LAMINATE FOR EYEGLASS FRAME WITH EMBEDDED DESIGN PATTERN AND MANUFACTURING METHOD THEREOF

Abstract

A laminate with internal decorative pattern for eyeglass frames, formed by the application of heat and pressure comprising: a plurality of core layers of thermoplastic sheets printed with patterns by transfer printing; a first overlay layer of thermoplastic sheet; and a second overlay layer of thermoplastic sheet; wherein the core layers are sandwiched between the first overlay layer and the second overlay layer; the core layers may further enclose three dimensional articles or fluids for decorative or functional purposes. The process for manufacturing the laminate includes: preparing a plurality of core layers, a first overlay layer and a second overlay layer from thermoplastic sheets; printing patterns on the core layers by transfer printing; layering from top to bottom the first overlay layer, the core layers and second overlay layer; applying to the layer of sheets a temperature of 0° C. to 300° C. and a starting pressure of 0 atm to bond the layers together; and removing from the heat and pressure a laminate; wherein the process for manufacturing can further include steps of creating cavity in the core layers to enclose the three dimensional articles or fluids.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

One or more embodiments are now described with reference to the drawings, in which:

FIG. 1 shows the exploded view of a laminate embedded with planar pattern;

FIG. 2 a shows the exploded view of a laminate embedded with three dimensional articles and fluids;

FIG. 2 b shows the cross sectional view of a laminate embedded with three dimensional articles;

FIG. 3 shows the exploded view of a laminate embedded with particles;

FIG. 4 shows the perspective view of a laminate embedded with immiscible fluids;

FIG. 5 shows the perspective view of a laminate embedded with immiscible fluids and floating articles.

DETAILED DESCRIPTION OF THE INVENTION

Where reference is made in any one or more of the accompanying drawings to steps and/or features, which have the same reference numerals, those steps and/or features have for the purposes of this description the same function(s) or operation(s), unless the contrary intention appears.

The preferred method described herein provides a laminate with internal pattern for eyeglass frames, such patterns and colors will not be affected by external conditions during use, and provide further advantages of simple configuration, low cost and short production cycle. The patterns can be in the form of two-dimensional art, particles, three dimensional articles, fluids, or a combination of the above.

In one embodiment, the laminate with internal pattern is assembled from a top layer, at least one middle layer or core layer, and a bottom layer. Adhered between the inner surface of the top and bottom layer is the core layer of thermoplastic sheets with decorative patterns printed by transfer printing. The top layer is a transparent thermoplastic sheet, whereas the middle and bottom layers can be transparent, semi-transparent, non-transparent thermoplastic sheet. The thermoplastic sheets can be made of common thermoplastic materials in the industry such as cellulose acetate, cellulose acetate propionate, polycarbonate, TPE or nylon.

The core layers described above are printed with patterns by transfer printing and adhered to the inner surface of the top layer or the inner surface of the bottom layer. The thermoplastic layers are bonded together by application of heat and pressure.

The method of transfer printing can be selected from common technologies in the industry including heat pressing transfer, water transfer, vapor transfer, screen printing, and stencil printing.

The layers can be adhered together by common method in the industry such as the use of adhesive substance, thermoform or lamination.

It is one of the advantages of the present invention that the printed patterns will not be affected by external conditions. Compared to conventional silk screen printing technology, the present invention provides a simple manufacturing process, short production cycle, and simple product configuration.

Disclosed in FIG. 1 is a laminate for eyeglass frames in accordance with an embodiment of the present disclosure. The laminate 100 comprises a top layer 110, a core layer 120, and a bottom layer 130. The bottom layer 130 is a thermoplastic sheet, the top layer 110 is a transparent thermoplastic sheet which can be chromatic or crystal clear. Adhered to the top layer 110 and bottom layer 130 is the core layer 120 printed with high density pattern 121 by transfer printing. The adhesion of the three layers can be accomplished by adhesive substances, such as UV glue or Acetone, thermoforming or any form of lamination. For complicated patterns or special pattern effects, more layers of pattered thermoplastic sheets can be adhered or sandwiched as a stack of thermoplastic between the top and bottom layers.

The thermoplastic used in the top layer 110, core layer 120 and bottom layer 130 is material that can re-soften and distort from its formed shape when heat above a critical temperature peculiar to the material. In the preferred embodiment of the disclosure, the thermoplastic material is cellulose acetate.

During transfer printing, a desired pattern with mirror image from a media is transferred to the core layer 120 by one of the following methods: heat pressing transfer, water transfer, vapor transfer, screen printing or any form of stencil printing. The media can be in the form of film, paper, fabric or any substance on which pattern is able to be printed. The heat pressing transfer involves a process in the temperature range from 0° C. to 300° C. The pattern being transferred to the core layer 120 can be monochrome or polychrome.

FIG. 2 a and 2b discloses a laminate according to the invention which has three dimensional articles or fluids embedded into the laminate, cavity 210 is created in the core layer 120 prior to adhering the top layer 110 to enclose the three dimensional articles 220 or fluids 230. The size and shape of the cavity 210 is created in a way to match the articles 220 or to contain the fluids 230. The process can be performed by drilling or grinding depending on the size and shape of the desired cavity. After the cavity 210 is created, the core layer 120 is adhered to the bottom layer 130. Articles are then positioned in the cavities of the core layer 120. In the case of fluid, it is filled in the cavities by injection apparatus or dropper.

FIG. 3 further discloses a laminate according to the invention which has particles embedded into the laminate. Since the size of the particles 310 are small relative to the thickness of the thermoplastic layers, no cavity is required to be made in the core layer 120. The particles 310 are positioned on the core layer 120 to form the desired patterns.

