US3343357A - Method and apparatus for fabricating artificial branches - Google Patents

Method and apparatus for fabricating artificial branches Download PDF

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US3343357A
US3343357A US436828A US43682865A US3343357A US 3343357 A US3343357 A US 3343357A US 436828 A US436828 A US 436828A US 43682865 A US43682865 A US 43682865A US 3343357 A US3343357 A US 3343357A
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fibers
wires
branch
wire
branches
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Edward S Goodridge
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    • A—HUMAN NECESSITIES
    • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47G—HOUSEHOLD OR TABLE EQUIPMENT
    • A47G33/00—Religious or ritual equipment in dwelling or for general use
    • A47G33/04—Christmas trees 
    • A47G33/06—Artificial Christmas trees
    • A—HUMAN NECESSITIES
    • A41—WEARING APPAREL
    • A41G—ARTIFICIAL FLOWERS; WIGS; MASKS; FEATHERS
    • A41G1/00—Artificial flowers, fruit, leaves, or trees; Garlands
    • A41G1/02—Implements, apparatus, or machines for making artificial flowers, or the like
    • A—HUMAN NECESSITIES
    • A46—BRUSHWARE
    • A46D—MANUFACTURE OF BRUSHES
    • A46D3/00—Preparing, i.e. Manufacturing brush bodies
    • A46D3/04—Machines for inserting or fixing bristles in bodies
    • A46D3/05—Machines for inserting or fixing bristles in bodies for fixing the bristles between wires, tapes, or the like

