Self-wrapping decorative article and method

Abstract

A self-wrapping decorative article and method for manufacturing is provided. Self-wrapping decorative article includes an elongate generally flat wrapping member having ends capable of coming together and capable of remaining extended is disposed between a first retroreflective decoratively shaped layer and a second layer.

Description

CROSS-REFERENCE TO RELATED APPLICATION

[0001] This application is a continuation-in-part application of the U.S. application Ser. No. 08/911,215 filed Aug. 14, 1997.

FIELD OF THE INVENTION

[0002] 1. Field of the Invention

[0003] The invention relates to self-wrapping decorative articles, and more particularly to self-wrapping decorative articles for toys, safety toys and devices, and for wrapping to legs, arms, posts, columns, cords or other similar structures, and methods for manufacturing self-wrapping decorative articles. Particularly, the invention relates to self-wrapping decorative articles made from materials, which are capable of retroreflecting light, and having a protective layer, which prevents retro-reflective capabilities of the materials from rapid deterioration as a result of extensive use.

[0004] 2. Background of the Invention

[0005] Self-wrapping wrist bands, such as snap bracelets or wrist wraps, that are thin and rectangular and can be coiled around a person's arm are known in the art. These self-wrapping products known in the art include a spring steel enclosed by a typically decorative or reflective vinyl or fabric.

[0006] Manufacturing processes known in the art for manufacturing these self-wrapping products tend to prevent the self-wrapping products from being provided in shapes other than rectangular, and are typically manufactured using a multi-step manufacturing process. These manufacturing processes require that a rectangular tube is first made from vinyl or fabric. Then a spring member is inserted into the tube. Only after the spring member is inserted, is it encased by sealing or fusing each open end of the tube. The layers forming the tube are typically fused together using a heated die or radio frequency welding.

[0007] A sheet of a plurality of self-wrapping decorative articles can be provided in the manufacturing processes known in the art for manufacturing the self-wrapping products but even with a plurality of them adjacent to one another on a sheet, a multi-step manufacturing process is still required.

[0008] What is desired, therefore, are self-wrapping decorative articles that are decoratively shaped and made by a more precise and simplified method of manufacturing self-wrapping decorative articles in an inexpensive manner. Also desired is a wrapping decorative article made from a retro-reflective material.

SUMMARY OF THE INVENTION

[0009] Accordingly, it is an object of the present invention to provide a self-wrapping decorative article and a method of making the same where a wrapping member is incorporated into the article in one manufacturing step.

[0010] Still another object of the present invention is to provide a self-wrapping decorative article wherein the decorative portions can have a variety of shapes and extend laterally from an encased elongate wrapping member.

[0011] It is another object of the present invention is to provide a self-wrapping decorative article that is made by a process including the steps of holding, without physical contact by a person or a machine, one or more elongate wrapping members in place over a first decoratively shaped layer, and while the member is so held covering it with another layer, followed by a single affixing step in which the layers are attached to each other and the wrapping member is encased between the layers.

[0012] Yet another object of the invention is to provide a self-wrapping decorative article made from a material capable of retroreflecting light.

[0013] These and other objects are achieved by one self-wrapping decorative article in accordance with the invention with an elongate wrapping member having a tendency to close on itself as well as a capability of remaining extended. The elongate member is encased between layers, at least one of which extends laterally from the elongate member for a substantial distance with decorative shape to impart to the article a large decorative image that can be quickly affixed to and then be worn by a person.

[0014] Elongate wrapping member is generally flat and can be a spring, clamp, coil or hinge capable of being held by a magnet, and it is preferred but not required that the elongate wrapping member be a steel spring coil. First and second layers encase the elongate member.

[0015] In one embodiment in accordance with the invention, a first decoratively shaped layer of vinyl bearing a decorative printing on one side overlies a second vinyl layer with an elongate spring steel as the generally elongate flat wrapping member between them to provide a coiling force. The first layer has a shape so that it extends, with a decorative shape, transversely of at least one elongate edge of the elongate wrapping member by a distance which is at least more than fifty percent of the lateral dimension of the elongate wrapping member. In some articles the first layer extends past both elongate edges of the wrapping member so that the lateral width of the decorative layer is at least more than fifty percent of the elongate dimension of the wrapping member.

