Abstract:
A bead-forming apparatus and method for its use are described. The bead-forming apparatus includes a base with a pair of legs extending from a top surface. First ends of the legs couple to respective eccentric elements. The eccentric elements removeably and rotatably couple to a platen. Second ends of the legs are rotatably and slideably mated with a gear train disposed within the base. The legs are slideably translatable into the base and the gear train maintains a rotational orientation of the legs and the eccentric elements coupled thereto. The platen is thus moveable through a circular path defined by the rotation of the eccentric elements and legs. As such, a plug of moldable material placed between the base and the platen and in contact with the platen, is formed into a double-cone shape by movement of the platen through the circular path.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This Application is a continuation-in-part of U.S. patent application Ser. No. 13/399,559, filed Feb. 17, 2012, entitled “Bead-Forming Apparatus,” which claims priority to U.S. Provisional Patent Application Ser. No. 61/444,355, filed Feb. 18, 2011, the disclosure of both of which are hereby incorporated herein in their entirety by reference. 
    
    
     SUMMARY 
     Embodiments of the invention are defined by the claims below, not this summary. A high-level overview of various aspects of the invention are provided here for that reason, to provide an overview of the disclosure, and to introduce a selection of concepts that are further described below in the detailed-description section below. This summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used as an aid in isolation to determine the scope of the claimed subject matter. 
     Embodiments of the invention include apparatus and methods for making beads from moldable materials such as modeling clay. A bead-forming apparatus is provided that includes an upper platen and a stationary base coupled via a pair of eccentric elements. A portion of one or more modeling materials are pressed together to form a generally spherical form and the materials are placed between the base and upper platen. The upper platen is pressed toward the base to contact the modeling material and is moved through a circular path defined by rotation of the eccentric elements; the circular path is larger in diameter than the upper platen. As such, the portion of modeling material is formed into a double cone shape and the modeling materials are swirled together. 
    
    
     
       DESCRIPTION OF THE DRAWINGS 
       Illustrative embodiments of the invention are described in detail below with reference to the attached drawing figures, and wherein: 
         FIG. 1  is a top view of a bead-forming apparatus and a number of beads made thereby in accordance with an embodiment of the invention; 
         FIG. 2  is an elevational view of the bead-forming apparatus depicted in  FIG. 1 ; 
         FIG. 3  is a bottom view of the bead-forming apparatus depicted in  FIG. 1 ; 
         FIG. 4  is a view of components of the bead-forming apparatus depicted in  FIG. 1  in a partially dismantled condition; 
         FIG. 5  is an exploded view of a bead-forming apparatus in accordance with an embodiment of the invention; 
         FIGS. 6A-6D  are series of top plan views of the bead-forming apparatus depicted in  FIG. 1  showing movement of a top platen along a circular path in accordance with an embodiment of the invention; 
         FIGS. 7A-7F  are a series of views of modeling materials being prepared for use with the bead-forming apparatus depicted in  FIG. 1  in accordance with an embodiment of the invention; 
         FIGS. 8A and 8B  are side elevational views of the bead-forming apparatus depicted in  FIG. 1  with the modeling materials of  FIG. 7  disposed therein in accordance with an embodiment of the invention; 
         FIG. 9  is a top plan view of the bead-forming apparatus depicted in  FIG. 1  with the modeling materials of  FIG. 7  formed into a double cone bead in accordance with an embodiment of the invention; 
         FIG. 10  is a perspective view of a bead-forming apparatus, in accordance with an embodiment of the invention; 
         FIG. 11  is a perspective view of the bead-forming apparatus of  FIG. 10 , with the pivoting arm in a partially raised position; 
         FIG. 12  is a perspective view of the bead-forming apparatus of  FIG. 10 , with an amount of modeling material being processed by the apparatus in accordance with an embodiment of the invention; and 
         FIG. 13  is a perspective view of a portion of the bead-forming apparatus of  FIG. 10 , with internal portions of the apparatus exposed, in accordance with an embodiment of the invention. 
     
    
    
     DETAILED DESCRIPTION 
     The subject matter of embodiments of the invention is described with specificity herein to meet statutory requirements. But the description itself is not intended to necessarily limit the scope of claims. Rather, the claimed subject matter might be embodied in other ways to include different steps, components, or combinations thereof in conjunction with other present or future technologies. Terms should not be interpreted as implying any particular order among or between various steps herein disclosed unless and except when the order of individual steps is explicitly described. 
