Synthetic cork with a natural cork appearance and method of making it

Abstract

A method of producing random and irregular markings and impressions on synthetic cork stoppers so as to closely mimic the surface texture of natural cork, and the stoppers produced thereby. In one embodiment, the stopper is produced in a mold featuring a textured inner surface. In another embodiment, the stopper is extruded.

1 . A method of producing a container stopper having the appearance of natural cork comprising: 
 forming a soft synthetic material into a size and shape to fit an opening in a container;    introducing the synthetic material to a forming device for impressing random and irregular pits and markings on the exterior surface of said material;    cutting the material into discrete lengths; and    hardening the material to a form suitable to fit into and seal the opening in the container.    
   
   
       2 . A method of producing random and irregular markings on synthetic stoppers, comprising: 
 forming a mold having on its inner surface randomly arranged contours, bumps, and ridges;    introducing a soft synthetic material into the mold, so as to impress the contours, bumps, and ridges into the surface of the synthetic material to form desired holes, markings, and dimples in the synthetic material, the resulting holes, markings, and dimples being the negative of the contours, bumps, and ridges;    allowing the synthetic material to harden so as to render the impressed holes, markings, and dimples permanent on the exterior surface of the synthetic material.    
   
   
       3 . A method of producing random and irregular markings on synthetic stoppers, comprising: 
 extruding soft synthetic material into a form having a smooth exterior surface;    introducing the synthetic material to impressing means so as to create random and irregular holes, markings, and dimples on the exterior surface of the synthetic material;    cutting the synthetic material into discrete lengths; and    allowing the synthetic material to harden.    
   
   
       4 . The method of  claim 3 , wherein the impressing step is performed concurrently with the extrusion step.  
   
   
       5 . The method of  claim 3 , wherein the impressing means comprise one or more stamps.  
   
   
       6 . The method of  claim 3 , wherein the impressing means comprise one or more cutting blades.  
   
   
       7 . The method of  claim 3 , wherein the extruded synthetic material has a circular cross-section, and the impressing means comprise rollers shaped to contact substantially the entire circumference of the material.  
   
   
       8 . A synthetic stopper produced by the method of  claim 7 .  
   
   
       9 . A synthetic stopper produced by a method comprising: 
 forming a mold having on its inner surface randomly arranged contours, bumps, and ridges;    introducing a soft synthetic material into the mold, so as to impress the contours, bumps, and ridges into the synthetic material to form desired holes, markings, and dimples in the synthetic material, the resulting holes, markings, and dimples being the negative of the contours, bumps, and ridges;    allowing the synthetic material to harden so as to render the impressed holes, markings, and dimples permanent on the exterior surface of the synthetic material.