US3834976A

US3834976A - Method of making artificial branch assemblies and resulting artificial branch assembly

Info

Publication number: US3834976A
Application number: US00395140A
Authority: US
Inventors: A Mottel
Original assignee: Consolidated Novelty Co Inc
Current assignee: Consolidated Novelty Co Inc
Priority date: 1973-09-07
Filing date: 1973-09-07
Publication date: 1974-09-10
Anticipated expiration: 1991-09-10

Abstract

A method of making artificial branch assemblies utilizes two elongated stiff wires, each of which is in a plastic sheath. First, one of the ensheathed wires is placed into a horizontal mode in a jig. A number of branches are space along the sheathed wire in the jig, each branch being centered on and at right angles to the sheathed wire. The second sheathed wire is placed over the branches so that the branches are sandwiched between them. Then, a number of temporary clamps hold the sheathed wires to one another so that the branches remain in place. Finally the wires are twisted along their long axes for form an artificial branch assembly.

Description

A. MOTTEL 3,834,976 METHOD OF MAKING ARTIFICIAL BRANCH ASSEMBLIES AND RESULTING Sept. 10, 1974- AR'IIFICIAb BRANCH ASSEMBLY 2 Sheets-Sheet 1 Filed Sept. '2, 1973 A. MOTTEL CIAL BRANCH ARTIFICIAL. BRANCH Sept 10 3,834,976 ASSEMBLIES AND RESULTING ASSEMBLY Y 1974 METHOD OF MAKING ARTIFI 2 Sheets-Sheet 2 Filed Sept. 7, 1973 METHOD OF MAKING ARTIFICIAL BRANCH ASSEMBLIES AND RESULTING ARTIFICIAL BRANCH ASSEMBLY Alan Mottel, Yonkers, N .Y., assignor to Consolidated Novelty Co., Inc., Paterson, NJ. Filed Sept. 7, 1973, Ser. No. 395,140 Int. Cl. A47g 33/06 US. Cl. 161-42 8 Claims ABSTRACT OF THE DISCLOSURE A method of making artificial branch assemblies utilizes two elongated stiff wires, each of which is in a plastic sheath. First, one of the ensheathed wires is placed into a horizontal mode in a jig. A number of branches are spaced along the sheathed wire in the jig, each branch being centered on and at right angles to the sheathed wire. The second sheathed wire is placed over the branches so that the branches are sandwiched between them. Then, a number of temporary clamps hold the sheathed wires to one another so that the branches remain in place. Finally the wires are twisted along their long axes to form an artificial branch assembly.

This invention relates to decorative articles and specifically to artificial branch assemblies used in the making of artificial Christmas trees, and a method of making such artificial branch assemblies.

Artificial Christmas trees have been popular for many years, and various methods and apparatus for making the same and their component parts are known. These prior methods have in general been costly, time-consuming and requiring of an extensive amount of hand labor.

It is the general object of the present invention to provide artificial branch assemblies for use in the making of artificial Christmas trees, which are capable of being made by mass production techniques, and which can be carried out at relatively low cost with a minimum amount of skilled hand labor, and which are attractive and simulate natural trees.

Among the relevant prior art is Raymond, Pat. No. 3,244,577. This patent demonstrates a method of making artificial Christmas tree components through the use of elongated twisted wires. Specifically, first an elongated wire is placed in tension between a pair of gripping heads. Branches comprising twisted wires capturing fiber glass filaments are reversely bent over, hairpin fashion, and are spaced along the tensioned wire in clusters. Then, each branch is bent further about itself to form a loop completely encircling the tensioned wire. A second wire is placed over the first wire, and the wires are twisted to capture the branches. The disadvantage in this technique, is the requirement of the time and hand labor needed to twist each branch individually about the tensioned wire, prior to the same being permanently captured and further: more, the resulting product is a poor imitation of a natural Christmas tree.