     The manufacture of beads for use as ornamentation and jewelry has been practiced since ancient times. Beads may be formed from moldable materials such as clay, glass, metals, plastics, and the like as well as non-moldable materials like gemstones. Many techniques are employed by bead makers to produce desired shapes or forms of beads. Techniques are also used to provide desired appearances to the beads, such as by layering, mixing, blending, or swirling together multiple constituent materials. 
     Embodiments of the invention provide apparatus and methods for producing beads from moldable materials. The materials include any modeling compounds or the like. For example, the materials might include flour-based doughs, rice-based doughs, earth clays, modeling clay, oil-based clays, and the like. In an embodiment, the materials are one or more of Dough, Air-Dry Clay, Modeling Clay, and Model Magic® available from Crayola LLC of Easton, Pa. The materials can be air-dry or kiln dry and can be reusable. 
     In an embodiment, the materials are sufficiently soft or malleable to be capable of forming by hand and with a bead-forming apparatus as described more fully below. The materials may require pre-working or softening prior to use. The materials also have sufficient viscosity to sufficiently retain a shape or form into which they have been formed. 
     The materials are provided in various colors and include any desired additives or other components to provide a desired physical property or appearance. In an embodiment, multiple separate materials are used; each having a different color or colors. 
     With reference to the figures, and to  FIGS. 1-5  in particular, a bead-forming apparatus  100  is described in accordance with an embodiment of the invention. The components described below are constructed by manufacturing methods and from materials known in the art such as, for example, and not limitation, injection molded plastics. However, any desired manufacturing methods and materials may be used in embodiments of the invention without departing from the scope described herein. 
     The apparatus  100  includes a base  102 , a pair of eccentric discs  104 , and an upper platen  106 . As depicted best by  FIGS. 4 and 5 , the base  102  includes a base plate  108  and a cover  110  with three gears  112 ,  114 , and  116  disposed therebetween. The cover  110  includes a pair of apertures  117  to provide access to the gears  112  and  116 , as described more fully below. The base plate  108  and/or the cover  110  also include one or more features extending from an interior surface thereof that form axles  118 ,  120 , and  122  upon which the gears  112 ,  114 , and  116  are disposed, respectively. The axles  118 ,  120 ,  122  are configured such that the gear  112  meshes with the gear  114  and the gear  116  also meshes with the gear  114 . The gears  112 ,  114 , and  116  are depicted herein as spur gears, however, any desired gear configuration and transmission design that produces the below described motion may be employed without departing from the scope of embodiments of the invention. 
     The gears  112  and  116  include a coaxially located projection  124  and an aperture  126  configured to accept a spring  128  and a leg  130 . The projection  124  extends perpendicular to a side surface of the gears  112 / 116  a distance to allow sufficient travel of the leg  130 , as described more fully below. The aperture  126  passes through the gear  112 / 116  and through the projection  124 . The aperture  126  has a cylindrical cross-sectional shape throughout the majority of its length and has a polygonal cross-sectional shape at a terminating face  132  of the projection  124 . In an embodiment, the cross-sectional shape is a square, however any desired shape might be employed. The polygonal cross-sectional shape is configured to accommodate a corresponding shape of the leg  130 . The polygonal cross-sectional shape of the leg  130  and the aperture  126  allow the leg  130  to be slideably disposed therein and also rotationally couples the leg  130  and the gear  112 / 116  such that rotation of the leg  130  rotates the respective gear  112 / 116  and vice versa. 
     The leg  130  also includes an annular flange  134  near a first end  136  of the leg  130 . The annular flange  134  is configured to fit within the aperture  126  but to interact with the polygonal cross-sectional shaped terminating face  132  of the projection  124  such that the leg  130  cannot be removed from the gear  112 / 116  through the terminating face  132 . Additionally, a hollow  138  is provided in the first end  136  of the leg  130 . The hollow  138  has sufficient dimensions to slideably accept the axle  118 / 122  therein. 
