Description:FIELD OF INVENTION
[001] The present disclosure relates to the field of jewellery manufacturing. More specifically, the disclosure pertains to a method for creating jewellery articles by embedding crushed gemstones into metal structures.
BACKGROUND OF INVENTION
[002] Traditional jewellery manufacturing has long relied on well-established gemstone-setting techniques such as prong settings bezel settings, and adhesive bonding. These methods are particularly effective for securely holding faceted gemstones with regular shapes such as round oval, princess or emerald cuts. However, their applicability is significantly constrained when dealing with irregularly shaped gemstone. The prong setting involves the use of tiny metal claws that grip the edges of a gemstone providing both security and visibility. The bezel setting encircles the stone with a continuous metal band offering enhanced protection but partially obstructing the gemstone’s surface. Moreover, these traditional techniques are inherently dependent on the geometry of the gemstones making them unsuitable for embedding irregular gemstones compromising the aesthetic appeal and structural integrity of the jewellery. Adhesive bonding offers design flexibility but often suffers from issues related to durability and long-term appearance as adhesives may degrade, discolour, or lose their adhesive strength over time.
[003] The limitations of traditional settings become even more pronounced when applied to a wide range of jewellery articles, including rings, earrings, pendants, bangles, bracelets, necklaces, and other accessories. Each of these jewellery types demands a secure, durable, and aesthetically pleasing method of gemstone embedding that can accommodate diverse designs and user preferences.
[004] Furthermore, the gemstone cutting and faceting process itself generates a substantial volume of waste in the form of small and irregular grains. These crushed gemstones despite their intrinsic value frequently disregarded due to the lack of suitable techniques for their secure and visually appealing integration into fine jewellery. As a result, significant value of the precious gemstone has lost and environment impact of gemstone mining is exacerbated.
[005] The present disclosure overcomes these limitations by enabling the secure and aesthetically appealing embedding the gemstones into metallic jewellery structures creating durable, versatile, and visually captivating jewellery articles.
OBJECTIVE OF INVENTION
[006] The principal object of the present disclosure is to provide a method for manufacturing jewellery articles but not limited to rings, earrings, pendants, bangles, bracelets, necklaces, and other accessories where crushed gemstones are securely embedded within metallic structures using a specialized photopolymer and UV curing process.
[007] Another object of the present disclosure is to maximize the utilization of crushed gemstones which are typically discarded as waste in traditional jewellery manufacturing processes. By embedding these crushed gemstones securely within the jewellery structure using the aforementioned photopolymer and UV curing process, thereby reducing waste and increasing the value derived from these otherwise discarded materials.
[008] Yet another object of the present disclosure is to enhance the aesthetic quality of the jewellery by utilizing the transparent photopolymer in a manner that allows the embedded gemstones to retain their natural optical properties, providing clarity and brilliance.
[009] Additionally, certain types of gemstones may be treated with colour-enhancing pigments to either enhance their natural colours or achieve specific desired hues, further improving the visual attractiveness of the jewellery article.
[010] Another objective of the present disclosure imbedded crushed gemstones into jewellery using a transparent photopolymer which is cured layer by layer with ultraviolet (UV) light. This process ensures that the gemstones are securely held in place while enhancing the durability and visual appeal of the jewellery.
SUMMARY OF INVENTION
[011] The present disclosure relates to a method for manufacturing jewellery articles including rings, earrings, pendants, bangles/bracelets, necklaces, and other jewellery accessories where gemstones are uniquely processed and embedded within the jewellery structure using a specialized method. The disclosure involves crushing gemstones and securely holding them in place within a metallic jewellery structure formed from precious metals such as gold alloys, silver alloys, platinum alloys and other precious metals using a transparent, light-cured photopolymer providing a visually attractive and durable finished product. The use of the photopolymer ensures that the crushed gemstones are securely integrated into the jewellery structures allowing for the display of the gemstone’s intrinsic beauty while simultaneously ensuring the safety and durability of the final product.
