NZ543128A - Polystyrene structures - Google Patents

Abstract

A 3-dimensional stand-alone polystyrene structure, such as a planter, includes a number of polystyrene segments 1 joined together. A resin and plaster coating 6 is applied to the surface of the structure and supporting mesh 5 is pressed into the plaster and resin coating 6.

Description

PATENTS FORM NO. 5 Fee No. 4: $250.00 PATENTS ACT 1953 COMPLETE SPECIFICATION After Provisional No: 543128 Dated: 19 October 2005 POLYSTYRENE STRUCTURES I Benjamin Schurmann a New Zealand citizen of 8 Arthur Place, Hamilton, New Zealand hereby declare the invention for which I pray that a patent may be granted to me, and the method by which it is to be performed to be particularly described in and by the following statement: intellectual Property Office of N.Z. ^ 8 OCT 2006 James & Wells Ref: 125250/55 POLYSTYRENE STRUCTURES TECHNICAL FIELD This invention relates to polystyrene structures, and the manufacture of same. BACKGROUND ART Planters and outdoor furniture have become increasingly popular recently, especially when updating or renovating houses, flats or apartments to provide greater indoor-outdoor flow, and greater use of outdoor areas for entertaining.

In the past planters have traditionally been made out of concrete, clay or terracotta. These are extremely heavy, even when empty, and more so when filled 10 with plants and soil. Clay, terracotta and cement pots also have the disadvantage in that in some climates and weather conditions they are inclined to crack or chip causing unsightly portions, especially when the exterior colour does not extend into the interior of the pot.

One light weight alternative to heavy and cumbersome concrete or clay planters 15 and/or outdoor furniture are plastic planters or furniture. Plastic planters, although being lightweight and cheap, also look cheap and often out of place in a formal or well decorated area. Plastic pots/planters can also be limited by their strength; this is often dramatically decreased by long term exposure to UV and other adverse weather conditions.

Plastic can also easily crack and break if large amounts of weight are put on same.

Therefore it would be beneficial to have available a planter or other structures, which while still being lightweight and easy to move around provide sufficient strength to be robust and have high and long term utility.

All references, including any patents or patent applications cited in this 2 specification are hereby incorporated by reference. No admission is made that any reference constitutes prior art. The discussion of the references states what their authors assert, and the applicants reserve the right to challenge the accuracy and pertinency of the cited documents. It will be clearly understood that, although 5 a number of prior art publications are referred to herein, this reference does not constitute an admission that any of these documents form part of the common general knowledge in the art, in New Zealand or in any other country.

It is acknowledged that the term 'comprise' may, under varying jurisdictions, be attributed with either an exclusive or an inclusive meaning. For the purpose of this 10 specification, and unless otherwise noted, the term 'comprise' shall have an inclusive meaning - i.e. that it will be taken to mean an inclusion of not only the listed components it directly references, but also other non-specified components or elements. This rationale will also be used when the term 'comprised' or 'comprising' is used in relation to one or more steps in a method or process.

It is an object of the present invention to address the foregoing problems or at least to provide the public with a useful choice.

Further aspects and advantages of the present invention will become apparent from the ensuing description which is given by way of example only.

DISCLOSURE OF INVENTION According to one aspect of the present invention there is provided a polystyrene structure, including: a number of polystyrene segments joined together, a resin and plaster finish applied to the polystyrene segments, characterised in that supporting mesh is pressed into the plaster and resin 3 coating.

According to a second aspect of the present invention there is provided a method of constructing a polystyrene structure, the structure including: a number of polystyrene segments joined together, a resin and plaster finish applied to the polystyrene segments, supporting mesh pressed into the plaster and resin coating. the method being characterised by the steps of: a) producing pre-shaped polystyrene segments, b) joining the pre-shaped polystyrene segments together, c) applying a resin and plaster coating to the outer surface of the joined polystyrene, and d) before the coating sets, pressing supporting mesh into same.

The term 'stand-alone' should be taken as meaning a structure which is not integral with a structural component or exterior surface of a building.

