AU2012201457B2 - A Vessel and Method of Manufacture Thereof - Google Patents

Abstract

Abstract A method of manufacturing a vessel involves providing a former, applying cementitious slurry to the former and hardening the applied slurry to form the vessel. The vessel preferably comprises a container which can contain a solid and/or a liquid. For example the container may comprise a pot. At least part of the surface of the vessel may be reinforced, for example by applying a reinforcing coating. The coating may comprise a curable coating. An example of a curable coating is an epoxy resin. In addition, reinforcing mesh or cloth may be added to which the curable coating is applied. The cloth or mesh may include fibreglass or polyester. The cloth may be in the form of a strip which is wound about the vessel. * co

Description

AUSTRALIA PATENTS ACT 1990 COMPLETE SPECIFICATION A VESSEL AND METHOD OF MANUFACTURE THEREOF The following statement is a description of the invention: 1 A VESSEL AND METHOD OF MANUFACTURE THEREOF TECHNICAL FIELD The present invention is directed to a method for making a vessel (e.g. a pot 5 for plants). BACKGROUND ART Vessels made from cementitious materials have advantages over plastic and clay. One advantage is strength. Another advantage is the ability to easily add 10 various colouring additives and surface finishes providing aesthetic appeal. These advantages are particularly apparent if the vessel is a plant pot. It is known to make pots from concrete using a mold. However, there are disadvantages in using a mold including the cost in the manufacture of the 15 mold and the time taken. Furthermore, the resulting molded pots are all substantially identical in shape and so appear machine made or mass produced. There would be an advantage if it were possible to manufacture a vessel 20 made from cementitious material and which could be manufactured in a variety of shapes and sizes without the need of an external mold. There would also be an advantage if it were possible to economically produce a durable shaped vessel (for instance a garden pot) . 25 Any references to methods, apparatus or documents of the prior art are not to be taken as constituting any evidence or admission that they formed, or form part of the common general knowledge. 30 SUMMARY OF THE INVENTION According to a first aspect of the present invention there is provided a method of manufacturing a vessel, the method comprising providing a former, applying cementitious slurry to the former by dipping the former into the 5 cementitious slurry and hardening the applied slurry to form the vessel, the slurry comprising cement, water and sand as the sole aggregate. In another form there is provided a vessel made from hardened cementitious material and containing an internal former. 10 The former preferably has a shape approximating the shape of the vessel. The former preferably has a size approximating the size of the vessel. 15 The vessel preferably comprises a container which can contain a solid and/or a liquid. The container may comprise a pot. The pot may comprise a plant pot. The shape and size of the vessel can vary depending, inter alia, on the ultimate use of the vessel. For instance, if the vessel is a plant pot, the pot may be sized to contain between 1-50 L of potting mix. However, it is not 20 envisaged that any unnecessary limitation should be placed on the invention merely by exemplification of certain sizes. The shape of the vessel can vary to suit. If the vessel is a plant pot, it is envisaged that the vessel will be substantially cylindrical , rectangular, frusto 25 conical, or have a bowl type shape. However, it is not envisaged that any unnecessary limitation should be placed on the invention merely by exemplification of certain shapes. The vessel contains a former. The former will typically have a shape 30 approximating the shape of the vessel. Thus, in respect of a cylindrical vessel, the former may have a cylindrical shape. Similarly, in respect of a rectangular vessel, the former may have a rectangular shape. The former will typically have a size which approximates the size of the vessel.

3 The former may be made from any suitable material or composite materials. In an example, the former may be made from relatively stiff material such as a cardboard, thin board, stiff paper and the like. It is also envisaged that the former may be made from plastics material, metal, wood and the like. The 5 former may be manufactured from composite materials such as laminates, sandwich materials, corrugated materials and the like. It is also envisaged that the former may be initially shaped or configured while in a flexible or plastic state and then hardened or otherwise made rigid. 10 The former may comprise sheet material which can be shaped and configured to the desired shape of the former. For instance, the former may comprise a blank of material containing cut lines and/or fold lines to enable the blank to be assembled into the shape of the former. Alternatively, the former may comprise a blank of material which can be bent or folded into the desired 15 shape. It is also envisaged that the former may comprise a plurality of separate components that can be assembled - possibly to form a more complex shape to the former. It is also envisaged that, if required, the former can be held in a desired position using adhesive, clips, clamps, tabs, bands, and the like. 20 The former may be substantially continuous or may contain openings, cutouts and the like. The openings may comprise slots, slits, round openings, and may function to reduce the weight of the former, to assist in embedding of the former into the cementitious material, and may also assist in the strength of 25 the vessel. The former may comprise a relatively rigid perforated material or mesh. There may be circumstances where it may be advantageous to roughen the surface of the former to improve the adhesion of the cementitious material to 30 the former.