[0016] In accordance with another embodiment of the invention, a self-wrapping decorative article is made from a reflective material typically employed for a variety of safety and decorative purposes. Based on one aspect of the invention, the retroreflective material is a glass bead reflective material.

[0017] Still another aspect of the invention relates to the use of a prismatic vinyl which is disclosed in a U.S. Patent Application No. owned by the same assignee and fully incorporated herein by reference.

[0018] With a decoratively shaped self-wrapping article in accordance with the invention, a great variety of shapes can be achieved and made in an economic manner and made available with attractive appearances and reflective features as seems desirable.

[0019] The invention and its particular features will become more apparent from the following detailed description considered with reference to the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0020] FIG. 1 is a top isometric view of one embodiment of a prior art wrist band;

[0021] FIG. 2 is a side sectional view of the prior art wrist band of FIG. 1 taken along the section line 2-2;

[0022] FIG. 3 is a perspective view showing the prior art wrist band in use;

[0023] FIG. 4 is a top view of one embodiment of self-wrapping decorative article;

[0024] FIG. 5 is a side sectional view of self-wrapping decorative article of FIG. 4 taken along section line 5-5;

[0025] FIG. 6 is a perspective view showing self-wrapping decorative article of FIG. 4 in use;

[0026] FIG. 7 is a top view of another embodiment of the present invention;

[0027] FIG. 8 is a side sectional view of the embodiment of FIG. 7 taken along section line 8-8;

[0028] FIG. 9 is a top view of another embodiment of the present invention; and

[0029] FIG. 10 is a plane view of base for manufacturing the invention.

[0030] FIG. 11 is a diagrammatic cross-sectional view of a self-wrapping decorative article provided with a glass bead reflective material.

[0031] FIG. 12 is a perspective view of a self-wrapping band incorporating the structure shown in FIG. 11.

[0032] FIG. 13 is a diagrammatic cross-sectional view of a self-wrapping article made from a prismatic vinyl.

[0033] FIG. 14 is a perspective view of a self-wrapping band incorporating the structure illustrated in FIG. 13.

[0034] FIG. 15 is a diagrammatic cross-sectional view of a protective layer provided with a plurality of recesses.

DETAILED DESCRIPTION OF THE DRAWINGS

[0035] FIGS. 4, 5 and 6 show self-wrapping decorative article 10 in accordance with the present invention for wrapping onto a person's limbs 12. Self-wrapping decorative article 10 is most likely used on a person's limbs 12 as shown in FIG. 6 as a safety article; it is understood, however, that self-wrapping articles 10 of the present invention may wrap around any structure, limb 12 or line thin enough for self-wrapping articles 10 to encircle, wrap or clamp. It is further understood that self-wrapping decorative article 10 of the present invention can be provided in rectangle strip form as shown in FIG. 6.

[0036] As shown in FIGS. 4 and 5, self-wrapping decorative article 10 includes elongate generally flat wrapping member 14 with ends 16, elongate side edges 18 and surfaces 20, the ends 16 being capable of wrapping together yet capable of remaining extended. Self wrapping decorative article 10 having a first decoratively-shaped layer 22 having surfaces 24, said layer 22 extending laterally outward from elongate generally flat wrapping member 14 a distance I that is substantially greater than the lateral dimension d of wrapping member 14 and having contoured edges 26. It is understood that elongate wrapping member 14 can be a coil, spring, clamp or hinge so long as it has the capability of springing closed yet of remaining open or extended. It is preferred but not required that elongate wrapping member 14 be a spring steel coil. It is further understood that self-wrapping decorative article 10 provided in strip form will have edges 26 that are straight and parallel with elongate wrapping member 14.

[0037] FIG. 5 shows second layer 28 opposite first layer 22 covering wrapping member 14. First and second layers 22 and 28 are fixed to each other at seam 30 thereby encasing wrapping member 14. As shown in FIG. 5, wrapping member 14 of this embodiment of the present invention is curved, and is a straight spring.