Throughout this specification the term structure should be taken to mean any structure which is capable of being made out of polystyrene. The term structure includes such structures such as planters, furniture, light weight sculptures, support structures which are not required to withstanding high pressures, for example support structures for pergolas. However, these should not be seen as limiting as the present invention could be used to make a wide variety of other structures.

In a particularly preferred embodiment the structure may be a planter, and shall be referred to as such herein.

In a preferred embodiment the planter includes a number of polystyrene segments 4 Intellectual Property Office of N.2. 18 JAN 2007 RECEIVED joined together. This allows a structure to be constructed from a number of smaller segments of polystyrene, or segments of polystyrene which are of varying shapes. This decreases the manufacturing cost as the same shape or sized segment may be used in a number of different planters or finished products, and 5 large blocks of polystyrene are not required to produce the structure. It also decreases the amount of waste, as a structure is not being cut out of one large block of polystyrene.

In a preferred embodiment the polystyrene segments may be pre-shaped so that any curves or unusual shapes are present before the segments are joined 10 together.

However, this should not be seen as limiting as in some instances the shaping, or some final shaping may be carried out once the segments have been joined together.

In a preferred embodiment the polystyrene segments may be joined together with 15 an adhesive. The adhesive must be one which does not dissolve the polystyrene; therefore 5pii ii-ua5cd auu55iV8S are preferred.

However, the use of adhesives should not be seen as limiting as other suitable attachment methods, such as staples or pins may be utilized with the present invention to join adjacent polystyrene segments.

In a preferred embodiment a resin and plaster coating may be applied, and the supporting mesh pushed into same during or soon after the application.

The resin and plaster mixture must still be wet when the mesh is applied to ensure that the strength of the mixture when dried and hardened has not been compromised.

The supporting mesh ends up embedded in the resin and plaster finish, giving maximum strength to the planter.

In an alternative embodiment supporting mesh may be fixed around the outer surface of the joined polystyrene segments prior to the application of the plaster and resin coating.

The supporting mesh provides extra strength and support to the structure. The supporting mesh also helps to secure the plaster finish to the polystyrene structure. Without the inclusion of supporting mesh, the plaster may flake off the outside of the structure easily, especially if the structure is regularly handled or moved, decreasing the aesthetics of the structure.

In a preferred embodiment the supporting mesh may cover substantially the entire outer surface of the polystyrene segments. However, this should not be seen as limiting as the support mesh may be applied only to portions of the polystyrene segments where greater strength or a plaster surface is required. For example, in some cases, the supporting mesh may not be applied to the inner surface of a 15 planter.

In a preferred embodiment the supporting mesh may be one of the range of mesh products which are already known, for example a plastic mesh.

In a preferred embodiment the mesh may include at least two components, one which is strong under tension and the other which is strong under compression. 20 This is the same principle as the use of reinforcing steel imbedded in concrete. However this should not be seen as limiting, as a single component mesh may also be utilized with the present invention.

One example of a preferred mesh is one made of fibreglass stiffened with an adhesive. This type of mesh is currently used in conjunction with polystyrene in 25 the building industry, for example in the construction of houses. 6 In a preferred embodiment the polystyrene structure may also include corner pieces configured to reinforce the corners of the polystyrene/polystyrene structure.

In a preferred embodiment the corner pieces may be made out of plastic; and shall be referred to as such herein. This allows the reinforcing corner pieces to be 5 lightweight but also strong.

In most preferable embodiments the plastic may be as lightweight as possible for the reinforcing desired/required.

However the inclusion of corner pieces should not be seen as limiting, as corner reinforcing may not always be utilised, and if it is, other suitable materials to 10 provide reinforcing may be utilized.

In one preferred embodiment the corner pieces may fit over a corner of the polystyrene structure, for example having a three sided inset which is configured to fit around the three sides of a square corner. However, this should not be seen as limiting as in some instances, corner reinforcing may be provided by a single strip 15 of reinforcing material positioned along one, two or three sides of the corner.

In a further alternative embodiment the corner may be reinforced by at least one strip extending over same.

