WO2018057903A1

WO2018057903A1 - Chainmaille layout tool and methods of making chainmaille using a layout tool

Info

Publication number: WO2018057903A1
Application number: PCT/US2017/052973
Authority: WO
Inventors: Nadja ALLER; Jason M. LYNCH; Wayne H. Rothschild; Jordan S. FINE
Original assignee: Ring Ring Ring Llc
Priority date: 2016-09-22
Filing date: 2017-09-22
Publication date: 2018-03-29
Also published as: US20200023423A1; EP3515631A1; EP3515631A4

Abstract

Layout tools for making chainmaille. The tool has a substrate with grooves, cuts, or slots formed through a top surface thereof. Each pair of cuts forms a generally v-shaped pattern along a length of the top surface. Each of the pairs of the cuts are spaced apart, have a length, and form an angle that provides a straight line path that intersects at least four of the cuts configured to receive rings to form a chainmaille. Another tool also has a substrate with grooves, cuts, or slots formed through a top surface thereof. Each cut passes through a common point. Each cut has a length corresponding to a diameter of a ring, and each of the cuts has a depth that is a function of at least the number of rings and a wire diameter of the rings.

Description

CHAINMAILLE LAYOUT TOOL AND METHODS OF MAKING CHAINMAILLE

USING A LAYOUT TOOL

FIELD OF THE INVENTION

[0001] Aspects of the present disclosure relate to chainmaille layout tools and methods of making chainmaille using a layout tool.

BACKGROUND OF THE INVENTION

[0002] The art of making chainmaille is over 1000 years old. Historically, certain chainmaille weaves required years of experience to master, due to the manual dexterity, complexity, and sequence of manipulation of the rings required to make the weaves. Rings can be hard to hold, can slip, can be interleaved incorrectly, and constant concentration is required to make sure the rings are interleaved in the proper sequence and with adjacent rings. One wrong move, and the entire chainmaille sequence can be broken, making corrections very time-consuming and frequently discouraging. Many rings need to be dangled in a partially attached form, making it easy for the builder to get lost in the process.

SUMMARY OF THE INVENTION

[0003] The layout tools disclosed herein make the 1000-year old art of chainmaille very easy for a novice. Weaves made using these tools and methods can be accomplished by a child in their first attempt making chainmaille, without any prior instruction or guidance, or even foreknowledge as to what a chainmaille is.

[0004] Several tools for making chainmaille are disclosed herein. An asterisk or star- shaped tool is for making a type of chainmaille weave called "Mobius." Another repeating v- shaped tool is used for making chainmaille weaves including one called the "European four- in-one."

[0005] Fundamentally, the tool holds rings in their proper position while weaving-in additional rings. Without the tool it is very easy to get lost in the dangling rings while weaving.

BRIEF DESCRIPTION OF THE DRAWINGS

[0006] FIG. 1A is a diagram showing a sequence of steps for making a Mobius chainmaille using a layout tool in accordance with an aspect of the present disclosure.

[0007] FIG. IB illustrates a sequence for opening a wire ring used to make chainmaille. [0008] FIG. 2A is an illustration of a completed chainmaille featuring a Mobius weave made using the steps and tool shown in FIG. 1 A.

[0009] FIG. 2B is an illustration of an example ring that can be used to make a chainmaille weave having a ring outer diameter and a ring wire diameter.

[0010] FIG. 2C is a top perspective view of a layout tool for making a Mobius chainmaille having up to seven interleaved rings.

[0011] FIG. 2D is a top view of the layout tool.

[0012] FIG. 2E is a schematic of a cross section taken along lines 2E-2E to show the different depth of the cuts or slots formed in the layout tool shown in FIG. 2C.

[0013] FIG. 3A is a photograph of a chainmaille weave featuring a European 4-in-l weave with kinging in which two connector rings are inserted between two pairs of connecting rings using a layout tool in accordance with another aspect of the present disclosure.

[0014] FIG. 3B is a top view of a layout tool that can be used to make the chainmaille shown in FIG. 3 A.

[0015] FIG. 3C is another top perspective view of the layout tool shown in FIG. 3 A.

[0016] FIG. 3D is a partial top perspective view of the layout tool shown in FIG. 3C with a few connecting rings inserted into cuts formed in the tool.