Definitions

  • Apparatus for the manufacture of artificial branches comprises a head stock guiding parallel wires which may be painted.
  • a dispenser for inserting a thermoplastic fiber between the wires is provided.
  • a rotatable tail stock twists the wires to clamp the fibers between the twisted wires and pulls the twisted wire from the head stock.
  • An induction heating generator is provided to heat the wires sufficiently to soften the thermoplastic fibers and the fibers are then bent by passing the wires through a sizing die to incline the fibers at an angle to the axis defined by-the twisted wire pair.
  • This invention relates to a method and apparatus for the fabrication ofartificial branches simulating pine, fir and like evergreens particularly used in the construction of artificial Christmas trees.
  • branches for artificial trees are made of two wires which are twisted around each other and containing between the twisted wires straight plastic fibers of predetermined lengths. These branches are constructed in a manner similar to the fabrication of circular brushes for such applications as bottle brushes, radiator brushes and the like.
  • the present branches have their fibers at right angles to the Stem formed by the twisted wire, which construction does not simulate natural tree branches.
  • the twisted wire can be seen, thus, detracting again from the natural appearance of the artificial branch. Further, due to manufacturing tolerances and variations in the manufacturing process, the twisted wire does not exert uniform pressure on all fibers and some may be displaced and/ or dislodged.
  • the art has deformed the fibers.
  • the art has subjected the formed branch to heat as by passing the branch through a liquid bath and then deflecting the fibers during cooling.
  • the heating imparts a curvature to the fibers extending them along the axis of the branch.
  • this curved deformation is not an accurate simulation of the natural branch.
  • the manufacturing speed and the expense of this type of added manufacturing stages has been, on the whole, intolerable and has caused many manufacturers to revert to the standard manufacturing processes with the fibers at right angles to the stern.
  • the primary object of this invention to provide an improved method and apparatus for the fabrication of artificial branches which is compatible with continuous processing methods.
  • equipment for the assembly of a plurality of heat-deformable fibers be- 3,343,357 Patented Sept. 26, 1967 tween adjacent wires which are then twisted together to retain the fibers therebetween.
  • An induction heating coil energized by high frequency current is provided to heat the surface of the twisted wires as they exit from the twisting apparatus. The heated surface of the wires will soften the plastic fibers held therebetween.
  • the fibers are heated, they are immediately passed through a sizing means to incline each fiber at a predetermined angle to the axis of the wires and are cooled while so inclined to retain this disposition.
  • the heating of the wire can be rapidly accomplished since induction heating will heat the wire surfaces.
  • the core of the wire may, in some cases, then serve as a heat sink to improve the cooling speed.
  • manufacturing speed can be maintained very high.
  • the inclination of the individual fibers tends to lock fibers in position to counteract spring-back of the twisted wire pair.
  • the control of the heating can be positively and accurately controlled so that the painted wires can be utilized in the process and the heat controlled to melt the plastic material without scorching of the painted wire surface.
  • the wires 10, 12 are fed respectively from storage spools 14, 16 over pulley 18 to place the wires in juxtaposed relationship.
  • a feed hopper 20 is provided which carries a supply of thermoplastic fibers chopped to a predetermined length. Bundles of the fibers are picked up in the teeth 22 of the feed wheel 24 and are fed between the wires. The wires and the bundles of fibers frictionally held therebetween are fed through a head stock 26 and are advanced axially as indicated by arrow 28 to a tail stock 30. The relative rotation between head and tail stocks twists the wires to engage the fibers therebetween in a frictional engagement.
  • This equipment is very similar to brush forming equipment and is only described briefly.
  • an induction heating supply source 36 which energizes the coil 38 positioned about the wires.
  • the high frequency induction heating apparatus generates a high frequency magnetic field within the coil to induce eddy currents in the wire thereby to heat the wire.
  • the heat induced in the wires is transferred by conduction to the fibers softening the fibers.
  • the branch enters a sizing tube 40, the interior surface of which is highly polished or coated to reduce frictional drag on the fibers. To prevent rotational tilting of the wires, the tube is preferably rotated with the wire twisted.
  • the sizing tube deflects the fibers at a predetermined angle to the stern wires.
  • the length of the tube is suflicient so that the wires and plastic are coupled sufliciently to return to a self-supporting state. Forced air may be utilized to cool the wires faster.
  • the sizing tube 40 may be fabricated of virtually any material such as highly polished metal or insulator material. If constructed of an insulator material, the induction coil may be mounted directly over the sizing tube. If made of metal, however, the sizing tube extending into the coil 42 must be separated therefrom and itself made of a non-conducting material, common to coil core.
  • the tail stock moves in close to the head stock to pick up the ends of a new branch.
  • the coil and sizing tube are then closed over the branch as the tail stock moves out.
  • the deflection induced in the individual fibers causes the fibers to assume a V-shaped form which assists in locking the fibers in the branch.
  • wire springback which is always encountered as the branches are cut does not result in dislodgement of the fibers quite so readily.
  • the speed of manufacture can be quite high since the induction heating coil can induce the desired heat very rapidly and with a precision of control adaptable for this type of processing. For example, in manufacturing, it is quite common to paint the wires green or brown for camouflaging or simulation of a tree stern respectively. With induction heating, the control can be maintained sufficiently precise so that the fibers may be heated without, however, scorching of the applied paint.
  • the induction heating has the distinct advantage that the heat is induced in the skin of the wire.
  • the body of the wire serves as a heat sink to more rapidly cool the wire after the fibers have been deformed by heat conduction. This distinctly increases the potential speeds of manufacture over arrangements which require heating of the entire fabricated branch including heating the wire throughout.
  • a typical installation might utilize an induction heating source operating at 3 megacycles and feeding a 3-turn induction coil. With 12 gauge wire, the production speed can be maintained at approximately 3 feet per second.
  • the method of fabricating an artificial branch having a plurality of thermoplastic fibers extending transversely to a twisted wire pair and held therebetween by frictional engagement which comprises heating the wires alone to soften the fibers held therebetween by conduction, deflecting the fibers about said softened material, and cooling the wires and fibers while the fibers are retained in their deflected positions.
  • a process fOr producing an artificial tree branch containing formed thermoplastic fibers comprising feeding fibers of predetermined length between two wires, twisting the wires to firmly hold the fibers between said wires, heating said twisted wires by induction heating sufficiently to soften said fibers adjacent to said wire conductively, simultaneously passing said heated wire through a sizing means to deflect said fibers at a predetermined angle to axis of the said wires, and cooling said fibers in angular position prior to leaving said sizing means, cutting and removing said branch after reaching its predetermined length.
  • An apparatus for producing an artificial tree branch having angular plastic fibers comprising a dispenser for fibers of predetermined length, a head stock guiding two parallel wires, means for placing fibers between said wires, a movable tail stock containing a means for twisting and pulling of said wires containing fibers, an induction work coil for heating said wires to soften said fibers and tubular sizing means surrounding said branch.
  • Apparatus according to claim 3 further comprising guiding means for guiding said branch through said coil and sizing means.
  • Apparatus for fabricating artificial branches consisting of at least two central wires twisted together to frictionally hold a plurality of short thermoplastic fibers poistioned between said wires, comprising means to heat said wire sufficiently to soften said fibers by heat transfer from said wires to said fibers in proximity to said wires, means to bend said fibers at a predetermined angle to said wires while softened, and means to cool said softened fibers to set said fibers at said predetermined angle.

