FIELD OF THE INVENTION

The present invention relates to methods for making synthetic non-adhesive picture or image cabochons and to the synthetic cabochons themselves. These cabochons can be part of a further article of manufacture such as jewelry, a button, rivet, snap, or zipper for various apparel items, or can be used with a wide variety of decorative items and household accessories. These cabochons are made from selected polymeric materials to provide a clear non-distorted image and to be heat-resistant, water-proof or water-resistant to minimize the risk for separation of the image from the synthetic cabochon.

BACKGROUND OF THE INVENTION

Cabochons, which are a variety of hemispherical, unfaceted gemstones that have been smoothly polished, have been used for centuries in decorative applications. Synthetic cabochons are a more recent creation that have gained widespread popularity in a wide range of applications. These cabochons are typically configured in a half-dome shape with a convex top half, and flat bottom, and can be made from a variety of polymers. Intended to resemble or evoke a gemstone cabochon, synthetic cabochons are versatile, low in manufacturing cost, and resistant to breakage.

Designers have attempted to build on the colored substrate concept with printed substrates, which can be viewed through the cabochon material. The options for these types of cabochons are varied, and can include highly detailed, full color substrate matter. See FIG. 1.

However, the materials and processes used in manufacturing synthetic cabochons are prone to a cloudy, yellow, or opaque appearance that can diminish or obscure the substrate. Alternatively, the synthetic cabochon can exhibit bubbling or other debris that diminishes the appearance of the finished article.

Prior processes have also attempted to prepare cabochons separate from the image substrate, and then use an adhesive to affix the image to the base of the cabochon, sometimes using an acrylic mixture. Such a configuration not only requires an additional manufacturing step, but introduces an adhesive layer between the image and cabochon, further impairing the clarity of the image and the risk that the image will detach from the cabochon, and not be heat-resistant, water-resistant or waterproof.

Furthermore it would be highly desirable to provide cabochons that can be affixed to a button, snap, or rivet for various clothing and other household and decorative items. Alternatively, it would be highly desirable to provide such button, snap, or rivet cabochons as a single article of manufacture. However, such cabochons would need to be sturdy enough to withstand normal wear and tear and to resist delamination or separation of the image from the cabochon. They would also need to be water-resistant or waterproof. This risk of delamination or separation is increased if the jewelry or clothing article with the button, snap, rivet, or zipper cabochon is subjected to heat, bathing, clothes washing or dry cleaning. Thus the cabochon needs to be water-proof or exhibit a sufficient degree of water-resistance and resistance to common dry-cleaning materials.

What is thus needed is a method for manufacturing a synthetic cabochon that is predominantly glass-like in appearance.

What is further needed is a method for manufacturing a synthetic cabochon that is substantially free from bubbles or other debris.

What is further needed is a method for manufacturing a synthetic cabochon that results in a finished product that is resistant to breakage and environmental factors such as heat, sunlight, chemicals, detergents, water, and the like.

What is further needed is a method for manufacturing a synthetic cabochon that is able to display a colored, printed substrate with an attractive and clear appearance, that resists yellowing, discoloration, and clouding.

What is further needed is a method for manufacturing a synthetic cabochon that is able to display a colored, printed substrate with an attractive and clear appearance, without the use of an adhesive to attach the printed substrate.

What is further needed is a method for manufacturing a synthetic cabochon as part of jewelry, a button, snap, rivet, or zipper for clothing and other articles that is resistant to heat and wear and tear and also to delamination or separation when subjected to heat, bathing, clothes washing or dry cleaning. The present invention was found to overcome the disadvantages and challenges faced with prior cabochon manufactures.

SUMMARY OF THE INVENTION

The present invention relates to methods for making synthetic non-adhesive, heat- resistant and water-resistant or waterproof image or picture cabochons. The present invention also relates to the synthetic cabochons made by the methods described herein. These cabochons can be part of a further article of manufacture such as jewelry, a button, rivet, snap, or zipper for various apparel items. These cabochons can also be used to enhance a wide variety of decorative items and household accessories. These cabochons are made from selected polymeric materials to provide a clear non-distorted image and to be water-proof or water-resistant to minimize the risk for separation of the image from the synthetic cabochon.

