Patent Publication Number: US-8522680-B2

Title: Apparatus for forming embossed and printed images

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a Continuation-in-Part and claims the benefit of the filing date of U.S. application Ser. No. 13/142,087 which is the National Stage under 35 U.S.C. §371 of International Application No. PCT/CN09/01119 filed Oct. 9, 2009, which claims the benefit of China Patent Application No. 200820136624.6, filed on Oct. 7, 2008. 
    
    
     BACKGROUND 
     1. Field of the Invention 
     The present invention relates generally to devices for creating embossed or printed images and more specifically, to an embossing or printing folder that includes interchangeable parts for producing embossed or printed images on paper when used in combination with a die press. 
     2. Background of the Invention 
     Various forms of die presses have been developed through the years which use individual die cutting blocks having blades, formed into a particular shape that are individually pressed against one or more sheets of paper to produce paper die cuts. More recently, such machines have been employed to produce embossed images in paper by subjecting an embossing device having a sheet of paper sandwiched therein to pressure generated by the die press. Each such prior art cutting or embossing device has been of a preset configuration with one or more preset images formed into the device. Thus, in order to generate a different image using such a device, a completely new device containing the desired image or pattern must be used. 
     Thus, there exists a need in the art to produce an embossing or printing folder that is capable of producing various embossed or printed images, patterns or other forms on paper using a single device with interchangeable components. 
     SUMMARY OF THE INVENTION 
     According to the present invention, a hinged paper embossing and printing device is provided with a plurality of interchangeable pieces that are temporarily held in the embossing device. In the case of embossing, a plurality of pairs of small plastic pieces having different patterns is inserted into small holes of large plastic sheets so as to press and emboss or print on paper inserted therein. 
     In one embodiment, the embossing and printing device is provided with a base panel and a top panel, the base and top panels being hingedly coupled to one another along one edge of each panel. The inner surfaces of each of the panels are provided with a plurality of holes for receiving protrusions provided on the back side of one or more pairs of insertable image pieces. 
     In an embossing configuration, each pair of insertable image pieces provides stereo relief images of one another so that recesses of one piece of the pair receive raised portions of the other piece of the pair, and vice versa. 
     In a printing configuration, a reverse image of the image to be printed on a sheet of paper is provided as a positive image on one or more of the image pieces. Corresponding pair pieces having flat surfaces are provided opposite the image pieces to provide a flat surface upon which the positive image can be pressed. Ink is placed on the positive image piece and a sheet of paper is placed between the top and base panels. Pressing of the top and base panel together, causes the ink on the positive image piece to be transferred to the paper. 
     To provide a hinge-type construction between the top and bottom panels, the base panel is provided with a pair of oppositely opposing tabs each having a pair of protrusions inwardly extending there from. The top panel is provided with a pair of tabs having through holes provided therein for engaging with the protrusions of the tabs of the bottom panel. The protrusions can snap into the through holes and pivot relative thereto thereby forming a hinge that allows the top and bottom panels to freely fold and unfold. 
     Each pair of image pieces are provided with positive and negative reliefs of the same image formed therein so that when pressed together raised portions of one piece will fit within the corresponding recessed portion of the corresponding piece. 
     The profiles of each piece can be machined or molded into the embossing and printing sides for generating printed patterns. The back sides of each piece are provided with protruding pegs for being received and held within corresponding holes formed in the inside surfaces of the base and top panels. 
     Accordingly, the present invention provides a device for embossing and printing that is of relatively simple construction and easy to assemble, of low cost and relatively easy to manufacture. The device for embossing and printing is easy to operate and allows end users to produce customized embossed and printed papers by selecting pieces of their own choosing. 
     The foregoing advantages and characterizing features will become apparent from the following description of certain illustrative embodiments of the invention. The above-described features and advantages of the present invention, as well as additional features and advantages, will be set forth or will become more fully apparent in the detailed description that follows and in the appended claims. The novel features which are considered characteristic of this invention are set forth in the attached claims. Furthermore, the features and advantages of the present invention may be learned by the practice of the invention, or will be obvious to one skilled in the art from the description, as set forth hereinafter. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The following drawings illustrate exemplary embodiments for carrying out the invention. Like reference numerals refer to like parts in different views or embodiments of the present invention in the drawings. 
         FIG. 1  is a perspective side view of a first embodiment of a printing and embossing folder according to the principles of the present invention. 
