Note : Les descriptions sont présentées dans la langue officielle dans laquelle elles ont été soumises.
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PLASTIC LINER FOR HOME ORGANIZATIONAL ITEMS
BACKGROUND OF THE INVENTION
1. Field of the Disclosure
(0001] The present disclosure is generally directed to storage containers and,
more
particularly, to containers with plastic liners.
2. Description of Related Art
[0002] Consumers use woven or- non-woven storage containers such as baskets,
storage
cubes, hampers, and the like to decorate and organize their houses.
Additionally, consumers
use woven or non-woven containers as trash cans, picnic baskets, planters and
the like.
Typically, woven containers are made primarily of natural or other decorative
materials
including but not limited to wicker, rattan, seagrass, water hyacinth, banana
leaf, wood,
metal, plastic and bamboo. Many consumers prefer the appearance of these woven
containers to non-woven alternatives such as solid plastic, chipboard, or
cardboard
containers. Woven products typically have an open pattern defining spaces or
interstices due
to their woven nature. This often results in a container that is unable to
hold small items.
Additionally, the interiors of these containers are difficult to clean because
the woven
construction creates small, hard to clean crevices that trap dust or dirt.
Moreover, woven
containers made of cellulosic natural materials are often subject to water
absorption and
prone to mildew growth.
[0003] Some of these woven and non-woven containers are paired with a pre-
formed,
drop-in plastic liner made of a synthetic material such as polyester or PVC.
These liners are
manufactured independently of the container by various types of molding and
forming
operations. After they are manufactured, the pre-formed liners are later
placed inside of the
containers in a separate assembly operation. The pre-formed plastic liners
provide a
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cleanable and solid or non-perforated surface able to hold small items.
However, the pre-
formed liners do not match or integrate with the material of the outer walls
of the container
and may impair the container's overall appearance. Additionally, tooling costs
associated
with creating a pre-formed plastic liner can be expensive due to the need for
a separate liner
tool unique to each shape and size of container.
[0004] Furthermore, the use of pre-formed plastic liners may create
difficulties fitting the
plastic liner to a woven storage container. Specifically, woven containers
have inherently
variable dimensions from container to container, thereby frustrating any
attempt to pre-form a
generic liner. While a pre-formed plastic liner produced from independent
tooling may flex
minimally to adapt to its container. these liners are generally unable to
accommodate
significant variations in height, width, and/or length. Additionally, these
dimensional
variations may result in a height differential between the woven container and
the liner, a gap
between the walls of the woven container and the liner or, conversely, an
interference
between the liner and container.
[0005] Other known containers are lined with fabric. Fabric liners typically
provide more
aesthetic appeal than plastic liners. However, fabric liners typically lack
the cleanability
and/or water resistance of a plastic liner. Furthermore, fabric is typically
less durable than
plastic. Moreover, fabric liners are generally stitched or sewn onto woven
containers or
adhered to non-woven containers, both of which add cost to the manufacturing
process. One
known product for increasing the d~_~rability and cleanability of fabric
liners includes coated
fabric liners. Coated fabric liners e~ften include some stain resistant
coating applied with a
sprayer or roller. While these coated fabric liners may have some degree of
improved
durability and cleanability, they still require the added attachment process
and are not
aesthetically pleasing to many consumers.
(0006] Still further known contai ner liners include plastic film liners.
Known plastic film
liners typically include plastic bag-like components deposited directly into a
container such
as a fabric container, a woven container, or any other container and fixed to
a rim thereof.
