Artificial tree and method of making

Abstract

The present invention is an artificial tree consisting of a shape such as conical wherein there is an artificial outer layer, e.g., artificial grass, a solidified foam core, and a post molded into the foam core.

Claims

1. An artificial tree consisting of: a) a polymeric woven outer layer in a predetermined shape resembling a tree; b) a solidified expanded foam core; c) a center straight tube or straight post molded into the solidified expanded foam core positioned in the center of the solidified expanded foam core positioned to be able for the tube or post to be stuck in the ground or put on a ground post; and d) wherein the polymeric woven outer layer is fused to the solidified expanded foam core.

2. The artificial tree according to claim 1 wherein the polymeric woven outer layer is woven artificial grass.

3. The artificial tree according to claim 1 wherein the predetermined shape is conical.

4. The artificial tree according to claim 1 wherein the straight tube is an aluminum tube.

5. The artificial tree according to claim 1 wherein the solidified expanded foam core is expanded polystyrene.

Description

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

(1) FIG. 1 is a perspective view of the artificial tree.

(2) FIG. 2 is an inside view of the polymeric woven outer layer before shaping.

(3) FIG. 3 is an inside perspective view of the polymeric woven outer layer formed into a desired conical shape.

(4) FIG. 4 is a perspective view of the polymeric woven formed outer layer positioned in a mold with a jig holding the center tube awaiting expanded foam core.

(5) FIG. 5 is a perspective view of the solidified expanded foam core with the tube jig removed.

(6) FIG. 6 is a view of additional bottom layer added to the tree.

DETAILED DESCRIPTION OF THE INVENTION

(7) While this invention is susceptible to embodiment in many different forms, there is shown in the drawings, and will herein be described in detail, specific embodiments with the understanding that the present disclosure of such embodiments is to be considered as an example of the principles and not intended to limit the invention to the specific embodiments shown and described. In the description below, like reference numerals are used to describe the same, similar, or corresponding parts in the several views of the drawings. This detailed description defines the meaning of the terms used herein and specifically describes embodiments in order for those skilled in the art to practice the invention.

Definitions

(8) The terms about and essentially mean10 percent.

(9) The terms a or an, as used herein, are defined as one or as more than one. The term plurality, as used herein, is defined as two or as more than two. The term another, as used herein, is defined as at least a second or more. The terms including and/or having, as used herein, are defined as comprising (i.e., open language). The term coupled, as used herein, is defined as connected, although not necessarily directly, and not necessarily mechanically.

(10) The term comprising is not intended to limit inventions to only claiming the present invention with such comprising language. Any invention using the term comprising could be separated into one or more claims using consisting or consisting of claim language and is so intended.

(11) Reference throughout this document to one embodiment, certain embodiments, an embodiment, or similar terms means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, the appearances of such phrases in various places throughout this specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner in one or more embodiments without limitation.

(12) The term or, as used herein, is to be interpreted as an inclusive or meaning any one or any combination. Therefore, A, B, or C means any of the following: A; B; C; A and B; A and C; B and C; A, B, and C. An exception to this definition will occur only when a combination of elements, functions, steps, or acts are in some way inherently mutually exclusive.

(13) The drawings featured in the figures are for the purpose of illustrating certain convenient embodiments of the present invention, and are not to be considered as limitation thereto. The term means preceding a present participle of an operation indicates a desired function for which there is one or more embodiments, i.e., one or more methods, devices, or apparatuses for achieving the desired function, and that one skilled in the art could select from these or their equivalent in view of the disclosure herein, and use of the term means is not intended to be limiting.

(14) As used herein, the term artificial tree refers to a constructed object made of synthetic and artificial materials, designed to resemble a real tree, bush, or the like. For example, the tree can be most any predetermined shape including globe, conical, and the like such that it resembles a tree. It has a straight artificial trunk in one embodiment, all the materials are synthetic. It is made of three parts: the polymeric woven outer layer, the solidified foam core, and the center straight tube. There are no fragile parts, loose pieces, or open cavities in which insects or animals could nest or inhabit.

(15) As used herein, the term polymeric-woven outer layer refers to material for the outside of the artificial tree which is made in polymeric-woven sheets. As an example, artificial grass is available woven as a polymeric artificial grass that resembles growing foliage. One advantage of polymeric woven layer is their resistance to weather which means such a tree will have a long life in the outdoors.

(16) As used herein, the term solidified expanded foam core refers to polymeric material which upon curing, e.g., by heat radiation or the like, solidifies. One common material is expanded polystyrene. Others include polyurethane expanding foam open and closed cell, cross-linked PVC foam, thermoplastic foam, syntactic foam, linear PVC foam, polymethacrylimide foam, and the like.

(17) As used herein, the term straight tube or straight post refers to a rigid member positioned in the center of the foam core such that it appears and acts like the straight trunk of a real tree. See especially FIG. 1. In one embodiment, it is a metal straight tube such as aluminum or other metal. In another embodiment, it is a straight wood or metal post. The chosen tube or post must be sufficiently strong to hold the tree upright. The tube or post can then be stuck in the ground, put on a post that is in the ground, or by any other means for planting the artificial tree outside. In one embodiment, it is a 2 inch diameter aluminum metal tube though other straight metals tubes can be used.

(18) As used herein, the term fused refers to the uncured foam core being positioned inside the shaped outer layer. Upon curing to its solidified form, the foam will bond the outer layer as well as hold the tube or post in a fused/attached manner.

(19) As used herein, the term predetermined shape refers to the final shape that the artificial tree will take. In the Figures is shown a conical shape, but other shapes are contemplated including more global and cubed, cylindrical, trapezoidal, and the like.

(20) As used herein, the term woven bottom layer refers to the fact the tree can just have the solidified foam core only covered on the sides by the outer layer, but in this embodiment, a piece of woven material is attached to the bottom of the foam core either during curing or after curing as a separate piece.

(21) As used herein, the term mold refers to a device on which the outer layer can be placed and support the shape for filling with the foam core. In one example seen in the figures, a conical shaped outer layer of artificial grass is placed inverted into a conical mold. The polymeric expandable foam can then be poured into the open portion of the outer layer.

(22) As used herein, the term jig refers to a device for holding the straight tube or straight post in place while the foam core is cured and solidifies. See the Figures for examples. One of skill in the art could propose other jigs in view of the disclosure herein.

(23) As used herein, the term cutting and joining refers to taking one or more pieces of material and cutting it to a shape which can be joined to form the predetermined shape. The Figures show the pieces for a conical tree.