In Dieffenbaeh, Pat. No. 3,594,260, another method of making artificial branches is shown. There, two long stiff wires are taken, and a branch is placed between them, adjacent to one set of ends thereof. Then, a small tubular spacer is slid over one set of ends of the wires to a point adjacent to this branch. Then, another branch is placed between the wires, and still another spacer is slid over the ends of the two wires. This continues until the two wires hold a number of branches crosswise between them, each separated by a spacer, and then the wires are twisted to form an assembly branch. The disadvantage of this method lies in the inherent slowness and labor of sliding one tubu- United States Patent lar spacer after another from one end of the pair of wires to a position along the length of the wires.

The present invention contemplates a method of making artificial branch assemblies which is considerably simpler, and requires less labor than the methods just mentioned. Specifically, two stiff wires are each ensheathed in plastic. One of these wires is placed in a horizontal mode in a jig. Then, branches are placed transversely of the stiff wire and spaced along its length, the branches being held in place by the same jig. Next, the second stifii wire, also ensheathed, is placed over the first stiff wire, thereby to form a sandwich comprising a pair of ensheathed stiff wires with cross branches between them. A number of removable clamps are then placed to hold these stiff wires to one another and to hold the branches temporarily in place. Lastly, the ends of the stiff wires are twisted to permanently capture the branches in place between them, whereupon the temporary clamps may be removed.

The manner in which the foregoing and other objects of the present invention are attained will be apparent from the accompanying specification and claims considered with the drawing, wherein:

FIG. 1 is a perspective view showing a stiff wire being ensheathed in plastic tubing;

FIG. 2 is a perspective view of the ensheathed wire having been placed into a jig;

FIG. 3 is a perspective view of the ensheathed wire in the jig, with a number of branches also in the jig being situated over the ensheathed wire perpendicularly thereof;

FIG. 4 is a view similar to FIG. 3, but with the second wire, also ensheathed, placed over the branches and first ensheathed wire;

FIG. 5 shows the placement of temporary clamps to hold the stiff wires and branches;

FIG. 6 shows, schematically, the application of a powered twisting apparatus to the remote ends of the stiff wires;

FIG. 7 shows, in an enlargement, the stiff wires after their twisting, and their capture of a cross branch;

FIG. 8 is a cross-sectional view of the branch assembly taken along the line 8-8 of FIG. 7; and

FIG. 9 is another cross-sectional view of the branch assembly, taken along the line 9-9 of FIG. 7.

Referring now in detail to the drawings, FIG. 1 shows an ensheathed wire 10, comprising an elongated substantially cylindrical stiff, desirably metal, wire 12 and a plastic sheath 14. The sheath 14 may be slipped over the length of the wire 12, or other methods may be utilized to obtain sheathed wires, as for example dipping the stiff wire in a plastic bath, and then cooling the same.

As best seen in FIG. 2, the ensheathed wire 10 is placed into a special jig 16. The jig comprises an elongated base 18 and a pair of

opposed end walls

20, 22. Each end wall is attached to the base 18, and has a central

vertical slot

24, 26 respectively, in it, the

slots

24, 26 bein open at the top and continuing to a location short of the bottoms of the end walls. The

slots

24, 26 are configured to receive at least the stiff wire component 12 of the ensheathed wire 10. Desirably only the wire 12 extends through the

slots

24, 26 in the end walls. The

slots

24, 26 serve to hold the ensheathed wire 10 somewhat above the base 18 of the jig, in a generally horizontal mode.

Holders 28 are situated in the jig in rows along each side of the sheathed wire 10, each holder constituting a pair of upright rods. Each holder 28a on one side of the ensheathed wire 10, has a counterpart 28b in alignment with it, on the other side of the ensheathed wire 10. The line of alignment is generally perpendicular of the axis of the wire 10.

Turning now to FIG. 3, it will be seen that the holders 28 serve to function as guides for artificial branches 30a,

30b, etc., which are placed therein. Each branch comprises a pair of twisted wires forming a twisted wire core 32, which capture a multitude of man-made, natural or synthetic yarns, fibers, needles, filaments or other decorative elements (hereinafter referred to for convenience as needles) of generally cylindrical external configuration. The making of such branches is well known in the art, and is shown in both the Raymond and Dietfenbach patents, previously mentioned. Desirably, the central portion 36 of each branch 30 is absent of filaments, so that there are no filaments on a branch, situated between each pair of holders 28a, 28b. However, each branch may have its entire length covered with filaments. To form shaped branch assemblies, which will be further explained, several branches may be placed in a pair of holders 28a, 28b, and the shape, size, color and length of the branches may vary in the holders along the length of the jig.

