Abstract:
An assembly is disclosed. The assembly includes an embossing device including a blank portion workpiece including a plurality of layers, wherein the blank portion workpiece is separated to include a first blank portion and a second blank portion, wherein each of the first and second blank portions include portions of at least two layers of the plurality of layers; and a blank portion retainer including a first flap and a second flap, wherein the first flap and the second flap are connected by a member consisting of a hinge, wherein the hinge and the first flap and the second flap define a folder, wherein each of the first and second flaps define an inner surface and an outer surface, wherein the first blank portion is attached to the inner surface of the first flap, wherein the second blank portion is attached to the inner surface of the second flap

Description:
RELATED APPLICATION 
       [0001]    This application claims the benefit of U.S. Provisional Patent Application Ser. No. 61/057,883 filed on Jun. 2, 2008, the contents of which are fully incorporated herein by reference. 
     
    
     FIELD OF THE INVENTION 
       [0002]    The disclosure relates to an embossing device, a method for using an embossing device, and a method for manufacturing an embossing device. 
       DESCRIPTION OF THE RELATED ART 
       [0003]    “Scrap-booking” is a method of associating visual media with a collection of album pages (often referred to as a “scrap-book”). The visual media associated with the scrap-book typically includes one or more photographs, decorations and/or printed material (e.g., a poem, short-story, newspaper article, or the like). An exemplar scrap-book that may retain visual media is shown, for example, in U.S. Pat. No. 140,245 to Samuel L. Clemens (also known under the pen-name, “Mark Twain”). 
         [0004]    Although conventional scrap-books like the one issued to “Mark Twain” on Jun. 24, 1873 are suitable for their intended purpose, with advances in modem technology, such scrapbooks are nevertheless susceptible to improvements that may enhance or improve their usage or method of manufacture. Therefore, a need exists in the art for the development of improved scrapbooks and scrapbook components that advance the art. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0005]    The disclosure will now be described, by way of example, with reference to the accompanying drawings, in which: 
           [0006]      FIG. 1A  is an exploded perspective view of an embossing device that includes a folder and a plurality of layers defining an embossing blank in accordance with an exemplary embodiment of the invention; 
           [0007]      FIG. 1B  is another exploded perspective view of an embossing device of  FIG. 1A  including the embossing blank that has been modified to define a first blank portion and a second blank portion in accordance with an exemplary embodiment of the invention; 
           [0008]      FIG. 1C  is an assembled perspective view of the embossing device of  FIG. 1B  in accordance with an exemplary embodiment of the invention; 
           [0009]      FIG. 2  is a perspective view of a system for modifying the plurality of layers defining the embossing blank of  FIG. 1A  in accordance with an exemplary embodiment of the invention; 
           [0010]      FIGS. 3A-3F  illustrate a method for manufacturing the embossing device of  FIG. 1C  in accordance with an exemplary embodiment of the invention; 
           [0011]      FIGS. 4A-4F  illustrate a cross-sectional view of the method for manufacturing the embossing device according to lines  4 A- 4 A through  4 F- 4 F of  FIGS. 3A through 3F  in accordance with an exemplary embodiment of the invention; 
           [0012]      FIG. 5A  illustrates a perspective view of a workpiece being inserted into and interfaced with the embossing device of  FIG. 1C  in accordance with an exemplary embodiment of the invention; 
           [0013]      FIG. 5B  illustrates a perspective view of the workpiece of  FIG. 5A  removed from the embossing device such that the embossing device has modified the workpiece to include an embossed pattern in accordance with an exemplary embodiment of the invention; and 
           [0014]      FIGS. 6A-6B  illustrate perspective views of a pressing device that interfaces with the embossing device and a workpiece in accordance with an exemplary embodiment of the invention. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0015]    The Figures illustrate an exemplary embodiment of an embossing device and method for using and manufacturing the same in accordance with an embodiment of the invention. Based on the foregoing, it is to be generally understood that the nomenclature used herein is simply for convenience and the terms used to describe the invention should be given the broadest meaning by one of ordinary skill in the art. This application claims the benefit of U.S. Provisional Patent Application Ser. No. 61/057,883 filed on Jun. 2, 2008, the contents of which are fully incorporated herein by reference. 
