U.S. patent application number 14/740335 was filed with the patent office on 2015-10-01 for apparatus with an exterior surface simulating a natural surface.
This patent application is currently assigned to Nature Blinds, LLC. The applicant listed for this patent is Nature Blinds, LLC. Invention is credited to Timothy L. Thomason.
Application Number | 20150275540 14/740335 |
Document ID | / |
Family ID | 51221605 |
Filed Date | 2015-10-01 |
United States Patent
Application |
20150275540 |
Kind Code |
A1 |
Thomason; Timothy L. |
October 1, 2015 |
Apparatus With an Exterior Surface Simulating a Natural Surface
Abstract
An apparatus having an exterior surface that simulates a natural
surface, comprising a polymer-foam sidewall having a concave first
surface, a first end, and a second end. According to one embodiment
in which the apparatus is a hunting blind, the sidewall is
generally cylindrical and further has an inner surface, and defines
a plurality of windows extending between the inner and outer
surfaces. A first endwall is adjacent to the first end of the
sidewall. A second endwall is adjacent to the second end of the
sidewall. The sidewall, first end wall, and second endwall define
an interior space that may be occupied by a hunter.
Inventors: |
Thomason; Timothy L.;
(Kerrville, TX) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Nature Blinds, LLC |
Kerrville |
TX |
US |
|
|
Assignee: |
Nature Blinds, LLC
Kerrville
TX
|
Family ID: |
51221605 |
Appl. No.: |
14/740335 |
Filed: |
June 16, 2015 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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13966170 |
Aug 13, 2013 |
9078424 |
|
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14740335 |
|
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61682554 |
Aug 13, 2012 |
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Current U.S.
Class: |
135/117 |
Current CPC
Class: |
E04H 15/001 20130101;
B29C 33/3857 20130101; Y10T 29/4998 20150115; B29C 44/04 20130101;
B29C 33/3842 20130101; A01M 31/025 20130101; B29C 2033/3871
20130101; B29C 44/06 20130101 |
International
Class: |
E04H 15/00 20060101
E04H015/00 |
Claims
1. An apparatus having an exterior surface simulating a surface
found in nature, the apparatus comprising: a sidewall having a
first end and a second end, the sidewall having a first surface
simulating a natural surface, the sidewall further having a second
surface, wherein the sidewall defines at least one window extending
between the first and second surfaces.
2. The apparatus of claim 1 further comprising: a first endwall
adjacent to the first end of the sidewall, said first endwall
having a concave exterior surface; a second endwall adjacent to the
second end of the sidewall; wherein the sidewall, first endwall,
and second endwall define an interior space; and wherein the
sidewall is generally-cylindrical.
3. The apparatus of claim 2 wherein said sidewall defines a first
plurality of channels establishing a fluid communication path from
the concave exterior surface of the first endwall to first surface
of the sidewall.
4. The apparatus of claim 2 wherein said sidewall defines a second
plurality of channels extending through said sidewall establishing
a fluid communication path between the interior space and the first
surface of the sidewall.
5. The apparatus of claim 1 further comprising a door assembly
connected to said sidewall, said door assembly having a door
rotatable to and from a closed position in which said door occupies
said door opening, and wherein said door has an outer door surface
textured to imitate a vegetation surface.
6. The apparatus of claim 1 further comprising a plurality of panes
movable to and from a position substantially covering one of said
at least one window.
7. The apparatus of claim 1 further comprising: at least one
metallic member associated with said at least one windows; and at
least one magnetic member attracted to said metallic members.
8. The apparatus of claim 1 wherein the sidewall comprises a first
layer of polymer foam having a first indention force deflection
(IFD) rating and a first thickness and a second layer of polymer
foam having a second IFD rating that is less than the first IFD
rating and a second thickness, and wherein thickness of the second
layer is greater than the thickness of the first layer.
9. The apparatus of claim 8 wherein said first IFD rating is ten
pounds and said second IFD rating is two pounds.
