranged in the frame.

According to one embodiment of the invention, the surface of the article is smooth, with the objects completely covered by the filling material. According to another embodiment, for example, for use as a reflexology surface, portions of the objects can protrude from the article, so as to provide a textured surface.

BRIEF DESCRIPTION OF THE DRAWINGS The present invention will be further understood and appreciated from the following detailed description taken in conjunction with the drawings in which: Figures la to lc are schematic illustrations of a method of forming a decorated article according to one embodiment of the present invention; Figures 2a to 2c are schematic illustrations of a method of forming a decorated article according to an alternative embodiment of the invention; Figures 3a and 3b are respective schematic illustrations of a toilet tank and toilet tank cover, constructed and operative in accordance with one embodiment of the present invention; Figure 4 is a schematic illustration of a sink, constructed and operative in accordance with one embodiment of the present invention; Figures 5a and 5b are respective plan and side views of a shower pan constructed and operative in accordance with one embodiment of the invention; Figures 6a, 6c, and 6b and 6d are respective plan and sectional illustrations of a clean-out cover constructed and operative in accordance with one embodiment of the present invention; Figures 7a, 7c, 7e and 7b, 7d are respective plan and sectional illustrations of a clean-out cover constructed and operative in accordance with an alternative embodiment of the present invention; Figures 8a and 8b are schematic illustrations of a surface prepared according to another embodiment of the invention; Figures 9a and 9b are schematic plan view and side sectional illustrations of a frame for forming an angled base in an article; and Figures 9c, 9d and 9e are schematic illustrations of a method for forming an angled base, according to one embodiment of the invention.

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to decorated articles and appliances, particularly for use in bathrooms, saunas, pools, and other humid locations. These functional articles are given a special, aesthetic finish, which is heat resistant, chemical resistant, resistant to plaque and waterproof, and which can be chosen to match the decor in the room where it will be used. According to the invention, these articles are formed partially or substantially entirely of transparent material, permitting viewing of objects molded inside the transparent material. In particular, a selected object or objects, whether stones, shells, feathers, toys, or other decorative objects, is embedded in the article, and at least the surface of the article is formed of a transparent material to permit viewing of the objects put in the transparent material during molding. Thus, the articles may include objects or colors chosen to match the decor in the room where they will be used.

The articles according to the invention include at least one solid object embedded in a transparent layer formed of epoxy, polyester or other polymerizable material. The article can be formed by shaping a mold to the desired shape, such as a sink, shower pan or toilet tank, or by using a pre-formed article having hollow areas which can be filled as a mold, such as the cover of a plumbing drainer or clean-out. (Clean-outs are plumbing fittings that provide access to drains without having to remove the plumbing fixtures.) Alternatively, a frame, which will become an integral part of the article, can be utilized as a mold for filling with objects in a transparent material.

Referring now to Figures la to lc, there are shown schematic illustrations of a method of forming a decorated article according to one embodiment of the present invention. The method includes providing a mold 10 in the form of a desired article, as shown in Figure la. A curable or polymerizable material, most preferably an epoxy material, is mixed with a hardening or other curing agent to provide a transparent material 12, which is poured into the mold at a controlled temperature and low humidity, as shown in Figure lb. At least one selected object 14, and preferably a plurality of objects, is placed in the transparent material, as shown in Figure lc. It will be appreciated that any object resistant to the filling material and able to withstand the curing process can be utilized, including, but not limited to, stones or pebbles, shells, feathers, small toys, shaped elements, such as plastic stars, or any other object selected by a builder or user of the decorated article. The transparent material will cover and surround the objects. Finally, the curable material is cured, so as to embed the objects. If the mold is not part of the finished product, it is now removed. In this way, a decorated surface is provided through which one can view objects held inside the curable material. This method provides a product having a substantially matte finish. If desired, the bottom surface of the decorated object can be polished.

If a flat, glassy surface is desired, an initial layer of transparent material, without embedded objects, can be provided in the mold. This layer is permitted to dry partially, and then the transparent material with embedded objects is added on top of it. Such a layer can also be used to adjust the depth of the embedded objects in the article.

It will be appreciated that, alternatively, the object or objects can be mixed with certain types of curable or polymerizable material, as shown in Figure 2a, and the mold filled with the mixture, as shown in Figure 2b.

