Molded solid lavatory made of recycled material

Abstract

The present application discloses a molded solid lavatory made of recycled material, and particularly provides a method of making a lavatory, comprising: mixing recycled glass waste, particulate matter, and resin to form a composition; pouring the composition into a mold; and curing the composition in a mold to make a lavatory. In addition, another method for manufacturing the wash basin comprises the following steps: mixing the glass waste material, the glass fiber resin composite material waste material, the particulate matters and the resin; pouring the composition into a mold; and curing the composition in a mold to make a lavatory.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims the benefit of priority to Provisional Application No. 63 / 597,478 (docket number 010222-23055B-US), filed on November 9, 2023, the entire contents of which are incorporated herein by reference. Technical Field

[0003] The present application relates to the manufacture of a moulded solid wash basin using recycled materials, the wash basin being used in a bathroom or kitchen environment. Background Art

[0004] Washbasins, commonly referred to as sinks or wash basins, are essential fixtures in residential, commercial, and industrial spaces as a fundamental element of personal hygiene and environmental sanitation. Traditional washbasins are primarily made of materials such as ceramic, porcelain, or stainless steel, which offer durability and aesthetic appeal. However, the manufacturing process of these traditional washbasins often involves high energy consumption, complex designs, and limited flexibility in shape and size.

[0005] In recent years, there has been a growing demand for environmentally friendly and sustainable solutions in various industries, including the production of wash basins. Manufacturers are constantly looking for innovative ways to reduce the impact on the environment, optimize production efficiency, and improve product performance. As a result, there is a need for a wash basin that combines environmental awareness with a high-quality end product.

[0006] The present disclosure aims to provide a sustainable solution that reduces waste, energy consumption and production costs. The combination of recycled materials, efficient molding techniques and curing processes allows for a more environmentally friendly production method in the manufacturing process. In addition, the adaptability of the present disclosure allows for the creation of wash basins of various shapes, sizes and designs to meet different consumer preferences and requirements. Summary of the invention

[0007] In an exemplary embodiment, a method of manufacturing a wash basin is described. The method includes: mixing glass waste, particulate matter, and resin to form a composition; pouring the composition into a mold; and curing the composition in the mold to form the wash basin.

[0008] In another exemplary embodiment, another method of making a wash basin is described. The method includes: mixing glass waste, glass fiber resin composite waste, particulate matter and resin; pouring the composition into a mold; and curing the composition in the mold to form the wash basin.

[0009] In another exemplary embodiment of manufacturing a wash basin, the process includes mixing glass waste, fiberglass resin composite waste, particulate matter, and resin; providing one or more coatings inside a mold; pouring the composition into the mold; and curing the composition in the mold to form the wash basin.

[0010] In yet another embodiment, a method of manufacturing a wash basin is described. The method includes assembling an ejection frame configured to: secure to a mold below a wash basin in an inverted position along a plurality of legs of the wash basin; inserting bolts of the ejection frame through a central drain opening of the wash basin; contacting a bowl of the wash basin; and lifting the wash basin out of the mold. BRIEF DESCRIPTION OF THE DRAWINGS

[0011] According to exemplary embodiments, exemplary embodiments are described herein with reference to the following drawings.

[0012] Figure 1 A flow chart for manufacturing a wash basin according to an exemplary embodiment of the present disclosure is shown.

[0013] Figure 2 Another flow chart for manufacturing a wash basin according to an exemplary embodiment of the present disclosure is shown.

[0014] Figure 3 The mixing of glass waste, glass fiber resin composite waste, particulate matter and resin according to an exemplary embodiment of the present disclosure is shown.

[0015] Figure 4 Pouring a composition into a mold is shown according to an exemplary embodiment of the present disclosure.

[0016] Figure 5 Sealing the mold before pouring the mixture is shown according to an exemplary embodiment of the present disclosure.

[0017] Figure 6 Curing of a composition in a mold to form a wash basin is shown according to an exemplary embodiment of the present disclosure.

