U.S. patent application number 13/790692 was filed with the patent office on 2014-04-10 for moldable sand compositions and methods for making the same.
The applicant listed for this patent is Crayola LLC. Invention is credited to Jie Li, Michael Moskal, Michael Spera, Leena Vadaketh.
Application Number | 20140099863 13/790692 |
Document ID | / |
Family ID | 49292642 |
Filed Date | 2014-04-10 |
United States Patent
Application |
20140099863 |
Kind Code |
A2 |
Moskal; Michael ; et
al. |
April 10, 2014 |
MOLDABLE SAND COMPOSITIONS AND METHODS FOR MAKING THE SAME
Abstract
The present invention relates to moldable sand compositions,
methods for making the moldable sand compositions, and methods for
using the moldable sand compositions. In a particular embodiment,
the moldable sand composition comprises between about 70% to about
95% sand, between about 5% to about 30% water, a polar polymeric
resin, a crosslinking agent, and a humectant. In an exemplary
embodiment, the composition contains no oils, waxes, glycols, or
rubbers. The composition is capable of becoming hardened over time
in order to maintain the achieved shape, and can be re-wetted and
molded again after becoming hardened.
Inventors: |
Moskal; Michael; (Pottstown,
PA) ; Li; Jie; (Allentown, PA) ; Vadaketh;
Leena; (Doylestown, PA) ; Spera; Michael;
(Mohnton, PA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Crayola LLC |
Easton |
PA |
US |
|
|
Prior
Publication: |
|
Document Identifier |
Publication Date |
|
US 20130267146 A1 |
October 10, 2013 |
|
|
Family ID: |
49292642 |
Appl. No.: |
13/790692 |
Filed: |
March 8, 2013 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61622145 |
Apr 10, 2012 |
|
|
|
Current U.S.
Class: |
446/490 ;
524/557 |
Current CPC
Class: |
B44C 3/04 20130101; C04B
26/04 20130101; C08K 5/053 20130101; C08L 29/04 20130101; A63H
33/32 20130101; C04B 14/06 20130101; C04B 26/04 20130101; A63H
33/001 20130101; C04B 24/02 20130101; C08K 3/36 20130101 |
Class at
Publication: |
446/490 ;
524/557 |
International
Class: |
A63H 33/00 20060101
A63H033/00; C08L 29/04 20060101 C08L029/04 |
Claims
1. A moldable sand composition comprising between about 70% to
about 95% sand, between about 5% to about 30% water, a polar
polymeric resin, a crosslinking agent, and a humectant.
2. The composition of claim 1, wherein the sand comprises silica
sand.
3. The composition of claim 1, wherein the crosslinking agent
comprises a boric compound.
4. The composition of claim 1, wherein the humectant comprises
glycerin.
5. The composition of claim 1, wherein the polar polymeric resin
comprises PVA.
6. The composition of claim 1 comprising between about 80% to about
90% sand.
7. The composition of claim 1 comprising between about 7% to about
20% water.
8. The composition of claim 1, wherein the ratio of sand to water
is between about 3 to about 15.
9. The composition of claim 1 comprising between about 0.5% to
about 3% polar polymeric resin.
10. The composition of claim 1 comprising between about 1% to about
3% humectant.
11. The composition of claim 1 further comprising one or more
additives, wherein the additives are selected from the group
consisting of pH adjusters, buffers, defoamers, dispersing agents,
scents, preservatives, colorants, and combinations thereof.
12. The composition of claim 11, wherein the composition comprises
less than about 1% of the one or more additives.
13. The moldable sand composition of claim 11 comprising between
about 84% to about 88% sand, between about 8% to about 12% water,
between about 1% to about 2% polar polymeric resin, between about
0.2% to about 0.4% crosslinking agent, between about 1.5% to about
2.5% humectant, and between about 0.5% to about 1% additives.
14. The composition of claim 1, wherein the composition contains no
oils, waxes, glycols, or rubbers.
