Note: Descriptions are shown in the official language in which they were submitted.
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TITLE
Paper-Based Malleable Dough for Moulding and Sculpting
Applications
BACKGROUND
[0001] Polystyrene is well known for its use as isolation panel.
Because of both its friability and lightness, polystyrene is also used to
create
decorative objects.
[0002] Drawbacks of the use of polystyrene to create objects include
its heavy environmental footprint, the fact that it is carcinogenic, its
irritability to
the skin and eyes, the lack of durability of the resulting object, etc.
[0003] The technique of papier-mâché is also well-known to create
decorative and artistic objects. While it does not share the negative
environmental characteristics and detrimental health issues of the
polystyrene,
it is far from being resilient and durable enough to be considered in
manufacturing long-lasting artistic, ornamental or functional objects.
[0004] Cork is also used to create decorative, artistic and functional
objects. A drawback of cork is its increasing scarcity which causes its price
to
rise. In additional, cork is not malleable, which limits its applications.
[0005] There is therefore a need for a material that is ecological,
durable, malleable and lightweight.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] In the appended drawings:
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[0007] Figure 1 is a flowchart of a process for manufacturing a
paper-based malleable dough according to an illustrative embodiment;
[0008] Figure 2 is a perspective view of an ornamental moulding
manufactured using the paper-based malleable dough resulting from the
process from Figure 1;
[0009] Figure 3 is a perspective view of the moulding from Figure 2,
illustrated with a soft mould cavity and a mould support used in its shaping;
[0010] Figure 4 is a perspective view of an ornamental shelf
manufactured using the paper-based malleable dough resulting from the
process from Figure 1;
=
[0011] Figure 5 is a perspective view of the shelf from Figure 4,
illustrated with a rigid cavity used in its shaping;
[0012] Figure 6 is a display board incorporating a panel
manufactured using the paper-based malleable dough resulting from the
process from Figure 1;
[0013] Figure 7 is a perspective view of a wall section made using
faux brick wall panels manufactured using the paper-based malleable dough
resulting from the process from Figure 1; and
[0014] Figure 8 is perspective view illustrating the sculpting of a
head using the paper-based malleable dough resulting from the process from
Figure 1.
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SUMMARY
[0015] An object of the present invention is to provide a paper-based
malleable dough for moulding and sculpting applications that allows creating
objects that are ecological, recyclable, durable, malleable and lightweight.
[0016] In accordance with an illustrative embodiment, there is
provided a paper-based malleable dough comprising:
[0017] paper and water, wherein the weight ratio of the shredded
paper to the water is between about 1:4 and 1:6 and
[0018] at least one joint compound in a weight ratio to paper of
between about 11:8 to 17:8.
[0019] In addition to the above mentioned qualities thereof, the
malleable paper-based dough can preserve a given form immediately after its
creation, allowing for example successive moulding and unmoulding at a fast
pace. Moreover, depending on the intended use, the drying time can be fine
tuned within a given range.
[0020] According to another illustrative embodiment, there is
provided a manufacturing process for a paper-based malleable dough,
comprising:
[0021] soaking and mixing shredded paper in water, yielding a paper
dough; and
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[0022] adding and
mixing at least one joint compound with the paper
dough, wherein all of the at-least one setting type compound is added in a
weight
ratio of setting type compound to shredded paper of between about 11:8 to
17:8.
[0022.1] According to
another embodiment, there is provided a paper-
based malleable dough manufacturing process, comprising:
providing a paper dough comprising paper and water; and
adding and mixing at least one setting-type joint compound
with the paper dough, wherein all of the at least one setting type compound is
added in a dry weight ratio of setting-type compound to shredded paper of
between about 11:8 to 17:8.
[0022.2] According to
another embodiment, there is provided a method
for manufacturing a paper-based product, comprising:
- providing a paper dough comprising paper and water;
- mixing the paper dough with at least one setting-type joint compound to
obtain a mixture comprising a dry weight ratio of setting type compound
to paper of between about 11:8 to 17:8;
- moulding said mixture to obtain a moulded product of a desired shape;
and
- allowing the moulded product to dry.