     With additional reference to  FIG. 7 , the eccentric discs  104  are each a generally circular plate having a coupling  140  to the leg  130  along a bottom side thereof and a pin  142  disposed on a top side thereof. In an embodiment the eccentric discs  104  have any desired shape. The coupling  140  and the pin  142  are located near opposite edges of the disc  104 , e.g. near opposite ends of a line drawn along a diameter of the disc  104 . In embodiments, the coupling  140  and pin  142  are configured in any desired positions on the eccentric discs  104  in which the pin  142  is not coaxially aligned with the coupling  140 . The pin  142  provides a removable coupling to the upper platen  106 . 
     With continued reference to  FIGS. 1-5 , the upper platen  106  is a generally circular plate having a pair of apertures  144  and associated coupling apparatus  146  disposed near opposite edges thereof. The apertures  144  are located in a bottom surface  148  of the platen  106  and are configured to simultaneously align with the pins  142  on both of the eccentric discs  104 . The coupling apparatus  146  includes a pair of jaws  147  that engage a depression (not shown) in the side of the pin  142  when inserted into the aperture  144 , however any known coupling apparatus might be employed. The coupling apparatus  146  and the pins  142  provide a rotatable coupling between the eccentric discs  104  and the upper platen  106 . An upper surface  150  of the platen  106  includes a handle  152  extending therefrom and a pair of release buttons  154  that correspond with each of the coupling apparatus  146  and apertures  144 . The handle  152  is rotatably coupled to the upper platen  106 . 
     With additional reference now to  FIGS. 6-9 , operation of the bead-forming apparatus  100  to produce a double cone bead  156  is described in accordance with embodiments of the invention. As depicted at  700  in  FIG. 7 , portions  702  and  704  of two differently colored modeling materials are selected. In an embodiment, any number of modeling materials, including a single modeling material, is used. As depicted at  706 , the portions  702  and  704  are pressed together and may be twisted, folded, or otherwise formed as shown at  708 . The combined two portions  702 / 704  might be formed into a generally spherical shape or plug  710  as depicted at  712  but, such is not required. The plug  710  is placed on top of the base  102  as shown at  714 . The upper platen  106  is coupled to the eccentric discs  104  by inserting the pins  142  into the apertures  144  and engaging the coupling apparatus  146 , as depicted at  816  and  FIG. 8A . 
     The upper platen  106  is depressed toward the base  102  thereby contacting and at least partially compressing the plug  710 , as depicted in  FIG. 8B . Depressing the upper platen  106  slides the legs  130  through the apertures  126  compressing the springs  128  between the first end  136  of the legs and the base plate  108 . 
     The upper platen  106  is moved along a circular path as depicted in  FIG. 6 . The upper platen  106  does not rotate with respect to the base  102  but rather, is translated through the circular path as defined by the eccentric discs  104 . Movement of the upper platen  106  rotates the eccentric discs  104  about their couplings  140  with the legs  130 . This rotation further rotates the legs  130  and thus the gears  112  and  116 . The rotation of the eccentric discs  104  and the legs  130  with respect to one another is maintained in synchronization by the gears  112 ,  114 , and  116 . As such, rotation of one eccentric disc  104  or leg  130  equally rotates the other eccentric disc  104  and leg  130  even without engagement of the upper platen  102 . 
     Movement and depression of the upper platen  106  continues until a desired form is produced from the plug  710 , as depicted in  FIG. 9 . The amount of depression of the upper platen  106  may be slowly reduced during movement of the upper platen  106  to allow formation of the plug  710  into the double cone bead  156  as depicted in  FIGS. 1 and 9 . Alternatively, depression may be maintained while movement of the upper platen  106  is halted to produce a more organic, oblong, flattened form as desired. 
     In addition to producing the double cone bead  156 , depression and movement of the upper platen  106  also produces swirling of the modeling materials  702  and  704  as depicted in  FIG. 1 . As such, an amount of depression and duration of movement of the upper platen  106  may be tailored to provide a desired amount of swirling of the modeling materials  702  and  704 . 
     With reference now to  FIGS. 10-13 , a bead-forming apparatus  200  is described in accordance with embodiments of the invention. The components described below are constructed by manufacturing methods and from materials known in the art such as, for example, and not limitation, injection molded plastics. However, any desired manufacturing methods and materials may be used in embodiments of the invention without departing from the scope described herein. 