Description
CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] This divisional application claims the benefit of and
priority to U.S. patent application Ser. No. 13/966,170, filed Aug.
13, 2013, which claims the benefit of and priority to U.S.
Provisional Application Ser. No. 61/682,554, filed Aug. 13, 2012.
Both of these prior filed applications are incorporated by
reference.
STATEMENT REGARDING FEDERALLY-SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not applicable.
BACKGROUND OF THE INVENTION
[0003] 1. Field of the Invention
[0004] The present invention relates to apparatuses for outdoor use
and having at least one surface designed to simulate the appearance
of a natural surface, such as a vegetation surface or rock
surface.
[0005] 2. Background of the Art.
[0006] In hunting, game are adept at identifying unnatural (e.g.,
human) motion and sounds, as well as unnatural structures in their
environment. One technique used by hunters to counter game's
ability to identify unnatural motion and sounds is to use a hunting
blind, which is a cover device designed to reduce the chance of
detection.
[0007] Hunting blinds come in two main varieties. Elevated blinds
are positioned above ground, such as within a tree or on a stand.
Ground blinds, on the other hand, sit directly on the ground.
[0008] Typical ground blinds often require a great deal of
preparation and patience prior to use. Because game such as deer
are cautious and unaccepting of new and unfamiliar structures, a
ground blind might have to be left in the desired hunting location
for extended time periods prior to use. In addition, the blind may
need to be "brushed in"--that is, brush from the surrounding area
gathered to place around the blind so the game does not see the
unnatural outline. Not only can this take a significant amount of
time, but it must be done frequently, as the foliage on the brush
that provides the concealment dies off over time and reduces the
amount of cover.
[0009] Several devices have been developed to attempt to address
these problems. For example, a blind sold under the trademark
GHOSTBLIND.RTM., by GhostBlind Industries of Marietta, Ohio,
comprises a set of adjacent mirrors that are angled downward toward
the ground surface. Thus, the natural appearance of the surrounding
ground surface is reflected by the mirrors to the nearby game.
[0010] The GHOSTBLIND.RTM. blind, however, has several drawbacks.
For one, the mirrors are relatively fragile, and cannot be left
unattended for extended periods of time without risk of damage.
Second, the blind is relatively small, is open to the environment
and elements, and does not include aspects for inhibiting the
transmission of unnatural sounds and scents. Third, there still
remains risk of an unnatural image inadvertently being reflected by
one or more misaligned mirrored panels.
[0011] Other proposed solutions were arrived at by assignee of this
application and are disclosed in U.S. Pat. Nos. D642,700, D652,343,
D642,699, and D661,404. For example, U.S. Pat. No. D642,699
discloses a tree-like observation blind that has the general shape
of a tree trunk. This patent, however, does not simulate a
vegetation surface, but rather simply the general outline and shape
of a tree. In fact, the design disclosed in U.S. Pat. No. D642,699
was determined to be inadequate, which resulted in development of
the inventions disclosed and claimed herein.
SUMMARY OF THE INVENTION
[0012] The present invention relates to an apparatus having an
exterior surface simulating characteristics of a natural surface,
such as the bark of the tree. The apparatus comprises a polymer
foam wall having a first end and a second end.
[0013] According to one embodiment, the sidewall has an outer
surface simulating a vegetation surface, such as the bark on the
trunk of a tree. The sidewall further has an inner surface, and
defines a plurality of windows extending between the inner and
outer surfaces. A first endwall is adjacent to the first end of the
sidewall. A second endwall is adjacent to the second end of the
sidewall. The sidewall, first endwall, and second endwall define an
interior space that may be occupied by a hunter.
[0014] In arriving at the present invention, one problem that was
addressed was the sheer detail and scope of the subject molded
articles. Molding processes that may be similar to those described
herein have been used in other areas, such as the field of special
effects make-up.
[0015] There are, however, fundamental differences between using
the technique for special effects and in the simulation of natural
surfaces.
