Abstract:
A process provides two or more strands of rope formed of a fibrous matrix material. Further, the process threads the strands singly and in parallel under tension into a coating container. In addition, the process applies a curable fluid matrix to at least some of the strands. The process also draws the strands through a constricting orifice to bond them together along their length to form a composite rope. Further, the process cures the composite rope to form a rigid structure. An apparatus comprises an armature, a wire mesh that is operably attached to the armature, and an epoxy coated rope that is operably attached to the wire mesh. The epoxy coated rope comprises glass fiber.

Description:
BACKGROUND 
       [0001]    1. Field 
         [0002]    This disclosure generally relates to the field of wood graining systems. More particularly, the disclosure relates to wood graining systems for artificial props. 
         [0003]    2. General Background 
         [0004]    Artificial props are typically used as an alternative to real objects in a variety of environments such as theme parks, zoos, aquariums, etc., since such artificial props are typically much less expensive than the corresponding real objects. Such props may include wood grained props, i.e., props that have the appearance of an arrangement of wood fibers and the texture of such arrangement. The wood grained props may have a straight grain arrangement of fibers, i.e., fibers that run parallel to the longitudinal axis of the artificial prop, or a cross grain arrangement of fibers, i.e., fibers that run in a spiral or a diagonal pattern with respect to the longitudinal axis of the artificial prop. Use of such artificial props typically necessitates significantly less expensive maintenance than real props. For example, watering and trimming of the artificial props is not necessary. 
         [0005]    Yet, the artificial wood props often lack the durability of the corresponding real props. For example, artificial wood props tend to lose their realistic appearance, melt, drip, fall apart, break, etc. when present in a harsh weather environment. Further, artificial wood props must be implemented in a way that meets the high safety standards of an entertainment environment, e.g., a theme park. For example, in the event of high heat or fire, the artificial wood props should resist burning, melting, and dripping. Further, construction of the artificial wood props often involves significant skilled manual labor. An expensive epoxy would typically have to be obtained and then manually sculpted to form the artificial props. In addition, current construction methods often lead to artificial wood props that are heavy. As a result, moving the artificial wood props to different locations in a particular environment can be quite difficult. Weight may constrain the construction of large props and may require more complex and expensive support structures such as flooring and framing to support them. 
         [0006]    Therefore, current wood graining processes do not provide a cost effective and resource effective approach to generating artificial wood props. A process for generating a safe, flexible, and durable artificial wood prop in a cost effective and realistic manner is needed. 
       SUMMARY 
       [0007]    A process provides two or more strands of rope formed of a fibrous matrix material. Further, the process threads the strands singly and in parallel under tension into a coating container. In addition, the process applies a curable fluid matrix to at least some of the strands. The process also draws the strands through a constricting orifice to bond them together along their length to form a composite rope. Further, the process cures the composite rope to form a rigid structure. 
         [0008]    Further, an apparatus comprises an armature, a wire mesh that is operably attached to the armature, and an epoxy coated rope that is operably attached to the wire mesh. The epoxy coated rope comprises glass fiber. 
         [0009]    In addition, an apparatus comprises a container. The apparatus also comprises a first wall that is operably attached to the container. Further, the apparatus has a plurality of orifices in the first wall. Each of the plurality of orifices is sized to receive strands of rope. The rope comprises an inflammable fiber. In addition, the apparatus has a second wall that is operably attached to the container and through which the strands of rope are intertwined to form a composite rope after epoxy is applied to the strands of rope in the container. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0010]    The above-mentioned features of the present disclosure will become more apparent with reference to the following description taken in conjunction with the accompanying drawings wherein like reference numerals denote like elements and in which: 
           [0011]      FIG. 1A  illustrates an epoxy applicator. 
           [0012]      FIG. 1B  illustrates a human using the epoxy applicator to apply epoxy to each of the strands of rope so that each of the strands of rope has an epoxy coating. 
           [0013]      FIG. 2A  illustrates an armature to which the composite rope illustrated in  FIG. 1B  can be applied. 
           [0014]      FIG. 2B  illustrates a wire mesh that is operably attached to the armature. 