The fixation is generally achieved with an adhesive or other means. While
these plastic film
liners tend to repel most stains and are capable of retaining small items,
they are also prone to
tearing and are rarely re-usable. Additionally, such plastic film liner
products are often not
very aesthetically pleasing as they do not match or integrate well with the
containers they are
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associated with. Accordingly, such plastic film liners are typically used in
gardening with
planters, pots and other containers.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] Objects, features, and advantages of the present invention will become
apparent
upon reading the following description in conjunction with the drawing
figures, in which:
[0008] FIG. I is a perspective view of a home decor product with an integrated
plastic liner
constructed in accordance with the veachings of the present disclosure;
[0009] FIG. 2 is a cross sectional view of the container depicted in FIG. 1
taken along line
II-II;
[0010] FIG. 3 is a magnified cross-sectional view of a wall of the container
taken from
Circle III in FIG. 2;
[0011] FIG. 4 is a magnified cross-sectional view of an alternate embodiment
of a wall of a
container constructed in accordance with the teachings of the present
invention and taken
from Circle III in FIG. 2;
[0012] FIG. 5 is a magnified cross-sectional view of yet another alternate
embodiment of a
wall of a container constructed in accordance with the teachings of the
present invention and
taken from Circle III in FIG. 2;
[0013] FIG. 6 is a magnified cro:;s-sectional view of yet another alternate
embodiment of a
wall of a container constructed in accordance with the teachings of the
present invention and
taken from Circle III in FIG. 2;
[0014] FIG. 7 is a perspective view of an alternate embodiment of a home decor
product
with an integrated plastic liner and one form of a rim component constructed
in accordance
with the teachings of the present disclosure;
[0015] FIG. 8 is a perspective view of another alternate embodiment of a home
decor
product with an integrated plastic liner and another form of a rim component
constructed in
accordance with the teachings of them present disclosure;
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[0016] FIG. 9 is a cross sectional view of a home decor product according to
the teachings
of the present disclosure and illustrating a manufacturing process
implementing a plug and a
barrier layer; and
[0017] FIG. 10 is a cross sectional view of a home decor product according to
the
teachings of the present disclosure and illustrating a manufacturing process
implementing an
exterior mask.
DETAILED DE;sCRIPTION OF THE DISCLOSURE
[0018] Referring to FIG. 1, a home decor product 1 including a container 10
with a plastic
liner 12 is shown. The container 10 has a base 14 and a sidewall 16 extending
up from the
base 14. The sidewall 16 and base 14 both have interior surfaces 16a, 14a,
respectively, and
exterior surfaces 16b, 14b, respecti~; ely. In the example shown, the sidewall
16 has four
panels, thereby defining a container 10 with a generally square cross-section.
The cross-
section of the container 10, however-., may be of any geometry or size
including but not
limited to square, rectangular, circular, cylindrical, partially spherical, or
any other polygonal
or non-polygonal geometry and ma,v or may not have a lid. The walls 16 and
base 14, as
depicted, are constructed in a wovev configuration from natural or other
decorative materials
including, but not limited to, wicker, rattan, seagrass, water hyacinth,
banana leaf, wood,
bamboo, metal, fabric wrapped cardboard, woven plastic or composite straps, or
any
combination of such materials with each other or with others. The walls 16 and
base 14 of
the disclosed container 10 may be constructed of multiple interwoven
components as an open
weave, knit, or mesh defining openings or spaces 18 (shown in FIGS. 3-5)
between its
various interwoven components. It should be appreciated, however, that the
container 10
may be any foreseeable container including a solid or substantially solid
container
constructed of plastic, metal, chipboard, leather-wrapped chipboard,
cardboard, fabric, or any
other suitable material for containin g items.
[0019] As stated above, the discl~,~sed container 10 has an integrated plastic
liner 12 that
conforms to the interior surfaces 16a, 14a of the walls 16 and base 14 of the
container 10, as
shown in FIGS. 1-6. The liner 12 provides a solid impermeable layer.
Additionally, in one
form, the liner 12 includes dimples l2a on its interior surface and
protrusions 12b on its
exterior surface, as shown in FIGS. 2-5. In the form depicted, the protrusions
12b at least
partial ly extend into the spaces 18 i n the walls 16 and base 14 of the
container 10, as shown
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in FIGS. 3-5. The protrusions 12b fractionally engage the container 10 at the
sides of the
spaces 18. The shear forces resulting from this frictional engagement
mechanically
interconnect and secure the liner 12 to the container l0. Additionally, the
plastic liner 12
may be bonded or adhered to the walls 16 and base 14 of the woven container
10, as will be
discussed in greater detail below. ~fhe liner may 12 cover as much or as
little of the container
as desired. Furthermore, the thickness of the liner 12 may be selected as
desired. While
the home decor product 1 has just been described as including a container 10
defining spaces
18, it should be appreciated that the container 10 may alternately be formed
to be solid or
substantially solid, as mentioned above. A solid or substantially solid
container 10 may
include a tightly woven container or simply a container made of solid material
such as plastic,
metal, wood, or any other material ~,vith or without openings formed in the
interior surface
thereof. FIG. 6 depicts a sidewall 16 of one such solid container 10 including
an interior
surface 16a with openings or pockets 21. In this form, the liner 12 includes
only protrusions
12b. The protrusions 12b interlock with the pockets 21 to secure the liner 12
and the
container 10 together. In another form, the container 10 may not include
openings at all, but
may have substantially smooth interior surfaces 14a, 16a. In such a case, the
liner 12 attaches
to the container 10 via shear stresses or adhesive or a combination of both.
