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.

What is claimed is: 
     
         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.