DEVICE AND METHOD OF MANUFACTURE FOR A METAL BRACELET

Abstract

A multi-substrate bracelet, a method of manufacturing the bracelet, and several tool assemblies used in the manufacturing process are presented. The tool assemblies include a cutting table assembly, a forming-device assembly, and other manual tools. The cutting table assembly is utilized to create an encasement blank from a stock of encasement raw material. The forming-device assembly includes both an encasement blank-forming male die element and an encasement blank-forming female die element. The forming-device assembly is used to form a metal pre-formed encasement blank from an octagonally-shaped planar blank. An insert is positioned within the pre-formed encasement blank. The completed insert and encasement assembly is formed into a semi-circular shape having a gap between the transverse ends of the encasement for placement onto an individual's arm.

Description

FIELD OF THE INVENTION

The present invention relates to jewelry, and more particularly, to a multi-substrate body having a primary substrate partially encapsulating and creating a frame about a periphery of a second substrate formed into a “C”-shape to be worn as a bracelet or similar accessory and a device and method of manufacturing the same.

BACKGROUND OF THE INVENTION

Fashion is one means of expression for each individual. Fashion includes contributions from many segments, including apparel, such as dresses, shirts, blouses, pants, skirts, jackets, etc.; shoes; headwear, such as hats, scarves, etc.; and accessories, such as jewelry, handbags, etc. Each of these has many variants that appeal to each person's individual taste and style.

Jewelry, as one contributor to fashion, introduces multiple options for self-expression. Jewelry includes a wide variety of classifications, including necklaces, rings, earrings, bracelets, anklets, pins and broaches, and the like. Each of these examples can be designed in any of a variety of shapes, fabricated using any of a variety of materials or combinations of materials, and manufactured using processes such as sculpting, casting, drawing, soldering, and the like.

Bracelets are one distinct form of jewelry. The term “bracelet” can collectively refer to a bracelet that is worn around one's wrist; an ankle bracelet or anklet, which is worn around one's ankle; a boot bracelet, which is used to decorate a shaft of a boot; and other applications.

Bracelets can be manufactured from metal, leather, cloth, plastic or other materials and sometimes contain gemstones or jewels, rocks, wood, shells, crystals, metal or plastic hoops, pearls and many more materials. In addition to fashion, bracelets are also used for medical and identification purposes, such as allergy bracelets and hospital patient-identification tags and also bracelet tags worn for newborn babies.

Bracelets are commonly classified by the following styles:

a) Charm bracelets, which are designed in a variety of shapes and commonly carry personal charms, decorative pendants, or trinkets which are signifiers of important things in the wearer's life.

b) Bangles, which are rigid bracelets usually fabricated from metal, wood, plastic or any other suitable material.

c) Slap-bracelets, which are felt covered metal strips that curved around one's wrist when gently hit against it.

d) Beaded bracelets, which are usually manufactured from loose beads with a center hole and connected by a piece of string or elastic band through the holes.

e) Link bracelets, which are bracelets made from connecting or linking various or similar components or jewelry findings. Link bracelets can be made of a variety of materials included metals and gemstones.

f) Alternative health bracelets, which are a separate group not distinguished by their design but by the beneficial function claimed for them by their manufacturers and distributors.

g) Sports bracelets, which are fabricated of a colored short tubular silicone rubber having an embossed identification for promoting awareness of information and/or charity campaigns.

The fashion industry constantly strives for new and unique styles. Some styles are fads, such as the slap bracelets. Others become a fashion statement, such as sports bracelets. Thus there remains a need for an innovative bracelet.

It is known to create bracelets from metal. This creation is often done manually using a sharp implement to cut the metal, pliers to bend the metal, and a round tool to shape the metal into a wrist-shaped cuff. Crafters may enjoy the hands-on creative experience and buyers appreciate the handmade quality, but manually creating metal bracelets with standard tools is slow and cumbersome. Other metal bracelets are created with fully automated tools; this type of fabrication is faster, but removes the personal touch and creativity of the craftsman. There remains a needs for specialized tools for manually creating a metal bracelet in a more efficient manner, while retaining the artistry of the craftsman.

SUMMARY OF THE INVENTION

The present invention introduces a multi-substrate bracelet, a method of manufacturing the multi-substrate bracelet, and several tool assemblies used in the manufacturing process. The tool assemblies include a cutting table assembly, a forming-device assembly, and other manual tools. The cutting table assembly is utilized to create an encasement blank from a stock of encasement raw material. The forming-device assembly includes both an encasement blank-forming male die element and an encasement blank-forming female die element. The forming-device assembly is used to form a metal pre-formed encasement blank into a U-shape.

The bracelet comprises an insert retained within an encasement. The encasement is fabricated from an octagonally-shaped planar blank. Four frame segments are formed by bending the planar blank along each of four fold lines. Each fold line bisects two chamfered edges of the planar blank. The insert is centrally located between each of the four fold lines. Each frame segment is folded inward approximately 180 degrees to encase and retain each associated edge of the insert. The sections of the chamfered edge located at the ends of the frame segments form a miter at each frame segment abutment. The visible surface of the insert can be embellished with artwork or any other aesthetically enhancing element. The completed insert and encasement assembly is formed into a semi-circular shape having a gap between the transverse ends of the encasement for placement onto an individual's arm.

