COMPOSITE BODY COMPRISING A DECORATIVE ELEMENT

Abstract

A method for preparing a composite body (1) comprising a support body (2) and at least one decorative element (3), preferably a gemstone (3a, 3b), the support body (2) comprising a thermoplastic material, the method being characterized by the steps of: arranging the decorative element (3) on the support body (2), heating the support body (2), pressing the decorative element (3) into the support body (2) by using a stamp (4) consisting of an elastically deformable material, the material of the stamp (4) being selected from the group of elastomers.

Claims

1. A method for preparing a composite body comprising a support body and at least one decorative element, wherein the support body comprises a thermoplastic material, the method being characterized by the steps of: arranging the decorative element on the support body, heating the support body, pressing the decorative element into the support body using a stamp made of elastically deformable material, wherein the material of the stamp is selected from the group of elastomers.

2. The method according to claim 1, wherein the support body comprises a single-layer or multilayer thermoplastic film or consists of a single-layer or multi-layer thermoplastic film.

3. The method according to claim 2, wherein the support body comprises a film that is substantially transparent to light in the visible spectrum.

4. The method according to claim 1, wherein the surface of the stamp is provided with a structure that is imprinted into the thermoplastic material of the support body by the pressing step.

5. The method according to claim 1, wherein the decorative element is arranged with a transfer film on the support body.

6. The method according to claim 1, wherein the decorative element is pre-fixed on the support body by pressing onto the support body with a stamp made of elastically deformable material.

7. The method according to claim 6, wherein the stamp for the pre-fixing is also used for pressing of the decorative element.

8. The method according to claim 1, wherein that region of the support body in which the decorative element is arranged has a lower melting point than regions of the support body that are remote therefrom.

9. The method according to claim 1, wherein the side of the support body facing away from the decorative element is attached to an article.

10. A composite body comprising a support body and at least one gemstone, wherein the support body comprises thermoplastic material, and wherein the composite body is prepared, by arranging a decorative element on the support body, heating the support body, and pressing the decorative element into the support body using a stamp made of elastically deformable material, wherein the material of the stamp is selected from the group of elastomers, characterized in that a decorative relief is imprinted at least in regions on the side of the support body on which gemstone is arranged.

11. The composite body according to claim 10, wherein the support body is elastically deformable.

12. The composite body according to claim 10, wherein the peripheral edge of the gemstone is enclosed at least in regions, preferably in an annular manner, by the thermoplastic material of the support body.

13. The composite body according to claim 10, wherein the gemstone is a chaton-shaped gemstone is a chaton-shaped gemstone the back side of which, converging into a tip, is arranged in the support body.

14. The method according to claim 1, wherein the at least one decorative element is a gemstone.

15. The composite body according to claim 10, wherein the support body comprises a single-layer or multilayer thermoplastic film or consists of a single-layer or multi-layer thermoplastic film.

16. The composite body according to claim 15, wherein the support body comprises a film that is substantially transparent to light in the visible spectrum.

17. The composite body according to claim 10, wherein the edge of the gemstone is enclosed in an annular manner.

18. Apparatus for making a composite body, the apparatus comprising a plurality of gemstones, a support body comprising a thermoplastic material, and a stamp for pressing the gemstones into the support body, the stamp made of an elastically deformable material, wherein the material of the stamp is selected from the group of elastomers.

19. The apparatus of claim 18, wherein the stamp comprises a relief-type structure.

20. The apparatus of claim 18, wherein the surface of the surface of the stamp is provided with a structure that is imprinted into the thermoplastic material of the support body.

Description

Further details and advantages of the present invention are described in greater detail hereinbelow, on the basis of the description of the figures in reference to the drawings. In the drawings,

[0034] FIGS. 1a to 1d illustrate schematic representations of the arrangement of two differently configured decorative elements on a support body;

[0035] FIGS. 2a to 2c illustrate schematic representations of the method step of pressing the decorative elements in with a stamp made of an elastically deformable material;

[0036] FIGS. 3a to 3d illustrate schematic representations of the arrangement of two differently configured decorative elements on a support body, the decorative elements being chaton-shaped gemstones;

[0037] FIGS. 4a to 4d illustrate schematic representations of the method step of pressing the decorative elements in with a stamp made of an elastically deformable material, the decorative elements being chaton-shaped gemstones;

[0038] FIGS. 5a and 5b illustrate composite bodies according to the invention,

[0039] FIGS. 6a to 6c illustrate schematic representations of the production of a setting for the decorative element with the method according to the invention;

[0040] FIGS. 7a to 7f illustrate photographs of composite bodies having decorative elements that have been set in support bodies;

[0041] FIGS. 8a to 8f illustrate photographs of different embodiments of the structure imprinted in the composite body;

[0042] FIGS. 9a to 9d illustrate schematic representations of the flexible deformability of a composite body according to the invention;

[0043] FIGS. 10a to 10f illustrate examples of articles that have been decorated with a composite body according to the invention, and a detail view thereof; and

[0044] FIGS. 11a and 11b illustrate photographs of articles that have been covered with a composite body according to the invention.