15. A method for making a moldable sand composition comprising
mixing between about 70% to about 95% sand, between about 5% to
about 30% water, a polar polymeric resin, a crosslinking agent, a
humectant, and one or more additives.
16. The method of claim 15, wherein the composition comprises
between about 84% to about 88% sand, between about 8% to about 12%
water, between about 1% to about 2% polar polymeric resin, between
about 0.2% to about 0.4% crosslinking agent, between about 1.5% to
about 2.5% humectant, and between about 0.5% to about 1%
additives.
17. The method of claim 15, wherein the composition contains no
oils, waxes, glycols, or rubbers.
18. The method of claim 15, wherein the ratio of sand to water is
between about 3 to about 15.
19. The method of claim 15, wherein there is no heating step.
20. A method of using a moldable sand composition comprising:
molding the moldable sand composition into a desired shape;
exposing the moldable sand composition to air for a period of time
sufficient for the moldable sand composition to become a hardened
composition; adding water to the hardened composition to make a
re-wetted moldable composition; and molding the re-wetted moldable
composition, wherein the moldable sand composition comprises
between about 70% to about 95% sand, between about 5% to about 30%
water, a polar polymeric resin, a crosslinking agent, and a
humectant.
21. The method of claim 20, wherein the moldable sand composition
contains no oils, waxes, glycols, or rubbers.
22. The method of claim 20 further comprising adding a decorative
agent to the composition, wherein the decorative agent is selected
from the group consisting of glaze, paint, glitter, shimmer, and a
combination thereof.
23. A kit comprising: a moldable sand composition inside a
container; and one or more molds, wherein the moldable sand
composition comprises between about 70% to about 95% sand, between
about 5% to about 30% water, a polar polymeric resin, a
crosslinking agent, and a humectant.
24. The kit of claim 23 further comprising one or more toys for
molding or shaping the composition.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority from U.S. Provisional
Application No. 61/622,145, filed Apr. 10, 2012, which application
is incorporated by reference herein, in its entirety and for all
purposes.
FIELD OF THE INVENTION
[0002] The present invention relates generally to moldable
compositions for use as a children's craft product, and more
particularly to moldable sand compositions that can dry and harden,
and are reusable after re-wetting.
BACKGROUND OF THE INVENTION
[0003] Many different types of modeling compositions for creating
figures or sculptures have been introduced over time, particularly
for use as craft products by children, and for general artistic
purposes. One of the most conventional types of modeling
composition is oil-based clay, which remains malleable even when
left for long periods in dry environments. Other modeling
compositions, such as water-based starch doughs, can typically dry
and harden when left out in the open air. However, starch-based
modeling compositions have a tendency to break apart during the
molding process, and to crack after they have dried.
[0004] Moldable compositions based on sand have a grainier texture
compared to those based on clay or starch. One of the disadvantages
of some sand-based compositions is that they contain components
such as oil, wax, or rubber, which can produce a greasy or sticky
feeling, in addition to the risk of staining clothes or the
surrounding environment. Sand-based compositions also do not
typically harden, and if they do harden, they cannot be re-wetted
and molded again. There remains a need for moldable craft materials
that provide the experience of playing with sand, that are suitable
to be handled by children, that provide the versatility of being
able to harden and maintain the achieved shape, and that can be
molded again after re-wetting.
SUMMARY OF THE INVENTION
[0005] An embodiment of the present invention provides a moldable
sand composition comprising between about 70% to about 95% sand,
between about 5% to about 30% water, a polar polymeric resin, a
crosslinking agent, and a humectant. In an exemplary embodiment,
the composition contains no oils, waxes, glycols, or rubbers.
[0006] Another embodiment of the present invention provides a
method for making a moldable sand composition comprising mixing
between about 70% to about 95% sand, between about 5% to about 30%
water, a polar polymeric resin, a crosslinking agent, a humectant,
and one or more additives. In particular embodiments, the
composition is capable of becoming hardened at room temperature
over time in order to maintain the achieved shape, and can be
re-wetted and molded again after becoming hardened.
