Patent Application
20070209390
1. Field of the Invention
Embodiments of the invention relate generally to the field of jewelry. More particularly, an embodiment of the invention relates to gemstones with embedded translucent images, and methods of making such gemstones.
2. Discussion of the Related Art
Prior art jewelry products composed of more than one piece of gemstone material, sometimes called multiplet gemstones, are known to those skilled in the art. For instance, a conventional multiplet gemstone is typically composed of two layers of gemstone material, a crown and a pavilion.
A problem with this technology has been the embedding of images within a gemstone. An image embedded within a gemstone is esthetically pleasing. Furthermore, the inclusion of a custom image selected by a wearer of the jewelry item adds significant sentimental value and personal meaning to a given gemstone within a jewelry item. Some examples of such custom images could include pictures of family members or friends, baby pictures or pictures of pets, or images having religious significance for the wearer. Therefore, what is needed is a multiplet gemstone with a custom image embedded within and a reliable method of manufacturing such a gemstone.
One unsatisfactory approach, in an attempt to solve the above-discussed problems involves coating one layer of a gemstone with an opaque material to form insignia thereon and then bonding it with another layer of gemstone to form a composite gemstone with the opaque insignia embedded therein. However, a disadvantage of this approach is that such an opaque image cannot show the details of an image and only appears as a silhouette by light passing through the image. Furthermore, conventional coating processes are inadequate for forming a detailed graphical image on the surface of a gemstone.
US Published Application 20050274144 discloses embedding a translucent image carried by a transparent film within a gemstone.
Another disadvantage of the above approaches has been the relatively high cost of producing custom designs. Therefore, what is also needed is a solution that meets the above-discussed requirements in a more cost-effective manner.
Heretofore, the requirements of embedding graphically detailed translucent images within gemstones and providing a cost effective method of embedding custom images within gemstones referred to above have not been fully met. What is needed is a solution that solves both of these problems.
There is a need for the following embodiments of the invention. Of course, the invention is not limited to these embodiments.
According to an embodiment of the invention, a jewelry product comprises a first and a second layer of gemstone material, the first and second layers each having an interfacial surface; wherein one of the interfacial surfaces has a translucent image printed thereon. According to another embodiment of the invention, a process comprises providing a first layer of gemstone material having at least one flat surface; providing a second layer of gemstone material having at least one flat surface; direct printing a translucent image onto the flat surface of the first layer; bonding the flat surface of the first layer to the flat surface of the second layer, thereby creating a multiplet gemstone product.
These, and other, embodiments of the invention will be better appreciated and understood when considered in conjunction with the following description and the accompanying drawings. It should be understood, however, that the following description, while indicating various embodiments of the invention and numerous specific details thereof, is given for the purpose of illustration and does not imply limitation. Many substitutions, modifications, additions and/or rearrangements may be made within the scope of an embodiment of the invention without departing from the spirit thereof, and embodiments of the invention include all such substitutions, modifications, additions and/or rearrangements.
The drawings accompanying and forming part of this specification are included to depict certain embodiments of the invention. A clearer concept of embodiments of the invention, and of components combinable with embodiments of the invention, and operation of systems provided with embodiments of the invention, will be readily apparent by referring to the exemplary, and therefore nonlimiting, embodiments illustrated in the drawings (wherein identical reference numerals (if they occur in more than one view) designate the same elements). Embodiments of the invention may be better understood by reference to one or more of these drawings in combination with the following description presented herein. It should be noted that the features illustrated in the drawings are not necessarily drawn to scale.
a-3g illustrate isometric views of a process for making duplets having an embedded directly printed image, representing an embodiment of the invention.
a-4g illustrate orthographic views of a process for making duplets having an embedded directly printed image, representing an embodiment of the invention.
Embodiments of the invention and the various features and advantageous details thereof are explained more fully with reference to the nonlimiting embodiments that are illustrated in the accompanying drawings and detailed in the following description. Descriptions of well known starting materials, processing techniques, components and equipment are omitted so as not to unnecessarily obscure the embodiments of the invention in detail. It should be understood, however, that the detailed description and the specific examples, while indicating preferred embodiments of the invention, are given by way of illustration only and not by way of limitation. Various substitutions, modifications, additions and/or rearrangements within the spirit and/or scope of the underlying inventive concept will become apparent to those skilled in the art from this disclosure.