[0020) To achieve any of the above-described home decor products l, the
integrated
plastic liner 12 may be constructed through a vacuum thermoforming process for
forming
molten or semi-molten plastic to the shape of the container walls 16 and base
14. During this
process, a nest, die, or cavity is used to hold the container 10 securely in
place and to affect
the container's shape if needed. Next, the molten or semi-molten plastic sheet
is placed over
the opening of the container such tloat the plastic sheet is adjacent to or in
contact with a rim
of the container 10. Alternately, the molten or semi-molten plastic sheet may
be directly
inserted into the container 10. During the vacuum thermoforming process, the
plastic sheet is
then drawn via vacuum pressure, which will be discussed in greater detail
below, to deform
and conformingly engage the interior surfaces 14a, 16a of the container 10.
The vacuum may
be created using vacuum ports loca~:ed in the nest, die, or cavity used to
secure the container
10. It should be understood that in the case of a solid container 10, the
container 10 should
include one or more vent holes for allowing air to escape during the vacuum
process.
[0021) Upon contacting the interior container surfaces 14a, 16a, the molten or
semi-molten
plastic sheet conforms to the geometry of the container 10. In one form, the
plastic inherently
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adheres to the interior surfaces 14a, 16a. In other forms, the plastic may not
adhesively bond
with the material of the container 10. As mentioned above, however, the
plastic liner 12 may
be drawn into the spaces 18 or pockets 21 of the container wall 16 and base 14
to create the
protrusions 12b and, if applicable, the dimples 12a. As stated above, the
protrusions 12b
mechanically interconnect and secure the container 10 to the plastic liner 12
by fractionally
engaging the container 10 adjacent to the spaces 18 or in the pockets 21,
thereby preventing
the liner 12 from easily slipping out of the container 10.
[0022 Alternately, as stated abo~~~e and depicted in FIG. 5, the outer surface
of the liner 12
may have an adhesive layer 22. Th" adhesive layer 22 may be active or at least
activated
during the above-described forming; process to adhere the liner 12 to the
container 10. It
should be appreciated that, in one form, the adhesive layer 22 is utilized in
combination with
the interlocking protrusions 12b and spaces 18 to retain the liner 12 inside
the container 10.
In another form, however, the liner 12 may not include the protrusions 12b
and, therefore, the
adhesive layer 22 is used as the sole device for retaining the liner 12 within
the container 10.
Additionally, while FIG. 5 depicts the adhesive layer 22 coating substantially
the entire
exterior surface of the liner 12, an alternate form may include the adhesive
layer 22 coating
less than the entire exterior surface of the liner 12. For example, the
adhesive layer 22 may
coat the exterior surface of the liner I 2 in parallel or cross-hatched bands
intended to
adheringly engage corresponding parallel or cross-hatched components of the
woven
container 10.
[0023] Additionally, if the rim 2C> of the container 10 has a rough surface, a
manufacturing
collar may be applied to the rim 20 prior to the molten sheet being positioned
on the rim 20
or inserted into the container 10. In one form, the collar may have a smooth
surface for
creating a seal between the molten plastic and itself. In another form, such a
smooth surface
may not be required. Thus, the collar will assure that the vacuum is able to
create a sufficient
suction to draw the molten plastic sfneet into engagement with the interior
surfaces 14a, 16a
of the container 10, as well as into the spaces 18 or pockets 21 to create the
protrusions 12b
and, if applicable, the dimples 12a. While the use of such a collar may be
beneficial in some
applications, it should be appreciated that it need not be used in all
applications.
