Patent Publication Number: US-7721784-B2

Title: Article of jewelry and method of manufacture

Description:
CROSS-REFERENCE TO RELATED PATENT APPLICATIONS 
   This application is a continuation of applicants&#39; co-pending patent application U.S. Ser. No. 11/324,932, filed on Jan. 4, 2006, which claims priority from U.S. provisional patent application U.S. Ser. No. 60/641,792, filed on Jan. 6, 2005. The entire disclosure of each of these patent applications is hereby incorporated by reference into this specification. 

   BACKGROUND OF THE INVENTION 
   1. Field of the Invention 
   This invention relates generally to articles of jewelry and methods of manufacturing articles of jewelry, and more particularly to an article of jewelry and a method of manufacturing an article of jewelry where the article of jewelry bears a reproduction of an anatomical part such as a fingerprint, a handprint, a footprint, or the like. 
   2. Description of the Related Art 
   The related art has disclosed various articles of jewelry that are ornamented with representations of fingerprints. Reference may be had, e.g., to U.S. Pat. No. 964,499 that discloses an impressionable mould used to create a casting of a fingerprint image. Other patents, for example, German Patent 2903728, U.S. Pat. No. 4,993,472, use hot wax to obtain the impression of a fingerprint for the purpose of creating a metal casting. U.S. Pat. No. 6,435,255 also uses wax to obtain the impression of a fingerprint, but improves upon the previous art by using a soft wax bonded to a hard wax substrate to obtain an impression of a fingerprint. U.S. Design Pat. No. 407,660 discloses an ornamental design for an article of jewelry with a textured surface in the form of a fingerprint. 
   The methods disclosed in the related art create a mirror image wax impression of a fingerprint that are capable of creating only a single casting per impression. Further, the methods previously disclosed in the related art subject an individual to direct contact with wax that may either create a residue on the individual&#39;s finger, or may expose the individual to hot wax and the discomfort associated with contacting hot wax. This discomfort is of particular concern to individuals such as young children or the elderly. In addition, often times it may be desirable to create an anatomical reproduction of a deceased family member&#39;s fingerprint, footprint, or handprint in an article of jewelry. The methods of the related art are limited in their ability to reproduce additional copies of a deceased individual&#39;s fingerprint or the like. 
   It is an object of the present invention to provide a method of manufacturing an article of jewelry that creates a true reproduction of an anatomical part such as a fingerprint, footprint, handprint, or the like. It is another object of the present invention to provide a method of manufacturing an article of jewelry that can produce multiple castings of an image of an anatomical part from a single impression of that anatomical part. It is a further object of the present invention to provide a method of manufacturing an article of jewelry that creates a true and accurate reproduction of a fingerprint that is of the same general shape as the fingerprint itself; e.g., an oval reproduction of said fingerprint. It is still another object of the present invention to provide an article of jewelry that contains a novel bail assembly for attaching the article of jewelry to a chain or the like in an aesthetically pleasing manner that hides an attachment hole of the article of jewelry. 
   BRIEF SUMMARY OF THE INVENTION 
   In accordance with the present invention, there is provided a method for creating an article of jewelry that contains an anatomical image, the method comprising the steps of taking a print of an anatomical part, creating a digital image file by taking a digital photograph of the print of an anatomical part, converting the digital image file to a computer numeric control machine language program, loading the computer numeric control machine language program on a computer numeric control machine, placing a sheet of machinable wax proximate the computer numeric control machine, executing the computer numeric control machine language program on the computer numeric control machine, cutting a wax model of an anatomical image in the sheet of machinable wax using the computer numeric control machine, removing the anatomical image from the sheet of machinable wax, creating a mould from the wax model of the anatomical image, using the mould to create a casting from the wax model of the anatomical image, and attaching a finding to the casting. 