[0022.3] According to
still another embodiment, there is provided a
moulded paper-based product, comprising: a mixture of paper dough and at least
one setting-type joint compound that has been moulded and dried, wherein said
dried mixture comprised prior to drying a weight ratio of setting-type
compound
to paper of between about 11:8 to 17:8.
[0023] According to
still another illustrative embodiment, there is
provided a kit for creating an object comprising:
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[0024] at least one joint compounds;
[0025] instructions relative to soaking and mixing shredded paper in
water for obtaining a paper dough and instructions for adding and mixing at
least
one setting-type joint compounds with the paper dough in order to obtain a dry
weight ratio of setting-type compound to paper of between about 11:8 to 17:8.
[0026] Other objects, advantages and features will become more
apparent upon reading of the following non-restrictive description of
illustrative
embodiments thereof, given by way of example only with reference to the
accompanying drawings.
DETAILED DESCRIPTION
[0027] In the following description, similar features in the drawings
have been given similar reference numerals, and in order not to weigh down the
figures, some elements are not referred to in some figures if they were
already
identified in a precedent figure.
[0028] The use of the word "a" or "an" when used in conjunction with
the term "comprising" in the claims and/or the specification may mean "one",
but
it is also consistent with the meaning of "one or more", "at least one", and
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"one or more than one". Similarly, the word "another" may mean at least a
second or more.
[0030] As used in this specification and claim(s), the words
"comprising" (and any form of comprising, such as "comprise" and
"comprises"), "having" (and any form of having, such as "have" and "has"),
"including" (and any form of including, such as "include" and "includes") or
"containing" (and any form of containing, such as "contain" and "contains"),
are
inclusive or open-ended and do not exclude additional, non-recited elements.
[0031] The expression "paper" is to be construed in the description
and in the claims as including any sheet-like material manufactured with
vegetable fibers pulped, including paper and cardboard which are new or
recycled, newspaper, etc.
[0032] A process 100 for manufacturing a paper-based malleable
dough 8 will now be described with reference to Figure 1.
[0033] The process 100 includes:
[0034] 102 - soaking shredded paper in the chlorinated water;
[0035] 104 - mixing the shredded paper in the chlorinated water so
as to yield a paper dough 6;
[0036] 106 - adding and mixing a colorant in the paper dough 6; and
[0037] 108 - adding and mixing one or a plurality of setting-type joint
compound in the paper dough 6.
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[0038] Each of the steps 102 to 108 will now be described in more
detail.
[0039] In step 102, shredded paper is first mixed in chlorinated
water.
[0040] The shredded paper can be provided in a wide size range of
its individual pieces. For example, the shredded paper is in the form of 5 mm
by
3 cm paper bands such as provided by a typical paper shredding machine.
[0041] Prior of or after the shredded paper is added in the water, a
chlorination tablet is added and mixed in the water. Chlorine is added in the
water to act as an antifungal agent. In addition to contribute to the long
lasting
of the final product, the chlorine also acts as a bleaching agent on the
paper.
This allows yielding a white paper or at least a lighter dough at the end of
step 102.
[0042] The chlorine is added in water according to a ratio of 1 g per
liters of water. For example, a typical chlorine tablet used in the
maintenance of a pool or spa can be used. According to another embodiment,
the chlorine is added in another form than tablet, such as in liquid or powder
form.
[0043] Also, the chlorine can be added in the water according to
another ratio, wherein a more dilute solution of chlorine may result in a
darker-
tone and/or a less clean dough following step 102.
[0044] According to still another embodiment, the chlorine is omitted
or substituted or complemented by other bleaching and/or antifungal agent.
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[0045] According to the first illustrated embodiment, the shredded
paper is added in the chlorinated water according to a weight ratio of the
shredded paper to the water of about 1:5.
[0046] As will become more apparent upon reading the remaining
description of the process 100, the quantity of water may vary from the above-
mentioned shredded paper to water ratio. Such a ratio will impact on the
consistency of the final product at the end of step 108 and its drying time.
