METHOD OF MAKING SAME This invention is in the combined fields of man¬ ufacturing chocolate candy and psychiatry. Chocolate is obviously one of the most popular condiments for complex 5 reasons of taste, various positive attributes persons of¬ ten associate with chocolate and the act of eating choco¬ late, and certain real or alleged favorable body chemistry or mental reactions from eating chocolate candy. The ac¬ tual manufacture of chocolate in its various chemical com- ⁰ positions is known in the prior art. The new invention herein disclosed concerns the creation on the surface of a chocolate candy of a sculpture or embossed image of a person's face adapted from a photographic image of same. The concept of creating and embossing a design or manufacturer's name on the surface of a chocolate or other candy is .well known. The novelty herein is sculpting a person's image in chocolate by taking a person's own pho¬ tographic image, adapting it in a manner to render it transferrable onto a chocolate candy surface, and carrying out the steps to complete such a process and simultane¬ ously creating a sealed container for each candy where the container top also bears the person's image.

While it is obvious that a person's facial appearance is of great concern to him or her, it was surprising to discover that many persons are very favorably disposed to having their images sculpted on a chocolate - candy that will be seen and eventually eaten by them¬ selves and others. It was also discovered, however, that a photographic image, when transferred directly onto a mold as by photo-etching, for example, and thence onto chocolate often produces a very unattractive and inaccurate replication of the photographic image and impression. It is due to the color, composition and texture of chocolate that direct photo-transfer processes, which might be

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obvious in the paper products industry, are wholly in¬ tolerable in making chocolate photo embossme ts. For example, freckles, eyes and dimples which usually com¬ prise beauty features, are likely to appear on chocolate as blemishes, pits or worse.

The present invention has recognized the passion millions of persons have to eat chocolate and some of the obvious and subtle reasons why persons would like to have their facial image appear on chocolates they and their friends eat or give as a gift to a friend bearing the friend's own facial image on each individual chocolate candy. The applicant herein has furthermore discovered the great difficulties in transferring a photo image onto chocolate without producing an unattractive and/or inac- curate replication, and has developed a new process to achieve this end as described in following sections.

SUMMARY OF THE INVENTION The invention comprises a sequence of steps beginning with a photograph or snapshot showing a person's face and ending with chocolate candies, each having a reasonable likeness of the photo image sculpted onto one surface of the candy. First the photo image is enlarged, or reduced as the case may be, until the height of the head of the image is about nine and a half inches, and a new photo or photoprint is thus made. This print is then placed front side downward on a trans-illumination table, a plastic frame forming a border is positioned to circumscribe the face, and then features and outline of the face are traced or drawn onto the rear side of the photoprint. One or more words, as a title or message or name of person, are applied under the face, the words being formed by self-adhering plastic letters which by their width will create an embossed effect on the choco¬ lates. The step of tracing facial features and out¬ line onto the rear surface of the enlarged photo or photo-

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print requires considerable understanding of the likely results in the final chocolate candy of each mark, in¬ dicia, or stroke one applies to the photo. To merely trace all features seen will not only produce disastrous results, but would be immensely time consuming and un¬ necessary for producing a reasonable likeness of the photo image. Consequently, to produce a successful and attractive chocolate sculpture one must be quite selec¬ tive in choosing which indicia of a photo to trace. The selective procedure is discussed in greater detail in the Description of the Preferred Embodiment in subsequent section.

The traced facial image plus message is placed in a photostate apparatus to produce a negative of the traced image in a greatly reduced size of 1 1/4" x

1 1/16". The negative is then photo-etched onto a zinc or magnesium plate which becomes the die plate. The etched features may be manually enhanced by appropriate grinding or drilling. The finished die plate is subse- quently mounted in a press where it is forced against an aluminum foil, thus producing the candy embossment foil die to be used in a chocolate mold.

For high volume manufacture of the sculpted candies it is obviously desirable to have an array of rows of embossments on a single foil sheet. This can be formed by pressing a single-image die plate succes¬ sively against a single foil sheet until the array of embossments is established; alternatively, one can pro¬ duce a plurality of negatives, position the negatives i the desired array; photo-etch the whole array on a single large die plate; and then press such die plate against a foil sheet, producing the final multiple candy embossment foil. One additional variation in making the foil embossments is to photo-etch a plurality of different negatives onto one die plate at once, and subsequently to separate the die plate into individual die plates of

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each separate image.

To manufacture the chocolate candy units, a mold of aluminum, steel or other suitable material is made having a matrix of cavities having side walls but open at both top and bottom. The foil sheet bearing an array of embossed areas of the photo image is placed on top of the mold, keyed into precise position, and a rigid plate is secured on top of the foil. This assembly is then inverted and liquid chocolate is poured into all the cavities with an embossed foil portion at the bottom of each cavity. After cooling, the assembly is dismantled and the chocolate is removed from the mold, but the indi¬ vidual chocolate units remain adhered to the foil.