The invention also describes the multi-substrate bracelet and a method of manufacturing the bracelet. This method includes sizing a sheet of planar raw material to a predetermined length and width; chamfering each of four corners of the sheet of planar material; using the forming-device assembly to bend the sheet of planar material to form a pair of longitudinal fold lines; orienting an insert with a contact side facing the planar encasement material; bending each longitudinal frame segment of the pair of longitudinal frame segments inward to cover a peripheral portion of an elongated edge of the insert; bending the sheet of planar material to form a pair of transverse fold lines; bending each transverse frame segment of the pair of transverse frame segments inward and substantially parallel to the central section of the planar material so that each of the pair of transverse frame segments covers a peripheral portion of a transverse edge of the insert; and forming the length of the encasing into a semi-circular shape.

In another aspect, the step of sizing a sheet of planar material to a predetermined length creates two parallel transverse edges.

In yet another aspect, the step of sizing a sheet of planar material to a predetermined width creates two parallel longitudinal edges.

In yet another aspect, the method further comprises a step of rolling each of the pair of longitudinal frame segments to adequately seat the pair of longitudinal frame segments against the insert.

In yet another aspect, the method further comprises a step of rolling each of the pair of transverse frame segments to adequately seat the pair of transverse frame segments against the insert.

In yet another aspect, the steps of rolling each of the pair of frame segments is accomplished by employing a cylindrically-shaped radial surface of a curve-forming tool.

In yet another aspect, the method further comprises a step of chamfering each sharp corner or edge formed as a result of each folding step. The chamfering step can be accomplished by filing each sharp corner or edge.

In yet another aspect, the method further comprises a step of de-burring at least a portion of the edges of the sized sheet of planar material.

In yet another aspect, the step of forming the length of the encasing into a semi-circular shape is accomplished employing a curve-forming tool.

In yet another aspect, the insert is fabricated from a beverage container.

In yet another aspect, the insert is fabricated from an aluminum beverage container.

These and other aspects, features, and advantages of the present invention will become more readily apparent from the attached drawings and the detailed description of the preferred embodiments, which follow.

BRIEF DESCRIPTION OF THE DRAWINGS

The preferred embodiments of the invention will hereinafter be described in conjunction with the appended drawings provided to illustrate and not to limit the invention, in which:

FIG. 1 presents an isometric view of a cutting table assembly;

FIG. 2 presents an isometric view of the cutting table assembly illustrating a first encasement blank formation step sizing an encasement raw material to a predetermined length defining a pair of transverse edges;

FIG. 2A presents a plan view of an exemplary first step of preparing the encasement raw material, the first step referencing a step accomplished in FIG. 2;

FIG. 3 presents an isometric view of the cutting table assembly illustrating a second encasement blank formation step sizing the encasement raw material to a predetermined width defining a pair of longitudinal edges;

FIG. 3A presents a plan view of an exemplary second step of preparing the encasement raw material, the second step referencing a step accomplished in FIG. 3;

FIG. 4 presents an isometric view of the cutting table assembly illustrating a third encasement blank formation step chamfering each corner of the sized encasement raw material;

FIGS. 4A, 4B, and 4C present plan views of an exemplary third step of preparing the encasement raw material, the third step referencing a step accomplished in FIG. 3;

FIG. 5 presents an isometric view illustrating a step of embossing the sized encasing blank;

FIG. 6 presents an isometric view of the die and the sized encasement blank illustrating a step of creating a pair of longitudinal frame segments in the sized encasement blank;

FIG. 7 presents a sectioned end view of the die and the sized encasement blank illustrating the step of creating the pair of longitudinal frame segments in the sized encasing blank;

FIG. 8 presents an isometric bottom view of the sized encasement blank having the pair of longitudinal frame segments in a partially bent state;

FIG. 9 presents an isometric top view of the sized encasement blank of FIG. 8, wherein the sized encasement blank is seated upon a frame segment forming station wherein each perpendicularly formed longitudinal frame segment transitions into an acutely angled longitudinal frame segment by additionally bending the longitudinal frame segment inward;

FIG. 10 presents an isometric top view of the sized encasement blank of FIG. 9, illustrating a step of sliding an insert into an assembly location between each of the pair of acutely angled longitudinal frame segments;

FIG. 11 presents an isometric top view of a bracelet as formed in FIG. 10, illustrating a step of rolling each of the pair of transverse frame segments to adequately seat the pair of transverse frame segments against the insert;

FIG. 12 presents an isometric front view of a bracelet assembly being formed about a curve-forming tool; and

FIG. 13 presents an isometric front view of the completed bracelet assembly.

Like reference numerals refer to like parts throughout the several views of the drawings.

DETAILED DESCRIPTION

Shown throughout the figures, the present invention is directed toward a multi-substrate bracelet 800, a method of manually manufacturing the multi-substrate bracelet assembly 800, and several tool assemblies used in the manufacture. The tool assemblies include a cutting table assembly 100, a forming-device assembly, and other manual tools. The cutting table assembly is utilized to create an encasement blank from a stock of encasement raw material. The forming-device assembly includes both an encasement blank-forming female die element 500 and an encasement blank-forming male die element 550. The forming-device assembly is used to form a metal pre-formed encasement blank into a U-shape.

The multi-substrate bracelet assembly 800, as illustrated in FIG. 13, includes a primary substrate, formed encasement blank 300, partially encapsulating and creating a frame about a periphery of a second substrate, insert 700, as best shown in FIGS. 10 and 11, which is then formed into a “C”-shape to be worn as a bracelet or similar accessory. An exemplary method of manufacturing the bracelet assembly 800 is described in FIGS. 1 through 12. For purposes of description herein, the terms “upper”, “lower”, “left”, “rear”, “right”, “front”, “vertical”, “horizontal”, and derivatives thereof shall relate to the invention as oriented in FIG. 1.