[0017] FIG. 3E is a side view of the rings inserted into the tool showing the gaps through which connector rings can be inserted.

[0018] FIG. 3F is a top view of the rings shown in FIG. 3E.

[0019] FIG. 4 is a top view of another layout tool that produces a X-Lock type chainmaille.

[0020] FIG. 5A is a schematic showing four example rings arranged in a v-shaped pattern and a path for inserting of a connector ring through two adjacent pairs of rings secured in the layout tool.

[0021] FIG. 5B is a schematic showing parallel paths for multiple connector rings that are inserted or interleaved through two adjacent pairs of connecting rings seated in the layout tool.

[0022] FIG. 6A is a schematic showing four example rings arranged in a v-shaped pattern and a connector ring inserted through two adjacent pairs of connecting rings secured in the layout tool along with example dimensions to ensure that the connector ring can pass through the four connecting rings. [0023] FIG. 6B is a schematic of the four connecting rings and various dimensions that can be taken into consideration depending on the dimensions of the connector ring.

[0024] FIG. 6C is an illustration of a ring and its cross-section showing its ring outer diameter, ring inner diameter, and wire diameter.

[0025] FIG. 7 A shows example indicia that can be printed on the top surface of the v- shaped patterned layout tool that also has a layout tool for making a Mobius chainmaille.

[0026] FIG. 7B is an illustration of a ring having a ring inner diameter, a ring outer diameter, and a ring wire diameter, along with exemplary values for each.

[0027] FIG. 7C is a schematic of example v-shaped cuts formed in the top surface of the layout tool substrate showing example values for various dimensions.

[0028] FIG. 8 is a schematic showing an example connector ring passing through six, instead of four, connecting rings to form a six-in-one chainmaille.

[0029] FIG. 9A is sample instruction sheet illustrating a method of making a 4-in-l chainmaille using the layout tools disclosed herein.

[0030] FIG. 9B is a schematic of a completed chainmaille about to be removed from the layout tool.

[0031] FIG. 9C is an illustration of the completed chainmaille removed from the layout tool.

[0032] FIGS. 10A-10D illustrate different example layout templates used to make different types of chainmaille.

[0033] FIGS. 10E-10H illustrate various formation and enhancements for the layout tool.

[0034] FIG. 11 is a photograph showing a cut formed in a layout tool without burnishing.

[0035] FIG. 12 is a photograph showing the benefits of burnishing the cuts.

[0036] FIGS. 13-15 are instruction sheets for forming a chainmaille using a layout tool in accordance with aspects of the present disclosure.

[0037] FIG. 16A shows an assembled 3-2 weave chainmaille.

[0038] FIG. 16B is an illustration of a side-by-side 3-2 weave chainmaille layout tool.

[0039] FIG. 16C is a cross-section schematic showing rings placed in the 3-2 weave chainmaille layout tool and connecting rings.

[0040] FIG. 16D is a photograph of a top view of rings positioned in the 3-2 weave chainmaille layout tool with connecting rings.

[0041] FIG. 16E is a photograph of a side view of rings positioned in the 3-2 weave chainmaille layout tool with connector rings. [0042] FIGS. 17-18 are instruction sheets for making a chainmaille using a plastic layout tool with a removable fork.

[0043] FIGS. 19A-19C are illustrations of perspective views of a plastic layout tool used to make a chainmaille.

[0044] FIG. 19D is an end view of the plastic layout tool shown in FIGS. 19A-19C.

[0045] FIG. 20 is a top view of a removable fork that is inserted into the plastic layout tool during chainmaille assembly and then removed from the tool to release the completed chainmaille.