[0047] The shredded paper is soaked in the chlorinated water for a
period of time within about 2 minutes and 24 hours.
[0048] After the above soaking time, a paper dough 6 is created by
further mixing the shredded paper/chlorinated mixture. This can be achieved
using for example a mixer that includes sharpened blade, but any mixing
device, implement or method can be used in step 104.
[0049] A colorant is then added and mixed to the paper dough
(step 106). Any mixing device, implement or method can be used to achieve a
homogenous mixture. The resulting mix then rests for about two (2) hours.
[0050] According to the first illustrated embodiment, an ecological
latex-based colorant is added in sufficient quantity to achieve a desired
aesthetic result. According to another embodiment, another colorant type is
used. According to still another embodiment, step 106 is omitted.
[0051] Since it is believed to be within the reach of a person skilled
in the art to add colors to a paper-based product, it will not be described
herein
in more detail for concision purposes.
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[0052] In step 108, three different joint compounds are added and
mixed in the paper dough 6.
[0053] Two of the three compounds added in step 108 are
chemically setting compounds for gypsum panels and ceiling boards such as
the asbestos-free Durabond 45 and Durabond 90 setting-type joint
compounds from CGC Inc. According to the manufacturer, the Durabond 45
has a setting time of between 30-80 minutes, while the Durabond 90 has a
setting time of between 85-130 minutes. Each compound is added to the paper
dough 6 in a weight ratio of compound to shredded paper of about 1:2. For
example, for a paper dough formed by mixing about 1.8 kg (4 lbs) of shredded
paper to about 9.1 kg (20 lbs) of water in step 102, 0.9 kg (2 lbs) of each
setting-type joint compound is added, which corresponds to about 1 liter of
each compound. Both compounds are homogeneously mixed with the dough 6.
[0054] It has been found that adding joint compound to the paper
dough resulting from step 104 or 106 yields a malleable paper pulp which can
be shaped and formed, for example by moulding or sculpture, and which holds
a given shape.
[0055] The third compound that is added in step 106 is a
SHEETROCK ceiling spray texture powder such as produced by CGC Inc.
According to the first illustrated embodiment, the SHEETROCK ceiling spray
texture powder is the CGC SHEETROCK Brand Ceiling Spray Texture E-Z
Spray. This third compound is added to the paper dough in a weight ratio of
compound to shredded paper of about 3:4. For the aforementioned exemplary
quantity, about 1.4 kg (3 lbs) is added. This corresponds to about 2 liters of
powder.
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[0056] This third compound adds texture to the finished product 8
after the malleable dough is given sufficient time to dry. The resulting
product
has a look similar to rock or concrete.
[0057] All three compounds added in step 108 are in powder form
and the total amount thereof is between 2.5 kg and 3.9 kg for each 1.8 kg of
shredded paper. In other words, the total amount of compound added in step
108 is in a weight ratio of compound to shredded paper of between about 11:8
to 17:8.
[0058] Adding more joint compound powder in step 108 for a given
weight of paper dough results in a malleable paper dough 8 which takes less
time to dry, but, as a tradeoff, that is more dense and heavy. Conversely,
adding less joint compound in step 108 results in a malleable paper dough 8
that takes longer to dry but that is lighter. The quantity of compounds added
in
step 108 can also be adapted to the quantity of water used in step 102. For
example, using a lesser quantity of water in step 102 for a given weight of
shredded paper may be compensated by using a lesser amount of joint
compounds in step 106.
[0059] Also, the quantity of SHEETROCK ceiling spray texture
powder may be compensated by adding more of the two chemically setting
compounds. According to another embodiment, the sheetrock ceiling spray
texture powder is omitted.
[0060] According to another embodiment, other joint compound than
those mentioned hereinabove are used in manufacturing a paper-based
malleable dough 8 which can keep a given shape immediately after step 108.
The brands and manufactures of joint compounds are only given for illustrative
purposes.
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[0061] The malleable paper dough 8 resulting from step 108 is ready
to be formed and/or used in manufacturing products.
