Abstract:
A method of manufacturing artificial foliage utilizes a plastic pipe framework. The pipes are secured together to form a spine with a number of lateral members extending from it. The framework is wrapped with a layer of permeable fiberglass tape. A resin layer is coated on the fiberglass tape. The resin layer has a color and texture to simulate bark. Some of the resin permeates the fiberglass tape and contacts the pipes. Some of the pipes on the lateral members have upturned ends. Artificial leaves are attached to the resin layer on the lateral members.

Description:
CROSS-REFERENCE TO RELATED APPLICATION  
       [0001]    This application claims the benefit of provisional patent application 60/283,499, filed Apr. 12, 2001. 
     
    
     
       TECHNICAL FIELD OF THE INVENTION  
         [0002]    This invention relates to artificial foliage, such as tree limbs and branches. More particularly, this invention refers to branches that are used for exterior Christmas trees, landscaping, utilities, and telecommunication systems that support aesthetic environments.  
         BACKGROUND OF THE INVENTION  
         [0003]    Artificial foliage has many uses. One use is to disguise telecommunication towers located in neighborhoods. A typical tower is a polygonal tapered pole with an antenna on top. It has been known in the past to attach artificial foliage to the pole and coat the pole with a resin layer to simulate tree bark. The result conceals the pole by making it appear to be a tree. This concealment techniques has been expensive, however. I is desirable that the limbs flex and move with the wind. They also must have adequate strength to avoid breakage.  
           [0004]    One technique in the prior art employs plastic pipe as a framework. The plastic pipe is coated with a resin layer to simulate a branch. However, it is difficult to cause the resin to adhere permanently to the plastic pipe in a manner that still provides flexibility and adequate strength.  
         SUMMARY OF THE INVENTION  
         [0005]    A method of manufacturing artificial foliage uses plastic pipes as a framework. Pipes are joined together to form a limb. Preferably the pipes of the spine or main limb of the foliage are of gradually smaller diameters from a larger end to a smaller end. At least some of the limb pipes are joined together with T-shaped couplings, each of the couplings having first and second coaxial open ends that receive two of the limb pipes, and a lateral open end, pointing 90 degrees from the first and second ends. Branches or lateral members for the main limb are formed by securing plastic pipes to each of the lateral open ends of the couplings. T-shaped couplings are also used in the branches, each having coaxial first and second open ends and a 90 degree open end. Curved pipes having non-coaxial first and second ends are secured at the ends of the branches branch with the free end of the curved pipe inclined upward. Branch tip pipes are secured in upright configurations to upward facing 90 degree open ends of the branch couplings.  
           [0006]    After forming the framework, the pipes and couplings are wrapped with a layer of permeable fiberglass tape. The fiberglass tape is then coated with a resin that has a color and texture to simulate bark. Some of the resin permeates the fiberglass tape and contacts the pipes and the couplings. Artificial leaves are secured to the resin layer on the lateral members.  
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0007]    [0007]FIG. 1 is a schematic view of a foliage assembly, shown during a first step in accordance with the invention.  
         [0008]    [0008]FIG. 2 is a schematic view of the foliage assembly of FIG. 1, shown during a second step in accordance with the invention.  
         [0009]    [0009]FIG. 3 is a schematic view of the foliage assembly of FIG. 1, shown during a third step in accordance with the invention.  
         [0010]    [0010]FIG. 4 is a schematic view of the foliage assembly of FIG. 1 after completion.  
         [0011]    [0011]FIG. 5 is an enlarged sectional view of a portion of the foliage assembly of FIG. 1, demonstrating the different layers.  
         [0012]    [0012]FIG. 6 is an enlarged sectional view of the base portion of the foliage assembly of FIG. 1.  
         [0013]    [0013]FIG. 7 is an enlarged sectional view of the foliage assembly of FIG. 1, taken along the line  7 - 7  of FIG.1.  
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT  