[0007] Another embodiment of the present invention provides a
method of using a moldable sand composition comprising molding the
moldable composition into a desired shape; exposing the composition
to air for a period of time sufficient for it to become a hardened
composition; adding water to the hardened composition to make a
re-wetted moldable composition; and molding the re-wetted moldable
composition, wherein the moldable composition comprises between
about 70% to about 95% sand, between about 5% to about 30% water, a
polar polymeric resin, a crosslinking agent, and a humectant.
DETAILED DESCRIPTION OF THE INVENTION
[0008] The present invention provides moldable sand compositions
for use by children and artists, particularly for use as a
children's craft product. The compositions have a grainy texture
and provide the user with the sensation of playing with wet sand,
but without the mess normally associated with sand (i.e., very
little residual sand comes off of the moldable composition onto the
user's hands or the surrounding environment). The compositions of
the present invention are moldable, which means a user can
manipulate the compositions into desired shapes and figures. The
compositions have a hardening characteristic, which means that they
are initially moldable but are capable of drying and hardening if
left in open air at room temperature for a period of time (i.e.,
left outside of any enclosure, such as a container, that would
substantially prevent moisture from evaporating off of the
composition), so that they maintain the achieved shape. The
compositions are no longer moldable if they harden, but become
moldable again after the addition of water. The compositions are
water-based and are preferably free of oily components, which means
they do not leave an oily residue on the user's hands or on the
surrounding environment. The compositions are also non-staining and
are suitable for use by children. The moldable sand compositions of
the present invention have a unique sandy texture and they are
visco-elastic (i.e., they can stretch and flow), unlike other
moldable sand compounds.
[0009] According to preferred embodiments, the moldable sand
composition of the present invention comprises sand, water, a polar
polymeric resin, a crosslinking agent, and optionally a humectant
and additives. The moldable sand composition preferably comprises
between about 70% to about 95% sand and between about 5% to about
30% water. As used herein, a percentage (%) refers to a weight
percentage of the composition (with the "composition" referring to
all of the components in the total composition, including any
components that are premixed prior to being combined with the rest
of the components), unless indicated otherwise. Any type of sand
may be used in the compositions of the present invention. In
preferred embodiments, the most common component of the sand (and
most preferably the only component) is silica sand. As used herein,
"sand" refers to either colored or non-colored sand, and may
include mixtures of different types of sand. The sand particles can
be any shape, but in preferred embodiments most of the sand
particles are spherical. Both the density and size of sand
particles contribute to the unique properties of the present
invention. Sand particles are large enough to yield a rough, sandy
texture to dried objects.
[0010] According to particular embodiments, the sand that is used
in the composition is pre-colored sand, which means that the sand
particles are pre-coated with a pigment dispersion to impart color,
prior to the sand being included in the composition. In alternative
embodiments, the sand is not pre-colored (i.e., it is unpigmented),
so that it has a neutral color, such as white or tan. In those
embodiments, a pigment can be added to the moldable sand
composition as an additive, preferably in the form of a pigment dry
blend. For example, the pigment can be added to the composition in
an amount between about 0.01% to about 10%, between about 0.01% to
about 7.5%, between about 0.01% to about 5%, between about 0.01% to
about 3%, between about 0.01% to about 2%, or between about 0.01%
to about 1%. According to particular embodiments, the color of the
composition becomes more intense (brighter) as the amount of
pigment that is added to the composition increases. In these
embodiments, it has been observed that the sand particles
themselves do not change color; rather, the color imparted by the
pigment tends to remain mixed with the other components of the
composition. According to certain embodiments, "special effect"
pigments can be used, such as fluorescent pigments, which can
impart a neon effect to the composition, or phosphorescent
pigments, which can impart a "glow in the dark" effect.
