Language selection

Search

Patent 2821322 Summary

Third-party information liability

Some of the information on this Web page has been provided by external sources. The Government of Canada is not responsible for the accuracy, reliability or currency of the information supplied by external sources. Users wishing to rely upon this information should consult directly with the source of the information. Content provided by external sources is not subject to official languages, privacy and accessibility requirements.

Claims and Abstract availability

Any discrepancies in the text and image of the Claims and Abstract are due to differing posting times. Text of the Claims and Abstract are posted:

  • At the time the application is open to public inspection;
  • At the time of issue of the patent (grant).
(12) Patent: (11) CA 2821322
(54) English Title: PAPER-BASED MALLEABLE DOUGH FOR MOULDING AND SCULPTING APPLICATIONS
(54) French Title: PATE MALLEABLE A BASE DE PAPIER POUR APPLICATIONS DE MOULAGE ET DE SCULPTAGE
Status: Granted
Bibliographic Data
(51) International Patent Classification (IPC):
  • D21J 3/00 (2006.01)
  • B28B 1/52 (2006.01)
  • C04B 18/24 (2006.01)
  • C04B 28/14 (2006.01)
(72) Inventors :
  • LESSARD, MARIO (Canada)
  • THIBEAULT, CHRISTINE (Canada)
(73) Owners :
  • LESSARD, MARIO (Canada)
  • THIBEAULT, CHRISTINE (Canada)
(71) Applicants :
  • LESSARD, MARIO (Canada)
  • THIBEAULT, CHRISTINE (Canada)
(74) Agent: FOURNIER, CLAUDE
(74) Associate agent:
(45) Issued: 2018-01-02
(22) Filed Date: 2013-07-18
(41) Open to Public Inspection: 2014-11-26
Examination requested: 2014-06-12
Availability of licence: N/A
(25) Language of filing: English

Patent Cooperation Treaty (PCT): No

(30) Application Priority Data: None

Abstracts

English Abstract

Embodiments of a process for manufacturing a paper-based malleable dough for moulding and sculpting applications are described herein that include: soaking and mixing shredded paper in water, yielding a paper dough; and adding and mixing at least one setting-type joint compound with the paper dough. 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. The paper-based malleable dough allows creating objects that are ecological, durable, malleable and lightweight and that brings out the creative side of the user.


French Abstract

Linvention concerne des modes de réalisation dun procédé de fabrication dune pâte malléable à base de papier, pour des applications de moulage et de sculptage. Le procédé comprend ceci : tremper et mélanger du papier effiloché, pour obtenir une pâte de papier; et ajouter et mélanger au moins une pâte à joint de type à prise avec la pâte de papier. Ladite pâte de type à prise est ajoutée dans un rapport de poids, entre la pâte de type à prise et le papier effiloché, allant denviron 11:8 à 17:8. La pâte malléable à base de papier permet de créer des objets qui sont écologiques, durables, malléables et légers; de plus, elle fait ressortir le côté créatif de lutilisateur.

Claims

Note: Claims are shown in the official language in which they were submitted.


18
CLAIMS:
1. 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 the at least one setting-type joint compound is added in a dry
weight ratio
of setting-type joint compound to paper of between about 11:8 to 17:8.
2. The process according to claim 1, further comprising adding and mixing
a colorant into the paper dough.
3. The process according to claim 1 or 2, wherein the at least one setting-
type joint compound comprises two (2) different types of setting-type joint
compounds,
each type having a different setting time.
4. The process according to any one of claims 1 to 3, wherein the at least
one setting-type joint compound further includes a textural setting-type joint
compound.
5. The
process according to claim 4, wherein the textural setting-type joint
compound is a Sheetrock.TM. ceiling texture powder.
6. The process according to any one of claims 1 to 5, wherein the paper
dough comprises a weight ratio of paper to water of about 1:5.
7. The process according to any one of claims 1 to 6, wherein the water
includes at least one of an antifungal agent and a bleaching agent.
8. The process according to any one of claims 1 to 7, further comprising
shaping the malleable dough in the shape of a desired product.
9. The process as recited in claim 8, wherein shaping the malleable dough
includes moulding the malleable dough.