[0018] Figure 7 It is shown that according to an exemplary embodiment of the present disclosure, a wash basin is removed from a mold with an ejection frame by rotating the bolts of the ejection frame. DETAILED DESCRIPTION

[0019] The following embodiments include methods of making a wash basin suitable for use in a bathroom environment or a kitchen environment. Various embodiments are described and shown separately. However, each of these embodiments can be used together in a single implementation, device or system. It should be understood that the present disclosure is not limited to the details and methods set forth in the detailed description or shown in the accompanying drawings. It should be understood that the terms used herein are for descriptive purposes only and should not be considered as limiting.

[0020] When a component, element, device, etc. of the present disclosure is described as having a purpose or performing an operation, function, etc., the component, device or element should be considered herein as “configured to” satisfy the purpose or perform the operation or function.

[0021] Natural and engineered stone surfaces have desirable aesthetics, including natural textures and unique geometric patterns. However, natural and engineered stone surfaces are expensive. The production of natural stone surfaces requires access to a quarry, and stone surfaces are limited to flat surfaces that must be sealed. In addition, the production of natural and engineered stone surfaces requires the use of expensive, specialized equipment. Therefore, there is a need for inexpensive solid surface products with desirable aesthetics.

[0022] Methods for manufacturing molded wash basins and assembling ejector frames to remove the wash basins from molds are described herein. More specifically, the present disclosure describes methods for manufacturing molded wash basins with recycled materials, which include glass waste, glass fiber resin composite waste, particulate matter and resin. The glass material or glass porcelain can be a crushed, or otherwise broken or fragmented part of a plumbing fixture such as a toilet, wash basin, bathtub or wash basin. As part of the original plumbing fixture manufacturing process, the plumbing fixture is fired at high temperatures until it hardens. Based on manufacturing defects or after the life (product cycle) of the plumbing fixture ends, the plumbing fixture can be recycled and become part of the glass waste. Compositions made from these recycled materials can provide wash basins with ideal aesthetics. The method can provide a cheaper alternative to natural and engineered stone surfaces. Other materials that can be used for any of the following examples include pottery waste, cast iron slag, waste glaze, enamel powder, casting dust and casting sand. In another example, part of the glass waste may not be fired. Examples include trimmings or scraps from another manufacturing process.

[0023] Figure 1 A flow chart is shown of a method 100 of manufacturing a wash basin 500. Additional, different or fewer acts may be provided.

[0024] In S101, glass waste, particulate matter and resin can be mixed to form composition.In step S101, resin material can be in liquid phase, and comprise the mixture of two or more liquids.For example, a kind of liquid can comprise the epoxy group used, and another kind of liquid can be hardener (such as epoxy curing agent).When resin material is in liquid phase, iron particles can be mixed into resin material.Iron particles can be mixed into resin material so that it is distributed in whole resin material.In some embodiments, filling material and / or colorant can be further mixed into resin material.

[0025] In some embodiments, the resin material may be acrylic, polystyrene, polyurethane, polyester, epoxy, hybrid composite, or eco-resin. The mixing process ensures uniform distribution of the components, thereby forming a homogeneous mixture.

[0026] In some embodiments, a catalyst is added to control the rate of polymerization, which aids the reaction without being consumed in the process.

[0027] Many resins undergo a process called cross-linking during polymerization. Cross-linking occurs when polymer chains chemically bond at specific points, forming a network structure. Cross-linked resins tend to be stronger, harder, and more heat resistant than non-cross-linked resins.

[0028] Eco-resins can be used as a replacement for resins in compositions. Eco-resins, also known as eco-friendly resins or bio-based resins, are a class of resins designed to have less impact on the environment than traditional petroleum-based resins. These resins are developed with a focus on sustainability, utilizing renewable resources and environmentally friendly manufacturing processes.

[0029] Unlike traditional resins that are derived from fossil fuels, eco-resins come from renewable materials. Common renewable resources include plant-based materials such as corn, soy, sugar cane and other biomass. By using renewable resources, eco-resins reduce dependence on finite fossil fuels and contribute to a more sustainable future.

[0030] Many eco-resins are biodegradable or compostable, meaning they naturally break down into harmless compounds over time. This property is a consideration in applications where the final product is not intended for single-use but where reducing environmental impact is a priority.