Reference is first made to
The image (10) in the gemstone of
Inks and paints are composed of three main ingredients, the carrier fluid, additives, and the colorant. The carrier fluid keeps the ink in a liquid state and allows delivery to the substrate. It evaporates as the ink dries and frequently includes a co-solvent to speed up drying time. The additives typically comprise a small fraction of the total ink volume and serve to control such factors as dot grain, drop formation, print head corrosion and clogging, pH level, fade resistance, adhesion, and abrasion resistance of the ink. The colorant is that which is left after the ink dries. The two main types of colorant are dyes and pigments. A dye is fully dissolved in the carrier fluid and typically comprises small organic molecules. Pigments consist of small solid particles suspended in the carrier fluid. What is desired is an ink that maximizes light transmission and minimizes scattering of light.
a shows the effects on light transmitted through an image printed with a pigment based ink. Light entering the gemstone (210) and getting internally reflected hits the image from below. This is the light which defines the brilliance of the gemstone and allows details of the image to come through. Since pigment particles are generally opaque, light hitting the particles will get absorbed or reflected (211). Light which hits the sides of the particles will tend to scatter (212). Only a small portion of the light will pass through and contribute to the visibility of the image. Light hitting the image from above (215) will get reflected, however, since the surface of the print will be uneven due to the pigment particles, which can have irregular shapes and be variable in size, much of it will be scattered (216). These issues can be mitigated by using pigments consisting of pigment particles less than 0.1 micron in diameter, which are substantially uniform in size, and have a substantially smooth and round shape. To improve adherence to a non-porous substrate such as a gemstone material, the pigment particles are typically coated with resin. Examples of pigments which can be used with the invention include, but are not limited to, metallic inorganic pigments and salts of multi-ring, nitrogen containing compounds. Pigments with more translucence, which are preferable, are resin pigments, for example styrene acrylate copolymer or polyester polymers, mixed with dyes, which are also used as toner. Such a toner may also be used with the invention with an electrophotographic printing method, although the use of toner will lead to a thicker image due to the larger particle size, and may impede the bonding of the two gemstone layers together.
Applicable toners preferably have resin particles that are 8 microns or smaller in size and have a substantially round and smooth shape.
b, in contrast, shows light transmission through a gemstone having an image printed using a dye-based ink. Light entering the gemstone (220) and getting internally reflected penetrates the image and exits back out through the table (222), due to the higher translucence and smoother surface. Likewise, light (225) entering from top and getting reflected (226) suffers less scattering and improves the color brilliance of the image. The translucency of such an ink is easily adjusted by adjusting the ratio of concentrations of the dye colorants and the carrier fluid, thereby obtaining the maximum desired transmission of light through the image.
Therefore, dye-based inks are preferred for the product and method of the invention, as they lead to higher translucency and minimize scattering. Another advantage of dyes is the larger color space compared to pigments. One main apparent disadvantage of dyes is their lack of durability, represented by such factors as water fastness, fade resistance, and abrasion resistance. However, these concerns are severely mitigated in the present application, since the image becomes embedded. Water fastness and abrasion resistance are thus not a concern. Most fade resistance is a result of oxidation under UV light exposure, and since the image is enclosed with no access to oxygen or other degrading chemicals, oxidation of the dyes does not occur. Dyes which are applicable for use with the invention include, but are not limited to, azo dyes (which comprise 60-70% of all dyes), anthraquinone dyes, aminostyryl dyes, disulphone dyes, oxonol dyes, carbonyl dyes, and phthalocyanine dyes.
The ink carrier or solvent controls the delivery of the ink and the drying time. Solvents applicable to the invention include, but are not limited to, water, methyl ethyl ketone (MEK), gamma-butyrolactone, isopropyl alcohol, or mixtures thereof. Water in not preferred, since it has a long drying time compared to the other solvents. MEK is a common inkjet solvent with a very fast drying time and is suitable for nonporous substrates, such as those of the invention.
Another type of ink which may be used in the context of the invention is a UV curable ink. After the droplet of UV ink hits the substrate, it is polymerized by being subjected to UV light. A UV ink consists of a monomer, an initiator which initiates polymerization, a pigment or a dye, a solvent, and a diluent. The monomer polymerizes into an epoxy resin. A more detailed discussion of epoxy resins is presented below in the discussion on adhesives. Any dyes or solvents mentioned above may be used. Diluents serve to reduce the viscosity of the epoxy and allow delivery through an inkjet print head. Examples of such diluents are vinyl pyrrolidine and n-isobutyl alcohol. UV inks based on biphenol epoxies are an effective choice, as the index of refraction matches that of many gemstone materials. The curing step may further be combined with the curing step for the adhesive, if a UV curable adhesive is used to bond the two pieces of gemstone material together. Alternately, the epoxy of the ink can serve as the adhesive as well, and the curing of the ink be performed after the second layer of gemstone is placed on top of the image, effectively curing the ink and bonding the two layers of gemstone material together. This would eliminate the need for the adhesive step.