   The foregoing paragraph has been provided by way of introduction, and is not intended to limit the scope of the following claims. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The invention will be described by reference to the following drawings, in which like numerals refer to like elements, and in which: 
       FIG. 1  is a perspective view of a wax jig and a sheet of machinable wax; 
       FIG. 2  is a bottom plan view of a wax jig with a sheet of machinable wax placed in the jig; 
       FIG. 3  is a perspective view of a wax jig and a sheet of machinable wax showing wax punches and wax alignment sprues; 
       FIG. 4  is a top plan view of a wax jig with a sheet of machinable wax placed in the jig; 
       FIG. 5  is a perspective view of a vacuum table; 
       FIG. 6  is a front elevation view of a CNC machine with the vacuum table installed; 
       FIG. 7  is another front elevation view of a CNC machine; 
       FIG. 8  is a front plan view of an article of jewelry portraying the image of a fingerprint; 
       FIG. 9  is a back plan view of an article of jewelry showing a cast inscription; 
       FIG. 10  is a front plan view of an article of jewelry portraying an image of a footprint; 
       FIG. 11  is a front plan view of an article of jewelry portraying an image of a handprint; 
       FIG. 12  is a front plan view of a tie tack portraying an image of a fingerprint; 
       FIG. 13  is a side elevation view of a bail showing a unique pin and socket assembly; 
       FIG. 14  is a process diagram showing a method of creating CNC machine code used to manufacture an article of jewelry; and 
       FIG. 15  is a process diagram showing a method of manufacture of an article of jewelry. 
   

   The present invention will be described in connection with a preferred embodiment, however, it will be understood that there is no intent to limit the invention to the embodiment described. On the contrary, the intent is to cover all alternatives, modifications, and equivalents as may be included within the spirit and scope of the invention as defined by the appended claims. 
   DESCRIPTION OF THE PREFERRED EMBODIMENTS 
   A portion of the disclosure of this patent document contains material which is subject to copyright protection. The copyright owner has no objection to the facsimile reproduction by anyone of the patent document or the patent disclosure, as it appears in the Patent and Trademark Office patent files or records, but otherwise reserves all copyrights whatsoever. 
   For a general understanding of the present invention, reference is made to the drawings. In the drawings, like reference numerals have been used throughout to designate identical elements. 
     FIG. 1  is a perspective view of a wax jig and a sheet of machinable wax. Referring to  FIG. 1 , a wax jig  2  is shown. The wax jig  2  is made from a rigid material such as aluminum using standard machining and fabrication techniques. The wax jig  2  is used to prepare a sheet of machinable wax  8  for machining and cutting an image or a plurality of images of an anatomical part in the sheet of machinable wax  8 . The wax jig  2  may be assembled from several flat elements and assembled using hardware such as bolts  6 . The wax jig  2  contains a wax jig slot  10  to receive a sheet of machinable wax  8 . The wax jig  2  may contain punch bit holes  4  that are used to retain a wax punch (not shown) that is used to cut alignment holes (not shown) in the sheet of machinable wax  8 . The purpose of the alignment holes, as will be further described in this specification, is to align and prevent motion of the sheet of machinable wax  8  while it is undergoing machining and cutting operations. 
     FIG. 2  shows a bottom plan view of the wax jig  2  with a sheet of machinable wax  8  placed in the jig. Punch bit holes  4  are shown. The purpose of the punch bit holes is to retain and guide wax punches as they are pushed through the sheet of machinable wax  8 , creating sprues in the sheet of machinable wax  8  that are used to align the sheet of machinable wax in subsequent machining operations that will be described later in this specification. Wax punches are illustrated in  FIG. 4 . 