In some embodiments, the present invention relates to a method for fixing an image in a synthetic cabochon comprising the steps of:

(a) generating an image on a substrate layer, i.e. a backing layer;

(b) cutting the image from step (a) to a predetermined shape and size;

(c) preparing an epoxy resin composition by combining an epoxy resin and a curing agent, which is also known as a hardener;

(d) degassing the epoxy resin composition from step (c);

(e) applying the degassed resin composition from step (d) to the image from step (b); and

(f) curing the applied resin composition at a temperature from about 120°F to about 150°F for about 12 hours to about 48 hours to produce the fixed image.

In further embodiments, the present invention relates to a method wherein said epoxy resin composition has a temperature between about 72°F to about 78°F, and steps (c) through (e) are performed in an environment between about 72°F to about 78°F and an ambient relative humidity of less than about 30%. In further embodiments, the present invention relates to a method wherein said substrate layer is selected from the group consisting of paper, photographic paper, photo metallic paper, and cardboard.

In further embodiments, the present invention relates to a method wherein said substrate layer is cut in step (b) to avoid frayed or rough edges. The cutting can be performed by a die so that the backing is die cut.

In further embodiments, the present invention relates to a method wherein said substrate layer is laser cut in step (b),

In further embodiments, the present invention relates to a method wherein said epoxy resin is a thermosetting epoxy resin.

In further embodiments, the present invention relates to a method wherein said epoxy resin composition comprises an epoxy resin corresponding to the CAS Registry Number 026085-99-8 and the curing agent comprises a mixture of an aliphatic amine, nonylphenol, aminoethylpiperazine, triethanolamine, and piperazine.

In further embodiments, the present invention relates to a method wherein said epoxy resin composition comprises an epoxy resin comprising from about 90-100% by weight of a resin corresponding to the CAS Registry Number 026085-99-8 and the curing agent comprises a mixture of from about 80-90% by weight of an aliphatic amine corresponding to CAS Registry Number 9046-10-0, from about 10-20% by weight of nonylphenol corresponding to CAS Registry Number 25154-52-3, less than about 1 % by weight of aminoethylpiperazine corresponding to CAS Registry Number 140-31-8, less than about 5% by weight of triethanolamine corresponding to CAS Registry Number 102- 71-6, and less than about 2% of piperazine corresponding to CAS Registry Number 1 10- 85-0. In further embodiments, the present invention relates to a method wherein the epoxy resin and the curing agent are combined in an approximate ratio of about 1 part by volume epoxy resin to about 1 part by volume curing agent or hardener.

In further embodiments, the present invention relates to a method wherein in step (f) the resin is cured at a temperature of about 120°F to about 150°F for about 12 to 24 hours to produce the fixed image.

In further embodiments, the present invention relates to a method wherein the degassing step (d) is performed by subjecting the resin composition from step (c) to a vacuum in a degassing chamber.

In further embodiments, the present invention relates to a method wherein said degassing step (d) is performed at a reduced atmospheric pressure from about 15 mm Fig to about 30 mmFIg for about 15 to about 30 minutes.

In further embodiments, the present invention relates to a method wherein said degassing is performed until the release of bubbles from the resin composition is no longer observed.

In further embodiments, the present invention relates to a method wherein said application step (e) is performed by applying said degassed resin from step (d) via a syringe to avoid introduction of air into the degassed resin.

In further embodiments, the present invention relates to a synthetic cabochon prepared according to the methods of the present invention.

In further embodiments, the present invention relates to a synthetic cabochon wherein said cured resin is transparent. In further embodiments, the present invention relates to a synthetic cabochon wherein said cured resin resists yellowing.

In further embodiments, the present invention relates to a synthetic cabochon wherein the fixed image is resistant to heat, water, separation or delamination from the cured resin.

In further embodiments, the present invention relates to a synthetic cabochon wherein the fixed image is resistant to delamination from the cured resin when the cabochon is immersed in water.

In further embodiments, the present invention relates to a jewelry item, button, rivet, snap or zipper further comprising a synthetic cabochon of the present invention.