One skilled in the art would be aware that a number of configurations of the corner pieces to reinforce corners could be utilised with the present invention.

The term corner should be taken to include the meeting of two or three flat planar sides or a rounded or curved portion of the structure which requires additional support or reinforcing.

Preferably the corner pieces are pre-moulded.

Preferably the corner pieces may be attached to the polystyrene segments before 7 the plaster and resin coating is applied to same.

Preferably the corner pieces may be attached to the polystyrene with an adhesive. As discussed above, spirit based adhesives are preferred as they do not dissolve the polystyrene.

In a preferred embodiment the corner pieces may be attached to all the corners on a structure. However this should not be seen as limiting as they may only be attached to corners requiring extra reinforcement.

One skilled in the art may realise that including reinforcing corner pieces may decrease the thickness of the resin and plaster coating applied to the structure, 10 and therefore decrease the strength of same. To avoid this problem, in some embodiments the reinforcing corner pieces may be indented into the polystyrene, or fitted into appropriate grooves in same.

In a preferred embodiment drainage or aeration holes may be included in the base of the planters. This allows excess water to drain out of the planter, in the case of 15 wet weather or over watering, thereby preventing the plants in the planter from dying or not having optimal growing conditions due to a build up of water in the base of the planter.

In a preferred embodiment, drainage holes may be created by inserting a piece of pipe into the polystyrene at the base of the planter, and shall be referred to as 20 such herein. However, this should not be seen as limiting, as a piece of pipe may not be necessary, for example, in some instances a hole may be cut in the polystyrene, this may or may not have the surface treated with supporting mesh, and/or plaster and resin coating.

In a preferred embodiment the pipe may be made of plastic so as to be as 25 lightweight and cheap to manufacture. However, this should not be seen as 8 limiting, as drainage holes may not also be used, and if it is, other suitable materials to provide reinforcing may be utilized.

Preferably the pieces of pipe used for drainage holes may be permanently attached to the polystyrene to prevent movement of same.

In a preferred embodiment adhesive may be used to permanently attach the pipe to the polystyrene. However this should not be seen as limiting, as the pipe may not always be permanently attached, and if so, it may be attached by any suitable attachment method.

In a preferred embodiment the drainage pipe may be added prior to the supporting 10 mesh and/or the plaster and resin coating being applied to the polystyrene structure.

In a preferred embodiment a resin and plaster coating is applied to the supporting mesh to give the polystyrene planter increased strength and an aesthetically pleasing finish.

This coating may have a variety of finishes applied to same, for example a smooth finish, or a range of textured finishes, depending on the intended use of the planter/structure or the wishes of the customer.

In a preferred embodiment the resin and plaster may be combined before the resin and plaster coating is applied to the supporting mesh. However this should not be 20 seen as limiting as it may in some cases be beneficial to apply a resin coating, allow drying and then applying a plaster finish.

Both the resin and plaster are required to give the polystyrene structure the required strength and provide the desired finish to the structure.

The term resin, as used herein should be taken as meaning a compound having 9 an adhesive nature; the resin used may be either synthetically or naturally produced.

The resin provides additional adhesion to easily allow the mesh and plaster coating to adhere to the polystyrene structure. This increases the strength with which the 5 coating is attached, and helps prevent the plaster coating flaking or breaking off under stress.

The term plaster should herein be taken as meaning having a soft pliable nature which forms to a hard nature when dried. The plaster provides the workability required of the resin and plaster mixture which allows it to be easily and 10 consistently applied to the exterior of the polystyrene structures.

A resin and plaster mixture also provides higher strength and resilience, than the use of either alone.

However, the use of resin and plaster should not be seen as limiting, the use of other materials which provide the required characteristics may also be utilised with 15 the present invention. These would be obvious to one skilled in the art.

Using a mixture of resin and plaster to coat the support mesh and polystyrene segments allows a thin coating to be applied while still provide sufficient strength to the structure than if plaster alone was used. This is also economical.