DETAILED DESCRIPTION

[0046] FIG. 1 A shows steps of an example method to make a Mobius chainmaille having 6 rings using a layout tool according to an aspect of the present disclosure. A Mobius chainmaille is a design where the rings are intertwined making it appear to be a multi-layer spiral. If any of the rings are woven out of the pattern, the design fails. Keeping track of the rings while weaving is difficult and confusing using conventional techniques, particularly when all the rings are of the same color. In step 100a, a foam block or substrate 110 has multiple cuts or slots or grooves oriented like spokes on a bike arranged around a central hub or point. For convenience, the terms cuts, slots, and grooves are used interchangeably herein. The cuts, depending on the number (e.g., 5 or 7), resemble positions on a clock face. At step 100b, a first closed ring 102a is inserted into a first of the cuts, such as the one oriented at the approximately 1 o'clock and 7 o'clock positions on the "clock face." At step 100c, a second open ring 102b is inserted through the first closed ring 102a into a second cut that is next to the first cut, such as one oriented at approximately 2 o'clock and 8 o'clock. By open, it is meant that the ring has a partial gap 103 (seen in FIG. IB) having a sufficient distance to allow another ring of the same wire diameter to be passed through the gap. In Fig. IB, the ring 102 can be opened by grasping either end and twisting as shown to produce a gap 103 to form an open ring 102'. At step lOOd, the second open ring 102b is closed to form a second closed ring 102b. At step lOOe, a third open ring 102c is inserted through both the first and second closed rings 102a, 102b into a third cut that is next to the second cut, such as one oriented at approximately 3 o'clock and 9 o'clock. At step lOOf, the third open ring 102c is closed to form a third closed ring. At step lOOg, a fourth open ring 102d is inserted through the first, second, and third closed rings 102a, 102b, 102c in a fourth cut that is next to the third cut, such as one oriented at approximately 4 o'clock and 10 o'clock. At step lOOh, the fourth open ring 102d is closed to form a fourth closed ring. At step lOOi, a fifth open ring 102e is inserted through the first, second, third, and fourth closed rings 102a, 102b, 102c, 102d in a cut that is next to the fourth cut. At step lOOj, the fifth open ring 102e is closed to form a fifth closed ring. At step 100k, a sixth open ring 102f is inserted through the first through fifth closed rings 102a, 102b, 102c, 102d, 102e, and then closed to form a sixth closed ring. Note that the last ring of the chainmaille need not be inserted into any cut of the layout tool, and the last ring 102f can have a smaller diameter compared to the other five rings 102a- 102e. At step 100m, the entire assembly of six closed rings 102a-102f interweaved to form a Mobius chainmaille can now be lifted out of the layout tool 110, such as by grasping the sixth closed ring 102f and pulling the other rings out of their corresponding cuts in direction A. Step 100η shows the completed Mobius chainmaille 104 next to the layout tool 110.

[0047] The layout tool of FIG. 1A is shown having an example seven cuts to make a Mobius chainmaille having between 3-7 rings. While the cuts can be of equal depth, or of varied depth, the tool is easiest to use when the depths are a function of the wire diameter and number of rings. The first cut is the deepest of the other five cuts. The other five cuts become progressively shallower in a clockwise or anti-clockwise direction relative to the first cut depth. In this example, each subsequent cut starting from the first cut is approximately 2mm shallower then its immediate predecessor's depth. This allows the rings to be seated securely at the bottom of the respective cuts without interfering with the wire of the ring inserted into the adjacent cut. The layout tool can be used for a minimum of three rings, or a maximum of eight rings. More than seven cuts permit assembling a Mobius of more than eight total rings.

[0048] FIG. 2 A illustrates an example Mobius chainmaille 104 having six rings, and FIG. 2B illustrates a ring having a ring wire diameter (typically expressed as a wire gauge) and a ring outer diameter OD (after the ring is closed). FIG. 2C illustrates a top perspective view of the layout tool 110 used in FIG. 1 A to make the chainmaille shown in the final step 100η of FIG. 1 A, with each of the seven cuts or slots numbered consecutively from one to seven on the drawing, indicating the seven distinct positions for inserting rings to make a Mobius chainmaille 104. As indicated above, the first cut into which the first ring is inserted is the deepest (relative to a top exposed surface of the layout tool 110), with each subsequent cut becoming progressively shallower compared to its predecessor. Example depth cuts can be seen in FIG. 2D for an example layout tool having five cuts (shown with five cuts for ease of illustration and discussion, though of course the present disclosure contemplates a layout tool having anywhere from three to seven cuts total). The inventors have found that the depth cuts can be expressed as a function of the ring wire diameter and the number of cuts. In this example, each of the cuts (the first cut) can be calculated as follows (assume five rings total, a ring outer diameter (OD) of 22mm and, a wire diameter of 1.5mm):

Depth Cut 1 = ring wire diameter * total number of rings + 1 mm = 8.5mm

Depth Cut 2 = ring wire diameter * (total number of rings - 1) + 1 mm = 7mm

Depth Cut 3 = ring wire diameter * (total number of rings - 2) + 1 mm = 5.5mm

Depth Cut 4 = ring wire diameter * (total number of rings - 3) + 1 mm = 4mm

Depth Cut 5 = ring wire diameter * (total number of rings - 4) + 1 mm = 2.5mm

[0049] Of course, these measurements and dimensions are merely exemplary and illustrative, but other measurements and dimensions are contemplated using the formulas given above.