[0016] For example, traditional molding techniques require
utilizing an enclosure into which a curable mixture is poured and
allowed to set. With the present invention, however, the scale of
the potential subject matter--i.e., full-size trees--generally
prevents the efficient use of such enclosures.
[0017] In addition, traditional molding techniques are focused on
accuracy and detail of the mold at the expense of speed and
manufacturing efficiency. While in the present application accuracy
is important, the degree of accuracy need not be as precise as in,
for example, the special effects industry. Rather, the ability to
manage and handle the mold during the manufacturing process is
prioritized over the precision required with other areas where
silicone molding is required.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIG. 1 is a top isometric view of an embodiment of the
present invention.
[0019] FIG. 2 depicts a sectional view through section line 2-2 of
FIG. 1.
[0020] FIG. 2A is an enlarged view of window 2A of FIG. 2.
[0021] FIGS. 3A & 3B show a window assembly of the embodiment
described with reference to FIG. 2 in a substantially open and a
substantially closed state, respectively.
[0022] FIGS. 4-8 show various stages of one embodiment being
manufactured according to the method of manufacture of the present
invention.
[0023] FIG. 9 is a front elevation of an alternative embodiment of
the present invention.
DESCRIPTION OF ONE OR MORE EMBODIMENTS OF THE INVENTION
[0024] FIG. 1 shows an embodiment of the present invention, which
embodiment is a hunting blind 20 that simulates the textures and
colors of a subject tree's bark and is manufactured according the
steps of the method disclosed herein. The blind 20 comprises a
generally trunk-shaped sidewall 22 having an exterior surface 24
that imitates the texture of natural tree bark. This texture may
include bare areas 26 that are smooth, such as are frequently found
in nature. Such natural textures and shapes generally do not
comprise straight lines and right angles. Although the blind 20 is
shown as having the bark of an oak tree, any number of different
trees may be simulated using the process described herein. The
exterior surface 24 of the sidewall 22 is coated with UV protective
paint selected to imitate the colors of the bark of the subject
tree. One such suitable paint is an exterior latex flat paint, C1
Series, sold under the tradename DURACRAFT by The Sherwin Williams
Corporation of Cleveland, Ohio.
[0025] The trunk-shaped sidewall 22 includes a first end 28 and a
second end 30. In the preferred embodiment as intended to be used,
the first end 28 is positioned proximal to a ground surface 32 and
is flared to simulate the root flare of a natural tree. The second
end 30 is positioned distally from the ground surface 32. Windows
34 are disposed through the sidewall 22 to provide six viewports
that are generally spaced equidistantly around the sidewall 22 to
provide for generally a three-hundred sixty degree viewing angle.
Preferably, the windows 34 are irregularly shaped so as not to use
straight lines or right angles.
[0026] A door opening 37 extends through the sidewall 22 to provide
access to the interior of the blind 20. A door 39 is fastened to
the sidewall 22 and is rotatable to and from a closed position
which it occupies in the door opening 37.
[0027] A first endwall 35 is positioned at the first end 28 of the
sidewall 22. A second endwall 36 is positioned at the second end 30
of the sidewall 22. The second endwall 36 has a convex exterior
surface 38 that directs liquids (e.g., rainwater) toward channels
40 spaced around the convex surface 38 and through the sidewall 22,
which allow liquid to pass through the sidewall 22 and fall to the
surrounding ground surface 32, thus preventing damage to the blind
20 from accumulation of liquid. A second group of channels 41 is
positioned proximal to each window 34, with each channel extending
through the sidewall 22 to the interior of the blind 20. The
sidewall 22 extends beyond the concave exterior surface 38 such
that the surface is generally not visible to game resting on the
surrounding ground surface 32.
[0028] As shown in FIG. 2 and FIG. 2A, the sidewall 22 is comprised
of a first foam layer 42 having a first indention force deflection
(IFD) rating of ten pounds, and a second foam layer 44 having a
second IFD rating of two pounds. Preferably, the foam is a polymer
foam. In this embodiment, the thickness of the sidewall 22 is
approximately four inches, with the second foam layer 44 being
thicker than the first foam layer 42.
