Patent Application
20070017066
The present disclosure relates to utensils or similar items with real natural or organic objects overmolded or encased in thermoplastic or thermo-rubber materials, which encapsulate and protect the objects inside from air, water or other environmental factors. The disclosure also describes methods of making such items.
Nature has always been a popular icon for household items. The kitchen remains a popular spot where we use natural ingredients to cook and prepare fine meals. As such, utensils or similar items often seek to integrate such natural objects. However, most reproductions of nature remain two dimensional or synthetic since real natural objects have special considerations making it obviously harder to include such objects into household items. So how does one bring life into a lifeless object? The challenge was to find a way to preserve nature's preciousness while merging real natural objects with items that withstand the abuses of household use.
Available household and industrial products have not yet found the way to merge with true nature while remaining suitable for their function. The compromise of synthetic material as replicas of natural objects only results in false impressions of nature's true beauty.
Also, many products do not take full advantage of the superb characteristics of thermoplastics or thermo-rubber. Thermoplastic or thermo-rubber materials, such as silicone, are excellent for handles because of their slip-proof nature, gripability, and thermal and chemical characteristics. But these materials can also preserve real natural objects incorporated into functional items.
U.S. Pat. No. 6,189,540 discloses a hair styling comb with a layer of resilient material overmolded on a core member. It does not disclose encasing natural or organic objects.
Thus, it is desirable to produce items with real natural objects encased in thermoplastic or thermo-rubber materials.
The present disclosure describes items having real natural or organic objects encased in thermoplastic or thermo-rubber materials. Overmolding and encasing real natural objects in thermoplastic or thermo-rubber materials aim to merge natural life symbols and objects with functional kitchen utensils or similar household items. The materials can include clear, translucent or lightly tinted thermoplastic or thermo-rubber materials, such as silicone, to encapsulate and protect the objects inside from air, water or other environmental factors, allowing the enjoyment of the encapsulated objects' natural beauty for a long time. Utensils or similar items with real natural or organic objects encased in thermoplastic or thermo-rubber materials may remain functional while capitalizing on the natural beauty of nature.
The characteristics of silicone are kitchen-friendly and are appropriate for encasing real natural or organic objects:
A variety of real natural objects can be encased in items. Cooking ingredients may include dried spices, peppers, citrus or pasta. Agricultural objects may include coffee beans, corn, wheat, and tea leaves. Landscape objects may include flower blossoms, petals, minerals and crystals.
Nature can be merged with contemporary household products to replace lifeless artificial replicas of nature that disgrace nature's true beauty. Fake applications with their audacious and boring looks may become obsolete because nature is absolute and timeless. By encasing or overmolding natural objects, like cooking spices (dried out pepper, lime, chilies etc.) or coffee beans, with food grade silicone, these methods preserve natural objects from wear and decay. Clearly visible through the encapsulating media, natural objects will keep their stunning looks as they are preserved for long lasting enjoyment. In addition, silicone provides excellent characteristics for daily use by people like grip comfort, slip-proof and flexibility.
A first way to successfully merge nature with functional items is airtight overmolding, which is a process where the natural object is directly encapsulated between two gummy thermo-rubber sheets. The object is totally preserved from the outside in a fixed state with no movement.
Another way to successfully merge nature with functional items is combination molding, which allows a much more advanced assembly of natural or organic objects. It includes a two-step process where one half of the overmold is premolded to shape cavities for the natural objects. This overmold tolerates complex forms of geometric or organic roots and can be applied to thermoplastics as well as thermo-rubbers. Once the first half is done, the prepared cavities are filled with the applicable natural objects and then returned to the machine for the second overmold step, which will seal the natural objects. The second overmold carries the same characteristics as the first overmold. Combination molding may also include the use of other materials, such as ferrous & non-ferrous metals/alloys or ceramics/glass, to form the first mold half. After the second overmold is merged with the first one, the objects encased are safe against any physical battering and kept locked into position without any movement.
A third way to successfully merge nature with functional products is encasing, which is a manufacturing process where the natural objects may be stored in a cavity of two or more already premolded pieces. The pieces or halves are secured and merged together by ultrasonic means, adhesive, mechanical lock or heat sealing. Products made by this process permit the encased objects either free or restricted movement within the encapsulated space while they are still kept safe from damage from outside the encasement.
These methods of encasing real natural or organic objects can be used to make functional handles, grips and knobs for kitchen utensils, tools, cookware, tableware, serving containers, mugs, and doors. Other items using these methods include cutting boards, coasters, mousepads, floormats, and placemats. Items with real natural objects encased in durable thermoplastic or thermo-rubber materials will have objects inside protected from outside factors for long lasting enjoyment.