[0024] In another form, the thermoforming method uses a one-piece pre-formed
plastic
liner. The pre-formed liner is created by heating a plastic sheet to a molten
or semi-molten
state and then molding the sheet using a male pre-forming tool such as a plug.
This molding
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may be accomplished inside or outside of the container. After the sheet is
heated, the exterior
surface of the forming tool is brought into engagement therewith. The sheet
then deforms
and takes the shape of the forming tool. It should be understood that the pre-
forming tool is
dimensioned such that it creates a plastic pre-form having external dimensions
slightly
smaller than the internal dimensions of the container 10. In the case where
the pre-form is
pre-formed outside of the container and while still in its molten or semi-
molten state, it is
then placed into the container 10 and thermoformed to the interior surfaces
14a, 16a, as
described above. This method may be useful to create liners 12 for containers
10 with steep
walls or to assist in controlling the thickness of the liner 12 throughout the
thermoforming
process. It should be appreciated that while the process just described
includes placing the
pre-formed liner into the container 10 still in its molten or semi-molten
state, an alternate
process may include allowing the pre-form to cool outside of the container 10.
The cooled
pre-form may then be placed into the container 10 and reheated to the molten
or semi-molten
state prior to performing the thermoforming operation.
[0025) In yet another form, a blow-molding process is used to form the liner
12.
Variations on this method include applying extrusion blow-molding, injection
blow-molding,
or injection stretch blow-molding techniques. Generally, during the
application of any of
these blow molding techniques, a fixture or adjustable table may be required
to hold the
container 10 steady.
[0026] During the application of an extrusion blow-molding technique, an
extruded
parison of molten plastic with a pinched-off bottom end is lowered into the
container 10.
Once the parison reaches the base 14 of the container 10, hot air is blown
into the interior of
the parison. The force created by the hot air creates a pressure that is
applied substantially
uniformly to the interior surfaces of the parison and stretches the parison
outward until it
conformingly engages the interior surfaces 14a, 16a of the container 10. After
the parison
has stretched to conform to the inner surfaces 14a, 16a of the container 10,
the plastic is
allowed to cool. Additionally, similar to that described above regarding the
thermoforming
vacuum process, one form of this process may include placing a collar on top
of the container
prior to applying the hot air. In such a case, the collar may serve to provide
a compressive
load to the parison at the rim 20 of the container 10, thereby securing the
parison in place.
Additionally, the collar may prevent or restrict the flow of the molten or
semi-molten parison
during the molding process relative to the rim 20.
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[0027] Alternatively, in the case of an injection blow-molding or injection
stretch blow-
molding process, an injection molded pre-form is made prior to beginning the
thermoforming
process. In one form, the pre-form is then placed inside of the container 10,
heated to a
molten or semi-molten state, and subsequently blown or stretched until the
plastic engages
and forms to the walls 14a, 16a of the container 10, as described above. In
another form, the
pre-form is heated prior to being placed inside of the container 10.
[0028] It should be appreciated that in any of the above-described forming
processes, an
excess portion of the liner 12 may remain extending beyond the rim 22 of the
container 10
after cooling. In such a case, the excess portion should be trimmed with a
trimming tool to
provide a clean and aesthetically pleasing finish to the home decor product 1.
In some
situations, the rim 20 of the container 10 may not provide a sufficiently
uniform or rigid
surface along which the trimming tool may travel for trimming the excess
liner. Therefore, in
one form, the manufacturing collar discussed in either of the above-described
processes may
be used to guide the trimming tool. In such cases, the trimming tool may
travel directly along
a rigid external surface of the manufacturing collar around the rim 20 of the
container 10 to
remove the excess liner 12. Alternately, the manufacturing collar may include
an elongated
recess or groove formed on an interior surface thereof. The recess or groove
would then
receive the trimming tool and guide it adjacent the rim 20 to trim the excess
liner. In another
alternative form, the container 10 itaelf may include an elongated recess
formed in its interior
surface 16a near the rim 20 for receiving and guiding the trimming tool. In
any of these
cases, the liner 12 is formed to extend beyond the rim 20 of the container 10
and is
subsequently trimmed.
[0029] In yet further forms, the liner 12 may be formed with the excess
serving as a top
flare that is rolled or folded over the rim 20. Subsequent to cooling, the top
flare is rolled
over the rim 20 and adhered or otherwise secured to the container 10.