There are essentially three ways of forming the mold for the decorated article, depending on the desired finished article. According to one embodiment of the invention, the mold is shaped to the shape of the desired article, for example a toilet tank, or several molds are provided for different parts of the article which will later be affixed to one another. One example is shown in Figures 3a, 3b and 3c for a toilet tank and cover. Here, molds are provided in the shape of the walls of tank 20 itself, and a complementary tank cover 22. Each wall and the bottom is molded separately and, while partially cured, the parts are affixed to one another at the corners by means of the epoxy or other material, or by means of an external frame holding them together. Alternatively, two halves of a tank can be molded as units and coupled to one another. Or, as shown in Figure la, a mold can be provided inside a mold, and the transparent material with objects cast between the two molds to provide a hollow tank.

Thus, instead of a conventional vitreous china or plastic toilet tank, a substantially transparent tank can be provided through which objects 24 in the filling material 26 can be viewed. If preferred, an opaque liner 28 or pigmented material can be provided in the mold, so the flushing mechanism is not visible.

In a similar fashion, using any of the methods for forming a toilet tank, a shower pan of selected shape and dimensions can be prepared, for installation in a bathroom or other shower stall.

According to another embodiment of the invention, illustrated in Figure 4, the mold is a metal or wood frame 30, which remains as an integral part of the finished article. In this case, the transparent filling material 32 with the selected objects 34 inside is poured into the frame and cured in situ. In this way, the filling material 32 adheres to the frame 30, resulting in a framed article.

Alternatively, one or more frame elements can be placed in a removable mold. The transparent filling material will adhere to the frame but the mold can be removed after curing or hardening the filling material. One example is shown in Figures 5a and 5b, for a shower pan 40 having a metal pan frame 42 and a decorative metal frame 44. The shower pan is formed as described below with reference to Figure 9a. A transparent filling material 46 with one or more objects 48 therein, is molded and affixed to base 42. The decorative frame 44 is affixed to the filling material 46. As the filling material cures, it adheres to the decorative frame 44, so that, when the removable mold is removed, a framed shower pan 40 remains. A drainage hole 49, as known, may be provided in pan frame 42.

According to another embodiment of the invention, illustrated in Figures 6a, 6b, 6c and 6d, there is shown a cover 50 for a drainer or clean-out 52 adapted for installation in a plumbing system. For example, the clean-out can be installed in a bathroom floor to permit inspection and cleaning of drainage pipes from a shower or bath tub. In the embodiment of Figure 6a, the clean-out cover 50 includes two parts: a sealing sleeve 54, illustrated in Figure 6b, and a cover element 60, illustrated in Figures 6c and 6d. A fixed frame 52 is provided about an aperture (not shown) in the floor defining the clean-out. Sealing sleeve 54 includes one or more external sealing rings 56 for sealing sleeve 54 in fixed frame 52 and in the aperture. Release grooves 58 may be provide for ease of removal of sleeve 54, in case of need.

Cover element 60 includes an external sealing ring 62 and is preferably arranged for snap-fitting into sleeve 54. Cover element 60 further includes a decorative frame 64, preferably of metal, and a depression forming a cup area 66. If the cover element will be used in a shower or other area where drainage is desired, the bottom surface of cup area 66 can have grooves. In this case, the transparent material will be provided with drainage holes or inserts, as well. Cup area 66 serves as a mold for the transparent material with selected objects 68 of the present invention, to provide a decorated clean-out cover. It will be appreciated that the epoxy and similar materials of the present invention are water proof and heat and chemical resistant, so are perfectly suited to use in plumbing applications.

This embodiment of the invention is also suitable for use with sunken lighting fixtures. A housing for a light bulb can be provided in a bottom of, or behind the sealing sleeve, with the required electrical connections, as known. In this way, the cover element 60 is provided with back-lighting, for providing gentle light in a desired are a, and for accenting the objects embedded in the transparent material.

According to a preferred embodiment of the invention, illustrated in Figure 7a, there is provided a three part cover 70 for a drainer or clean-out. Cover 70 includes an external sealing sleeve 74, illustrated in Figure 7b, a cover element 80, illustrated in Figures 7c and 7d, and a base 82, shown in Figure 7e. A fixed frame 72 is seated on the tile or mounted in an indentation around the clean-out aperture (not shown). Sealing sleeve 74 includes one or more external sealing rings 76 for sealing sleeve 74 in fixed frame 72. Release grooves 78 may be provide for ease of removal of sleeve 74, in case of need.

Cover element 80 is, itself, formed of two parts - threaded base 82 and a closure portion 84 having complementary screw threads. Threaded base 82 seats in closure portion 84 and can be screwed into and out of closure portion 84. In this way, the height of a hollow, cup-like area 86 defined by closure portion 84 can be fixed. Closure portion 84 preferably includes an external sealing ring 88 and is preferably arranged for snap-fitting into sleeve 74.