The formed encasement blank 300 is fabricated from a planar sheet of material, referred to as an encasement raw material 200 (introduced in FIG. 2). The encasement raw material 200 is subjected to a series of shearing steps that shape a peripheral edge into a designed outline. The shaping process can be accomplished using any suitable edge defining process. The exemplary embodiment employs a cutting table assembly 100 for shearing the encasement raw material 200, creating the desired outline. The exemplary cutting table assembly 100 includes three shaping guide stations, a length cutting station 120 (FIG. 1), a width cutting station 140, and a corner chamfering station 160, assembled to a cutting table object support surface 112 of a cutting table 110. Each of the shaping guide stations are designed and located upon the cutting table object support surface 112 to position the encasement raw material 200 passing across a shearing edge 199 of the cutting table 110 to shear the encasement raw material 200 creating the desired respective edge.

An initial step of shaping the encasement raw material 200 into a formed encasement blank 300, as illustrated in FIG. 2 and reference illustration 2A, is accomplished utilizing the length cutting station 120 (FIG. 1). The initial step of shaping the encasement raw material 200 into a formed encasement blank 300 shortens the encasement raw material 200 to a target encasement substrate blank longitudinal length 229 (FIG. 2A). The length cutting station 120 is defined by a longitudinal edge support element 122 and a length establishing element 126. A longitudinal edge support surface 124 of the longitudinal edge support element 122 is preferably oriented at a right angle (90°) to the shearing edge 199. The length cutting station 120 includes a length establishing element 126 having a length establishing abutment surface 128. The length establishing abutment surface 128 is located to define a template longitudinal span 129. The length establishing abutment surface 128 is preferably oriented at a right angle (90°) to the longitudinal edge support surface 124, also being parallel to the shearing edge 199. The preferred encasement raw material 200 is initially provided having two reference edges at right angles (90°) to one another. The longer of the two reference edges is located abutting the longitudinal edge support surface 124. The shorter of the two reference edges is located abutting the length establishing abutment surface 128. A longitudinal excess raw material 220 is removed from the encasement raw material 200 by shearing the encasement raw material 200 along the shearing edge 199 reducing the overall length of the encasement raw material 200 to the encasement substrate blank longitudinal length 229.

A second step of shaping the encasement raw material 200 into a formed encasement blank 300 is accomplished utilizing the width cutting station 140 as illustrated in FIG. 3 and reference illustration 3A. The second step of shaping the encasement raw material 200 into a formed encasement blank 300 narrows the encasement raw material 200 to a target encasement substrate blank transverse width 249 (FIG. 3A). The width cutting station 140 is defined by a transverse edge support element 142. A transverse edge support surface 144 of the transverse edge support element 142 is oriented parallel to the shearing edge 199 at a distance defining a template transverse span 149. The encasement raw material 200 in its current state has three of four dimensional edges defined. One of the longer edges is located abutting the transverse edge support surface 144. A transverse excess raw material 240 is removed from the encasement raw material 200 by shearing the encasement raw material 200 along the shearing edge 199 reducing the overall width of the encasement raw material 200 to the encasement substrate blank transverse width 249.

A third step of shaping the encasement raw material 200 into a formed encasement blank 300 is accomplished utilizing the corner chamfering station 160 as illustrated in FIG. 4 and reference illustrations 4A, 4B, and 4C. The third step comprises a series of sub-steps to form chamfers across each of four corners of the encasement raw material 200.

The corner chamfering station 160 is defined by a first elongate edge supporting element 162, a second elongate edge supporting element 166, and a chamfer location establishing element 172. A first elongate edge supporting surface 164 of the first elongate edge supporting element 162 defines a chamfer angle 169 (FIG. 1). The chamfer angle 169 preferably establishes a forty-five degree (45°) angle to the shearing edge 199. A second elongate edge supporting surface 168 of a second elongate edge supporting element 166 is located parallel to the first elongate edge supporting surface 164 having a distance therebetween that is equal to the encasement substrate blank transverse width 249 (FIG. 3A). The second elongate edge supporting surface 168 similarly defines the chamfer angle 169 at a forty-five degree (45°) angle to the shearing edge 199.

