GB2157673A

GB2157673A - Improvements relating to the manufacture of porous articles

Info

Publication number: GB2157673A
Application number: GB08410353A
Authority: GB
Inventors: Ronald Parry
Original assignee: Individual
Current assignee: Individual
Priority date: 1984-04-19
Filing date: 1984-04-19
Publication date: 1985-10-30
Also published as: GB8410353D0

Abstract

The present specification discloses a method of manufacturing porous articles for use in the garden, such as ornamental flower pots and shaped tiles. The method first requires dust free and lime-free stone chippings to be mixed with a resin so that the chippings each become coated with the resin. The coated chippings are then compacted in a suitably shaped mould, around an internal core if required, and the resin is allowed to cure at a constant temperature. The mould is subsequently opened to allow the finished article to be extracted. The irregular shapes of the chippings results in the finished article being porous due to the interstitial spaces unavoidably formed between adjacent chippings.

Description

SPECIFICATION Improvements relating to the manufacture of porous articles The present invention relates to the manufacture of porous articles.

More particularly, the present invention relates to the manufacture of porous articles for use in the garden, such as ornamental flower pots and shaped tiles for use in laying a path or patio area.

The aim of the present invention is to thus provide a method of manufacturing porous articles, which is simple but enables an infinite number of shapes to be produced.

According to the present invention there is provided a method of manufacturing porous articles comprising the steps of mixing stone chippings with a resin so that the chippings each become coated with the resin, packing the coated chippings into a mould and allowing the resin to cure.

In a preferred embodiment of the present invention dust free and lime-free stone chippings which are dry and preferably no larger than 4mm maximum dimension, are mixed with a resin and appropriate hardener. The resin is advantageously Hermetites RS 3294. The resin coated stones are then compacted into appropriate fibreglass moulds and the resin is allowed to cure at a constant temperature. The mould can then be opened to allow the finished article to be extricated, the hardened resin holding the chippings together.

As the stone chippings are dry, the resin effectively completely coats each chipping and due to the irregular shapes of the chippings, interstitial spaces are formed between the chippings in the finished article, so that the article is porous.

The stone chippings of the preferred embodiment are dust-free and also lime-free to allow flower pots to be formed without subsequent danger to plant life contained therein. Various shapes of flower pot can be formed dependent solely on the shape of the mould e.g. conventional flower pots of all sizes, flower pots in the shape of a frog, pelican, swan, elephant and/or owl.

Further the method of the present invention may be used to produce a flat tile or brick of desired configuration e.g. hexaginal. Such a porous tile or brick may be used to construct a path, patio or swimming pool surround; the porous quality providing a safe surface at virtually all times. Whilst the brick or tile may be moulded completely from stone chippings in accord with the present invention, alternatively an internal core may be located in the mould and the chippings moulded therearound to thus encase the core.

The present invention will now be further described, by way of example, with reference to the accompanying drawings, in which: Figure 1 is a perspective view of one embodiment of flower pot constructed by the method of the present invention; Figure 2 is a perspective view of one embodiment of the tile constructed by the method of the present invention; and Figure 3 is a partially cutaway view of a further embodiment of tile constructed by the method of the present invention.

In the accompanying drawings, Figure 1 shows a porous flower pot made by the method of the present invention, and in the shape of a frog. The frog is made from stone chippings, the chippings being clean, dry and free from any dust or any lime. Preferably the chippings are of 4mm maximum dimension, though of course any size chippings can be used in the method of the present invention.

To manufacture the frog-shaped flower pot, the loose stone chippings are placed in a mixer e.g. a rotating mixer, and any epoxy resin is added in a two to one ratio. Hermetites RS 3294 is a suitable resin for use in the present invention. The stone chippings and resin are then mixed for a period of time so that the chippings each become coated with the resin. Then the coated chippings are placed in a frog shape mould, compacted, and then left for a further period of time e.g. twelve hours, at a constant temperature, to allow the resin to harden. The mould is then opened to reveal a frog-shaped porous pot; the pot being porous due to the interstitial spaces formed between the irregular shaped chippings.

As will be appreciated, any desired shape of pot or ornament can be made by the present invention, the shape being purely dependent upon the shape of the mould.

Figure 2 of the accompanying drawings shows a hexagonal tile or brick manufactured by the method of the present invention, the tile being manufactured completely of stone chippings. Any desired alternative shape of tile or brick e.g. rectangular, can of course be made by the present invention, these tiles or bricks being especially suitable for a path or patio area, or even the surround of a swimming pool.

An alternative tile or brick construction is shown in Figure 3, where the mould (not illustrated) has a core around which the stone chippings are moulded. The core may be made of any suitable material e.g. concrete.

The present invention thus provides a simple method of constructing an infinite number of porous products, especially suited for garden use.

1. A method for manufacturing porous articles comprising the steps of mixing stone chippings with a resin so that the chippings each become at least partially coated with resin, packing the coated chippings into a mould and allowing the resin to cure.