[0029] The sidewall 22, first endwall 35, second endwall 36, and
door opening 37 define an interior space 46 for isolating an
occupant from the environment. More specifically, the interior
space 46 is defined by the second layer 44 of the sidewall 22, a
floor surface 48, and the second endwall 36. A window assembly 50
is associated with each window 34.
[0030] Referring to FIGS. 3A & 3B, each window assembly 50
includes a pane 52, pane frame 54 and metallic member 56 that is
associated with each of the windows 34. Each metallic member 56 is
generally elongate and positioned proximal to a window 34.
[0031] In this embodiment, each pane 52 is one-way glass that
allows an occupant of the blind to see through the pane 52, but
impedes game from seeing movement by the occupant within the
interior space. In alternative embodiments, a semi-transparent
decal (e.g., a camouflage window decal) may be applied to the panes
52. The frame 54 and sidewall 22 define slots on opposing sides of
the window 34 that guides the pane 52 as it slidably moves to and
from a closed position. Channels 41 extend through the sidewall 22
and have openings positioned proximal to the frame 54 to inhibit
fluid accumulation in the frame 54.
[0032] Each pane 52 is connected to a magnetic member 58 (e.g., a
neodymium magnet) with a length of cordage 60 (e.g., rope, string)
that is positioned through eyebolts 62 or pulleys that are mounted
to the sidewall 22. The magnetic member 58 is attracted to the
metallic member 56 with sufficient strength to resist the force
applied to the magnetic member 58 by the weight of the pane 52
transferred through cordage 60. Each pane 52 may be moved between
an open and a closed position (and positions in between) by moving
the position of the magnetic member 58 to various positions on the
associated metallic member 56. When the magnetic member 58 is
positioned at or near a first end 64 of the metallic member 56, the
pane 52 is held in an open or substantially open position. When the
magnetic member 58 is moved to a position at or near the second end
66 of the metallic member 56, the pane 52 moves to the closed, or a
substantially closed, position.
[0033] The method of manufacturing the blind described with
reference to the previous figures is a generally a two-step
process. First, a master mold is made. Second, the blind 20 is
manufactured from the master mold.
[0034] Making the master mold comprises the follows steps. First, a
subject tree is identified. The subject tree should have an outer
trunk surface (e.g., bark) that will remain intact during the
mold-creation process. The bark should be relatively new and
supple, as older and/or brittle bark will become inadvertently
distressed or removed during later steps of the mold-making
process. Importantly, however, while older, brittle bark will not
suffice for the methodology presented herein, a tree section may be
too supple to accept the silicone mixture without deformation.
[0035] Second, a trunk section of the subject tree is cut. If the
subject tree has a natural root flare proximal to the ground
surface, the trunk section preferably includes the root flare. The
length of the trunk section should be at least equal to the desired
maximum exterior height of the blind. As shown in FIG. 4, the trunk
section 72 is preferably cut to have parallel, planar surfaces 74,
which may or may not have irregular profiles depending on the
characteristics of the selected trunk section 72.
[0036] Third, as shown in FIG. 4, a spindle 70 having opposing ends
76 is disposed through the trunk section 72. Preferably, the
spindle 70 is disposed at a right angle relative to the planar
surfaces 74 of the trunk section 72 and through the center of mass
to allow even rotation of the trunk section 72 during later steps
of the process. The opposing ends 76 of the spindle 70 are
supported by elevated rollers 78, which allows the spindle 70 to
turn freely in this position.
[0037] Fourth, when the trunk section 72 is in the position shown
in FIG. 4 a release agent is applied to the trunk section 72. A
suitable release agent repels water, and, for example, is
petrol-based. Preferably, the release agent is vegetable oil, but
may be any other suitable agent. The release agent is applied to
the trunk section 72 with a cloth, brush, or other suitable
applicator.
