WO2002070223A1

WO2002070223A1 - Decorative ornaments

Info

Publication number: WO2002070223A1
Application number: PCT/SG2001/000028
Authority: WO
Inventors: Richard Siong Sen Kwok; Kai Huan Quek; Tian Boon Tay
Original assignee: Globevision Pte Ltd
Priority date: 2001-03-07
Filing date: 2001-03-07
Publication date: 2002-09-12

Abstract

A cold-casted ornament (11, 12, 13) comprising at least a cured mixture of particulate filler, and a resin moulded to a desired shape, which includes decorative features and a recess of hole for receiving a portion of a structure that the ornament is to be affixed to.

Description

DECORATIVE ORNAMENTS

Field of the Invention

The present invention relates to a method for producing cold-casted ornaments suitable for affixing to structures such as, but not limited to wrought iron gates, grilles and railings.

Background of the Invention

Traditionally gates, grilles and railings are made from metal alloys such as wrought iron, aluminium and mild steel. Decorative ornaments attached to such structures are generally made of metal and are affixed to the structure by welding. Such ornaments, due to the method of manufacture, produce only limited designs.

It is an object of the present invention to provide a decorative ornament that provides greater versatility in the design of the ornament.

Summary of the Invention

Accordingly the present invention provides a method of producing a cast ornament including the steps of: providing a mould for casting the ornament, the mould provided with a first surface shaped to provide decorative features to the cast ornament, the mould further provided with a second surface shaped to provide a recess for receiving a portion of a structure that the ornament is to be affixed to; producing a liquid mix comprising at least a plastics resin; pouring said liquid mix into the mould; allowing the liquid mix to cure to produce the cast ornament; and removing the cast ornament from the mould.

Compared to existing metal designs available on the market the cast resin ornament can be more intricate, detailed, larger and more colourful. The present method increases flexibility of the design pattern and a variety of subject matter. Preferably the liquid mix includes a particulate filler. Preferably the filler includes metallic particles. Preferably the metallic particles are metal filings or metal powder.

Preferably the filler includes, one or more of pecan flour, calcium carbonate, plaster of paris, baking soda, wood dust, stone dust, silica powder, china clay, talcum powder, microspheres and/or appropriate dyes.

Preferably the filler is selected to produce a desired appearance of the cast ornament.

Preferably the ratio of resin to filler particles in the liquid mix is a ratio of between 2:1 and 20:1, more preferably, of a ratio of between 4:1 and 10:1, more preferably still of a ratio of about 5:1.

Preferably the resin is a polyester resin. Alternatively, the resin is one of an epoxy resin, polyurethane resin, acrylic resin, or copolymers thereof.

Preferably the liquid mix includes a catalyst and an accelerator. Preferably the resin is cured by a catalytic reaction. Preferably the catalyst is MEK peroxide (methyl-ethyl- ketone peroxide). Preferably the liquid mix includes between 0.5% to 2% catalyst by weight. Preferably the liquid mix includes between 0.4% to 1 % accelerator by weight. More preferably the liquid mix includes about 1% catalyst by weight. More preferably the liquid mix includes about 0.5% accelerator by weight. Preferably the catalytic reaction occurs at room temperature.

Preferably the mixing of the filler into the resin is performed under vacuum.

Preferably the size of the filler particles ranges from 80 to 400 mesh and more preferably between 100 and 300 mesh.

The invention also provides a cold-casted ornament comprising at least a cured mixture including a plastics resin moulded to a desired shape, which includes decorative features and a recess for receiving a portion of a structure that the ornament is to be affixed to. Preferably the ornament includes a filler dispersed amongst the cured resin.

Preferably the filler comprises between 60%) and 95%) (by weight) of the ornament. More preferably the filler comprises between 75% and 90%) (by weight) of the ornament. More preferably still the filler comprises between about 83% (by weight) of the ornament.

Preferably the ornament includes a fixing means for fixing the ornament to the structure.

Preferably the ornament is cast in two halves, each ornament half having in interior face and an exterior face. Preferably at least one of the interior faces having a recess for receiving a part of the structure the ornament is to be fixed to. Preferably the halves are fixed together by the fixing means so as to encapsulating the part of the structure thereby fixing the ornament to the structure.

Preferably the fixing means is in the form of at least one pin projecting rearwardly from the interior face of one ornament half and corresponding sockets for receiving the at least one pin in the interior face of the other ornament half.

