Artificial Christmas tree with foldable branching and method of making same

Artificial Christmas tree, including a trunk with a plurality of transversely extending axially spaced holes. A pivotal mounting member, preferably U-shaped, is press fitted into each hole with a front end portion of each extending outwardly from the trunk. A branch is pivoted on each member by means of a securing element extending between the legs of the U-shaped front end portion, about each extends an arcuately formed end portion of the branch.

BACKGROUND OF THE INVENTION 
1. Field of the Invention 
This invention relates to artificial Christmas trees, and particularly, to 
artificial Christmas trees having foldable branches to facilitate the 
storage thereof. 
2. The Prior Art 
Artificial Christmas trees have been known for many years. To reduce the 
storage volume of such trees, it has been also known for many years to 
removably mount the branches on the trunk of the artificial tree by 
plugging the branches into complementary holes in the trunk. While this 
arrangement does permit the storage of an artificial tree in a relatively 
small space, the process of assembling the tree and, to a lesser extent, 
of disassembling the tree are quite time consuming. Thus, it has been 
suggested in the past of color code the holes in the tree trunks and the 
ends of the branches, whereby to readily arrange the branches on the 
trunk. This has reduced the assembly time, but it is still relatively time 
consuming. 
It has also been suggested for many years to pivotally mount branches on a 
trunk whereby to permit the branches to be swung from a folded position in 
which they are substantially parallel to the trunk to an extended position 
in which they extend outwardly from the trunk to define a simulated or 
artificial tree. Such a structure was suggested in U.S. Pat. No. 1,683,637 
granted to E. H. Trimpe on Sept. 11, 1928 and in U.S. Pat. No. 3,030,720 
granted to Osswald et al on Apr. 24, 1962. However, both of these patents 
require elaborate assembly techniques, and, in the case of the Oswald et 
al patent, a somewhat complex structure, whereby to render both of these 
prior art patents of little importance in commercial development of 
artificial Christmas trees. 
More recently, U.S. Pat. Nos. 3,574,102 and 3,639,196 have been granted to 
T. Hermanson, which have disclosed an artificial Christmas tree with 
foldable branches. The structure described in the two Hermanson patents 
require some form of bifurcation at the ends of the branches in order to 
enable the branches to be pivotally mounted on the trunk, which 
bifurcation requires special tooling not heretobefore employed in the 
making of artificial Christmas trees.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
Referring now to the drawings in detail, an artificial Christmas tree 
embodying the present invention is generally designated by the reference 
character 10. The tree comprises a stand 12, a base 14 and a top 16. The 
stand 12 may be of any suitable construction and forms no part of the 
invention per se. Suffice it to say, it should be relatively rugged and 
stable and easily connected to the balance of the tree 10. As shown herein 
in FIGS. 1 and 2, the base 12 is a tripod structure having three legs 13 
joined by a connecting ring 15 and a retaining disc 17. The connecting 
ring 15 has a central opening (not seen) through which the trunk 18 of the 
base 14 may fit. The trunk may be firmly joined to the base by means of 
adjustable screws 19. 
As already noted, the base 14 is provided with a central vertically 
extending trunk 18 from which extend a plurality of branches 20, which 
branches are pivotally mounted on the trunk 18 by pivotal mounting means 
forming the present invention. Specifically, with reference especially to 
FIG. 3, the trunk 18 is provided with a plurality of blind holes 22 which 
are longitudinally and circumferentially distributed about the surface of 
the trunk 18 to provide attachment means for securing the branches 20 to 
distributed points along the surface of the trunk 18 so as to extend away 
from said trunk in the manner of a natural Christmas tree. Although not 
preferred, the apertures 22 may be the end portions of a single through 
hole without departing from this invention 
Secured in each hole 22 is a pivotal mounting member 24, one form of which 
is illustrated in FIGS. 4 through 6. Specifically, each of the members 24 
is preferably generally U-shaped and has a rear portion 26 thereof force 
fitted into a hole 22 for fixedly securing the member 24 to the trunk 18. 