[0062] It is important to note that implementing the process 100
using the fixed quantities and ratio values provided hereinabove yields a
paper-
based malleable dough 8 than can maintain a given form and therefore which
can be unmoulded immediately after moulding.
[0063] Figure 2 shows an example of an ornamental moulding 10
formed using the paper-based malleable dough 8.
[0064] With reference to Figure 3, the moulding 10 is obtained by
filling a soft mould cavity 12 with the paper-based malleable dough 8. The
mould cavity 12 is made of a latex mould making rubber, such as the one sold
by Smooth-On corporation. A rigid support cavity 14 is provided to receive the
soft mould cavity 12 when the dough 8 is casted therein.
[0065] The soft mould cavity 12 has a first concave side 16 that is
complementary shaped to yield the ornamental moulding 10 and a second
convex opposite side 18 that generally complements the rigid support cavity
14.
[0066] In operation, while the soft mould cavity 12 is received within
the rigid support cavity 14, the paper-based malleable dough 8 is filled
therein
and a spatula, a scrapper or any other leveling tool is used to evenly
distribute
and compact the dough 8 in the soft mould cavity 12. Any excessive amount of
dough 8 is also removed by leveling the dough 8 with the flange 20 and by
removing any dough 8 onto the flange 20.
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[0067] Even though the dough 8 remains malleable as soon as the
process 100 is completed, it is sufficiently consistent to keep a given form.
This
allows the ornamental mould 10 to be unmoulded at any time. A manual or
automatic process can then be provided wherein a single mould cavity 12 is
repeatedly filled and emptied in sequentially creating a plurality of moulds
10.
[0068] The use of a soft mould cavity 12 has been found to ease the
unmoulding step.
[0069] It is to be noted that the quantity of dough 8 required to
create a given form by moulding or else can be pre-determined considering the
volume of the resulting moulded piece.
[0070] After the paper-based malleable dough 8 has been shaped,
such as for example after moulding, the resulting object 10 is set aside for
drying for about twenty four (24) to thirty six (36) hours.
[0071] According to the first illustrated embodiment, the object 10 is
dried by laying it on a grid (not show) in a drying chamber at a temperature
of
about twenty seven degrees Celsius (27 C). To improve the drying time, the
drying chamber includes conventional humidity control and ventilation.
[0072] According to another embodiment, the object 10 is
unmoulded onto a plate (not shown) and remains thereon for about twenty four
(24) to thirty six (36) hours. After that first drying period, the object 10
is laid on
a grid (not shown) until it is sufftiently dried for its intended purposes.
[0073] It is to be noted that the drying time varies with the geometry
and dimension of the object and according to the environmental condition
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surrounding the object 10. It is believed to be within the reach of a person
skilled in the art to evaluating the drying time and estimate when the object
is
dried.
[0074] According to some embodiment, a finishing step is provided
after drying. According to this step, any imperfection of the object 10 is
removed and the contour of the object 10 is sanded.
[0075] The resulting product 10 can be painted as needed using for
example a latex-based paint.
[0076] To extend the life of the object 10, it is then sealed prior to
be
exhibited, used or installed in accordance with its function. This sealing
step
aims at improving the solidity of the object 10 and to protect it against
humidity,
water, common cleaning products and more generally any domestic liquid
products, including most drinks.
[0077] The sealer used is for example a common wood varnish such
as the Satin water based varnish produced by SamaNTM. Other water-based or
oil-based wood varnishes can also be used and so is another sealer suitable
for wood or paper. According to another embodiment, a sealing paint is used to
seal and color the object 10.
[0078] According to some embodiment, the sealing step is omitted,
for example in the case of a disposable object.