Finally, the chocolate and foil subasseπtbly is inverted with the foil now on top. A plastic tray having an array of cavities corresponding to the array of chocolate units on the foil is made ready by applying a FDA-approved double-sided adhe'sive tape to the top peri¬ pheral edges of each cavity in the tray. Then the foil- chocolate cluster is placed such that the chocolate units fit into the cavities respectively and the foil between the units contacts the adhesive-covered edges of the tape. Pressure is applied to join the foil to the tape on the top edges of each cavity, thereby sealing the chocolate therein. Next this total assembly is cut and separated into individual cups, each with its own foil top adhered to the cup.

These cups may be further gift packaged attrac¬ tively by placing the separate sealed cups in a tray de- fining a plurality of depressions, followed by a mask or cover sheet having cut-outs to allow visibility of only the foil tops or container seals which bear the photo images. On top of the mask can be placed an in¬ taglio image-bearing greeting card made by inking and pressing one of the foil dies onto the card, thereby creating a color-printed and embossed card of the choco¬ late image.

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For purposes of inventory control and records, a code number for the particular photo-image, the quan¬ tity and arrangement of candy units and other data can be incorporated into the original tracing and adapted image and thereafter onto the foil, the die and the candies.

BRIEF DESCRIPTION OF THE DRAWINGS Fig. 1 is a single sculptured chocolate candy made by the method disclosed therein. Fig. 2 shows an initial step of the method, namely embossing a sheet of aluminum foil with photo- etched die.

Fig. 3 shows a subsequent step of the method, namely securing the embossed foil onto the steel frame into which chocolate is poured.

Fig. 4 shows the step of inverting the frame of Fig. 3 and pouring liquid chocolate into the cavities.

Fig. 5 shows the step of removing chocolate candy units from the frame which units remain adhered to the foil.

Fig. 6 shows the step of applying a double- sided adhesive mask to top edges of the tray, placing the tray cups onto the candies adhered to the foil and applying pressure to the adhesive, thus at least partially sealing the individual chocolates in cups.

Fig. 7 shows the step of cutting the closed cups apart.

Fig. 8 shows the step of placing closed cups in a tray for final packaging. Figs. 9A-19 depict various aspects of a facial image with reference numbers to explanatory notes found ■ on subsequent pages hereto under the sub-title "Table A".

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DESCRIPTION OF THE INVENTION

The process of sculpting photo-images onto chocolate candy requires a thorough understanding of how photo-etched features later appear as embossments on a candy surface. The method developed herein is a sculpting technique comprising both rules and artistic sensitivity as set forth in Appendix A attached hereto for incorporation herein. It is apparent with negative-positive transfers, that to produce a projection such as an ear, the die must have a corresponding recess. Similarly for the face as a whole to be elevated as a cameo from the candy surface, the die must have a corresponding recess. Thus during the tracing step, the unused areas of the photo should be blackened so that later they are not photo-etched. The instructions and guidelines in Appendix A are set forth as a preferred embodiment that has been found to be highly satisfactory.

The steps subsequent to the tracing step, for creating the photo-etched die and for creating the sculpted chocolate candies have been set forth in considerable detail in the Summary and Description of the Drawing sec¬ tions and the Table found below.

Figure 1 illustrates an individual embossed chocolate candy product 10 produced according to the pre- sent invention, the candy having slightly tapered side walls 11 and the embossed image 12 of a person's head on the top surface. Figure2 illustrates schematically how a photo-etched die 14 is positioned below pressure plate 13 and aginst foil 15 which rests upon cushion 16 and base 17. The photo-etched die 14, formed and prepared by techniques described elsewhere in the specification (see Table A), is pressed against the foil to produce an array of embossments on foil 15. Next, as indicated in Figure 3, a mold 18 is covered by the foil which is precisely positioned thereon, followed by a rigid plate 19

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which results in a molding assembly 20. This assembly is then inverted as shown in Figure 4, and liquid choco¬ late 21 is poured into the empty cavities 22 from a source of chocolate 23. After the poured chocolate has cooled, the assembly is dismantled, leaving individual chocolates 24 adhered to the foil 15, as indicated in Figure 5.

As indicated in Figure 6, a plastic tray 25 having cavities 26 corresponding to the array of candies 24 on the foil, is prepared by having a mask 27 of double-sided adhesive tape adhered to the top peripheral edges of each cavity. Then the foil and adhered can¬ dies is positioned above the tray, and plate 28 presses the candies into the cavities and urges the foil 15 to adhere and seal with the foil. Removal of plate 28 leaves the sealed assembly 29 seen in Figure 7 which is cut apart by cutter 30 to produce individual sealed can¬ dies, ^' each in its own plastic cup 31 with a foil lid 32 sealed on top. Lastly said individual candy units 33 are placed in a tray or container 34 for final gift packaging.