[012] The method is characterized by the use of a photopolymer composed of specific components including but not limited to polyurethane acrylates, polyester acrylates, and epoxy acrylates, combined with a photo initiator, Diphenyl(2,4,6-trimethylbenzoyl) phosphine oxide (TPO). The photopolymer is cured in a controlled layer-by-layer process using ultraviolet (UV) light with a wavelength ranging from 365 nm to 405 nm to provide optimal curing conditions that ensure the photopolymer holds the crushed gemstones securely in place of jewellery structure without detracting from the visual appeal of the jewellery. The layer-by-layer curing process allows for the gradual and precise embedding of the crushed gemstones into the jewellery structure ensuring a strong bond between the crushed gemstone and the metal of the jewellery structure avoiding any potential damage to the gemstones during the manufacturing process.
[013] The jewellery structure is formed from high-quality precious metals such as but not limited to gold alloys, silver alloys, and platinum alloys. These metals provide a durable and aesthetically pleasing foundation for the jewellery, which is further enhanced by the secure embedding of the crushed gemstones. The method enables the incorporation of crushed gemstones materials that would otherwise be considered waste in traditional jewellery manufacturing processes. By utilizing this method, significant amounts of gemstone waste are reduced hence maximizing the utilization of valuable gemstones and reducing the environmental impact of gemstone mining and processing.
[014] An additional advantage of the disclosure is the colour enhancement of certain gemstones. Some gemstones may undergo a colour enhancement process using colour pigments to achieve a more natural, vibrant, and visually appealing appearance. This feature ensures that even crushed gemstones can be processed and transformed into jewellery that rivals the aesthetic qualities of faceted gemstones.
[015] The method begins with preparing the jewellery structure, wherein the metal surface of the jewellery is treated to create tiny recesses, approximately 0.10 mm in size on the surface. These recesses create traction between the metal and the photopolymer to ensure that the photopolymer adheres securely to the metal surface. A mechanical retention slot ranging from 0.1 mm to 0.5 mm is formed in the metal structure of jewellery structure allow the liquid photopolymer to flow into the slot further enhancing the mechanical strength of the bond between the crushed gemstone and the jewellery structure. This mechanical retention system ensures that the photopolymer remains securely in place even under conditions of wear and tear.
[016] The use of the photopolymer and the layer-by-layer curing process offers several benefits over traditional jewellery manufacturing methods. Notably, the process allows for the integration of crushed gemstones into jewellery structure without compromising the structural integrity or aesthetic appeal of the final product. Additionally, the method is scalable and can be applied to a wide variety of jewellery types and designs such as but not limited to rings, earrings, pendants, bangles, bracelets necklaces & other accessories which provides versatility in terms of both functionality and aesthetics. The process may be employed to create intricate and custom jewellery designs that incorporate a variety of gemstone types and sizes. This method offers jewellers the ability to create unique, one-of-a-kind jewellery pieces that are both visually striking and structurally sound.
[017] The key aspects of the present disclosure include the use of a transparent photopolymer to securely hold gemstones in place. The layer-by-layer curing method using UV light and the creation of mechanical retention features within the jewellery structure to enhance the strength of the bond between the crushed gemstone represent a significant improvement over traditional gemstone-setting methods, which are often limited by the shape and size of the stones, as well as the type of setting used.
[018] The present disclosure provides a highly effective, efficient, and aesthetically pleasing method for manufacturing durable jewellery pieces, incorporating crushed gemstones into jewellery items using a layer-by-layer UV curing process. This novel approach addresses various challenges in traditional jewellery manufacturing method including the waste of valuable gemstone material, the limitations of conventional setting techniques, and the need for an environmentally sustainable solution in the jewellery industry.