         [0016]    An embossing device is shown generally at  10  (see, e.g.,  FIGS. 1B-1C ) in accordance with an embodiment of the invention. Referring to  FIGS. 1A-1C , the embossing device  10  generally includes a folder portion  12  and first and second blank portions  14   a ,  14   b  (see, e.g.,  FIG. 1B ) that are formed from a blank portion workpiece  14  (see, e.g.,  FIG. 1A ). In an embodiment, the folder portion  12  and a blank portion workpiece  14  may be sold in a kit such that the blank portion workpiece  14  may be modified to include the first and second blank portions  14   a ,  14   b  that are later attached to the folder portion  12 ; accordingly, in an embodiment, the folder portion  12  and the blank portion workpiece  14  may be provided together (in an un-attached state) within one enclosure (not shown), or, alternatively in individual enclosures. In an embodiment, the enclosure may include, for example, a bag, box or the like). Further, when it is desired to assemble the embossing device  10 , the folder portion  12  and blank portion workpiece  14  may be removed from the one or more enclosures. 
         [0017]    In an embodiment, the folder portion  12  is generally defined by a first flap  16   a  and a second flap  16   b  that are utilized for respectively retaining the first and second blank portions  14   a ,  14   b  thereto. The folder portion  12  is also defined by a hinge  18  that connects the first flap  16   a  to the second flap  16   b  while also ensuring that the first and second blank portions  14   a ,  14   b  are repeatably and consistently aligned with one another (see, e.g.,  FIG. 4E ) when the first flap  16   a  and second flap  16   b  are moved toward one another during, e.g., an embossing procedure. Further, in an embodiment, each of the first and second flaps  16   a ,  16   b  may define a length, L, and a width, W; accordingly, the inclusion of the hinge  18  permits the folder portion  12  to act as a one-piece structure that may have a length approximately equal to L×2 and a width approximately equal to W×1. As such, it will be appreciated that the hinge  18  permits the folder portion  12  to provide an integral, simplified, compact structure that is free of/eliminates the need for separate connection structure (e.g., pins, holes, notches, flanges, or the like) while permitting alignment of the first and second blank portions  14   a ,  14   b  during an embossing procedure. Although the folder portion  12  is shown as a one-piece structure such that the hinge  18  is integral with and formed from the same material as that of the first and second flaps  16   a ,  16   b , it will be appreciated that the hinge  18  may alternatively include one or more separate components (e.g., a first flange pivotably joined to a second flange by way of a pin, not shown) that join a first flap,  16   a  to a second flap  16   b  that are not integrally-formed with one another (not shown); however, it will be appreciated that a one-piece structure shown and described in the Figures obviates separate forming procedures (for the above-described alternative embodiment) while also saving time in assembling the components to one another (for the above-described alternative embodiment) while also preventing the possibility of losing one or more of the components (i.e., one or more of the first flap  16   a , second flap  16   b  or hinge  18  for the above-described alternative embodiment). 
         [0018]    In an embodiment, the first flap  16   a  generally defines an inner surface  20   a  (see, e.g.,  FIG. 1C ) and an outer surface  22   a  (see, e.g.,  FIGS. 1A ,  1 B) as the second flap  16   b  similarly defines an inner surface  20   b  and an outer surface  22   b  (see, e.g.,  FIGS. 1A ,  1 B). When the first flap  16   a  is moved proximate the second flap  16   b  (see, e.g.,  FIG. 4E ), the inner surface  20   a  of the firsts flap  16   a  may be disposed near or substantially adjacent the inner surface  20   b  of the second flap  16   b.    
         [0019]    In an embodiment, the folder  12  may include any desirable rigid material. In an embodiment, the folder  12  may include a substantially rigid thermoplastic material including, for example, polycarbonate (PC), polyvinylchloride (PVC) or the like. In an embodiment, the folder  12  may include a substantially transparent material in order to permit a user to see a design, pattern or the like defined by the first and second blank portions  14   a ,  14   b.    