In preferred embodiments the resin and plaster mixture may be premixed. This 20 ensures the consistency is consistent, and decreases the manual labour associated with making the polystyrene planter(s). However this should not be seen as limiting as the resin and plaster may be mixed on site, or specifically for particular batches of polystyrene planters, in the case that a dryer, wetter mixture is wanted to give a desired finish.

In a preferred embodiment the resin and plaster, either separately or premixed may be commercially available.

In a preferred embodiment the resin and plaster finish may be substantially 4 to 5 millimetres thick. However this should not be seen as limiting, as thicker or thinner thicknesses of the resin and plaster finish may be applied in accordance with the 5 present invention.

Four to five millimetres is a thickness which is capable of providing the required strength, without making the planter too heavy.

In a preferred embodiment the resin and plaster coating may be applied in more than one coats or applications, this allows the mesh to be embedded in the first 10 layer and also allows a coarser and cheaper resin and plaster mixture to be used to some of the coating. However this should not be seen as limiting as the resin and plaster may be applied in one or any other number of coats.

In a preferred embodiment once the resin and plaster finish has been applied the planter may also have a waterproofing coating applied. This prevents water and 15 the damp environment within the planter, when filled with soil and plants to seep into the planter and decrease the strength, robustness and length of usability of same. It also prevents water from the exterior, for example from rain or a sprinkler doing same.

In some embodiments the waterproof coating on the exterior of the planter may be 20 provided by painting the exterior. This also allows the colour of the planter to be easily changed as desired. The exterior surface of the planter should be taken as meaning the portion of the planter which is exposed to the environment, and is not adjacent to soil, or other planting matter within the planter. Similarly the term interior of the planter should be taken to mean the inside, or portion of the planter 25 to which soil, or other planting matter is adjacent. 11 In a preferred embodiment the waterproof coating to the interior of the planter may be provided by latex rubber paint. However this should not be seen as limiting as other suitable waterproofing agents may be utilised, these would be apparent to one skilled in the art. The use of latex rubber paint provides significant advantages 5 over the use of normal paint on the interior of the planter. Normal paint does not provide sufficient waterproofing when adjacent to soil within the planter, this is due to the paint breaking down after a period of time.

In alternative embodiments the latex rubber paint may be utilised on both the interior and exterior surfaces of the planter.

In some preferred embodiments, either before, or after the application of a waterproof coating or colouring the planter may have additional decorative features added. These may include, for example, a wood, stone, tile or other edge around the top of the planter, mosaic, or other designs applied to the exterior surface to increase the aesthetic appeal of the planter, or to co-ordinate with other features in 15 the garden.

One skilled in the art would also realise that the structures could be used for purposes other than planters, for example, as water features or stand alone features in a garden, outdoor, or indoor area.

In some preferred embodiments the planter, or other polystyrene structure may 20 also include portions to raise the base of same off the ground.

The polystyrene structure as described in the present invention has advantages over other polystyrene planters or other structures, including the following: ■ They are stronger per thickness/amount of polystyrene used, due to the addition of a supporting mesh, optional resin coating and plaster finish.

■ The plaster finish can be adapted to the intended use or customers aesthetic 12 requirements for the planters. For example they are easy to paint or coat to resemble clay, terracotta, sculptured cement or any other surface.

■ Polystyrene planters and other structures according to the present invention are very light weight and easy to install, making it easy for people to move these around. In the case of planters, they are easier to move even when filled with plants and soil than equivalent sized concrete planters, either from one part of the garden to another, or between indoor and outdoor environments.

■ Polystyrene planters according to the present invention can be produced in a 10 very wide range of sizes, styles and colours.

■ The plaster/resin finish is increased in strength and 'stickability' onto the polystyrene structure due to the presence of the supporting mesh.

BRIEF DESCRIPTION OF DRAWINGS Further aspects of the present invention will become apparent from the following 15 description which is given by way of example only and with reference to the accompanying drawings in which: Figure 1 shows a cut away schematic of the cross section of the planter, showing the polystyrene, mesh and resin/plaster finish, and Figure 2 shows a cut away schematic of the cross section of the planter 20 without reinforcing corner pieces.