The corner chamfering station 160 includes a chamfer location establishing element 172 having a chamfer location establishing abutment surface 174. The chamfer location establishing abutment surface 174 is distanced from shearing edge 199 the proper distance to establish the dimensions of each chamfer. The dimensions of the chamfers additionally define the width of each frame member (to be described in more detail later within this disclosure). The chamfer location establishing abutment surface 174 is preferably oriented at a right angle (90°) to the first elongate edge supporting surface 164 and second elongate edge supporting surface 168, resulting in a forty five degree (45°) angle of chamfer location establishing abutment surface 174 respective to the shearing edge 199. The current configuration of the exemplary encasement raw material 200 is a rectangular shaped planar stock of material. The encasement raw material 200 is seated between and abutting each of the first elongate edge supporting surface 164 and second elongate edge supporting surface 168. The encasement raw material 200 is slid towards the chamfer location establishing element 172 until the transverse edge of the encasement raw material 200 abuts the chamfer location establishing abutment surface 174. This establishes a process for repeatedly forming all four (4) chamfers having like dimensions. A first chamfered corner 262 is formed, as shown in the reference illustration of FIG. 4A. The encasement raw material 200 is rotated about a longitudinal axis in accordance with a longitudinal axial rotational motion 260. The encasement raw material 200 is reseated within the corner chamfering station 160 in preparation for creating a second chamfered corner 264. The encasement raw material 200 is sheared creating the second chamfered corner 264 as shown in the reference illustration of FIG. 4B. The encasement raw material 200 is removed and rotated along a plane defined by the material in accordance with a planar rotational motion 270 and reseated within the corner chamfering station 160 to form a third chamfered corner 266. The encasement raw material 200 is again removed and rotated about a longitudinal axis in accordance with the longitudinal axial rotational motion 260 and is reseated within the corner chamfering station 160 to form a fourth chamfered corner 268. Once the edges are sheared, the encasement raw material 200 can be subjected to a post shearing de-burring or other edge softening process to alleviate risk of injury to an individual wearing the bracelet assembly 800. With the outline of the encasement raw material 200 finished, the encasement raw material 200 is transformed into a formed encasement blank 300 and prepared for further processing. Though this method has been presented with specific rotational motions 260, 270, other series, steps and types of rotational motions can be utilized to turn each corner toward shearing edge 199 to remove the encasement raw material 200. Also, though this method has been described with specific angles, such as chamfer angle 169, the alignment of the elements of the corner chamfering station 160 can be modified to create other angles, as desired.

Although the above presented steps describe a series of steps collectively characterizing a single exemplary process for manually defining a peripheral edge of the formed encasement blank 300, it is understood that any suitable process may be employed to create the desired outline of the formed encasement blank 300. This can include laser cutting, stamping, water-jet cutting, machining (such as end-milling), and the like.

Features of the formed encasement blank 300 are referenced in FIG. 5 as an encasement blank exposed surface 310, an encasement blank concealed surface 312, a pair of longitudinal edges 320, a pair of transverse edges 340, and four (4) chamfers 362, 364, 366, 368 across each respective corner.

As seen in FIG. 5, a marking or embossing 380 can be applied to the encasement blank exposed surface 310 of the formed encasement blank 300 using any suitable marking application process. The exemplary marking process creates an embossing within the material. The embossing is created by positioning and striking an embossing die 400 against the encasement blank exposed surface 310 as illustrated in FIG. 5. The formed encasement blank 300 is supported by placing the encasement blank concealed surface 312 against a planar supporting surface. The embossing die 400 includes a volume of material (preferably a metal) formed having an embossing die front face 410, an embossing die side edge 412, an embossing die hammer surface 414, and an embossing die striking surface 420. A die formed having a mirrored image of the desired marking 380 extends proud of the embossing die striking surface 420. The die (not shown, but well understood by those skilled in the art) is placed resting against the encasement blank exposed surface 310 in a desired location for marking the formed encasement blank 300. The fabricator strikes the embossing die hammer surface 414 with a striking tool (such as a hammer), transferring a force to the die, which creates an emboss of the embossing 380. It is understood that the denser the material of the embossing die 400, the better the transfer of the striking force to the die.

A pair of perpendicularly formed longitudinal frame segments 322 are formed using an encasement blank-forming female die element 500 in combination with an encasement blank-forming male die element 550 as illustrated in FIGS. 6 and 7 for use in forming the formed encasement blank 300 into a “U”-shape as illustrated in FIG. 8.

The encasement blank-forming female die element 500 is fabricated having an upper surface 521 configured with a die surface, lower surface 525 (FIG. 7) opposite the upper surface 521 (FIG. 6), opposing end surfaces 526, and opposing longitudinally-extending side surfaces 523. The lower surface 525, opposing end surfaces 526, and opposing longitudinally-extending side surfaces 523 are generally planar forming a longitudinally extended rectangular shape. The die surface is formed as a concave U-shaped channel in the upper surface 521 of the encasement blank-forming female die element 500, which is shown as an inverted “U” in the orientation of the images. The concave U-shaped channel is formed with two troughs separated by a blank supporting surface 530. The U-shaped channel is shaped to support the formed encasement blank 300 and form each of the perpendicularly formed longitudinal frame segments 322.

The concave U-shaped central channel of encasement blank-forming female die element 500 is defined by a pair of female die engaging guide surfaces 522, a pair of female die blank edge-forming tongues 520, a pair of female die blank edge-forming surfaces 524, and a blank supporting surface 530. The two female die engaging guide surfaces 522 are parallel in arrangement and define the outer edges of the inverted U-shaped channel. The distance from the upper surface 521 of the encasement blank-forming female die element 500 to the female die blank edge-forming tongue 520 defines a depth of the U-shaped channel. The distance between each of the pair of female die engaging guide surfaces 522 defines a channel span 529. The channel span 529 is approximately equal to the encasement substrate blank transverse width 249 (FIG. 3A) of the formed encasement blank 300. The U-shaped channel includes a raised rectangular ridge extending centrally parallel to the pair of female die engaging guide surfaces 522. The raised rectangular ridge is defined by a pair of female die blank edge-forming surfaces 524 extending upward from the female die blank edge-forming tongue 520 and longitudinal edge 320 extending horizontally (or generally perpendicularly to each of the female die blank edge-forming tongues 520) between each of the distal or upper ends of the female die blank edge-forming tongues 520. The longitudinal edge 320 (FIG. 5A)provides a platform for supporting the formed encasement blank 300. Each corner created between the blank supporting surface 530 and the female die blank edge-forming surface 524 defines a breakpoint for forming each respective perpendicularly formed longitudinal frame segment 322.