           [0015]      FIG. 3A  illustrates the human applying the composite rope illustrated in  FIG. 1B  to the wire mesh illustrated in  FIG. 2B . 
           [0016]      FIG. 3B  illustrates the epoxy partially applied to the wire mesh. 
           [0017]      FIG. 4  illustrates an artificial prop that is constructed via the epoxy application process illustrated in  FIGS. 1A-3C . 
       
    
    
     DETAILED DESCRIPTION 
       [0018]    An artificial wood process is provided to generate an artificial wood prop that is heat resistant, exhibits improved safety performance, and that also provides a realistic natural wood grain texture. The resulting artificial wood prop is a realistic, cost effective, lightweight, drip resistant, flexible, and melt resistant prop that can be used in harsh weather environments, entertainment environments that use special effects, etc. 
         [0019]      FIG. 1A  illustrates an epoxy applicator  100 . The epoxy applicator  100  is used to apply an epoxy to strands of rope  101  that comprise a fibrous matrix material. The fibrous matrix material may be an inflammable fiber such as glass fiber, carbon fiber, Kevlar fiber, hybrids that comprise more than one of the preceding fibers, and the like. The radius of each strand of rope  100  can range from a yarn, twine, cord, thread, rope, etc. Further, the strands of rope  101  can each have the same dimensions or differ in dimensions to provide a particular aesthetic look, strength, and texture. In addition, the strands of rope  101  may vary in composition or color. The strands of rope  101  are wound around a spindle  103 . Each of the strands of rope  101  is then inserted through one of a plurality of orifices  102  of a wall of  104  of a container  105  and through an orifice  106  of a wall  112  on the other end of the container  105 . The container  105  maintains tension in each of the strands of rope  101  so that epoxy can be effectively applied. Further, the container  105  has an opening on the top of the container  105  so that epoxy can be applied through the container  105 . The epoxy application may be situated on a table  113  or other structure to elevate the epoxy applicator  100  for epoxy application. 
         [0020]      FIG. 1B  illustrates an operator  107  using the epoxy applicator  100  to apply epoxy  109  to each of the strands of rope  101  so that each of the strands of rope  101  has an epoxy coating. The operator  107  may use an implement  110  such as a shovel, scraper, etc. to apply the epoxy  109 . The epoxy  109  is just an example of a curable fluid matrix that is fluid during application, but hardens upon curing. The epoxy  109  is applied to the strands of rope  101  as the epoxy  109  is drip resistant at high temperatures. Other types of a curable fluid matrix that are drip resistant at high temperatures may be used instead or in addition to the epoxy  109 . For instance, fillers such as colorant, flame retardant, strengtheners, etc. may be used in conjunction with the epoxy  109 . As an example, bentonite clays can improve fire resistance and dripping performance in epoxy. 
         [0021]    In one embodiment, the epoxy  109  coats the surface of at least some of the strands of rope  101 . In another embodiment, the epoxy  109  saturates or fills the volume of at least some of the strands of rope  101 . The operator  107  may then pull the rope  101  through the orifice  106  such that the strands of rope  101  take the form of a composite rope  111 . For example, the composite rope  111  may be the strands of rope  101  twisted in a form that provides the appearance of a vine. The dimensions of the orifice  106  may vary. For example, the dimensions of the orifice  106  may have small enough dimensions relative to the strands of rope  101  to squeegee off excess epoxy. Further, the dimensions of the orifice  106  may have small enough dimensions relative to the strands of rope  101  to compress the composite rope  111  to ensure bonding. 
         [0022]    Although the epoxy applicator  100  is illustrated in  FIGS. 1A and 1B  for applying the epoxy  109  to the strands of rope  101 , the epoxy applicator  100  is just an example of a device that may be used for such application. Other configurations may be used to apply the epoxy  109  to the strands of rope  101  so long as they provide adequate coverage and saturation of strands  101  to meet the structural and aesthetic needs of a particular application. 