     FIG. 3  shows a perspective view of a wax jig  2  and a sheet of machinable wax  8  showing the wax punches  12  removed from the punch bit holes  4 . The wax punches  12  in some embodiments of the present invention are made of brass and stainless steel, although other metals and plastics would work equally as well. The wax punches  12  contain a sharp wax punch bit  16  that is used to cut alignment sprues  18  in the sheet of machinable wax  8 . In use, the sheet of machinable wax  8  is inserted in the wax jig slot  10 . The wax punch bits  16  are inserted into the punch bit holes  4  with sufficient force to cut alignment sprues  18  in the sheet of machinable wax  8 . The insertion of the wax punch bits  16  into the punch bit holes  4  and through the sheet of machinable wax  8  may be performed by hand, or, in some embodiments of the present invention, the insertion of the wax punch bits  16  into the punch bit holes  4  and through the sheet of machinable wax  8  may be performed with the assistance of a mechanical or electrical device such as a hydraulic cylinder or a solenoid. The primary purpose of the wax jig  2  is to position the alignment sprues  18  and rigidly retain the sheet of machinable wax  8  while the wax punch bits  16  are pushed through the sheet of machinable wax  8 . 
   Referring now to  FIG. 4 , a top plan view of a wax jig with a sheet of machinable wax placed in the wax jig is shown. In  FIG. 4 , wax punches  12  are clearly visible, and are inserted in the punch bit holes  4  that are shown previously in  FIGS. 1 and 2 . While a sheet of machinable wax is placed in the wax jig  2 , the wax punches  12  are pushed through the punch bit holes  4  to cut alignment sprues in the sheet of machinable wax  8  to assist in subsequent machining operations.  FIG. 4  also shows holes  14  that are used to assemble the wax jig  2  using hardware such as bolts  6  that are shown previously in  FIGS. 1 and 2 . 
   In manufacturing the article of jewelry, once the sheet of machinable wax  8  is punched to create alignment sprues  18 , the sheet of machinable wax  8  is now ready to be machined and cut as will be further described by way of  FIGS. 5 ,  6 , and  7 . 
   Referring now to  FIG. 5 , a perspective view of a vacuum table is shown. The primary purpose of the vacuum table  50  is to retain the sheet of machinable wax  8  (not shown in  FIG. 5 , see FIGS.  1 , 2 , 3  and  4 ) while subsequent machining operations are performed, as will be described later in this specification. Using a sheet of machinable wax  8  that has been prepared with alignment sprues  18  as previously described (not shown in  FIG. 5 , refer to  FIG. 3 ), the sheet of machinable wax  8  (not shown) is placed on the vacuum table  50 . The alignment sprues  18  of the prepared sheet of machinable wax  8  (not shown) are placed over the alignment stubs  51 , the result of this operation being that the sheet of machinable wax  8  is properly aligned on the vacuum table  50 . Proper alignment refers to the correct placement of the sheet of machinable wax with respect to subsequent machining operations that will be described later in this specification. Proper alignment refers to placement of the sheet of machinable wax  8  (not shown) in all three dimensions, including adequate physical contact between the sheet of machinable wax  8  (not shown) and the gasket  52  to provide for a vacuum seal. The vacuum table  50  is supplied with vacuum through a series of channels (not shown) within the vacuum table  50 . The series of channels are supplied vacuum through a vacuum line  58  that is connected to the vacuum table  50  with a vacuum connector  60 . Each of the channels within the vacuum table  50  terminate at a vacuum hole  54 . In some embodiments of the present invention, each vacuum hole  54  may be located below a location on the machinable wax sheet  8  where a wax workpiece will be cut in subsequent machining operations. A wax workpiece is defined as a representative image of an article of jewelry to be used in a lost wax casting operation that is defined later in this specification, and is commonly known to those skilled in the art. In one embodiment of the present invention, there are twenty vacuum holes  54 . More or less vacuum holes  54  may be used depending on the quantity of workpieces to be cut from the machinable wax sheet  8 . Surrounding each vacuum hole  54  may be an outline  56  of the workpiece to be cut from the machinable wax sheet  8 . 
