NZ337278A - Laminate comprising a sliced shell (preferably paua) on a flexible substrate - Google Patents

Abstract

[ Patent 337278 This composite material comprises a flexible sheet substrate and a plurality of shell elements affixed to a major surface of the substrate in a tessellated configuration. Also included is a method of preparing this material.

Description

NEW ZEALAND PATENTS ACT, 1953 No: 337278 Date: 17 August 1999 COMPLETE SPECIFICATION 'A Flexible Material and Method of Manufacturing of such from a Substantially Rigid Material" We, FIORDLAND SOUVENIRS LIMITED, a company duly incorporated under the laws of New Zealand of 35 Bath Road, Riverton, New Zealand do hereby declare the invention for which we pray that a patent may be granted to us, and the method by which it is to be performed, to be particularly described in and by the following statement: Ll:\OFFICE j OF N1. -1" 15 AUG 2000 337278 The present invention relates to a flexible material and its related method of manufacture from a substantially rigid material. In particular although not solely the present invention relates to a flexible material and its related method of manufacture which incorporates a visible shell of a shell fish.

Shells of shellfish such as paua or abalone have a particular and to some, appealing visual appearance. Such an appearance is difficult to re-create as the appearance is normally of a metallic and almost holographic nature. It is to this extent that people who are wishing to utilise this material for such applications as in the souvenir industry have had to rely on the actual shell to economically provide such an appearance to products. Paua shell has been successfully processed to allow for thin slices of material to be removed from the shell. Such slices are then able to be manipulated in very limited ways to conform to a desired shape. As an example, sliced paua shell has been manipulated to contour about and provide a decorative appearance to pens, lipstick cases and the like. Although the material is able to be manipulated in shape to a limited extent, the material still remains brittle and very limited in its flexibility. The novelty of the appearance of the shellfish material is such that people have also attempted to incorporate this material in clothing. Although successful to a certain extent, the clothes made from this material are normally very rigid and prone to breaking as a result of there inflexibility and therefore lack utility. To the extent that in for example the clothing industry where paua shell has been utilised previously, people have been struggling with the manipulation of this material to adapt certain shapes, and provide such material in a flexible form, the inventor recognised a need for such a flexible material incorporating the visual appearance of shell. To the extent that this need has not been satisfied by anyone previously, the inventor set about creating the present invention.

It is therefore an object of the present invention to overcome the abovementioned disadvantages or to at least provide the public with a useful choice.

Accordingly in a first aspect the present invention consists in a method of making a flexible material comprising: affixing to a flexible substrate, a sheet of shell material, cutting a pattern through said shell but not through said flexible substrate, to create a plurality of substantially discrete shell elements from said sheet of said shell material in a tessellated configuration.

Preferably said cutting of said pattern is in a manner to provide a repeating pattern.

Preferably said pattern is a polygon shape selected from at one having at least three sides and no more than six sides. i;., cLLfcfuAL^RO^innDrocE' OF NZ 13 OCT 2000 RECEIVED ... ■ -.t 3372/y Preferably the exposed surface of said shell is lacquered.

Preferably said affixing is by means of an adhesive.

Preferably said affixing is by heat sealing, RF or ultrasonic welding wherein said substrate is of a plastics material.

Preferably said shell is of a thickness of about lA mm.

Preferably said cutting is by laser directed onto the outwardly facing surface of said shell and is to a depth substantially that of the thickness of said shell.

Preferably said sheet of shell material is selected from a paua shell, abalone shell, a black mother of pearl shell and white mother of pearl shell.

Preferably said flexible substrate is of a sheet material selected from a PVC, cotton, leather and neoprene.

In a second aspect the present invention consist in a composite material comprising a substrate of a flexible sheet nature a plurality of shell material elements affixed to at least one major surface of said substrate, in a tessellated configuration.

Preferably the shell material elements are affixed in an arrangement which provides continuity to the natural pattern visibly provided by the shell material elements.

Preferably said plurality of shell materials were created by cutting though a sheet of shell material subsequent to being affixed to said substrate.

Preferably said pattern is a repeating pattern.

Preferably said pattern is of a polygon selected from at least three sides and no more than six sides.

Preferably said exposed surface of said shell is lacquered.

