Bowls comprising acrylic plastics filled with alumina trihydrate, and

Abstract

Processes for producing durable three-dimensional bowls such as water basins comprising acrylic plastics heavily filled with alumina trihydrate, some embodiments including colorants and visible particles such as those used for simulating stone such as granite. A preferred process for manufacturing the bowls of such material includes defining a flat rigid blank in the approximate top outline shape of bowl to be formed, e.g., the blank being a flat oval for an oval bowl and circular for a circular bowl. The flat blank is provided a smooth side or sides which will be the concave finished side in use. The blank is heated to a point of softening and of uniform temperature throughout, and located within a molding die such as a matched molding die having a female cavity of the desired bowl shape. The heated blank is indexed to the die, but left generally unrestrained so that the heated blank and edges thereof are un-clamped, thereby allowing the edges to be moved inward to help minimize tension loads during forming. Force is applied to the blank, such as from a male portion of the die, to compress the blank into the female cavity and desired bowl shape. The bowl is cooled, removed from the die, the top edge trimmed, a drain hole with surrounding bevel applied, and as-needed re-facing is applied on the exposed or finished side(s).