In further embodiments, the present invention relates to a button further comprising a synthetic cabochon of the present invention.

In further embodiments, the present invention relates to a rivet further comprising a synthetic cabochon of the present invention.

In further embodiments, the present invention relates to a snap further comprising a synthetic cabochon of the present invention.

In further embodiments, the present invention relates to a zipper further comprising a synthetic cabochon of the present invention.

In further embodiments, the present invention relates to an article of clothing comprising one or more buttons, rivets, snaps, or zippers further comprising a synthetic cabochon of the present invention. In further embodiments, the present invention relates to a household good, accessory, decorative item, or consumer good comprising one or more buttons, rivets, snaps, or zippers further comprising a synthetic cabochon of the present invention.

In further embodiments, the present invention relates to a household good, accessory decorative item, or consumer good selected from the group consisting of furniture, pillows, greeting cards, scrapbooks, pill boxes, stich markers, wallets, and magnets comprising one or more buttons, rivets, snaps, or zippers further comprising a synthetic cabochon of the present invention.

These and other embodiments of the present invention will become apparent from the disclosure herein.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an illustration of various options for the cabochons of the present invention, and can include highly detailed, full color substrate matter.

FIG. 2 shows a sample manufacturing set-up for making the cabochons of the present invention.

FIG. 3 shows some of the equipment and mixing vessels for making the cabochons of the present invention.

FIG. 4 shows some of the equipment and mixing vessels for making the cabochons of the present invention.

FIG. 5 shows a stirring bar (an X-shaped stirring bar was used in the prototype configuration) and can be used in the beaker containing the measured resin and hardener, i.e. curing agent, and the beaker is then placed on the magnetic stirring plate.

FIG. 6 shows that the resin composition is treated in a vacuum chamber. Here the cover is open.

FIG. 7 shows that the resin composition is treated in a vacuum chamber. Here the cover is closed and a vacuum is being applied . FIG. 8 shows that the impressions, i.e. the images, are supported by and arranged in rows on a glass or acrylic platform or work surface prior to treatment with the epoxy resin mixture.

FIG. 9 shows that an eyedropper can be used to gather and remove excess epoxy resin that has spilled over the edge of the impression.

DETAILED DESCRIPTION OF THE INVENTION

The present invention provides methods for making synthetic heat-resistant, water-resistant, waterproof, non-adhesive picture cabochons that have excellent clarity and that are robust enough for incorporation into jewelry, a button, snap, rivet or zipper for clothing or other articles of manufacture.

In some embodiments, a method is described for manufacturing an epoxy resin cabochon, that is suitable for use with an enhanced resolution image fixed to a substrate, while maintaining resistance to breakage, wear, and other environmental factors.

Synthetic Cabochons and Processes for Making

Our process leads to extreme clarity of product and provides for the water-resistant properties that make our product unique. Primary differences in our process versus conventional prior methods include the following:

1. The enitre process is conducted in a temperature and humidity-controlled environment. Environmental exposure of the epoxy resin leads to their degradation. UV radiation, moisture and temperature can all contribute to the breakdown of the matrix mixture. AtTiigher temperatures, the curing process can occur too rapidly. Low humidity, generally between about 10 to 30 percent relative humidity, provides for cross-linking, which improves the mechanical properties of the resin. If the process is performed in a high humidity environment it can lead to the final product delaminating (i.e. the substrate layer image detaching from the cabochon) or the product turning cloudy. In addition, high humidity can affect the adhesion between the epoxy resin mixture and the substrate layer.

2. In the present invention it is preferable to mechanically mix the mixture. If the mixture is not thoroughly mixed through and the 1 to 1 ratio of resin to curing agent is not obtained while hand mixing because some of the resin or curing agent did not mix through, the resin will not cure and remain sticky.

3. While mixing, the resin and curing agent is placed into a vacuum chamber to degas the mixture. This has two effects. The first effect is that it removes any unwanted bubbles that one can visually see in the final product. The second is that the resin is reactive to oxygen which can lead to the formation of a yellowish or brown color which is indicative of oxygen. By removing the air bubbles, i.e. the oxygen within the mixture, this prolongs the life of the resin before it turns yellow.

