GB2364265A

GB2364265A - Moulded article

Info

Publication number: GB2364265A
Application number: GB0015270A
Authority: GB
Inventors: Anthony Montalbano
Original assignee: PULLEN LEE JASON
Current assignee: PULLEN LEE JASON
Priority date: 2000-06-23
Filing date: 2000-06-23
Publication date: 2002-01-23
Also published as: GB0015270D0

Abstract

The invention provides an moulded article together with a method and mould for making the same. The moulded article (32) comprises a body (33) and several optical fibres (18) embedded in the body (33). The front or leading ends (20) of the fibres (18) form a pattern visible in a front face (30) of the body (33) of the article (32). Trailing ends (24) of the optical fibres (18) are gathered together to form a cable (26) which is connected to a light source (28). The article is moulded by securing the fibres to a mould wall, preferably by anchoring the leading ends of the fibres 18 which project through the mould wall and introducing mould mix into the mould cavity to cover the parts of the fibres 18 extending through the cavity.

Description

2364265 5 TITLE: A MOULDED ARTICLE 10 DESCRIPTION is The present invention

relates to moulded articles and methods of moulding the same.

Moulded articles are often decorative and form parts of visual displays. However, the aesthetic appeal of such decorative moulded articles is lost in darkened locations 2 0 or at night. The applicant has recognised the need for decorative moulded articles which may be used in darkened locations or at night.

In accordance with a first aspect of the present invention, there is provided a method for making a moulded 25 article, comprising the steps of providing a mould comprising a mould wall defining a mould cavity, securing at least one optical f ibre to the mould wall with a part of the at least one optical fibre extending though the mould cavity, and introducing mould mix into the mould cavity to cover the part of the at least one optical fibre extending though the mould cavity.

There are preferably a multiplicity (e.g. tens or 5 hundreds) of optical fibres secured in the mould.

The mould wall may comprise one or more perforations in which the or each optical fibre is secured. The perforated mould wall may be detachable from other parts of the mould to facilitate insertion of the or each optical 10 fibre in the one or more perforations. The number of perforations may for example correspond to the number of optical fibres to be secured so that each optical fibre may be secured in a corresponding perforation. The optical fibres may be secured in the perforations with a leading 15 end of each optical fibre projecting through the mould wall. The perforations may be arranged in a pattern, for example, a numeral, a letter, a message etc.

The optical fibres may be secured to the mould wall generally perpendicular to the mould wall. In this way, 20 light emerging from the optical fibre will be directed away from the surrounding surface of the moulded article.

The method may further comprise the steps of removing the moulded article from the mould and removing any optical fibres projecting proud of a peripheral surface of the 25 moulded article which will be visible when the article is in use. For example, the leading ends of the optical fibres may be trimmed so that the optical fibres are flush with the peripheral surface of the moulded article. The method may further comprise the step of smoothing the peripheral surface of the moulded article, for example, by polishing etc.

The trailing ends of the optical fibres may be 5 gathered together to form a cable. The cable may be configured to receive light from a light source. A power supply for the light source may be charged by a solar panel during the day so that the light source is illuminated by night.

10 The mould mix may be any desired substance, for example, a plastics mix, a concrete mix or a speciality mix for example one containing marble chippings sold under the trade name "TORRAZZO". If necessary, the mix may be cured, for example using heat, to ensure the mix sets.

15 In accordance with a second aspect of the present invention, there is provided a moulded article comprising a moulded body and at least one optical fibre embedded in the moulded body, with a trailing end of the or each optical fibre configured to receive light from a light source and a 20 leading end of the or each optical fibre disposed in the surface of the moulded body to direct light from the light source away from the moulded body.

The light source may be spaced f rom the leading end and may be concealed within a housing associated with the 25 moulded article. A multiplicity of optical f ibres are preferably embedded in the moulded article so that the leading ends f orm a pattern in the peripheral surf ace of the moulded article. The pattern may be illuminated by the light source.

In accordance with a third aspect of the invention, there is provided a mould for making a moulded article the mould comprising a mould wall defining a mould cavity, the 5 mould wall having at least one aperture, each for securing an optical fibre to the mould wall when extending though the mould cavity.

The apertured mould wall may comprise a detachable plate. optical fibres may be secured in the or each 10 aperture with a leading end of each projecting through the mould wall.

Embodiments of the invention will now be described by way of example with reference to the accompanying Figures in which:

15 Figure 1 shows a cut away perspective of a moulded article made according to the present invention, Figure 2 shows a plan view of a moulded article made according to the present invention, Figure 3 shows a plan view of a mould for use according to the first embodiment of the present invention, Figure 4 shows a schematic cross-section view of a mould for use according to the first embodiment of the present invention and Figure 5 shows a flow chart embodying a first embodiment of the present invention.

Figures 1 and 2 show moulded articles (32) made according to the present invention. The article may be a variety of shapes for example rectangular as shown in Figure 1 or hexagonal as shown in Figure 2. The article (32) comprises a body (33) and comprises several optical fibres (18) embedded in the body (33).

