Embossed Polymeric Sheet Needles for Lightweight Artificial Trees
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Solution Overview
Problem
Existing artificial trees with molded needles are expensive and heavy, making them costly to produce and transport, and less convenient for consumers to handle and set up, while also being less environmentally friendly due to higher material costs and energy usage.
Innovation Solution
A method of making artificial tree needles by embossing and cutting a polymeric sheet to create lightweight, realistic needles, using a process that includes printing patterns, embossing along folding lines, and cutting between these lines to form individual needles, which can be made from PVC or PE materials to mimic natural tree appearances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If molded needles are used to create realistic appearance, then the realistic look is improved, but the weight and cost increase
Solution Approach 1:
The patent uses thin polymeric sheets (PVC or PE) instead of traditional molded needle structures. These thin films are embossed with patterns and folded to create realistic needle appearances while maintaining lightweight properties. The embossed surfaces provide visual realism without the weight of solid molded needles.
Solution Approach 2:
The patent transitions from three-dimensional molded needles to two-dimensional embossed sheets that are then folded. By working in 2D and folding along predetermined lines, the invention creates 3D-like realistic appearances from flat materials, significantly reducing weight while maintaining visual fidelity.
2Shape
If molded needles are used to create realistic appearance, then the realistic look is improved, but the manufacturing cost increases
Solution Approach 1:
The patent divides the needle structure into multiple segments by creating fold lines and cutting lines on the polymeric sheet. This segmentation allows for efficient cutting and assembly, reducing manufacturing complexity and cost while maintaining realistic appearances through the embossed patterns on each segment.
Solution Approach 2:
The patent uses embossing to create surface patterns that copy the appearance of natural needle textures and shapes. This copying approach provides realistic visual effects without requiring expensive molded three-dimensional structures, reducing manufacturing costs while maintaining aesthetic quality.
3Shape
If molded needles are used, then the realistic appearance is improved, but the environmental impact worsens
Solution Approach 1:
The patent changes the material parameter from traditional heavy molded materials to thin polymeric sheets (PVC or PE). This parameter change reduces material consumption and weight, leading to lower energy usage during production and transportation, thereby reducing environmental impact while maintaining realistic appearances through embossing and folding techniques.
Data Source
AI summary
A method of making needles of a decorative product includes following steps: embossing embossments along folding lines onto a sheet; and cutting the embossed sheet along cutting lines between folding lines to form needles.