BRIEF DESCRIPTION OF THE DRAWINGS
[019] The accompanying schematic flow diagram illustrates the process of manufacturing the jewellery wherein;
[020] Figure 1 illustrates the process flow diagram the sequential steps involved in the manufacturing method of jewellery articles using crushed gemstones and UV-cured photopolymer. These processes are provided to facilitate understanding of the invention and are not intended to limit its scope. It must be noted that the process disclose in the present disclosure is in a detailed enough way to be implemented.
DETAILED DESCRIPTION
[021] Throughout the specification and claims, the following terms take the meanings explicitly associated herein unless the context clearly dictates otherwise. The meaning of "a", "an", and "the" include plural references. The meaning of "in" includes "in" and "on." Additionally, a reference to the singular includes a reference to the plural unless otherwise stated or inconsistent with the disclosure herein.
[022] Throughout the present disclosure, the terms "metal structure" and "jewellery structure" may be used interchangeably and are intended to be understood as one and the same referring to the structural metallic base of the jewellery in which the crushed gemstones are securely embedded using the photopolymer.
[023] The present invention provides a method for manufacturing jewellery articles including but not limited to rings, earrings, pendants, bangles, bracelets, necklaces and other ornamental accessories. The gemstones are uniquely processed, crushed and securely embedded within a jewellery structure using a specialized transparent photopolymer cured via ultraviolet (UV) light exposure.
[024] The manufacturing method of a jewellery article that combines the aesthetic appeal of crushed gemstones with the clarity and durability of a transparent photopolymer matrix. The method begins with the preparation of a jewellery structure formed from a precious metal. This jewellery structure includes a specifically designed recess which features micro-forms or surface texturing to enhance mechanical adhesion of a subsequently applied transparent photopolymer. In addition to this texturing, one or more mechanical interlocking retention slots are formed within the structure to further ensure the physical anchoring of the photopolymer and crushed gemstone composite. In some cases, crushed gemstones are also selected for their colour, refractive properties and luster carefully deposited within the recess. A transparent UV-curable photopolymer is applied over the crushed gemstone layer. To further enhance the visual appeal, a colour pigment may be incorporated either into the photopolymer itself or applied directly onto the gemstone layer allowing for the simulation of natural gemstone coloration or the creation of unique artistic effects. The photopolymer is cured in a controlled layer-by-layer manner using ultraviolet (UV) light to ensure thorough polymerization and achieve high optical clarity. This sequential curing process allows for superior integration of the gemstone particles within the polymer matrix while maintaining structural integrity.
[025] Referring to figure 1, at step 102, the jewellery structure is fabricated using a selected precious metal such as but not limited to gold alloys, silver alloys, or platinum alloys and other precious metals depending on the desired final product. The jewellery structure may be shaped to form various jewellery items, including rings, earrings, pendants, bangles, necklaces, or other jewellery accessories.
[026] The shape of the jewellery items in accordance with the present disclosure is but not limited to any specific shape and may vary depending upon the desired final product. The jewellery items may be designed in various geometric shapes including but not limited to circular, oval, rectangular, square, polygonal, or freeform designs, and may also include intricate artistic patterns, floral designs, or customized shapes as per user preference.
[027] The surface of the jewellery structure is prepared with a series of micro-recesses each having a depth of approximately 0.1 mm to enhance adhesion between a photopolymer and the jewellery structure surface. These recesses serve as a setting area for the crushed gemstones are configured to provide traction and mechanical bonding for the photopolymer. Within this recess, an array of extremely fine metal forms is created each having a height of approximately 0.10 mm. These fine metal forms which may be in the form of micro-protrusions, ridges or texturing, are strategically distributed across the recess surface. The purpose of these fine metal forms is to enhance the traction between the photopolymer and the metal surface, thereby improving adhesion.