[0050] In these examples, the length of each of the cuts is equal to the ring OD plus a clearance or tolerance. Clearance should not be less than 0.5mm or greater than 3mm for best fit and control of the rings. For example, the clearance can be 1mm, such as used in the above example calculations. Self-centering of the rings occurs with a cut length sized for specific ring ODs. This was a unique and surprising discovery as the inventors sorted out the proper lengths and depths of the cuts. The cut length can be made very large for use on a wider range of ring ODs, but this can provide less control over the ring placement. Alternately, all of the cuts can have the same depth = Number of Rings * Wire Diameter + lmm, but such a layout tool would be more challenging to use as it would provide less control and less placement of the rings.

[0051] A different layout tool will now be described with reference to FIG. 3A, which shows a completed chainmaille 300 that has a weave known as a European 4-in-l . This beautiful weave 300 has existed for over one thousand years and is very difficult to make because each ring is primarily connected to four adjacent rings (hence the name, four-in-one). Keeping all of the rings under control during conventional weaving without the layout tool of the present disclosure requires significant artisan skill, coordination and concentration. Until now, this weave required extensive experience with chainmaille. Many people have wanted to make this complex chainmaille but lacked the stills and dexterity to do so.

[0052] FIG. 3B illustrates a top view of a layout tool 302 for making a chainmaille featuring a European 4-in-l weave. FIGS. 3B and 3C show an array or pattern of in-line v- shaped cuts (grooves or slots) 304, 306 formed in a top surface of the tool, which has a foam, silicon or similar resilient substrate. FIG. 3D illustrates how rings 306 are inserted in the direction of the arrow into the cuts to form a repeating v-shaped pattern along a major length of the tool 302. An important consideration of the design of the layout tool 302 can be seen with reference to FIGS. 3D-3F. Placing rings into the tool 302 orients the rings to create an open path whereby an additional connector ring can easily threaded through the respective trailing ends of Rings 1 and 2 306, 308, and the leading edge of Rings 3 and 4 310, 312, keeping in mind that the connector ring (not shown) is curved and so are each of the connecting rings 1-4. The tool 302 keeps the connecting Rings 1-4 306, 308, 310, 312 in place, while the connector Ring 5 moves through the path indicated by the arrowed line A in FIG. 3F. In FIG. 3E, viewed from the side, a gap 320 that passes through Rings 1-4 306, 308, 310, 312 can be seen, and it is through this gap 320 that the open connector ring can be inserted along the path A before being closed.

[0053] FIG. 4 illustrates another layout tool 402 for making an X-lock type chainmaille weave. Example dimensions are shown on the figure schematic. In the center of the tool 402 is a pattern of cuts 404 into which rings are inserted to form an x-lock type chainmaille weave. The rings form an "X" in the cross-section of the weave, and the type of weave known as X-lock is familiar to those skilled in the art of chainmaille weaving. However, without the layout tool 402, making an X-lock type chainmaille weave is extremely difficult and requires a very high level of skill, expertise, patience, and dexterity. The cuts 404 shown in the figure schematic are to scale (in inches), so with the exemplary dimensions, the angles and dimensions of the cuts can be determined and scaled appropriately to any size layout tool 402.