[0011] The sand particles of the present invention are preferably
greater than 150 .mu.m in diameter, more preferably between about
150 .mu.m to about 400 .mu.m in diameter, and most preferably
between about 200 .mu.m to about 300 .mu.m in diameter.
Compositions of the present invention preferably comprise between
about 70% to about 95% sand, more preferably between about 80% to
about 90% sand, and most preferably between about 84% to about 88%
sand. In an exemplary embodiment, a composition of the present
invention comprises about 86% sand.
[0012] The compositions of the present invention comprise a
sufficient amount of water to act as a solvent for the other
components, but not so much water that the compositions shrink
substantially after the water evaporates. The compositions
preferably maintain a high dry strength upon hardening. In an
exemplary embodiment, water is the only solvent in the composition
(i.e., the composition does not contain any other solvents,
including water-miscible solvents such as glycols). This provides
the beneficial characteristic that, once the composition becomes
dry and hardened at room temperature, only water needs to be added
to the dried composition so that it becomes moldable again. This
also provides an advantage over moldable compositions that cannot
be re-wetted and re-molded after they have hardened. In preferred
embodiments, compositions of the present invention comprise between
about 5% to about 30% water, more preferably between about 7% to
about 20% water, and most preferably between about 8% to about 12%
water. In an exemplary embodiment, a composition of the present
invention comprises about 9.5% water. The amount of water in the
composition may decrease over time as the composition is left in
open air and the water evaporates.
[0013] According to certain aspects of the invention, the sand and
water together comprise greater than 90% of the total composition,
more preferably greater than 92% of the total composition, and most
preferably greater than 95% of the total composition. In certain
embodiments of the invention, the ratio of sand to water is between
about 3 to about 15, more preferably about between about 4 to about
12, and most preferably about between about 7 to about 10. In an
exemplary embodiment, a composition of the present invention
comprises a ratio of sand to water of about 9. The relative amounts
of sand and water help the composition remain moldable while
providing a high dry strength when the composition hardens at room
temperature.
[0014] The compositions of the present invention include a polar
polymeric resin as a binder. According to preferred embodiments,
the polar polymeric resin is poly(vinyl alcohol) (PVA). However,
other polar polymeric resins known by those skilled in the art may
also be used. In certain embodiments, compositions of the present
invention comprise between about 0.5% to about 3% polar polymeric
resin, more preferably between about 0.75% to about 2.75% polar
polymeric resin, and most preferably between about 1% to about 2%
polar polymeric resin.
[0015] PVA is made by the hydrolysis of poly(vinyl acetate) and,
when commercially purchased, may be partially or fully hydrolyzed.
PVA varies in molecular weight according to the length of the resin
chain. In a preferred embodiment, the composition includes PVA
which is partially hydrolyzed (about 87-89%). A particularly
preferred type of PVA is Celvol.RTM. 523. In certain embodiments,
compositions of the present invention comprise between about 0.5%
to about 3% PVA, more preferably between about 0.75% to about 2.75%
PVA, and most preferably between about 1% to about 2% PVA.
[0016] The compositions of the present invention include one or
more crosslinking agents. The one or more crosslinking agents
preferably comprise a boric compound, such as boric acid or a
borate salt. Boric acid is the most preferred crosslinking agent.
According to alternative embodiments, the one or more crosslinking
agents may not comprise a boric compound. Non-limiting examples of
such crosslinking agents include titanates and zirconates (e.g.,
those commercially available under the Tyzor.RTM. tradename),
dialdehydes such as glutaraldehyde, polyfunctional acids such as
adipic and citric acids, polyfunctional acid anhydrides such as
trimellitic anhydride, non-monovalent cations such as Ca.sup.2+,
Fe.sup.3+, etc. In certain embodiments, compositions of the present
invention comprise between about 0.1% to about 0.5% crosslinking
agent(s), more preferably between about 0.15% to about 0.45%
crosslinking agent(s), and most preferably between about 0.2% to
about 0.4% crosslinking agent(s).
