Forming a thick printed sheet of material is an expensive and difficult task.
The structural support for the relief area, as taught by the prior art, is a natural consequence of the inherent rigidity of the plastic material used to make the globe.
Subsequently, the vinyl sheet 34 with the print 36 thereon, as exemplified by FIG. The resultant hemisphere 35 as exemplified by FIGS.
A polar opening 38 having a key notch 40 is preferably cut through the hemisphere 35.
Other means for orienting the hemisphere 35 may also be utilized.
The globe 10 is mounted on a polar axis 18 by means of polar supports 20 and 22.
A support ring 24 is attached to the supports 20, 22 and, in turn, is affixed to a stand 26 in a conventional manner to support the globe 10.
3 is an enlarged cross sectional view of the sheet of FIG. 4 is a side cross sectional view of the sheet of FIG. 6 is a side cross sectional view illustrating the manner in which the hemispherical sheet shown in FIGS. 9 is a side cross sectional view illustrating separation of the mold core and mold cavity subsequent to the step shown in FIG. 10 is an enlarged cross sectional view of the globe mold core and mold cavity during the forming operation of FIG. 11 is an exploded cross sectional view of the globe of FIG.
2 subsequent to forming the sheet into a hemispherical shape; FIG. 1 illustrating the manner in which the globe sections are assembled; and FIG.
A second molded hemisphere is produced in substantially the same manner and is attached to the first hemisphere to form a complete globe. Another object of the present invention is to provide a method of globe manufacture wherein the relief areas are formed simultaneously with providing a solid, rigid backing for the globe form.
The printed map design of the globe is positioned in the mold cavity to insure that the relief areas are properly positioned with respect to the design.a rigid, thin walled, molded plastic inner wall with an outside surface adhered to said outer sheet and defining a relief pattern impressed on the outer sheet by the outside surface of the inner wall, said inner wall having a generally smooth, uniform inner surface, said inner wall having sufficient thickness to maintain and define the shape of the globe. Globes or spherical representations of the earth having relief areas were known at least since 1962, see e.g., Case, U. Another object of the present invention is to provide a globe with a relief surface and a method for manufacturing such a globe in which the relief areas have greater structural integrity and durability than is achieved by prior art globe manufacturing techniques.
This invention comprises a globe in relief and a method for manufacture of such a globe including the steps of: printing a predetermined substantially two dimensional map pattern onto a thin, flexible, flat plastic sheet; shaping the plastic sheet into a substantially hemispherical shape or into some other curved configuration that represents a portion of a sphere; positioning the shaped sheet in a mold cavity which includes a relief area pattern; positioning a mold core in spaced relation to the back side of the flexible plastic sheet; injecting a hardenable plastic material between the mold core and sheet to form the sheet against the mold cavity and thereby define relief areas in a predetermined three-dimensional pattern on the sheet; and hardening a layer of the plastic material onto the back side of the sheet to fill the cavities with a substantially solid material and provide a solid backing for the entire surface of the sheet.