[0038] Fifth, while the trunk section 72 is rotated in the position
shown in FIG. 4 a first coat of a low viscosity silicone mixture
having a high Shore value is applied. Preferably, the Shore value
is greater than or equal to twenty-eight and the viscosity of
thirty-thousand cps. One suitable silicone is Model HY628#
available from Shenzhen Hongyejie Technology Co., Ltd. of Shenzhen,
China.
[0039] Fifth, after allowing the first coat to dry, and while the
trunk section 72 is rotated in the position shown in FIG. 4, a
second coat of the low viscosity silicone mixture used for the
first coat is applied. Preferably, the second coat is applied with
the same silicone mixture as is applied as the first coat.
[0040] Sixth, a coat of a second silicone mixture, which has a
higher viscosity than the first silicone mixture, is applied.
Preferably, application of the second silicone mixture occurs when
the trunk section 72 is in a vertical position rather than the
horizontal position shown in FIG. 4. The second silicone mixture
may be derived from the first silicone mixture being combined with
a thickening agent and/or a suitable accelerant to decrease cure
time.
[0041] Seventh, a layer of barrier material is applied over the
second silicone mixture. Preferably, the barrier layer is a cotton
fabric, such as a cheesecloth, which is a loose-woven gauze-like
cotton cloth.
[0042] Eighth, a coat of a third silicone mixture is applied over
the layer of barrier material. Preferably, the third silicone
mixture is the same as the first silicone mixture previously
applied.
[0043] Ninth, as shown in FIG. 5, attachment members 95 for hanging
the master mold from an overhead support are attached to at least
one of the silicone mixture layers. In the described embodiment,
the attachment members 95 are fully immersed in at least one
silicone layer. Once the silicone layers have cured, the attachment
members 95 are impeded from movement relative to the remainder of
the master mold 80 and will support the weight of the master mold
80 without detaching.
[0044] After the steps identified supra are completed, the
composite layers of the master mold are inspected for defects in
the silicone, such as spots or tears, and patched as needed with
the high viscosity silicone mixture.
[0045] Still referring to FIG. 5, a seam 81 is formed between the
first and second ends 84, 86 of the master mold 80, which define
opposing seam ends 82. Straps or magnets 83 are fused with silicone
near the seam ends 82 to allow for later reconnection of the seam
ends 82. Thereafter, the master mold 80 is removed from the trunk
section (not shown) by separating the seam ends 82.
[0046] Referring to FIG. 6, which shows the master mold 80 with the
seam ends 82 unconnected, areas proximal to the opposing ends 84,
86 of the interior surface 88 of the master mold 80 are coated with
an elastomer 90 (e.g., polyurea) to improve durability. The
elastomer coating 90 is applied along the opposing ends 84, 86 of
the master mold 80. This elastomer coating 90 hardens these areas
to inhibit chipping, breaking, or other damage of the master mold
80.
[0047] While the preferred method contemplates applying the
silicone mixtures to a trunk section, an alternative embodiment of
the method contemplates a "flat pour." According to this
alternative embodiment, the exterior surface of the identified
trunk section (i.e., the phellum) is removed and kept intact.
Typically, this is done by removing the entire bark layer, which
includes the phellum (or cork), the phellogen (or cork cambium),
the phelloderm, the cortex, and the phloem.
[0048] After completion of the master mold 80, an individual blind
may be manufactured as follows. First, referring back to FIG. 5,
the master mold 80 is hung from overhead supports 93 by chains or
ropes 91 to the attachment members 95, and stretched to the desired
form using cordage 92 connected between the master mold 80 and a
support framework 94. The desired shape is a generally tree-trunk
shaped cylinder having open ends that is at least substantially
similar to the shape of the trunk section from which the master
mold 80 was formed. Once the desired form for the master mold 80 is
obtained, the seam ends 82 are closed by connecting the magnets 83
or straps.