In the embodiment of FIGS. 4 to 6, the end 26 which will hereinafter be 
referred to as the rear end of the member 24 is bent into a U-shape 
wherein the legs of the "U" are relatively close as compared with the legs 
of the U-shaped front end 28. This can be accomplished by providing a 
transverse slit 30 on each leg between the front and rear portion 28 and 
26 respectively, which slits extend to but not through the bight of the 
"U". Thus, when the member 24 is bent into its U-shape from its initial 
flat shape in which it comes from a stamping machine or the like, the rear 
and front portions can be bent separately while remaining integral along 
the bits of the "U". 
In order to assure a firm mounting of the member 24 in its aperture or hole 
22, at least one dimension of the rear end portion 26 must be of 
sufficient dimensional extent to require and to be able to be force fitted 
into the hole. In the embodiment shown in FIGS. 4 to 6, that dimension is 
the length of the leg of the "U" of rear end portion 26. 
To facilitate insertion of the rear end 26 into the blind hole 22 and to 
enhance the security of the connection therebetween, the rear end surfaces 
30 of the legs of the U-shaped rear portion 26 are preferably upwardly 
sloping so that they may penetrate the blind ends of the holes 22 a short 
distance for good securement. Additionally, if desired, the front ends of 
the legs of the U-shaped rear end portion 26 may also be forwardly 
upwardly sloped as at 32 whereby to provide for a wedging action when the 
rear end 26 is forced into the blind holes 22. 
The front end 28 of the pivotal mounting member 24 is provided with a pair 
of ears 34 at the rear end thereof, which ears will be located closely 
adjacent the surface of the trunk 18 when the mounting members 24 are 
properly inserted. The ears 34 are provided with through holes 36 which 
are in register with one another for reasons which will become apparent 
hereinafter. The remainder of the front end portion 28 is of lesser 
vertical extent than the ears 34, but is nevertheless preferably U-shaped. 
As already suggested, the member 24 can be made initially by stamping the 
member from a flat plate of sheet metal and thereafter bending it into the 
described shape. All of this could, of course, be automated by metal 
working equipment well known to those skilled in that art. 
To form the lower portion or base 14 of the tree 10, pivotal mounting 
members 24 are driven into each blind hole 22 in the trunk 18. This may be 
done manually as by hammer or the like, or a suitable machine such as a 
"gun" can be fashioned for automatically "shooting" each of the members 24 
into its associated hole 22. However, the insertion of the member 24 into 
the hole 22, whether it be accomplished manually or by some automatic 
device, should be sufficient to cause the pointed rear end of the rear end 
portion 26 to bite into the blind end of the hole 22 with the upwardly 
sloping front end surface 32 wedging into the front end portion of the 
blind hole 22 to effect a secure connection between the member 24 and the 
trunk 18. Clearly, the front end portion 28 of member 24 will extend 
outwardly from the trunk 18 a short distance of the order of magnitude of 
about an inch and one-half, by way of example and not by way of 
limitation. As will be more fully understood, the front end portion will 
act as a rest or abutment for the end of the branch mounted on the member 
24 when that branch is positioned for use. 
Referring now to FIG. 7, the rear looped end 40 of a branch 20 is shown. 
Branch 20 may be of any suitable type of artificial branch. Preferably, 
however, the branch 20 has a central limb member in the form of twisted 
wires from which extend a multiplicity of artificial needles which are 
permanently held between the wires of the limb member as by twisting. Such 
a branch may be made in accordance with U.S. Pat. No. 2,742,327, the 
contents of which are hereby incorporated by reference. Preferably, 
although not necessarily, the branches 20 may be furcated at their outer 
ends to form twigs. The twigs may be affixed to the branch in any suitable 
fashion, such as, for example, in accordance with the description of U.S. 