[0054] FIG. 5A is a schematic showing the arrangement of four closed rings and how the initially open connector ring can be inserted through all four closed rings. Viewed as a v- shaped formation, the part of the ring that forms the apex of the "V" is referred to as a leading edge, whereas the other part of the same ring is referred to as a trailing edge. In this example, the first ring 502 has a trailing edge 510, and the second ring 504 has a trailing edge 516. A third ring 506 has a leading edge 512, and a fourth ring 508 has a leading edge 514. The path along direction A for the open connector ring is defined as a path A that passes first through the trailing edge 516 of ring 2 504, then through the leading edge 514 of ring 4 508, then through the leading edge 512 of ring 3 506, and finally through the trailing edge 510 of ring 1 502. The spacing or gap formed by the path A must ensure clearance as a function of the ring wire diameter and outer diameter OD, as is discussed in more detail below. FIG. 5B illustrates an example layout tool 520 already loaded with rings, and shows the arrowed parallel paths for each of the connector rings that is inserted through respective groupings of four rings as shown in FIG. 5A. Note that there is no theoretical limit to the length of the v- shaped pattern. The minimum length is shown in FIG. 5A, but the maximum length of any layout tool disclosed herein is constrained only by practical considerations.

[0055] FIGs. 6A, 6B, and 6C reflect additional considerations that must be accounted for in forming the cuts (length, depth, and angle of the "V") in the layout tool 520 to accommodate rings of various wire diameters and outer diameters ODs so that a 4-in-l weave can be constructed in a manner that allows each open connector ring to be easily slipped through the corresponding closed connecting rings already secured in situ into cuts of the layout tool 520. FIG. 6A shows the constraints on the inner and outer diameters of the connector ring 612 (shown in cross section in lighter lines). The inner diameter ID5 of the connector ring 612 must be able to fit around the trailing edges of the connecting rings 602 and 604 as numbered in FIG. 6A. In addition, the wire diameter WD5 and the outer diameter OD5 of the connector ring 612 must be selected so that it can clear both distal parts of the trailing inner edges of the connecting rings 602 and 604, otherwise the connector ring 612 will not be able to be closed completely around the connecting rings 602, 604, 606, 608. As discussed above, the connector ring 612 also passes through the leading edges of rings 606 and 608, which must be positioned in the layout tool 520 so that they can accommodate the wire diameter WD5 of the connector ring 612. The following example observations can be made about the various rings and dimensions:

[0056] Assuming that rings 602, 604, 606, 608 are the same size (i.e., share the same wire diameter WD and the same outer diameter OD), and the connector ring 612 has a different size:

[0057] Dimension C >= WD5, so that the wire of ring 612 fits through rings 602, 604, 606, 608;

[0058] Dimension A > WD2 because the wires will be no less than adjacent ones;

[0059] 10 degrees < Θ < 85 degrees so that connecting and connector wires alike can feather over one other;

[0060] WD5 + WD1 <= B <= D-A because the connector ring 612 must be able to pass through rings 602, 604, 606, 608; and

[0061] E > WD2 so that wires can be feathered over each other.

[0062] Note that although the above example constraints assume that rings 602, 604, 606, 608 have the same size, though rings 602, 604, 606, 608 need not be the same size.

[0063] Example dimensions for a given ring size can be seen with reference to FIGS. 7A- 7C. Each of the connector rings when inserted are spaced about 1 cm apart in this example. FIG. 7B illustrates an example ring having a ring ID of 14.3mm, a ring OD of 17.7mm, and a wire diameter of 1.7mm. FIG. 7C show example dimensions of the V-shaped cuts to accommodate rings of the size shown in FIG. 7B. The angle Θ of the "V" is 60 degrees, the length of each cut is 14.2mm, and the space between each "V" is 8.3mm. Note that the 14.2mm length of each cut is slightly smaller than the ring's ID of 14.3mm because the ring only engages to a chord, not to its entire diameter, given the depth of the cut, which in this example is 5mm, shorter than the widest part of the ring which appears at half of its OD, or 8.85mm. The trailing edge distance between two cuts is 4.3mm, and the length of each cut taken horizontally is 13.5mm. Note that ascertaining these dimensions and relationships are not trivial, taking into the account the geometries of wire rings, angles, and available spacing through co-alignment of multiple rings arranged at an angle.

[0064] FIG. 8 illustrates a six-in-one weave configuration 800 with a connector ring 814 having a sufficient ring outer diameter and wire diameter to pass through six connecting rings 801, 802 806, 808, 810, 812 inserted into corresponding V-shaped cuts in the layout tool. Using the dimensions and relationships given above, the tool can be expanded to accommodate this 6-1 weave, an 8-1 weave, and so on.