As a next step, as seen in FIG. 4, a second wire 38, also ensheathed, is placed in the jig 16 and in the

slots

24, 26 thereof, over the first ensheathed wire 10, and over the branches on the jig. Desirably, the

ensheathed wires

10, 38 are identical in construction.

Temporary, relatively small clamps 40, seen in FIG. 5, are placed to grip and hold together the

ensheathed wires

10, 38 along the lengths thereof. Although shown as such, it is not necessary to utilize clamps 40 between each pair of branches 30. The clamps 40 serve to temporarily secure the

ensheathed wires

10, 38 to one another and further serve to temporarily capture the branches 30 in position.

Next, as best seen in FIG. 6, the opposed ends of the

ensheathed wires

10, 38 are twisted relatively in opposite directions. This is done conventionally by placing a powered head 44 at one set of ends of the ensheathed wires, and powered chuck 42 at the other ends and applying a twisting movement to form a twisted wire core. The chuck 42 and the head 44 are both situated externally of the

end walls

20, 22 of the jig. Such torque application units are mentioned in the Raymond and Diefienbach patents, previously discussed, The head 44 twists the ensheathed wires with respect to one another so as to firmly and securely engage the branches 30 in place. At this point, the clamps 40 may be removed, and may be retained for use in the next cycle of operations.

FIGS. 7 through 9, show, in enlarged detail, the resulting branch assembly. As soon there, the ensheathed wires are tightly twisted, each such ensheathed wire including a central stiff wire 12 and a sheath 14. As best seen in FIG. 7, due to the twisting action, the sheaths have a spiraling outward appearance, somewhat resembling gnarled wood, and a desirable trunk-imitative look.

The twisted wire of the branch, as its central needlefree center 36, passes between the ensheathed wires, but is slightly misshapen due to the relative twisting of the

ensheathed wires

10, 38. This distortion is best seen in FIG. 9, and such distortion aids in the secure fixation of the branch to the pair of twisted wires and aids in achieving a natural look.

From the foregoing, it will be appreciated that an artificial branches assembly has been presented which is suitable for mass production techniques and which can be manufactured by a method simply in concept and execution.

What is claimed is:

1. A method of making artificial branch assemblies from branches and still wires, including the steps of:

(a) ensheathing each of the wires individually;

(b) placing the branches spacedly along and perpendicularly to one of the wires;

(c) placing the other wire over the branches and adjacent the first wire;

(d) temporarily holding the wires and branches in place; and

(e) intertwisting the wires so as to capture the branches therebetween.

2. A method of making artificial branch assemblies as set forth in claim 1 where the branches have their central portions free of needles.

3. A method of making artificial branch assemblies as set forth in claim 1 wherein the branches have needles along their entire length.

4. A method of making artificial branch assemblies as set forth in claim 1 further comprising utilizing a jig to maintain the stiff wires and branches in perpendicular relation.

5. A method of making artificial branch assemblies as set forth in claim 2 further including holding the wires at their ends and holding the branches at the ends of their needle-free central portions.

6. A method of making artificial branch assemblies as set forth in claim 1 further including, as step (d), clamping the wires along their lengths at spaced locations.

7. An artificial branch assembly of the type comprising an array of artificial branches, and a pair of intertwisted wires, the branches passing between and being captured by the twisted wires,

the improvement comprising tubing ensheathing each individual wire, the tubings, when twisted, pressing against the branches to secure the same and having a twisted, gnarled look.

8. An artificial branch assembly as set forth in claim 7 wherein the tubings run substantially the entire length of the wires.

References Cited UNITED STATES PATENTS 1,633,637 9/ 1928 Trimpe l6 l-l7 3,234,073 2/ 1966 Raymond et al l61-24 3,244,577 4/ 1966 Raymond 16122 3,594,260 7/1971 Dieffenbach l6124 WILLIAM E. SCHULZ, Primary Examiner US. Cl. X.R. 1566l; 16124