The specific steps and techniques for tracing caricatures of faces and heads to form a suitable die and creating the sculptured chocolate candies are set forth in the schedule of general rules and Table A of references for clarifying the Figures 9A - 19:

SECTION A (BASICS) Rule 1: The faces (or heads) on copy print should be as near 5 inches as possible (or larger) for best results. Less than 4 inches is difficult for the artist. This adapted or copy print is placed onto a viewing box for transillu ination, face down, and direct¬ ly onto the back of the copy print the face/head is traced and caricatured by the artist. Rule 2: Every line or mark or shading is equi¬ valent to it being sucked back into the chocolate. The

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surrounding chocolate subsequently mounts outwards around the lines or marks. Using this phenomena as a desirable effect, faces of people can be done in chocolate. A form of sculpturing on chocolate can be attained using this knowledge.

Rule 3: Blacken all the areas around the face and head to "suck-in" the unused surrounding chocolate-. This helps the whole head to assume a more protuberant position and take on a cameo effect. Using sculpturing (Rule 2) and cameo (Rule 3) together in various artistic combinations, finely finished faces and heads can be molded on the surface of chocolate.

Rule 4: Artist must use black ink. Draw un¬ interrupted, continuous, thin lines of same fine width. They should be mostly straight or slightly curved and they should mostly join up with one another, except in certain special areas, where special desired effects are required, e.g. bridged nose, receding hair, etc. For these details, see special areas, section B. Rule 5: Neck ties, collars, shoulders are necessary. Never cross lines. "Close-off" necks and upper torso to give one a "tighter" more "economical" caricature and if this is not done then open ends allow for "loss of" face or head into the surrounding chocolate. SECTION B (SPECIAL AREAS)

Hair: (Figs. 9A-10); For "pulled-back hair" draw waves from anterior hair border to posterior hair border. The more hairlines that touch and join these borders the less the hair stands up, i.e. it looks pulled (oiled) down.

For "fluffed-up hair" allow a space of no lines or waves between the borders. This space allows chocolate to swell up and fill up the spaces, and pushes the hair up and out ( "fluffed-up") . Avoid too many wavy lines. Hair shows up well on chocolate. Don't leave hair open (i.e. posterior border

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should be uninterrupted).

Forehead (Figs. 11A and 11B) :

(a) For "embossed foreheadshape" frame it with boundaries on all sides using hair lines in an unbroken line.

(b) To limit embossing, have hair streaks going down into the forehead area. (Streaks from hair on top, or from sides, or from eyebrows). Hair streaks can be drawn into the forehead, and from these areas one can "close off the hairs", eyebrows, side burns, anterior borders, etc. or leave open the hairs in these areas. Eyes (Figs. 12A-12Q:

(a) Eyeballs and irises can be done just one way on chocolate. Once this is accomplished, then further other characteristics can be added, i.e. lashes, bags, crows feet, eyelids, etc. and this is the only way an eyeball and iris will appear on this chocolate.

The fewer lines around the eyes, the better, generally. (b) If eyelashes are prominent, then add just a few and allow for sufficient space between them and the eyebrows over the upper lids. Don't cross any lines.

(c) To minimize lower bagging, add double lower lids centrally. This also increases upper nose bridging - see nose section for details. And it also adds to cheek molding.

Mouth and Teeth (Figs. 14 and 15): (a) Mouth - All mouths must have smiles (good on chocolate). All must have.upper lips, smkll characteristi on lips must be done small. Otherwise the result in chocolate is grossly exaggerated.

- Generally one line for upper lip is all that is necessary except for fat lips.

- Generally lower lips do best with both borders of the lip drawn.

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- Generally leaving "lip-joinings" open en¬ hances the smile at the angles.

(i) A one-line lower lip leaves gross "swel¬ ling" below this line, even when chin markings are put in very well;

(ii) Moustaches should be drawn with a few hairs and only with good spaces between hairs. To much hair will make for loss of the mouth. Too much hair blends with lips and teeth and one gets a mess on choco- late.

(b) Teeth - Teeth are done only one way on chocolates. Each tooth is outlined from upper lip line to its edge.

Each tooth joins with the adjacent tooth. Use minimal numbers of teeth for same reason as moustache hairs. Lower border of teeth - preferably they should not touch lower lip. Darken in area below teeth edges and lower lip.

Tongues are very difficult, except if they are large.

Note: All lines straight and clean. Chin (Fig. 16):

The chin is part of the lower face border, and should be clearly drawn. It stands out on chocolate like hair. One can do a double chin, if warranted. Use con¬ tinuous unbroken lines for the chin. Highlight its character and exaggerate it.

