Diamond art canvas

A diamond art kit includes a diamond art canvas which includes a substrate upon which an image is printed. A layer of adhesive is applied above the image, and a protective film (which can have perforated tear lines) releasably covers the adhesive. The substrate includes a textile layer that can be sealed by front and back sealing layers. A backing layer can be applied to the back sealing layer. The backing layer can be configured with fibers that are sufficiently flexible to allow the diamond art canvas to be rolled and placed within a tube for storage and shipping, but also has sufficient tensile strength to urge the diamond art canvas toward laying flat when unrolled.

BACKGROUND

The present disclosure relates to hobby art, and more particularly to diamond painting.

Diamond painting is a form of mosaic art in which small beads, referred to as jewels, diamonds or drills, are attached to a sticky canvas. Typically the canvas is pre-printed with an image divided into a grid of spaces. Each space includes a symbol corresponding to a particular color of drill, and the user places appropriate drills into spaces in order to create the image, similar to the paint-by-numbers concept.

A diamond art canvas includes a substrate that makes up the structural support for the canvas. The substrate can include a flexible textile with one or more layers, including a print layer configured to receive an image printed thereon. An adhesive layer is applied to the substrate atop the print layer so as to hold the drills that are placed thereon. A plastic protective film is disposed over the adhesive. During diamond painting, the user will peel back the protective film in order to access and place drills onto the canvas. After some time, the user may wish to take a break from diamond painting, and will re-place the protective film in order to protect the remaining exposed adhesive.

Upon manufacture, a diamond art canvas typically is rolled up and deposited into a cylindrical tube for storage and shipping. To use the diamond art canvas, a consumer will remove it from the tube, unroll it, and proceed to place drills for diamond painting. Due to the various layers and materials used, the canvas may be liable to wrinkle, curl at the ends, or otherwise tend to not lay flat.

SUMMARY

The present specification discloses aspects that improve a diamond art canvas by reducing its tendency to wrinkle and curl. The improved canvas has a backing layer that is flexible enough to allow the diamond art canvas to be rolled and placed in a cylindrical tube for storage and shipping, but also urges the canvas toward a lying-flat disposition, thus resisting curling of the edges of the canvas and resisting wrinkling. The backing layer is a composite of fibers entrained in an adhesive, and is cured in a manner so that when the diamond canvas is laid flat, the fibers are generally straight. The fibers may have their lengths extend generally within a plane or may be randomly placed such as by spraying the bamboo fibers into the adhesive. When the diamond canvas is rolled up and placed in a tube for shipping, the fibers will bend. When the diamond canvas is taken out of tube, the fibers will urge the diamond canvas back to the flat configuration to thereby prevent wrinkles. Put simply, the fibers embedded within the adhesive will urge the backing layer, and thus the entire diamond art canvas, towards a lying-flat disposition. In order to accomplish this the fibers have a tensile strength between about 700-2000 MPa and a Young's modulus between about 15-45 GPa. The fibers for the backing layer can be bamboo fibers configured and treated to have suitable properties.

In some variations the fibers may have a tensile strength between about 900-1800 MPa and a Young's modulus between about 20-40 GPa. In still further variations the fibers can have a tensile strength between about 930-1770 MPa and a Young's modulus between about 15-45 GPa.

In accordance with one embodiment, the present disclosure comprises a diamond art canvas, comprising a substrate having a front side and a back side. The substrate comprises a flexible textile, a print layer defined on a front side of the textile layer, and a backing layer defined on a back side of the textile layer. An image is printed upon the print layer, the image including a plurality of markers with unique printed indicia. An adhesive is applied to the image surface. A plurality of unique diamond drills are attachable to the substrate via the adhesive and attachable in a pattern corresponding to the unique printed indicia. A protective film is disposed atop the adhesive, the protective film configured to be releasably removed from and reengaged with the adhesive. The backing layer comprises a composite comprising a plurality of fibers entrained in an adhesive, each of the plurality of fibers having a length. The backing layer is configured so that an at-rest condition of the fibers in the backing layer is generally planar. The fibers have a tensile strength greater than about 700 MPa and a Young's modulus greater than about 15 GPa.

In some variations the fibers have a tensile strength less than about 2000 MPa and a Young's modulus less than about 45 GPa. In further variations the fibers have a tensile strength greater than about 900 MPa and less than about 1800 MPa and a Young's modulus greater than about 20 GPa and less than about 40 GPa. In further variations the fibers can have a Young's modulus greater than about 25 GPa.