[0017] In preferred embodiments, compositions of the present
invention comprise one or more humectants. Humectants inhibit
drying and increase the amount of time that the composition remains
moldable prior to drying and becoming hardened. A wide variety of
humectant materials may be employed. In a preferred embodiment, the
composition comprises glycerin as a humectant. The composition
preferably comprises between about 1% to about 3% humectant, more
preferably between about 1.25% to about 2.75% humectant, and most
preferably between about 1.5% to about 2.5% humectant.
[0018] According to certain embodiments, compositions of the
present invention comprise one or more additional additives. These
additives may include, but are not limited to, pH adjusters,
buffers, defoamers, dispersing agents, scents, preservatives,
and/or colorants. The compositions preferably comprise less than
about 1% additives, more preferably less than about 0.9% additives,
most preferably less than about 0.8% additives. In preferred
embodiments, the compositions of the present invention comprise
between about 0.1% to about 2% additives, more preferably between
about 0.25% to about 1.5% additives, and most preferably between
about 0.5% to about 1% additives. Alternatively, the one or more
additives may be present in larger amounts if the additive(s)
include one or more pigments for imparting color to compositions
that include sand which is not pre-colored (as discussed above);
for example, the additive(s) may be present in the composition in
an amount between about 0.01% to about 10%, between about 0.01% to
about 7.5%, between about 0.01% to about 5%, between about 0.01% to
about 3%, between about 0.01% to about 2%, or between about 0.01%
to about 1%.
[0019] Such additives are readily available from numerous sources.
Common pH adjusters include phosphoric acid and triethanolamine.
Defoamers, such as Foamex.RTM. 825, can be added to eliminate air
bubbles upon mixing of the components. One or more preservatives,
such as anti-microbial agents and fungicides, can be added to
increase the shelf life of the composition. Some examples of
preservatives include Kathon.RTM. LX, Nuosept.RTM. 95,
Acticide.RTM. LA, and Polyphase.RTM. P100. One or more colorants,
such as pigments (e.g., as discussed above with respect to pigments
that may be used with sand that is not pre-colored) or dyes, may
optionally be used in the composition. A scent or fragrance may
also be added to the composition.
[0020] According to certain aspects of the present invention, the
moldable sand composition comprises sand, water, a polar polymeric
resin, a crosslinking agent, a humectant, and one or more additives
(e.g., one or more pH adjusters, buffers, defoamers, dispersing
agents, scents, preservatives, colorants, or a combination
thereof). According to particular embodiments, the moldable sand
composition comprises between about 70% to about 95% sand, between
about 5% to about 30% water, between about 0.5% to about 3% polar
polymeric resin (e.g., PVA), between about 0.1% to about 0.5%
crosslinking agent, between about 1% to about 3% humectant, and
between about 0.01% to about 10% additives (e.g., between about
0.01% to about 7.5% additives, between about 0.01% to about 5%
additives, between about 0.01% to about 3% additives, between about
0.01% to about 2% additives, or between about 0.01% to about 1%
additives). According to preferred embodiments, the moldable sand
composition comprises between about 70% to about 95% sand, between
about 5% to about 30% water, between about 0.5% to about 3% polar
polymeric resin (e.g., PVA), between about 0.1% to about 0.5%
crosslinking agent, between about 1% to about 3% humectant, and
between about 0.1% to about 2% additives. According to more
preferred embodiments, the moldable sand composition comprises
between about 80% to about 90% sand, between about 7% to about 20%
water, between about 0.75% to about 2.75% polar polymeric resin
(e.g., PVA), between about 0.15% to about 0.45% crosslinking agent,
between about 1.25% to about 2.75% humectant, and between about
0.25% to about 1.5% additives. According to most preferred
embodiments, the moldable sand composition comprises between about
84% to about 88% sand, between about 8% to about 12% water, between
about 1% to about 2% polar polymeric resin (e.g., PVA), between
about 0.2% to about 0.4% crosslinking agent, between about 1.5% to
about 2.5% humectant, and between about 0.5% to about 1% additives.
