Abstract:
The present invention relates to an image in relief created by thermo, pressure or vacuum forming a sheet of printed, clear or opaque plastic, styrene, PVC, PET or any similar material capable of forming and holding a form against stacked levels of die cut (or pre-cut) materials (the tool or pattern), one on top of another. The tool is left inside the relief cavity to provide structure, making it durable and therefore commercially viable for one-off, personalized relief images.

Description:
[0001]    This application claims the benefit of U.S. provisional patent application Ser. No. 61/072,050, filed Mar. 27, 2008, for single use thermoforming tool and method. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    (a) Field of the Invention 
         [0003]    The present invention relates to a relief image and a method for making said relief image, created by thermo, pressure or vacuum forming a sheet of printed, clear or monochromatic styrene, PVC, PET, plastic, polymer or any material capable of forming and holding a form against a molding tool composed of stacked levels of die cut materials, one on top of another. The molding tool is left inside the relief cavity to provide structure, making it durable and therefore commercially viable. The tool creates a low-cost, single-use relief pattern. 
         [0004]    (b) Background of the Invention 
         [0005]    The thermoforming process is a process by which a thermoplastic sheet or film is heated between infrared, natural gas, or other heaters to its forming temperature and molded over a temperature-controlled, single-surface molding tool. Customarily, the same tool is used over and over again to produce multiple relief images. Typically, durable, rigid, costly materials such as cast or machined aluminum, epoxy, hard resins, and wood materials are used to create the molding tool in order to withstand thousands of thermoforming cycles. Due to the high costs associated with tool making and thermoforming, the process has generally been relegated to large projects ranging from thousands to millions of units. Furthermore, the process typically requires someone with high technical skills familiar with CAD/CAM software programs and is expensive. The expertise needed typically results in time consuming, high billable hours. Even hand crafting or sculpting molding tools can be time consuming and somewhat expensive. The expense of producing a molding tool prevents the creation of “one-of-a-kind” personalized relief images for the average consumer. A need exists for creating single-use relief images using low-cost, disposable components. 
         [0006]    The Inventor is not aware of any prior art addressing the problem of a single use relief image and tool. 
       SUMMARY OF THE INVENTION 
       [0007]    The present invention addresses the shortcomings of the prior art and provides for, among other things, a low cost single-use, three dimensional print. 
         [0008]    The molding tool of the present invention uses low-cost, disposable materials such as cardboard, dense foam, plastic, wood, among other similar materials capable of being formed against. The materials are preferably cut from a single substrate in one or more layers based on the desired projection of the elements in a base image. The layers are stacked upon one another with the rearmost layer being at the base and the foremost layer being at the top. Preferably layers are numbered once they are outlined and cut from the substrate to simplify the making of the molding tool. Each layer is adhered to the layer above and below it using any means of adhesion, such as glue. 
         [0009]    A thermoplastic or polymer sheet or film that is printed, clear or opaque is preferably used. The thermoplastic sheet or film is then covered in a material such as a laminate or coating to protect the inks during and after the thermoforming process. The thermoplastic or polymer sheet or film is then heated between infrared, natural gas, or other heaters to reach its forming temperature. The thermoplastic sheet or film is then molded over the molding tool to form a relief cavity. In producing “one-of-a-kind” personalized relief images, the tool remains inside the relief cavity to provide structure, adding durability and value to the relief image. 
         [0010]    The purpose of the present invention is to provide quick, affordable three-dimensional prints for the average consumer. The present invention utilizes a simple software program that allows one to trace and cut elements or vectors of a two-dimensional image to create a three-dimensional relief image. The process also provides for a quick, low cost mechanism for rapid prototyping, as opposed to known, more expensive techniques, which require expertise with vectors, tool paths, etc. The process for creating a single-use molding tool comprises selecting a base image, indicating one or more elements at least partially corresponding to the base image, cutting a substrate to correspond with the one or more elements, repeatedly indicating elements and cutting substrate for each of one or more layers of substrate, wherein the indicated elements for each layer of substrate are a subset of the elements indicated for the previous layer of substrate, aligning and stacking the one or more layers of substrate, and adhering together the one or more layers of substrate. Even more particularly, the substrate is an inexpensive, disposable material, such as cardboard, foam, plastic, or wood. 
         [0011]    In another embodiment, the present invention is a decoration comprising a molding tool and a thermoplastic material. More particularly, the molding tool comprises one or more layers of elements, the elements substantially corresponding to at least a portion of a base image. Even more particularly, at least a portion of the thermoplastic material is raised and formed into contours of varying elevations, the contours substantially corresponding to the molding tool. 