It must be noted that the use of pigment based inks still falls within the scope of the invention, as do inks whose colorants are combinations of dyes and pigments.
Methods of printing the image onto the gemstone will now be described. Drop-on-demand inkjet printing is a versatile printing method known to all skilled in the art. Inkjet printers work by either creating a drop of ink to be delivered to the substrate through pressure created by activating a piezoelectric ceramic, or by vaporizing an ink vapor bubble through heat created by activating a heating element (also known as bubblejet printers). Inkjet printers deliver photographic quality prints with high resolution, are cost effective, fast, and reliable. Inkjet printers can print on a variety of substrates, including nonporous materials such as gemstones. Inks can be quickly switched by replacing a cartridge and allow for cost effective printing of custom images.
Another printing method sharing many of the same advantages is dye sublimation printing. Dye sublimation is a type of thermal transfer printing utilizing a transfer medium, such as a ribbon, with an ink layer. The thermal medium is placed in close proximity with the substrate and small heating elements are selectively applied to the back side of the transfer medium, vaporizing the dye and transferring it to the substrate. Since the ink is vaporized, more blending of the ink on the substrate occurs, reducing dot grain and resulting in clean, sharp, photographic images. Clearly, only dye-based inks may be used in dye sublimation. Any of the dyes mentioned above may be used. However, the use of dye sublimation requires some absorption of the dye by the substrate, and thus for nonporous materials, an image receiving layer must be deposited onto the substrate. Examples of materials for the image receiving layer include, but are not limited to, vinyl copolymers, such as vinyl chloride and vinyl acetate, aromatic polyesters, and styrene acrylonitrite acrylates. Additionally, and adhesive layer may be provided underneath the image receiving layer to bond it to the substrate, or binder may be included in the image receiving layer. Examples of binders include, but are not limited to, polycarbonate, polyurethane, polyester, and polyvinyl chloride polymers.
Electrophotographic printers (laser printers) may also be used. Toner, made of particles 8-12 microns in size and typically a pigment or a mixture of resin and dyes, is picked up by a drum which has been selectively charged, for example a with a laser, to correspond with the image. The toner is then transferred through heat and pressure to the substrate, where it partially melts and fuses with the substrate. Electrophotographic printers are fast, offer high quality images, but are more expensive. As stated above, toner is very similar to a pigment-based ink in terms of light properties and in addition leads to a thicker image and thus this is not the most preferred method for this invention.
Three common methods are employed in the art for bonding crystalline layers. The first method is that of optical contacting, which is done at room temperature and does not use any adhesive. Optical contacting requires a very thorough preparation of the bonding surfaces, which must be thoroughly cleaned to remove any contaminants and polished to minimize surface roughness. The surfaces are then brought together and pressure is applied to achieve a chemical bond. However, this method is highly sensitive to contamination, does not result in reliable bond strength, is sensitive to thermal shock, and requires flat surfaces. In the invention, the thickness of the printed image would interfere with this contact, unless it was printed into a recess in the interfacial surface, which would unnecessarily add processing steps and expense. The second method employed is that of high temperature frit bonding. This method uses low melting point glass frit and is carried out at temperatures of 400-650° C., which is too high for the present application, as it would destroy the printed image. Furthermore, frit bonding is not suitable for precision structural work and generally leaves an opaque bond.
The third, and most applicable method, is through the use of an adhesive, typically an epoxy resin. The three most common methods of setting, or curing, such an epoxy are through the use of heat (typically low temperatures under 60° C.), UV light, using a hardener, or a combination thereof. A conventional two-pack epoxy consists of the epoxy, such as a bisphenol resin base, and a hardener or curing agent, such as an aliphatic polyamine. Numerous epoxy resin compositions exist, which vary greatly in the refractive indices, optical losses, and adhesive strengths. The refractive indices of bisphenol A epoxies derived from polyglycols are in the 1.54-1.60 range. It is of course desirable to match the refractive index of the epoxy to that of the gemstone material. The refractive indices of some common gemstone materials are 2.4 for diamond, 2.1-2.2 for cubic zirconium, 1.7-1.75 for spinel, 1.6 for topaz, 1.76-1.78 for sapphire, 1.57-1.6 for beryl, 1.54 for quartz. Bisphenol A epoxies are thus quite suitable for some of these materials. The epoxy with the closest index of refraction may be selected for the gemstone used. The index of refraction of epoxies may be altered by the addition of reactive diluents, which polymerize upon curing. Examples of diluents which will increase the index of refraction are N-vinyl-2-pyrrolidone, 2′-oxybenzophenone-2-ethoxy-ethyl acrylate and 2-phenoxy-ethyl acrylate. Examples of diluents which decrease the index of refraction are 2-ethoxy-ethyl acrylate and 2′-ethoxy-2-ethoxy-ethyl acrylate. In general, adding ring structures and increasing the molecular weight of the epoxy will lead to higher indices of refraction. Lowering of the index of refraction may also be accomplished by fluorinating the resin, the hardener, as well as the active diluents. Flourinating also increases the wettability of the epoxy.