The invention also provides a structure having an ornament as defined above fixed thereto.

Detailed Description of the Preferred Embodiments In order to provide a better understanding a preferred embodiment of the present invention will now be described in detail, by way of example only, with reference to the accompanying figures, in which:

Figure 1 is a front view of a wrought iron gate having a preferred form of ornament according to the present invention attached thereto; Figure 2 is a representation showing two portions of the ornament separated from a part of the wrought iron gate of Figure 1 ; Figure 3 shows a side view of the parts of the ornament of Figure 2 positioned so as to be ready to be fixed to the part of the wrought iron gate of Figure 2; Figure 4 shows the parts of the ornament so as to form the complete ornament fixed to the part of the wrought iron gate of Figure 2;

Figure 5 is a front view of the ornament of Figure 4 fixed to the wrought iron gate;

Figure 6 is a front view of a representation of a flower shaped ornament fixed to a curved part of a wrought iron gate;

Figure 7 is a rear view of a first part of a flower ornament;

Figure 8 is a second part of the flower ornament;

Figure 9 is a ornament including the words HOME SWEET HOME fixed to a structure;

Figure 10 is a flower and stem ornament ready to be fixed to a structure;

Figure 11 is a ornament with the words BEWARE OF DOGS fixed to a structure;

Figure 12 shows two ornaments, one with the words THE LIM'S and the second with a decorative grape or berry shaped ornament;

Figure 13 shows another flower ornament with an alternative attachment to a wrought iron structure;

Figure 14 shows the ornament of Figure 13 attached to the wrought iron structure;

Figure 15 shows a cross-sectional view of the ornament of Figure 16 attached to the structure;

Figure 16 shows a side view of the ornament of Figure 13 attached to the structure;

Figure 17 shows the pouring of a liquid mix into a mould for forming the flower ornament of Figure 13 ;

Figure 18 shows yet another ornament fixed to a structure;

Figure 19 shows a further ornament fixed to a structure;

Figure 20 shows an ornament being cast with a part of a structure being cast into the mould of the ornament; and Figure 21 shows the cast ornament of Figure 20 and the part of the structure secured to the whole structure.

In the preferred form of the invention the ornaments are cold cast from a liquid mixture. The liquid mixture includes a resin and a filler. The preferred form of resin is polyester resin, however epoxy, polyurethane, or acrylic resins or their copolymers may be used. The filler used depends on the visual finish desired. Where a metallic finish is desired metal particles are used as the filler. Preferably the metal particles are of between 100 and 300 mesh. Preferably the ratio of metal particles to resin ranges from 5:1 to 5.4. Other fillers may be added to produce different effects. Other fillers used include one or more of pecan flour, calcium carbonate, plaster of paris, baking soda, wood dust, stone dust, silica powder, china clay, talcum powder, microspheres and/or appropriate dyes. The liquid mixture is generally prepared in a vacuum or low pressure conditions to reduce or eliminate air bubbles in the mixture.

The shape and features of the ornament to be cast are designed and a mould constructed. The mould is a negative of the ornament to be cast. The mould is prepared before the preparation of the liquid mixture and may be reused.

Moulds can be constructed of silicone rubber; either hot or cold pour compounds. Before making the mould an original or model ornament is produced. Silicon rubber is a suitable mould medium due to its resistance to high temperature (to 500°C), and nonstick properties which allows the castings to be made without requiring a release agent.

In the preferred form, the ornament is cast in two halves, each half of having the external design features of the ornament on an external surface of each half. An internal surface of each half is used to fix the halves together and to fix the ornament to the structure. A separate mould may be required to cast each half.

Once prepared, the liquid mix is poured into the mould. The pouring process may be conducted in one or more stages. It is desirable to have the pouring conducted in at least two stages, i.e. at least two layers. Where more than one pouring stage is used, separate liquid mixtures may be used with different fillers. The first stage produces the surface effect. Fine particles or colours may be used in the first layer so that the first liquid mix penetrates into the crevasses of all of the features of the mould so as to produce fine detail. In addition the first pour may also incorporate appropriate fillers and/or dyes so as to colour the surface and produce various effects such as milky, opal, stone, metal, wood, marble, coloured glass, and jade effects. Fillers are not used for ornaments that are clear or transparent. Fillers are used where an opaque finish is desired. Fillers are generally less expensive than resin and reduce the amount of resin required to cast a ornament. Therefore the use of fillers is generally desirable.