[0038] FIGS. 7 and 8 depict another embodiment of the self-wrapping decorative article 100 of the present invention wherein elongate generally flat wrapping member 104 has ends 106, elongate side edges 108 and surfaces 110, and a hinge 112 for allowing ends 106 to wrap onto themselves and for remaining extended. As shown in FIG. 8, self-wrapping decorative article 100 has a first layer 114 extending laterally outward from wrapping member 104 a distance I that is substantially greater than the lateral dimension d of wrapping member 104 and has contoured edges 116. It is understood that self-wrapping decorative article 100 provided in strip form will have edges 116 that are straight and parallel with elongate wrapping member 104.

[0039] FIG. 8 shows second layer 118 opposite first layer 114 covering wrapping member 104. First and second layers 114, 118, respectively, are fixed to each other in one step at seam 120 thereby encasing wrapping member 104. As shown in FIG. 8, wrapping member 104 of this embodiment of the present invention is relatively flat.

[0040] As shown in FIG. 9, another embodiment of self-wrapping article 200 can comprise more than one or a plurality of elongate generally flat wrapping members 202 with ends 204, inner elongate side edges 206 and outermost elongate side edges 208, the ends 204 being capable of wrapping together yet capable of remaining extended. Wrapping members 202 being fixed adjacent to one another so that each will wrap in the same direction when wrapped onto a person's limbs 12 and are parallel (p) to one another. Elongate wrapping member 202 can be substantially the same as wrapping members 14 and 104, above, and can be encased as described above. First decorative layer 210 has lateral dimension d that is substantially greater than lateral dimension e of wrapping member 202 and extends from outermost elongate side edges 208 of wrapping member 202.

[0041] FIGS. 4, 5, 7 and 8 show self-wrapping articles 10 and 100, respectively, extended. FIG. 6 shows self-wrapping decorative article 10 or 100 wrapped onto a person's limbs 12.

[0042] Elongate wrapping members 14, 104 and 202 wrap around a structure or limb by snapping elongate members 14, 104 or 202 in the middle of their length against structure or limb 12. Preferably elongate wrapping members 14, 104 and 202 are high carbon steel with a thickness of approximately 0.006 inches, although a thickness range of approximately 0.005 to 0.010 inches can be used. Elongate wrapping members 14, 104 and 202 are preferably 9 to 15 inches in length. For wrist band applications, the preferred length is approximately 9.25 inches, and for arm band or ankle bands the length is preferably approximately 12.5 inches in length.

[0043] First layers 22 or 114 can have contoured edges 26 and 116 extending beyond edges of second layers 28 and 118, respectively, so that first layers 22 and 114 may be fixed to second layers 28 and 118, yet first layers 22 and 114 extend beyond seam 30 or 120. First layers 22 or 114 are preferably decorative and reflective. First layers 22 or 114 may comprise multiple layers, such as a clear vinyl outer layer overlaying a colored, fluorescent, printed or reflective layer. First layers 22 or 114 may also be made of puffy or foam material and contoured shapes 32 or 122. First and second layers 22, 114, 28 and 118 are preferably made of the same polymeric material and are preferably vinyl. A thin gauge reflective vinyl, sold under the trademark REFLEXITE, or an encapsulated glass bead reflective vinyl, sold under the trademark EXCELLITE, have been found to be particularly suited to the invention. Exposed glass bead films have also been found to be useful as a reflective layer. Plain, decorative non-reflective vinyl may also be used, as may glow-in-the-dark vinyl, holographic vinyl and others. Second layers 28 or 118 may be made of a flocked material for added comfort when placed on a person's bare limb 12.

[0044] FIG. 11 illustrates a cross-sectional view of the self-wrapping article 10 made of a glass bead reflective material. A flocked vinyl backing layer 212 serves as a foundation receiving a spring element 214, which is preferably made from steel. A reflective glass bead layer 216 is interposed between the spring elements and a top vinyl layer 218, which can be clear or tinted. After all of the layers have been positioned in a desirable spatial relationship relative to one another, such as the one as shown in FIG. 11, a one step method is implemented for attaching the layers to one another to manufacture, for example, a band 220, as seen in FIG. 12.