UV curable epoxy may also be used with the invention. Examples of UV curable epoxies are aliphatic urethane-based oligomers or ester-based acrylate compounds. Typical curing times range from 30 seconds to 10 minutes with UV light in the 254 to 420 nm range. The exact curing conditions can be adjusted according to the specific requirements of the materials used. Caution must be exercised when using dye-based inks, however, as these inks are susceptible to UV damage and the curing conditions can cause a degradation of the image.
Within the scope of the invention, the epoxy is preferably applied with an inkjet printer around the border of each of the first set of gemstone layers. In order to reduce the viscosity of the epoxy and allow delivery through an inkjet print head, diluents are added. Examples of such diluents include, but are not limited to, vinyl pyrrolidine and n-isobutyl alcohol. Other methods of applying the adhesive may be used, such as mechanical syringes.
Specific embodiments of the invention will now be further described by the following, nonlimiting examples which will serve to illustrate in some detail various features. The following examples are included to facilitate an understanding of ways in which an embodiment of the invention may be practiced. It should be appreciated that the examples which follow represent embodiments discovered to function well in the practice of the invention, and thus can be considered to constitute preferred mode(s) for the practice of the embodiments of the invention. However, it should be appreciated that many changes can be made in the exemplary embodiments which are disclosed while still obtaining like or similar result without departing from the spirit and scope of an embodiment of the invention. Accordingly, the examples should not be construed as limiting the scope of the invention.
a-g and 4a-g show a preferred embodiment of the method of the invention, illustrating the various steps in the manufacture of the gemstone product. In
It is imperative that the flat surfaces of the gemstones be secured and horizontally leveled with the surface of the tray to facilitate the printing of the image. This can be accomplished in several ways. In
It is further imperative that the tray be aligned with the print head to ensure the correct printing of each image on the gemstones. The correct manufacture of the tray will ensure the precise location of the recesses, which correspond to a predetermined template in the software used to print the custom images. The tray is aligned with the print head through methods known to one skilled in the art, such by providing an alignment mark on the tray.
After the gemstones are secured and aligned, the surface of the gemstones are cleaned (340) to prepare them for printing. This is illustrated in
e and
After the ink has dried, the adhesive is applied to the gemstones.
g and 4g show the next step in the process. A second tray (370) is provided, which has recesses shaped to accommodate the plurality of second gemstone layers, in this case the crown portions (380). The same requirements for securing and leveling the crown portions within the recesses must be met as was stated above for the first tray. However, a lattice cannot be used at this point and must also be removed from the first tray to allow for the mating of the crown and pavilion sections. The crown portions can be secured in the second tray through vacuum suction or through the use of a non-setting adhesive, such as a poly-butene adhesive. Alignment of the first and second tray is crucial and may be realized through matching alignment marks on the first and second tray, or through matching projections and recesses in the two trays. The two trays may also be aligned with robotic arms or hydraulic plates. Pressure is then applied and if the adhesive or ink used is a curable adhesive, heat or UV light is applied. The top tray is then removed and the composite gemstones are taken out.
Even though the present embodiment illustrates printing the images on the pavilion section of the resulting composite gemstone, the image can equally be printed onto the crown section.
An embodiment of the invention can also include the printing of a magnetic strip containing digital information. This would require the inclusion of magnetic pigment in the ink. Embedding a magnetic strip would allow the composite gemstone to be used as an identifying device. It would also allow the embedding of a credit card (510) with a magnetic strip (520) into a gemstone as shown in
Reference will now be made to
An embodiment of the invention can also be included in a kit-of-parts. The kit-of-parts can include some, or all, of the components that an embodiment of the invention includes. The kit-of-parts can be an in-the-field retrofit kit-of-parts to improve existing systems that are capable of incorporating an embodiment of the invention. The kit-of-parts can include software, firmware and/or hardware for carrying out an embodiment of the invention. The kit-of-parts can also contain instructions for practicing an embodiment of the invention. Unless otherwise specified, the components, software, firmware, hardware and/or instructions of the kit-of-parts can be the same as those used in an embodiment of the invention.