The encasement blank-forming male die element 550 is fabricated having an upper die striking surface 560, a lower tongue distal surface 570 opposite the striking surface 560 that is configured with a die surface, opposing end surfaces 566, and opposing longitudinally-extending side surfaces 563. The die surface forms a U-shaped die that mimics the shape of the die surface of the encasement blank-forming female die element 500. A width of the encasement blank-forming male die element 550 spans between a pair of male die engaging guide surfaces 562. The pair of male die engaging guide surfaces 562 is parallel in arrangement and defines a male die width 579. The male die width 579 is substantially equal to the channel span 529 providing a snug fit when the encasement blank-forming male die element 550 is inserted into the U-shaped channel. The die portion of the encasement blank-forming male die element 550 includes a pair of projecting legs, each leg being defined by a male die blank edge-forming surface 574, a portion of the male die engaging guide surface 562 opposite the male die blank edge-forming surface 574 and a tongue distal surface 570 extending between the male die blank edge-forming surface 574 and the associated section of the male die engaging guide surface 562. A recess or clearance is created between each of the pair of legs. The recess or clearance is defined by a combination of the pair of male die blank edge-forming surface 574 and a male die vertical surface stop 580 extending therebetween.

The forming surface of the encasement blank-forming female die element 500 and the forming surface of the encasement blank-forming male die element 550 differ slightly in dimension to accommodate for a thickness of the formed encasement blank 300, wherein the thickness is defined as the distance between the encasement blank exposed surface 310 and the encasement blank concealed surface 312. The length of the blank supporting surface 530 (referenced as a blank supporting platform width 539) defines the finished width of the bracelet assembly 800 as well as the width of each of the perpendicularly formed longitudinal frame segments 322.

In use, the formed encasement blank 300 is placed into the U-shaped channel of the encasement blank-forming female die element 500 oriented where the encasement blank concealed surface 312 contacts the blank supporting surface 530. Each longitudinal edge 320 of the formed encasement blank 300 contacts each respective female die engaging guide surface 522, centering the formed encasement blank 300 within the U-shaped channel. The encasement blank-forming male die element 550 is inserted into the U-shaped channel. Each male die engaging guide surface 562 slidably engages with the associated female die engaging guide surface 522, aligning each leg of the encasement blank-forming male die element 550 with the associated downward opening in the encasement blank-forming female die element 500. The corner defined by the intersection between the female die blank edge-forming surface 524 and the blank supporting surface 530 provides a break location, which forms a longitudinal edge break 321 (FIG. 8). The longitudinal edge break 321 segments the formed encasement blank 300 into a pair of perpendicularly formed longitudinal frame segments 322 and an exposed rear segment. The perpendicularly formed longitudinal frame segments 322 are bent to approximately right angles (90°) from the plane of the exposed rear segment as best illustrated in FIG. 7.

The encasement blank-forming female die element 500 and encasement blank-forming male die element 550 are separated from one another and the “U”-shaped formed encasement blank 300 is removed from the forming tool set.

For completion of the next steps, the “U”-shaped formed encasement blank 300 is placed upon a frame segment forming station 600 as illustrated in FIGS. 9 and 10. The frame segment forming station 600 includes a forming station longitudinal edge support element 622 assembled to a forming station platform work surface 612 of a frame segment forming station platform 610. A forming station longitudinal edge support surface 624 of the forming station longitudinal edge support element 622 is preferably located at a distance from an edge of the frame segment forming station platform 610 equaling a span between each of the longitudinal edge breaks 321. The formed encasement blank 300 is oriented with the encasement finished exposed surface 311 facing the forming station platform work surface 612 and placing onto the forming station platform work surface 612. One of the perpendicularly formed longitudinal frame segment 322 is located abutting the forming station longitudinal edge support surface 624. A longitudinal edge frame member bending force 650 is exerted upon the exposed perpendicularly formed longitudinal frame segment 322 further bending the perpendicularly formed longitudinal frame segment 322 to an angle and is subsequently referenced as an acutely angled longitudinal frame segment 324. The formed encasement blank 300 is then rotated about a plane defined by the forming station platform work surface 612 and reseated, placing the acutely angled longitudinal frame segment 324 abutting the forming station longitudinal edge support surface 624 as illustrated in FIG. 10. The remaining perpendicularly formed longitudinal frame segment 322 is subjected to the longitudinal edge frame member bending force 650 and further bent to an angle and is also subsequently referenced as an acutely angled longitudinal frame segment 324. An insert 700 is fabricated having a width that is proximate or slightly shorter than a span between each of the longitudinal edge breaks 321 and a length that is proximate or slightly shorter than a span between each of the fold corners created at the ends of each of the longitudinal edge break 321. The insert 700 is fabricated of a thin sheet of material, where a first side is designated as an insert exposed surface 710 and a second, opposite side is designated as an insert contact surface 714. Artwork 712 can be applied to the exposed surface 710 of the insert 700 using any suitable artwork creation process, such as painting, screening, etching, and the like. In one example, the insert exposed surface 710 is fabricated by cutting an aluminum beverage container to the required dimensions, where the artwork 712 is pre-applied to the beverage container. In a second example, the insert 700 can be fabricated of a contrasting material, such as a different metal, a similar metal having a different finish, a section of fabric, a section of leather, a thin section of wood veneer, a section of thin, planar plastic, and the like. Although the insert 700 would lack distinction, it is also understood that the insert 700 and the formed encasement blank 300 can be fabricated of the same material and the same finish. While discussing aesthetically distinguishing features, it is also understood that decorative features can be applied to portions or the entire formed encasement blank 300.