After positioning the particles or three dimensional articles, or filling the fluids to the core layer 120, the top layer 110 is adhered to the core layer 120 as a coating to the patterns. The composite structure is then applied with temperature in the range of 0° C. to 300° C. and a pressure starting from 0 atm to bond the layers together and form a patterned laminate 100.

The articles or fluids embedded in the eyeglass frame can serve decorative or functional purpose. The three dimensional articles to be enclosed in the laminate can be selected from articles including dry flowers, rhinestones, dry leaves and metal foil logo. The fluids to be enclosed in the laminate can be selected from fluids including colored or clear water, oil based fluid, and liquid silicone.

FIG. 4 describes a laminate in accordance with another embodiment of the invention, in which more than one type of immiscible fluid (410, 420) of different color can be embedded in the thermoplastic layers.

FIG. 5 describes a laminate in accordance with another embodiment, in which the cavity may further embed articles 510 which suspend in the fluid 520, or articles 530 which float on the surface of the fluid, or float at the boundary between two layers of fluids (520,540).

The foregoing describes only some embodiments of the present invention, and modifications and/or changes can be made thereto without departing from the scope and spirit of the invention, the embodiments being illustrative and not restrictive.

While the invention has been described in connection with what is presently considered to be the most practical and preferred embodiment, it is to be understood that the invention is not to be limited to the disclosed embodiment, but on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims.

Claims

1. A laminate with internal decorative design for eyeglass frames, comprising: a plurality of core layers of thermoplastic sheets printed with patterns by transfer printing,a first overlay layer of thermoplastic sheet;a second overlay layer of thermoplastic sheet;wherein said core layers are sandwiched between said first overlay layer and said second overlay layer.

2. A laminate with internal decorative pattern according to claim 1, wherein said core layers further enclose particles or three dimensional articles.

3. A laminate as claimed in claim 2, wherein said three dimensional articles enclosed in core layers are selected from a group of articles consisting of: dry flowers, rhinestones, dry leaves and metal foil logo.

4. A laminate with internal decorative pattern according to claim 1, wherein said core layers further enclose at least one kind of fluid, said fluids are immiscible with each other.

5. A laminate as claimed in claim 3, wherein said fluid enclosed in core layers are selected from a group of articles consisting of: colored or clear water, oil based fluid, and liquid silicone.

6. A laminate with internal decorative pattern according to claim 1, wherein said transfer printing are selected from a group consisting of: heat pressing transfer, water transfer, vapor transfer, screen printing, and stencil printing.

7. A laminate with internal decorative pattern according to claim 1, wherein said thermoplastic is selected from a group of thermoplastic consisting of: cellulose acetate, cellulose acetate propionate, polycarbonate, TPE and nylon.

8. A laminate with internal decorative pattern according to claim 1, wherein said core layers and overlay layers are adhered together by a bonding method step selected from a group consisting of: application of an adhesive substance, application of heat, and application of pressure.

9. A laminate with internal decorative pattern according to claim 1, wherein said core layers and overlay layers are bonded together by thermoform or lamination.

10. A laminate with internal decorative pattern according to claim 1, wherein said patterns printed on core layers are monochromatic or polychromatic.

11. A process for manufacturing a laminate with internal decorative pattern for eyeglass frames, comprising: a) preparing a plurality of core layers, a first overlay layer and a second overlay layer from thermoplastic sheets,b) printing patterns on said core layers by transfer printing,c) layering from top to bottom said first overlay layer, said core layers and said second overlay layer, andd) bonding the layer of sheets from step (c).

12. The process for manufacturing a laminate with internal decorative pattern according to claim 11, wherein said bonding step includes a step selected from a group consisting of: application of an adhesive substance, application of heat, and application of pressure.

13. The process for manufacturing a laminate with internal decorative pattern according to claim 11, wherein said bonding step comprises the step of thermoform or lamination.

14. The process for manufacturing a laminate with internal decorative pattern according claim 12, wherein said bonding step comprises the step of applying a temperature in the range of 0° C. to 300° C. and a pressure starting from 0 atmosphere.

15. The process for manufacturing a laminate with internal decorative pattern according to claim 11, further comprising laying particles on core layers before bonding said composite layer of sheets.

16. The process for manufacturing a laminate with internal decorative pattern according to claim 11, further comprising: a) making cavities in said core layers before applying heat to said composite layer of sheets to enclose three dimensional articles or fluids, andb) positioning or filling said articles or fluids in said cavities.

17. The process for manufacturing a laminate with internal decorative pattern according to claim 11, wherein said thermoplastic is selected from the group of thermoplastic consisting of: cellulose acetate, cellulose acetate propionate, polycarbonate, TPE and nylon.

18. The process for manufacturing a laminate with internal decorative pattern according to claim 11, wherein said transfer printing are selected from the group comprising of: heat pressing transfer, water transfer, vapor transfer, screen printing, and stencil printing.

19. The process for manufacturing a laminate with internal decorative pattern according to claim 18, wherein said heat pressing transfer is a process of temperature in the range of 0° C. to 300° C.

20. A laminate as claimed in claim 16, wherein said three dimensional articles enclosed in core layers are selected from the group of articles consisting of: dry flowers, rhinestones, dry leaves and metal foil logo.

21. A laminate as claimed in claim 16, wherein said fluid enclosed in core layers are selected from the group of articles consisting of: colored or clear water, oil based fluid, and liquid silicone.