         [0020]    Referring to  FIG. 1A , in an embodiment, the blank portion workpiece  14  may include a plurality of layers  24  that are defined, for example, by a base material layer  24   a , a first film layer  24   b  and a second film layer  24   c . In an embodiment, each layer  24   a - 24   c  of the blank portion workpiece  14  includes a length, L, and a width, W, that is substantially the same as that of the length, L, and width, W, of each of the first and second flaps  16   a ,  16   b.    
         [0021]    In an embodiment, the base material layer  24   a  defines an upper surface  26  and a lower surface  28 . In an embodiment, each of the upper surface  26  and the lower surface  28  includes an adhesive material, A. 
         [0022]    In an embodiment, when the plurality of layers  24  defining the blank portion workpiece  14  are assembled together, the adhesive material, A, disposed upon the upper surface  26  is covered by the first film layer  24   b  by disposing the first film layer  24   b  adjacent the upper surface  26  of the base material layer  24   a . Similarly, the adhesive material, A, disposed upon the lower surface  28  is covered by the second film layer  24   c  by disposing the second film layer  24   c  adjacent the lower surface  28  of the base material layer  24   a.    
         [0023]    When it is desired to expose the adhesive material, A, at least a portion  36 ,  40  of the first and second film layers  24   b ,  24   c  may be removed from the base material layer  24   a  (see, e.g.,  FIGS. 3A ,  4 A and  3 D,  4 D respectively). Accordingly, each of the first and second film layers  24   b ,  24   c  may also be referred to as release-liner layers. 
         [0024]    As seen in  FIG. 1A , the blank portion workpiece  14  may be referred to as an unmodified, “virgin” blank portion. Conversely, as seen in  FIG. 1B , the “virgin” blank portion workpiece  14  is modified to define the plurality of layers  24  to be separated to define the first blank portion  14   a  (that includes portions  30 ,  38  of layers  24   a ,  24   c  described in the foregoing disclosure) and the second blank portion  14   b  (that includes portions  32 ,  34  of layers  24   a ,  24   b  described in the foregoing disclosure). 
         [0025]    In an embodiment, as seen in  FIG. 2 , a system  100  may be employed to cut/score all of the plurality of layers  24  defined by the blank portion workpiece  14  in order to permit the formation of the first blank portion  14   a  and the second blank portion  14   b . In an embodiment, the system  100  may include a device  102  having a movable cutting/scoring head  104 , which is hereinafter referring to as the head  104 . The head  104  may include a blade, liquid, or the like that cuts or scores the blank portion workpiece  14  to define the first blank portion  14   a  and the second blank portion  14   b.    
         [0026]    It will be appreciated that the terms “cut” and “score” have unique meanings when discussing the modification of the blank portion workpiece  14 . For example, if the blank portion workpiece  14  is said to be “cut,” the blank portion workpiece  14  may be modified by an incision that extends substantially all the way through a thickness, T, of the blank portion workpiece  14 . Further, for example, in an embodiment, if the blank portion workpiece  14  is said to be “scored,” the blank portion workpiece  14  may be modified by an incision that extends partially into the thickness, T, of the blank portion workpiece  14 . In an embodiment, it will be appreciated that a length of the “cutting” or “scoring” of the blank portion workpiece  14  may include a plurality of/series of “cuts” or “scores” that defines the blank portion workpiece  14  to be substantially perforated. 
         [0027]    In an embodiment, the device  102  may be an electronic apparatus, and, for example, movements of the head  104  may be controlled by a processor, controller, or the like. In an embodiment, the device  102  is described in detail in application Ser. No. 11/457,419, filed Jul. 13, 2006, to Robert Workman et al., the contents of which are incorporated herein by reference. However, it will be appreciated that the device  102  is not limited to an electronic apparatus and that a non-electronic, manually operated device may be provided in order to cut/score the blank portion workpiece  14 . 