4 There may be circumstances where it may be advantageous to provide more than one former. In this alternative, each former may comprise part of the final shape of the vessel. If more than one former is provided, these may be attached to each other. 5 The cementitious slurry will typically comprise a mixture of cement, fine sand and water. The composition of the slurry is preferably such that the former can be dipped into the slurry with the slurry adhering to the former. The slurry may contain further ingredients or additives. For instance, it may be advantageous 10 to include one or more adhesive additives to assist in the adhesion of the slurry to the former. These may include PVA and acrylic additives. If it is desired for the vessel to be somewhat waterproof, it may be advantageous to add at least one waterproofing agent to the slurry. Various 15 waterproofing agents are available including acrylics. If it is desired to accelerate the manufacturing process, it may be advantageous to add at least one cure accelerator to the slurry. Various cure accelerators are available including urethane cure accelerator. Typical other 20 materials used for acceleration are Ca(N03)2 and NaNO3. If it is desirable to enhance the aesthetic appeal of the vessel, it may be advantageous to add at least one colourant. Various colourants are available which may comprise coloured sands, powders, liquids and the like. 25 The cementitious slurry may contain aggregates if desired. It should be appreciated that no particular limitation should be placed on the invention merely by the illustration of certain additives to the cementitious 30 slurry. The cementitious slurry is applied to the former (or vice versa). It is preferred that the former is dipped at least one and preferably more than once into the cementitious slurry. This can be done manually or using a dipping apparatus.

5 The thickness of the slurry adhering to the former will depend, inter alia, on factors such as the viscosity, the adhesive character of the slurry mix, amount of water added to the slurry, the type of former that is used and the like. Plasticizers may also be used to lessen the viscosity of the slurry without 5 adding additional water. The thickness of the slurry on the former may affect the strength of the ultimately formed vessel. If the thickness is to be increased, the cementitious slurry may be applied to the former at repeated intervals. In a simple embodiment, this can be achieved by dipping the former into the slurry more than once and as an example the former can be dipped 10 three times into the slurry. There may be circumstances where there would be an advantage in applying the slurry in a manner other than by dipping the former into the slurry. For instance, there may be circumstances where there would be an advantage in 15 painting the slurry onto the former or applying the slurry by some other means. However, it is considered that the dipping process may be the quickest and most expedient way to apply the slurry to the former. If necessary, excess slurry can be removed from the former or can be 20 repositioned onto the former, or the slurry coating on the former can be "touched up". There may be circumstances where there may be an advantage in applying further cementitious slurry or other material to various parts of the former after 25 the cementitious material has been applied to the former (for instance by dipping). The further addition may be to strengthen certain parts of the vessel, or to add parts to the vessel. As an example, if the vessel is to be a plant pot, there may be an advantage in strengthening the base of the vessel by adding further cementitious material to the base portion. 30 Alternatively, the former may approximate the shape of the ultimate vessel but may have some parts missing which will need to be applied after application of the cementitious material to the former.

6 Thus, in this embodiment, if the vessel is to be a plant pot, the former may comprise the side wall of the pot only and the bottom wall can be formed separately and attached to complete the basic pot form. 5 The applied slurry is allowed to harden/cure/set. It is preferred that the hardening process is carried out in a moist environment as this will improve the strength of the hardened slurry. Thus, in a simple embodiment, the slurry/former is placed in a sealed moist container to harden/cure. This can be achieved over several days or weeks. If desired, heat or steam may be 10 applied, or other means used, to assist in the hardening or setting process of the cementitious slurry on the former to form the vessel. If a stronger vessel is desired, it is possible to reinforce the vessel after the hardening process. Various reinforcements are envisaged. At least part of the 15 surface of the vessel may be reinforced. The surface may be the external surface and/or the internal surface. The external surface may be reinforced by applying a reinforcing coating. The coating may comprise a curable coating. An example of a curable coating is an epoxy resin. Another example of a curable coating is a polyester resin. The coating may be applied by any 20 suitable means. This may include spray coating, application using a brush or roller and the like. If desired, further reinforcement may be used. This may comprise a physical reinforcement. For instance, reinforcing mesh or cloth may be added to which 25 the curable coating is applied. The cloth or mesh may include fibreglass or polyester. The cloth may be in the form of a strip which is wound about the vessel. If desired, decorative or aesthetic material can be applied to the vessel and 30 typically to the exterior of the vessel. The decorative or aesthetic material may comprise colourants, decorative sand (to give the vessel a rustic look), or other materials. The material may be applied by any suitable method however one suitable method may be to apply the material to the curable coating prior to curing.

7 The invention may also include a vessel made substantially from a hardened cementitious material containing an internal former. BRIEF DESCRIPTION OF THE DRAWINGS 5 Preferred features, embodiments and variations of the invention may be discerned from the following Detailed Description which provides sufficient information for those skilled in the art to perform the invention. The Detailed Description is not to be regarded as limiting the scope of the preceding Summary of the Invention in any way. The Detailed Description will make 10 reference to a number of drawings as follows: Figure 1. Illustrates a blank of material from which the former is made. Figure 2. Illustrates the partially assembled former to form a cylindrical plant pot. 15 Figure 3. Illustrates the dipping process where the former is dipped into a cementitious material. Figure 4. Illustrates the former coated with the cementitious material into the desired pot shape. Figure 5. Illustrates the addition of further cementitious material into the 20 former to thereby make a base. Figure 6. Illustrates further reinforcement and decoration of the hardened pot. DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS 25 The invention will be described primarily with reference to a plant pot as the vessel and which is made from a cementitious material. However it should be appreciated that no unnecessary limitation should be placed on the invention merely by reference to a plant pot as an example of a vessel. 30 Referring initially to figure 1, there is illustrated a former 10 which, in the particular embodiment, comprises a side wall portion 11 made from thin cardboard (approximately 175 g/m 2 thickness), although the portions can also be made from other materials.