19
10. The process as recited in claim 9, wherein moulding the malleable
dough includes using a soft mould cavity received in a rigid support cavity.
11. The process according to any one of claims 8 to 10, further comprising
drying the desired product.
12. The process as recited in claim 11, wherein moulding the malleable
dough includes unmoulding the product before the product is dried.
13. The process as recited in any one of claims 8 to 12, wherein shaping
the malleable dough further includes adding ashes thereon.
14. The process as recited in claim 11, further comprising sealing the
desired product after drying.
15. The process as recited in claim 13 or 14, further comprising removing
imperfections from the desired product after drying.
16. The process as recited in any one of claims 8 to 15, wherein the desired
product is selected from the group consisting of a bulletin board panel, a
faux brick wall
panel, an ornamental moulding, a faux stone panel and a sculpture.
17. A kit for creating an object comprising:
at least one setting-type joint compound;
instructions relative to soaking and mixing shredded paper in water for
obtaining a paper dough; and
instructions for adding and mixing the at least one setting-type joint
compound with the paper dough in order to obtain a dry weight ratio of
chemically-
activated setting-type compound to paper of between about 11:8 to 17:8.

20
18. The kit as recited in claim 17, further comprising at least one of a
mixing
tool, paper and a mould.
19. A paper-based malleable dough comprising:
paper and water, wherein the weight ratio of paper to water is between about
1:4 and 1:6; and
at least one chemically-activated setting-type joint compound,
wherein said joint compound is mixed with the paper and water in a dry weight
ratio of
joint compound to paper of between about 11:8 to 17:8.
20. A solid object made from the paper-based malleable dough of claim 19.
21. The solid object of claim 20, wherein said object is selected from the
group consisting of a bulletin board panel, an isolation panel, a faux brick
wall panel, an
ornamental moulding, and a faux stone panel.
22. 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.
23. The method of claim 22, wherein the at least one setting-type joint
compound comprises a setting-type joint compound for gypsum panels and ceiling

boards.
24. The method of claim 22 or 23, wherein the at least one setting-type joint
compound further includes a textural setting-type joint compound.

21
25.The method according to claim 24, wherein the textural setting-type joint
compound is a Sheetrock.TM. ceiling texture powder.
26. The method of any one of claims 22 to 25, wherein the at least one
setting-type joint compound comprises two (2) different types of chemically-
activated
setting-type joint compounds, each type having a different setting time.
27. The method of any one of claims 22 to 26, wherein the paper dough
comprises a weight ratio of paper to water of about 1:5.
28. The method of any one of claims 22 to 27, wherein the water includes
at least one of an antifungal agent and a bleaching agent.
29. The method of any one of claims 22 to 28, further comprising adding
and mixing a colorant into the paper dough.
30. The method of any one of claims 22 to 29, wherein moulding the
malleable dough includes using a soft mould cavity received in a rigid support
cavity.
31. The method of any one of claims 22 to 30, wherein moulding the
malleable dough includes unmoulding the product before the product is dried.
32. The method of any one of claims 22 to 31, wherein moulding the
malleable dough includes adding ashes thereon.
33. The method of any one of claims 22 to 32, further comprising sealing
the product after drying the product.
34. The method of any one of claims 22 to 33, further comprising removing
imperfections from the product after drying.
35. The method of any one of claims 22 to 34, wherein the paper-based
product is selected from the group consisting of a bulletin board panel, an
isolation panel,
a faux brick wall panel, an ornamental moulding, and a faux stone panel.
36. A paper-based product obtained according to the method of any one of
claims 22 to 35.

