Emulational Christmas tree branch and manufacturing process therefor
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Solution Overview
Problem
Existing artificial Christmas trees are costly, prone to deformation, require extensive manual labor for production and assembly, and lack uniformity, leading to inconsistent quality and increased customer assembly effort.
Innovation Solution
An artificial Christmas tree branch with a socket and hook design, manufactured using 3D software for precise mould creation, injection moulding with steel wire reinforcement, and optional tree bark texture, allowing for automated production and easy assembly without machinery.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If manual binding machinery is used to produce artificial Christmas trees, then production can be automated to some extent, but the cost becomes excessively high and the trees deform easily with layers falling off
Solution Approach 1:
The Christmas tree is divided into modular layers with standardized sockets and hooks, allowing each layer to be independently manufactured and then assembled. This segmentation enables automated production of individual layers while maintaining structural integrity through precise connection points, resolving the contradiction between automation and structural stability.
Solution Approach 2:
The invention changes the connection mechanism from traditional binding to a socket-hook system with specific geometric parameters. The sockets are positioned at predetermined locations with exact dimensions, and hooks are designed to fit precisely, enabling automated assembly while ensuring reliable structural connections that prevent deformation and layer detachment.
2Ease of operation
If manual operations are used to spread out each leaf in each layer, then the Christmas tree can be assembled, but a large amount of manual labour is required during production and after purchase
Solution Approach 1:
The leaves are pre-arranged in their final positions during the injection molding process, with each leaf held in place by the mold cavity. This preliminary action eliminates the need for manual spreading during both production and customer assembly, as the leaves are already in their correct positions when the layer is removed from the mold, thereby improving productivity while maintaining ease of operation.
Solution Approach 2:
The injection molding process itself performs the function of arranging and positioning the leaves, making the system self-servicing. The mold design automatically ensures proper leaf orientation and spacing without requiring external manual intervention, thus increasing production efficiency while keeping the final assembly process simple for the customer.
3Productivity
If traditional manufacturing methods are used, then production can proceed, but the gaps between leaves are not uniform and every Christmas tree produced is different
Solution Approach 1:
The invention replaces traditional mechanical binding and manual positioning with an injection molding system that uses mold cavities to precisely position each leaf. The rigid mold structure ensures uniform gaps between leaves through precise machining of the cavity dimensions, while the automated injection process maintains consistent production volume, resolving the contradiction between productivity and manufacturing precision.
4Productivity
If socket technology is used instead of binding technology, then assembly is simplified and production efficiency is increased, but the structure becomes more complex
Solution Approach 1:
The socket and hook components serve multiple functions: they provide structural connection between layers, position leaves during molding, and enable automated assembly. This multi-functionality reduces the need for separate positioning mechanisms, thereby simplifying the overall structure while maintaining high assembly speed and productivity, resolving the contradiction between productivity and device complexity.
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 reduces costs, simplifies production, enhances assembly efficiency, improves product lifelikeness, safety, and versatility, enabling precise control over branch spacing and shape, while eliminating customer assembly hassles and increasing production efficiency.
Implementation Method 1
a starting material is softened with the cooperation of an injection moulding machine; the starting material may be injected into the mould by means of the injection moulding machine, in order to injection-mould the artificial Christmas tree branch
Implementation Method 2
water-cooling is used for auxiliary temperature reduction during cooling and demoulding
Data Source
AI summary
An artificial tree branch includes a tree branch body formed by injection molding a first material over an internal structural member of a second material. The tree branch body includes a main body portion having an elongated shape with a first end and a second end, and a plurality of sockets formed at various positions along the main body. Each socket is formed as an outward bulge from the main body portion, with the outward bulge defining a cavity to receive and retain artificial tree leaves.