2. A method as claimed in claim 1, in which dust free and lime-free stone chippings, which are dry, are used.

3. A method as claimed in claim 1 or claim 2, in which the stone chippings have a maximum dimension which is no larger than 4mm.

4. A method as claimed in any one of claims 1 to 3, in which the resin is Hermetites RS 3294.

**WARNING** end of DESC field may overlap start of CLMS **.

Claims

**WARNING** start of CLMS field may overlap end of DESC **. SPECIFICATION Improvements relating to the manufacture of porous articles The present invention relates to the manufacture of porous articles. More particularly, the present invention relates to the manufacture of porous articles for use in the garden, such as ornamental flower pots and shaped tiles for use in laying a path or patio area. The aim of the present invention is to thus provide a method of manufacturing porous articles, which is simple but enables an infinite number of shapes to be produced. According to the present invention there is provided a method of manufacturing porous articles comprising the steps of mixing stone chippings with a resin so that the chippings each become coated with the resin, packing the coated chippings into a mould and allowing the resin to cure. In a preferred embodiment of the present invention dust free and lime-free stone chippings which are dry and preferably no larger than 4mm maximum dimension, are mixed with a resin and appropriate hardener. The resin is advantageously Hermetites RS 3294. The resin coated stones are then compacted into appropriate fibreglass moulds and the resin is allowed to cure at a constant temperature. The mould can then be opened to allow the finished article to be extricated, the hardened resin holding the chippings together. As the stone chippings are dry, the resin effectively completely coats each chipping and due to the irregular shapes of the chippings, interstitial spaces are formed between the chippings in the finished article, so that the article is porous. The stone chippings of the preferred embodiment are dust-free and also lime-free to allow flower pots to be formed without subsequent danger to plant life contained therein. Various shapes of flower pot can be formed dependent solely on the shape of the mould e.g. conventional flower pots of all sizes, flower pots in the shape of a frog, pelican, swan, elephant and/or owl. Further the method of the present invention may be used to produce a flat tile or brick of desired configuration e.g. hexaginal. Such a porous tile or brick may be used to construct a path, patio or swimming pool surround; the porous quality providing a safe surface at virtually all times. Whilst the brick or tile may be moulded completely from stone chippings in accord with the present invention, alternatively an internal core may be located in the mould and the chippings moulded therearound to thus encase the core. The present invention will now be further described, by way of example, with reference to the accompanying drawings, in which: Figure 1 is a perspective view of one embodiment of flower pot constructed by the method of the present invention; Figure 2 is a perspective view of one embodiment of the tile constructed by the method of the present invention; and Figure 3 is a partially cutaway view of a further embodiment of tile constructed by the method of the present invention. In the accompanying drawings, Figure 1 shows a porous flower pot made by the method of the present invention, and in the shape of a frog. The frog is made from stone chippings, the chippings being clean, dry and free from any dust or any lime. Preferably the chippings are of 4mm maximum dimension, though of course any size chippings can be used in the method of the present invention. To manufacture the frog-shaped flower pot, the loose stone chippings are placed in a mixer e.g. a rotating mixer, and any epoxy resin is added in a two to one ratio. Hermetites RS 3294 is a suitable resin for use in the present invention. The stone chippings and resin are then mixed for a period of time so that the chippings each become coated with the resin. Then the coated chippings are placed in a frog shape mould, compacted, and then left for a further period of time e.g. twelve hours, at a constant temperature, to allow the resin to harden. The mould is then opened to reveal a frog-shaped porous pot; the pot being porous due to the interstitial spaces formed between the irregular shaped chippings. As will be appreciated, any desired shape of pot or ornament can be made by the present invention, the shape being purely dependent upon the shape of the mould. Figure 2 of the accompanying drawings shows a hexagonal tile or brick manufactured by the method of the present invention, the tile being manufactured completely of stone chippings. Any desired alternative shape of tile or brick e.g. rectangular, can of course be made by the present invention, these tiles or bricks being especially suitable for a path or patio area, or even the surround of a swimming pool. An alternative tile or brick construction is shown in Figure 3, where the mould (not illustrated) has a core around which the stone chippings are moulded. The core may be made of any suitable material e.g. concrete. The present invention thus provides a simple method of constructing an infinite number of porous products, especially suited for garden use. CLAIMS

5. A method as claimed in any one of claims 1 to 4, in which the resin coated stone chippings are compacted into a mould and the resin is allowed to cure at a constant temperature.

6. A method as claimed in any one of claims 1 to 5, in which the resin coated stone chippings are compacted in a mould completely around an internal core.

7. A flower-pot when made by the method claimed in any one of the preceding claims.

8. A tile or brick when made by the method claimed in any one of claims 1 to 6.

9. A method of manufacturing porous articles, substantially as hereinbefore described with reference to the accompanying drawings.

10. A flower pot constructed substantially as hereinbefore described with reference to and as illustrated in Figure 1 of the accompanying drawings.

11. A tile or brick constructed substantially as hereinbefore described with reference to and as illustrated in Figure 2 or Figure 3 of the accompanying drawings.