WO1995003173A1

WO1995003173A1 - Multi-layer formable material

Info

Publication number: WO1995003173A1
Application number: PCT/US1994/008109
Authority: WO
Inventors: Richard Kimbrough
Original assignee: Toyvision, Inc.
Priority date: 1993-07-19
Filing date: 1994-07-19
Publication date: 1995-02-02
Also published as: AU7337994A

Abstract

The multi-layer formable material has at least two layers, including a malleable first foil layer, such as a metal foil, and a second layer of resilient material such as a foam, adhered to the first layer. Both layers in combination form a malleable material capable of being molded into any shape desired by the user. The material further provides a wrinkly, life-like texture when the user creases the material. A third layer of backing material can be adhered to the first foil layer to protect the first foil layer, and a fourth layer of velvet loop material can be adhered to the top of the second foam layer to provide a more life-like surface and a surface more readily accepting of paint.

Description

MULTI-LAYER FORMABLE MATERIAL

BACKGROUND OF THE INVENTION

Field of the Invention;

This invention relates generally to a formable material, and more particularly concerns a multi-layer formable material with life-like qualities.

Description of Related Art:

Formable materials such as various types of modelling clay and putty have been useful for forming a wide variety of desired shapes and abstract designs. New improvements in such formable material have been in constant demand for artistic and play purposes. It would be useful to provide a new formable, moldable sheet material which is malleable, and can provide a wrinkled, creviced appearance, as desired. One known type of sheet material is a multi-layer textile floor covering that consists of: (1) a velourized knitted fabric from polyamide yarn; (2) an intermediate layer of a vinyl or polyurethane polymer; and (3) a stitched fiber fleece having a supporting fabric stitched to its surface. This material is not easily malleable, has a high degree of resilience as its design as a floor covering requires, and is not capable of producing a desired wrinkled appearance.

Another known type of multi-layer material is an insulating multi-layer quilted wallpaper web. This multi-layer material is comprised of: (1) a non-woven facing sheet having fire retardant properties; (2) a face side provided with a decorative pattern; (3) an intermediate insulating layer substantially co-extensive with the facing sheet; and (4) a non- woven backing sheet substantially co-extensive with the intermediate insulating layer. This multi-layer material provides neither a first layer for support and malleability, nor a second layer for providing a desired wrinkled appearance.

Another conventional multi-layer laminate provides a high strength, low flam ability improved moisture vapor barrier for use in producing improved construction panels. These construction panels are comprised of: (1) a polyurethane foam interior; (2) an outer skin aluminum foil; (3) a scrim; and (4) an adhesive tie coat. The aluminum foil is adhered to the scrim which is adhered to the inner layer of polyurethane foam. This scrim/foil laminate has a primary function as a permanent, light-weight and efficient insulation. The laminate is rigid and has a high tensile strength. It does not have the characteristics of malleability and formability to provide a desired wrinkled appearance.

Another laminate having enhanced flame-proofing and low smoke development properties is also known. The laminate is comprised of: (1) a urethane modified polyisocyanurate foam as a core material; and (2) an aluminum foil or sheet as a surface material applied on at least one surface of the foam. The foam and outer foil layer are bonded through a self-adhesion of the foam. The laminate is also composed of a polystyrene foam plastic, a rigid material which is not bendable. The urethane modified polyisocyanurate foam is also not resilient, and when adhered to a foil layer does not form a malleable, formable material that produces a desired wrinkled appearance.

Another type of wall covering material is comprised of:

(1) a front decorative cover layer containing textile fibers; and

(2) a rear foam plastic layer. This material is directed to a foam plastic layer which contains flame retardant additives and closed cell inorganic hollow spheres or small balls, which rigidify or stiffen the foam plastic layer. The wall covering material is not malleable or formable, and does not provide a desired wrinkled appearance. Another known laminate for wearing apparel is comprised of: (1) a fibrous web; (2) a synthetic foam resin web joined to the fibrous web to form a pre-laminate; and (3) a resin film web adhered to the exposed foam surface of the pre-laminate. The exposed surface of the non-woven fibrous web of the pre-laminate is napped to form the internal surface of the wearing apparel; and the exposed surface of the film web is creped. The laminate does not provide a malleable, formable material, and does not contain a malleable metal foil layer for providing a desired wrinkled, creviced appearance.