Pat. No. 3,499,818, the contents of which are hereby incorporated by 
reference. As already noted, the limb of a branch 20 is formed of twisted 
wires. The rear or inner end of such a branch is shown in FIG. 7 with the 
rear most portion bent to form a loop 40 that is disposable between the 
ears 34 of the front end portion 28 of the connecting member 24. The 
central aperture 42 of the looped end 40 of the branch 20 is registrable 
with the registered apertures 36 in the ears 34 of the member 24. When so 
registered, a suitable securing element such as, for example, a rivet 44 
(see FIG. 3) may be inserted through the registered apertures 36 and the 
aperture 42 and secured in such position to act as a pivot for the branch 
20. The branch so constructed is clearly pivotally movable between a 
lowermost position, essentially horizontal in FIG. 3, in which the rear 
end 38 rests against the front end portion 28 of the connecting member 24 
and to and from a substantially vertical position shown in dotted line in 
FIG. 3. Thus, the trunk 18 can be assembled with a multiplicity of 
branches 20, all connected by connecting members 24 so that the branches 
may be swung upwardly to a vertical position where they lie closely 
against the trunk 18 and are thus relatively compact and to a horizontal 
position for use as a simulated Christmas tree. This enables compact 
storage of the trunk 18 with its branches connected thereto and for very 
rapid unfolding of those branches for use when desired. 
While the pivotal mounting of the branches 20 on the trunk 18 of the base 
section 14 is desirable, it is deemed unnecessary for the upper portion 
thereof, which upper portion does not occupy a large volume even in use 
and thus may be permanently arranged with its branches in an outwardly 
extending condition. Thus, the upper portion 16 of the tree 10 may be 
permanently constructed with an axial trunklike member 46 and a 
multiplicity of branches 48 permanently affixed thereto and extending 
outwardly therefrom. The trunk 46 of upper portion 16 may be constructed 
similarly to the trunk 18. However, it is presently preferred that the 
trunk 46 of the upper portion 16 be constructed of heavy gauged twisted 
wires 50 and that branches 48 of the upper portion be permanently secured 
thereto as by clips 52 encircling the entrapped ends of the branches 48 
and a portion of the twisted wire trunk 46 (see FIG. 15). Naturally, the 
branches 48 are preferably also made of twisted wires with needles 54 
entrapped between them in the same manner as the construction of the lower 
branches 20. As an alternative, the branches 48 of the upper portion may 
be secured to trunk 30 by twisting the branches about the trunk. 
The upper portion 16 may thus be connected to the base 14 of the tree 10 as 
a single finally shaped unit. While the manner of connecting upper portion 
16 to base 14 may be in accordance with any desired construction, it is 
presently preferred that a pair of axially extending apertures 56 be 
provided at the upper end of the trunk 18, the apertures being 
proportioned to receive with relatively close tolerance the lower end 
portions 58 of the wires forming trunk 46 of the upper section 16. Thus, 
to assemble the upper portion 16 with the base 14, all that need be done 
is to insert the lower end portions 58 of the upper trunk wires into the 
axially extending apertures 56 at the upper end of the trunk 18. 
Other forms of pivotal connecting members may be employed without departing 
from the present invention. Thus, with reference to FIGS. 8 through 10, a 
connecting member 24' is illustrated that is generally similar to the 
connecting member 24 of FIGS. 4 through 6. That is to say, the connecting 
member 24' is generally U-shaped with a rear end portion 26' and a front 
end portion 28' here shown to be in the same U-shaped configuration rather 
than the rear being of a smaller or narrower "U" as was true in the 
embodiment of FIGS. 4 to 6. Also, the rear end edge 32' is shown to be 
vertical and not upwardly sloping as is true of the surface 30 in the FIG. 
4 to 6 embodiment. However, if desired, the surface 30' could be upwardly 
sloping rather than vertical. The two major differences between connecting 
member 24' and connecting member 24 is the provision of a downstruck 
portion 60 in the bight of the "U" of the rear shaped portion 26' which 
downstruck portion serves as a barb to positively prevent removal of the 
connecting member 24' from a hole 22 once the member is fully inserted. 