The front or leading ends (20) of the fibres (18) 5 form a pattern (e.g. the numeral two) visible in a front face (30) of the body (33) of the article (32). Trailing ends (24) of the optical fibres (18) are gathered together to form a cable (26) which is connected to a light source (28) The light source (28) is powered by a solar power 10 cell (not shown) which is charged during the day for use at night.

Figures 3 and 4 show a mould (10) according to a third aspect of the above invention. The mould (10) comprises a frame (12) and a front plate (14) attached to 15 the frame (12) via screws (not shown). Together the frame (12) and front plate (14) define a cavity (13) into which mould mix may be poured. The frame (12) is rectangular, although it will be appreciated that the frame may be of any desired shape, for example hexagonal, circular or 20 irregularly shaped.

The front plate (14) comprises a multiplicity of holes (16). In Figure 3 the holes (16) are arranged in a pattern of three diagonal lines, whereas in Figure 4, five holes (16) are arranged in a line.

25 In Figure 3, there are shown several optical fibres (18) each of which is secured in a corresponding hole (16). Leading ends (20) of the optical fibres (18) extend perpendicularly from a front face (22) of the front plate (14) A portion (23) of the optical fibres extends through the mould cavity (13) and trailing ends (24) of the optical fibres (18) are bunched together.

Figure 5 is a f low chart of the method of one embodiment of the present invention and illustrates the following steps of the method:

(a) Preparing a mould as shown in Figures 2 and 3 (and as described above) .

(b) Securing optical fibres in the mould, e.g. by 10 anchoring the leading ends of the optical fibres which project through the mould wall using adhesive tape.

(c) Pouring mould mix into the mould. The mix may be of and desired substance, for example, binder (e.g. cement) mixed with stone chippings.

(d) Allowing the mix to set. If necessary, the mould may be heated or otherwise treated as required by the mix used.

(e) Removing moulded article from the mould and smoothing a front face of the article. Portions of the optical 20 fibres extending from the article are also trimmed so one end of the fibres are flush with the front face of the article.

(f) The ends of the f ibres extending from the rear of the moulded article are gathered together so that they 25 may be connected to a light source, for example via an optical fibre cable and connector.

Claims

1 A method for making a moulded article, comprising the steps of providing a mould comprising a mould wall defining a mould cavity, securing at least one optical fibre to the mould wall with a part of the at least one optical fibre extending though the mould cavity, and introducing mould mix into the mould cavity to cover the part of the at least one optical fibre extending though the mould cavity.

2. A method according to claim 1, wherein there are a multiplicity of optical fibres secured in the mould.

3. A method according to claim 1 or claim 2, wherein the mould wall comprises one or more perforations in which the or each optical fibre is secured.

4. A method according to claim 3, wherein the perforated 15 mould wall is detachable from other parts of the mould to facilitate insertion of the or each optical fibre in the one or more perforations.

S. A method according to clam 3 or claim 4, wherein the optical fibres are secured in the perforations with a leading end of each optical fibre projecting through the mould wall.

6. A method according to any one of claims 3 to 5, wherein the perforations are arranged in a pattern.

7. A method according to any one of the preceding claims, 25 wherein the optical fibres are secured to the mould wall generally perpendicular to the mould wall.

8. A method according to any one of the preceding claims, wherein the method further comprises the steps of removing the moulded article from the mould and removing any optical fibres projecting proud of a peripheral surface of the moulded article which will be visible when the article is in use.

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9. A method according to claim 8, wherein the method further comprises the step of smoothing the peripheral surface of the moulded article.

10. A method according to any one of the preceding claims, wherein trailing ends of the optical fibres are gathered together to form a cable.

11. A method according to claim 10, wherein the cable is configured to receive light from a light source.

12. A method according to claim 11, wherein a power supply for the light source is charged by a solar panel during the day so that the light source is illuminated by night.

13. A method according to any preceding claim, wherein the mould mix is selected from the group consisting of a plastics mix, a concrete mix and a speciality mix.

14. A moulded article comprising a moulded body and at 20 least one optical fibre embedded in the moulded body, with a trailing end of the or each optical fibre configured to receive light from a light source and a leading end of the or each optical fibre disposed in the surface of the moulded body to direct light from the light source away from the moulded body.

15. A moulded article according to claim 14, wherein the light source is spaced from the leading end and is concealed within a housing associated with the moulded article.

16. A moulded article according to claim 14 or claim 15, wherein a multiplicity of optical fibres are embedded in the moulded article so that the leading ends form a pattern in the peripheral surface of the moulded article.

17. A moulded article according to claim 16, wherein the pattern is illuminated by the light source.

18. A mould for making a moulded article the mould comprising a mould wall defining a mould cavity, the mould 10 wall having at least one aperture, each for securing an optical fibre to the mould wall when extending though the mould cavity.

19. A mould according to claim 18, wherein the apertured mould wall comprises a detachable plate.

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20. A mould according to claim 18 or claim 19, wherein optical fibres are secured in the or each aperture with a leading end of each projecting through the mould wall.