According to an exemplary embodiment, the moldable sand composition
comprises about 86% sand, about 9.5% water, about 1.5% polar
polymeric resin (e.g., PVA), about 0.3% crosslinking agent, about
2% glycerin, and about 0.7% additives.
[0021] Advantageously, there are numerous ingredients in other
commercially available moldable compositions which are not included
in compositions of the present invention. In a preferred
embodiment, the composition does not include any cellulose
compounds, such as hydroxypropyl cellulose, which could promote
undesirable microbial growth. The composition also preferably does
not include any glycols, such as propylene glycol. A glycol
compound would be likely to impede drying and would therefore
interfere with the ability of the composition to become hardened.
In embodiments where the compositions are solely water-based and do
not include solvents such as glycols, the compositions can more
easily harden due to water evaporation and can become moldable
again after the addition of water.
[0022] In additional preferred embodiments, the composition does
not include any oils or oily components, such as mineral oil,
petroleum, paraffin oil, or silicone oil. It is also preferred that
the composition does not include any rubbers, such as
polyisobutylene, or waxes, such as silicon wax. These components
commonly produce a greasy or sticky feeling, in addition to the
risk of staining clothes or the surrounding environment. They may
also interfere with the ability of the composition to become
hardened, and to then become moldable again after the addition of
water.
[0023] Because the composition preferably has a grainy texture,
rather than a smooth texture that is characteristic of other
moldable compositions, it is not necessary to coat the sand
particles with an additional component that imparts a smooth
texture rather than a grainy texture. Thus, the composition is
preferably free of calcium carbonate, talc, alumina trihydrate, and
titanium dioxide, which are commonly added to other commercially
available products.
[0024] According to certain aspects of the present invention, the
moldable sand composition consists of, or consists essentially of,
sand, water, a polar polymeric resin, a crosslinking agent, a
humectant, and one or more additives (e.g., one or more pH
adjusters, buffers, defoamers, dispersing agents, scents,
preservatives, colorants, or a combination thereof). Thus,
according to certain aspects, the moldable sand composition is
absent (i.e., contains 0%) cellulose compounds, glycols, oils,
rubbers, and waxes. According to particular embodiments, the
moldable sand composition consists of, or consists essentially of,
between about 70% to about 95% sand, between about 5% to about 30%
water, between about 0.5% to about 3% polar polymeric resin (e.g.,
PVA), between about 0.1% to about 0.5% crosslinking agent, between
about 1% to about 3% humectant, and between about 0.01% to about
10% additives (e.g., between about 0.01% to about 7.5% additives,
between about 0.01% to about 5% additives, between about 0.01% to
about 3% additives, between about 0.01% to about 2% additives, or
between about 0.01% to about 1% additives). According to certain
embodiments, the moldable sand composition consists of, or consists
essentially of, between about 70% to about 95% sand, between about
5% to about 30% water, between about 0.5% to about 3% polar
polymeric resin (e.g., PVA), between about 0.1% to about 0.5%
crosslinking agent, between about 1% to about 3% humectant, and
between about 0.1% to about 2% additives. According to more
preferred embodiments, the moldable sand composition consists of,
or consists essentially of, between about 80% to about 90% sand,
between about 7% to about 20% water, between about 0.75% to about
2.75% polar polymeric resin (e.g., PVA), between about 0.15% to
about 0.45% crosslinking agent, between about 1.25% to about 2.75%
humectant, and between about 0.25% to about 1.5% additives.
According to most preferred embodiments, the moldable sand
composition consists of, or consists essentially of, between about
84% to about 88% sand, between about 8% to about 12% water, between
about 1% to about 2% polar polymeric resin (e.g., PVA), between
about 0.2% to about 0.4% crosslinking agent, between about 1.5% to
about 2.5% humectant, and between about 0.5% to about 1% additives.