         [0012]    In yet another embodiment, the present invention is a method of producing a relief image, wherein a user will indicate one or more elements of a base image to be in relief, indicate a subset of the one or more elements of the previous step to be in relief from the one or more elements of the previous step, repeat the previous step until all elements corresponding to the desired relief image are indicated, cut each element from a substrate, align, stack, and attach each of the one or more elements atop the one or more elements of the previous step, forming a molding tool, align the molding tool on a backer, print the base image on a material capable of forming and holding a form, align the base image on the material capable of forming and holding a form with the molding tool, form the material capable of forming and holding a form against the molding tool, and attach the material capable of forming and holding a form to the backer using an attachment means, whereby the molding tool is retained between the material capable of forming and holding a form and the backer. More particularly, the material capable of forming and holding a form is plastic, styrene, PVC, PET, or a polymer. Even more particularly, the material capable of forming and holding a form is laminated or coated. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0013]    A better understanding of the present invention will be had upon reference to the following description in conjunction with the accompanying drawings, wherein: 
           [0014]      FIG. 1  shows the multiple layers of the relief image of the present invention; 
           [0015]      FIG. 2  shows the process of creating the molding tool; 
           [0016]      FIG. 3  shows the process of forming the relief image; 
           [0017]      FIG. 4  shows a base photo from which a relief image will be made; 
           [0018]      FIG. 5  shows an outline of a first layer of the molding tool; 
           [0019]      FIG. 6  shows an outline of a second layer of the molding tool; 
           [0020]      FIG. 7  shows an outline of a third layer of the molding tool; 
           [0021]      FIG. 8  shows an outline of a fourth layer of the molding tool; 
           [0022]      FIG. 9  shows an outline of a fifth layer of the molding tool; 
           [0023]      FIG. 10  shows an outline of a sixth layer of the molding tool; 
           [0024]      FIG. 11  shows an outline of a composite of the layers of  FIGS. 5-10  stacked to created the molding tool; and 
           [0025]      FIG. 12  shows another view a composite of the layers of  FIGS. 5-10  stacked to create the molding tool. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
       [0026]    With reference to the figures, the relief image  10  of the present invention comprises a thermoplastic  11  or polymer sheet or film, an adhesive  13 , a molding tool  12 , and a backing material  14 . The thermoplastic  11  or polymer may be any type, such as styrene, PVC or PET, capable of being molded through use of a heating element  33 , a molding tool  12 , and a molding means  35 , such as temperature, pressure, or a vacuum. 
         [0027]    Initially, a base image  21  from which a relief image  10  is to be made is imported  22  into a computer. An outline of the elements  23  is created of each of the elements  23  of the base image  21  for which the relief is desired. Image elements  23  may be outlined manually, or through software applications such as CorelDraw® or Adobe Photoshop®, saved and sent  25  to the laser for cutting. In a preferred embodiment, the outline of the elements  23  will have varied widths based upon the purpose of the line. For example, if the line is intended to be cut for the layer, it may be of a thicker width  51 , whereas a line intended for the purposes of alignment may be a more narrow width  52 . Alternatively, lines  51  and  52  can be distinguished in other ways, such as by color, dashed, or dotted lines. 
         [0028]    A relief image  10  will have multiple layers as a function of the elements  23  in the base image  21  and client preferences. A first layer  15  consists of a total relief area (i.e., the entire subject of the relief image). Each additional layer will be created in the same manner as the first, except that the elements  23  being outlined will vary based further upon the elements  23  of the base image  21  and client preferences. Each layer  15 ,  115 ,  215 ,  315 ,  415 ,  515  represents a farther projection of the elements  23  into three dimensional space. Referring to  FIG. 4 , the base image  21  is of a man holding a fish standing next to a second man. A user can determine individual elements  23  of the base image  21  that would give the base image  21  a natural three dimensional appearance. By projecting certain elements  23  of an image, a degree of realism can be obtained.  FIG. 5  shows the first layer  15  as an outline of the man  41  holding the fish, the fish  42 , and the second man  43  standing next to the man  41  holding the fish.  FIG. 6  shows the second layer  115  as a further outline of the man  41  holding the fish and the fish  42 .  FIG. 7  shows the third layer  215  as a further outline of the head  44 , right arm  45  and left hand  46  of the man  41  holding the fish, and the fish  42 .  FIG. 8  shows the fourth layer  315  as a further outline of the fish  42 .  FIG. 9  shows the fifth layer  415  of the right arm  45  and left hand  46  of the man  41  holding the fish.  FIG. 10  shows the sixth layer  515  of outlines of the fins  47  of the fish.  FIG. 11  shows a top view of each layer  15 ,  115 ,  215  &amp;  315  as the overlay of  FIGS. 5-10  to create the molding tool  12 .  FIG. 12  shows an angular view of the composite of  FIG. 11 , showing the three dimensions of the molding tool  12 . 