BEST MODES FOR CARRYING OUT THE INVENTION Figure 1 shows a piece of polystyrene (1).

On one edge of the polystyrene (1) are shown corner reinforcing portions (2) and 13 (3). Each of these are an L shaped plastic moulded configured to increase the strength of the polystyrene in the finished planter. The corner potions (2) and (3) are preferably made of plastic and have holes (such as (4) along same. There are usually two rows of holes (4) spaced so that the holes are alternating between 5 rows. The corner portions are attached to the polystyrene before the mesh or resin and plaster mixture is applied.

Mesh (5) is attached over the exterior surface of the polystyrene (1) and corner portions (2) and (3). Preferably the mesh made up of plastic strips with a thickness of 0.5 millimetres and a width of 1 millimetre. The mesh has an 10 approximate mesh space of 3 mm. The mesh may be attached prior to the resin and plaster coating being applied or a first layer of same may be applied and the mesh pushed into same with a trowel during application. This ensures that the mesh is positioned within the resin and plaster layer thereby providing the greatest support to the planter.

The mesh (5) and reinforcing corner portions (2) and (3) are covered by a resin and plaster coating (6). This preferably has a total thickness of approximately 4 to 5 mm thick. The resin and plaster coating may be smooth or textured, depending on the desired appearance of the finished product.

The resin and plaster coating (6) may then optionally be waterproofed (7), this may 20 be done with paint. This also allows the planter to be coloured to the desired colour. Alternatively a colouring agent may be added to the resin and plaster mix prior to application of same, and the exterior waterproofed with a clear waterproofing agent.

Figure 2 shows a cut away schematic of the planter as shown in Figure 1 without 25 the reinforcing corner pieces.

Figure 2 uses the same numbering as Figure 1 shows the polystyrene (1), mesh 14 (5), resin and plaster coating (6) and waterproof coating (7).

The preferred method of making the polystyrene planters is as follows: 1. The polystyrene is cut to the correct sized and shaped pieces. 2. The polystyrene pieces are attached to each other using a spirit based 5 adhesive. The glued edges are pinned together with galvanised nails in order to hold the pieces in position until the adhesive dries and to provide greater strength to the joins between pieces. The nails remain attached for the following steps, and are not removed before same (however they could be removed once the adhesive has set). 3. The external corners of the planter are fitted with pre-mesh plastic extruded mouldings. These are glued into place using a spirit based adhesive. 4. Holes are drilled into the base of the planter, and plastic pipes inserted into same to act as drainage holes for the planter. The plastic pipes are glued into place using a spirit based adhesive.

. The mesh is cut so that pieces are sizes which fit all faces of the polystyrene. This includes both the interior and the exterior of the planter. 6. The first coat of resin and plaster mix is applied to the polystyrene. This is approximately 3 mm thick. The mesh pieces are pushed into same with a trowel during the application of the layer. 7. The resin and plaster first coat is allowed to become firm to the touch, but not allowed to completely dry. This step takes approximately two hours. A coarse plaster mix may be used for this first coat, for example Insulclad coarse mix. 8. A second coat of resin and plaster mix is applied. This is approximately 2 mm thick. The second coat is used to create a smooth finish. 9. The second coat of resin and plaster mix is allowed to dry and harden. This takes approximately 48 hours. A finer plaster mix may be used for this coat, for example Multiplast.

. If a textured finish is desired on the plaster a textured coat may be sprayed onto the planter to achieve the required finished textured effect. This is approximately 1 mm thick. 11. The textured coat is allowed to dry completely, this takes approximately 24 hours. Steps 10 and 11 are omitted if the desired finish is smooth. 12. The planter is sealed with two coats of paint. The paint should be UV resistant and waterproof to provide a long lasting finish. Examples of suitable paints include, exterior paints and Resene's X200.. 13. .Waterproofing the interior of the planter. This may be by paint as above or by any other suitable waterproofing method.

Aspects of the present invention have been described by way of example only and it should be appreciated that modifications and additions may be made thereto without departing from the scope thereof as defined in the appended claims.