When curing, the resin will usually react exothermically. The filler mixed with resin assists in absorbing the heat and this reduces density of heat producing resin. Selecting a certain type of filler can make the resin look like something else, for example stone, bronze, wood or whatever. Stone powder cast ornaments can either be polished to resemble smooth stones like marble, or sandblasted to produce a rough finish, like sandstone. Metal power cast ornaments can be buffed and polished to look like real metal. In addition, most cast ornaments can be painted.

A second layer may incorporate microspheres of fumed silica sold under the brand name Aerosol Powder 200. This is a very light weight powder that acts as a thixotropic agent. A mixture of resin and fumed silica microspheres forms a paste when resin is added into it. The paste becomes liquified when it is stirred. Aerosol Powder 200 is formed of fumed silica, generally from volcanic ash. Another brand of microspheres is Fillit. The second layer is also moulded so as to have a recess within which will be received a part of the structure that the ornament is to be affixed to. Additionally this layer may also include pins cast into an interior surface in one half of the ornament and sockets arranged so as to receive the pins on another half of the ornament, so that together the pins will align with the sockets so that the halves of the ornament may be joined together to form the complete ornament.

The thixotropic nature of the mixture makes it less inclined to spill but relatively easy to brush on or spread onto the underside of the mould. It is therefore more manageable to control compared to a watery resin. An Aerosol Powder 200 resin mix makes applying this resin mix in a vertical position or upright it is less likely to drip. In addition patchwork can also be done with it. The poured liquid mix within each mould is allowed to cure. If the pouring is conducted in stages, each stage is allowed to cure. A catalyst is normally added to the polymer resin to cause it to cure by catalytic reaction. The catalyst is normally added to the resin so that the liquid mix includes between 0.5% and 2%> catalyst by weight. An accelerator will also be added to the liquid mix, so that the liquid mix includes between 0.4%) and 1%> accelerator by weight. The liquid mix normally includes 1% catalyst by weight and 0.5% accelerator by weight. Quantities of catalyst and accelerator may be adjusted for shorter or longer gel times by increasing the content of catalyst, accelerators or both in the liquid mix. The polymer resins react with monomers to produce a cast ornament or ornament part. Once the ornament, or ornament part has been cast, it may be removed from the mould.

The cast ornaments are easily removed by simply flexing the rubber moulds. Due to there being little or no exothermic heat produced in the production of the cast products there is little or no degradation of the mould. After airing and hardening, metal content of the ornament can be surface treated, finished and coloured. The cast ornaments are incorporated with existing wrought iron structures. The cast ornament could be glued or capped onto the wrought iron structure. The cast ornament would firmly adhere to a bar or portion of the wrought iron structure by a small protruding piece welded to the bar. The ornament may be cemented in place by inserting a resin mix in gaps between a recess that receives the bar. The pins and grooves hold the two pieces together while the cementing resin cures.

Figure 1 depicts a first embodiment of the present invention. A wrought iron structure 10, in the form of a wrought iron gate that includes a plurality of ornaments 11 and 12 that are in the form of stars and ornament 13 is the in form of a cat.

Referring to Figure 2, star ornament 11 is shown in two parts 14 and 16. A bar or part 18 of the wrought iron structure 10 is also shown. The first part 14 of the ornament 11 is a front half that has an interior surface 20 shown and an exterior surface 22 (not shown in this figure). It can be seen that the interior surface 20 includes a recess 24 of a shape so as to receive the bar 18. In particular, the bar 18 includes protrusions 26. The recess includes a receiving portion 28 shaped so as to receive the protrusions 26.

Also in the interior surface 20 is a plurality of sockets 30. The sockets will be explained in more detail below.

The second part 16 of the omament is a rear half that has an interior surface 32 shown and a exterior surface 34 (not shown in this figure). Like the first half 14 the second half 16 also includes a recess 24 the receiving portion 28 shaped to receive the protmsions of the part 18 of the structure. In addition, the interior surface 32 has a plurality of pins 36 rearwardly projecting from the rear half. The pins are arranged to align with the sockets 30 and the sockets are shaped so as to receive the pins 36.

As seen in Figure 3 when the front half 14 and rear half 16 are positioned on either side of the bar 18 of the structure 10 and aligned so that the pins 36 align with the sockets 30, the halves may be fixed together to form the complete ornament. In addition the bar 18 recesses within the recess 24 of each of the halves so that the complete ornament 11 is formed as shown in Figure 4. The pins and sockets may be arranged so as to provide an interference fit so that each of the halves may not he separated or at least easily separated or they may be glued together by an adhesive or resin.