22
37. 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 mixture comprised prior to drying a dry weight ratio of setting-type
compound to
paper of between about 11:8 to 17:8.
38. The moulded paper-based product of claim 37, wherein the at least one
setting-type joint compound comprises a compound for gypsum panels and ceiling

boards.
39. The moulded paper-based product of claim 37 or 38, wherein the at
least one setting-type joint compound further includes a textural setting-type
joint
compound.
40.The moulded paper-based product according to claim 39, wherein the
textural setting-type joint compound is a Sheetrock.TM. ceiling texture
powder.
41. The moulded paper-based product of any one of claims 37 to 40,
wherein the at least one setting-type joint compound comprises two (2)
different types of
setting-type joint compounds, each type having a different setting time.
42. The moulded paper-based product of any one of claims 37 to 41, further
comprising at least one of an antifungal agent and a bleaching agent.
43. The moulded paper-based product of any one of claims 37 to 42, further
comprising a colorant.
44. The moulded paper-based product of any one of claims 37 to 43, further
comprising ashes.
45. The moulded paper-based product of any one of claims 37 to 44,
wherein said product is sealed.
46. The moulded paper-based product of any one of claims 37 to 45,
wherein said product has been processed to remove imperfections.

23
47. The moulded paper-based product of any one of claims 37 to 46,
wherein said product is selected from the group consisting of a bulletin board
panel, an
isolation panel, a faux brick wall panel, an ornamental moulding, and a faux
stone panel.
48. A
paper-based malleable dough manufacturing process, comprising:
providing a paper dough comprising paper and water; and
adding and mixing at least two different types of setting-type joint compound
with the paper dough, wherein said at least two types of setting-type joint
compound are
added in a dry weight ratio of setting-type joint compound to paper of between
about 11:8
to 17:8, and wherein said at least two types of setting-type joint compound
have different
setting times.
49. A method for manufacturing a paper-based product, comprising:
- providing a paper dough comprising paper and water;
- mixing the paper dough with at least two different types of 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, wherein said at least two types of
setting-type joint
compound have different setting times;
- moulding said mixture to obtain a moulded product of a desired shape;
and
- allowing the moulded product to dry.
50. The method of claim 49, wherein the moulded product is selected from
the group consisting of a bulletin board panel, an isolation panel, a faux
brick wall panel,
an ornamental moulding, and a faux stone panel.

Description

Note: Descriptions are shown in the official language in which they were submitted.


CA 02821322 2015-06-10
1
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:

CA 02821322 2015-06-10
2
[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.

CA 02821322 2015-06-10
3
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

CA 02821322 2016-02-26
4
[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:

CA 02821322 2016-02-26
[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

CA 02821322 2015-06-10
6
"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.

CA 02821322 2015-06-10
7
[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.

CA 02821322 2015-06-10
8
[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.

CA 02821322 2015-06-10
9
[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.

CA 02821322 2015-06-10
[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.

CA 02821322 2015-06-10
11
[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.

CA 02821322 2015-06-10
12
[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

CA 02821322 2015-06-10
13
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:

CA 02821322 2015-06-10
14
[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

CA 02821322 2015-06-10
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

CA 02821322 2015-06-10
16
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

CA 02821322 2015-06-10
17
by the preferred embodiment, but should be given the broadest interpretation
consistent with the description as a whole.

Representative Drawing
A single figure which represents the drawing illustrating the invention.
Administrative Status

For a clearer understanding of the status of the application/patent presented on this page, the site Disclaimer , as well as the definitions for Patent , Administrative Status , Maintenance Fee  and Payment History  should be consulted.

Administrative Status

Title Date
Forecasted Issue Date 2018-01-02
(22) Filed 2013-07-18
Examination Requested 2014-06-12
(41) Open to Public Inspection 2014-11-26
(45) Issued 2018-01-02

Abandonment History

There is no abandonment history.

Maintenance Fee

Last Payment of $125.00 was received on 2023-07-14


 Upcoming maintenance fee amounts

Description Date Amount
Next Payment if standard fee 2024-07-18 $347.00
Next Payment if small entity fee 2024-07-18 $125.00

Note : If the full payment has not been received on or before the date indicated, a further fee may be required which may be one of the following

  • the reinstatement fee;
  • the late payment fee; or
  • additional fee to reverse deemed expiry.