Claims (23)

WHAT l/WE CLAIM IS:

1. A three-dimensional stand-alone polystyrene structure having at least two differing surface orientations, including: a number of polystyrene segments joined together, a resin and plaster finish applied to substantially the entire surface area of the three-dimensional structure, characterised in that supporting mesh is pressed into the plaster and resin coating.

2. A polystyrene structure as claimed in claim 1 wherein the structure is a planter.

3. A polystyrene structure as claimed in either claim 1 or claim 2 wherein the polystyrene segments are pre-shaped prior to joining.

4. A polystyrene structure as claimed in any one of claims 1 to 3 wherein adjacent polystyrene segments are joined together with an adhesive.

5. A polystyrene structure as claimed in any one of claims 1 to 4 wherein the supporting mesh was pushed into the resin and plaster coating before the coating dries.

6. A polystyrene structure as claimed in any one of claims 1 to 4 wherein the supporting mesh has been attached to the polystyrene structure prior to the resin and plaster coating being applied.

7. A polystyrene structure as claimed in any one of claims 1 to 6 wherein the supporting mesh covers substantially the entire outer surface of the polystyrene structure. 17 Intellectual Property Office of N.Z. 18 JAN 2007 RECEIVED

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17 A polystyrene structure as claimed in any one of claims 1 to 7 wherein the mesh is a plastic mesh. A polystyrene structure as claimed in any one of claims 1 to 8 wherein the mesh includes at least two components, one which is strong under tension and one which is strong under compression. A polystyrene structure as claimed in any one of claims 1 to 9 wherein the mesh is made of fiberglass stiffened with an adhesive. A polystyrene structure as claimed in any one of claims 1 to 10 wherein the polystyrene structure also includes reinforcing corner pieces. A polystyrene structure as claimed in claim 11 wherein the corner pieces are pre-molded. A polystyrene structure as claimed in either claim 11 or 12 wherein the corner pieces are attached to the polystyrene structure prior to the supporting mesh and/or plaster and resin coating being applied. A polystyrene structure as claimed in any one of claims 11 to 13 wherein the corner pieces are attached to the polystyrene via an adhesive. A polystyrene structure as claimed in any one of claims 2 to 14 wherein the planter also includes at least one drainage hole. A polystyrene structure as claimed in any one of claims 1 to 15, wherein the resin and plaster mixture is premixed prior to application. A polystyrene structure as claimed in any one of claims 1 to 16 wherein the resin and plaster finish is approximately 4-5 mm thick. 18 Intellectual Property Offlpfe of N.Z. 18 JAN 2007 RECEIVED

18. A polystyrene structure as claimed in any one of claims 1 to 17 wherein the resin and plaster coating is applied in two or more separate applications.

19. A polystyrene structure as claimed in any one of claims 1 to 18 wherein the polystyrene structure also has a water proofing coating applied.

20. A method of constructing a polystyrene structure as claimed in any one of claims 1 to 19, the method being characterised by the steps of: a) producing pre-shaped polystyrene segments, b) joining the pre-shaped polystyrene segments together, c) applying a resin and plaster coating to the outer surface of the polystyrene, and d) before the coating sets, pressing supporting mesh into the resin and plaster coating.

21. A method of constructing a polystyrene structure as claimed in any one of claims 1 to 19, the method being characterised by the steps of: a) cutting polystyrene to the correct size and shape, b) attaching the polystyrene pieces to one another, c) fitting the external corners with corner pieces (if desired), d) cutting supporting mesh to fit, e) applying a first coat of resin and plaster, f) pushing the mesh pieces are pushed into the first coat of resin and plaster, 19 Intellectual Property Office of N.Z. 18 JAN 2007 DECEIVED g) applying a second finishing coat of resin and plaster, h) allowing the resin and plaster to dry and harden.

22. A polystyrene structure substantially as herein described with reference to the accompanying description and Figures.

23. A method of constructing a polystyrene structure substantially as herein described with reference to the accompanying description and Figures. BENJAMIN SCHURMANN by his authorised agents & WELLS 20 Intellectual Property Office of N.Z. 18 JAN 2007 F1ECEIVED