It should be appreciated, that yellowing is a performance issue for acrylics and epoxies as a medium that needs to have a clarity to it. Without degassing, the cured resin can yellow as quickly as few weeks. The quality of the resin matters, it must contain both a UV and HALS stabilizer to slow the yellowing process.

4. When cutting out the images of the substrate layer that will be used in the cabochon, the present invention utilizes an extremely sharp die to stamp out the desired shape. In the event the die is not sharp or a pair of ordinary scissors are used, it can it result in a slightly perforated edge. The perforated edge can create a more porous surface and undesirable seepage of the resin mixture into the substrate layer causing the erosion of the image and compromising the water-resistant properties.

5. Exactly measuring the dosing that the piece allows for, i.e. which can accommodate a give quantity of resin, allows for the mass production of the cabochons and prevents the leaking over the side of the cabochon. This leaking can irrevocably damage the final product so that it is non-usable. In addition, small batch production can control the curing process by slowing it down to provide a longer window during which the liquid resin can be applied to the substrate layer

6. Once the resin mixture has been poured on the substrate, it can be spot heated in a continuous moving motion to remove any remaining bubbles.

7. The curing of the resin can be enhanced by heating the cabochons between about 6 to about 24 hours, depending on the final produce size. In addition, by speeding up the curing process by heating the mixture a greater degree of cross-linking can occur, which can enhance the water-resistant properties. Left to cure at room temperature, this can lead to the incomplete polymerization of the resin. By using a thermosetting resin, it is stronger and more resistant to conditions generally seen in laundering a garment and are better suited to high-temperature applications. When the resin mixture is poured in a thin layer (approximately 2mm thick) it takes longer to cure naturally at room temperature. By speeding up the curing process by heating the mixture this also helps to delay the yellowing due to uptake of the not-fully cured resin by atmospheric oxygen.

8. The substrate layer can be a photo-metallic paper, this paper has less porous properties then regular printer paper and photo paper. When pouring the resin mixture onto a porous substrate, it may cause the substrate to outgas and form unwanted bubbles in the resin coating. Not only can one then visually see the bubbles in the final product, but this can increase the rate at which the product yellows.

EXAMPLES

The following examples further describe and demonstrate embodiments within the scope of the present invention. The Examples are given solely for purpose of illustration and are not to be construed as limitations of the present invention, as many variations thereof are possible without departing from the spirit and scope of the invention.

Examples: Methods of Making the Cabochons

In some embodiments, an empty clean 150 ml beaker can be provided, along with a magnetic stirrer. In a prototype configuration, a Hanna H1 190 magnetic mini-stirrer was used, though any of a number of magnetic stirrers can be used with this present invention. In embodiments, additional components can include a spatula, stirring bar for the magnetic stirrer, acetone, and timing devices. See FIG. 2.

It should be noted that although the foregoing setup was used with a relatively small batch test process, that the components and ingredients used can vary as the output is scaled to higher capacity. Nonetheless, the fundamental process and ingredients remain the same even at scale and fall within the scope of the present disclosure.

It has been found that to maintain the temperature of the preparation room at between 72° to 78° F can prevent the epoxy resin mixture from either hardening too quickly (which could inhibit the ability to correct manufacturing defects) or from becoming too viscous (which could cause the epoxy resin to run over the edges). The materials and equipment used in the inventive process is preferably kept within this temperature range.

In embodiments, epoxy resin and hardener are utilized in the preparation. In a preferred embodiment, 100 mg of epoxy resin can be used, along with 28 mg of hardener, by weight. See FIG. 3 and FIG. 4.

A stirring bar (an X-shaped stirring bar was used in the prototype configuration) can be dropped into the beaker containing the measured resin and hardener, and the beaker is then placed on the magnetic stirring plate. See FIG. 5.

Using a spatula, the mix can be stirred together until the stirring bar spins freely. As the mixture combines, a spatula may be used to scrape the sides of the beaker to release the hardener from the sides of the glass as needed. By scraping the spatula against the side of the beaker, hardener can be released back into the beaker. Since the hardener will cling to the spatula when first mixing, this step may need to be performed multiple times. If this is not performed carefully, the 1 to 1 ratio is changed, causing the resin not to cure and harden.