In additional variations the fibers comprise bamboo fibers.

In still further variations the fibers have a tensile strength between about 930-1770 MPa and a Young's modulus of between about 26-35 GPa.

The plurality of fibers can be randomly disposed in the backing layer.

Additional variations can additionally comprise a cylindrical tube having a diameter, wherein the fibers are selected to be flexible enough so that the diamond art canvas can be rolled up and deposited into the tube, and the fibers are selected to be stiff enough so that when the diamond art canvas is removed from the tube and unrolled the backing layer urges the diamond art canvas toward a planar at-rest configuration.

In accordance with another embodiment, the present specification discloses a method of making a diamond art painting kit. The method includes forming a substrate, which comprises applying a back sealing layer to a back side of a textile layer, applying a front sealing layer to a front side of the textile layer, and applying a backing layer behind a back side of the textile layer. The backing layer comprises a composite having a plurality of fibers entrained in an adhesive, each of the plurality of fibers having a length, the fibers having a tensile strength greater than about 700 MPa and a Young's modulus greater than about 15 GPa. The method can further comprise curing the backing layer when the textile layer is lying flat so that an at-rest configuration of the fibers in the backing layer, when cured, is generally planar.

Some variations additionally comprise applying an image to a front surface of the substrate, applying an adhesive layer atop the image, and applying a removable protective film to the adhesive layer.

Further variations additionally comprise rolling the diamond art canvas and placing the rolled diamond art canvas into a cylindrical tube.

In some variations the backing layer is applied prior to the image being applied.

In additional variations, the fibers of the composite layer are bamboo fibers.

The fibers of the composite layer can have a tensile strength between about 900-1800 MPa and a Young's modulus between about 20-40 GPa.

The fibers of the composite layer can have a tensile strength between about 930-1770 MPa and a Young's modulus of between about 26-35 GPa.

The fibers of the composite layer can be bamboo fibers.

In some variations, applying the backing layer comprises applying an adhesive to the back sealing layer and flocking bamboo fibers onto the adhesive.

In further variations, applying the backing layer comprises applying an adhesive to the back sealing layer and applying a textile comprising bamboo fibers onto the adhesive.

DESCRIPTION

The present specification discloses an improved diamond art canvas that is flexible enough to be rolled and placed in a cylindrical tube for storage and shipping, but also tends toward a lying-flat disposition after removal from the tube, resisting curling of the edges of the canvas and resisting wrinkling.

A diamond art canvas22includes a substrate24having an image surface26upon which a layer of adhesive30(seeFIG.2) is deposited. A protective film33sits atop the adhesive30. The substrate24includes a flexible textile layer80. A backing layer90(seeFIG.7) of the substrate24is made up of fibers entrained in an adhesive. The backing layer90is cured in a manner so that when at rest, the fibers have their lengths extending generally within a plane. The fibers thus will urge the backing layer90—and thus the entire diamond art canvas22—towards a lying-flat disposition. To effectively accomplish this the fibers have a tensile strength between about 700-2000 MPa and a Young's modulus between about 15-45 GPa. The fibers for the backing layer can be bamboo fibers configured and treated to have suitable properties.

In some variations the fibers may have a tensile strength between about 900-1800 MPa and a Young's modulus between about 20-40 GPa. In still further variations the fibers can have a tensile strength between about 930-1770 MPa and a Young's modulus between about 15-45 GPa.

With initial reference toFIGS.1and2, a diamond art kit20includes a canvas22comprising a substrate24having an image surface26(seeFIG.2) upon which an image28is printed. A layer of adhesive30is applied over the image surface26. A protective film33is applied atop the adhesive30. As shown, the protective film33can be peeled back to expose the adhesive30.

The image28is divided into a grid36defining spaces38, each of which includes a symbol. A plurality of drills40are provided. Drills are an industry term for clear or colored faceted resin bodies that absorb and reflect light similar to diamonds. It is anticipated that one drill40will be placed in each space38. The symbol in each space corresponds to a particular color of drill40, and the user is to place the corresponding drill40in each space38so as to create a mosaic matching the printed image28. The drills40typically are resin beads having a flat side for placement on the image surface26, and a plurality of facets adapted to produce a shimmering, reflective effect. Drills40are also sometimes called diamonds, gems, or rhinestones, and can be made of a variety of materials and also have a variety of specific shapes.

With continued reference toFIG.1, the drills40often are provided in bags42which preferably have a label44corresponding to, for example, the symbol associated with the particular drill color contained in the bag42. In use, a user will often pour several drills40into a tray46configured to support them with the facet-side up. An elongated applicator50can include a handle52and a tip54.