Moreover, in the connecting member 24', an upstruck portion 62 in the 
bight of the "U" adjacent the ears 34' is provided which serves as an 
arcuate bearing surface for the looped end 40 of the end 38 of a branch 
20. Clearly, the connecting member 24' can be driven into a hole 22 by a 
hammer or a suitable mechanical gun and once driven in the barb will 
effectively prevent removal thereof. 
Referring now to FIGS. 11 through 13, a still further modified form of 
connector members designated by the reference numeral 24" is shown which 
is in all respects identical to the member 24' save that there is no 
downstruck portion 16 or upstruck portion 62. This member relies wholly on 
the friction of a pressed fit of the rear end portion 26" to hold the 
member 24" in the blind hole 22. 
Referring now to FIG. 14, yet another modification of the invention is 
shown. In FIG. 14, the connector element is designated character 24'" and 
is a simple U-shaped member with a pair of registered apertures 36'" in 
the leg of the U-shaped member at some point intermediate the two ends of 
the member. Preferably, although not necessarily, a downstruck portion 
60'" in a V-shaped form is provided to serve as a barb for preventing 
withdrawal of the member. Clearly, in the embodiment of FIG. 14, the 
entire member is configured for press fitting into a blind hole 22. 
It will be obvious that with respect to each of the embodiment 24', 24" and 
24'" hereinbefore described, that the branch 20 can be mounted in the same 
manner as it is mounted on the connecting member 24 of FIGS. 4 to 6. That 
is to say, the looped end 40 is disposed within the member so that the 
aperture 42 defined by the loop end 40 registers with the holes 36', 36" 
or 36'" and when so registered a suitable securing element such as a 
rivet, a screw or the like is inserted through the registered hole to 
provide a pivot for the branch. In all embodiments, it will be obvious 
that the branch is pivotal between a horizontal position limited by the 
front end of the pivotal connecting member 24, 24', 24" or 24'" and a 
substantially vertical position for storage 
While the preferred shape of both the front and rear portion is a U-shape, 
it will be apparent that other cross-sectional shapes may be employed for 
both portions. The rear portion may be of any cross-section that will 
yield a press fit with holes 22; the front portion should have a lower 
element extending forwardly of and below the pivot to serve as a stop for 
the branch. The U-shape is preferred for the rear portion as it provides 
some flex to render a tight fit. The stop function automatically is 
provided by the bight of the "U". Moreover, the overall U-shaped form 
renders the pivotal mounting member readily formable from sheet metal by 
first stamping and then bending the piece. 
Referring now to FIG. 16, the presently preferred form of pivot member 44 
designated by the reference numeral 44"" is shown in combination with the 
now presently preferred embodiment of pivotal connecting member 24"". This 
connecting member 24"" is generally the same as the connecting member 24' 
shown in FIGS. 8 and 9, excepting that the downstruck portion 60 and the 
upstruck portion 62 of the FIG. 8 and 9 embodiment is deleted and the 
apertures 36' are of different diameter for reasons which will become 
apparent hereinafter. Accordingly, a detailed description of the 
connecting member 24"" is deemed unnecessary. 
The pivot member 44'" which may be used with any of the forms of connecting 
members 24 previously described is a member having a head 70 and a shank 
72. The shank is divided into two portions, a head end portion 74 adjacent 
said head 70 and a tail end portion 76 which is tapered. The aperture 36"" 
in the ear 34"" adjacent the head 70 is of a diameter larger than the 
diameter of the head end portion 74 of the shank 72, whereby to permit 
passage of the shank therethrough. The aperture 36a"" in the ear 34a"" 
remote from the head 70 is of somewhat smaller diameter than the head end 
portion of the shank so as to prevent its passage therethrough. Provided 
in the shank 72 in the zone of meeting of the head end portion and the 
tail end portion thereof is a circumferential groove 78 which is 
preferably somewhat smaller in diameter than the aperture 36a"". However, 
the edge of the groove defined by the tail end portion, that is the edge 
80, is of larger diameter than the aperture 36a"". 