As shown in Figures 4 and 5 the ornament is then firmly fixed to the part 18 of the structure 10.

Figure 6 shows another embodiment of the present invention. This time the ornament is in the form of a flower 40. Surface detail is also cast into the external surface of the ornament. Colouring may be provided including dyes and/or fillers in the resin mix. Alternatively the cast omament may be painted.

Figures 7 and 8 each depict the front portion 42 and back portion 44 of the flower 40. Recesses 46 are provided in the interior surfaces so as to receive a bar 41 or part of the structure to which the ornament is to be affixed. In this case the front portion 42 will be glued to the rear portion 44 as there are no pins and sockets present. Figure 9 shows flower omament 40 attached to the bar 41. Other ornaments 54 in the form of leaves are fixed to the bar 41. In this instance the leaf ornaments 54 are welded pieces of iron. The bar forms the stem and leaves of the flower and may be painted accordingly. In this way the flower and stem arrangement, collectively indicated as 58, can be precontracted and then affixed at a later point to the remainder of the structure 10.

Figure 10 shows a further alternative of an ornament 48 in the form of a casting shaped like a wooden plank with the words HOME SWEET HOME superimposed on top. In this version the ornament 48 is fixed to three bars 50 which form part of the structure that the omament is affixed to. This is achieved by having three recesses correspondingly positioned in the interior surface of the omament. The casting looks like a wooden plank because of the type of filler used, in this case wood dust, along with a dye that colours the resin appropriately. The wood grain effect is achieved by surface texture and shape of the cast.

Referring to Figure 11. In this instance the ornament 60 is in the form of a sign with the words BEWARE OF DOGS. The words may be formed by shaping the mould suitably to either provide raised or depressed shapes forming the letters of the words. In addition a dye or other colouring agent may be used to colour the letters so as to provide a greater contrast with the background of the omament 60. In this instance the ornament 60 will be moulded with at least a first link of a short chain 62 projecting from the cast omament so that by means of the chain it can be affixed to the rest of the structure 10'.

In Figure 12 another sign 60 is provided that is fixed to the rest of the structure 10'again by a short chain or other simple means such as a spring. In addition, a further ornament 64 in the form of a decorative arrangement of berries or grapes is shown. In this instance it is affixed to a curved part of the structure so that the curved part 18 'has the appearance of a vine.

Figure 13 shows another decorative motif 70 which is cast in the shape of a flower and backing. The backing portion includes a slot 78 and recess 72 for receiving a part of a structure 74. The part of the structure 74 is a bar of wrought iron with a protrusion 76 for keying the bar 76 into the omament 70. As seen in Figure 14 the bar 74 is inserted through the slot 78 so that the decorative flower part of the omament 70 faces in a particular direction so that it can be orientated for display. As seen in Figure 15 the bar 74 passes through the slot 78 and is keyed with the protrusion 76 situated within the recess 72.

A resin mix is inserted into the slot 78 prior to insertion of the bar. Alternatively the resin mix is added after insertion of the bar to cement the bar in place within the ornament.

As seen in Figure 17 the pouring of the mould includes pouring a prepared liquid mix 81 into a mould 80 so that the liquid mix becomes, once set, the decorative ornament 70, whereupon it is removed from the mould 80.

Figures 18 and 19 show alternative forms of fixing a decorative omament 82 and 86 respectively to a structure 84 and 88 respectively. In the case of Figure 18 the bar 84 is moulded into the omament 82 and an interference fit is relied upon to hold the ornament in place. Where the omament is lightweight this is sufficient. In the case of Figure 19 again, the bar 88 is moulded into the omament 86, here there is both an interference fit and, due to curving of the bar, the ornament 86 is mechanically coupled to the bar 88.

Figure 20 shows the process of moulding a bar 90 into an omament. A mould 80 includes a void 92 into which the liquid mix is poured for curing. On each side of the mould, the bar 90 projects through a respective wall of the mould and rests on stands 94.

In this case a first layer 91 of the ornament has been poured and a second layer is poured on top into the void 92. Once cured, the silicon mould may be removed from the cast omament and slots above each of the bars can be expanded to remove the bar from the mould.

