Other soap compression moulds involve pre-soaking the solids in a separate vessel then transferring the pre-softened solids to a mould of various designs for compression into a specific shape and bonding (see Publication Number CN204455059 U, Application number CN 201420797007 and U.S. Pat. No. 4,035,122 and Publication number U.S. Pat. No. 5,030,405 A). This method complicates the process which discourages mass adoption of the technology and process.
Another existing method which is used in bonding smaller disparate soap pieces in the same vessel as the “softening” process uses a heating element to vaporize water, the steam then softens the soap pieces and a flat plunger/stamp compresses the softened pieces together (see Publication number CN201873662 U, Application number CN 201020591642). The proposed process and apparatus addresses three important aspects not addressed by Publication number CN201873662 U, Application number CN 201020591642. First, Publication number CN201873662 U, Application number CN 201020591642 requires electricity to vaporize the water which limits its location of use to where there is electricity available and unnecessarily complicates the process which discourages mass adoption of the process. Second, Publication number CN201873662 U, Application number CN 201020591642 can only use water to soften the soap pieces so they can be bonded together under pressure (i.e. no essential oils or scents can be used). Third, the steam created in Publication number CN201873662 U, Application number CN 201020591642 is created under the soap pieces so it must have holes in the bottom of the mould cavity so the steam can surround the soap pieces. Therefore when the soap pieces are compressed to form a bond, the softened soap can protrude through the access holes for the steam which when solidified makes it difficult to remove and limits the embossed shapes to only one side of the newly formed solid (i.e. soap). The proposed Cold Mould Process and Apparatus addresses all these issues.
Device
This device simplifies the entire process for bonding a plurality of disparate solids into a single moulded solid by using a fluid tight mould cavity to immerse the solids in the bonding/softening/solvent fluid for a period of time and then using the plunger to both force the bonding/softening/solvent agent out from between the solids and compress the solids into a single mass to bond together. Further, the plunger has been designed to collect the exudates for reuse, disposal or recycling reducing the clean-up time. Although this may not be necessary for the application of the cold mould process, this apparatus design feature eliminates an inhibiting factor in the mass adoption of the device. The plunger is also designed to obviate the need for mechanical alignment/stabilization of the plunger while moving under force axially/longitudinally during the compression phase within the mould. Although this simplifies the device and encourages mass adoption it does not preclude the use of a mechanical compression method. Further, a stabilizing platform is designed to collect any exudates that might escape the plunger/mould device and will encourage users of all ages and abilities to use the device. Finally, please be advised that this process and apparatus could be used to bond/shape a plurality of disparate solids of a variety of composition, as long as the surface of the disparate solids can be made “bondable” (i.e. plastic pieces immersed in the appropriate solvent, soap immersed in water mixture, etc . . . ).
Design
Overview
The mould consists of a cap (bottom and/or top), a shaped enclosure (which may or may not be extruded, typical cross-sectional shapes would be round or some other polygon but in reality any cross-sectional shape or size is possible) that is secured to the cap by pressure and/or other mechanical means forming a liquid tight seal that may or may not include a flexible sealing gasket, and a form fitting plunger that fits the inside of the shaped enclosure very closely but that there is enough space between the sides of the shaped extruded enclosure and cap assembly and the plunger to both allow the plunger to move longitudinally/axially within the shaped enclosure and to allow the fluid softening/bonding/solvent agent to escape the cavity formed by the bottom of the plunger and the fitted enclosure when a longitudinal/axial force is applied but not allow the solids to escape. Alternatively, channels/holes can exist in the sides or body of the plunger to allow the softening/bonding/solvent agent whatever the case may be to be expelled from the solids. Furthermore, the plunger may or may not be hollow with a solid bottom and/or top with holes in the sides to allow the exuded liquid bonding/softening/solvent agent to enter the hollow cavity in the middle of the plunger thereby collecting the liquid and preventing the liquid from overflowing the enclosure or returning to the solids. The “cap” of the enclosure may be constructed of one or more pieces to create one “cap”. As an option, this expelled softening/bonding agent/liquid that escapes the enclosure can also be collected on a dish, a collection vessel attached to the cap and/or stabilizing base or other vessel/base. This liquid collection vessel/base may or may not be part of the cap and/or plunger or attached to the cap and/or plunger by pressure or other mechanical means. Other options include shapes in the cap and/or plunger that can imprint or