[0079] Generally stated, an object manufactured using a paper-
based malleable dough 8 resulting has the following structural
characteristics:
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[0080] - it is relatively lightweight;
[0081] - once sealed, it is impermeable and durable;
[0082] - it is hard enough to resist a normal impact, but is also
resilient enough so as not to be abrasive or cutting;
[0083] - when it is made from a dough that has been colored, its
appearance is uniformed throughout its volume. This allows the object to keep
its finished look when it is chipped;
[0084] - because the dough 8 is malleable for a sufficiently long time,
it is possible to incorporate other materials or objects on or in the dough,
including stones, implements, sticks, straws, etc. These incorporations will
be
locked in place, once the dough 8 is dry;
[0085] - the default aspect of the object, i.e. its appearance without
adding any color thereon or other treatment is very similar to concrete. This
renders the paper-based malleable dough 8 suitable to easily create imitation
pieces of concrete or rock.
[0086] Figure 4 illustrates a wall brick 30 created using a process
similar to the one described above with reference to the ornamental moulding
piece 10. The difference resides in the mould cavity 32 used in the moulding
process, which is rigid. The cavity 32, which is illustrated in Figure 5, can
be
made of steel or of any other rigid material that can withstand humidity.
[0087] As mentionea hereinabove, an object made from the dough 8
is resilient, even after it is dried. Without being necessarily identical, its
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resilience and plasticity are similar to Styrofoam and cork. This makes the
material suitable to be formed as a panel to be used as a bulletin board.
Figure
6 shows a framed embodiment of such a bulletin board 34. Indeed, the
resiliency of the bulletin board 34 allows repeatedly receiving pins 36.
[0088] Figure 7 shows two identical faux brick wall panels 40
moulded with the dough 8. Wood ashes (not shown) are sprinkled onto the
paper-based dough 8 before it is imprinted with the mould. The ashes bind to
the corresponding surface of the object 40 to better the stone-like finish.
More
specifically, it has been found economically efficient to use wood pellets
ashes
resulting from a wood pellet steve that is used, for example, as the heat
source
in the drying chamber (not shown).
[0089] Each panel 40 has one lateral side that complements the
opposite side thereof to ease the assembly of a plurality of panels 40 into a
faux brick wall (not shown). The gap 42 between adjacent panels 40 can be
filled with mortar joints (not shown) or silicone grout to better the illusion
of a
conventional brick stone wall in complementing the faux-joint between adjacent
bricks 44.
[0090] Compared with a conventional brick stone wall, a wall made
from the panels 40 is much lighter and easier to wash. It is also easier to
install
and repair. Indeed, the panels are sufficiently light to be glued on a flat
wall
and/or secured using finishing nails (not shown). The dough 8, once dry,
having
the above-mentioned plasticity, it is possible to hide the finishing nails by
manual touchups, even though such touchups are usually rendered
unnecessary by the inherent plasticity of the material.
[0091] As mentioned hereinabove, the dough 8 is not limited to be
shaped by moulding. As illustrated in Figure 8, the dough 8 can be sculpted in
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an infinity of forms, such as the head 50. Also, as mentioned hereinabove, the
dough 8 remains deformable for a few hours which allows adding decorative or
structural elements thereon or therein.
[0092] According to another embodiment, a kit (not shown) is
provided that includes all or some of the ingredients allowing to create a
small
batch of dough 8 with instructions therefore. Such a kit is intended for both
children and adults and would empower them to create a sculpture of their own
design and/or would include one or a plurality of small mould cavities
allowing
to create one or more object or parts thereof. A painting set or colorant can
also
be included in such a kit.
[0093] It is to be noted that many modifications could be made to the
process for manufacturing a paper-based malleable dough described
hereinabove and illustrated in the appended drawings and to an object made
from such a dough.
[0094] For example, even if the joint compounds used in the process
for manufacturing a paper-based malleable dough described hereinabove are
silica-based, other types of such compounds can also be used.
[0095] Even though the above-mentioned moulding process of the
paper-based malleable dough have been described as being of the
compression type, injection moulding can also be used to shape the dough.
[0096] Although the present invention has been described
hereinabove by way of illustrated embodiments thereof, it can be modified. It
is
therefore to be understood that numerous modifications may be made to the
illustrative embodiments and that the scope of the claims should not be
limited
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by the preferred embodiment, but should be given the broadest interpretation
consistent with the description as a whole.