[0031] Some eco-resins are designed to be recyclable, allowing the material to be recovered and reused in new products. Recycling helps reduce the demand for raw materials and minimizes waste. In addition, eco-resins are often formulated to have low toxicity, making them safer for both the environment and human health. Reducing emissions of hazardous materials helps improve air and water quality.

[0032] The mold 400 can be pre-treated with one or more coatings or layers that adhere to at least the inner surface of the mold 400. The first layer or coating can be applied (e.g., sprayed) directly on the inner surface of the mold 400. The first layer or coating can include at least a polyurethane component. The first layer or coating can improve the color fastness of the wash basin (e.g., reduce yellowing). The first layer or coating can provide UV protection for the wash basin.

[0033] A second layer or coating can be applied (e.g., sprayed) to the first layer or coating and indirectly applied to the inner surface of mold 400. The second layer or coating can be a clear gel coat. The second layer or coating can protect the mold surface from the abrasive properties of waste or other materials in the composition placed in mold 400. Mold 400 can be a high temperature resistant aluminum gel coat with a fiberglass backing.

[0034] At S102, the composition 300 is poured or placed into the mold 400. The composition 300 may be placed into the mold by a mechanical drive device. Figure 3 One example is shown. Another example may include a pump connected to a hose to pneumatically drive the composition 300 into the mold 400.

[0035] The mold may include an upper mold half 401 and a lower mold half 402. At S102, the mold may be closed so that the upper mold half 401 and the lower mold half 402 form a sealed closed space having a desired shape of the wash basin 500.

[0036] The homogenous mixture is then poured into a pre-designed mold 400. The mold 400 is a hollow cavity having the exact negative shape of the desired wash basin 500. The poured composition 300 fills the mold 400 and takes on its shape and contours.

[0037] At S103 , the composition 300 is cured in the mold 400 to form the wash basin 500 .

[0038] Curing begins after the composition is poured into the mold 400. The curing process may involve various techniques, including chemical reactions or exposure to specific environmental conditions, such as heat, pressure, or ultraviolet (UV) light. The choice of curing technique depends on the composition 300 and the materials used.

[0039] In some embodiments, curing involves a chemical reaction between the components of the mixture. For example, in the presence of a catalyst, the resin undergoes a polymerization reaction - a chemical reaction in which small molecules (monomers) combine to form large interconnected molecules (polymers). This reaction causes the composition 300 to harden.

[0040] During the curing process, the molecules within the resin cross-link, or form bonds, with adjacent molecules. This process creates a three-dimensional network of interconnected molecules, transforming the material from a liquid or semi-liquid state to a solid structure.

[0041] As curing progresses, the material continues to solidify. The bonds between molecules strengthen and the material becomes harder and more stable. This curing process ensures that the final product has the necessary strength and durability.

[0042] In some embodiments, the solidification process is referred to as vitrification or vitrification and may be utilized.

[0043] Vitrification is the process of converting a material into glass or a glass-like substance. The process typically involves heating the material to a high temperature until it melts, followed by rapid cooling to form an amorphous, noncrystalline solid. Vitrification produces a smooth, shiny, and usually transparent or translucent surface.

[0044] Curing is the process of hardening a material, usually involving a chemical reaction, while vitrification is the specific process of converting a material into a glassy state through controlled heating and cooling. The two processes serve different purposes but can be connected to each other in certain manufacturing applications.

[0045] After the curing process is complete, the wash basin 500 is allowed to cool and fully harden within the mold 400. Once the material has reached its optimal strength and stability, the wash basin 500 can be removed from the mold 400.

[0046] Figure 2 A flow chart of a method 200 for manufacturing a wash basin 500 is shown. The mold 400 may be similar to the method 100 and Figure 1 The mold discussed is the same. The resin and particles can be the same as those described above with reference to method 100 and Figure 1 The resins and pellets discussed are the same. Additional different or fewer actions may be provided.