Alternatively, the top
flare may be rolled or folded over the rim 20 while the liner 12 is still in a
semi-molten state
and then allowed to cool.
[0030] In still another form, a trim jig may be used to trim the excess liner.
In such a case,
the trim jig would include both a trimming tool and a guiding surface, against
which the liner
12 is to be trimmed. The trim jig rr~ay be configured to engage the excess
liner in slight
tension, travel around the container l 0 at some predetermined distance from
the rim 20, and
simultaneously trim the liner 12.
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[0031] In still yet another form, it is foreseeable that the container 10 may
include a
foldable rim portion including, for example, the top one or two inches of the
container 10
adjacent the rim 20. In such a case, subsequent to forming the liner 12, the
rim portion is
folded outward, any excess liner is trimmed with a trimming tool, and the rim
portion is
returned to its original position.
[0032] It should be appreciated that the various processes described herein
are merely
examples and foreseeable alternatives are intended to be within the scope of
the present
disclosure. Additionally, it should be appreciated that while the processes
have been
described as including various seduences of actions, alternative sequences of
the disclosed
actions and sequences including supplemental actions not explicitly described
herein are
intended to be within the scope of t-he present disclosure. Furthermore, while
some of the
above-described processes have been disclosed as alternatives, variations and
combinations
thereof are also intended to be within the scope of the present disclosure.
[0033] FIGS. 7 and 8 depict alternative forms of the home decor product 1 of
the present
disclosure. The home decor products depicted in FIGS. 7 and 8 may be
manufactured in any
of the foregoing molding processes and are identical to the home decor product
1 depicted in
FIG. 1, with the exception that they further include a rim component 24. The
rim component
24 is fixed to the rim 20 to provide a clean aesthetically pleasing finish to
the home decor
product 1. For example, as stated above, some manufacturing processes may
produce excess
liner 12 extending beyond the rim ~',C> that needs to be trimmed away. In such
cases, the
component 24 serves to cover any inconsistencies or roughness in the trimmed
liner 12 and/or
rim 22. In another form, the rim component 24 may actually serve to increase
the rigidity or
durability or some other structural characteristic ofthe home decor product 1.
[0034) Specifically, FIG. 7 depicts a rim component 24 including a rim cap 26.
The rim
cap 26 generally includes a one-piece component constructed of the same
general geometry
of the rim 20 of the container 10. It should be appreciated, however, that, as
stated above, the
container 10 may take on virtually uny form and therefore, so might the rim 20
and the rim
cap 26.
[0035] According to one form, the rim cap 26 may include a wooden cap 26 fixed
to the
rim 20 with an adhesive. The adhesive may be wood glue, silicone caulk, rubber
cement,
epoxy, or any other type of adhesi~; e. Accordingly, during manufacture of the
home decor
product 1 depicted in FIG. 7, adhesive is applied to one or both of the rim 20
and the rim cap
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26 after the liner 12 is thermoformed. Thereafter, the rim cap 26 is placed
onto the rim 20, or
vice versa, and secured in place with a clamp or some other device until the
adhesive cures,
thereby fixing the two components together. Although the rim cap 26 has been
described as
being fixed to the rim 20 of the container 10 with an adhesive, it should be
appreciated that
any device for fixing the two components together is intended to be within the
scope of the
present disclosure. For example, the rim cap 26 may be fixed to the rim 20
with nails,
threaded fasteners, double-sided adhesive strips, staples, or any other device
capable of
serving the intended purpose. Additionally, while the rim cap 26 has been
described as being
manufactured of wood, it may alternatively be manufactured of metal, plastic,
cardboard,
wicker, rattan, seagrass, water hyacinth, banana leaf, bamboo or any other
material capable of
serving the intended purposes. Fun hermore, although the rim cap 26 has been
disclosed as
being a one-piece rim cap 26, it ma.v alternately be constructed of multiple
pieces that are
fixed independently or dependently to the container 10. Finally, while the rim
cap 26 and
manufacturing collar discussed above have been described as being distinct
components, the
two may foreseeably be the same component.