         [0028]    As seen in FIGS.  1 B and  3 A- 4 F, as a result of the blank portion workpiece  14  defined by the plurality of layers  24  being cut or scored by the head  104 , the base material layer  24   a  is generally separated into a first portion  30  and a second portion  32 . Similarly, the first film layer  24   b  is generally separated into a first portion  34  and a second portion  36 . Similarly, the second film layer  24   c  is generally separated into a first portion  38  and a second portion  40 . 
         [0029]    As will be described in the foregoing disclosure, the second portions  36 ,  40  of the first and second film layers  24   b ,  24   c  are removed from the plurality of layers  24  and discarded (shown generally being disposed into a garbage can, G, at  FIGS. 3B and 3E ) during the manufacture of the embossing device  10 . Accordingly, as seen in  FIG. 1B , the first blank portion  14   a  is generally defined by the first portion  30  of the base material layer  24   a  and the first portion  38  of the second film layer  24   c , and, the second blank portion  14   b  is generally defined by the second portion  32  of the base material layer  24   a  and the first portion  34  of the first film layer  24   b.    
         [0030]    In an embodiment, as seen in  FIG. 2 , if the device  102  is an electronic apparatus, the device  102  may be interfaced with a cartridge  106  and/or a computer workstation  108 . The cartridge  106  may be, for example, a memory device (e.g., flash memory, a jump drive, or the like) that includes movement instructions for the head  104 . In an embodiment, the cartridge  106  may include a label or indicia, I, representing an image in order to communicate to a user how the head  104  will be moved so as to define the first and second blank portions  14   a ,  14   b.    
         [0031]    Alternatively, in an embodiment, a user may operate the computer workstation  108  to manually create an electronic design, pattern or the like defined by a plurality of pixels on a monitor  110  of the computer workstation  108 . The pixel pattern may be provided as an input to a program that creates instructions for defining movement of the head  104  in order to create the first blank portion  14   a  and the second blank portion  14   b . In an embodiment, the electronic, manually-created pattern or design created by the user on the monitor  110  may be saved in memory of the computer workstation  108 , and/or, saved to the cartridge  106 . 
         [0032]    In an embodiment, the cartridge  106  may be directly connected to the device  102  at a data port  112  defined by the device  102 ; accordingly, it will be appreciated that the device  102  may be operated separately from and without the computer workstation  108 . Although the cartridge  106  is shown to be directly interfaced with the device  102 , it will be appreciated that the cartridge  106  may be directly interfaced with the computer workstation  108  at a data port (not shown) that is substantially similar to the data port  112 . In an embodiment, the data port  112  may be, for example, a universal serial bus (USB) port or the like. 
         [0033]    In an embodiment, it will be appreciated that the device  102  may be utilized to cut/score all of the plurality of layers  24  in the comfort of one&#39;s home such that the first and second blank portions  14   a ,  14   b  may be connected to the folder portion  12  as described in the foregoing disclosure at  FIGS. 3A-3F  and  4 A- 4 F. However, it will be appreciated that the first and second blank portions  14   a ,  14   b  do not have to be created locally within one&#39;s home by the device  102  and that pre-modified first and second blank portions  14   a ,  14   b  may be manufactured remotely from the user&#39;s home such that the first and second blank portions  14   a ,  14   b  may be purchased as a commercially available accessory as an after-market component. 
         [0034]    Further, it will be appreciated that a user may purchase one or more cartridges  106  having previously-saved designs or patterns for forming first and second blank portions  14   a ,  14   b . Even further, it will be appreciated that a single cartridge  106  may store a plurality of designs or patterns that are either previously-created by a manufacturer, manually-created by an end-user, and/or downloaded from the Internet from a manufacturer&#39;s or user&#39;s website. Although it is described above that a cartridge (i.e., an external, interfacable memory device) may be utilized in a number of ways to save/download designs, patterns or the like, it will be appreciated that the device  102  may include an internal, non-interfacable memory device that may be wired to or wirelessly interfaced with the Internet in order to save/download designs, patterns or the like as described above in a substantially similar manner as that with the removable cartridge  106 . 
