Synthetic cork with a natural cork appearance and method of making it
A method of producing random and irregular markings and impressions on synthetic cork stoppers so as to closely mimic the surface texture of natural cork, and the stoppers produced thereby. In one embodiment, the stopper is produced in a mold featuring a textured inner surface. In another embodiment, the stopper is extruded.
This application claims priority from U.S. provisional application No. 60/751,299.
FIELD OF INVENTIONThis invention relates to the field of container closures commonly utilizing natural or basic synthetic cork.
BACKGROUND OF THE INVENTIONProducers of wine and other products that are sold in bottles or other containers that are traditionally closed and sealed with cork stoppers have long been concerned about contamination of the cork, which can lead to spoilage of the product within the container. In the case of wine or olive oil, for example, such spoilage is immediately noticeable by the consumer and renders the product unfit for consumption.
For that reason, there has been a movement in recent times toward the use of synthetic stoppers in place of cork. The material used in the synthetic stopper will depend on the characteristics of the container's contents. If the synthetic materials used are non-reactive with the contents of the container, the synthetic stopper is a complete solution to the problem of contamination of the cork, and consequently the contents of the container.
However, penetration of synthetic stoppers into the food and wine container industry has been slow. Many producers of food and wine are reluctant to switch from traditional corks to synthetic stoppers for purely aesthetic reasons. Cork has a distinctive color and appearance in that it is rarely smooth, but rather is pockmarked with dark spots and often covered with pits and small voids in the surface of cut cork. Synthetic cork products have been produced to approximate the color, but not the physical appearance, of natural cork. Attempts have been made to create a synthetic stopper that realistically imitates natural cork. U.S. Pat. No. 4,363,849 (Paisley et al.) discloses an injection molding process wherein “coils” of synthetic material are injected into a mold; the boundaries between the “coils” create random lines in the stopper surface. U.S. Pat. No. 4,507,405 (Paisley et al.) discloses that these coils may be injected along with a colorant to accentuate the boundary lines. U.S. Pat. No. 4,522,856 (Paisley et al.) discloses a method of coloring the synthetic stopper to appear more like natural cork. However, these references disclose only methods of effectively “drawing” a cork-like appearance on the stopper surface in two dimensions. In order to gain wider acceptance, a need exists for synthetic stoppers with textured surfaces that appear more like the natural cork to which people are accustomed.
SUMMARY OF INVENTIONIn order to more accurately simulate the appearance of natural cork, the appearance of the exterior surface of the synthetic stopper should feature random and irregular holes, markings, or dimples. The surface may also feature color variations as found in natural cork. Viewed broadly, the invention provides a method of producing random and irregular holes, markings, and dimples on the surface of a synthetic stopper. The invention includes, in another aspect, the stopper made to appear as if it was formed of natural cork.
BRIEF DESCRIPTION OF THE DRAWINGS
Methods of creating the random and irregular markings of the present invention include molding the details directly into the surface of the stopper and extruding the synthetic material into a desired shape before passing it through forming cylinders or rollers that contain the negative of the desired surface texture, and which imprint the texture onto the material's exterior surface.
It should be clear to persons skilled in the art that the cross-sectional shape of material 20 (and thus stopper 10) is not limited to a circle, and that rollers 24 may likewise be shaped to conform to the desired final cross-sectional shape of stopper 10. Although molding and extrusion are discussed herein, other methods of forming synthetic stoppers are known in the art. Likewise, while the impressing step is preferably performed by rollers, it may also be performed by other means; as used in this invention, “impressing” includes 3-dimensional detailing of the stopper surface by any means. The desired impressions could be stamped into the extruded soft synthetic material by stamps preferably shaped so as to contact substantially all of the material's exterior surface. The impressions could be cut by blades into the surface of the material, either before or after it hardens. The material also may be routed through the impressing step in any orientation, and need not be processed individually. For example, individual stoppers could be arranged in a layer, and impressed in batches.
Synthetic material suitable for use in stoppers is well-known in the art. Suitable materials include hot resin in either compact form or expanded via foaming/expanding agents. The guiding characteristics for selecting a material are non-reactivity with the expected container contents and softness, determined by compressibility and recuperation. Roughness is not necessarily a limitation, as it will depend on the individual application. Any color may be used, but will preferably mimic natural cork. The color also may or may not include dark points as found in natural cork.
The preferred embodiments of the present invention are used to store wine; however, use of the stoppers as described is not limited to wine, or even food; the stoppers may be used any container where use of a compressible, non-reactive stopper is desirable.
Claims
1. A method of producing a container stopper having the appearance of natural cork comprising:
- forming a soft synthetic material into a size and shape to fit an opening in a container;
- introducing the synthetic material to a forming device for impressing random and irregular pits and markings on the exterior surface of said material;
- cutting the material into discrete lengths; and
- hardening the material to a form suitable to fit into and seal the opening in the container.
2. A method of producing random and irregular markings on synthetic stoppers, comprising:
- forming a mold having on its inner surface randomly arranged contours, bumps, and ridges;
- introducing a soft synthetic material into the mold, so as to impress the contours, bumps, and ridges into the surface of the synthetic material to form desired holes, markings, and dimples in the synthetic material, the resulting holes, markings, and dimples being the negative of the contours, bumps, and ridges;
- allowing the synthetic material to harden so as to render the impressed holes, markings, and dimples permanent on the exterior surface of the synthetic material.
3. A method of producing random and irregular markings on synthetic stoppers, comprising:
- extruding soft synthetic material into a form having a smooth exterior surface;
- introducing the synthetic material to impressing means so as to create random and irregular holes, markings, and dimples on the exterior surface of the synthetic material;
- cutting the synthetic material into discrete lengths; and
- allowing the synthetic material to harden.
4. The method of claim 3, wherein the impressing step is performed concurrently with the extrusion step.
5. The method of claim 3, wherein the impressing means comprise one or more stamps.
6. The method of claim 3, wherein the impressing means comprise one or more cutting blades.
7. The method of claim 3, wherein the extruded synthetic material has a circular cross-section, and the impressing means comprise rollers shaped to contact substantially the entire circumference of the material.
8. A synthetic stopper produced by the method of claim 7.
9. A synthetic stopper produced by a method comprising:
- forming a mold having on its inner surface randomly arranged contours, bumps, and ridges;
- introducing a soft synthetic material into the mold, so as to impress the contours, bumps, and ridges into the synthetic material to form desired holes, markings, and dimples in the synthetic material, the resulting holes, markings, and dimples being the negative of the contours, bumps, and ridges;
- allowing the synthetic material to harden so as to render the impressed holes, markings, and dimples permanent on the exterior surface of the synthetic material.
Type: Application
Filed: Dec 19, 2006
Publication Date: Aug 30, 2007
Inventors: Alberto Baban (Noale), Miguel Escobar (Col. Bellavista)
Application Number: 11/640,999
International Classification: D02G 3/00 (20060101);