Preferably said shell is affixed to said substrate by an adhesive.

Preferably said shell is affixed by heat sealing, RF or ultrasonic welding, where said substrate is a plastics material.

Preferably said shell is of a thickness of about lA mm.

Preferably said shell material is selected from a paua shell, abalone shell, a black mother of pearl shell and white mother of pearl shell.

Preferably said flexible substrate is of a sheet material selected from a PVC, cotton, leather and neoprene.

In a further aspect the present invention consists in an article of clothing which includes a composite material as herein before described.

In a further aspect the present invention consists in use of a composite material herein before described in clothing. -r - i, -, e ! ..dxfcCTUAL PnJPtrtTY OFFICE1 OF N.Z. 13 oct 2000 received 3372 7 This invention may also be said broadly to consist in the parts, elements and features referred to or indicated in the specification of the application, individually or collectively, and any or all combinations of any two or more of said parts, elements or features, and where specific integers are mentioned herein which have known equivalents in the art to which this invention relates, such known equivalents are deemed to be incorporated herein as if individually set forth.

The invention consists in the foregoing and also envisages constructions of which the following gives examples.

One preferred form of the present invention will now be described with reference to the accompanying drawings in which; Figure 1 is an exploded perspective view of a portion of the material of the present invention prior to being processed to induce flexibility, Figure 2 is a perspective view of part of a material of the present invention in an assembled condition but prior to being subjected to a process to induce flexibility, Figure 3 is a side view of part of the material of the present invention, Figure 4 illustrates a sample of the material of the present invention subsequent to being proceeded to induce it's flexibility illustrating the form of pattern which may be cut (preferably by laser).

The present invention is preferably adapted to utilise sliced shell originating from for example a paua shell (e.g. the New Zealand paua shell) or abalone such as the Australian abalone or the like shellfish. Known techniques of providing thin sliced shells can be employed for this purpose. The slicing is normally in the form of strips of material which can be arranged in a juxtaposed condition substantially side by side to form a sheet material of a desired usable width.

The distinctive characteristic of the New Zealand paua shell or abalone are such that the appearance can be highly desirable. The appearance is a visually enhancing appearance and the paua shell or abalone has been known to be utilised for many different applications and is very popular in souvenir like products. The naturally occurring patterns on the shell make it desirable for the shell to be utilised for such applications in a substantially uninterrupted arrangement. Although the length and width of strips which can be cut from the shell are limited, and hence the placing of strips adjacent each other does from some kind of an interruption in the patterns, at least within each of the strip regions uninterrupted patterns can be provided. The shell material including the strips which may be cut therefrom are inherently substantially rigid. Although it can be '>•' ^LLE JTUALT^ jrifiif orncf OF N.Z. 13 oct 2000 RECEIVED deformed to a certain extent, the material will remain brittle due to its inherent rigidity.

With reference to figure 1 it can be seen how a sheet of shell material 1 can be brought into contact with a flexible substrate. Such a flexible substrate 2 may be for example a cotton or any other like man made or alternatively artificial flexible material including plastics, neoprene, nylon PVC or other flexible plastics material. The contact which aims to be permanent is preferably achieved by utilising a suitable adhesive between the surfaces of the shell material 1 and the flexible material 2 to be in contact with each other. Such a suitable adhesive may include a contact adhesive or for example a 2 pot rubber based flexible glue.

Alternatively said contact may be achieved, where a plastics material substrate is use, by heat sealing or ultrasonic or RF welding.

Once the sheet(s) of shell material and the substrate 2 have been sufficiently adhered to each other, that side of the arrangement which presents the shell material is then subjected to a cutting process. Although it is to be appreciated that further substrates can be provided onto the shell material 1 and/or the substrate 2 such is for example a lacquer or further strengthening substrates, this is purely optional.