         FIGS. 2A and 2B  illustrate a top and cross-sectional side view, respectively of a base panel member of  FIG. 1 . 
         FIGS. 3A and 3B  illustrate a top and cross-sectional side view, respectively of a top panel member of  FIG. 1 . 
         FIG. 3C  illustrates a partial cross-sectional side view of a hinge structure in accordance with the principles of the present invention. 
         FIGS. 4A and 4B  illustrate a design tile having a positive relief in accordance with the principles of the present invention. 
         FIGS. 5A and 5B  illustrate a design tile having a negative relief that corresponds to the positive relieve of the design tile illustrated in  FIG. 4A  in accordance with the principles of the present invention. 
         FIG. 6  is a plan view of the printing and embossing folder with the design tiles illustrated in  FIGS. 4A and 5A  attached thereto. 
         FIG. 7  is a plan view of the printing and embossing folder with a plurality of different design tiles attached thereto according to the principles of the present invention. 
         FIG. 8  is a perspective side view of the printing and embossing folder with a sheet of paper disposed therein and the folder in an open position. 
         FIG. 9  is a perspective side view of the printing and embossing folder with the sheet of paper disposed therein and the folder in a closed position. 
         FIG. 10  is a perspective side view of the printing and embossing folder with the sheet of paper having been embossed and the folder in an open position. 
         FIG. 11A  is a top and side view of a printing and embossing tile in accordance with the principles of the present invention. 
         FIG. 11B  is a top and side view of a printing tile in accordance with the principles of the present invention. 
         FIG. 12  is a perspective top view of an alternative embodiment of a bottom panel member of an embossing folder in accordance with the principles of the present invention. 
         FIG. 13  is a perspective bottom view of the bottom panel member illustrated in  FIG. 12 . 
         FIG. 14  is a perspective back side view of a second embodiment of a printing and embossing folder according to the principles of the present invention. 
         FIG. 15  is a back side view of the printing and embossing folder illustrated in  FIG. 14 . 
     
    
    
     DETAILED DESCRIPTION OF THE ILLUSTRATED EMBODIMENTS 
     As shown in  FIG. 1 , there is illustrated a hinged paper embossing and printing folder, generally indicated at  10 , in accordance with the principles of the present invention. The folder  10  is comprised of a bottom panel member  1  and a top panel member  2  that are hingedly attached to each other with hinge mechanism  6 . The bottom and top panel members  1  and  2 , respectively, are of substantially the same size and shape so that the opposing surfaces  21  and  22 , respectively, are aligned and positioned adjacent to each other in a closed position. It should be noted that while the panel members  1  and  2  are referred to herein as top and bottom, respectively, the embossing and printing folder  10  can function equally well with the panel member  1  positioned on top and the panel member  2  positioned on the bottom. Thus, reference herein to the “top” and “bottom” is made for convenience and not by way of limitation. 
     To help align the bottom and top panel members  1  and  2 , each is provided with elongate protrusions  24  and  25  and recesses  26  and  27  positioned along the edges of each panel member  1  and  2 . When folded together, the protrusions  24  and  25  mate with respective recesses  26  and  27 . Because the protrusions are essentially trapezoidal in cross-sectional shape, the sides of the protrusions  24  and  25  can enter the respective recesses  26  and  27  even if not perfectly aligned and as they are forced together will bring the two into substantially perfect alignment as the sides of the protrusions  24  and  25  slide into engagement with the inside surfaces of the recesses  26  and  27 . Alignment of the top and bottom panel members  2  and  1 , respectively, is important for the embossing function to make sure that the corresponding embossing tiles  3  and  4  will properly mate when pressed together. 