[0036) Alternatively, as mention.°d above, FIG. 8 depicts an alternate
rim component 24
including an internal trim component 28. The internal trim component 28 serves
generally
the same purpose as the rim cap 26. but instead of being attached directly to
the rim 20, it is
attached to the interior surface 16a cof the sidewall 16 adjacent the rim 20.
It should be
understood that the internal trim co rnponent 28 may be constructed of any of
the materials
listed above for the rim cap 26 and may be fixed to the container 10 by any of
the devices
discussed above regarding the rim c:ap 26. In one form, the internal trim
component 28 is
stapled to the interior surface 16a of the container 10. Furthermore, while
FIG. 8 depicts the
internal trim component 28 as bein<.; a one-piece rim component 24, it may
alternatively
include multiple pieces secured together or to the container 10 in any
desirable fashion.
Further yet, while the rim component 24 has been described herein as including
either a rim
cap 26 or an internal trim component 28, it may foreseeably include any type
or configuration
of a rim component 24 located adjacent to or in proximity to the rim 20 of the
container to
thereby increase at least one of the aiesthetic appeal of the home decor
product l, the
structural integrity of the home decor product l, or any other feature. For
example, in one
alternate form, the rim component :~4 may be attached to the exterior surface
16b of the
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sidewall 16 of the container 10 or any combination of attachment to the
interior surface 16a,
the rim 20, and the exterior surface 16b so as to serve the principles of the
present disclosure.
[0037] While the liner 12 has been generally disclosed as being plastic, it
should be
appreciated that, in light of the disclosure provided herein, any melt-
processable material may
be used to construct the liner 12. To maintain the aesthetic value of the
container 10,
however, a suitable material is a flexible thermoplastic elastomer which
provides a rubber-
like appearance or a polymer that produces a transparent, semi-transparent, or
opaque glass-
like appearance such as poly-vinyl ~~hloride, polyester, or polystyrene.
However, any
material capable of being thermofoo~med or blow-molded may be used including
olefins such
as, for example, polyethylene and polypropylene.
[0038] Additionally, while the liner 12 has, thus far, been disclosed as
including a single
layer liner, in other forms, the liner 7 2 may include multiple layers. These
multiple layers
may be provided in the form of, for example, co-extruded plastic sheets or
thermoformable
laminates. In one example, a two-color co-extruded sheet is thermoformed to
construct the
liner 12. The two-color plastic sheet has two layers of different colors
creating a top color
and a bottom color. When the plastic sheet is thermoformed to construct the
liner 12, the
interior surface of the liner 12 is defined by the top color of the sheet and
the exterior surface
of the liner 12 is defined by the bottom color of the sheet. In another
example, the liner 12
includes a plastic sheet with a soft material top layer and hard material
bottom layer. The soft
material top layer forms the interior surface of the liner 12 and the hard
material bottom layer
forms the exterior surface of the liner 12. Alternately, the hard material may
serve as the
internal layer and the soft material -may serve as the external layer, if
desired. If this is the
case, during thermoforming, the soft external layer may deform and protrude
through the
spaces 18 in the container 10, while the hard internal layer may remain
smooth. This may
further enhance the cleanability of ~:he liner 12. Further, it should be
understood from the
description provided that thermofiormable co-extruded materials or laminates
not expressly
disclosed herein may be used to ccnnstruct the liner 12.
[0039) In light of the foregoing, the disclosed plastic lined home decor
product 1 provides
a number of advantages. The liner 12 is durable and cleanable and enables a
woven container
to accommodate small items. The liner 12 further provides a durable protectant
for the
container material, whether it is w~c~i~en material or non-woven material.
This protectant
serves to extend the useful life of thc: home decor product, thereby
increasing its consumer
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appeal. The disclosed invention guarantees a tight-fitting liner, since the
process inherently
accounts for dimensional variation, which is common to woven containers. In
contrast, pre-
formed plastic liners such as die cut plastic or traditional liners will not
conform to the shape
of the container walls. Furthermore, because such containers are often
manufactured in a
multitude of shapes and sizes, a multitude of unique tools or dies are
required to manufacture
the pre-formed plastic liners off line. Producing this multitude of tools and
dies can be costly
and inefficient. The present disclos~.ire eliminates the cost of producing
these tools by
providing at least one process for forming a plastic liner into a container
using thermoforming
processes. These processes, as should be understood from the description
herein, are readily
adaptable to be performed on generally any shape or size container.
