Patent Application
20080241477
1. Field of Invention
The invention relates to the field of goods manufactured from flexible sheet material, and more specifically to a method and an article manufactured by this method comprising a raised design embossed onto a natural or synthetic animal hide.
2. Description of Related Art
Articles made from animal hide, or leather, are desirable for, among other reasons, durability, texture, and practicality. Additionally, clothing and accessories incorporating leather are often considered fashionable. In order to enhance the appearance of leather goods, many methods exist to integrally incorporate indicia into the leather. For example, U.S. Pat. No. 4,144,594 to Chapman discloses a leather belt having openings punched in it corresponding to the desired indicia. A backing is applied to the leather belt to contrast the openings with the remaining leather.
U.S. Pat. No. 4,319,523 discloses a leather embossing method and embossed article. According to this patent, indicia are pressed into the leather. This method has certain drawbacks, however. In the first instance, the indicia are sunken into the leather. Further, the depth of impression is limited to some fraction of the thickness of the leather itself. Each of these drawbacks limits the impact of the indicia applied.
On the other hand, it is desirable to provide a natural or synthetic leather article having dynamic raised indicia having a three-dimensional appearance integrally formed with the natural or synthetic leather.
In order to overcome these and other drawback of the prior art, provided according to the present invention is a method of forming a flexible sheet material having a raised design permanently embossed therein, including capturing the flexible sheet material between mating die halves, each die half having either a relief inverse negative of the raised design or a raised facsimile of the raised design, respectively, formed therein. The raised design has maximum height out of the plane of the flexible sheet material by an amount greater than or equal to the thickness of the flexible sheet material, and applying sufficient heat and pressure to the flexible sheet material through the die halves for a sufficient amount of time to emboss the design on the flexible sheet material, before releasing the flexible sheet material from the die halves. Optionally, the cavity beneath the raised design in the flexible sheet material is back-filled with a flexible solid material. Also provided according to the present invention is an article produced according to the method.
These and other features, advantages and benefits of the present invention will be made apparent with reference to the following descriptions and drawings, wherein:
Referring now to
A predetermined raised design 14 to be embossed on the flexible sheet material 12 is arbitrarily selected. It is desired that the raised design 14 have a three-dimensional appearance. In order to take full advantage of the present invention, the raised design 14 will vary in height from the plane of the flexible sheet material 12, preferably, wherein the height of at least a portion of the raised design 14 is at least the thickness 16 (see,
According to the present invention, the article 10 is formed by a pressing process that will now be described. Having chosen a raised design 14, a two-part die is prepared having two halves, each half bearing a either a positive (raised) or negative (relief) of the design 14. The two die halves should be complementary, with the raised image of the design 14 on the positive half corresponding to the sunken image of the design 14 in the negative half.
A variety of methods are known in the art for such die making, including manual forming, cast molding, injection molding, etc. A preferred method, according to the present invention, includes forming a negative relief portion of the two-part die in a stock material. The negative die half should preferably have at least a metal surface, or alternately may be metal throughout, as will be apparent, infra. More preferably, the features of the raised design 14 are input into a computer-controlled material forming machine, for example a CNC milling machine, which automates the process with great precision and accuracy. The CNC milling machine removes material from the selected stock according to the features of the raised design 14, thereby forming a negative die half 50 (see
Referring now to
The corresponding positive die counterpart can be similarly machined. Alternately, the positive die can be formed by taking an impression of the negative die. For example, a border may be installed surrounding the negative die, and optionally a de-mold release chemical, such as stearic acid, EVIROSHIELD or WATERSHIELD brand release agents from Zyvax, Inc. of Boca Raton, Fla., UNIVERSAL MOLD RELEASE™ from Smooth-On company of Easton, Pa., or other mold release agent is applied to the negative relief die. A liquid casting material which is preferably acrylic or plaster based material known to the skilled artisan can then be introduced into the bordered negative die. An exemplary liquid casting material is sold under the brand name SMOOTHCAST®, with SMOOTHCAST® 320 material being suitable. Other plaster or acrylic based molding materials that are resistant to the temperatures required in the article embossing process may also be utilized. Once the material comprising the positive die has set, the two die halves can be separated, and prepared for embossing. Other manners of making an impression mold will be apparent to those skilled in the art in light of the present disclosure. However, a more precise impression mold of the negative die to form the positive die is facilitated with flowing materials that are allowed to solidify in the negative die.
