Method of making an artificial tree

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Solution Overview

Problem

Existing artificial trees are fragile, costly, and lack outdoor weather resistance, limiting their use and durability, especially when made with heavy metal framing and requiring extensive labor and injection molding.

Innovation Solution

An artificial tree design featuring a lightweight, solidified expanded foam core with a flexible outer layer and a rigid tube or post, where the outer layer is fused to the foam core, allowing for a cheaper production process and enhanced outdoor durability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If heavy metal framing and injection molding are used to make durable outdoor trees, then strength and outdoor weather resistance are improved, but weight increases, manufacturing complexity increases, and production cost increases

Engineering Contradiction:

Improveoutdoor weather resistanceVSAvoidtree weight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The patent changes the material parameters by using expanded foam core instead of heavy metal framing, and using UV-resistant materials specifically designed for outdoor conditions. This allows the tree to maintain strength and weather resistance while significantly reducing weight compared to traditional metal-framed artificial trees

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent employs composite material construction by combining expanded foam core with UV-resistant artificial foliage and branches. This composite approach creates a durable outdoor tree that resists weathering without requiring heavy metal support structures, achieving both strength and weight reduction

Inventive Principle:

Principle #40Composite materials

2Strength

If heavy metal framing and extensive labor are used to construct durable trees, then strength and outdoor weather resistance are improved, but device complexity and manufacturing complexity increase

Engineering Contradiction:

Improveoutdoor weather resistanceVSAvoidmanufacturing complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The patent segments the tree construction into modular components (foam core, branches, foliage) that can be independently manufactured and assembled. This segmentation simplifies the manufacturing process compared to traditional metal framing, allowing for easier production and assembly while maintaining outdoor durability through UV-resistant materials

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent uses cost-effective expanded foam core material that can be easily molded and assembled, replacing expensive metal framing and complex injection molding processes. This approach reduces both manufacturing complexity and production cost while achieving sufficient durability for outdoor use through proper material selection

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Reliability

If traditional artificial tree materials are used, then indoor use is achieved, but reliability and outdoor weather resistance deteriorate

Engineering Contradiction:

Improveoutdoor durabilityVSAvoidweather damage

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent changes the material parameters by selecting UV-resistant artificial foliage and branches specifically engineered to withstand outdoor exposure. This parameter change enables the tree to resist harmful UV radiation and weather elements, transforming it from an indoor-only product to a durable outdoor fixture

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent addresses the harmful effect of UV radiation by incorporating UV-resistant materials that convert the potentially damaging UV exposure into a non-harmful condition. The UV-resistant coating or material treatment protects the artificial foliage and branches from degradation, allowing the tree to thrive in outdoor environments

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The solution results in a more durable and cost-effective artificial tree with superior outdoor weather resistance, eliminating the need for a subframe and reducing assembly complexity, making it suitable for outdoor use.

Implementation Method 1

adding uncured foam designed for solidification expansion to an inside of the woven outer layer

Methodology Applied

Scientific EffectFoam expansion: Foam

Implementation Method 2

curing the uncured foam to create a solidified expanded foam core

Methodology Applied

Scientific EffectCuring: Phase Change

Data Source

PatentUS10932508B2Method of making an artificial tree

Publication Date: 2021.03.02 WEBB TERRY K

AI summary

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.