[0049] Thereafter, as shown in FIG. 7, the first foam layer 42 is
applied (e.g., sprayed, stamped, poured, etc.) on the inner surface
of the master mold 80. After the first foam layer 42 cures, a door
frame 96 is fastened to the first foam layer 42, and foam applied
therearound to secure the door frame 96 in place relative to the
first foam layer 42. In this embodiment, the first foam layer 42
has an IFD of ten pounds. One suitable B-side component is a
urethane system resin component sold under the designation High
Density Foam 1006 Resin, available from PolyGreen Solutions, LLC of
Atlanta, Ga. This B-side component may be combined with a
polymethylene polyphenylisocyanate A-side component designated PM
200, also available from PolyGreen Solutions, LLC.
[0050] After the first foam layer 42 has cured, the second foam
layer 44 (see FIG. 2A) is applied to the inner surface of the first
foam layer 42. The second foam layer 44 has an IFD of two pounds.
One acceptable B-side foam component for the second foam layer 44
is a urethane system resin component sold under the designation
Wall Foam 186 Resin, which is available from PolyGreen Solutions,
LLC of Atlanta, Ga.
[0051] The first and second foam layers 42, 44 together are
approximately four inches thick. After the second foam layer 44 has
cured, the master mold 80 may be lowered from the overhead supports
93, and the master mold 80 separated at the seam 81, leaving behind
the blind 20, as shown in FIG. 8.
[0052] A typical embodiment of a blind has the following
specifications: (a) exterior height of eighty-eight inches (b)
exterior diameter of seventy-seven inches (c) an interior height of
seventy-eight inches; (d) interior diameter of sixty-seven inches;
and (e) a weight of three hundred pounds. Among other advantages,
these dimensions allow a bow hunter adequate space to fully draw
the string of a typical bow.
[0053] The blind also provides sound and temperature insulating
benefits as well. Data shows that the insulating layer of foam
provides a temperature differential of +31 degrees (F.) (relative
to the exterior of the blind) in the winter, and -16 degrees (F.)
(relative to the exterior) during the summer. The insulating layer
foam further inhibits sound transmission from the interior space to
the surrounding environment.
[0054] FIG. 9 shows another embodiment of an apparatus having the
features of the present invention, which embodiment is a hunting
blind 120 that simulates the textures and colors of a subject
tree's bark. The blind 120 comprises a generally trunk-shaped
sidewall 122 having an exterior surface 124 that imitates the
texture of natural tree bark, except that the sidewall is not
generally-cylindrically shaped. This texture may include bare areas
126 that are smooth, such as are frequently found in nature. Such
natural textures and shapes generally do not comprise straight
lines and right angles. Although the blind 120 is shown as having
the bark of an oak tree, any number of different trees may be
simulated using the process described herein. The exterior surface
124 of the sidewall 122 is coated with UV protective paint that is
selected to imitate the colors of the bark of the subject tree.
[0055] The trunk-shaped sidewall 122 includes a first end 128 and a
second end 130. In the preferred embodiment as intended to be used,
the first end 128 is positioned proximal to a ground surface 132
and is flared to simulate the root flare of a natural tree. The
second end 130 is positioned distally from the ground surface 132.
A window 134 is disposed through the sidewall 122 to provide a
viewport. Preferably, the window 134 is irregularly shaped so as
not to use straight lines or right angles.
[0056] The present disclosure includes preferred or illustrative
embodiments in which a specific blind and method of manufacturing
are described. Alternative embodiments of such a blind and method
can be used in carrying out the invention as claimed and such
alternative embodiments are limited only by the claims themselves.
For example, while the specific embodiments described herein
related to hunting blinds, the method of the present invention may
be used for planters, bird feeders, and the like. Moreover, in
addition to vegetation, the simulated natural surface may include
various other surfaces, such as rocks. Other aspects and advantages
of the present invention may be obtained from a study of this
disclosure and the drawings, along with the appended claims.
* * * * *