[0045] FIG. 13 illustrates another embodiment of the self-wrapping article shown in FIGS. 4, 10, 12 and 14. The critical feature of this embodiment includes the use of a top reflective prismatic vinyl layer 228. Comparing the prismatic layer to the reflective glass bead layer, where the glass beads are embedded in a layer of polymeric material separating the glass bead and the spring element, the prisms 230 directly face a spring element 224. During use, the spring element, typically made from steel, can scratch the prisms and reduce the brightness of the vinyl. To prevent such deterioration of the article, a thin protective vinyl layer 226 is interposed between the prismatic reflective vinyl layer and the spring element. Additionally, the protective layer 226 is preferably tinted to prevent the prism layer being influenced by the color of the spring element. A flocked vinyl background layer 222 completes an article 230, as shown in FIG. 14.

[0046] A reliable peripheral seal between extremities of the welded layers is characteristic of both embodiments shown in FIGS. 11-15. As a consequence, the space between the spring element 214, 224 and top layer 218, 228 is formed with bottom and top chambers 232, 234 separated by the glass bead layer 216 (FIG. 11) and the protective layer 226 (FIG. 13), respectively. It has been noted that air trapped in the top chamber 234 forms a large air bubble or air pocket providing the top vinyl layers 218 and 228 with a wavy surface after the article has been wrapped around a bearing surface, such as a wrist. To overcome this, small slits 240 are die cut on a surface of the layers 216, 226 to facilitate air communication between the top and bottom chambers. As a result, the air accumulated in the top chamber penetrates into the bottom chamber 232 as the article is being wrapped around the wrist to prevent formation of an air bubble within the top chamber. Note that slits are shown to extend parallel to one an other on a greatly exaggerated cross-sectional view of the protective layer (FIG. 15). However, any other spatial arrangement of the slits formed to allow air penetration from the top chamber into the bottom chamber is readily contemplated within the scope of the invention.

[0047] The preferred method of making self-wrapping decorative articles 10, 100, 200, 220 or 230 is using radio-frequency sealing to fix first layers 22, 114, 218 or 228, respectively, to second layers 28, 118, 212 and 222, respectively, while holding elongate wrapping members 14, 104, 202, 214 and 224 within the sealing edges of a radio frequency die using magnets 300 and retractable guides 302. Alternate to using magnets 300 to hold elongate wrapping members, small dots of a light tack adhesive may be applied to first layers 22 or 114 also holding elongate wrapping members in place during manufacture, but will not hamper action during use of the article 10, 100 or 200. This method allows the layers to be fixed to each other, and the elongate wrapping members 14, 104 or 202 to be encased in one step, thereby improving productivity and reducing costs. Other sealing methods may be used in the one-step method described, such as heat welding and vibration welding.

[0048] An array of a plurality of separable self-wrapping articles 10, 100 or 200 can be made using a multiple-up die, such as seven-up, twelve-up or fourteen-up dies having the shape of seven, twelve or fourteen self-wrapping decorative articles 10, 100 or 200 adjacent to one another. Scoring edges of the die define contoured edges 26 or 116 of first layers 22, 114 or 210. Cutting edges of the die are positioned so as to sever the sheet containing a plurality of removable self-wrapping decorative articles 10, 100 or 200.

[0049] Although the invention has been described with reference to a particular arrangement of parts, features and the like, these are not intended to exhaust all possible arrangements or features, and indeed many other modifications and variations will be ascertained by those skilled in the art.

Claims

1. A self-wrapping decorative article comprising:

at least one an elongate generally flat wrapping member having ends and elongate side edges and surfaces extending between the ends, the flat wrapping member being formed of a type such that the ends are capable of coming together and remaining extended;

a first decoratively shaped retroreflective layer located over one surface of said one elongate wrapping member, said first decoratively shaped layer having a lateral dimension that is substantially greater than the lateral dimension of said wrapping member, so that said first decoratively shaped layer extends with a decoratively shaped portion past at least one of said edges;

a second layer overlying another surface of said wrapping member opposite to said one surface; and

said first and second layers being affixed to each other so as to encase said elongate wrapping member and form a decoratively shaped retroreflective article capable of self wrapping around an object.