     The opposing faces  21  and  22  are each divided into a grid of a plurality of individual squares  28 . Each square  28  is provided with four holes  11  that are positioned proximate the corners of each square  28 . The holes may be spaced approximately 0.5 inches apart. The squares are in abutting arrangement and are fixedly integrated into each panel member  1  and  2 . Individually designed tiles  3  and  4  are temporarily coupled to the panel members  1  and  2  with legs or pegs (not visible) that protrude from the back of the tiles  3  and  4  and engage with the holes  11  to hold the tiles  3  and  4  in place. The pegs engage with the holes  11  with a slight friction fit or a snapping action to hold the tiles  3  and  4  in place during use that also allows the tiles  3  and  4  to be easily removed from the panel members  1  and  2 . In this particular example, the tile  3  includes a protruding relief design on the top surface thereof. The tile  4  includes a recessed relief of the same design. When a sheet of paper is placed between the panels  1  and  2 , the panels  1  and  2  are firmly pressed together, as by running the folder  10  through a roller press machine known in the art, the raised relief design of the tile  3  and overlying sheet of paper is forced into the recessed relief design of the tile  4  causing the paper to be imprinted or embossed with the design. The other tiles illustrated in  FIG. 1  have a similar mating relationship so as to cause paper embossing in a similar fashion with the design of the particular tiles. Of course, the positive and negative relief tiles could be intermixed so that some of the positive relief tiles, such as tile  3 , are coupled to the panel member  1  while other positive relief members of other designs are positions on the panel member  2 . This allows various embossing designs to be created with both negative and positive reliefs simultaneously formed in the paper. Moreover, because there is virtually no limit to the designs of the tiles or to the positions of the tiles on the panel members  1  and  2 , a limitless number of custom embossed images can be created. It should also be noted that while the present embodiment is illustrated as having holes in the panel members  1  and  2  for holding the tiles with pegs, the panels could provide pegs with holes provided in the backs of the tiles. 
     As illustrated in  FIGS. 2A and 2B , the base panel member  1  includes a grid of equally spaced squares  28  disposed over a substantial portion of the inner surface  21 . Each square is defined by a small groove  29  that circumscribes each square  28 . The entire grid  30  of squares  28  is slightly recessed into the surface  21  such that a raised perimeter  32  is formed around the grid  30 . Each square  28  is provided with a plurality of holes  11  (four in this embodiment) that are disposed proximate the corners of each square  28 . The holes  28  extend a distance into the panel member  1 , but do not extend completely through the panel member  1 . To form a hinge  6 , as shown in  FIG. 1 , a pair of laterally positioned hinge pins  12  is attached to the panel member  1  with protruding hinge pin support members  34  and  36  along the hinge side  13  of the panel member  1 . The hinge pins  12  are configured to snap into hinge components provided in the upper panel member as shown in  FIGS. 3A and 3B  herein. It is further contemplated that other hinge-type arrangements may be employed including forming the two panels  1  and  2  from a single piece of material, such as plastic with a “living” hinge interconnecting the two panel members along an entire length of one side or partially along one side. Likewise, the hinge may be provided by a piece of adhesive tape that interconnects the two panels to form a hinge. 
     The sizes of base member  1  may be of any reasonable size and shape and may be configured to fit within the throat of a particular brand and model of die cut press known in the art. Thus, folder  10  may have a width W to length L ratio of 4 to 6, with the height H to width ratio being about 4 to 1. The height H may be 1 to 4 mm and the diameter of each hole  11  may be about 1.6 mm with the hole depth H 1  being 0.8 to 3.8 mm. 
     As illustrated in  FIGS. 3A and 3B , the top panel member  2  is similarly configured to the base member  1 , but in essentially an opposite configuration. That is, the panel member  2  includes a grid  30  of squares  28 , each having identically configured holes  11  in identical arrangement, in this example four per square. The hinge side  123  is provided with hinge pin brackets  124  that define pin retaining channel  122 . As shown in  FIG. 3C , the channel  122  has a slightly narrower opening  125  than the width of the hinge pin  12  so that the hinge pin  12  can snap into the hinge pin bracket  124 . This way, the hinge pin bracket  124  can retain the hinge pin therein to form a hinge between the panel members  1  and  2 . As shown in  FIG. 3B , a cross-section along line A-A, the top panel member  2  includes holes  11  having a depth H 1  that is less than the thickness of the panel member  2  at that location and a width diameter D that is similar to the depth H 1 . 