As seen in FIG. 10, the insert 700 is slidably inserted against the encasement finished concealed surface 313, between each of the acutely angled longitudinal frame segments 324 into a centered position in accordance with an artwork substrate insertion motion 720. Once the insert 700 is properly positioned, the pair of acutely angled longitudinal frame segments 324 are bent or folded further until each acutely angled longitudinal frame segment 324 is substantially parallel with the central or primary segment of the formed encasement blank 300, entrapping the insert 700 within the formed encasement blank 300. Each of the trapazoidally shaped ends, referred to as a transverse frame segment 344 (FIG. 11) are bent inwardly or folded over using any suitable folding process. Each transverse frame segment 344 is folded along a transverse edge break 341 (FIG. 13), in a manner similar to the folding of the acutely angled longitudinal frame segment 324 about a longitudinal edge break 321 (FIG. 10). The fold line is naturally defined by the rigidity created folded sections, which created each of the acutely angled longitudinal frame segments 324. Each of the fold lines 321 of the frame segments 324 (FIG. 10) bisects the chamfered corners 362, 364, 366, 368 (FIG. 8). The portion of the chamfered edges terminating each end of the frame segments 324 (FIG. 10) is referred to as an acutely angled chamfered edge 374, 376 (FIG. 8). The acutely angled chamfered edges 374, 376 are preferably designed to create a nearly seamless mitered joint when the longitudinal frame segments 324 and the transverse frame segments 344 are folded into a planar configuration as illustrated in FIG. 11. The longitudinal frame segments 324 and the transverse frame segments 344 can be subsequently pressed using any suitable tool. In the exemplary embodiment, the fabricator is using a curve-forming tool 900 to press the longitudinal frame segments 324 and the transverse frame segments 344. The curve-forming tool 900 is shown with a smaller diameter in FIG. 12 and with a larger diameter in FIG. 13.

The curve-forming tool 900 is preferably a suitable cylindrical body having a distance between a curve-forming tool first end wall 910 (FIG. 12) and a curve-forming tool second end wall 912 (FIG. 12) that is greater than a finished width of the formed encasement blank 300. It is also desirable that the curve-forming tool 900 has a curve-forming tool diameter 919 matching a desired bracelet inside diameter 319 (FIG. 13) of the bracelet assembly 800. This enables a dual function for the curve-forming tool 900. A cylindrically-shaped radial surface 920 of the curve-forming tool 900 is placed upon the exposed surfaces of the longitudinal frame segments 324 and the transverse frame segments 344 and rolled, in accordance with a curve-forming tool rolling motion 950, to apply a suitable and distributed pressure to the longitudinal frame segments 324 and the transverse frame segments 344, resulting in a desirable, generally uniform finished surface. Each of the corners of the formed encasement blank 300 can be finished using any suitable abrasive tooling to soften the sharpness that may result from the bending and forming processes. This can be accomplished by filing the corners, sanding the corners, or any other suitable smoothing process.

A final step for fabricating the bracelet assembly 800 would be to form the planar assembly into a semi-circular assembly, as illustrated in FIG. 12. The bracelet assembly 800 is bent about the cylindrically-shaped radial surface 920 of the curve-forming tool 900 using any suitable bending process. If desired, multiple sizes of curve-forming tool 900 can be used in the bending process, beginning with a larger diameter and going to a smaller diameter. In a preferred embodiment, a circumference of the curve-forming tool 900 is greater than a length of the finished formed encasement blank 300. This enables a complete formation of the semi-circular shape without overlap and more importantly, creates a gap between each of the pair of transverse edge breaks 341 as illustrated in FIG. 13. The gap provides access for placement of the bracelet assembly 800 over an individual's wrist without deforming the bracelet assembly 800.

The bracelet assembly 800 is presented as one exemplary embodiment. It is understood that the exemplary bracelet assembly 800 can be modified based upon the original disclosure submitted herein. For example, although the exemplary formed encasement blank 300 includes a pair of acutely angled longitudinal frame segment 324 and a pair of transverse frame segment 344, it is understood that the formed encasement blank 300 may be limited to a pair of acutely angled longitudinal frame segment 324. The formed encasement blank 300 can be shaped including a pair of elongated edges and a pair of transverse edges, wherein the edges can be of any suitable shape, such that when folded forming the respective frame segments, the elongated edges and the transverse edges provide a shaped inner frame edge. The exemplary formed encasement blank 300 includes chamfered corners. In an alternative embodiment, the formed encasement blank 300 can exclude chamfering.

It is understood that the bracelet assembly 800 can be adorned with any of a variety of ornamental items. Although it is not shown, it is understood that chains or other features can be attached to each of the pair of transverse frame segments 344 in a manner extending therebetween. The bracelet assembly 800 can be adorned with studs, stones, rhinestones, glitter, paint, carvings, etching, shaped metal attachments, selective or complete plating, and the like and any combination thereof.

Each of the tools can be customized, adjustable, or adaptable to create custom sized and/or shaped bracelets 800. For example, spacer blocks can be employed to adjust the length of the corner chamfering station 160 or the angles produced by the various tools can be modified.