The cutting process of the shell material is preferably such as to provide a pattern to said shell material. The pattern is preferably a repeating pattern such as for example a honeycomb pattern or any other polygonal pattern. As for example shown in figure 4 the pattern provided in the sheet of shell material 1 is trapezoidal. When the sheet of shell material is cut the cutting is providing discrete elements of shell material which are in a tesselated arrangement provided on said substrate. The cutting of the shell material after it has been applied to the substrate will, after cutting provide an immediately useable material. Although the present invention may not be limited to cutting after adhesion to the flexible substrate, it will be appreciated that the cutting of the shell material and subsequent application to the In the preferred form such cutting of the sheet of shell material 1 in the pattern which is desired is preferably achieved by laser cutting. Laser cutting such as CNC laser cutting has the benefit of both accuracy in the cut to provide if necessary an accurately repeating pattern, the cut width is minimal and the control of power of the laser ensures that the substrate is not also cut. Although the substrate may be subjected to slight cutting as a result of the laser, such cutting should not be straight through the substrate. It is however preferred that the cutting by the laser of the shell is through the entire shell thickness.

T.^TfCtTiAL PROPERTY GFriCE OF N.Z.

AUG 2000 received 337278

Claims (23)

CLAIMS:

1. A method of making a flexible material comprising: affixing to a flexible substrate, a sheet of shell material, cutting a pattern through said shell but not through said flexible substrate, to create a plurality of substantially discrete shell elements from said sheet of said shell material in a tessellated configuration.

2. A method as claimed in claim 1 wherein said cutting of said pattern is in a manner to provide a repeating pattern.

3. A method as claimed in claims 1 to 2 wherein said pattern is a polygon shape selected from at one having at least three sides and no more than six sides.

4. A method as claimed in any one of claims 1 to 3 wherein the exposed surface of said shell is lacquered.

5. A method as claimed in any one of claims 1 to 4 wherein said affixing is by means of an adhesive.

6. A method as claimed in any one of claims 1 to 4 wherein said affixing is by heat sealing, RF or ultrasonic welding wherein said substrate is of a plastics material.

7. A method as claimed in any one of claims 1 to 6 wherein said shell is of a thickness of about Vz mm.

8. A method as claimed in any one of claims 1 to 7 wherein said cutting is by laser directed onto the outwardly facing surface of said shell and is to a depth substantially that of the thickness of said shell.

9. A method as claimed in any one of claims 1 to 8 wherein said sheet of shell material is selected from a paua shell, abalone shell, a black mother of pearl shell and white mother of pearl shell.

10. A method as claimed in any one of claims 1 to 4 wherein said flexible substrate is of a sheet material selected from a PVC, cotton, leather and neoprene.

11. A composite material comprising a substrate of a flexible sheet nature a plurality of shell material elements affixed to at least one major surface of said substrate, in a tessellated configuration.

12. A composite material as claimed in claim 12 wherein the shell material elements are affixed in an arrangement which provides continuity to the natural pattern visibly provided by the shell material elements.

13. A composite material as claimed in claims 11 or 12 wherein said plurality of shell materials were created by cutting though a sheet of shell material subsequent to being affixed to said substrate. JLLEOTUAL PiiJPERTY Qff$jF OF NX 13 oct 2000 received 337278 -7-

14. A composite material as claimed in claims 11 to 13 wherein said pattern is a repeating pattern.

15. A composite material as claimed in claims 11 to 14 wherein said pattern is of a polygon selected from at least three sides and no more than six sides.

16. A composite material as claimed in claims 11 to 15 wherein said exposed surface of said shell is lacquered.

17. A composite material as claimed in claims 11 to 16 wherein said shell is affixed to said substrate by an adhesive.

18. A composite material as claimed in claims 11 to 17 wherein said shell is affixed by heat sealing, RF or ultrasonic welding, where said substrate is a plastics material.

19. A composite material as claimed in claims 11 to 18 wherein said shell is of a thickness of about Vi mm.

20. A composite material as claimed in claims 11 to 19 wherein said shell material is selected from a paua shell, abalone shell, a black mother of pearl shell and white mother of pearl shell.

21. A composite material as claimed in claims 11 to 20 wherein said flexible substrate is of a sheet material selected from a PVC, cotton, leather and neoprene.

22. An article of clothing which includes a composite material as claimed in any one of claims 11 to 22.

23. The use of a composite material as claimed in any one of claims 11 to 22 in clothing. /ATED THIS HAY OF OcSobr A] Park AGENTS FOflT THE'APPLICANT l.-idUfCillrtL hOPERTY OFFICE i OF N.Z. j 3 oct 2000 RECEIVED