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Yarns And Mechanical Finishing Of Yarns Or Ropes (AREA)

Description

Sept. 26-, 1967 E. s. GOODRIDGE METHOD AND APPARATUS FOR FABRICAT ING ARTIFICAL BRANCHES Filed Mafoh 5, 1965 M M R, mm
M m D R w w w N ATTORNEYS.
United States Patent 3,343,357 METHOD AND APPARATUS FOR FABRICATING ARTIFICIAL BRANCHES Edward S. Goodridge, 23 Broadmoor Road, Scarsdale, NY. 10583 Filed Mar. 3, 1965, Ser. No. 436,828 7 Claims. (CI. 57-24) ABSTRACT OF THE DISCLOSURE Apparatus for the manufacture of artificial branches comprises a head stock guiding parallel wires which may be painted. A dispenser for inserting a thermoplastic fiber between the wires is provided. A rotatable tail stock twists the wires to clamp the fibers between the twisted wires and pulls the twisted wire from the head stock. An induction heating generator is provided to heat the wires sufficiently to soften the thermoplastic fibers and the fibers are then bent by passing the wires through a sizing die to incline the fibers at an angle to the axis defined by-the twisted wire pair.
This invention relates to a method and apparatus for the fabrication ofartificial branches simulating pine, fir and like evergreens particularly used in the construction of artificial Christmas trees.
At present, branches for artificial trees are made of two wires which are twisted around each other and containing between the twisted wires straight plastic fibers of predetermined lengths. These branches are constructed in a manner similar to the fabrication of circular brushes for such applications as bottle brushes, radiator brushes and the like.
There are some disadvantages to the present construction. The present branches have their fibers at right angles to the Stem formed by the twisted wire, which construction does not simulate natural tree branches. The twisted wire can be seen, thus, detracting again from the natural appearance of the artificial branch. Further, due to manufacturing tolerances and variations in the manufacturing process, the twisted wire does not exert uniform pressure on all fibers and some may be displaced and/ or dislodged.
In order to more closely simulate natural branches, the art has deformed the fibers. For example, the art has subjected the formed branch to heat as by passing the branch through a liquid bath and then deflecting the fibers during cooling. The heating imparts a curvature to the fibers extending them along the axis of the branch. However, this curved deformation is not an accurate simulation of the natural branch. Perhaps more important, however, the manufacturing speed and the expense of this type of added manufacturing stages has been, on the whole, intolerable and has caused many manufacturers to revert to the standard manufacturing processes with the fibers at right angles to the stern.
It is, therefore, the primary object of this invention to provide an improved method and apparatus for the fabrication of artificial branches which is compatible with continuous processing methods.
It is a further object of this invention to provide an improved method and apparatus for forming the individual fibers in a manner to control the positioning of such fibers within the twisted wire.
It is a further object of this invention to provide an improved method of manufacturing artificial tree branches having improved accuracy of control of the process and improved speed of manufacturing. I
In accordance with these objects, there is provided in a preferred embodiment of this invention, equipment for the assembly of a plurality of heat-deformable fibers be- 3,343,357 Patented Sept. 26, 1967 tween adjacent wires which are then twisted together to retain the fibers therebetween. An induction heating coil energized by high frequency current is provided to heat the surface of the twisted wires as they exit from the twisting apparatus. The heated surface of the wires will soften the plastic fibers held therebetween. When the fibers are heated, they are immediately passed through a sizing means to incline each fiber at a predetermined angle to the axis of the wires and are cooled while so inclined to retain this disposition. By this method, the heating of the wire can be rapidly accomplished since induction heating will heat the wire surfaces. The core of the wire may, in some cases, then serve as a heat sink to improve the cooling speed. Thus, manufacturing speed can be maintained very high. The inclination of the individual fibers tends to lock fibers in position to counteract spring-back of the twisted wire pair. Further, the control of the heating can be positively and accurately controlled so that the painted wires can be utilized in the process and the heat controlled to melt the plastic material without scorching of the painted wire surface.
This invention is more fully described in the following drawing which is a partially sectioned elevation view of apparatus useful in explanation of the method and apparatus of the present invention.
In the figure, there is shown apparatus for manufacturing an artificial branch containing a twisted wire pair.
The wires 10, 12 are fed respectively from storage spools 14, 16 over pulley 18 to place the wires in juxtaposed relationship. A feed hopper 20 is provided which carries a supply of thermoplastic fibers chopped to a predetermined length. Bundles of the fibers are picked up in the teeth 22 of the feed wheel 24 and are fed between the wires. The wires and the bundles of fibers frictionally held therebetween are fed through a head stock 26 and are advanced axially as indicated by arrow 28 to a tail stock 30. The relative rotation between head and tail stocks twists the wires to engage the fibers therebetween in a frictional engagement. This equipment is very similar to brush forming equipment and is only described briefly.