     FIG. 6  is a front elevation view of a computer-numeric controlled (CNC) machine  64  with the vacuum table  50  installed. The machinable wax sheet  8  is shown in position on the vacuum table  50 . The vacuum table  50  is attached to an X-Y table  70 . The X-Y table  70  allows for translation and alignment in two dimensions (the X-axis and the Y-axis) in relation to a computer-numeric controlled (CNC) cutter head  62 . As is known to those skilled in the art, the computer-numeric controlled (CNC) machine moves a computer-numeric controlled (CNC) cutter head  62  in response to a computer program. The computer-numeric controlled (CNC) cutter head  62  contains a rotating bit (not shown), and moves in all three dimensions in response to control logic contained either within the computer-numeric controlled. (CNC) machine  64  or within an external computer connected to the computer-numeric controlled (CNC) machine  64 . A computer monitor  66  may be used to convey information about the machining operation to the operator of the computer-numeric controlled (CNC) machine  64 . A positioning readout  68  may also be used to assist with the manufacturing process. 
   The CNC machine  64  cuts multiple wax workpieces that are used in a subsequent lost wax casting process. To create the wax workpieces, a fingerprint or other image is taken using a technique such as placing the finger on a sheet of carbon paper, removing the finger from the carbon paper, and impressing the finger upon a sheet of paper. The fingerprint or other image is then photographed using a digital camera that is set up to take close range images. Other images may include footprints, handprints, noseprints, and the like. The digital image of the fingerprint or other image is then stored in a digital file format such as a jpeg file format or other file format known to those skilled in the art. The digital file may then be further processed and enhanced on a computer to obtain desired properties such as shading, depth, and the like. The digital file is later converted to a computer language that is used to control a CNC machine, such as G code. This technique eliminates the risk of hot wax burns, creates a direct image (not a mirror image) of the fingerprint or other image, and allows for the creation of multiple wax workpieces and subsequently multiple lost wax castings. The image can also be archived. The backside of the wax workpiece may also contain letters and numbers such as a person&#39;s name, date of birth, and the like. The letters and numbers may be cast by creating a digital image of the inscription, storing the digital image in a digital file format such as a jpeg format, and converting the digital file to a computer language that is used to control a CNC machine, such as G code. Other embodiments of the present invention may use laser etching equipment in place of the CNC machine, as would be known to those skilled in the art. 
   Referring again to  FIG. 6 , to create the wax workpieces from the machinable wax sheet  8 , the machinable wax sheet  8  is installed on the vacuum table  50  using the alignment sprues  18  and the alignment stubs  51 . The vacuum is applied through the attached vacuum line  58 , and the CNC machine  64  is operated with the appropriate machine control software. The X-Y table  70  moves in accordance with the machine control software to cut one side of the wax workpieces. Once the CNC cutting is complete, the machinable wax sheet  8  is removed from the vacuum table  50 , flipped over, and reinstalled on the vacuum table  50  in such a manner as to allow the second side of the wax workpiece to be cut by the CNC cutter head  62 . The proper alignment of the machinable wax sheet  8  and subsequent wax workpieces is accomplished through the use of the alignment sprues  18  and the alignment stubs  51  in conjunction with proper operator procedures. 
   Once the wax workpieces are cut from the machinable wax sheet  8 , each machined wax workpiece is invested and cast using the age-old technique of lost wax casting. The casting metal may be gold, silver, platinum, an alloy, or the like. The finished casting may be fabricated into a necklace, bracelet, ring, or other article of jewelry. The article of jewelry may be decorated with faceted stones, cabochons, or other decorative items that are known to those skilled in the art. 
     FIG. 7  provides another front elevation view of a CNC machine showing in more detail the cutter head  62  and the machinable wax sheet  8  that is in place for machining operations. 
   Referring now to  FIG. 8 , a front plan view of an article of jewelry portraying the image of a fingerprint is shown. The article of jewelry is a pendant  80 , and was manufactured using an inventive method that is one object of the present invention. The pendant  80  was cast with a fingerprint image  82 . Other anatomical images such as, but not limited to, footprints, handprints, noseprints, and the like, may also be used without departing from the spirit and scope of the present invention. The pendant further contains a bail hole  84 . The bail hole  84  contains a novel bail  86  that is another object of the present invention, and is shown in more detail in  FIG. 13 . The bail  86  provides an attachment point for securing the pendant  80  to a chain  88 . The bail  86  may further be decorated with faceted stones, cabochons, or other items known to those skilled in the art. 