Other conventional types of laminate sheets are known to contain at least three layers including: a perforated sheet layer, and two flexible sheet layers laminated one on each side of the perforated sheet layer. Such laminate sheets do not contain a resilient foam material, and do not provide a desired wrinkled, creviced appearance when formed into the desired shape. Another type of flexible, fire-resistant, decorative laminate includes (1) a laminar fire-resistant layer including an aluminum foil sheet bonded to a first inner polyvinyl fluoride sheet; (2) an underlying flexible paper-like base laminate; (3) an adhesive for bonding the first polyvinyl fluoride sheet to the panel-like base laminate; (4) a resinous embossing film bonded to the aluminum foil sheet; (5) an outer decorative surface bonded with the resinous embossing film; and (6) an outer transparent sheet of clear polyvinyl fluoride bonded to the decorative surface. This material does not contain a resilient foam layer, and does not provide a desired wrinkled appearance. A composite foam article is also known which is comprised of multiple layers- of foam selectively adhered to each other forming selected shapes. This article does not contain any metal foil for providing malleability and rigidity to the formable material. The material can achieve its desired shapes by selectively stretching and adhering the multiple layers to each other. The article does not provide a desired wrinkled, creviced appearance.

A multi-layer composite sheet is also known which is especially designed for use as a padding layer under artificial grass. The multi-layer composite sheet is comprised of: (1) a bottom layer of expanded synthetic resin, particularly of closed cell polyethylene foam; (2) an aluminum foil; and (3) an intermediate layer for bonding the foam to the foil.. The multi¬ layer composite sheet does not provide a wrinkled and life-like surface. Further, the composite sheet requires an intermediate layer for bonding the foam to the foil. It would be desirable to provide a multi-layer formable sheet material that is light weight, has thermal insulating properties, is malleable, moldable, is capable of receiving paint to.take on a life-like appearance, and can provide a wrinkled, creviced appearance. It would be desirable that such a material could be capable of taking on a wrinkled, life-like appearance when used to form shapes and abstract designs, or molded over a mandrel or a natural form such as a person's face. The present invention meets these needs.

SUMMARY OF THE INVENTION

Briefly, and in general terms, the present invention provides for a formable material adapted to conform its shape to any shape that the user molds it into, and to provide a wrinkled, life-like quality. The formable material according to the principles of the invention has a first layer of a malleable metal foil that is adhered to a second layer of resilient foam material. When proper thicknesses of the two materials are adhered to each other, the resulting laminate material is malleable and capable of retaining the shape the user molds it into, and further takes on and maintains a desired wrinkled appearance.

A backing material may also be laminated to the first malleable foil layer on the side opposite the second foam layer. This backing material layer has a primary function of protecting the foil from breaking down due to continuous molding and shaping. A backing material that is easily washable is chosen to offer ease of cleaning and to add strength to the material.

The invention is particularly adaptable to a variety of novelty items and toys in which the material can be painted or formed to take on the appearance of a character face or the like. In one such application, the face of a cartoon character or animal character can be formed in the material, which then forms the outer surface of a bag or article of clothing for use by a child. In another aspect of the invention, the material can be used to form a mask or the like for wear or display. A layer of velvet loop material can additionally be adhered to the top of the foam layer. The velvet loop layer provides an excellent surface for the reception of paint thereon, which contributes to the life-like, wrinkled, appearance of the material. Further, the velvet loop material is adapted to releasably secure objects to the material via hook and loop fastening means.

These and other aspects and advantages of the invention will become apparent from the following detailed description, and the accompanying drawings, which illustrate by way of example the features of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

Fig. 1 is a perspective view of a bag formed of a multi-layer formable material according to the principles of the invention;

Fig. 2 is a cross-sectional view of a two-layer formable material according to the principles of the invention, taken along line 2-2 of Fig. 1;

Fig. 3 -is a cross—sectional view similar to that of Fig. 2 of a four-layer formable material according to the principles of the invention;

Fig. 4 is an elevational sectional exploded view of a section of a formable material incorporating a layer of thermoplastic backing material being formed by heat and compression;

Fig. 5 is a cross-sectional view illustrating the shaped section of formable material of Fig. 4 heat sealed to another section of similar formable material;

Fig. 6 is a front perspective view of a shaped bag formed by heat sealing as illustrated in Figs. 4 and 5;

Fig. 7 is an elevational sectional view illustrating another method of heat sealing two sections of formable material with thermoplastic backing material together;

Fig. 8 is a perspective exploded view of the illustration of Fig. 7; Fig. 9 is a front view of the formable material according to the principles of the invention formed in the shape of packaging for a sandwich;

Fig. 10 is a front view of the formable material 5 according to the principles of the invention formed in the shape of packaging for french fries; and

Fig. 11 is a front view of the formable material according to the principles of the invention formed in the shape of packaging for a drink cup.

10 DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Known multi-layer sheet materials commonly do not provide malleability and a wrinkled, creviced type of surface that would provide for a formable material with a life-like appearance.