In order, however, to form the fibers 32 at an angle to the axis of the twisted wire pair 34 which constitutes the stem of the branch, there is provided an induction heating supply source 36 which energizes the coil 38 positioned about the wires. The high frequency induction heating apparatus generates a high frequency magnetic field within the coil to induce eddy currents in the wire thereby to heat the wire. The heat induced in the wires is transferred by conduction to the fibers softening the fibers. The branch enters a sizing tube 40, the interior surface of which is highly polished or coated to reduce frictional drag on the fibers. To prevent rotational tilting of the wires, the tube is preferably rotated with the wire twisted. The sizing tube deflects the fibers at a predetermined angle to the stern wires. The length of the tube is suflicient so that the wires and plastic are coupled sufliciently to return to a self-supporting state. Forced air may be utilized to cool the wires faster.
The sizing tube 40 may be fabricated of virtually any material such as highly polished metal or insulator material. If constructed of an insulator material, the induction coil may be mounted directly over the sizing tube. If made of metal, however, the sizing tube extending into the coil 42 must be separated therefrom and itself made of a non-conducting material, common to coil core.
On some existing equipment, the tail stock moves in close to the head stock to pick up the ends of a new branch. In such cases, it is desirable to fabricate the sizing tube and induction heating coil so that they may be split and removed quickly to clear the tail stock. The coil and sizing tube are then closed over the branch as the tail stock moves out.
The deflection induced in the individual fibers causes the fibers to assume a V-shaped form which assists in locking the fibers in the branch. Thus, wire springback which is always encountered as the branches are cut does not result in dislodgement of the fibers quite so readily. The speed of manufacture can be quite high since the induction heating coil can induce the desired heat very rapidly and with a precision of control adaptable for this type of processing. For example, in manufacturing, it is quite common to paint the wires green or brown for camouflaging or simulation of a tree stern respectively. With induction heating, the control can be maintained sufficiently precise so that the fibers may be heated without, however, scorching of the applied paint.
In addition, the induction heating has the distinct advantage that the heat is induced in the skin of the wire. In this way, the body of the wire serves as a heat sink to more rapidly cool the wire after the fibers have been deformed by heat conduction. This distinctly increases the potential speeds of manufacture over arrangements which require heating of the entire fabricated branch including heating the wire throughout.
For the purposes of illustration, but not by way of limitation, a typical installation might utilize an induction heating source operating at 3 megacycles and feeding a 3-turn induction coil. With 12 gauge wire, the production speed can be maintained at approximately 3 feet per second.
Although in the preferred embodiment, I have illustrated the equipment as comprising the induction heating coil operating in conjunction with the fabricating equipment, it must be recognized that such illustration is preferred solely because of manufacturing speeds in typical installations. Finished branches may also be fabricated by passing them through the induction heating coil and a sizing tube as an independent manufacturing step.
This invention may be variously modified and embodied within the scope of the subjoined claims.
What is claimed is:
1. The method of fabricating an artificial branch having a plurality of thermoplastic fibers extending transversely to a twisted wire pair and held therebetween by frictional engagement which comprises heating the wires alone to soften the fibers held therebetween by conduction, deflecting the fibers about said softened material, and cooling the wires and fibers while the fibers are retained in their deflected positions.
2. A process fOr producing an artificial tree branch containing formed thermoplastic fibers, comprising feeding fibers of predetermined length between two wires, twisting the wires to firmly hold the fibers between said wires, heating said twisted wires by induction heating sufficiently to soften said fibers adjacent to said wire conductively, simultaneously passing said heated wire through a sizing means to deflect said fibers at a predetermined angle to axis of the said wires, and cooling said fibers in angular position prior to leaving said sizing means, cutting and removing said branch after reaching its predetermined length.
3. An apparatus for producing an artificial tree branch having angular plastic fibers comprising a dispenser for fibers of predetermined length, a head stock guiding two parallel wires, means for placing fibers between said wires, a movable tail stock containing a means for twisting and pulling of said wires containing fibers, an induction work coil for heating said wires to soften said fibers and tubular sizing means surrounding said branch.
4. Apparatus according to claim 3 wherein said sizing means is rotatable.
5. Apparatus according to claim 3 further comprising guiding means for guiding said branch through said coil and sizing means.
6. Apparatus according to claim 3 wherein said sizing means and said induction coil are longitudinally split.
7. Apparatus for fabricating artificial branches consisting of at least two central wires twisted together to frictionally hold a plurality of short thermoplastic fibers poistioned between said wires, comprising means to heat said wire sufficiently to soften said fibers by heat transfer from said wires to said fibers in proximity to said wires, means to bend said fibers at a predetermined angle to said wires while softened, and means to cool said softened fibers to set said fibers at said predetermined angle.
References Cited UNITED STATES PATENTS 2,276,124 3/ 1942 Unger. 2,430,748 11/1947 Unger 57-143 XR 2,814,897 12/1957 Hellrich 16122 3,056,223 10/1962 Crane 161-22 3,084,465 4/ 1963 Hellrich 161--22 3,109,277 10/ 1963 Raymond et a1 5724 FOREIGN PATENTS 1,311,325 10/1962 France.
506,183 5/1939 Great Britain.
618,843 2/ 1949 Great Britain.
702,980 1/ 1954 Great Britain.
FRANK J. COHEN, Primaly Examiner.
D. E. WATKINS, Assistant Examiner.