2. The self-wrapping article defined in

claim 1 wherein said second layer has a like shape and size as said first layer.

3. The self-wrapping article defined in

claim 1 wherein said layers laterally extend past both elongate side edges of said one wrapping member at a substantial distance with a decoratively shaped portion.

4. The self-wrapping article defined in

claim 1 wherein the first retroreflective layer is made from a glass bead vinyl reflective material.

5. The self-wrapping article defined in

claim 4 wherein the first retroreflective layer has a surface provided with an array of slits, the self-wrapping article further having a cover atop the surface of the first retroreflective layer, so that the space between the cover layer and the spring element is divided into top and bottom chambers, wherein the air trapped in the top chamber is penetrated through the array of slits into the bottom chamber upon wrapping the article around a bearing surface.

6. The self-wrapping article defined in

claim 1 wherein the first retroreflective layer is made from a prismatic vinyl.

7. The self-wrapping article defined in

claim 6, further comprising a protective layer interposed between the prismatic vinyl and the flat wrapping member and forming top and bottom chambers between the prismatic and layer and sprig element, the protective layer having a surface which is provided with an array of slits to facilitate air-flow communication between the top and bottom chambers.

8. The self-wrapping article defined in

claim 1, further comprising another flat self-wrapping member parallel to the flat member so that said one and another elongate members each wrap in the same direction relative to one another, said parallel wrapping members having inner elongate side edges adjacent to one other and having outer most elongate side edges opposite the inner edges;

said first decoratively shaped layer having a lateral dimension that is substantially greater than the cumulative lateral dimension of said wrapping members between its elongate side edges so that said layer extends from the outer most elongate side edges of said elongate wrapping members with a decoratively shaped portion extending past the outer most edges.

9. A self-wrapping article comprising:

an elongate generally flat wrapping member having opposite ends and elongate edges and surfaces extending between the ends, the flat wrapping member being formed of a type such that the ends are capable of coming together and remaining extended; and

top and bottom decoratively shaped layers affixed to one another along an endless sealing region to form a space receiving the wrapping member, at least one of the decoratively shaped layers being retroreflective.

10. The self-wrapping article defined in

claim 9 wherein the retroreflective layer is made from glass beads embedded in a vinyl layer and has a surface provided with an array of slits, the self-wrapping article further comprising a cover vinyl layer atop the surface of the retroreflective layer.

11. The self-wrapping article defined in

claim 9 wherein the retroreflective layer is made from a prismatic reflective vinyl layer, the self-wrapping article further comprising an intermediate protective layer between the retroreflective layer and the flat wrapping member, said protective layers having an arrangement of slits which are formed on a surface facing the retroreflective layer to facilitated air flow between a top chamber formed between the protective and cover layers and a bottom chamber formed between the protective layer and the spring element.

12. A process for producing self-wrapping decorative articles comprising the steps of:

providing an elongate generally flat wrapping member having ends, elongate side edges and surfaces and being formed of a type such that the ends are capable of coming together and remaining extended;

positioning the elongate wrapping member in its extended position over one surface of a flat decoratively-shaped layer;

providing a first decoratively shaped layer made from a retroreflective material and a second decoratively shaped layer;

remotely holding the elongate wrapping member in position between the first and second decoratively shaped layers; and

fixing the first and second layers together thereby encasing the elongate wrapping member therebetween.

13. The process defined in

claim 12 further comprising the steps of providing a protective layer fixed to the first and second layers and interposed between the first layer made from a prismatic reflective vinyl layer and the flat wrapping member, and providing a surface of the protective layer with an arrangement of slits.

14. The process defined in

claim 12 further comprising the steps of providing a cover layer made from vinyl atop the retroreflective layer embedded with glass beads, and forming an array of slits on a surface of the retroreflective layer embedded with glass beads to facilitate air flow from a top chamber between the retroreflective and cover layer to a bottom chamber between the retroreflective layer and the spring element as the article is being wrapped around a bearing surface.