   Referring to  FIG. 9 , a back plan view of an article of jewelry is shown. The article of jewelry was manufactured using an inventive method that is an object of the present invention. The back plan view of the article of jewelry may, in one embodiment, contain an inscription  90 . The inscription  90  may be cast using the lost wax method of casting. 
   Referring now to  FIG. 10 , a front plan view of a pendant  100 , is shown with an image of a footprint  102 . The footprint image  102  was reduced in size using a digital photographic technique, and was manufactured using an inventive method that is an object of the present invention. The pendant  100  was cast with a footprint image  102 . The pendant further contains a bail hole  104 . The bail hole  104  contains a novel bail  106  that is another object of the present invention, and is shown in more detail in  FIG. 13 . The bail  106  provides an attachment point for securing the pendant  100  to a chain  88 . The bail  106  may further be decorated with a faceted stone setting  108 , cabochons, or other items known to those skilled in the art. The back of the pendant  100  may contain an inscription such as shown in  FIG. 9 . 
   Referring now to  FIG. 11 , a front plan view of a pendant  200  is shown with an image of a handprint  202 . The handprint image  202  was reduced in size using a digital photographic technique, and was manufactured using an inventive method that is an object of the present invention. The pendant  200  was cast with a handprint image  202 . The pendant further contains a bail hole  204 . The bail hole  204  contains a novel bail  206  that is another object of the present invention, and is shown in more detail in  FIG. 13 . The bail  206  provides an attachment point for securing the pendant  200  to a chain  88 . The bail  206  may further be decorated with a faceted stone, cabochons, or other items known to those skilled in the art. The back of the pendant  200  may contain an inscription such as shown in  FIG. 9 . 
   Referring to  FIG. 12 , a front plan view of a tie tack  300  portraying an image of a fingerprint  302  is shown. The tie tack  300  was manufactured using an inventive method that is an object of the present invention. In other embodiments, the tie tack  300  may portray an image of a footprint, a handprint, or the like. 
   The pendants  80 ,  100 , and  200  previously described and illustrated in  FIGS. 8 and 9 ,  10 , and  11  respectively use a novel bail to attach the cast article of jewelry to a chain. The bail  86 ,  106 , and  206  also illustrated in  FIGS. 8 and 9 ,  10 , and  11  respectively are designed to both provide a secure attachment point of the article of jewelry to a chain and to hide the bail hole  84 ,  104  and  204  as shown in  FIGS. 8 and 9 ,  10 , and  11  respectively. The bail holes  84 ,  104 , and  204  detract from the aesthetically pleasing qualities of the article of jewelry. 
   Referring to  FIG. 13 , a bail  106  is shown. The bail  106  is manufactured using traditional casting techniques for creating jewelry findings that are known to those skilled in the art. In some embodiments of the present invention, the bail  106  may contain a faceted stone setting  110 , a cabochon, or other decorative item known to those skilled in the art. The bail  106  contains a pin  112  and a hole  114 . To attach the bail  106  to an article of jewelry, the pin  112  is inserted through the bail hole  84 ,  104  or  204 . The bail  106  is then compressed using a jeweler&#39;s pliers or similar tool in a direction indicated as  116  in  FIG. 13 . Once the bail  106  is compressed such that the pin  112  is inserted into the hole  114 , a TIG welder, jeweler&#39;s soldering torch, laser welder, or the like is used to permanently attach the pin  112  into the hole  114 . 