[028] At step 102 and 104, a retention slot is precisely formed within the jewellery structure having a width ranging from 0.1 mm to 0.5 mm strategically positioned to ensure that the photopolymer penetrates this slot providing enhanced mechanical interlocking and structural integrity. The jewellery structure is designed these retention slots having a width ranging from 0.1 mm to 0.5 mm extend through the metal structure in such a way that when liquid photopolymer is applied over the crushed gemstones placed within the recess, the liquid photopolymer is able to flow into the slots. This configuration ensures that the photopolymer once cured, forms a mechanical interlock within the slots and providing enhanced mechanical strength and secure fixation of the crushed gemstones.
[029] At step 106, the natural or synthetic gemstones are selected and subjected to a uniquely controlled crushing process to produce fine crushed gemstone into fine particles of varying sizes suitable for creating a visually appealing and textured gemstone layer. These crushed gemstones are then carefully arranged within a recess formed on the surface of the jewellery structure.
[030] A controlled method of crushing gemstones is employed to achieve fine and uniformly sized gemstone particles suitable for secure placement within the jewellery structure. This method begins with the selection of gemstones that are first cleaned and inspected for quality. The gemstones are then subjected to a controlled crushing process using specialized crushing equipment, such as but not limited to hydraulic press, roller mill, or high-impact crusher machine depending on the desired particle size and gemstone type.
[031] The crushing process is carefully regulated by adjusting the pressure, impact force, and duration to ensure that the gemstones are reduced to fine particles without excessive fragmentation or loss of luster. A sieve or mesh grading system is used to separate the crushed gemstones into uniform size ranges depending on the aesthetic and structural requirements of the jewellery design. To further enhance the quality of the crushed gemstones, an optional polishing step may be performed, wherein the crushed particles are gently tumbled or treated with a polishing compound to enhance their brilliance and colour. This controlled crushing method ensures that the gemstone particles are of consistent size, shape, and quality, making them ideal for secure encapsulation within the jewellery structure using the photopolymer.
[032] At step 108 and 110, a specialized transparent photopolymer is then applied over the arranged crushed gemstones. This photopolymer is selected from a group consisting of polyurethane acrylates, polyester acrylates, and epoxy acrylates, and is further formulated with a photoinitiator, specifically Diphenyl(2,4,6-trimethylbenzoyl) phosphine oxide (TPO). The photopolymer is cured using ultraviolet (UV) light, with a wavelength ranging from 365 nm to 405 nm. A strong and durable bond is formed between the metal surface of the jewellery structure and the photopolymer effectively encapsulating and securing the crushed gemstones within the recess, while the mechanical interlock created by the photopolymer flowing into the slots further enhances the structural integrity of the gemstone setting.
[033] In certain embodiment, the crushed gemstones may be treated with colour pigments to enhance their visual appeal, achieve a natural gemstone colour, or create custom colour variations depending on the design preferences. The crushed gemstones are then sorted and graded based on size and optical properties to maintain uniformity in the final jewellery product. Such pigment treatment is performed in a controlled manner ensuring colour uniformity and stability within the final jewellery product. This process involves the selection and application of appropriate colour pigments which may be either natural or synthetic depending on the desired visual effect. The pigments are chosen to either intensify the gemstone’s inherent colour or to impart a new vibrant hue to the gemstones. Prior to pigment application, the crushed gemstones are thoroughly cleaned to remove any impurities, dust, or oils to ensure optimal adhesion of the pigments.
[034] In certain embodiments, the gemstones may undergo light abrasion or etching to increase surface area and improve the bonding of the pigments. The pigment application may carry out through methods such as dipping, spraying or coating, wherein the gemstones are exposed to a solution or suspension containing the colour pigments and a suitable binder such as a clear resin or polymer. This binder ensures the secure attachment of the pigment to the gemstone surface. After the pigments are applied, the gemstones undergo a curing or setting process, which may involve heat curing, UV light exposure, or air drying, depending on the specific pigment and binder system used. This step ensures that the colour is permanently fixed to the gemstone. Following the curing process, the gemstones are polished to achieve a smooth, glossy finish and to enhance the overall appearance ensuring that the applied colour is evenly distributed and the gemstones exhibit optimal shine. This method provides a versatile means for enhancing or altering the colour of crushed gemstones, offering increased control over the aesthetic properties of the final product, suitable for high-quality jewellery, decorative objects, and other applications requiring precise colour manipulation.