15 As is illustrated in the drawings, the present invention is embodied in a multi-layer formable material that is lightweight, thermally insulating, malleable, moldable, capable of receiving paint, and can be used to form shapes and abstract designs capable of taking on a wrinkled, life-like appearance.

20 Referring to Fig. 1, a multi-layer formable material 4 according to the principles of the invention is illustrated in the form of a bag 6. Formable material 4 is capable of taking on a life-like appearance. This life-like appearance is due in great part to its ability to mold and wrinkle. Wrinkles 7 are formed by the

25 bending of the inner metallic layer thereby causing the outer foam layer to bend accordingly. Formable material 4 is capable of being rolled into a roll without breaking, as is shown by rolled portion 10.

Referring specifically to Fig. 2, a two-layer

3.0 embodiment of the formable material is depicted. The first layer 11 consists of a metallic foil, or other type of malleable material. The second layer 12 is a pliable resilient foam that is adhered to the first foil layer 11. The multi-layer material is bent or shaped and the foil layer 11 retains the shape that

35 the user molds it into. The foam layer 12 adheres to the shape of the metal foil 11. Wrinkles 7 are formed when the foil layer 11 is sharply bent as shown at bent region 15. The second foam layer 12 which is adhered to first foil layer 11 bends accordingly at bent region 15, but the soft pliable foam layer 12 smoothes out the rigid bump 15 to form a softer wrinkle 7. Thus, the foam has the effect of softening the crinkled appearance of the malleable foil that retains every indentation and contour applied thereto.

Furthermore, when the metal is wrinkled upward as shown in region 17 of Fig. 2, the metal foil 11 may have a very sharp bend in it while the upper foam layer 12 has a softer, rounder bump. Thus, the foam layer smoothes out the wrinkles in both an upwardly extending bump 17 and a downwardly extending crease 15, thereby producing a multi-layer material capable of assuming the shape a user applies to it, and receiving wrinkles or bumps where the user desires.

The metal foil layer 11 does not become smooth when the user straightens out the area where a bump or wrinkle once was. Foil creases 20, 21, 22, 23 and 24 represent areas in which inadvertent bending occurred, or a prior bend was molded into the material and later removed.- Fig. 2 illustrates those areas in which creases 20-24 are present in the foil layer 11, but no respective irregularity is created on the surface of the foam 12a. Thus, formable material 4 is capable of retaining the shape that the user molds it into, and then changing shape each time the user reshapes the material. Furthermore, all the bumps and creases once present on the surface 12a of the formable material can later be smoothed out so they can not be seen.

With particular reference to Fig. 3, a multi-layer formable material is depicted wherein first layer 11 is a metallic foil or other malleable material. The second layer 12 is a soft foam layer that receives the shape of the first foil layer 11. The third layer 13 is a backing material, and the fourth layer 14 is a velvet loop type material. The first and second layers are as described in Fig. 2, so that further discussion of these layers is omitted. The third layer 13 consists of a backing material which is adhered to the foil layer 11 on the opposite side of the foam layer 12. The backing layer 13 serves multiple functions. The first function of the backing layer is to provide protection for the foil layer. Backing material 13 protects the foil 11 from breakdown that can result from extended bending and reshaping. Metallic foils are prone to receiving small tears that readily accelerate into long tears or cuts. Backing material 13 provides a means for protecting against the acceleration of tears in the foil layer.

A second function of the backing material 13 is to provide a smooth surface that is easily cleanable, and can readily be sewn in a sewing machine. The backing material also helps to make stitching through the formable material secure. Therefore, a large variety of materials can be used as backing material to serve the two purposes described hereinabove, for example a thin layer of cotton, or plastic, including a thermoplastic such as polyethylene or nylon may be used.

When a thermoplastic is used as the backing material, a third function of the backing material 13 is to also allow heat sealing of one sheet of the -formable material to another, or to itself, such as by heat sealing the thermoplastic layers of material together, or heat sealing the backing material to the foam second layer or the velvet loop fourth layer as will be explained further below.

The fourth layer 14 consists of a velvet loop material or other such porous material that adds to the life-like characteristics of the formable material. This layer is adhered to the foam along surface 12(a) of Fig. 2. The velvet loop material 14 adds a further smoothing effect to the appearance of formable material 4. Wrinkle 7 depicts loop material 14 smoothing out the effect of a bend in the metal foil layer 11, but adds to the appearance of the wrinkle by the doubling over effect of the velvet loop material at the point of the bend. When the velvet loop is colored the doubling over effect of the velvet loop material at the bend causes interior 27 of the crease 7 to become darker, thus giving a life-like wrinkled appearance. Furthermore, velvet loop material 14 provides an excellent surface for application of paint. Velvet loop material can take on many different appearances when applied with paint. Areas 7 where wrinkles are formed take on a dark life-like image due to the cross-over effect of the velvet loop material. In the region of bumps 26 upon the surface of the velvet loop 14 the coloration appears lighter, because the loop material becomes more porous.