To place a drill40, a user first peels the protective film33back, exposing the adhesive30. The user then dips the tip54of the applicator50into a wax pad56. The wax56provides a light adhesive affect so that when the user applies the tip54onto the facet side of a drill40in the tray46, the drill will stick to the tip54(as shown inFIG.1). The user can then apply the drill40to the corresponding space38. Once applied to the space38, the strong adhesive30will hold the drill40in place on the canvas22, and the applicator50can be removed. As shown, however, peeling back the protective film33can expose far more of the adhesive30than is necessary for placing the drill40in the space38.

The protective layer33can be configured as a unitary film applied to the adhesive30. However, with reference next toFIG.3, in one variation, the protective layer33comprises a plurality of tear lines60at which the protective film33is biased to preferentially tear. In the variation shown inFIG.3, the protective film33can be divided by the tear lines60into sections A1-A25. A user thus may tear the protective film33along one or more of the tear lines60in order to expose one or more of the sections A1-A25while keeping the protective film33in place on the remaining sections. This limits exposure of the adhesive to only the section upon which the user is currently working.

In the variation shown inFIG.3, each tear line60is straight and parallel to one of the edges of the canvas22. As such, each section A1-A25forms a rectangular shape. The illustrated variation also has sections of various sizes so that a user can choose to open a larger or smaller section depending on how much time they wish to spend working on their diamond painting. It is to be understood that variations can be configured so that all sections are the same size, and variations can also be configured with sections of various sizes and shapes, in which tear lines60may or may not be parallel to one another and may or may not extend across the entire canvas22.

In the variation depicted inFIG.3, the tear lines60are placed without consideration of the underlying image28printed on the canvas22. With reference next toFIG.4, an additional variation is depicted in which tear lines60of the protective film33are arranged to define sections B1-B11that generally conform to at least some image features I1-I5of the image28. For example, image feature I1in the illustrated image28appears to be a round sun. A correspondingly round tear line60circumscribes this image feature I1, defining section B7, which corresponds to this image feature I1. As such, a user wishing to work on this particular image feature I1can tear out and remove section B7of the protective film33to expose the image feature I1so drills40can be appropriately placed on this portion of the canvas22while adhesive30in surrounding sections remains protected. Similarly, image features including the tail12, head13or body14of a fox are respectively defined by sections B2, B9and B3. Such sections can be defined as broadly or narrowly as desired. For example, section B7is made up almost entirely of the sun of image feature I1, but section B2includes not only the tail of image feature12, but also surrounding environmental features. It is to be understood that sections can be defined even more narrowly—such as a separate section for each of the petals of the flower in image feature15.

FIGS.4and5also depict another variation in which the protective film33comprises multiple separately-formed films, here a first protective film33A and a second protective film33B. The first protective film33A extends from a first end62A that is aligned with an edge of the canvas22to a second end64A positioned midway across the canvas22. The second protective film33B extends from a first end62B that is generally aligned with and adjacent the second end64A of the first protective film33A to a second end64B that is aligned with an opposing edge of the canvas22. Tabs66can be provided along the first edge62B, which tabs66overlap the second edge64A so as to help a user obtain purchase on the second protective film33B.

In some variations the sections B1-B11can be configured to correspond to one or a limited number of colors of drills40, so that when a user removes the protective film33within a particular section only a limited number of different types of drills40will be used for the exposed portion. In some variations the drills40can be packaged in bags42corresponding to particular sections. In such instances a label44of a bag42can correspond to a particular section B1-B11, which section number can be printed, for example, on the appropriate location of the protective film33. A limited number of different types of drills40can correspond to that section, and each different type of drill40can be placed in its own bag (and with its own label) within the larger bag42that corresponds to the selected section. Thus, each section's drills40can be separately bagged for the convenience of the user in 1) exposing only the particular section being worked on in that diamond painting session; and 2) opening bags only for drills40being placed in that particular section. Thus, exposure of adhesive30is limited, and exposure of loose drills40is also limited to only those drills40relevant to the particular section.

As shown inFIG.4, the tear lines60, and first ends62B, can be straight, curved, or combinations of straight and curved portions. Also, it is to be understood that various materials can suitably be used for the substrate24, adhesive30and protective film33. For example, typically the substrate comprises a flexible fabric having one or more layers, which layers can comprise woven and/or non-woven textiles. Also, the adhesive can be a poured or sprayed adhesive layer, and in some variations can be a double-sided adhesive film or other structure and method used for applying adhesive atop the image surface26.