     The apparatus  200  includes a base  202 , a pair of side supports  204  and  206 , a first roller  208 , a second roller  210 , and a third roller  212 . As will be understood, although apparatus  200  is depicted as including first, second, and third rollers  208 ,  210 , and  212 , apparatus  200  may include, in further embodiments, additional rollers and/or gears that operate in conjunction with the rollers and gears depicted in association with apparatus  200 . In embodiments, side supports  204  and  206  include knobs  214  and  216  coupled to the base  202  of apparatus  200 . In embodiments, rotation of one or both of knobs  214  and  216  causes rotation of the corresponding rollers coupled directly or indirectly to knobs  214  and  216 . For example, rotation of knobs  214  and  216  causes rotation of first roller  208  in a first direction, rotation of second roller  210  and third roller  212  in a second direction. 
     First, second, and third rollers  208 ,  210 , and  212  are generally cylindrical in shape, having a curved outer surface against which a moldable material may be advanced and/or formed during operation of the apparatus  200 . The curved outer surface of first, second, and third rollers  208 ,  210 , and  212  may be smooth in texture, or may have an amount of surface texture added to the roller&#39;s outer surface. Accordingly, in one embodiment, second roller  210  has a texture on the curved outer surface that allows an amount of modeling material  230  to grip and/or conform to the surface of the second roller  210  as it advances between the first and second rollers  208  and  210 . In one example, the rough texture of second roller  210  contacts at least a portion of a modeling material  230  advancing between the first roller  208  and the second roller  210 , which is then detached from the rough surface of second roller  210  using a lead-in edge  220  adjacent the second roller  210 . In further embodiments, first, second, and third rollers  208 ,  210 , and  212  vary in size, such as the circumference of second roller  210  being larger than first roller  208 , which may in turn be larger than the circumference of third roller  212 . 
     As shown in  FIG. 11 , the lead-in edge  220  is adjacent the second roller  210 , having a first edge  222  that contacts the modeling material  230  advancing over the outer surface of second roller  210 . The lead-in edge  220  may be any sort of surface for contacting the modeling material  230  advancing off of second roller  210 , such as a plastic or metallic surface integral to a top surface the base, which separates the modeling material  230  from the outer surface of the second roller  210 . In one embodiment, the first edge  222  of lead-in edge  220  is a curved tip that shears the modeling material  230  off of the second roller  210 . In other embodiments, the first edge  222  of lead-in edge  220  is a straight blade. 
     In one embodiment, as depicted in  FIG. 12 , an amount of modeling material  230  is processed by the bead-forming apparatus  200  by passing the modeling material  230  between first roller  208  and second roller  210  from a back side of the apparatus  200 . For example, modeling material  230  is advanced between first roller  208  and second roller  210  based on the counter-rotation of each roller (i.e. the first roller  208  rotating in a first direction and the second roller  210  rotating in a second direction). As such, modeling material  230  becomes flattened between first roller  208  and second roller  210 , and continues advancing through the apparatus  200  based on continued rotation of one or both of the knobs  214  and  216  on each side of the apparatus  200 . In embodiments, based on an amount of pressure applied to modeling material  230  by the first roller  208  and second roller  210 , the thickness of the flattened portion of the modeling material  230  may vary. In some embodiments, the thickness of the flattened portion of modeling material  230  depends upon an amount of space between first roller  208  and second roller  210 , as well as the rotation of each roller with respect to one or more gears associated with the apparatus  200 , as discussed below. 
     Having passed between first and second rollers  208  and  210 , a first end  232  of modeling material  230  is sheared from contact with the second roller  210  based on contact with at least a portion of the lead-in edge  220 . The modeling material  230  then contacts the surface of rotating third roller  212  and forms a coiled bead  234 . Accordingly, rotation of knobs  214  and  216  causes the coordinated rotation of first, second, and third rollers  208 ,  210 , and  212  to advance modeling material  230  through the apparatus  200  to produce a coiled bead  234 . In embodiments of the invention, coiled bead  234  is formed when the first end  232  of modeling material  230 , flattened between first and second rollers  208  and  210 , disengages from the surface of second roller  210 , contacts the surface of third roller  212 , and coils back upon itself, as shown in  FIG. 12 . In other words, rotation of first roller  208  in a first direction and second roller  210  in a second direction causes coiling of modeling material  230  into a coiled bead  234  formed upon rolling the first end  232  of modeling material back into the first direction (based on contacting the third roller  212  rotating in the second direction). 