[0047] In S201, glass waste, glass fiber resin composite waste, particulate matter and resin can be mixed to form composition 300. In action S201, the resin material can be in liquid phase and include a mixture of two or more liquids. For example, one liquid can include the epoxy group used, and another liquid can be a hardener (e.g., epoxy resin curing agent). In some embodiments, a filling material and / or a colorant can be further mixed into the resin material.

[0048] At S202, the composition 300 is poured into the mold 400. The mold 400 may include a mold upper half 401 and a mold lower half 402. At S202, the mold 400 may be closed so that the mold upper half 401 and the mold lower half 402 form a sealed closed space having a desired shape of the wash basin 500. At S203, the composition 300 is cured in the mold 400 to form the wash basin 500.

[0049] Specific details regarding the composition and curing process can be found above with reference to method 100 and Figure 1 Same as discussed.

[0050] Figure 3An example apparatus for mixing a composition 300 is shown. The apparatus may include a vacuum chamber 301, a hopper 302, a vibration generator 303, and a mixing chamber 304. The mixing chamber 304 includes a shaft 305 supporting one or more blades 306. The blades 306 may be bent and angled to cut the composition 300. Figure 3 As shown, the mixing chamber 304 is connected to the vacuum chamber 301, which is connected to the hopper 302. Thus, the composition 300 is provided from the mixing chamber 304 to the vacuum chamber 301 and then to the hopper 302. The hopper 302 may include a trap door 307 or another type of ramp or channel to release the composition 300 from the hopper 302 and the device. Other arrangements are also possible. In one example, the vacuum chamber 301 is located upstream of the mixing chamber 304. Additional, different or fewer components may be included.

[0051] Mixing chamber 304 is configured to mix waste glass, waste glass fiber resin composite material, particulate matter, and resin to form composition 300. Prior to mixing, it may be advantageous to break the waste glass into pieces less than one inch in length, width, and height to make the raw materials small enough for effective mixing. Depending on the specific application, molding technique, or desired end product, the size of the raw material pieces after breaking may be the above recommended sizes, or may be smaller or larger.

[0052] In some embodiments, mechanical methods such as stirring, agitating, shaking or mixing can be used to mix the raw materials to form the composition 300. The choice of tools depends on the viscosity and properties of the raw materials. High-speed stirring methods, such as using a blender or mixer, are effective for producing a uniform mixture, especially for materials of different densities.

[0053] Maintaining consistent mixing techniques, such as stirring in the same direction at a constant speed, helps to evenly distribute the ingredients. Reversing the stirring direction can sometimes help break up lumps and ensure uniformity.

[0054] In some embodiments, homogenization, a mechanical process that can reduce the particle size in the composition 300 to achieve a uniform texture, can be used.

[0055] The mixing chamber 304 provides the composition 300 to the vacuum chamber 301. The vacuum chamber 301 may be sealed. After the composition 300 or a portion thereof flows into the vacuum chamber 301, the door between the mixing chamber 304 and the vacuum chamber 301 may be closed. The vacuum chamber 301 may include a pump to extract air from the sealed vacuum chamber 301. The vacuum may help release trapped bubbles from the composition 300.

[0056] The hopper 302 can be directly connected to the vacuum chamber 301. The vacuum chamber 301 can include an outlet that is opened and closed by a valve so that the composition 300 can fall from the vacuum chamber 301 into the hopper 302. The hopper 302 provides a flow path to help release trapped bubbles from the composition 300. The vibration generator 303 can be configured as a motor with a weight or an unbalanced load. The vibration generator 303 can be configured as a speaker with a low frequency. The vibration can help release trapped bubbles from the composition 300.

[0057] Figure 4 Sealing mold 400 is shown prior to pouring composition 300 into mold 400 and curing composition 300 in mold 400 to form wash basin 500 . Figure 4 It includes an upper mold half 401 and a lower mold half 402. The sealed closed interior of the upper mold half 401 and the lower mold half 402 can form the desired shape of the molded wash basin.

[0058] Coating the mold 400 with a release agent can prevent the composition 300 from adhering to the mold 400. Steps can be taken to ensure that the mold 400 is clean and dry. For example, the mold 400 can be dried and / or cleaned by contact or air flow. The preparation of the mold 400 encourages easy demolding (e.g., removing the sink from the mold 400) and a smooth surface finish.