[0065] FIGS. 9A, 13, 14, and 17-18 11 illustrate example instruction sheets for using various layout tools for making chainmaille weaves according to various aspects of the present disclosure. FIG. 9A is an instruction sheet for making a European 4-in-l weave 900. In FIG. 9B, the user is instructed to grasp a free end of the weave 900 and pull the rings out of the cuts formed in the layout tool. FIG. 9C is a photograph 900 of an example European 4-in-l weave made by a European 4-in-l layout tool according to the present disclosure. Once lifted out of the tool, the rings flatten out due to gravity, creating the design shown when laid on a flat horizontal surface.

[0066] FIGS. 10A-10D illustrates various layout templates for use in making a layout tool. A template 1000a in FIG. 10A features a first set of cut locations 1002a and a second set of cut locations 1004b. FIG. 10E illustrates how in one example the template 1000a can be used to form the cuts in a foam substrate 1010a by blade cutting with a blade 1008, by heat cutting, or by heat pressing. Any of the templates shown in FIGS. 10B, IOC, or 10D can be screen printed onto the foam 1010a as shown in FIG. 10F. In FIG. 10G, a molded plastic base or shrink wrap band 1012 is wrapped around the foam substrate 1010a, or the foam substrate 1010a can undergo a paint or rubber dip to add a color and protection to the exposed sides and bottom of the foam substrate 1010a. FIG. 10H illustrates how a heat source 1014 can apply heat to a screen printed surface of the foam block 1010a to affix the pattern to the foam substrate 1010a. [0067] The V-shaped patterns 1002a in FIG. 10A can be spaced apart at 1 cm spacings, for example. On the same foam substrate, more than one layout tool can be present, such as shown in FIG. 10B, IOC, 10D. Here, both a European 4-in-l (or 6-in-l or 8-in-l) 1002a and a Mobius layout 1004a tools are disposed on the same foam substrate 1010a. The cuts, notches, or slots can be formed by cutting with a blade, die, laser, heat, or heat-press. Indicia on the top surface of the tool can be printed on the tool's surface by screen printing such as shown in FIG. 10F. An optional color edge can encase the layout tool, and can be in the form of a shrink wrap band, a paint or rubber (to resist slipping) dip, or a molded plastic base such as shown in FIG. 10G. FIG. 10H also shows optionally application of a heat treatment to the top surface of the tool. The heat treatment can be used to set the printed indicia, or to burnish the edges of the cuts.

[0068]

[0069] As can be seen in FIG. 11, at step 1, the user closes all connecting rings (Al) unless they are already closed. At step 2, each of the connecting rings is inserted into a corresponding cut of the layout tool. Views from the side and top of the tool with the connecting rings installed are shown. At step 3, as indicated by the arrows, gaps can be seen all the way through groupings of four connecting rings from the side of the layout tool. At least one open connector ring A2 is inserted through corresponding ones of these gaps and then they are closed. At step 4, optional finishing pieces can be added to the respective ends of the chainmaille. At step 5, an optional final check to verify that all connecting and connector rings are closed can be carried out. At step 6, the chainmaille can be removed from the layout tool by pulling one of the ends of the chainmaille until all of the connecting rings are freed from the cuts that held them in place during assembly of the chainmaille, which is also shown in FIG. 9B.

[0070] The rings of the assembled chainmaille once freed from the layout tool can lay flat. When different colors are used for the connecting and connector rings, a nearly infinite variety of designs can be created very quickly using any of the layout tools disclosed herein with very little effort and with a negligible if not entirely non-existent risk of incorrectly weaving the rings.

[0071] Ring sizes can vary considerably. Wire diameters range from 0.5mm to 5mm or even larger. Common wire diameters are 1.2mm to 2.5mm. Wire materials can include aluminum, stainless steel, bronze, and precious metals like gold and silver, just to name a few. Rings are commonly used to make jewelry, such as necklaces or wrist/ankle bracelets, or can be used to accessorize, such as a keychain. For jewelry that uses interconnected rings, jump rings are commonly used and the interconnecting of the rings is commonly known as weaving. For complicated designs, it is difficult to keep track of the placement of the rings when weaving. To address keeping the rings organized and held in place during weaving, layout tools have been created. A slot formed in a foam layout tool works acceptably for rings with wire diameters of less than 0.5mm. However, as the ring wire diameter increases, it becomes increasingly difficult to insert the ring into the slot. The foam of the layout tool also tends to squeeze the rings and pop them out of the tool. Therefore, there is a need to create layout tools that can easily accommodate a range of wire diameters and provide easy insertion and provide stable positioning of the rings without squeezing the wires out.