Claims (1)

  1. 3. AN APPARATUS FOR PRODUCING AN ARTIFICIAL TREE BRANCH HAVING ANGULR PLASTIC FIBERS COMPRISING A DISPENSER FOR FIBERS OF PREDETERMINED LENGTH, A HEAD STOCK GUIDING TWO PARALLEL WIRES, MEANS FOR PLACING FIBERS BETWEEN SAID WIRES, A MOVABLE TAIL STOCK CONTAINING A MEANS FOR TWISTING AND PULLING OF SAID WIRES CONTAINING FIBERS, AN INDUCTION WORK COIL FOR HEATING SAID WIRES TO SOFTEN SAID FIBERS AND TUBULAR SIZING MEANS SURROUNDING SAID BRANCH.
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Cited By (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3513063A (en) * 1967-03-31 1970-05-19 Jack Sloane Artificial christmas tree construction
US3657870A (en) * 1970-08-31 1972-04-25 American Tech Ind Apparatus for making artificial tree having exposed branch ends of weblike material
US3900539A (en) * 1973-03-07 1975-08-19 Salvatore J Puleo Artificial christmas tree with slanted needles
US4292797A (en) * 1980-02-13 1981-10-06 Auger Arnold J Dubbing winder
US4573247A (en) * 1984-03-16 1986-03-04 Mr. Christmas Incorporated Artificial tree limb maker machine
US4609989A (en) * 1984-04-02 1986-09-02 Hudson Valley Tree, Inc. Method and machine for manufacturing artificial branches
US4872647A (en) * 1987-09-29 1989-10-10 Paradise Francis M Decorative attachment for a chain link fence
EP1095575A1 (en) * 2000-05-12 2001-05-02 Calzavara Spa Method and machine to produce needle-shaped foliage