To mount the branch 20 on the connecting member 24"", the looped end 
thereof is positioned so that the central aperture defined by the looped 
end registers with the apertures 36"" and 36a"". The shank of the securing 
element is then aligned with the registered apertures on the side of the 
connecting member adjacent the ear 34"". It is then inserted through the 
aperture 36"" and through the aperture defined by the looped end of the 
branch 20 and thence to the aperture 36a"" where it will bear against said 
aperture because it is of greater diameter than said aperture. At that 
point, longitudinal thrust applied to head 70 will force the tail end 76 
to move against the wall of the aperture 36a"" which will deflect or 
compress the tail end, which compression is permitted by a slot 82. 
Further longitudinal movement will continue until the groove 78 straddles 
the ear 34a"" at which point the tail end will snap out to thereby seat 
the ear 34a"" in the groove 78 of the shank 72 to hold the securing 
element in the illustrated position. 
Clearly, the width of the slot 82 must be sufficient to permit enough 
deflection or compression of the tail end so that that end may clear the 
aperture 36a"". Thus, the slot width is a function of the diameter of the 
aperture 36a"" and of the tail end edge of the groove and is readily 
determinable by anyone skilled in the art. It will also be obvious from a 
persual of FIG. 16 that the length of the shank between the head 70 and 
the head end edge of the groove 78 must be somewhat larger than the 
distance between the outer surface of the ear 34"" and the inner surface 
of the ear 34a"" in order to permit the groove to become aligned with the 
ear 34a"". Preferably, it is only slightly longer than said distance. It 
will further be obvious that the width of the groove 78 must be at least 
slightly larger than the thickness of the ear 34a"". Moreover, it is 
preferred that the diameter of the groove 78 be less than the diameter of 
aperture 36a"" although this is not absolutely necessary so long as the 
shank can be compressed to yield a groove of such diameter. 
Clearly, at least the tail end portion of the securing element 44"" must be 
elastically deformable. Preferably, the entire securing element is a 
unitary member made of elastically deformable material, such as, for 
example, steel or a wide number of plastics, for example, polystyrene, 
polypropylene or any of a myriad of well known materials. Most preferably, 
the elastically deformable plastic materials should be injection moldable 
whereby to permit the injection molding of the unitary securing element 
44"". 
Irrespective of the form of connecting member employed, the tree 10 is 
generally stored in a box or similar container in a disassembled condition 
with the branches 20 of the base 14 folded to be essentially parallel to 
the trunk 18. To assemble the tree for use, as at the Christmas season, 
the three parts 12, 14 and 16 are removed from the box, the stand 12 is 
placed on the floor or table or the like, and the lower portion of base 14 
is brought into operative relation with the stand by putting the lower end 
of the trunk 18 through the center of the connecting ring 15. Thereupon, 
the screws 19 are turned to tighten them to thereby fix the base to the 
stand. The branches 20 may then be pivoted outwardly from their vertically 
extending positions as shown in dot-dash lines in FIG. 3 to their angular 
positions as shown in solid lines in FIG. 3 which angular positions are 
defined by the relationship between the end portions 28 of the limbs and 
the balance thereof. After the lower branches 20 are moved to their 
outstanding position, the top 16 may be connected to the upper end of the 
base 14 as by inserting the bottom 42 of upper trunk member 30 into the 
aperture 56 in lower trunk 18. Assuming the tree has been properly 
fabricated and there has been no damage to the lower branches 20, the tree 
will quickly assume the conical configuration as shown in FIG. 2. In the 
event that there has been some damage to the tree, a very easy bending of 
the branches 20 and 48 can be performed to shape the branches and hence 
the tree to the desired configuration as shown in FIG. 2. 
While I have herein shown the described and preferred form of the present 
invention and have suggested modifications therein, other changes and 
modifications may be made therein within the scope of the appended claims 
without departing from the spirit and scope of this invention.