The features of this disclosure and the manner of obtaining them will become more apparent, and the disclosure itself will be best understood by reference to the following description of embodiments of items including real natural or organic objects encased in thermoplastic or thermo-rubber materials taken in conjunction with the accompanying drawings showing particular embodiments of the items and methods, wherein:
While the present invention will be fully described hereinafter with reference to the accompanying drawings, in which particular embodiments are shown, it is to be understood at the outset that persons skilled in the art may modify the embodiments disclosed herein while still achieving the desired result. Accordingly, the description that follows is to be understood as a broad informative disclosure directed to persons skilled in the appropriate art and not as limitations of the present disclosure.
Thermoplastic or thermo-rubber materials, such as silicone, are excellent for handles because of their slip-proof nature, gripability, and thermal and chemical characteristics. The materials can be clear, translucent or lightly tinted thermoplastic or thermo-rubber material, such as silicone, to encapsulate and protect the objects 14 inside from air, water or other environmental factors. Pure silicone has excellent thermal and chemical properties. The preferred material 16 is a high grade elastic silicone that withstands heat up to at least 600° F./315° C. Ideally, the material 16 is clear food grade silicone.
As shown in the
In various embodiments, the layer or piece 18 may be considered the top as closest to the viewer's eye and may be clear, and the layer or piece 20 may be translucent and lightly tinted to complement the natural object 14. For example, for a coffee bean as the natural object 14, layer or piece 20, if farthest from the viewer's eye, could be tinted light brown.
Several methods of encasing real natural objects 14 in thermoplastic or thermo-rubber materials 16 can be used to make functional handles, grips and knobs or other items.
Overmolding includes a process where the natural object 14 can be directly encapsulated between two gummy thermo-rubber sheets, such as 18 and 20. The natural object 14 is totally preserved from the outside in a fixed state with no movement of the object 14. The method includes situating an item 10 or a portion of an item, such as a handle 12, along with natural objects 14. A method of making a utensil 10 with a natural object 14 encased in a handle 12 of the utensil 10 includes obtaining the natural object 14 and obtaining the handle 12 with a core, such as loop 23 or shaft 30. Heat is applied to a first and a second thermo-rubber sheet 18 and 20 so the sheets 18 and 20 become gummy. The first and the second gummy thermo-rubber sheets 18 and 20 can be secured together to completely encapsulate in an airtight manner the natural object 14 between the first and second gummy thermo-rubber sheets 18 and 20 and to encase a portion of the shaft 23 or 30 of the handle 12 to preserve the natural object 14 in a fixed state from outside exposure. The natural object 14 can be initially adhered to the first gummy thermo-rubber sheet 18 before the first gummy thermo-rubber sheet 18 is secured together with the second gummy thermo-rubber sheet 20.
Combination molding allows a more advanced assembly of natural objects 14. It includes a two-step process where one half of the overmold piece 18 is premolded to shaped cavities (i.e. 22) for the natural objects 14. This overmold tolerates complex forms of geometric or organic roots, and can be applied to thermoplastics as well as thermo-rubbers. Once the first portion is done, the prepared cavities 22 are filled with the applicable natural objects 14 and then returned to the machine for the second overmold step, which will seal the natural objects 14. The second overmold piece 20 carries the same characteristics as the first overmold piece 18 and preferably is the same material. Combination molding may also include the use of other materials, such as ferrous & non-ferrous metals/alloys or ceramics/glass, to form the first mold half. After the second overmold piece 20 is merged with the first piece 18, the objects 14 encased are safe against any physical battering and kept secured into position without any movement.
A method of making a utensil 10 with a natural object 14 encased in the utensil 10 may include premolding a first thermoplastic overmold piece 18 with a shaped cavity 22 that is compatible with the natural object 14. The natural object 14 is inserted into the shaped cavity 22. The second thermoplastic piece 20 is secured to the first thermoplastic overmold piece 18 to completely encase the natural object 14 within the first and second pieces 18 and 20. The second piece 20 can be flat or it can be premolded with a shaped cavity 22 (mirror image of
Encasing objects 14 in a cavity 22 is a manufacturing process where the natural objects 14 may be stored in a cavity 22 of two or more already premolded pieces 18 and 20. The pieces or halves (i.e. 18 and 20) can be secured and merged together by ultrasonic means, adhesive, mechanical lock or heat sealing. Items 10 made by this process permit the encased objects 14 free or restricted movement within the encapsulated space while they are still kept safe from outside harm.
The natural objects can correspond to the product. For example, coffee beans can be used with coffee mugs, coffee cups, coffee carafes, coffee servers, coffee sets, coffee scoops, and coffee presses. Similarly, tea leaves can be used with tea services sets and handles on tea kettles. Grass, leaves and petals can be used with garden tools and other theme items, such as door knobs, coasters and mouse pads.
Although preferred methods and embodiments are illustrated and described in connection with particular steps and features, they can be adapted for use with a wide variety of items and methods. Other embodiments and equivalents of the items and related methods of making those items are envisioned within the scope of the claims. Various features of the disclosure have been particularly shown and described in connection with illustrated embodiments. However, it must be understood that the particular examples merely illustrate and that the invention is to be given its fullest interpretation within the terms of the claims.