The particular manufacturing process used for printing the image should be inexpensive and reproducible. Conveniently, an embodiment of the method of the invention can be carried out by using any printing method. It is preferred that the process be inkjet printing
However, the particular manufacturing process used for printing is not essential to an embodiment of the invention as long as it provides the described functionality. Normally those who make or use an embodiment of the invention will select the manufacturing process based upon tooling and energy requirements, the expected application requirements of the final product, and the demands of the overall manufacturing process
The term substantially is intended to mean largely but not necessarily wholly that which is specified. The term approximately is intended to mean at least close to a given value (e.g., within 10% of). The term generally is intended to mean at least approaching a given state. The term coupled is intended to mean connected, although not necessarily directly, and not necessarily mechanically. The term proximate, as used herein, is intended to mean close, near adjacent and/or coincident; and includes spatial situations where specified functions and/or results (if any) can be carried out and/or achieved. The term deploying is intended to mean designing, building, shipping, installing and/or operating.
The terms first or one, and the phrases at least a first or at least one, are intended to mean the singular or the plural unless it is clear from the intrinsic text of this document that it is meant otherwise. The terms second or another, and the phrases at least a second or at least another, are intended to mean the singular or the plural unless it is clear from the intrinsic text of this document that it is meant otherwise. Unless expressly stated to the contrary in the intrinsic text of this document, the term or is intended to mean an inclusive or and not an exclusive or.
Specifically, a condition A or B is satisfied by any one of the following: A is true (or present) and B is false (or not present), A is false (or not present) and B is true (or present), and both A and B are true (or present). The terms a and/or an are employed for grammatical style and merely for convenience.
The term plurality is intended to mean two or more than two. The term any is intended to mean all applicable members of a set or at least a subset of all applicable members of the set. The term means, when followed by the term “for” is intended to mean hardware, firmware and/or software for achieving a result. The term step, when followed by the term “for” is intended to mean a (sub)method, (sub)process and/or (sub)routine for achieving the recited result.
The terms “comprises,” “comprising,” “includes,” “including,” “has,” “having” or any other variation thereof, are intended to cover a non-exclusive inclusion. For example, a process, method, article, or apparatus that comprises a list of elements is not necessarily limited to only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus. The terms “consisting” (consists, consisted) and/or “composing” (composes, composed) are intended to mean closed language that does not leave the recited method, apparatus or composition to the inclusion of procedures, structure(s) and/or ingredient(s) other than those recited except for ancillaries, adjuncts and/or impurities ordinarily associated therewith. The recital of the term “essentially” along with the term “consisting” (consists, consisted) and/or “composing” (composes, composed), is intended to mean modified close language that leaves the recited method, apparatus and/or composition open only for the inclusion of unspecified procedure(s), structure(s) and/or ingredient(s) which do not materially affect the basic novel characteristics of the recited method, apparatus and/or composition.
Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. In case of conflict, the present specification, including definitions, will control.
The described embodiments and examples are illustrative only and not intended to be limiting. Although embodiments of the invention can be implemented separately, embodiments of the invention may be integrated into the system(s) with which they are associated. All the embodiments of the invention disclosed herein can be made and used without undue experimentation in light of the disclosure. Although the best mode of the invention contemplated by the inventor(s) is disclosed, embodiments of the invention are not limited thereto. Embodiments of the invention are not limited by theoretical statements (if any) recited herein. The individual steps of embodiments of the invention need not be performed in the disclosed manner, or combined in the disclosed sequences, but may be performed in any and all manner and/or combined in any and all sequences. The individual components of embodiments of the invention need not be formed in the disclosed shapes, or combined in the disclosed configurations, but could be provided in any and all shapes, and/or combined in any and all configurations. The individual components need not be fabricated from the disclosed materials, but could be fabricated from any and all suitable materials. Homologous replacements may be substituted for the substances described herein.
It can be appreciated by those of ordinary skill in the art to which embodiments of the invention pertain that various substitutions, modifications, additions and/or rearrangements of the features of embodiments of the invention may be made without deviating from the spirit and/or scope of the underlying inventive concept. All the disclosed elements and features of each disclosed embodiment can be combined with, or substituted for, the disclosed elements and features of every other disclosed embodiment except where such elements or features are mutually exclusive. The spirit and/or scope of the underlying inventive concept as defined by the appended claims and their equivalents cover all such substitutions, modifications, additions and/or rearrangements.
The appended claims are not to be interpreted as including means-plus-function limitations, unless such a limitation is explicitly recited in a given claim using the phrase(s) “means for” and/or “step for.” Subgeneric embodiments of the invention are delineated by the appended independent claims and their equivalents. Specific embodiments of the invention are differentiated by the appended dependent claims and their equivalents.
