Abstract:
The invention is a device for protecting a selected surface of a musical instrument, and a method of making such a device.

Description:
SUMMARY OF THE INVENTION  
       [0001]     The invention is a device for protecting a surface of a musical instrument, and a method for making such a device.  
       THE INVENTIVE DEVICE  
       [0002]     The inventive device includes a pliable planar sheet having an inner face configured to engage a surface of a musical instrument. The sheet also has an outer face, and fabric is positioned on at least a portion (preferably substantially covering) the outer face. The invention also includes a thermoplastic elastomer positioned on at least a portion of the inner face and configured to removably adhere to the surface.  
         [0003]     Optionally, the inventive device may include an intermediate layer of cushioning material positioned between the inner face and the outer face. In preferred embodiments of the invention, the device will be used with a guitar bass, banjo, violin, ukulele, or mandolin.  
         [0004]     In a preferred embodiment of the inventive device, a thermoplastic elastomer engages within fibrous substrate of the fabric and substantially covers the entire inner face. The thermoplastic elastomer may comprise any known low-tack TPE, such as a combination of mineral oil and a styrene-ethylene/butylene-styrene block copolymer.  
         [0005]     In a preferred embodiment of the device, the fabric includes velveteen; of course, other fabrics may be used, such as denim, cotton, muslin, corduroy, brushed leather, suede, or the like.  
       THE INVENTIVE METHOD  
       [0006]     The inventive method includes the steps of providing a fabric having a first face and a second face, and heating a pelletized thermoplastic elastomer. The method will also include the step of applying a thin film of molten thermoplastic elastomer to the first face of the fabric to form a sheet.  
         [0007]     Next, the sheet is cooled and spread flat, where a stamp is used to stamp (or score) a pattern onto the sheet. The stamped/scored figures are then removed from the sheet. These figures are the above-described device(s).  
         [0008]     Optionally, the inventive method may also include the step of removably adhering a backing to the first face of the fabric.  
         [0009]     In a second preferred embodiment of the method, the invention will include the step of providing an unwind roll containing the fabric rolled thereon, and a rewind roll distal the unwind roll for receiving the sheet. In this embodiment, the fabric is rolled from the unwind roll and the sheet is received on the rewind roll.  
         [0010]     In a preferred embodiment, the invention will include the step of positioning a die to spray the molten thermoplastic isomer onto the first face of the fabric; and, also positioning a hot roll between the unwind roll and the rewind roll. This hot roll engage (and warms) the fabric by applying heat to the second face.  
         [0011]     Optionally, the method may include the step of positioning the hot roll upstream of the dye, so that a portion of the fabric first engages the hot roll before molten thermoplastic isomer is sprayed onto the portion. Additionally a chill roll may be placed between the unwind roll and the rewind roll so that the chill roll engages the thin film.  
         [0012]     Of course, the method may also include the step of positioning the stamped figure (i.e., the inventive device) on a selected surface of the musical instrument, such as a guitar, bass, banjo, violin, ukulele, or mandolin.  
         [0013]     Various choices exist for the fabric and pelletized thermoplastic elastomer. For example, the fabric may be velveteen, and the thermoplastic elastomer may comprise styrene-ethylene/butylene-styrene block copolymer.  
         [0014]     Other objects, advantages and novel features of the present invention will become apparent from the following detailed description of the invention when considered in conjunction with the accompanying drawings. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0015]      FIG. 1  is a plan view of the inventive device, according to the principles of the invention.  
         [0016]      FIG. 2  is a plan views of the inventive device, as viewed from the opposite side as  FIG. 1 .  
         [0017]      FIGS. 3-5  are respective perspective views showing layers of embodiments of the inventive device.  
         [0018]      FIG. 6  is a perspective view showing how the layers of the device are assembled.  
         [0019]      FIG. 7  shows the stamping of the device from sheets.  
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0020]      FIGS. 1 and 2  show plan views of the basic preferred shape of the inventive device, according to the principles of the invention. Specifically,  FIG. 1  shows a first face  12 , which will generally bear a fabric-like cover, such as velveteen or the like. In contrast,  FIG. 2  shows a plan view of second face, which will generally have a non-tack or low-tack material such as a thermoplastic elastomer. Of course, the coverings of first and second  12 , 14  may be reversed if desired, in order to accommodate a left handed guitarist for example  
         [0021]      FIG. 3  shows a perspective view of a sheet  16  and its component. As discussed herein, the device  10  will be stamped from a sheet  16  that will comprise a plurality of layers. The outer layer  18  comprises a general fabric finish, such as velveteen, denim, curdoroy, or the like. The fabric layer  18  of the sheet  16  is coated with a layer  20  of a thermoplastic elastomer.  
         [0022]      FIG. 4  shows a perspective view of a sheet  16  comprising a fabric layer  18  coated with a layer  20  of low-tack thermoplastic elastomer; this layer  20  is then protectively coated with a cover  24  over the layer  20 . This cover  24  is generally a clear pliable plastic or polyester that is removably adherable to the layer  20 . When a musician desires to attach the device  10  to a musical instrument, the cover  24  from the device  10  and selectively places the device  10  on the musical instrument in order to protect a selected area of the musical instrument (not shown) from scratches, dings, and other harms. The thermoplastic elastomer of layer  20  is selected so that it will adhere to the musical instrument without damaging its finish.  
         [0023]      FIG. 5  shows a perspective view of another preferred embodiment of a sheet  16  from which devices  10  may be made. In this embodiment, sheet  16  includes a fabric layer  18  coated with a thermoplastic elastomer layer  20  with a cover  24  engaging the thermoplastic elastomer layer  20 . In this embodiment, a cushioning layer  22  is first applied to the fabric layer  18  in order to provide additional protection against dings or dents to the musical instrument.  
         [0024]      FIG. 6  is a detailed perspective view showing how sheets  16  are made. Fabric  18  is provided on an unwind roll  36 . The fabric rolls across a hot roll  32 , then under a chill roll  34 , and is received on a rewind roll  38 .  
         [0025]     Still referring to  FIG. 6 , pelletized thermoplastic elastomer  26  is inserted into an extruder  28  which heats and at least partially liquefies the thermoplastic elastomer. A die  30  then expels the thermoplastic elastomer layer  20  onto the fabric  18  to form a sheet  16  that will be received on the rewind roll  38 . In order to expedite the cooling of the product, a chill roll  34  is positioned to engage the sheet  16  and smooth the thermoplastic elastomer layer  20  to form a smooth and generally uniform sheet  16 .  
         [0026]      FIG. 7  shows a perspective view giving a general example of how devices  10  may be stamped from the sheets. In preferred embodiments of the invention, the cover  24  is applied to the sheet  16  before it is laid flat for stamping. A stamp  42  then creates a scored outline  40  onto the sheet, where a device  10  may be removed.  
         [0027]     Having described and illustrated the invention in detail, it is to be understood that the above and foregoing is for illustration and demonstration only. The descriptions herein are not intended to limit the breadth of this invention. The scope and breadth of the invention shall be limited only by the appended claims.