Cup-like portion 86 serves as a mold for the transparent material with selected objects of the present invention, to provide a decorated clean-out cover. Closure portion 84 further includes a canted flange 87 for seating on sleeve 74. A circular indentation 89 may be provided in frame 72, so the closure portion will seat flush with the floor. Canted flange 87 is preferably formed of metal, and may also serve as a decorative frame for the cover 70. It will be appreciated that this embodiment provide additional flexibility in interior design of bathrooms, etc., as the objects that can be embedded in the cover are less limited in size.

As in the case of the two part cover, if the cover element will be used in a shower or other area where drainage is desired, the bottom surface of closure portion 84 can have grooves 85 or define a screen.

It will be appreciated that, in the embodiments described above, the surface of the article is substantially smooth, with the objects completely covered by the filling material. According to another embodiment of the invention, illustrated in Figures 8a and 8b, portions of the objects 92 can protrude from the surface 94 of the object 90, so as to provide a textured surface. One example of such an article is for use as a reflexology surface, i.e., a shower pan or floor surface. In this case, the surface may be designed in advance with the desired protrusions in the desired locations. The article 90 is formed by providing a bottom layer of transparent or other material 91, with or without embedded objects 95, and a top layer is provided having depressions 96 where the protruding objects belong, as shown in Figure 8a. The protruding objects 92, which can be, for example, stones selected for mystical or medicinal properties, are then placed in the prepared depressions 96, and a layer of sealing material is provided around, and possibly over, the protruding objects, to firmly entrench them in position, while permitting them to protrude, as desired (Figure 8b).

According to one embodiment of the invention, illustrated schematically in Figures 9a to 9e, there is provided a novel method for forming a bottom for an article having slanted sides. This method is particularly useful for shower pans, sinks and toilet tanks, and will now be described with reference to a shower pan. Transparent material 100 for forming a shower pan, for example of 80cm by 80cm by 2cm, is cast in a mold 102 ( Figure 9c) with selected embedded objects 101 and partially cured. At the same time, a pan frame 104 (Figures 9aand 9b), preferably of metal, is formed of smaller dimensions than pan 100, of a selected height, for example 2cm. Pan frame 104 will serve as an integral base for the finished article. Two lower ribs 106 are provided across frame 104, so as to define the desired slant for the finished product. For example, ribs 106 can be 1 cm high and about 20 cm apart from one another. The force of gravity will pull the partially dried material 100 downwards onto ribs 106, as seen in Figure 9d. The contacting corners 108 of the frame 104 and ribs 106 are preferably affixed to the transparent material 100, preferably by an epoxy material, as seen in Figure 9e, to permanently affix the frame to the finished shower pan.

It is a particular feature of preferred embodiments of the invention that the filling material dries or hardens relatively rapidly. This permits a worker to mold or shape the material during curing. Thus, the articles of the invention can be made anywhere, and it is not necessary to rely on machinery (like an extruder) to make the articles. Preferably, the finished product is polished to provide a smooth bottom surface.

It is another feature of the invention that the use of epoxy or polyester and similar polymerizable materials permits the decorated articles of the invention to function in locations and in ways where plastic would not function properly. Thus, these articles can be heat resistant, as well as moisture-proof, for use in bathrooms and shower stalls, as sinks or toilet tanks, in saunas or pool areas, etc. Furthermore, they are not brittle and are resistant to most chemicals.

While the invention has been described with respect to a limited number of embodiments, it will be appreciated that many variations, modifications and other applications of the invention may be made. It will further be appreciated that the invention is not limited to what has been described hereinabove merely by way of example. Rather, the invention is limited solely by the claims which follow.

Claims (30)

1. A method for forming a decorated article, the method comprising: providing a mold in a form of a desired article; mixing a curable material with a hardening agent to provide a transparent material; pouring said transparent material in said mold; placing at least one object in said transparent material; and curing said curable material to embed said object in said material, in order to provide at least a decorated surface through which objects embedded in the curable material can be viewed.

2. The method according to claim 1, further comprising: providing a first layer of material in said mold before the step of mixing.

3. The method according to claim 1 or claim 2, wherein said step of placing includes placing at least one object in said mixed curable material and said step of pouring includes pouring said object together with said material into said mold.

4. The method according to any of the preceding claims, wherein said step of providing includes shaping a mold to a pre-selected shape.

5. The method according to any of claims 1-3, wherein said step of providing includes providing a pre-formed article having a hollow volume, and said step of pouring includes pouring into said hollow volume.

6. The method according to any of claims 1-3, wherein said step of providing includes providing a frame and said step of pouring includes pouring onto said frame, whereby said frame becomes a permanent part of said article.