[0072] FIG. 11 is a photograph of a traditional slot 1100a formed in a foam substrate. This slot is created with a blade and no material has been removed from the foam. As can be seen, the slot is closed foam-to-foam. There is visible evidence of the squeeze around the ring. The ring is difficult to insert and the foam tends to push or pop the ring out of the foam. The deformation is permanent.

[0073] However, the inventors have discovered that heat-treating the cuts or slots post- formation in a foam substrate, such as with a hot air gun, results in localized shrinking or "burnishing" of the foam, which creates an open slot 1100b, such as having a width of 1 mm as shown in FIG. 12. The open slot 1100b allows for a wide range of ring wire diameters to be easily inserted and stay in position without slipping or popping out of the slot. Compared to cutting the unburnished slots only, there is little or no deformation of the tool after removal of the ring. The 1mm opening shown in FIG. 12 is optimal for working with rings having a wire diameter between 1-2.5mm. The width of the opening to accommodate other wire diameters can be scaled accordingly.

[0074] FIGS. 13-15 illustrate layout tools and instructions for making a chainmaille weave, including by using a weave technique known by those skilled in the art of chainmaille as "kinging" (see FIG. 14). As mentioned above, at least one connector ring can be weaved through four or more connecting rings, but with a kinging weave, two connector rings A2, B 1 are weaved through connecting rings Al . Like the first connector ring A2, the second connector ring B l is inserted through the same gap through which the first connector ring A2 was inserted. The gap must be sized to accommodate the wire diameters of the two connector rings A2, Bl . As can be seen, the second connector ring B l has a larger OD compared to the first connector ring A2, but a thinner wire diameter. FIG. 15 shows how to make the chainmaille weave into a necklace, though the present disclosure is not limited to any particular item that may incorporate a chainmaille weave made using any of the techniques or tools disclosed herein.

[0075] FIG. 16A shows a chainmaille weave of 3-2 where three concentric rings, numbered Ring 1600, 1602, 1604 of different diameters, are connected by two connector rings 1620, 1622. FIG. 16B shows the 3-2 weave layout tool 1630 with alternating slots 1632. The overlap of the alternating slots 1632 provides for a path for the connector rings 1620 and 1622 to join rings 1600, 1602, 1604 with rings 1606, 1608, 1610. Because the tool 1630 holds the rings 1600, 1602, 1604, 1606, 1608, 1610 in place, the user avoids struggling to keep the six rings in place while connecting them with the two connector rings 1620, 1622. FIG. 16C shows the cross-section interrelationship of the rings 1600, 1602, 1604, 1606, 1608, 1610 and the connector rings 1620, 1622. As can be seen in FIG. 16C, the wire diameters are key to defining the required overlap in the tool 1630 because there must be sufficient overlap to provide for the ring wire diameters and sufficient clearance for the connecting ring wire diameters. FIGS. 16D and 16E are photographs of the rings positioned in the 3-2 weave layout tool 1630 just before being removed as a 3-2 weave chainmaille 1650.