Additionally, use of the
disclosed processes with woven or non-woven containers creates a novel and
desirable
appearance. In one form, the disclosed home decor product using a clear
plastic liner
material, the process produced rounded protrusions that protrude from the
openings in the
weave, giving the aesthetically plea::urable appearance of blown glass, as
shown in FIGS. 2-
5.
[0040] With reference to FIGS. 9 and 10, a yet further home decor product 101
according
to the principles of the present discl~asure and various processes for
manufacturing the home
decor product 101 are described. Because the product and processes disclosed
in FIGS. 9 and
include features similar to those described above, like features are assigned
like reference
numerals increased by one hundred. The home decor product 101 includes a
container 110
and a liner 112.
[0041) The liner 112 can be created by a number of methods using a variety of
materials.
In a first example, as shown in FIG. 9, the container liner 112 is
manufactured using a casting
process. In this example, foam or casting resins are poured into the woven
container 110 and
cured to form the liner 112. The woven container 110 may be placed in a nest,
die, or cavity
to securely locate the container 1 l 0 and to affect its shape if needed.
[0042) A barrier layer 111 may be needed for containers constructed with a
more porous
weave or from certain materials. In one example, as shown in FIG. 9, the
barrier layer 111 is
applied to the inside of the container' 110 prior to the application of a
resin, plastic or foam
liner 1 12 to prevent material from s~;;eping through the woven material. This
barrier 111 can
be a cellulosic material with an adht~~sive backing, a polypropylene film, or
any solid adhesive
21530!x39.1 12
CA 02549400 2006-05-31
backed substrate or other material that can provide a substantially foam or
resin impermeable
barrier to prevent the foam or casting resins from penetrating the weave of
the container 110.
[0043] Once the container 110 is secured in the nest and any necessary barrier
layer 111 is
in place, a predetermined amount of casting material is poured into the bottom
of the
container 110. A plug 113, as shoe%n in FIG. 9, is lowered into the cavity of
the container
and clamped in place to hold a fixed position relative to the container 110.
The plug 113 may
be made of wood, aluminum, or other suitable material and may be coated with a
release
coating such as a silicone boot or silicone spray. The plug 113 is dimensioned
to reflect the
interior shape desired of the liner 1 12 in the container 110. The plug 113 is
also dimensioned
such that it is smaller than the inside walls of the container 110. The
difference in size
creates a cavity between the interior walls of the container 110 or surfaces
of the barrier layer
111 and the outer surface of the plug 113. The poured foam expands or the
liquid resin rises
to fill this cavity. The resin is then cured for a predetermined time period
dependant upon
material selection, liner thickness, and other factors before the plug 113 is
removed. The use
of a barrier layer 111 may not be needed if the weave of the container is
tight enough to
prevent the casting material from seeping through the interstices in the woven
container 110
or if the casting material is viscous enough such that it does not seep
through the interstices in
the woven container 110.
[0044] Another method to create an integrated lined container 101 is to spray
coat the
interior of the container 110 with the desired liner material. In this
example, materials such
as elastomers, powder coats, adhesives, urethanes or other similar materials
can be sprayed to
construct the liner. The interior of the container 110 is sprayed to create a
network of layers
to form the liner 112 on the interior walls of the container 110. This method
works well for
tightly-woven or solid-wall containers, and also where an initial barrier
layer 111 has been
applied.
[0045] For loose-weave containers, construction of a sprayed liner may require
the use of
either an outer mask 115 (shown in FIG. 10) or inner barrier 111. To construct
a liner 112
with an outer mask 1 15, the exterior surfaces of the walls and base of the
container 110 are
coated with a release coating such a.s a wax label, low surface energy
plastic, silicone, or
other such material. Then, the interior surface of the walls and base of the
container 110 is
sprayed with the liner material. NIa erial that passes through the weave of
the container 110,
bonds to itself to create a solid wall, but releases from the outer mask 115
when the mask is
21530939.1 13
CA 02549400 2006-05-31
removed. The mask 115 may be either physically removed, or it may be made from
a soluble
material and dissolved.