According to an exemplary embodiment, the moldable sand composition
consists of, or consists essentially of, about 86% sand, about 9.5%
water, about 1.5% polar polymeric resin (e.g., PVA), about 0.3%
crosslinking agent, about 2% glycerin, and about 0.7%
additives.
[0025] A method according to the present invention comprises
combining all of the components of the compositions described above
and thoroughly mixing them until they display a substantially
uniform color, consistency, and texture. According to certain
aspects of the present invention, a method for making a moldable
sand composition comprises mixing the components of the
compositions described above, namely, sand, water, a polar
polymeric resin, a crosslinking agent, a humectant, and one or more
additives (e.g., one or more pH adjusters, buffers, defoamers,
dispersing agents, scents, preservatives, colorants, or a
combination thereof) in the weight percentages described above,
preferably at room temperature (i.e., the method is preferably free
of any heating steps).
[0026] According to a preferred embodiment, the components of a
"polar polymeric resin premix" (e.g., a "PVA premix") are
separately combined and mixed together, with the premix comprising
water, a humectant (e.g., glycerin), a polar polymeric resin (e.g.,
PVA), and one or more optional additives. The premix is combined
with the other components of the composition, namely, sand, water,
a crosslinking agent, and one or more optional additives. All of
the components are then mixed together until a substantially
uniform color, consistency, and texture are achieved. It is not
necessary to heat any of the components during the process. Thus,
all of the combining and mixing steps can be performed at room
temperature (about 20.degree. C.-about 25.degree. C.).
[0027] The polar polymeric resin premix preferably comprises
between about 5% to about 15% of the total composition, more
preferably between about 7.5% to about 12%, and most preferably
between about 9% to about 11%. In certain embodiments, the premix
comprises between about 50% to about 75% water, more preferably
between about 55% to about 70% water, and most preferably between
about 60% to about 65% water. In certain embodiments, the premix
further comprises between about 10% to about 30% humectant, more
preferably between about 15% to about 25% humectant, and most
preferably about 20% humectant. In certain embodiments, the premix
further comprises between about 0.1% to about 10% additives, more
preferably between about 2% to about 8% additives, and most
preferably between about 3% to about 5% additives.
[0028] A method for using a moldable sand composition of the
present invention comprises molding the moldable sand composition
into a desired shape, exposing the moldable sand composition to air
(preferably ambient air at room temperature, about 20.degree.
C.-about 25.degree. C.) for a period of time sufficient for the
moldable sand composition to become a hardened composition (i.e.,
exposing the composition to air comprises leaving the moldable sand
composition outside of any enclosure, such as a container, that
would substantially prevent moisture from evaporating off of the
composition), adding water to the hardened composition to make a
re-wetted moldable composition, and molding the re-wetted moldable
composition, wherein the moldable sand composition comprises any of
the moldable sand compositions described herein.
[0029] According to alternative embodiments, additional
modifications may be made to the composition after it has been
molded into a desired shape. For example, the method may further
comprise adding a decorative agent to the composition, either
before or after it has hardened. The decorative agent may be
selected from the group consisting of glaze, paint, glitter,
shimmer, and a combination thereof. After the composition has
hardened, the method may further comprise chiseling the hardened
composition (e.g., to add texture) or further sculpting the
hardened composition.