     Referring now to  FIGS. 4A and 4B  and  FIGS. 5A and 5B , there are illustrated cooperating embossing tiles  50  and  51 , each representing the letter “H” in this example. The embossing tile  50  is comprised of a base  52  defining a top surface  53  and a bottom surface  54 . The surfaces  53  and  54  are essentially planar. A raised design  56  is provided on the top surface  53  to define a positive relief thereon. A plurality of legs or pegs  58  are provided on and depend from the bottom surface  54  to extend outwardly therefrom. The pegs  58  are configured to mate with the holes  11  provided on the base or top panel members  1  and  2  and have a height H 3  that is substantially equal to the depth H 1  of the holes  11 . The corresponding embossing tile  51  has a similar but mirrored configuration such that the design element  60  is recessed into the top surface  62  of the base  64  of the tile. The design element  60  forms a negative relief in the top surface  62  of the base  64  and is slightly larger in all dimensions than the positive relief design  56 . This allows the positive relief design  56  to at least partially fit within the negative relieve design  60  along with an interposed sheet of paper to be embossed. As with the tile  50 , a plurality of legs or pegs  66  are configured to engage with and be retained by the holes  11  in the surfaces of the panel members  1  and  2 . Each tile may vary in size from about inch squares representing the smallest tile to 2×3 inches or more depending on the size of the folder. It is noted that the size of each tile is irrelevant so long as it can fit inside the folder and snap into the holes. The base and top panels, as well as the individual tiles, can be made from plastic materials such as PE, PS, PVC, PP, and ABS, or other materials known in the art. 
     As illustrated in  FIG. 6 , the tiles  50  and  51  can be positioned in any position on the panel members  1  and  2  so long as the pegs mate with the holes  11 . Thus, the tiles  50  and  51  can be positioned within certain squares  28  or across squares  28 . To use properly, however, the tiles  50  and  51  must be positioned in the same relative location of each panel member  1  and  2 . As illustrated, when the two panels members  1  and  2  are brought together once hinged together, the tiles  50  and  51  would be offset in their current locations. Thus, either the tile  50  needs to be moved down one and a half squares or the tile  51  needs to move down one and a half squares. The grooves forming gridlines on each panel help the user easily visually position the tiles to be exactly opposite each other for proper embossing functionality. 
     As shown in  FIG. 7 , various corresponding tiles, tiles  70  and  70 ′,  71  and  71 ′,  72  and  72 ′, etc., may be placed on the panel members  1  and  2  to form a particular embossed design. Where no tiles are needed for the desired design that would otherwise result in gaps between design tiles or along the edge of a design, blank tiles  71  and  71 ′ may be employed. The blank tiles  71  and  71 ′ have a thickness that matches the thickness of the design tiles minus any positive relief element. This provides a uniform and substantially planar surface so as to prevent the edges of the design tiles from forming creases in the paper during the embossing process. 
     In use, as illustrated in  FIG. 8 , the folder  10  is opened and various design tiles and blank tiles, such as the tiles  70 ,  70 ′,  71 ,  71 ′,  72  and  72 ′ shown in  FIG. 7 , are placed on the panels  1  and  2  as illustrated. A sheet of paper  5  to be embossed is inserted between the two panel members  1  and  2 . As shown in  FIG. 9 , the top panel member  2  is closed in a clam-shell fashion over the paper  5  and the folder  10  is pressed as by running the folder  10  through a roller die press, placing the folder  10  in another type of hand operated press as is known in the art, or by hand by applying pressure with a hand-held object such as a rolling pin. When opened, the paper  5  will include embossed designs  5 ′ that match the designs provided by the tiles as illustrated in  FIG. 10 . While illustrated as extending beyond the width and length of the folder  10 , the paper  5  could be of any size, including a smaller size that completely fits within the folder  10  when closed. 
     As illustrated in  FIGS. 11A and 11B , the same positive relief image tile  50 ′ can be employed to print onto the sheet of paper  5 , previously shown, rather than embossing. To print, rather than providing a corresponding tile  51  that has a similar design image but in negative relief, a printing tile  80  is positioned opposite the design tile  50 ′. The printing tile  80  is a blank tile that presents a flat surface to allow the raised portion  56 ′ to press against the flat surface  82  of the printing tile  80 . Because the raised portion  56 ′ is not allowed to fit within the printing tile  80 , as is the case when used with an embossing tile  51 , the thickness of the base  84  of the tile  80  has a thickness H 4  that is thinner than the corresponding base of the tile  51  by the height H 5  of the raised design  56 ′. This provides the same effective combined height of the tiles  50 ′ and  80  when the folder  10  is closed as with the tiles  50 ′ and  51  and thus allows the folder to completely close so that the panels  1  and  2  are substantially parallel during the printing process to ensure uniform pressure along the entire surface of the paper being printed. This improves print quality and prevents damage to the folder  10  that may otherwise occur from uneven pressures. 