[0045] In the case of a plurality of decorative elements, a design template in terms of the set pattern for the decorative elements may be created in advance, wherein a setting machine can be used for automation.

[0046] For the preparation of a stamp 4 provided with a structure 5, first, the positive image of the structure 5 is set. If, for example, a stamp 4 made of silicone with which the surface of a composite body 1 according to the invention is to be modeled after the appearance of an artificial leather surface is to be prepared, then the artificial leather is stretched in a frame and fixed so that silicone poured into the frame cannot flow out. The size of the frame depends on the size of the stamp 4, which depends in turn on the size of the decorative elements 3 that are to be pressed into the support body 2 with the stamp 4. This frame also prevents the silicone from being displaced laterally during the pressing process.

[0047] With this process, it is possible to mold a variety of structure positives, by means of the stamp, into the composite body 1, such as, for example, surfaces that have been geometrically structured or imprinted with an image, or even randomly structured surfaces, such as leather surfaces, sand paper, and the like.

[0048] With a stamp 4 made of silicone, it is possible to use silicones in the Shore hardnesses A0 to A15, such as, for example, Wacker silicones, Elastosil RT 623 A/B with silicone oil, Wacker AK 35, or Elastosil M 4511 with curing agent T51.

[0049] FIG. 1a depicts how two gemstones 3a, 3b of different sizes that have a flat back side 11a, 11b are arranged on a transfer film 6. The back sides 11a, 11b serve as contact surfaces for the support body 2. One possible example for the transfer film 6 is a silicone adhesive transfer film from the company Nagel & Hermann (silicone glue, intensity adhesive with ripple film). The size, shape, and distances of the gemstones 3a, 3b are largely freely selectable. The decorative elements 3 may then be applied mechanically or manually. Alternatively, it would also be possible to arrange the decorative elements 3 directly on the support body 2.

[0050] As is schematically represented in FIG. 1b, the transfer film 6 moved with the gemstones 3a, 3b arranged thereon to the support body 2, which is arranged on a still-cold heating plate 12. In this embodiment, the support body 2 is consists of a two-layered thermoplastic film 15, optionally supplemented by a support film. The gemstones 3a, 3b are set with the flat back sides 11a, 11b on the thermoplastic film 15. Above the transfer film 6, a stamp 7 made of an elastically deformable material is set onto the gemstones 3a, 3b. In this embodiment, the stamp 7 is also made of silicone. The stamp 7 does not have a structure for imprinting into the support body 2. The stamp 7 for the pre-fixing may then have a Shore hardness between A0 and A30.

[0051] In this embodiment, the support body 2 is configured as a two-layered film 15 having a polyurethane melt film 15a and a support film 15b. Possible examples of such support bodies 2 configured as films 15 are the transparent three-layered film Nr. 963344 and the black two-layered film Nr. 963347 from the company Callan0 Adhesive. Alternatively, polyamides (PA), polyethylene (PE), amorphous polyalphaolefin (APAO), polyester elastomers (TPE-E), polyurethane elastomers (TPE-U), or copolyamide elastomers (TPE-U) may be used for the thermoplastic film 15 or the thermoplastic support body 2.

[0052] As mentioned above, decorative elements of different sizes, shapes, and colors can be used for the method according to the invention. In particular, gemstones 3a, 3b having flat back sides may be used, but so too may chaton-shaped gemstones 20a, 20b. If decorative elements 3 made of different elements are used, it is assumed that these decorative elements 3 are resistant to temperatures above the melting point of the thermoplastic material.

[0053] FIG. 1c depicts how the gemstones 3a, 3b are pre-fixed on the thermoplastic film 15, in order to subsequently allow for the transfer film 6 to be removed from the gemstones 3a, 3b. First, light pressure is applied to the stamp 7. The pressure must be so strong that the gemstones 3a, 3b are readily pressed into the thermoplastic film 15. A continuous press or a plate press can be used for applying the pressure. One possible example is a flatbed laboratory vulcanizing press KWS VP 320 from the company KWS Kachele GmbH. With large-scale industrial manufacturing, for example, flatbed laminating installations from the company Firma Maschinenfabrik Herbert Meyer GmbH may be used.