8 Side wall 11 is bent to form a cylindrical tube (figure 2) and can be held into the tubular form by the use of adhesive strips 13 (or some other means). The former 10 is dipped into larger container 14 containing cementitious slurry 5 15 which comprises water, sand, water proofing additives, adhesive admixtures, colourings and curing accelerators. In the particular embodiment, the dipping is repeated three times. The coated former 16 (figure 4) can then be further treated to form a base. 10 In a simple but effective option, the annular coated former can be placed on a horizontal surface and cementitious material can be poured/pressed 17 into the bottom of the former to form the base wall 18 of desired thickness. The cementitious material may comprise a stronger concrete to provide a good strong base wall. A bonding agent can be added to the base mixture to assist 15 adhesion to the sidewall. Reinforcement may be present if required. Alternatively, the base wall can be formed separately and attached to complete the basic pot form. In a further alternative the base can form part of the initial former. 20 The pot is kept moist during the construction period to optimise curing strength. The uncured "green" slurry coated former can then be hardened by drying in a 25 separate container in a moist environment (not illustrated). The curing time can vary but in the preferred embodiment the curing time may be several weeks at ambient temperature. The dried and hardened vessel can then be used and sold or can be 30 subjected to further reinforcement which will be described below and with reference to figure 6. If it is desired to further reinforce the vessel, the vessel 19 (see figure 6) can be attached to a horizontal shaft 20 and slowly rotated.

9 Epoxy resin 21 can then be sprayed onto the outside of vessel 19 as the vessel is being slowly rotated with the rotation being continued while the epoxy cures. The epoxy resin 21 may also be sprayed onto the inside surface if desired. Further reinforcement can be provided by applying 5 fibreglass/polyester cloth 22 to the outside of the vessel 19 prior to spraying with the epoxy resin. A colour tint can be applied to the epoxy resin to give the outside of the vessel a pleasing appearance. 10 In the embodiment illustrated in figure 6, sand 23 is sprinkled onto the outside of the vessel and held by the epoxy resin. The sand may be coloured and provides an aggregate layer. 15 Prior to applying the epoxy resin, it may be necessary to prep the vessel with an acid agent such as hydrochloric acid solution to remove any lime bloom. The invention provides a method to economically produce a durable shaped vessel such as a garden pot and allows vessels of various shapes to be 20 produced economically. The appearance of the vessel can be varied with colourants, aggregates and the like. The vessel can be made without the need for external molds or expensive equipment. In compliance with the statute, the invention has been described in language 25 more or less specific to structural or methodical features. The term "comprises" and its variations, such as "comprising" and "comprised of' is used throughout in an inclusive sense and not to the exclusion of any additional features. It is to be understood that the invention is not limited to specific features shown or described since the means herein described 30 comprises preferred forms of putting the invention into effect. The invention is, therefore, claimed in any of its forms or modifications within the proper scope of the appended claims appropriately interpreted by those skilled in the art.

10 Throughout the specification and claims (if present), unless the context requires otherwise, the term "substantially" or "about" will be understood to not be limited to the value for the range qualified by the terms. Any embodiment of the invention is meant to be illustrative only and is not meant to be limiting to the invention. Therefore, it should be appreciated that various other changes and modifications can be made to any embodiment described without departing from the spirit and scope of the invention.

Claims (13)

1. A method of manufacturing a vessel, the method comprising providing a former, applying cementitious slurry to the former by dipping the former into the cementitious slurry and hardening the applied slurry to form the vessel, the slurry comprising cement, water and sand as the sole aggregate.

2. The method of claim 1, wherein the former has a shape approximating the shape of the vessel.

3. The method of claim 1 or claim 2, wherein the former has a size approximating the size of the vessel.

4. The method of any one of the preceding claims, wherein the vessel is a plant pot.

5. The method of any one of the preceding claims, wherein the former comprises cardboard.

6. The method of claim 5, wherein the cardboard comprises a sheet material bent into a tube shape.

7. The method of any one of the preceding claims, wherein the former is dipped between 1-3 times in the cementitious slurry.

8. The method of claim 7, wherein a base is formed by pouring cementitious slurry into an upright orientated former.

9. The method of any one of the preceding claims, wherein the hardening process is carried out in a moist environment.

10. The method of any one of the preceding claims, wherein the hardened vessel is sprayed with epoxy resin. IL/

11. A vessel made according to any one of the preceding claims.

12. A method substantially as hereinbefore described with reference to the illustrations.

13. A vessel substantially as hereinbefore described with reference to the illustrations.