[0046] Alternately, to construct a sprayed coated lined container using an
inner barrier 11 l,
an inner barrier 111 is placed on the interior surfaces of the container 110,
as shown in FIG.
9. The inner barrier I 11 is adhered or otherwise affixed to the interior
container surfaces.
Once the inner barrier 111 is in place the liner material is sprayed on top of
the barrier 111.
A layer of liner material can be suff iciently thick to cover the natural
defects found in the
hand-woven containers and seal the interstices in the weave.
[0047] Numerous materials are suitable for construction of the liner 112. In
one example,
liners have been constructed using a 2-part urethane material that is mixed
immediately prior
to pouring into the container 110. Any other suitable urethane system can be
used instead.
Furthermore, other mufti-part reactive materials may be used instead of
urethane.
Additionally, colorants may be added to one or more of the components prior to
mixing to
achieve a desired visual effect. Mcareover, numerous other materials are
suitable for
construction of the liner including, ~~ut not limited to, rigid or flexible
foam, cast flexible
urethane, rubber, cast stiff urethane, or the like.
[0048] When forming the liner 1 12 from urethane foam, it is desirable to
select a foam that
will generate a solid, sufficiently thick skin on the interior surface of the
container 1 I 0. This
will provide an easy to clean, durable, non-permeable surface. Often, the best
way to create a
durable non-permeable skin on the interior surface of a foam liner is to use
an aluminum plug
113 with internal water cooling to achieve maximum heat transfer at the
surface of the foam
in contact with the plug 113. Alternatively, self skinning foams can also be
used in place of
the aluminum tooling.
[0049] The interior barrier layer t 1 1 used for containers with loose weave
or for less
viscous liner materials may be made from any material that can provide a
substantially foam
or resin impermeable barrier to precedent the uncured liner material from
penetrating the barrier
layer 111. In one example of an interior barrier layer 111, a cellulosic
material with an
adhesive backing is applied to the interior of the container 110 such that the
adhesive surface
of the barrier layer contacts the interior surface of the container 110 to
hold the barrier layer
111 in place prior to application of the uncured liner material. The interior
barrier layer 111
may be relatively thin in comparison to the thickness of the liner 112. The
barrier layer 111
may be a polypropylene film, or any other material that can provide a
substantially foam or
21530939.1 14
CA 02549400 2006-05-31
resin impermeable barrier to prevent the uncured liner material from
penetrating the weave of
the container 110.
[0050] The exterior mask 115 used for containers with loose weave or for less
viscous liner
materials may be constructed from a low surface energy material that will not
adhere to the
liner material. The exterior mask 1 15 may be formed using a coating such as
low surface
energy plastic, silicone, or other such material. Alternately, the exterior
mask 115 may be
constructed from a wax coated paper- or other sheet of material used to cover
the exterior
surface of the container 110, as shoNm in FIG. 10. After the liner material
has cured, the
mask layer 115 may be physically peeled away from the woven container 110 or,
in the case
of a mask 1 15 made from soluble material, may be dissolved.
(0051 The disclosed coating lined woven storage container 101 has a number of
advantages. The disclosed liner 11 ~ is cleanable and moisture resistant while
economical to
manufacture. Unlike separately tooled plastic liners the disclosed
manufacturing processes
can easily be adapted to accommodate different sizes and shapes of containers.
Moreover,
the process for creating the integrated liner 112 readily adapts to and
accommodates
dimensional variation commonly f~:vund in woven containers and ensures a tight
fit between
the liner and the container wall. The lining process is robust because the
disclosed liners and
methods easily adapt to container variation in a way that pre-formed plastic
liners can not. It
is also likely that this invention provides economic advantages over the
current methods,
depending on the selection of liner materials.
[0052] Additionally, the disclosed processes create a tight-fitting or even
permanent liner.
In contrast, traditional plastic liner; are loose fitting, removable, and
often contain gaps
between the liner and the surrounding container.
[0053] Although certain lined containers, materials, and methods for
manufacturing such
lined containers have been described. herein in accordance with the teachings
of the present
disclosure, the scope of coverage crf~this patent is not limited thereto. On
the contrary, this
patent covers all embodiments of the teachings of the disclosure that fairly
fall within the
scope of permissible equivalents.
21530939.1 15