[035] At step 112, The curing process is performed in a layer-by-layer fashion, where each applied layer of the photopolymer is exposed to UV light, causing it to solidify and securely encapsulate the crushed gemstones. This method not only ensures that the gemstones are securely held in place but also provides a clear, durable, and aesthetically appealing surface finish. The layer-by-layer curing approach further allows for precise control over the thickness and distribution of the photopolymer, enhancing the overall strength and visual quality of the final jewellery product. The photopolymer is applied onto the prepared jewellery structure in a layer-by-layer fashion where each layer having a precisely controlled thickness. This allows for incremental build-up of the photopolymer while maintaining high optical clarity of the crushed gemstone.
[036] In one embodiment, the photopolymer used in the crushed gemstone jewellery may be a transparent polymer allowing for the clear visibility of the embedded crushed gemstones. This transparent photopolymer may be selected from materials such as but not limited to polyurethane acrylates, polyester acrylates, or epoxy acrylates, which are cured using a UV-initiated polymerization process facilitated by a suitable photo initiator such as TPO (Diphenyl(2,4,6-trimethylbenzoyl) phosphine oxide). The transparency of the photopolymer ensures that the intrinsic colours, luster, and brilliance of the crushed gemstones are prominently visible to creating an aesthetically appealing. Additionally, the transparent photopolymer forms a robust, durable matrix around the gemstones, securely holding them in place while providing a smooth and polished surface finish. This configuration enhances both the visual appeal and structural integrity of the jewellery piece.
[037] The crushed gemstones are evenly distributed onto each layer of the photopolymer while it is in an uncured state. The gemstones are manually or mechanically adjusted for even distribution and to achieve the desired visual pattern. Additional layers of photopolymer may be sequentially applied followed by further crushed gemstone embedding to create a multi-layered optically dynamic appearance.
[038] The jewellery structure with the applied photopolymer and embedded crushed gemstones is exposed to ultraviolet (UV) light with the help of the UV lamp externally. In one embodiment, the ultraviolet (UV) light required for curing the photopolymer is provided by a UV lamp configured to emit light within a wavelength range of 365 nm to 405 nm, which is suitable for initiating the curing reaction of the photopolymer containing the photoinitiator Diphenyl(2,4,6-trimethylbenzoyl) phosphine oxide (TPO). Various types of UV lamps may be employed for this purpose including mercury vapor UV lamps, LED UV lamps, and excimer UV lamps. A mercury vapor UV lamp provides high-intensity UV light with a broad spectrum including the specified wavelength range. An LED UV lamp offers precise wavelength control, energy efficiency, and reduced heat generation making it particularly suitable for temperature-sensitive applications. In contrast, an excimer UV lamp provides highly controlled and uniform UV exposure ideal for applications requiring high precision.
[039] The UV lamp is positioned at an optimal distance from the jewellery structure to ensure uniform exposure and efficient curing of each photopolymer layer. The curing process is performed in a layer-by-layer fashion, where each applied layer of the photopolymer is exposed to UV light for a predetermined duration, ensuring complete and uniform solidification. The duration of UV exposure may be adjusted depending on the photopolymer composition, layer thickness, and desired curing speed, allowing for precise control over the appearance and strength of the final jewellery product. The wavelength of the ultraviolet light supplied to the jewellery structure embedded with gemstone ranging from but not limited to 365 nm to 405 nm. The supplied UV light initiates rapid polymerization of the photopolymer and start forming secure bonding between the gemstones to the jewellery structure in each applied layer in curing state. In curing state, the phot polymer starts hardening due to exposure to ultraviolet (UV) light that initiate a chemical reaction to transforms the photopolymer resin from a liquid or malleable state to a solid durable form. The exposure of ultraviolet light to the embedded crushed gemstone with the photopolymer initiates this curing process ensuring uniform distribution, superior bonding, and enhanced optical clarity of the embedded gemstones. This process initiates a chemical reaction that solidifies the material, transforming it from a liquid or malleable state into a rigid, durable form. This UV exposure is performed in a controlled layer-by-layer manner to ensure that each layer of photopolymer is fully cured before the next layer is applied to ensures secure encapsulation of the crushed gemstones within the photopolymer and providing a durable and optically clear appearance.