         [0029]      FIG. 5-10  consist of both thick, dark lines  51  and narrow, light lines  52 . The thick, dark lines  51  are used as an indication that the substrate is to be cut there along to create the layer. The narrow, light line  52  is used as a means to assist alignment  26  of the layers  15  during the stacking  27  process. In a preferred embodiment, a laser cutting device, such as, for example, an Epilog® laser, is capable of receiving instructions based on line width, and will cut  24  the substrate all the way through, or using a “kiss cut” method, along line widths of a thickness range determined by the user and will partially cut  24 , or “etch” the substrate along line widths not within that range. A kiss cut is a technique where the cut is completely through the substrate and adhesive up to, but not including an adhesive backing liner. The narrow, light lines  52  should be significant lines of the base image to aid the alignment of important features. Template of cut-out elements of the image may also be used to assist in the alignment of certain layers during the stacking  27  process. 
         [0030]    Once the layers  15 ,  115 ,  215 ,  315 ,  415 ,  515  are cut, the layers  15 ,  115 ,  215 ,  315 ,  415 ,  515  should be aligned  26 , stacked  27  and adhered  28  together, until the entire molding tool  12  is created. The order of the outlined layers  15 ,  115 ,  215 ,  315 ,  415 ,  515  should begin with the entire outlined area as the base layer  15 , followed by continually more projected layers, until the final layer  15  is the foremost layer  515 , comprised of the foremost elements  23  in the base image  21 . Each layer  15 ,  115 ,  215 ,  315 ,  415 ,  515  should generally, but not necessarily, be cut  24  from the same substrate to minimize costs and ensure consistency in the molding tool  12 . The substrate should be a lost-cost, disposable material such as cardboard, dense foam, plastic, or wood. Depending upon the substrate used to create the molding tool  12  (i.e. rigid polymer or thin flexible wood), layers  15 ,  115 ,  215 ,  315 ,  415 ,  515  could be shaved or sanded to create modeling or rounding if desired. 
         [0031]    In a preferred embodiment, the base image  21  is then printed  31  in color (if desired) on a thermoplastic  11  or polymer sheet or film such as 15 ml styrene and in black and white on a printable substrate such as card stock. A cost-effective way to do this would be through digital printing with the use of an HP Indigo Printer or Xerox iGen. In an alternative embodiment, the molding tool may be used to thermoform a thermoplastic or polymer sheet or film without a printed base image, wherein the projection of the layers create the image. Preferably, the styrene will be laminated  32  or coated to protect any inks of the base image. 
         [0032]    Corner guides or holes are punched into card stock and printed thermoplastic  11  for sheet or pin registration  34  on thermoforming equipment. The card stock or other printed substrate is placed on a platen using pin registration  34 . A platen is typically a flat metal plate having holes to allow vacuum suction. A registration pin  34  or corner guide is a device intended to hold a piece of film, paper or other material in place. Registration pins  34  or corner guides are used in the thermoforming process, in order to accurately position the different films or plates for multi-layer work. 
         [0033]    The layers are stacked and aligned using the registration pin or corner guides and the printed image on card stock. A non-printed sheet of card stock, or template, with a cut-out of the image to be formed in relief, could serve as an alternative means of aligning the tool. The printed styrene is formed  34  with the print side up on top of molding tool using pin registration to form the printed styrene relief image. A molding means  35 , such as a vacuum, thermo, or pressure is then applied to create a tight fit of the thermoplastic  11  around the molding tool  12 . Once registered and formed, any excess portion of the thermoplastic  11  or polymer is cut away and the molding tool  12  is left in back of printed styrene  11  to serve as its structure. An adhesive  13 , such as a pressure sensitive adhesive (PSA) is placed on a separate card stock  14  or other material backing to adhere  36  the card stock  14  to the styrene  11 , and being adhered  36  in such as fashion as to prevent movement of the molding tool  12  inside the relief image  10 . The PSA  13  in the present invention may be a sheet adhesive or, alternatively, just an adhesive coating. Alternatively, the molding tool  12  can be left out of the relief image for a hollow thermoform relief image. 
         [0034]    The foregoing detailed description is given primarily for clearness of understanding and no unnecessary limitations are to be understood therefrom for modifications can be made by those skilled in the art upon reading this disclosure and may be made without departing from the spirit of the invention.