The chin should be demarcated from the neck. The neck has its own highlights separate from the chin, its not just that part of the chocolate below the chin. If you give it a collar, etc. the neck is highlighted, otherwise the neck just melts into the surrounding choco¬ late taking the chin with it. Cheeks (Fig. 17): Cheeks are mounds and must be elevated. The same directions as apply to embossed foreheads apply to

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cheeks. Any line will create embossing of chocolate around it, so marking for cheeks must be made so as to elevate surrounding chocolate. No line should be left ending blindly, as chocolate will swell up around its ends. Drawing curved and angled lines will make choco¬ late rise in the curve and angles. This way cheeks can be placed and highlighted.

Shallow cheeks are forged by doubling the lines that outline the face. Nose: (Fig. 18):

Bridged noses require both edges or sides to be drawn. For flat noses (flat bridge) do not draw bor¬ ders up to eyes. Don't leave borders uncompleted; they must meet with other lines or chocolate will gather around the ends except at the bulb of the nose, which is built up anyhow.

For thin, small noses, draw thin, small mark¬ ings — these should be very narrow as there is always some spreading. Use markings under eyes to add to nose bridge and cheek borders.

Draw nose carefully.

Ears: (Fig. 19) :

Draw with same instructions as for drawing of last tooth; the inner folds of the ears can be well drawn on chocolate. Use minimum lines and draw them smallish if they are not a prominent part of the face.

Additional details concern mainly dimensions of components used in the preferred embodiment as follows. Aluminum foil sheets 0.002 inches thick have been found satisfactory. During photo-etching the die plate is etched to a depth of about 1/16". The liquid chocolate used may be standard commercial chocolate. The actual chocolate molding techniques of preparing, liquifying, pouring, and cooling the chocolate are well known in the art. Also known are standard processes of photo-etching

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and photographic printing of positives and negatives. What is new is the achievement and process of sculpting photo images onto chocolate candy, as described above and defined in the claims following which are intended to cover any variations in this disclosure falling within the scope and spirit of these claims.

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^• -13- TABLE A

Feature Figure Note Text Overall & Hair 9A 101 Blacked area on copy print

102 Unused chocolate

103 Uninterrupted posterior border of hair

104 Closed borders

105 Neck tie, collar, jacket

Hair 9B 106 Uninterrupted anterior bor¬ der of hair

107 Open neck

108 Open borders result in loss of head into the unused chocolate

9C 109 Hair waves from anterior hair border to posterior hair border 110 Closed neck and lower bor¬ ders ( conomical)

Hair 10 111 Posterior border

112 Fluffed hair

113 Closed off hair

114 Closed off collar and neck

115 Hair fluffed up

116 Hair pulled (oiled) down

117 Anterior border

118 Opened hair (not good)

119 Blackened background (com¬ pletely)

Forehead 11A 120 Closed off eyebrows (Encapsulated)

121 Closed off continuous anterior borders

122 Embossed forehead surrounded by unbroken lines of eye¬ brows and anterior hair border

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Feature Figure Note Text

11B 123 Hair streaks going into forehead area but closed off hair streaks

124 Open, non-continuous an¬ terior borders-hair lines going down into forehead

125 Un-embossed forehead

126 Open eyebrows (not encap¬ sulated)

Eyes 12A 127 Opening allows for eyeball to "fill out" 12A & 12B 128 Iris (pupil) best results 12B 129 Eye ends are open; good on chocolate 12C 130 Separate eyeball from nose area 131 Adds to nasal bridge

Eyes 13 132 Decreases lower lid bagging, helps nose and defines cheeks very well

Mouth, Teeth & Tongue 14 133 Darken "hollow" of mouth

134 Single lines, upper lip

135 Open at lip joinings, in¬ creases smiling potential

136 Double line, lower lip (upper & lower borders)

15 137 End tooth edge blends with lip

138 Darken for mouth-pulls choco¬ late inward

139 Open lip end for smile

140 Both borders for lower lip

141 Few moustachehairs, too many will "destroy" the whole mouth effect

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Feature Figure Note Text

Chin 16 142 Roundness for chin's upper border

143 Chin border square 144 Collar

Cheeks 17 145 Shallow cheek, i.e. double lines in this side of face 146 Gives cheek more upper definition 147 Chocolate builds up and gives cheek more defined lower border

148 Shallow area between lines 149 Join lines or ends become surrounded by raised choco¬ late

150 Don't cross lines

Nose 18 151 Building up at loose end but offset by other side of nose and line x under eye

152 Adds to bridge of nose 153 Line should not be left unfinished, can be joined with eye

154 Loose ends, build up will occur

Ears 19 155 Blend with side of face.

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