The embossing method according to the present invention includes the application of heat and pressure under conditions sufficient to emboss the design onto the flexible material for some duration of time. The amount of heat, pressure and time is dependent upon various factors, such as the type of flexible material used, the type of design embossed thereon, the maximum height thereof, and the weight and thickness of the flexible material. Generally, however, the greater the heat and pressure the smaller is the amount of time required for the embossing process. As an exemplary manner of effecting embossing, the die halves may be fitted in a heat press machine. In addition to providing pressure to the flexible material, the heat press machine applies heat to the flexible sheet material 12. Preferably, at least one half of the die has at least a metal surface, as described above, to assist in conducting heat to the flexible sheet material 12. On the other hand, although it may be optionally present, the complementary half of the die need not be metal. This has the effect of avoiding direct heat to the corresponding side of the flexible sheet material 12, if desired.
According to the present method, the heat press applies a temperature of preferably between about 100 to about 400° C., depending on the type of material being embossed, and increasing within that range as the weight and thickness of the flexible sheet material 12 increases. For the range of exemplary materials disclosed herein and tabulated hereinbelow, the pressure applied can be up to about 150 PSI, but it will increase with thickness of the flexible sheet material 12 and with the increase of the maximum height of the raised design 14 relative to the thickness 16 of the flexible sheet material 12.
The flexible sheet material is held between the die halves for a dwell time sufficient to fix the raised design 14 in the flexible sheet material 12. The dwell time is selected based upon the properties of the particular flexible sheet material 12, including among these its weight and thickness, and the features of the raised design 14, among these its height and complexity. For the range of exemplary materials disclosed herein and tabulated hereinbelow, the dwell time in the press can be up to about 60 seconds, and increases with the weight and thickness of the flexible sheet material 12, and also with the maximum height 18 and detail of the raised design 14. The particular parameters will vary with the individual design, and the particular flexible sheet material 12 chosen. The following chart gives a range of temperature, pressure and time exemplary of certain sample materials.
More preferably, the heat press machine is automated and programmable. This facilitates the entire process and certain additional method steps. A programmable press may be set to store the parameters of a particular design mold, and to facilitate later production from a previous mold. Alternately or additionally, irrespective of whether the heat press is manually operated or automated, the pressure applied may be increased during the press cycle. This has the advantage of avoiding possible tearing of the flexible sheet material 12, and also of improving the sharpness of detail in the raised design 14 in the final article 10.
The article 10, per se, is complete upon the conclusion of the press cycle. Optionally, an additional step may be performed to extend the permanence and durability of the raised design 14. A back-fill 24 material can be introduced into the cavity 26 formed beneath the raised design 14. Preferably, back-fill 24 comprises a flexible solid compound. Thereby, the raised design 14 would better retain its shape, yet remain flexible to move with the outlying flexible sheet material 12. In a more preferred embodiment, back-fill 24 comprises a liquid rubber or silicone based material, which is allowed to set to a solid. In another embodiment, back-fill 24 comprises a flexible rubbery foam type material or silicone foam type material which is allowed to set to a solid. Preferably, back fill 24 is introduced into the (inverted) cavity 26 in a liquid state and permitted to solidify in the shape of the cavity 26.
Optionally, the raised design 14 and/or the surrounding flexible sheet material 12 can be treated for color or texture to highlight or enhance its appearance. Flexible sheet material 12 may be stained, colored or printed across the entire material prior to undergoing the press cycle or after. Texture modification to the flexible sheet material 12, as by stamping, pressing, rolling or steaming, may be applied across the entire material before the press cycle. Preferably, if texture modification is applied after the press cycle, it is applied outside the area of raised design 14, so as not to detract from it.
The present invention has been described with regard to certain exemplary and/or preferred embodiments. These embodiments are meant as merely illustrative, and not limiting, on the scope of the claimed invention, which is construed solely with reference to following appended claims.
| Number | Date | Country | Kind |
|---|---|---|---|
| 60726067 | Oct 2005 | US | national |
| Filing Document | Filing Date | Country | Kind | 371c Date |
|---|---|---|---|---|
| PCT/CA06/01690 | 10/12/2006 | WO | 00 | 4/14/2008 |