   Referring now to  FIG. 14 , a process diagram  1400  showing a method of creating CNC machine code used to manufacture an article of jewelry is shown. In step  1401 , an image of an anatomical part is taken using a technique such as that used for taking fingerprints where an inked or inkless pad is used to contact a finger, and the finger is then pressed onto a paper. The resulting image is that of a fingerprint. Images of footprints may be rendered using similar techniques. Footprints of newborns are often taken in hospitals shortly after birth for identification purposes. The rendered image of the anatomical part from step  1401  is then photographed in step  1403  using a digital camera. The resulting digital image file from step  1403  is then transferred to a computer in step  1405  using techniques commonly known to those skilled in the art. In step  1407 , the digital image file of step  1405  may be preprocessed and enhanced using digital photography software to provide improved image quality. In step  1409 , the digital image file or files are archived and stored on computer media for future use. In step  1411 , a message or an additional image file is created for use on the back side of the resulting article of jewelry. In step  1413 , the digital image file or files are converted to computer numeric controlled machine language such as G code using commercially available software conversion programs such as a jpeg to G code converter. In step  1415 , wax machining and subsequent casting is performed as described in further detail by way of  FIG. 15 . 
   Referring now to  FIG. 15 , a process diagram of a method of manufacture according to one embodiment of the present invention is shown. In step  1501 , a machinable wax sheet is inserted into a wax jig. In step  1501 , the machinable wax sheet is cut with alignment sprues using a wax punch pushed through holes in the wax jig. In step  1505 , the machinable wax sheet is removed from the wax jig. In step  1507 , the machinable wax sheet is placed on a vacuum table, and in step  1509  the machinable wax sheet is aligned on the vacuum table. In step  1511 , the operator ensures that the wax sheet is adequately seated on a gasket to allow for adequate vacuum on the wax sheet. In step  1513 , vacuum is applied to the vacuum table and the wax sheet is firmly retained. In step  1515 , a computer numerical controlled routine is executed to cut messages into the wax sheet. In step  1517 , an inspection is made to ensure that the messages have been properly cut into the wax sheet. This inspection may be performed manually, or may be performed using imaging or machine vision inspection techniques known to those skilled in the art. If the messages are properly cut into the wax sheet, the wax sheet is removed from the vacuum table in step  1519  and the wax sheet is flipped over to allow for machining on the back side of the wax sheet. If the messages are not properly cut from the wax sheet, the wax sheet is discarded, and a new wax sheet is inserted into the wax jig and the process is started over. Prior to the restart of the process, an operator or other individual may wish to determine why the message was not properly machined in the wax sheet, allowing for necessary corrections to ensure that the message will be properly cut. Upon satisfactory cutting of a message in step  1519 , and removal of the wax sheet and flipping of the wax sheet in  1519 , the wax sheet is again aligned on the alignment stubs of the vacuum table in step  1521 . In step  1523 , the operator ensures that the wax sheet is adequately seated on a gasket to allow for vacuum on the wax sheet that is sufficient to retain the wax sheet during machining operations. In step  1525 , vacuum is applied to the vacuum table and the wax sheet is firmly retained. In step  1527 , a computer numerical controlled routine is executed to cut images of an anatomical part into the wax sheet. In step  1529 , an inspection is made to ensure that the images of an anatomical part have been properly cut into the wax sheet. This inspection may be performed manually, or may be performed using imaging or machine vision inspection techniques known to those skilled in the art. If the images of an anatomical part are properly cut into the wax sheet, in step  1531  a computer numeric controlled routine is executed to cut wax workpieces from the wax sheet. In step  1533 , the wax workpieces are cast using techniques known to those skilled in the art. In step  1535 , the castings are desprued, polished and finished. Lastly, in step  1537 , findings are attached to the finished casting. Findings may include rings, bails, posts, prongs, gemstones, semi-precious stones, cabochons, chains, links, bezels, and the like. In one preferred method of the present invention, findings include the novel bail  106  illustrated in  FIG. 13 . 
   It is, therefore, apparent that there has been provided, in accordance with the various objects of the present invention, an article of jewelry and a method of manufacturing an article of jewelry. While the various objects of this invention have been described in conjunction with preferred embodiments thereof, it is evident that many alternatives, modifications, and variations will be apparent to those skilled in the art. Accordingly, it is intended to embrace all such alternatives, modifications and variations that fall within the spirit and broad scope of the appended claims.