Patent fees are adjusted on the 1st of January every year. The amounts above are the current amounts if received by December 31 of the current year.
Please refer to the CIPO Patent Fees web page to see all current fee amounts.

Payment History

Fee Type Anniversary Year Due Date Amount Paid Paid Date
Application Fee $200.00 2013-07-18
Request for Examination $400.00 2014-06-12
Extension of Time $200.00 2015-02-24
Extension of Time $200.00 2015-02-24
Maintenance Fee - Application - New Act 2 2015-07-20 $50.00 2015-07-16
Maintenance Fee - Application - New Act 3 2016-07-18 $50.00 2016-07-11
Maintenance Fee - Application - New Act 4 2017-07-18 $50.00 2017-07-11
Final Fee $150.00 2017-11-10
Maintenance Fee - Patent - New Act 5 2018-07-18 $100.00 2018-07-17
Maintenance Fee - Patent - New Act 6 2019-07-18 $100.00 2019-07-18
Maintenance Fee - Patent - New Act 7 2020-07-20 $100.00 2020-07-08
Maintenance Fee - Patent - New Act 8 2021-07-19 $100.00 2021-07-12
Maintenance Fee - Patent - New Act 9 2022-07-18 $100.00 2022-07-13
Maintenance Fee - Patent - New Act 10 2023-07-18 $125.00 2023-07-14
Owners on Record

Note: Records showing the ownership history in alphabetical order.

Current Owners on Record
LESSARD, MARIO
THIBEAULT, CHRISTINE
Past Owners on Record
None
Past Owners that do not appear in the "Owners on Record" listing will appear in other documentation within the application.
Documents

To view selected files, please enter reCAPTCHA code :



To view images, click a link in the Document Description column. To download the documents, select one or more checkboxes in the first column and then click the "Download Selected in PDF format (Zip Archive)" or the "Download Selected as Single PDF" button.

List of published and non-published patent-specific documents on the CPD .

If you have any difficulty accessing content, you can call the Client Service Centre at 1-866-997-1936 or send them an e-mail at CIPO Client Service Centre.


Document
Description 
Date
(yyyy-mm-dd) 
Number of pages   Size of Image (KB) 
Maintenance Fee Payment 2021-07-12 1 33
Maintenance Fee Payment 2022-07-13 1 33
Abstract 2013-07-18 1 15
Description 2013-07-18 16 484
Claims 2013-07-18 4 82
Drawings 2013-07-18 7 348
Representative Drawing 2014-11-19 1 7
Cover Page 2014-12-02 1 37
Claims 2015-06-10 6 177
Description 2015-06-10 17 503
Claims 2016-02-26 6 202
Description 2016-02-26 17 498
Claims 2016-11-29 6 202
Maintenance Fee Payment 2017-07-11 1 35
Final Fee 2017-11-10 1 32
Representative Drawing 2017-12-07 1 8
Cover Page 2017-12-07 1 39
Maintenance Fee Payment 2019-07-18 1 33
Prosecution-Amendment 2015-03-31 1 4
Assignment 2013-07-18 3 100
Prosecution-Amendment 2014-06-12 2 56
Correspondence 2014-09-24 1 3
Prosecution-Amendment 2014-11-25 1 3
Prosecution-Amendment 2014-12-11 5 337
Correspondence 2015-02-24 1 46
Correspondence 2015-02-24 1 46
Correspondence 2015-03-24 1 24
Correspondence 2015-03-24 1 26
Prosecution-Amendment 2015-06-10 56 1,640
Maintenance Fee Payment 2015-07-16 1 40
Examiner Requisition 2015-08-28 4 310
Amendment 2016-02-26 31 996
Examiner Requisition 2016-06-13 3 195
Maintenance Fee Payment 2016-07-11 1 38
Prosecution-Amendment 2016-11-29 4 100
Maintenance Fee Payment 2023-07-14 1 33