         [0035]    Referring now to  FIGS. 3A-3F  and  4 A- 4 F, a method for manufacturing the embossing device  10  is described in accordance with an embodiment of the invention. First, as seen in  FIGS. 3A and 4A , a user removes the second portion  36  of the first film layer  24   b  in order to expose a portion of the adhesive material, A, disposed upon the upper surface  26  of the first portion  30  of the base material layer  24   a.    
         [0036]    Referring to  FIGS. 3B and 4B , upon removing the second portion  36  of the first film layer  24   b , the first film portion  34  is carried by the upper surface  26  of base material layer  24   a . In an embodiment, the second portion  36  of the first film layer  24   b  may be no longer needed, and, as such, may be discarded into a receptacle, recycling bin, trash can, garage can, G, or the like. 
         [0037]    Then, as seen in  FIGS. 3B-3C  and  4 B- 4 C, the user places the exposed adhesive material, A, of the upper surface  26  of the first portion  30  of the base material layer  24   a  adjacent the inner surface  20   a  of the first flap  16   a  of the folder portion  12 . As a result of placing the exposed adhesive material, A, of the upper surface  26  of the first portion  30  of the base material layer  24   a  adjacent the inner surface  20   a  of the first flap  16   a  of the folder portion  12 , the first blank portion  14   a  is said to be attached to the first flap  16   a  of the folder portion  12 . It will be appreciated that upon attaching the first blank portion  14   a  to the first flap  16   a  as described above, the second blank portion  14   b  is joined to and carried by the first blank portion  14   a.    
         [0038]    Then, as seen in  FIGS. 3D and 4D , the user removes the second portion  40  of the second film layer  24   c  in order to expose a portion of the adhesive material, A, disposed upon the lower surface  28  of the second portion  32  of the base material layer  24   a . Then, as seen in  FIGS. 3E and 4E , the user moves the first flap  16   a  of the folder portion  12  in a first direction according to the arrow, D, in order to locate the inner surface  16   a  of the first flap  16   a  of the folder portion  12  proximate the inner surface  20   b  of the second flap  16   b  of the folder portion  12  in order to place the exposed adhesive material of the lower surface  28  of the second portion  32  of the base material layer  24   a  adjacent the inner surface  20   b  of the second flap  16   b . In an embodiment, the second portion  40  of the second film layer  24   c  may be no longer needed, and, as such, may be discarded into a receptacle, recycling bin, trash can, garage can, G, or the like. 
         [0039]    Referring to  FIGS. 3F and 4F , the user moves the first flap  16   a  in a second direction according to the arrow, D′, that is substantially opposite the direction of the arrow, D, in order to move the inner surface  20   a  of the first flap  16   a  of the folder portion  12  away from the inner surface  20   b  of the second flap  16   b  of the folder portion  12 . As a result of placing the exposed adhesive material of the lower surface  28  of the second portion  32  of the base material layer  24   a  adjacent the inner surface  20   b  of the second flap  16   b  of the folder portion  12 , the second blank portion  14   b  is said to be attached to the second flap  16   b  of the folder portion  12 . 
         [0040]    Further, as seen in  FIGS. 3F and 4F , by moving the first flap  16   a  according to the direction of arrow, D′, the second blank portion  14   b  is no longer joined to or carried by the first blank portion  14   a . As illustrated, the second blank portion  14   b  is separated from the first blank portion  14   a  by moving the first flap  16   a  according to the direction of arrow, D′. 
         [0041]    Further, as seen in  FIG. 4F , it will be appreciated that the first blank portion  14   a  attached to the first flap  16   a  of the folder portion  12  does not include all three layers  24   a - 24   c  of the plurality of layers  24 . As illustrated, the first blank portion  14   a  attached to the first flap portion  16   a  includes the first portion  30  of base material layer  24   a  and the first portion  38  of the of the second film layer  24   c . Similarly, the second blank portion  14   b  attached to the second flap  16   b  of the folder portion  12  does not include all three layers  24   a - 24   c  of the plurality of layers  24 ; as illustrated, the second blank portion  14   b  attached to the second flap portion  16   b  includes the second portion  32  of the base material layer  24   a  and the first portion  34  of the first film layer  24   a.    