The protective film33can be formed of a variety of flexible materials, mostly plastics, that are configured to releasably adhere to the adhesive30. In one variation the protective film33comprises a polyethylene terephthalate (PET) film having a thickness about 3.8c (0.38 mm) and having a silica oil coating. Such a film, and other acceptable films, can be obtained from manufacturers such as Dow Corning. In one variation the tear lines60comprise lines of perforations through the protective film33, and it is desired that the perforations are such that the protective film33tears readily along the tear lines60. In one variation the PET film mentioned above is used as the protective film33, and the tear lines60are made up of elongated perforations through the film, each elongated perforation having a cut length of 4 mm, and an uncut space between adjacent perforations is 0.5 mm. Other variations can include a similar, 8:1 ratio of cut/uncut portions defining the tear lines, or may employ greater or lesser ratios as desired and/or as allowed by the film material.

Upon manufacture, a diamond art canvas22typically is rolled up tightly and deposited in an elongated, cylindrical tube70for storage and shipping. Depending on the size of the canvas22, it may be rolled so as to have a rolling diameter of about ½ inch to 5 inches, and more likely between about 1-3 inches. With reference next toFIG.6, to use the diamond art canvas22, a user will remove it from the tube70, unroll it to lay it flat, and proceed with diamond painting.

As discussed above, the diamond art canvas22comprises a substrate24having a front surface upon which the adhesive30is deposited and the protective film33is placed atop the adhesive30. With reference next toFIG.7, the substrate24comprises multiple layers. A textile layer80can be made of a woven cloth, such as an oxford-woven cloth, or a non-woven cloth, and can be formed from chemical or natural fibers. The textile layer80typically makes up a majority of the thickness of the substrate24. A back side of the textile layer80can be coated and treated with, for example, an acrylic acid so as to form a back sealing layer82that coats and seals gaps in the textile layer80. A front side of the textile layer80can also be coated and treated with, for example, an acrylic acid so as to form a front sealing layer84that coats and seals gaps in the textile layer80.

With continued reference toFIG.7, a print layer86can be formed on or above—and fixedly connected to—the front sealing layer84. In some variations the print layer86can be formed by coating the surface of the front sealing layer84with, for example, an acrylic emulsion and heat drying at or around 150° C. to form a film configured to acceptably receive inks. Optionally, a flash layer88, which may include visual effect-enhancing materials such as paillettes, can be applied to the print layer86. The image surface26is defined as the front surface of the print layer86, or flash layer88if so equipped. As depicted inFIG.3, the adhesive30can be applied atop the image surface26.

Each of the above-described layers have properties that may be liable to wrinkling or remaining at least partly curled when the canvas22is unrolled for use. In some variations, a backing layer90, comprising a composite of fibers entrained in an adhesive matrix, is applied to or behind the back sealing layer82and is configured to urge the substrate24—and entire canvas22—to lie flat and minimize wrinkling. The fibers of the backing layer90can be disposed embedded within an adhesive layer. The fibers embedded within the adhesive layer urges the diamond canvas to lay flat after it is removed from the shipping tube.

In some variations the backing layer90is applied to the back sealing layer82when the layers are in a flat disposition. Preferably, the fibers are applied so that their lengths are randomly embedded within an adhesive or the fibers may substantially lie in the plane of the backing layer when lying flat. Also, preferably the fibers are applied randomly so that elongated fibers extend in all directions within the plane. Such application can be, for example, via entraining the fibers within an adhesive matrix that gets applied to the back sealing layer82, by flocking the fibers onto an adhesive layer, by attaching and adhering a woven or non-woven cloth containing the fibers thereto, or the like when the canvas is flat.

The fibers should be chosen to have sufficient elasticity to accommodate rolling of the diamond art canvas22to a diameter of about 1-3 inches without exceeding the elastic limit of the fiber when the diamond art canvas is rolled up and placed in a shipping tube, but sufficient stiffness to urge the canvas22back to the fibers' at-rest position in which the diamond art canvas22can lay flat, substantially without wrinkles or curved edges. It has been determined that fibers having a length of about 1-10 mm (preferably 1 to 4 mm) and a tensile strength greater than about 700 MPa, or more preferably greater than about 900 MPa, and/or a Young's Modulus of greater than about more preferably greater than about 20 GPa, and even more preferably greater than about will sufficiently bias the diamond art canvas22to lie flat so as to overcome most or all of the tendency of other layers to wrinkle or maintain a curve when being unrolled after being rolled up for some time. In order to accommodate such rolling, however, it has been determined that fibers should have a tensile strength less than about 2000 MPa, and more preferably less than about 1800 MPa, and/or a Young's modulus less than about 45 GPa, and more preferably less than about so as to allow rolling of the canvas22as needed to place the canvas22in the tube70for storage and transport.

