Apparatus for making acrylic coated structural elements

Abstract

An apparatus for forming acrylic sheet for use in manufacturing a structural member wherein the acrylic sheet forms the outer surface of the structural member and a composite material is formed within the formed sheet to provide a decorative appearance, utilizes a movable linear heating element positioned adjacent the sheet to heat a region of the sheet and a bending tool to bend the sheet along the heated portion such that a the acrylic is permanently deformed.

1 . An apparatus for forming acrylic for use in structural members comprising: 
 a. A support for a sheet of acrylic to be formed;    b. at least one heating element selectively positioned above said support at selected orientation to said acrylic sheet for heating a region of said acrylic sheet to a temperature at which said sheet may be deformed;    c at least one breaking element proximal said acrylic sheet and selectively movable into engagement with said sheet proximal said heated region thereof such that pressure may be applied to said sheet to deform the sheet about an axis defined along said heated region.    
   
   
       2 . An apparatus as described in  claim 1  wherein said heating element is an elongated linear element.  
   
   
       3 . Apparatus as described in  claim 1  wherein said heating element is an elongated electrical resistance heater.  
   
   
       4 . Apparatus as described in  claim 3  wherein said electrical resistance heater is linear.  
   
   
       5 . Apparatus as described in  claim 3  wherein said heater is aligned along a side of said acrylic sheet at a position corresponding to a corner to be formed in said acrylic sheet.  
   
   
       6 . Apparatus as defined in  claim 5  wherein said heater and said support are selectively positionable relative to said acrylic sheet to form transitions in said sheet such that portions of said sheet lie in intersecting planes with said intersections formed in regions of said acrylic sheet that have been heated to allow deformation.  
   
   
       7 . Apparatus as defined in  claim 6  wherein said breaking device comprises a movable a plate hingedly mounted adjacent said acrylic sheet for movement about an axis parallel to the surface of said acrylic sheet, said plate supported by said hinge for engagement with said sheet adjacent said heated region for applying force normal to said sheet surface, and at least one clamp positioned to engage said acrylic sheet adjacent said heated region with said heated region intermediate said clamp and said plate, such that movement of said plate about said hinge urges the portion of said sheet engaged by said plate away from the plane of said sheet engaged by said clamp.  
   
   
       8 . An article of manufacture made with the apparatus of  claim 1  wherein said acrylic sheet forms the outer surface of said article and wherein layers of pigment are interposed between said acrylic sheet and a layer of polystyrene foam to provide a faux stone appearance to said article.  
   
   
       9 . An article of manufacture as defined in  claim 8  wherein said article of manufacture is selected from the group consisting of counter tops, backsplashes, shower enclosures, vanity tops, cabinet tops, tubs, enclosures for tubs, cornices, baseboards, wainscots, door inserts, doorframes, and window frames.