Furthermore, when a velvet loop material is used it adds enhanced play value to the material, because the material can be assimilated into a toy for children. This process is simple if removable pieces are provided with hook and loop fasteners. For example, in the face shaped bag of Fig. 1, removable features such as eyes and teeth could be releasably affixed to the bag, thus adding enhanced play value.

Two pieces of the multi-layer material can be attached together, such as at the union 30 shown in Fig. 3. Multi-layer material 4 is capable of being attached to other sections of multi-layer material 4, such as by an appropriate adhesive, heat sealing, stitching, or other similar suitable methods well known in the art.

The specific thicknesses of each layer of multi-layer material 4 can vary according to the specific use for which it is intended. In general, foam having a thickness ranging between 1/16 inch and 1/4 inch works best with foil ranging from 1/4 thousandth inch to 4 thousandth inch thick.

As is illustrated in Figs. 4, 5 and 6, when the backing material of the formable material is thermoplastic, a section 30 of the formable material can advantageously be pressed and heated between heated metal forms 32 and 34, heat sealing and crimping the formable material into a shape that is held when the formable material cools. As is shown in Fig. 5, the ends of the section 30 of formable material can be heat sealed to another section of formable material, with the thermoplastic backing layers of material facing each other, so that the thermoplastic layers are joined when heat sealed by methods well known in the art. Fig. shows a bag formed in this manner, with heat seals .along three sides of the sheets of formable material.

As is shown in Figs. 7 and 8, the thermoplastic layer backed formable material can also be heat sealed by placing the thermoplastic backing layer of one section 36 against the foam or velvet loop layer of a second section 38. Fig. 8 illustrates the heat sealing of a shaped piece of formable material with another sheet of formable material in this manner.

It will be appreciated that, while the multi-layer formable material of the invention has been illustrated in the form of a face shaped bag, the material can be molded by hand, or over a mandrel for example, to take on a desired shape, and in a more specific example the material can be molded over a person's face to assume a life-like appearance of a face. The formable material can also be pressed and shaped in a variety of shapes that can be utilized as packaging or bonded -to existing packaging as a decorative material, as is illustrated in Figs. 9, 10 and 11.

It will be apparent from the foregoing that while particular forms of the invention have been illustrated and described, various modifications can be made without departing from the spirit and scope of the invention. Accordingly, it is not intended that the invention be limited, except as by the appended claims.

Claims

WHAT IS CLAIMED IS:

1. A multi-layer formable material, comprising: a first layer of malleable metal foil, said first layer being chosen to have a thickness to provide malleability and shape retention; a second layer of resilient foam material, said first layer being adhered to said second layer, said second layer chosen to have a thickness to allow malleability and shape retention of said first layer, and to provide a desired wrinkled, creviced appearance.

2. The multi-layer formable material of Claim 1, wherein said first layer of malleable metal foil has a thickness between about 1/4 thousandth inch and about 4 thousandth inch, said second layer has a thickness between about 1/16 inch and about 1/4 inch, and said first layer is adhered to said second layer.

3. The multi-layer formable material of Claim 1, wherein said second layer has a paintable surface.

4. The multi-layer formable material of Claim 1, further including a third layer of backing material adhered to the first layer.

5. The multi-layer formable material of Claim 4, wherein said backing material protects said first layer.

6. The multi-layer formable material of Claim 4, wherein said backing material provides an easily cleanable surface.

7. The multi-layer formable material of Claim 4, wherein said backing material is a thin plastic layer.

8. The multi-layer formable material of Claim 4, wherein said backing material is a thin cotton layer.

9. The multi-layer formable material of Claim 4, wherein said backing material is a thin nylon layer.

10. The multi-layer formable material of Claim 4, wherein said backing material conforms to the shape of said first layer.

11. The multi-layer formable material of Claim 1, further including a top layer of a loop type material adhered to said second layer.

12. The multi-layer formable material of Claim 11, wherein said loop type material is velvet loop material.

13. The multi-layer formable material of Claim 12, wherein said velvet loop type material readily accepts paint.

14. The multi-layer formable material of Claim 12, wherein said velvet loop type material adds a life-like quality to the appearance of said formable material.

15. The multi-layer formable material of Claim 4, further including a top layer of a loop type material adhered to said second layer.

16. The multi-layer formable material of Claim 15, wherein said loop type material is velvet loop material.

17. The multi-layer formable material of Claim 16, wherein said velvet loop type material readily accepts paint.

18. The multi-layer formable material of Claim 16, wherein said velvet loop type material adds a life-like quality to the appearance of said formable material.