After a predetermined time interval, the mixture should be checked for oily residue. In a preferred embodiment, a time interval of 3-5 minutes is used. If residue is present in the mixture, the sides of the beaker can be further scraped and the mixture stirred until the mix is well combined. In embodiments of the invention, the mix might continue to contain bubbles at this stage, but will not have oily streaks. When the mixture has been sufficiently combined, the magnetic stirrer can be turned off and the stirring bar lifted out of the mix using the spatula. Excess epoxy resin on the stirring bar can be allowed to drip back into the beaker, and excess epoxy resin on the spatula can be scraped back into the beaker. The stirring bar and spatula can then be cleaned with acetone or a similar solvent.

In embodiments of the invention, acetone can be released onto a paper towel or cloth by depressing the towel or cloth onto the top of the acetone container. The paper towel or cloth may then be used to wipe the epoxy resin from both sides of the spatula and from the stirring bar. In embodiments, steps can be taken to remove air bubbles from the epoxy resin mixture. In a preferred embodiment, the epoxy resin mixture is processed in a vacuum chamber. FIG. 6 shows the beaker after placement in the vacuum chamber in an open configuration. FIG. 7 shows the vacuum chamber in a closed configuration with the vacuum applied.

The beaker containing the epoxy resin mixture can be placed directly in the vacuum chamber. In embodiments, a vacuum chamber can be constructed from a rigid cylinder that is open at one end onto which a lid can be fitted. The lid can contain an opening that connects to a vacuum pump that, when fitted to the open end of the cylinder, can impart a negative pressure to the chamber. A convenient vacuum range that can be utilized is from about 15 mm Fig to about 30 mm Fig, although other ranges can be used depending upon the equipment available.

In embodiments, it has been found that the epoxy resin mixture can be allowed to degas in the vacuum chamber for an interval of a minimum of 15 minutes to release air bubbles from the mixture. A running timer of 15 minutes can thus be set when the beaker is placed in the vacuum chamber.

It has further been found that the epoxy resin mixture should not be allowed to degas for longer than 30 minutes total. Degassing lasting beyond 30 minutes can result in premature hardening of the epoxy resin. In situations where the epoxy resin mixture is allowed to degas for longer than 15 minutes, a second timer can be used to prevent the degassing time from exceeding 30 minutes total.

It has been found that the epoxy resin mixture can require 60 minutes to set, as measured from the commencement of the degassing step. A 60 minute timer should thus also be set upon initiating degassing.

In embodiments, after 15 minutes of degassing, the epoxy resin can be inspected through the window of the vacuum chamber. If the epoxy resin mixture in the beaker is bubbling actively, the mixture should remain in the vacuum chamber for no longer than a total of 30 minutes, with the operator inspecting the chamber at five-minute intervals to determine whether the bubbling activity has subsided.

In embodiments, the epoxy resin mixture will remain in the vacuum chamber for a total of 15-30 minutes. Even if bubbles remain in the mixture after 30 minutes, it should be removed from the vacuum chamber. Remaining air bubbles will be released after the cabochons are formed and placed in the vacuum chamber prior to curing in a later step.

After the epoxy resin mixture has been brought back to atmospheric pressure, it can then be loaded into syringes for dispensing.

In embodiments, one or more syringes can be filled with the epoxy resin mixture. The syringe can be tilted at a 45° angle, and the epoxy resin mixture poured into the syringe until the resin level is approximately one inch from the opening. The cap can then be inserted and the syringe inverted to the cap is on the bottom.

In embodiments, the plunger on the syringe should be depressed to gently squeeze out the air until the epoxy resin has reached the tip. The foregoing steps should be repeated for each syringe until the epoxy resin mixture in the beaker has been exhausted.

In embodiments, a programmable digital syringe dispense can be used to dispense the resin. The digital syringe can have adjustable pressure and timing to control the flow of epoxy resin onto the base.

Following preparation of the epoxy resin mixture and loading into syringes, the resin is then ready to be applied to the image substrate, which is referred to herein as an imposition.