It will be understood that the disclosed embodiments are merely exemplary of the invention that may be embodied in various and alternative forms. The figures are not necessarily to scale, and some features may be exaggerated or minimized to show details of particular embodiments, features, or elements. Specific structural and functional details, dimensions, or shapes disclosed herein are not limiting but serve as a basis for the claims and for teaching a person of ordinary skill in the art the described and claimed features of embodiments of the present invention. The following detailed description is merely exemplary in nature and is not intended to limit the described embodiments or the application and uses of the described embodiments. As used herein, the word “exemplary” or “illustrative” means “serving as an example, instance, or illustration.” Any implementation described herein as “exemplary” or “illustrative” is not necessarily to be construed as preferred or advantageous over other implementations. All of the implementations described below are exemplary implementations provided to enable persons skilled in the art to make or use the embodiments of the disclosure and are not intended to limit the scope of the disclosure, which is defined by the claims.

Furthermore, there is no intention to be bound by any expressed or implied theory presented in the preceding technical field, background, brief summary or the following detailed description. It is also to be understood that the specific devices and processes illustrated in the attached drawings, and described in the following specification, are simply exemplary embodiments of the inventive concepts defined in the appended claims. Hence, specific dimensions and other physical characteristics relating to the embodiments disclosed herein are not to be considered as limiting, unless the claims expressly state otherwise.

Thus the above-described embodiments are merely exemplary illustrations of implementations set forth for a clear understanding of the principles of the invention. Many variations, combinations, modifications or equivalents may be substituted for elements thereof without departing from the scope of the invention. Therefore, it is intended that the invention not be limited to the particular embodiments disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all the embodiments falling within the scope of the appended claims.

Claims

1. A method of manufacturing a bracelet, the method comprising steps of:

sizing a sheet of planar material to a predetermined length defining a pair of transverse edges;

sizing a sheet of planar material to a predetermined width defining a pair of longitudinal edges;

chamfering each of four corners of said sized sheet of planar material;

bending said sheet of planar material forming a pair of longitudinal fold lines, wherein each of said longitudinal fold lines are parallel to each respective longitudinal edge of said pair of longitudinal edges defining a pair of longitudinal frame segments;

orienting an insert with a contact side facing said planar encasement material;

centrally locating said insert between each of said pair of longitudinal fold lines;

bending each longitudinal frame segment of said pair of longitudinal frame segments inward and substantially parallel to said central section of said planar material, wherein each of said pair of longitudinal frame segments covers a peripheral portion of an elongated edge of said insert;

bending said sheet of planar material forming a pair of transverse fold lines, wherein each of said transverse fold lines are parallel to each respective transverse edge of said pair of transverse edges defining a pair of transverse frame segments;

bending each transverse frame segment of said pair of transverse frame segments inward and substantially parallel to said central section of said planar material, wherein each of said pair of transverse frame segments covers a peripheral portion of a transverse edge of said insert; and

forming said length of said encasing into a semi-circular shape.

2. The method of manufacturing a bracelet as recited in claim 1, wherein said step of sizing a sheet of planar material to a predetermined length defining a pair of transverse edges creates two parallel transverse edges;

wherein said step of sizing a sheet of planar material to a predetermined width defining a pair of longitudinal edges creates two parallel longitudinal edges; and

wherein said pair of longitudinal edges and said pair of transverse edges are perpendicular to one another.

3. The method of manufacturing a bracelet as recited in claim 2, wherein said step of creating two parallel transverse edges and said step of creating two parallel longitudinal edges orients said pair of longitudinal edges and said pair of transverse edges perpendicular to one another.

4. The method of manufacturing a bracelet as recited in claim 1, further comprising a step of fabricating said insert from a sheet of material.

5. The method of manufacturing a bracelet as recited in claim 1, further comprising a step of applying artwork to an exposed surface of said insert.

6. The method of manufacturing a bracelet as recited in claim 1, further comprising a step of fabricating said insert from a beverage container, wherein said beverage container comprises artwork provided upon an exposed outer surface.

7. The method of manufacturing a bracelet as recited in claim 1, wherein said step of bending said sheet of planar material forming a pair of longitudinal fold lines is performed by a forming-device assembly comprising:

an elongated generally rectangular encasement blank-forming female die element comprising: a first upper surface configured with a U-shaped channel female die surface; a first lower surface opposing said first upper surface;

two opposing first end surfaces; and

two opposing longitudinally-extending first side surfaces;

wherein said female die surface comprises: a first female die engaging guide surface, a first female die blank edge-forming tongue, and a first female die blank edge-forming surface that cooperate to form a first trough; a second female die engaging guide surface, a second female die blank edge-forming tongue, and a second female die blank edge-forming surface that cooperate to form a second trough; and a blank supporting surface extending horizontally between said first trough and said second trough; wherein the distance between said blank supporting surface and said first lower surface is less than the distance between said female die upper surface and said first lower surface; and wherein said first trough, said second trough, and said blank supporting surface cooperate to form said a U-shaped channel female die surface; and

an encasement blank-forming male die element comprising: an upper die striking surface; a male lower surface configured with a concave furrow surface, wherein said male lower surface corresponds in shape to said U-shaped female die surface; a lower tongue distal surface opposing said upper die striking surface; two opposing second end surfaces; and two opposing longitudinally-extending second side surfaces; wherein said male concave furrow surface comprises: a first male die blank edge-forming surface extending inwardly and forming a right angle with said male lower surface; a second male die blank edge-forming surface extending inwardly and forming a right angle with said male lower surface; and a blank supporting surface extending between said first male die blank edge-forming surface and said second male die blank edge-forming surface.