[0054] Subsequently, in this embodiment, the heating plate 12 is heated to a temperature between 120 C. and 160 C., the pressure on the stamp 7 being maintained. In the embodiment depicted, the distance d between the stamp 7 and the thermoplastic film 15 is between 0.2 and 0.5 mm.

[0055] After the melting point of the thermoplastic film 15 has been reached, the heating of the heating plate 12 is stopped, so that the film 15 can cool. The pressure on the stamp 7 is held constant. At a temperature of around 80 C., the silicone stamp 7 is removed and the transfer film 6 is peeled off. This is illustrated schematically in FIG. 1d, with reference to the curved arrow.

[0056] For the pressing in of the gemstones 3a, 3b into the support body 2 in order to finally fasten same, the support body 2 is positioned with the pre-fixed gemstones 3a, 3b on the cold heating plate 12 in the press. The stamp 4, which consists of silicone in this embodiment as well, is pressed in a coplanar manner onto the support body 2 when the press is closed (cf. FIG. 2a). The stamp 4 has a structure 5 of which a negative copy is imprinted in the support body 2 due to the pressing operation. The stamp 4 may have a thickness between 3 and 10 mm, just as the stamp 7 may. If no structure is to be imprinted into the composite body 1, the stamp 7 that is used to pre-fix the gemstones 3a, 3b may also be used for the pressing in of the gemstones 3a, 3b in this method step.

[0057] Pressure is then applied to the stamp 4. This is depicted in FIG. 2b. Then, the pressure depends on the size of the decorative elements 3 and the Shore hardness of the stamp 4. In this embodiment, the pressure amounts to p=25 kN. The lateral displacement of the silicone can be prevented by the use of a frame, which is not shown in FIGS. 2a and 2b in order to preserve the clarity. As a result of the application of pressure, the elastically deformable stamp 4 fits snugly around the gemstones 3a and 3b. However, the stamp 4 has only a limited malleability, so that cavities 13 form at the rim of the gemstones 3a, 3b. More cavities 14 form with the relief-type structure 5 of the stamp.

[0058] The pasty or molten liquid thermoplastic material of the support body 2 is pressed into these cavities 14, whereby the relief-type structure 8 of the support body 2 and the settings 9 for the decorative elements 3 subsequently form. Then, the heating plate 12 is heated to a temperature between 120 C. and 160 C., until the melting temperature of the thermoplastic film 15 is achieved, and is held at this temperature for a holding time that, in this embodiment, amounts to between 1 and 3 minutes. Then, pressure is always applied to the stamp 4. The holding time depends on the size of the decorative elements 3. During this method step, the cavities 13 on the peripheral edge 16 of the gemstones 3a, 3b and the cavities 14 that occur due to the structure 5 are filled with plasticized thermoplastic material of the support body 2. Under application of pressure, the heating plate 12 is switched off and cooling is preferred to a temperature of about 80 C. Thereafter, the stamp 7 is removed and the finished composite body 1 having fixed gemstones 3a, 3b and decorative relief 8 is taken out of the press. This is depicted in FIG. 2c.

[0059] With the method according to the invention, decorative elements 3 having a side that converges into a point may also be arranged in the support body 2. The necessary adaptations of the method shall be described by way of example, on the example of two chaton-shaped gemstones 20a, 20b of different sizes. Chaton-shaped gemstones 20a, 20b consist of a front side having a flat table and a back side 21a, 21b having a tip 19a, 19b. The tip 19a, 19b is inserted into the support body 2, so that the front side with the table projects at least partially out of the support body 2. If chaton-shaped gemstones 20a, 20b having a transfer film 6 are arranged on or in the support body 2, the gemstones 20a, 20b are arranged with the flat table on the transfer film 6. Then, a precise alignment is required, so that the longitudinal direction of the chaton-shaped gemstone 20a, 20b is aligned perpendicularly on the transfer film 6. FIG. 3a depicts how two chaton-shaped gemstones 20a, 20b of different sizes are arranged on a transfer film 6.