[0076] FIG. 17 is an instruction sheet for making three bracelets and two pendants using the chainmaille layout tools disclosed herein. On the right side, a plastic layout tool featuring a removable fork is shown and described in more detail in connection with FIGS. 18 and 19A-19D. FIG. 18 is a continuation of the instruction sheet shown in FIG. 17, showing in more detail the use of the plastic layout tool with the removable fork. As can be seen in step 13, the fork 2000 (FIG. 20) is finally pulled out of the tool, instead of pulling the rings out of the foam. The fork allows horizontally placed rings to be centered and fixed between the vertically oriented rings until the fork can be removed. Without the fork, it would be extremely difficult to keep the vertical rings in situ while attempting to attach each of the horizontal rings (in this case there are two layers of horizontal rings) between adjacent pairs of vertical rings. FIG. 19A shows an isometric photograph of the plastic layout tool 1900 shown in the instruction sheets shown in FIGS. 17 and 18. FIG. 19B is another view of the same tool 1900, and FIG. 19C is an end perspective view of the tool 1900. A cross-section schematic of the tool can be seen in FIG. 19D. A pair of legs 1902, 1904 connect to a body 1912 in which a channel 1910 is formed. The channel 1910 can include a raised feature 1914, which allows two rings to stand on either side of the raised feature 1914. Horizontally placed rings rest on the top surface of the body 1912. A pair of arms 1906, 1908 each include a respective slot 1908, 1909 that are angled slightly downwardly as shown, and these slots receive the fork 2000 shown in FIG. 20. Example dimensions in FIG. 19D are as follows: W = 1.13 inches or 28.70 mm; D 0.022 inches or 0.559 mm; and H = 0.48 inches or 12.19 mm.

Claims

CLAIMS What is claimed is:

1. A layout tool for making chainmaille, comprising: a substrate having a plurality of cuts or slots formed through a top surface thereof, adjacent pairs of the cuts forming a generally v-shaped pattern along a length of the top surface, wherein each of the pairs of the cuts are spaced apart, have a length, and form an angle that provides a straight line path that intersects at least four of the cuts configured to receive rings to form a chainmaille.

2. A layout tool for making chainmaille, comprising: a substrate having a plurality of cuts or slots, each one passing through a common point, each of the cuts having a length corresponding to a diameter of a ring, the ring having a wire diameter,

3. The layout tool of claim 2, wherein each of the cuts has a depth that is a function of at least the number of rings and the wire diameter of the rings.

4. The layout tool of claim 2, wherein a first of the cuts has the deepest depth of the other cuts, and subsequent cuts next to the first of the cuts have progressively shallower depths compared to the preceding cuts.

5. A layout tool for making chainmaille, comprising: a substrate having a first plurality of cuts and a second plurality of cuts, the first plurality of cuts formed through a top surface thereof, adjacent pairs of the cuts forming a generally v-shaped pattern along a length of the top surface, wherein each of the pairs of the cuts are spaced apart, have a length, and form an angle that provides a straight line path that intersects at least four of the cuts configured to receive rings to form a chainmaille, and each of the second plurality of cuts passing through a common point, each of the second plurality of cuts having a length corresponding to a diameter of a ring, the ring having a wire diameter, and each of the second plurality of cuts having a depth that is a function of at least the number of rings and the wire diameter of the rings.

A layout tool for making chainmaille, comprising: a substrate having a first plurality of cuts and a second plurality of adjacent cuts, the first plurality of cuts formed through a top surface thereof, the second plurality of adjacent cuts forming a generally alternating slot pattern along a length of the top surface, wherein each of the pairs of the cuts are spaced apart and have lengths that provide an overlap of the wire diameters of the rings such that connector rings can encircle the ring where they overlap.

A method of making a chainmaille using a layout tool having a substrate, comprising: providing a substrate having a plurality of cuts, each one passing through a common point, each of the cuts having a length corresponding to a diameter of a ring, the ring having a wire diameter,; inserting a first closed ring having the wire diameter into a first of the cuts; inserting a second open ring having the wire diameter through the first closed ring and into a second of the cuts adjacent to the first of the cuts and then closing the second open ring; and inserting a third open ring having the wire diameter through the first closed ring and through the second closed ring and into a third of the cuts adjacent to the second of the cuts and then closing the third open ring.

A method of making chainmaille using a layout tool having a substrate, comprising: providing a substrate having a plurality of cuts or slots formed through a top surface thereof, adjacent pairs of the cuts forming a generally v-shaped pattern along a length of the top surface, wherein each of the pairs of the cuts are spaced apart, have a length, and form an angle that provides a straight line path that intersects at least four of the cuts configured to receive rings to form a chainmaille; inserting a plurality of closed rings into at least some of the cuts such that one of the closed rings is inserted into each of the at least some of the cuts; and inserting at least one open ring along the straight line path through two adjacent pairs of the plurality of closed rings arranged in the v-shaped pattern and then closing the open ring.

9. The method of claim 8, further comprising inserting a second open ring along the straight path through the two adjacent pairs of the plurality of closed rings and then closing the second open ring.