[0030] The present invention also provides kits comprising a
moldable sand composition. According to a particular embodiment, a
kit comprises a moldable sand composition in accordance with
embodiments of the present invention, and one or more molds. The
composition is preferably provided in one or more containers, such
as one or more tubs. Multiple portions of the composition can be
removed from the container(s) and molded into a multitude of
desired shapes. For example, after a portion of the moldable sand
composition is packed into a mold, and then removed from the mold,
the composition preferably retains the shape of the mold. The
mold(s) provided in the kit may be any shape, for example, they may
be in the shape of a star, square, circle, sphere, rectangle, or
action figure. The kit may provide molds according to a particular
theme, for example, a construction kit may comprise mold(s) in the
shape of one or more bricks or concrete blocks. According to one
embodiment, after a user has molded multiple portions of the
composition into the shapes of multiple objects (e.g., bricks), the
molded objects can be stacked next to each other and/or on top of
each other to create a structure. The kit may further comprise one
or more tools or toys (e.g., one or more toy cars or trucks) which
can be used to mold or shape the composition, e.g., to reshape the
composition after it has been molded into the shape of the one or
more molds. For example, the kit may comprise one or more rollers
for flattening a molded composition (e.g., for flattening portions
of the molded composition that have been shaped into bricks). The
roller(s) may be provided as part of a toy, such as a truck (e.g.,
a construction truck). The kit may also comprise one or more
decorative agents (e.g., glaze, paint, glitter, and/or
shimmer).
[0031] The following examples are provided to describe the
invention in greater detail and are intended to illustrate, not
limit, the invention.
EXAMPLES
Example 1
[0032] While only certain compositions are set forth below,
alternative compositions will be apparent to those skilled in the
art. Such artisans will be able to modify the compositions with an
eye toward the desired performance properties and intended use.
[0033] The moldable sand compositions disclosed below were made by
first mixing the components of the PVA Premix provided in Table 1
at room temperature (about 21.degree. C.).
TABLE-US-00001 TABLE 1 PVA Premix Component Weight Percentage Water
61.64 Glycerin 20.03 Celvol .RTM. 523 PVA 14.02 Foamex .RTM. 825
1.00 Phosphoric Acid 0.90 Nuosept .RTM. 95 1.81 Kathon .RTM. LX
0.60 Total 100.0
[0034] The PVA Premix was then combined at room temperature with
the other components of the composition, as set forth in Table 2
below.
TABLE-US-00002 TABLE 2 Component Weight Percentage Sand 86.2 PVA
Premix 9.7 City Water 3.5 Boric Acid 0.3 Triethanolamine 0.3 Total
100.0
[0035] All of the components were mixed until a uniform color,
consistency, and texture were achieved. The final composition is
provided in Table 3 below.
TABLE-US-00003 TABLE 3 Component Weight Percentage Sand 86.20 Water
9.48 Glycerin 1.94 Celvol .RTM. 523 1.36 Foamex .RTM. 825 0.10
Phosphoric Acid 0.09 Nuosept .RTM. 95 0.18 Kathon .RTM. LX 0.06
Boric Acid 0.30 Triethanolamine 0.30 Total 100.0
Example 2
[0036] Table 4 provides data with respect to the % weight loss and
hardening characteristics over time for a 20 gram composition of
the present invention under ambient conditions (70.degree. F.,
21.degree. C., 45% relative humidity) that had been molded into a
round shape. As shown in Table 4, the composition began to harden
after approximately two hours. After approximately 24 hours, the
composition exhibited approximately 11% weight loss and was
hardened to the extent that it was no longer moldable or deformable
by hand.
TABLE-US-00004 TABLE 4 Dry Time % Weight Loss Comments 0.5 Hours 1
Moist Surface 1.5 Hours 2 Dry Surface 2 Hours 3 Dry Surface -
beginning to harden 4 Hours 4 Continuing to harden 5 Hours 5
Continuing to harden 7 Hours 6 Continuing to harden - still deforms
with pressure 24 Hours 11 Hardened - does not deform
[0037] Although the present invention has been described in
connection with specific embodiments, it should be understood that
the invention as claimed should not be unduly limited to such
specific embodiments. Indeed, various modifications and variations
of the described compositions and methods of the invention will be
apparent to those of ordinary skill in the art and are intended to
be within the scope of the appended claims.
* * * * *