[0060] When the chaton-shaped gemstones 20a, 20b are used, unlike the embodiment according to FIGS. 1 and 2, the thermoplastic film 15 is not laid directly on the heating plate 12, but on a protective plate 22, e.g., a silicone plate, which may have the same Shore hardness as the stamp 7. The pressure on the stamp 7 must be so strong that the tip of the chaton-shaped gemstones 20a, 20b is readily pressed into the melt film 15. For this embodiment, the stamp 7 for pre-fixing the gemstones 20a, 20b need not have a relief-type structure, or only a very slight relief-type structure, so as to influence as little as possible the position and orientation of the chaton-shaped gemstones 20a, 20b. FIG. 3b, depicting this process, corresponds substantially to FIG. 1 b, wherein a protective plate 22 such as is described above is arranged under the multilayer thermoplastic film 15a, 15b, due to the chaton-shaped gemstones 20a, 20b having a tip 19a, 19b, the protective plate being arranged in turn on the heating plate 12.

[0061] The method steps schematically illustrated in FIGS. 3c and 3d correspond to the method steps described in connection with FIGS. 1c and 1d, so that reference may be made to the relevant passages.

[0062] In the case of a support body 2 consisting of a thermoplastic film 15, when the method is used for chaton-shaped gemstones 20a, 20b, the film 15 must be placed on a protective plate 22, e.g., made of silicone, during the pressing process as well, such as is depicted in FIGS. 4a to 4d. The protective plate 22 may then have approximately the same Shore hardness as the stamp 4. The resulting composite body 1 may, depending on this thickness of the support body 2, have a relief-type underside due to the pressing in of the tip 19a, 19b. This relief-type underside can be flattened, e.g., by application of a suitable material from below, until a flat surface is created.

[0063] Therein, the method steps depicted schematically in FIGS. 4a to 4c correspond substantially to those of FIGS. 2a to 2c, wherein, however, the gemstones 20a, 20b are pressed into the protective plate 22 together with the thermoplastic film 15 due to the tip 19a, 19b of the chaton-shaped gemstones 20a, 20b. It may then be provided that the protective plate 22 is a component of the support body 2, in which, for example, the film 15 is adhered with the protective plate 22, such as is depicted in FIG. 4d. It may, however, also be provided that the protective plate 22 is again removed from the support body 2 after the decorative elements 3 have been pressed in.

[0064] FIG. 5a depicts a composite body 1 according to the invention, with which gemstones 3a and 3b of different sizes have been fastened onto the support body 2, wherein the support body 2 in this case consists of a thermoplastic film 15 having layers 15a and 15b. The composite body 1 has a relief-type structure 8 in the regions outside of the gemstones 3a, 3b. Then the peripheral edge 16 of the gemstones 3a, 3b is set by the setting 9 made during the pressing process. Then, the gemstones 3a, 3b are held in a positive-locking manner on the support body 2. This setting 9 considerably reinforces the adhesive adherence. Depending on the configuration of the edge region of the decorative elements 3, the setting 9 may encircle the peripheral edge 16 in an annular manner, producing an especially stable fastening.

[0065] FIG. 5b depicts a composite body 1 with which, in contrast to FIG. 5a, the gemstones 20a, 20b are chaton-shaped.

[0066] FIGS. 6a to 6c illustrate schematically how the setting 9 and the structure 8 are made during the pressing process. First the decorative element 3 is arranged on the support body 2. Then, the stamp 4 is placed on the decorative element 3, and pressure is applied thereto. The stamp 4 then does fit snugly onto the decorative element 3, due to the elastic deformability thereof. Due to the limited malleability of the stamp 4, there occurs a cavity 13 around the peripheral edge 16 at the foot of the decorative element 3. When the melting temperature is reached, the thermoplastic material of the support body 2 begins to become molten liquid or pasty, whereby thermoplastic material from the support body 2 rises up and fills the cavity 13, as is depicted with the arrows in FIG. 6a. After the cooling, a positive-locking connection is formed. Similarly, the thermoplastic material flows into the cavities 14 that arise with the structured regions 5 of the stamp 4. This is illustrated in the schematic representation of FIG. 6b, with reference to the arrows.

[0067] A suitable geometry of the peripheral edge 16 of the decorative element 3 makes it possible to optimize the mechanical connection between the decorative element 3 and the support body 2. FIG. 6c illustrates one example of a positive lock-optimized design of the peripheral edge 16 of the decorative element 3.

[0068] FIGS. 7a to 7f illustrate photographs of sections of embodiments of the composite bodies 1 according to the invention. FIG. 7a illustrates a section of a composite body 1 with which a plurality of gemstones 3a, 3b of different sizes have been set in a random arrangement in a support body 2. The structure 8 between the set gemstones 3a, 3b is easily recognizable and, in this example, imitates the surface of ostrich leather.