Citations (10)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB506183A (en) * 1937-12-01 1939-05-24 Harold Harrison Improvements in or relating to machines for making garlands or streamers
US2276124A (en) * 1938-11-12 1942-03-10 Coneord Chenille Co Inc Device for curling chenille
US2430748A (en) * 1942-04-28 1947-11-11 Duro Persian Mfg Co Inc Textile
GB618843A (en) * 1938-10-22 1949-02-28 Marc Solomonoff Astrakan substitute and method for the manufacture thereof
GB702980A (en) * 1951-01-15 1954-01-27 Jacques Finkelsteinas Improvements in and relating to the production of gibused chenille
US2814897A (en) * 1954-04-09 1957-12-03 Hellrich Tobias Artificial christmas tree
US3056223A (en) * 1960-06-27 1962-10-02 Samuel P Crane Insulated fringed branch for artificial trees and method
FR1311325A (en) * 1961-10-25 1962-12-07 Method for looping artificial astrakhan caterpillars and machine for implementing said method
US3084465A (en) * 1960-03-10 1963-04-09 Hellrich Tobias Artificial tree
US3109277A (en) * 1962-04-26 1963-11-05 Raymond Gerald Lyle Garland forming apparatus and method

Patent Citations (10)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB506183A (en) * 1937-12-01 1939-05-24 Harold Harrison Improvements in or relating to machines for making garlands or streamers
GB618843A (en) * 1938-10-22 1949-02-28 Marc Solomonoff Astrakan substitute and method for the manufacture thereof
US2276124A (en) * 1938-11-12 1942-03-10 Coneord Chenille Co Inc Device for curling chenille
US2430748A (en) * 1942-04-28 1947-11-11 Duro Persian Mfg Co Inc Textile
GB702980A (en) * 1951-01-15 1954-01-27 Jacques Finkelsteinas Improvements in and relating to the production of gibused chenille
US2814897A (en) * 1954-04-09 1957-12-03 Hellrich Tobias Artificial christmas tree
US3084465A (en) * 1960-03-10 1963-04-09 Hellrich Tobias Artificial tree
US3056223A (en) * 1960-06-27 1962-10-02 Samuel P Crane Insulated fringed branch for artificial trees and method
FR1311325A (en) * 1961-10-25 1962-12-07 Method for looping artificial astrakhan caterpillars and machine for implementing said method
US3109277A (en) * 1962-04-26 1963-11-05 Raymond Gerald Lyle Garland forming apparatus and method

Cited By (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3513063A (en) * 1967-03-31 1970-05-19 Jack Sloane Artificial christmas tree construction
US3657870A (en) * 1970-08-31 1972-04-25 American Tech Ind Apparatus for making artificial tree having exposed branch ends of weblike material
US3900539A (en) * 1973-03-07 1975-08-19 Salvatore J Puleo Artificial christmas tree with slanted needles
US4292797A (en) * 1980-02-13 1981-10-06 Auger Arnold J Dubbing winder
US4573247A (en) * 1984-03-16 1986-03-04 Mr. Christmas Incorporated Artificial tree limb maker machine
US4609989A (en) * 1984-04-02 1986-09-02 Hudson Valley Tree, Inc. Method and machine for manufacturing artificial branches
US4872647A (en) * 1987-09-29 1989-10-10 Paradise Francis M Decorative attachment for a chain link fence
EP1095575A1 (en) * 2000-05-12 2001-05-02 Calzavara Spa Method and machine to produce needle-shaped foliage

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