         [0023]    Further, the epoxy  109  may be applied to only one rope  101  rather than strands of rope  101 . In other words, the epoxy  109  may be used for a rope  101  that is not combined into a composite rope  111 . Similarly, epoxy  109  may be applied to fewer than all the strands  101 . 
         [0024]    The composite rope  111  may be used in environments in a fire-safe manner since the rope  101  is heat resistant as a result of its glass fiber composition and the epoxy  109  is drip resistant when exposed to high temperatures. The epoxy  109  provides the composite rope  111  with a wood grain texture that is realistic and that can be applied over a variety of substrates. Further, the epoxy  109  can have a color that conforms to the artificial prop to which the composite rope  111  is a part of so that the need for repainting is diminished. In other words, an intrinsic colorant can be used in the composite rope  111  to match the color of the artificial prop. 
         [0025]      FIG. 2A  illustrates an armature  200  to which the composite rope  111  illustrated in  Figure 111  can be applied. For example, the operator  107  illustrated in  FIG. 1B  may want to construct an artificial prop that resembles a tree branch. The armature  200  can be assembled, e.g., welded, with a durable material, e.g., steel. The armature  200  comprises a plurality of wires  201 , e.g., steel wires. Other materials other than steel may be used for the armature  200  and the plurality of wires  201 . The selection of the materials can be based on rigidity, malleability, cost, fire resistance, environmental robustness, etc. Further, a plurality of reinforcing rings  202  are operably attached to the plurality of wires  201 . The armature  200  can be the artificial prop or can surround the artificial prop. 
         [0026]    The armature  200  is configured to be lightweight so that the armature  200  can be moved to different locations, e.g., different theme park shows, without difficulty. Yet, the armature  200  is also durable enough to maintain its form through inclement weather, e.g., hurricane force winds. 
         [0027]      FIG. 2B  illustrates a wire mesh  203  that is operably attached to the armature  200 . In other words, the wire mesh  203  is attached to the armature  200  in a manner that allows for malleability so that the wire mesh  203  takes the shape of the artificial prop, but that is stiff and durable enough to withstand inclement weather conditions such as wind. The wire mesh  203  can be clipped, nailed, screwed, welded, etc., to the plurality of wires  201  and/or the plurality of reinforcing rings  202  of  FIG. 2A . The wire mesh  203  can be constructed from steel or another material that is selected based upon factors such as rigidity, malleability, cost, fire resistance, environmental robustness, etc. The wire mesh  203  is shaped to take the form of the artificial prop, e.g., a tree branch. 
         [0028]      FIG. 3A  illustrates the operator  107  applying the composite rope  111  illustrated in  FIG. 1B  to the wire mesh  203  illustrated in  FIG. 2B . The composite rope  111  is used to resemble a vine that is attached to a branch. 
         [0029]      FIG. 3B  illustrates the epoxy  109  partially applied to the wire mesh  203 . The same epoxy  109  that is used to coat the composite rope  111  is also used to coat the wire mesh  203  so that the color of the artificial tree branch resembles the color of the artificial tree vines.  FIG. 3C  illustrates the epoxy  109  fully coating the wire mesh  203 . 
         [0030]      FIG. 4  illustrates an artificial prop  400  that is constructed via the epoxy application process illustrated in  FIGS. 1A-3C . As an example, the artificial prop is a tree branch with vines. Artificial moss  402  is added to provide further realism to the artificial prop  400 . 
         [0031]    The epoxy  109  of the composite rope  111  can be cured according to a variety of curing mechanisms to ensure that the composite rope  111  is heat resistant. For example, catalyst/UV stimulation, heat simulation, etc. may be used to cure the composite rope  111 . Further, homopolymerisation is a process by which the epoxy  109  is reacted with itself. Curing may also be performed by forming a copolymer with a hardener or polyfunctional curative. 
         [0032]    It is understood that the apparatuses and processes may also be applied in other types of apparatuses and processes. Those skilled in the art will appreciate that the various adaptations and modifications of the aspects of the apparatuses and processes described herein may be configured without departing from the scope and spirit of the present apparatuses and processes. Therefore, it is to be understood that, within the scope of the appended claims, the present apparatuses and processes may be practiced other than as specifically described herein.