     In order to keep the ink from smearing or bleeding, the positive relief is configured to be slightly higher than with the similar tile for embossing. This provides additional space between the paper and the top surface  53 ′ of the tile  50 ′ to reduce the possibility of contact of the paper and the surface  53 ′ that may contain ink. It is also contemplated that the folder and tiles could be used to imprint clay or other moldable material to create embossed or recessed designs in the material. 
     To print, an ink is applied to the raised surface  56  of the design tile  50  and the folder is used as previously described with the tile  50  pressing against the tile  80  with the paper  5  interposed therein between. The result is similar to that illustrated in  FIG. 10  except that the designs on the paper will be in ink rather than embossed. Likewise, an ink containing sheet, such as those used for carbon copies, or label making could be inserted with the ink side facing the paper and the non-ink side against the raised tile or the blank tile. The pressure of the raised design of the raised tile against the blank tile will cause the ink on the sheet to transfer to the paper, similar to the ribbon of a typewriter. 
     As illustrated in  FIGS. 12 and 13 , a bottom panel, generally indicated at  102 , of an embossing folder is provided with a hinge assembly, generally indicated at  104 , that includes a cylindrically shaped elongate member  106 , that spans the space between a first hinge structure  108  and a second hinge structure  109 . The hinge structure  108  and  109  is positioned on an edge  110  of the panel  102  proximate to a corner  112 . The hinge structure  108  includes a first tab  114  depending from the edge  110  and a second tab  116  spaced from the first tab  114  also depending from the edge  110 . A cylindrical hinge pin  118  spans the space between the first and second tabs  114  and  116  and is also spaced from and substantially parallel to the edge  110 . The hinge pin  118  is held in place by the first and second tabs  114  and  116 . The hinge structure  109  is similarly configured but positioned proximate the opposite side of the panel  102 . The elongate member  106  is held between the first and second hinge structures  108  and  109 . To do so, the hinge pin  108  may extend from the hinge structure  108  to the hinge structure  109 . The elongate member  106  may be provided with a central bore through which the hinge pin  118  may pass. Likewise, the elongate member  106  may be provided with end recesses to receive protrusions extending from the facing walls of the tabs, such as tab  116 . It is also contemplated that the elongate member  106  could be integrally formed with the bottom panel  102  along the edge  110  thereof. 
     As illustrated in  FIGS. 14 and 15 , when assembled to a top panel  120 , the space  121  that would otherwise exist between the adjacent edges  110  and  122  of the panels  102  and  120 , respectively, is primarily occupied by the elongate member  104 . In operation, as the bottom and top panels  102  and  120  are laid open relative to each other as shown in  FIG. 15 , the space edges  124  and  126  that define the space  121  decreases in size. Without the elongate member  104 , a user could potentially pinch a finger in the space  121 . The elongate member  104  thus provides a safety feature that allows the panels  102  and  120  to freely pivot relative to each other while occupying the space  121  to prevent pinching of skin. 
     Of course, a combination of printing and embossing could be simultaneously employed during the same pressing process so that the sheet of paper  5  is simultaneously printed with ink, paint or other pigmented material and embossed. It should be noted that the folder  10  of the present invention and tiles, such as tiles  3 ,  4 ,  50 ,  51  and  80  herein described may be formed of any material, such as plastic or metal and may be formed by injection molding, machining or other methods known in the art. 
     While there have been described what are believed to be the best embodiments of the present invention, those skilled in the art will recognize that other and further changes and modifications may be made thereto without department from the spirit of the invention, and it is intended to claim all such changes and modifications that fall within the true scope of the invention. In addition, while the devices set forth herein have been described with specific reference to a particular structure and shape, the device of the present invention could be modified to any desired shape or size. Thus, while various methods and systems of the present invention are described herein, any methods or devices similar or equivalent to those described herein may be used in the practice or testing of the present invention. All references cited herein are incorporated by reference in their entirety and for all purposes. 
     While the foregoing advantages of the present invention are manifested in the illustrated embodiments of the invention, a variety of changes can be made to the configuration, design and construction of the invention to achieve those advantages. Hence, reference herein to specific details of the method and function of the present invention is by way of example only and not by way of limitation. Unless defined otherwise, all technical and scientific terms used herein have the same meanings as commonly understood by one of ordinary skill in the art to which this invention belongs. It is also to be understood that, as used herein and in the appended claims, the singular forms “a,” “an,” and “the” include plural reference, unless the context clearly dictates otherwise.