7. The method according to any of claims 1-4, further comprising: providing an outer frame of a selected height; providing an inner frame disposed inside said outer frame, said inner frame having a lower height than said outer frame; during said step of curing, turning said mold upside down onto said outer frame so that some of said transparent material can contact said inner frame and provide a slanted bottom.

8. A decorated article formed by the method of any of claims 1-7.

9. A sink formed by the method of any of claims 1-7, the sink comprising: a transparent cured material in a form of a sink; and at least one object embedded in said transparent cured material; so as to provide at least a decorated surface of a sink through which objects embedded in the curable material can be viewed.

10. The sink according to claim 9, further comprising a decorative frame integrally formed with said sink.

11. 1 1. A cover for a clean-out formed by the method of any of claims 1-6, the cover comprising: a sealing sleeve; and a cover element constructed and operative for fitting into sleeve; said cover element including a depression forming a cup area, said cup area serving as a mold for said transparent material and said objects, to provide a decorated clean-out cover.

12. The cover according to claim 11, further comprising a decorative frame integrally formed with said cover element.

13. A cover for a clean-out formed by the method of any of claims 1-6, the cover comprising: a sealing sleeve; and a cover element constructed and operative for fitting into sleeve; said cover element including: a threaded closure portion; and a complementary threaded base for seating in said closure portion and forming a cup-shaped area; said cup-shaped area serving as a mold for said transparent material and said objects, to provide a decorated clean-out cover.

14. The cover according to claim 13, further comprising a canted frame integrally formed with said cover element.

15. A shower pan formed by the method of any of claims 1-7, the shower pan comprising: a transparent cured material in a form of a shower pan; and at least one object embedded in said transparent cured material; so as to provide at least a decorated surface of a shower pan through which objects embedded in the curable material can be viewed.

16. The shower pan according to claim 15, further comprising a decorative frame integrally formed with said shower pan.

17. The shower pan according to claim 15 or claim 16, further comprising an external layer of material, and a plurality of objects embedded in, and protruding from, said external layer.

18. A reflexology surface formed by the method of any of claims 1-7, the reflexology surface comprising: a base; a layer of cured material on said base; and at least one object embedded in, and protruding from, said transparent cured material; so as to provide a reflexology surface on which objects embedded in the curable material can be felt.

19. A toilet tank formed by the method of any of claims 1-7, the toilet tank comprising: a transparent cured material in a form of a toilet tank; and at least one object embedded in said transparent cured material; so as to provide at least a decorated surface of a toilet tank through which objects embedded in the curable material can be viewed.

20. The toilet tank according to claim 19, further comprising a internal layer of opaque material, said transparent cured material being affixed to said internal layer.

21. The toilet tank according to claim 19, further comprising a complementary lid formed of a transparent cured material in a form of a toilet tank lid; and at least one object embedded in said transparent cured material.

22. A sink comprising: transparent epoxy molded in a form of a sink; and at least one object embedded in said epoxy; so as to provide at least a decorated surface of a sink through which objects embedded in the epoxy can be viewed.

23. A shower pan comprising: transparent epoxy molded in a form of a shower pan; and at least one object embedded in said epoxy; so as to provide at least a decorated surface of a shower pan through which objects embedded in the epoxy can be viewed.

24. A toilet tank comprising: transparent epoxy molded in a form of a toilet tank; and at least one object embedded in said epoxy; so as to provide at least a decorated surface of a toilet tank through which objects embedded in the epoxy can be viewed.

25. A cover for a clean-out comprising: a sealing sleeve; and a cover element constructed and operative for fitting into sleeve; said cover element including a depression forming a cup area, said cup area serving as a mold for transparent epoxy; and at least one object embedded in said epoxy; so as to provide at least a decorated surface of a clean-out cover through which objects embedded in the epoxy can be viewed.

26. The cover according to claim 25, said cover element further comprising: internal screw threads; a threaded base having complementary screw threads, adapted and configured for rotational mounting in said cover element.

27. A reflexology surface comprising: transparent epoxy molded in a selected shape; at least one depression adapted and configured to receive an object; and at least one object seated in said depression and embedded in said epoxy; so as to provide at least a decorated surface of a clean-out cover through which objects embedded in the epoxy can be viewed.

28. A decorated article comprising: a frame in a shape of an article; and a transparent polymerizable filling in said frame; and a plurality of selected objects arranged in said transparent filling.

29. The article according to claim 28, wherein said frame is selected from metal or wood.

30. The article according to claim 28 or claim 29, wherein said filling is an epoxy material. AGENT FOR APPLICANT