[040] To achieve the desired results in the curing process, the method involves carefully regulating three critical factors: the intensity, duration, and wavelength of the ultraviolet (UV) light applied to the photopolymer material. These factors work together to ensure that the material undergoes complete polymerization, meaning that the monomers or oligomers within the photopolymer are fully converted into a solid, cross-linked structure. The intensity of the UV light controls how much energy is delivered to the material, the duration dictates how long the material is exposed to the light, and the wavelength determines the specific energy range that is most effective for initiating the polymerization reaction.
[041] The key challenge addressed by this method is ensuring that the polymerization process does not interfere with the optical properties of the material. By adjusting these parameters, the process prevents over-curing, which could lead to issues such as cloudiness or distortion, while ensuring that the material is fully hardened and durable. This careful balance allows the photopolymer to retain its transparency and optical clarity, which is essential for applications where the visual quality of the final product is crucial, such as in lenses, displays, or other optical components.
[042] At step 112, After the curing process, the jewellery article is subjected to a precision finishing process, including surface polishing, edge refinement, and any other necessary surface treatments. The final jewellery article exhibits a visually striking appearance with securely embedded crushed gemstones, maintaining high durability and aesthetic quality.
, Claims:We Claim:
1. A method for manufacturing jewellery article, comprising the steps of:
a) preparing a jewellery structure formed from a precious metal, the structure having a recess with micro-forms or surface texturing to enhance adhesion of a transparent photopolymer;
b) forming one or more mechanical interlocking retention slots in the jewellery structure;
c) depositing crushed gemstones within the recess of the jewellery structure;
d) applying the transparent photopolymer over the crushed gemstones;
e) curing the photopolymer in a layer-by-layer fashion using an ultraviolet (UV) light to achieve complete polymerization and optical clarity; and,
f) obtaining a durable, optically clear, and aesthetically appealing jewellery article with securely embedded crushed gemstones.
2. The method as claimed in claim 1, wherein the surface micro-forms have a depth of approximately 0.10 mm and the retention slots have a width ranging from 0.1 mm to 0.5 mm.
3. The method as claimed in claim 1, wherein the UV-curable transparent photopolymer is selected from a group consisting of polyurethane acrylates, polyester acrylates, epoxy acrylates, and includes a photoinitiator selected from TPO or other suitable photoinitiators.
4. The method as claimed in claim 1, wherein the UV light used for curing has a wavelength range of 365 nm to 405 nm.
5. The method as claimed in claim 1, wherein the jewellery structure is formed from a precious metal selected from gold, silver, platinum, their alloys, or other precious metals.
6. The method as claimed in claim 1, wherein the UV light source is selected from mercury vapor lamps, UV LED lamps, or excimer lamps.
7. The method as claimed in claim 1, wherein the curing process is controlled by adjusting the intensity, duration, and wavelength of the UV light to ensure complete polymerization of the photopolymer while maintaining optical clarity.
8. The method as claimed in claim 1, wherein the crushed gemstones are treated with colour pigments to achieve an enhanced or natural colour appearance.
9. The method as claimed in claim 1, wherein the jewellery articles manufactured include rings, earrings, pendants, bangles, bracelets, necklaces, or other jewellery accessories.
10. The method as claimed in claim 1, wherein incorporating a colour pigment within the photopolymer or directly onto the crushed gemstones to achieve an enhanced or natural colour appearance of the jewellery article.