In some variations, the backing layer90comprises a composite material comprising bamboo fibers entrained in an adhesive matrix. The bamboo fibers can have an average length between about 10-40 mm and an average diameter of about 10-30 μm. Such bamboo fibers can be chemically or mechanically treated and can have a tensile strength between about 930-1770 MPa and/or a Young's modulus of between about 26.85-34.62 GPa, or about 26-35 GPa. The bamboo fibers preferably are applied within the backing layer90so as to, when at rest, lie at a plane. In other words, the bamboo fibers may be entrained in the adhesive matrix when the diamond art canvas is in a flat position. After entraining the bamboo fibers in the adhesive matrix, the adhesive matrix is allowed to cure while flat. In this regard, when the diamond art canvas is rolled up, the fibers bend within the adhesive matrix but does not exceed its elastic limit. When the diamond art canvas is removed from the tube, the fibers help to bias the diamond art canvas to the flat position or its original position when it was first cured (i.e., in the flat position). In some variations, the bamboo fiber backing layer90can comprise an adhesive upon which bamboo fiber are flocked, typically using a puffer or blown application method so that the fibers are randomly applied with their lengths oriented randomly and within the plane of the backing layer90(and applied adhesive). The adhesive can be applied to the back sealing layer82prior to application of the fibers. By curing the adhesive with the backing layer90in a flat, or planar, disposition, the at-rest configuration of the fibers is established to urge the diamond canvas toward a flat disposition when taken out of the tube. Once cured, the bamboo fiber-reinforced backing layer90will be flexible enough to allow the diamond art canvas22to be rolled up and placed within a tube70. However, when the diamond art canvas22is removed from the tube70and unrolled, the bamboo fiber-reinforced backing layer90will urge the diamond art canvas22toward a flat orientation, resisting curled edges or wrinkles.

The composite backing layer90can be applied and configured in other ways. For example, in another variation fibers can be coated with adhesive and sprayed onto the back sealing layer82. Alternatively, an adhesive can be applied to the back sealing layer82and a woven or non-woven fabric made up of fibers having the desired tensile strength and Young's modulus characteristics can be applied to the adhesive. Such application preferably is performed while the substrate24is flat so that the at-rest configuration of the backing layer90(and the fibers that make it up) is flat.

In some variations, the backing layer90can be applied to the back sealing layer82prior to printing an image on the print layer86or flash layer88.

In still another variation, the textile layer can comprise a fabric made up of the same or similar fibers as are used in the backing layer. Such fibers can be bamboo fibers and/or other fibers having the desired tensile strength and Young's modulus characteristics as discussed herein. By way of example and not limitation, the various aspects discussed herein has been discussed in relation to bamboo fibers. However, other fibers can be used instead of or in combination with bamboo fibers. These other fibers include but are not limited to hemp fibers, fibers from the ramie plant, flax fibers, jute fiber, kenaf orhibiscus cannabinusfiber, sisal or agave sisalana fiber, pineapple orAnanas comosusfiber, coconut coir fiber, or combinations thereof.

The embodiments discussed above have disclosed structures with substantial specificity. This has provided a good context for disclosing and discussing inventive subject matter. However, it is to be understood that other embodiments may employ different specific structural shapes and interactions.

Although inventive subject matter has been disclosed in the context of certain preferred or illustrated embodiments and examples, it will be understood by those skilled in the art that the inventive subject matter extends beyond the specifically disclosed embodiments to other alternative embodiments and/or uses of the invention and obvious modifications and equivalents thereof. In addition, while a number of variations of the disclosed embodiments have been shown and described in detail, other modifications, which are within the scope of the inventive subject matter, will be readily apparent to those of skill in the art based upon this disclosure. It is also contemplated that various combinations or subcombinations of the specific features and aspects of the disclosed embodiments may be made and still fall within the scope of the inventive subject matter. Accordingly, it should be understood that various features and aspects of the disclosed embodiments can be combined with or substituted for one another in order to form varying modes of the disclosed inventive subject matter. Thus, it is intended that the scope of the inventive subject matter herein disclosed should not be limited by the particular disclosed embodiments described above.