         [0042]    Referring to  FIG. 5A , once the embossing device  10  is formed as described in the embodiment above, the embossing device  10  may be utilized for creating an embossed pattern, P (see, e.g.,  FIG. 5B ), design or the like upon a workpiece, W. The workpiece, W, may include any desirable material, such as, for example, paper, construction paper, poster-board, cardboard or the like. 
         [0043]    In an embodiment, the workpiece, W, including the embossed pattern, P, may be associated with a scrap-book. However, it will be appreciated that the workpiece, W, including the embossed pattern, P, may be utilized in any desirable, non-scrap-booking application, as desired. 
         [0044]    In general, the folder portion  12  carrying the first and second blank portions  14   a ,  14   b  is moved to an open position (by moving the first flap  16   a  away from the second flap  16   b  according to the direction of arrow, D′) such that the workpiece, W, may be permitted to be interfaced with the embossing device  10 . Then, the workpiece, W, is disposed between the inner surfaces  20   a ,  20   b  of the first and second flaps  16   a ,  16   b . Then, the folder portion  12  is moved to the closed position (by moving the first flap  16   a  toward the second flap  16   b  according to the direction of the arrow, D) by moving the inner surfaces  20   a ,  20   b  proximate one another in order to sandwich the workpiece, W, by the first and second flap portions  16   a ,  16   b.    
         [0045]    Once the workpiece, W, is sandwiched by the first and second flaps  16   a ,  16   b , the user may pinch/apply pressure to each of the outer surfaces  22   a ,  22   b  of the first and second flap portions  16   a ,  16   b  in order to cause the first blank portion  14   a  to be disposed proximate the inner surface  20   b  of the second flap portion  16   b  as the second blank portion  14   b  is disposed proximate the inner surface  20   a  of the first flap portion  16   a  so as to impart the pattern, P, or design defined by the first and second blank portions  14   a ,  14   b  upon the workpiece, W. In an embodiment, the pinching/application of pressure to each of the outer surfaces  22   a ,  22   b  of the first and second flap portions  16   a ,  16   b  may be done manually with a user&#39;s hands. 
         [0046]    In an alternative embodiment, as seen in  FIGS. 6A-6B , it will be appreciated that the embossing device  10  including the sandwiched workpiece, W, may be interfaced with a pressing device  200  that imparts the above-described pinching/application of pressure to each of the outer surfaces  22   a ,  22   b  of the first and second flap portions  16   a ,  16   b . In an embodiment, the device  200  is described in detail in application Ser. No. 11/669,088, filed Jan. 30, 2007, to Gerry Ayala et al., the contents of which are incorporated herein by reference. 
         [0047]    In an embodiment, the embossing device  10  including the sandwiched workpiece, W, may be inserted into an insertion slot  202  formed in the pressing device  200 , and, upon turning a crank  204  of the pressing device  200 , the embossing device  10  and workpiece, W, may be fed through the pressing device  200  and out of a discharge slot (not shown) formed opposite the insertion slot  202 . As the embossing device  10  and workpiece, W, are fed through the insertion slot  202 , a force-imparting portion, such as, for example, a pair of opposing rollers (not shown), may contact the outer surfaces  22   a ,  22   b  with sufficient force in order to compress the embossing device  10  such that the first and second blank portions  14   a ,  14   b  impart the embossed design, pattern, P, or the like to the workpiece, W, that is sandwiched between the first and second flaps  16   a ,  16   b  of the folder portion  12 . 
         [0048]    The present invention has been described with reference to certain exemplary embodiments thereof. However, it will be readily apparent to those skilled in the art that it is possible to embody the invention in specific forms other than those of the exemplary embodiments described above. This may be done without departing from the spirit of the invention. The exemplary embodiments are merely illustrative and should not be considered restrictive in any way. The scope of the invention is defined by the appended claims and their equivalents, rather than by the preceding description.