[0059] Figure 5 Another manual embodiment is shown for pouring the composition 300 into a mold 400 having the desired shape of a wash basin. Figure 3 Alternatives to the mixing and pouring apparatus shown. One or more pouring techniques may be used to ensure that the composition 300 uniformly fills the mold 400, thereby forming a high quality, defect-free final wash basin 500.

[0060] In some embodiments, composition 300 can be poured into mold 400 in a controlled manner while avoiding splashing or pouring too quickly to reduce the amount of air bubbles introduced into the mixture. Air bubbles can weaken the final product and affect the appearance of wash basin 500.

[0061] The viscosity of the composition 300 may also determine the appropriate pouring technique. For low viscosity compositions, a steady, continuous pour may be appropriate. For thicker mixtures, consider pouring in layers, allowing each layer to settle and degas before adding the next layer. This pouring technique may also help reduce the entrapment of air bubbles.

[0062] In some embodiments, other methods can be used to remove trapped bubbles, such as tapping the mold gently after pouring the composition, or using a vibrating tool to help the material settle and eliminate air pockets. The vibrations encourage the composition 300 to flow throughout the mold 400, ensuring uniformity.

[0063] In some embodiments, particularly where mold 400 must be filled to a particular height, a leveling tool may be used to maintain a smooth surface to ensure that composition 300 and mold 400 are level.

[0064] In some embodiments, a hose or tube may be used to place the composition 300 into the mold 400. The hose or tube may be driven pneumatically or hydraulically to advance the composition 300.

[0065] Figure 6 Composition 300 is shown curing in mold 400, where upper mold half 401 is located on top of lower mold half 402. One or more clamps 403 may be used to couple and press upper mold half 401 and lower mold half 402 together.

[0066] Details regarding the curing process may be found in the above reference method 100 and Figure 1 Same as discussed above. The sink may also be glazed by spraying or otherwise applying a glass coating to the sink surface.

[0067] Figure 7 A method of assembling an ejector frame 700 is shown, which is configured to: secure to a mold upper half 401 below a wash basin 500 in an inverted position along a plurality of legs 701 of the wash basin 500; insert bolts 703 of the ejector frame 700 through a center drain opening 704 of the wash basin 500; contact a bowl 702 of the wash basin 500; and lift the wash basin 500 from the mold upper half 401.

[0068] A bolt 703 may be inserted through a central drain opening 704 of the wash basin 500, the bolt 703 having an end piece that may contact the bowl 702 of the wash basin 500. The bolt 703 may be raised by rotating a rotation mechanism at the end of the bolt opposite the end piece.

[0069] If desired, multiple feet 701 of the wash basin 500 can be fixed to the mold upper half 401 and / or another surface. The multiple feet 701 of the wash basin 500 generate a force opposing the bolts 703, which allows the wash basin 500 to be removed from the mold upper half 401.

[0070] In some embodiments, the lavatory 500 is leveraged from the upper mold half 401 by rotating a bolt 703 passing through the central drain opening 704 to slowly and precisely apply an upward force to the lavatory 500 and ultimately remove the lavatory 500 from the upper mold half 401 .

[0071] The description of the embodiments described herein is intended to provide a general understanding of the structures of various embodiments. The illustrations are not intended to be a complete description of all elements and features of the equipment and systems utilizing the structures or methods described herein. When reading this disclosure, many other embodiments may be obvious to those skilled in the art. Other embodiments may be utilized and derived from this disclosure, so that structural and logical replacements and changes can be made without departing from the scope of this disclosure. Additionally, the illustrations are merely representative and may not be drawn to scale. Certain proportions in the illustrations may be exaggerated, while other proportions may be minimized. Therefore, this disclosure and the accompanying drawings will be considered illustrative and not restrictive.

[0072] Although this specification contains many specific contents, these contents should not be understood as limitations on the scope of the present invention or the content claimed for protection, but should be understood as descriptions of the features of specific embodiments of the present invention. Certain features described in the context of a separate embodiment in this specification may also be implemented in combination in a single embodiment. On the contrary, the various features described in the context of a single embodiment may also be implemented individually or in any suitable sub-combination in multiple embodiments. In addition, although features may be described above as working in certain combinations and even initially claimed for protection, in some cases, one or more features in the claimed combination may be deleted from the combination, and the claimed combination may point to a variation of a sub-combination or a sub-combination.