In embodiments, impositions can be printed as a sheet that from which the individual impositions are separated. The die used to cut the images should be kept sharp to prevent frayed edges to allow the epoxy resin to bond to he surface of the substrate layer. In embodiments, mechanical cutting and perforations have been utilized. In further embodiments, individual impositions can be generated. In a preferred embodiment, impressions are printed on photo metallic paper using a conventional laser printing process. Inkjet printing can also be used, though the image quality might be diminished as compared to a dry laser-based printing process, and is less preferred. In embodiments, the paper can be treated with pressurized air prior to printing to keep the finished image free of dust and debris.

Whatever printing method and paper is chosen, the image should be able to withstand the expected exposure to light, heat, and other environmental factors without a significant reduction in image quality. In a preferred embodiment, impositions are substantially circular in shape and can vary in size depending on the application. Alternate shapes can also be generated, including rectangular, square, and oval, as well as other shapes.

In embodiments, as shown FIG. 8, the impressions are arranged in rows on a glass or acrylic platform or work surface prior to treatment with the epoxy resin mixture. It has been found that a glass platform or work surface is preferable because of low cost and ease of cleaning.

The epoxy resin mixture can then be dispensed onto the center of each individual impression, using a quantity of epoxy resin mixture sufficient to cover the impression, allowing for the effects of gravity and surface tension to pull the epoxy resin to the outer edge of the impression. Care should be taken at this step as to not overload the impression with epoxy resin, which may cause the epoxy resin to spill over the edge of the impression damaging not only the individual unit, but adjacent units as well. In embodiments, a digital syringe may be preprogrammed to release a specific amount of epoxy resin (or dispense for a predetermined time interval) that corresponds to the size of the impression, or thickness of the cabochon.

In embodiments, an eyedropper can then be used to gather excess epoxy resin that has spilled over the edge of the impression, as shown in FIG. 9.

The individual units can then be visually inspected for air bubbles or other imperfections. If air bubbles remain in the epoxy resin at this point, a heat gun is used to apply heat to individual units, which causes air bubbles to rise to the surface. If more significant bubbling is present, the units can be put into the vacuum chamber until the bubbles disperse, approximately 15 minutes.

In embodiments, after the cabochons have been dripped and inspected, and all bubbles removed, they can be put in an oven for four hours at 120°F. Following the oven step, the cabochons can set on the tray for an additional 6-12 hours to ensure that the epoxy resin has completely cured and that the cabochons cannot be damaged. The individual cabochons can then be removed from the glass.

Incorporation by Reference The entire disclosure of each of the patent documents, including certificates of correction, patent application documents, scientific articles, governmental reports, websites, and other references referred to herein is incorporated by reference herein in its entirety for all purposes. In case of a conflict in terminology, the present specification controls.

Equivalents

It will be understood that there are numerous modifications of the illustrated embodiments described above will be readily apparent to one skilled in the art, including any modified process parameters (e.g., time, pressure, temperature), combinations of features disclosed herein that are individually disclosed or claimed herein, explicitly including additional combinations of such features. These modifications and/or combinations fall within the art to which this invention relates and are intended to be within the scope of the claims, which will follow. It is noted, as is conventional, the use of a singular element in a claim is intended to cover one or more of such an element.

The invention can be embodied in other specific forms without departing from the spirit or essential characteristics thereof. The foregoing embodiments are to be considered in all respects illustrative rather than limiting on the invention described herein. In the various embodiments of the methods and systems of the present invention, where the term comprises is used with respect to the recited steps or components, it is also contemplated that the methods and systems consist essentially of, or consist of, the recited steps or components. Furthermore, the order of steps or order for performing certain actions is immaterial as long as the invention remains operable. Moreover, two or more steps or actions can be conducted simultaneously.

In the specification, the singular forms also include the plural forms, unless the context clearly dictates otherwise. Unless defined otherwise, 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 the case of conflict, the present specification will control. Furthermore, it should be recognized that in certain instances a composition can be described as composed of the components prior to mixing, because upon mixing certain components can further react or be transformed into additional materials.

All percentages and ratios used herein, unless otherwise indicated, are by weight.