[0069] FIG. 7b depicts a photograph of another embodiment of a composite body 1 according to the invention, wherein the setting 9 surrounds the peripheral edge 16 of the decorative elements 3, configured as gemstones, and thereby provides an especially stable mechanical hold.

[0070] FIG. 7c, in turn, depicts a section of a composite body 1 with which the imprinted structure 8 constitutes a geometric pattern. In the detailed view of FIG. 7d, the setting 9s is especially visible. The peripheral edge 16 of the decorative element 3, configured in the form of a gemstone, is surrounded thereby. In this case, the support body 2 comprises a multilayer thermoplastic film 15, wherein the outermost film 15a is configured so as to be substantially transparent to light in the visible spectrum, so that the setting 9 has the least possible effect on the brilliance through the gemstone.

[0071] FIG. 7e depicts another photograph pertaining to a section from a composite body 1 according to the invention, in whichin addition to gemstones 3a, 3b of different sizesstar-shaped decorative elements 3 are also arranged in a support body 2, wherein a structure 8 that imitates a leather surface has been imprinted into the support body 2. The detailed view according to FIG. 7f illustrates how the setting 9 is arranged around the rim of the star-shaped decorative element, and ensures a particularly stable hold.

[0072] FIGS. 8a to 8f illustrate photographs of different embodiments of the structure 8 imprinted into the composite body 1, wherein the structure 8 according to FIGS. 8a and 8b imitates the surfaces of two different textile fabrics, whereas the structure according to FIG. 8c imitates the surface of ostrich leather, and the structure 8 according to FIG. 8d illustrates the surface of calfskin. In FIGS. 8e and 8f, a geometric pattern is imprinted as a structure 8 into the surface of the composite body 1. There are many design possibilities.

[0073] FIGS. 9a to 9d illustrate the advantages of a composite body 1 in which the support body 2 consists of a thermoplastic film 15. In FIG. 9a, the composite body 1 is to be affixed onto a curved or flexible article 10, for example, a computer mouse or a handbag. Due to the flexibility of the thermoplastic film 15 and the secure hold on the decorative elements 3a, 3b, it is possible to use the composite body 1 to decorate articles 10 that have a variety of shapes and are even themselves flexible.

[0074] Similarly, FIG. 9b illustrates how the elastic article 10, which is provided with a composite body 1 consisting of a thermoplastic film 15 having decorative elements 3a, 3b fastened therein can be stretched by about 30 to 40% at room temperature without losing the decorative elements 3a, 3b.

[0075] FIGS. 9c and 9d are similar to FIGS. 9a and 9b, with the difference that the decorative elements 3 are configured as chaton-shaped gemstones 20a, 20b and are embedded with the tips 19a, 19b thereof and the support film 15 in a protective layer 23 made of a flexible material, thereby preventing the gemstones 20a, 20b from being pushed out. As the protective layer 23, for example, the protective plate 22 may be provided.

[0076] FIGS. 10a to 10e depict computer mice 10 having a rear region that has been covered in each case with a composite body 1 according to the invention, wherein adaptation to the surface of the computer mice 10 is readily possible due to the elastic properties of the support body 2. Then, there is no danger of losing the decorative elements 3, due to the extremely stable hold of the decorative elements 3 in the support body 2. In the case of the computers mice 10 depicted in FIGS. 10a to 10e, a plurality of decorative elements 3 are respectively arranged in the form of gemstones 3a, 3b of different sizes. The embodiments differ from one another in the relief-type structure 8 that is imprinted into the composite body 1. Whereas geometric patterns are imprinted in FIGS. 10c and 10d, the surface of a leather or a textile fabric is imitated in FIGS. 10a, 10b, and 10e.

[0077] In another embodiment, the detailed view of FIG. 10f illustrates a composite body 1 that is arranged on an article 10, wherein a variety of decorative elements 3in the form of gemstones, but also bodies 3 configured so as to be star-shapedare arranged in the composite body.

[0078] FIG. 11a depicts a photograph of an eyeglass case 10, the housing of which is covered with a composite body 1 that consists of a flexible support body 2 having a plurality of gemstones 3 arranged therein.

[0079] FIG. 11b depicts a photograph of a loudspeaker 10 having a housing that is covered on one side with a composite body 1, in which a plurality of gemstones 3 have been set in a regular arrangement.