[0073] One or more embodiments of the present disclosure may be referred to herein individually and / or collectively as the term "invention", which is merely for convenience and is not intended to voluntarily limit the scope of the present application to any particular invention or inventive concept. In addition, although specific embodiments have been illustrated and described herein, it should be understood that any subsequent arrangement intended to achieve the same or similar purpose can replace the specific embodiments shown. The present disclosure is intended to cover any and all subsequent adaptations or variations of various embodiments. After reading the specification, the combination of the above embodiments and other embodiments not specifically described herein will be obvious to those skilled in the art.

[0074] The above detailed description is intended to be considered illustrative rather than restrictive, and it should be understood that the following claims including all equivalents are intended to define the scope of the present invention. Unless explicitly stated, the claims should not be understood to be limited to the described order or elements. Therefore, all embodiments falling within the scope and spirit of the attached claims and their equivalents are considered to be the present invention.

Claims

1. A method for manufacturing a wash basin, the method comprising: mixing recycled glass waste, particulate matter and resin to form a composition; removing air bubbles from the composition; pouring the composition into a mold; as well as The composition is cured in the mold to form the wash basin.

2. The method according to claim 1, wherein: The composition comprises: At least 65% by weight of recycled glass waste; At least 3% by weight of particulate matter; and At least 20% by weight of resin.

3. The method according to claim 1, wherein: The recycled glass waste includes portions of a pipeline facility.

4. The method according to claim 1, further comprising: Assemble the ejector frame.

5. The method according to claim 1, wherein: Assemble the ejector frame including: a mold secured to the underside of the basin in an inverted position along a plurality of feet of the basin; inserting a bolt of the ejector frame through a center drain opening of the wash basin; contacting a bowl of the wash basin; and The wash basin is lifted out of the mould.

6. The method according to claim 5, further comprising: The wash basin is removed from the mold with the ejection frame by turning the bolts of the ejection frame.

7. The method according to claim 1, further comprising: Prior to mixing, the glass waste was broken into pieces less than one inch in length, width and height.

8. The method according to claim 1, further comprising: The mould is sealed before pouring the composition.

9. The method according to claim 1, wherein: The resin is acrylic acid, polystyrene, polyurethane, polyester, epoxy resin, hybrid composite material or ecological resin.

10. The method according to claim 1, wherein: The recycled glass waste is unfired.

11. The method according to claim 10, wherein: The recycled glass waste includes trimmings from the manufacturing process.

12. A method of manufacturing a wash basin, the method comprising: mixing recycled glass waste, fiberglass resin composite waste, particulate matter and resin to form a composition; pouring the composition into a mold; as well as The composition is cured in the mold to form the wash basin.

13. The method according to claim 12, wherein: The composition comprises: At least 45% by weight of glass waste; At least 20% by weight of particulate matter; and At least 15% by weight of resin.

14. The method according to claim 12, wherein: The resin includes acrylic, polystyrene, polyurethane, polyester, epoxy resin, hybrid composite material or ecological resin.

15. The method according to claim 12, wherein: The recycled glass waste includes portions of a pipeline facility.

16. The method according to claim 10, further comprising: a plurality of feet along the basin secured to the mold below the basin in an inverted position; inserting a bolt from the ejector frame through a center drain opening of the wash basin; contacting a bowl of the wash basin; and The wash basin is lifted out of the mould.

17. The method according to claim 16, further comprising: The wash basin is removed from the mold with the ejection frame by turning the bolts of the ejection frame.

18. The method according to claim 12, further comprising: Prior to mixing, the glass waste and glass fiber resin composite waste were broken into pieces less than one inch in length, width and height.

19. The method according to claim 12, further comprising: The mould is sealed before pouring the composition.

20. The method according to claim 12, wherein: The recycled glass waste includes trimmings from the manufacturing process.

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