     Embodiments of the apparatus  200  may also be used to produce a flattened portion of modeling material  230 , without forming a coiled bead  234 . For example, with reference to  FIG. 11 , first roller  208  and third roller  212  are supported at least in part, by pivoting arm  218 . In embodiments, pivoting arm  218  is coupled to third roller  212  at a first end  226 , and first roller  208  at a second end  228 . First end  226  of pivoting arm  218  may be “locked” into position with respect to the base  202  by engaging at least a portion of the first end  226  of pivoting arm  218  against a contact surface  224  of the base  202 , thereby restricting the pivoting of pivoting arm  218  at the second end  228 . In embodiments, detent snaps on one or both sides of the pivoting arm  218  engage with the contact surface  224  to restrict movement of the first end  226  of pivoting arm  218 . For example, during processing of a coiled bead  234 , the pivoting arm  218  is locked into a first position engaged against the contact surface  224  of base  202 , such as the locked position depicted in  FIGS. 10 and 12 . In another example, as shown in  FIG. 11 , the pivoting arm  218  may be raised and/or disengaged from base  202  (and from contact surface  224 ). By raising pivoting arm  218  into an upward position with respect to the base  202 , the third roller  212  is removed from the path of travel of modeling material  230 , and therefore does not contact the first end  232  of modeling material  230  as it advances between first and second rollers  208  and  210 . 
     Turning now to  FIG. 13 , internal portions  236  of a bead-forming apparatus  200  are depicted according to an embodiment of the invention. In one embodiment, the internal portions  236  include a side panel  238  of the pivoting arm  218 , and a plurality of features  240  on the side panel  238  that mate to a plurality of gears  242  for rotation of one or more of the first, second, and third rollers  208 ,  210 , and  212 . In one embodiment, the plurality of gears  242  includes third gear  256  that is coupled to third roller  212 , thereby causing rotation of third roller  212  in the second direction. 
     In one example, projections  246  and  248  extend from the sides of pivoting arm  218  to couple to knobs  214  and  216 .  FIG. 13  also depicts first gear  252  rotating in a first direction and second gear  254  rotating in a second direction. In embodiments of the invention, rotation of first gear  252  in a first direction causes rotation of first roller  208  in the same, first direction, while rotation of second gear  254  in a second direction causes rotation of second roller  210  in the same, second direction, and rotation of third gear  256  causes rotation of the third roller  212  in the same, second direction. Accordingly, in one embodiment, the coupling of the plurality of gears  242  causes synchronous rotation of the plurality of gears  242  (including third gear  256 ) with first gear  252  and second gear  254 , based on rotation of the first gear  252 . The gears  242 ,  252 ,  254 , and  256  are depicted herein as spur gears, however, any desired gear configuration and transmission design that produces the motion described herein may be employed without departing from the scope of embodiments of the invention. 
     In one embodiment, the synchronous rotation of the respective gears provides for the controlled and/or continuous rotation of the first, second, and third rollers  208 ,  210 , and  212  during formation of a coiled bead  234  using the apparatus  200 . For example, rotation of the first gear  252  may cause rotation of the first roller  208  in a first direction, as well as rotation of the second gear  254  (causing rotation of the second roller  210 ) and third gear  256  (and corresponding third roller  212 ) in a second direction. In embodiments of the invention, the counter-rotation of first roller  208  and second roller  210  flattens modeling material  230 , as shown in  FIG. 12 , which is then tightly coiled by way of the third roller  212  applying pressure against the first end  232  of the modeling material  230 , to produce a coiled bead  234 . 
     Many different arrangements of the various components depicted, as well as components not shown, are possible without departing from the scope of the claims below. Embodiments of the technology have been described with the intent to be illustrative rather than restrictive. Alternative embodiments will become apparent to readers of this disclosure after and because of reading it. Alternative means of implementing the aforementioned can be completed without departing from the scope of the claims below. Certain features and subcombinations are of utility and may be employed without reference to other features and subcombinations and are contemplated within the scope of the claims.