emboss art or other shapes on the softened pieces of solids when pressure is applied. These shapes can form part of the cap and/or plunger but also may be separate pieces that are inserted between the cap and plunger and the solid/liquid mixture. Due to the design of the plunger, the pressure to be applied to the plunger may or may not be mechanical to prevent binding of the plunger within the enclosure. That is to say the hands, the feet, other body part or other mechanical means will be used to apply direct pressure to the plunger that then is forced longitudinally within the enclosure compressing the solid/liquid mixture. Under pressure, the space and/or channels between the plunger and enclosure is such that it does not allow the solids to escape but the liquid can escape “up” between the sides of the shaped enclosure and the plunger. This forces the softening/bonding agent out from surrounding the solid pieces. This bonding agent may or may not be collected in a vessel/base or the hollow plunger which may or may not be attached to the mould. Additionally, the “mould” assembly may be secured to a stabilizing platform onto which the user can step thereby using their own weight to stabilize the “mould” assembly while another body part (i.e. foot or arms) applies a compression force to the plunger or some other mechanical means of depressing the plunger. The design of the device that enables the user with or without any mechanical device to use their own body weight to apply axial force to the plunger without concern for binding is important to mass adoption of the device opening its use to a wide range of users regardless of age or ability. The addition of the stabilizing base although not key to the use of the device further increases the safety of the use of the device. After the user determines enough pressure has been applied to the plunger to fuse the solid pieces and expel the softening/bonding agent/liquid, the “mould” may be turned over and allowed to “dry” for a period of time. This is an optional step since because the exudates can be collected within the cavity of the plunger with any extra exudates collected elsewhere (i.e. the stabilizing platform), the exudates is no longer able to return to the mould cavity where the newly formed solids are. This “mould” may or may not be placed on a liquid/bonding agent collection vessel/base that may or may not be attached permanently or temporarily to the mould. After a length of time determined by the user which is dependent on the type of liquid softener/bonding agent used, the length of immersion of the solids in the softening/bonding agent and the softness of the solids pieces when the plunger was depressed, the cap on the end of the mould can be removed and pressure applied to the plunger to force the moulded solids out the other end of the enclosure. The solids will have taken the shape (in whole or in part) of the cavity formed by the enclosure and the cap and depressed plunger, including any custom imprints or embossing applied there. To aid removal of the newly formed solid shape, the cap can be removed and the plunger used to push the solid shape out of the enclosure. This is then allowed to dry further until the user determines the product is solid enough to be removed from the mould. To aid the removal of the fused product from the mould a release agent (i.e. Vaseline or other lubricant/wax) may be applied to any or all contact surfaces between the soap and mould). Alternatively a non-stick surface permanently applied to any or all of the surfaces of the mould. As a third alternative, any or the entire mould may be constructed of a non-stick material (i.e. plastics or metals). As a fourth alternative a thin barrier may be applied to any or all the surfaces of the mould (i.e. Teflon sheet, wax paper, etc . . . ).
Plunger
The plunger is the most unique and innovative aspect of this design. It can be any cross section except the outside cross section must match the inside cross-section of the enclosure closely while allowing longitudinal movement within the enclosure and fluid movement between the outside surface of the plunger and the inside surface of the enclosure. The plunger may also have holes or channels in the sides to allow the softening/bonding/solvent fluid to escape the cavity formed by the cap, enclosure and plunger when under pressure yet not allow the solids to escape. The plunger must be able to move freely longitudinally within the enclosure. Furthermore, the plunger can be hollow with holes leading from the outside longitudinal surface of the plunger to the inner cavity (see
Enclosure
Inside and outside of the enclosure may be any shape/cross-section but the inside cross-section must allow the plunger to move freely longitudinally inside and be of similar shape to the exterior cross section of the plunger while allowing the softening /bonding agent a route to escape between the walls of the plunger and the enclosure when an axial force is applied to the plunger but not allowing the solids to escape the cavity formed by the cap (see
Cap
The cap is designed to create a fluid tight seal on one end or both ends of the enclosure (see
Stabilizing Base
A base may be permanently or temporarily attached to the cap using either pressure or other mechanical means (see
Filing Document | Filing Date | Country | Kind |
---|---|---|---|
PCT/CA2016/051515 | 12/20/2016 | WO | 00 |
Number | Date | Country | |
---|---|---|---|
62349800 | Jun 2016 | US |