As seen in Figure 21 the moulded omament 96 is attached to the bar 90 and may be welded to the remaining part of the structure 98. Other moulded ornaments already fixed to respective bars, indicated as 104, have already been welded in place. Other decorative parts of the structure, indicated by 102, can also be welded in place.

The embodiments and examples of the present invention have hereinbefore been described in detail, it will apparent to those skilled in the art that various modifications and variations may be undertaken without departing from the basic inventive concept. One such modification may include casting the ornament in many parts. The cast parts are then assembled and fixed to the structure.

All such modifications and variations, together with other modifications and variations that would be obvious to a person skilled in the art, are deemed to be within the scope of the present invention, the nature of which is determined from the above description.

Claims

1. A method of producing a omament including the steps of: providing a mould for casting the omament, the mould provided with a first surface shaped to provide decorative features to the cast omament, the mould further provided with a second surface shaped to provide a recess for receiving a portion of a structure that the ornament is to be affixed to; producing a liquid mix comprising at least a plastics resin; pouring said liquid mix into the mould; allowing the liquid mix to cure to produce the cast omament; and removing the cast omament from the mould.

2. A method according to claim 1, wherein the liquid mixture includes a filler.

3. A method according to claim 2, wherein the filler includes metallic particles.

4. A method according to claim 3, wherein the metallic particles are metal filings or metal powder.

5. A method according to claim 2, wherein the ratio of resin to filler in the liquid mix is a ratio of between 2:1 and 20:1.

6. A method according to claim 2, wherein the ratio of resin to filler in the liquid mix is of a ratio of between 4:1 and 10:1.

7. A method according to claim 2, wherein the ratio of resin to filler in the liquid mix is of a ratio of about 5:1.

8. A method according to claim 2, wherein the filler includes, one or more of pecan flour, calcium carbonate, plaster of paris, baking soda, wood dust, stone dust, silica powder, china clay, talcum powder, microspheres and/or appropriate dyes.

9. A method according to claim 2, wherein the filler is selected to produce a desired appearance of the cast omament.

10. A method according to claim 1 , wherein the resin is a polyester resin.

11. A method according to claim 1, wherein the resin is one of an epoxy resin, polyurethane resin or acrylic resin, or copolymers thereof.

12. A method according to claim 1, wherein the liquid mix includes a catalyst.

13. A method according to claim 1, wherein the resin is cured by a catalytic reaction.

14. A method according to claim 12, wherein the catalyst is MEK peroxide (methyl- ethyl-ketone peroxide).

15. A method according to claim 2, wherein the mixing of the filler into the resin is performed under vacuum.

16. A method according to claim 2, wherein the size of the filler particles ranges from 80 to 400 mesh and more preferably between 100 and 300 mesh.

17. A cold-casted omament comprising at least a cured mixture of particulate filler, and a plastics resin moulded to a desired shape, which includes decorative features and a recess for receiving a portion of a structure that the omament is to be affixed to.

18. An omament according to claim 17, wherein a filler is dispersed amongst the cured resin.

19. An omament according to claim 18, wherein the filler comprises between 60% and 95% (by weight) of the ornament.

20. An omament according to claim 18, wherein the filler comprises between 75% and 90% (by weight) of the omament.

21. An omament according to claim 18, wherein the filler comprises between about 83% (by weight) of the omament

22. An omament according to claim 17, wherein the omament includes a fixing means for fixing the ornament to a stracture.

23. An omament according to claim 22, wherein the omament is cast in two halves, each omament half having in interior face and an exterior face.

24. An omament according to claim 22, wherein at least one of the interior faces having a recess for receiving a part of the stracture the omament is to be fixed to.

25. An ornament according to claim 23, wherein the halves are fixed together by the fixing means so as to encapsulating the part of the stracture thereby fixing the omament to the structure.

26. An omament according to claim 23, wherein the fixing means is in the form of at least one pin projecting rearwardly from the interior face of one omament half and corresponding sockets for receiving the at least one pin in the interior face of the other omament half.

27. A structure having a omament according to claim 17 fixed thereto.

28. An omament according to claim 22, wherein the omament includes a cavity for receiving part of a structure the omament is to be fixed to.

29. An omament according to claim 22, wherein the omament includes a fixture cast into the body of the ornament for fixing the omament to a stracture.

30. A method according to claim 1, wherein a coupling means is moulded into the omament for fixing the omament to a structure.

31. An omament according to claim 17, wherein the omament includes a rod embedded in the omament for fixing the omament to a stracture.