8. The method of manufacturing a bracelet as recited in claim 1, wherein said steps of sizing a sheet of planar material to a predetermined length defining a pair of transverse edges; sizing a sheet of planar material to a predetermined width defining a pair of longitudinal edges; and

chamfering each of four corners of said sized sheet of planar material are performed on a cutting table assembly, wherein said cutting table assembly comprises:

a cutting table including a cutting table object support surface;

a length cutting station assembled onto said cutting table object support surface;

a width cutting station assembled onto said cutting table object support surface; and

a corner chamfering station assembled onto said cutting table object support surface.

9. The method of manufacturing a bracelet as recited in claim 1, wherein said step of bending each longitudinal frame segment of said pair of longitudinal frame segments inward and substantially parallel to said central section of said planar material is performed on a frame segment forming station, comprising:

a frame segment forming station platform including a forming station platform work surface; and

a forming station longitudinal edge support element assembled to said forming station platform work surface.

10. A device for forming a sheet of metal used in forming a bracelet comprising:

an elongated generally rectangular encasement blank-forming female die element comprising: a first upper surface configured with a U-shaped channel female die surface; a first lower surface opposing said first upper surface; two opposing first end surfaces; and two opposing longitudinally-extending first side surfaces; wherein said female die surface comprises: a first female die engaging guide surface, a first female die blank edge-forming tongue, and a first female die blank edge-forming surface that cooperate to form a first trough; a second female die engaging guide surface, a second female die blank edge-forming tongue, and a second female die blank edge-forming surface that cooperate to form a second trough; and a blank supporting surface extending horizontally between said first trough and said second trough; wherein the distance between said blank supporting surface and said first lower surface is less than the distance between said female die upper surface and said first lower surface; and wherein said first trough, said second trough, and said blank supporting surface cooperate to form said a U-shaped channel female die surface; and

an encasement blank-forming male die element comprising: an upper die striking surface; a male lower surface configured with a concave furrow surface, wherein said male lower surface corresponds in shape to said U-shaped female die surface; a lower tongue distal surface opposing said upper die striking surface; two opposing second end surfaces; and two opposing longitudinally-extending second side surfaces; wherein said male concave furrow surface comprises: a first male die blank edge-forming surface extending inwardly and forming a right angle with said male lower surface; a second male die blank edge-forming surface extending inwardly and forming a right angle with said male lower surface; and a blank supporting surface extending between said first male die blank edge-forming surface and said second male die blank edge-forming surface.

11. The device for forming a sheet of metal into a bracelet, as recited in claim 10 wherein:

said blank supporting surface is parallel to said first lower surface, said first female die blank edge-forming tongue, and said second female die blank edge-forming tongue; and

said first female die engaging guide surface is parallel to said second female die engaging guide surface.

12. The device for forming a sheet of metal into a bracelet, as recited in claim 11 wherein said blank supporting surface, said first trough, and said second trough form a raised rectangular ridge.

13. The device for forming a sheet of metal into a bracelet, as recited in claim 12 wherein said blank supporting surface is between 0.5 and 4 inches.

14. A bracelet comprising:

an encasement, said encasement being fabricated from an elongated octagonally-shaped, planar sheet of material having: a pair of parallel longitudinal edges; a pair of parallel transverse edges; four chamfered edges, each chamfered edge extending angularly between a longitudinal edge and a transverse edge; a pair of longitudinal fold lines, each of said pair of longitudinal fold lines are formed parallel to a respective longitudinal edge and defining a longitudinal frame segment; a pair of transverse fold lines, each of said pair of transverse fold lines are formed parallel to a respective transverse edge and defining a transverse frame segment; and an insert-receiving segment defined as an area of said elongated octagonally-shaped, planar sheet of material extending between said pair of longitudinal fold lines and said pair of transverse fold lines; and

an insert, said insert being fabricated from an elongated parallelogram-shaped, planar sheet of material having: an exposed surface; a contact surface; a length, wherein said length is approximately a distance between transverse fold lines; and a width, wherein said width is approximately a distance between longitudinal fold lines;

wherein said insert oriented having said contact surface facing said encasement and is placed within said encasement insert-receiving segment; and

wherein said insert is encased by said encasement by each of said longitudinal frame segments and said transverse frame segments, wherein each of said longitudinal frame segments and said transverse frame segments are folded into an inward directed orientation and generally parallel to said encasement insert-receiving segment, covering a peripheral edge of said insert.

15. The bracelet as recited in claim 14, said insert further comprising artwork applied to said exposed surface.

16. The bracelet as recited in claim 14, wherein said elongated edges are linear.

17. The bracelet as recited in claim 14, wherein said pair of parallel longitudinal edges are perpendicular to said pair of transverse edges.

18. The bracelet as recited in claim 14, wherein said chamfered edge is formed at a 45 degree angle to each connected longitudinal edge and transverse edge.

19. The bracelet as recited in claim 14, wherein each of said pair of longitudinal fold lines is additionally formed equidistant to said respective longitudinal edge, and each of said pair of transverse fold lines is additionally formed equidistant to said respective transverse edge.

20. The bracelet as recited in claim 14, wherein each of said chamfered edges forms a miter between each adjacent longitudinal frame segment and transverse frame segment.