       [0014]    Referring to FIGS.  1 - 4  in the drawings, the preferred embodiments of process steps of assembling the foliage member  11  according to the present invention are schematically illustrated. First, as demonstrated in FIG. 1, a plurality of plastic pipes  17  are cut to a certain length which varies based on overall length of the spine of foliage member  11 , the spine serving to simulate the woody portion of a limb or branch. The first pipe  17  is the largest in diameter and forms a base  13  of the limb or branch. Branches  4 ′ to  7 ′ in length require a  3 ″ base, while branches  8 ′ to  10 ′ in length require a  4 ″ base in the preferred method. Schedule  80  PVC (polyvinylchloride) pipes  17  are preferably used to form the spine. Though fairly rigid, once joined to form a limb, pipes  17  are capable of flexing along the lengths of the limb.  
         [0015]    Pipes  17  are of gradually smaller diameter from base  13  to the tip. Some of the pipes  17  are secured directly to each other by inserting one pipe  17  into the bore of another pipe  17 . Couplings  18  are also used to join pipes  17 . Couplings  18  are T-shaped, having coaxial first and second ends  18   a ,  18   b  and a lateral end  18   c  that faces 90 degrees from ends  18   a ,  18   b.  Each end  18   a ,  18   b,  and  18   c  is open.  
         [0016]    A lateral pipe  20  inserts into each open lateral end  18   c  to form branches or smaller limbs from the central limb or spine. Each lateral pipe  20  is also a PVC plastic pipe. Although not shown, depending upon length, the lateral pipes could also decrease in diameter and insert into one another. At least one coupling  22  is preferably located in each lateral member, joining two of the lateral pipes  20 . Couplings  22  are also T-shaped, having two open coaxial ends and one 90 degree end facing 90 degrees from the coaxial ends.  
         [0017]    A curved end pipe  19  is attached to the second end of each of the couplings  22 . The end pipes  19  are elbow-shaped, with the ends  19   a  and  19   b  being non-coaxial, preferably at 90 degrees relative to one another. Also, end pipes  19  are secured to couplings  22  so that their free ends  19   b  are out of the plane  16  (FIG. 7) that contains lateral pipes  20  and spine pipes  17 . As illustrated in FIG. 7, spine pipes  17  and lateral pipes  20  are typically installed on a pole (not shown) in the horizontal plane  16 . End pipes  19  are secured in lateral couplings  22  so their free ends  19   b  incline upward at an angle b that is preferably 30 degrees upward relative to plane  16 . End pipes  19  are also plastic pipes.  
         [0018]    A tip pipe  24  of plastic is inserted into the 90 degree end of each coupling  22 . Tip pipes  24  are fairly short pipes that terminate in a free end. Lateral couplings  22  are oriented so that tip pipes  24  will be parallel to the free ends  19   b  of end pipes  19 . Tip pipes  24  will thus also be 30 degrees out of plane  16 . Once foliage assembly  11  is installed, tip pipes  24  and the free ends of end pipes  19  point upward at a 30 degree angle. The various pipes  17 ,  19 ,  20 ,  24  and couplings  18 ,  22  are joined to respective members by an adhesive.  
         [0019]    Once the framework of plastic pipes  17 ,  19 ,  20 ,  24  is secured as in FIG. 1, fiberglass mesh tape  21  is used to wrap around all of the pipes and couplings, as illustrated in FIG. 2.. Tape  21  has an adhesive backing  21   a  that causes it to adhere to pipes  17 ,  19 ,  20 ,  24  and couplings . The wrapping provides interior substrength and flexibility. Fiberglass mesh tape  21  is made of a woven material, which is not unidirectional. Additionally, tape  21  is porous to ensure penetration. Fiberglass is advantageous over nylon material in providing flexibility.  
         [0020]    As demonstrated in FIG. 3 and shown in FIG. 5, exterior structural skin or resin layer  23  is applied by hand to pipe and coupling structure of foliage assembly  11 . Exterior structural skin  23  is preferably a simulated bark material, having the color and shape of tree bark. This process consists of mixing specific materials and quantities for adhesion, strength and appearance. A specific example of the structural bark materials includes Freman 40-5711 Resin (about 2 gallons), Flex Resin S-628 (about 4 oz), Norac Catalyst (about 2 oz),½′ chopped fiber strands (about 5 cups), Sierra Brown Chrome Tex Pigment (about 2 oz), Aerosil or Renfill 3080 (about 5 cups) and fiberglass mesh (about 100 feet). When applied, some of the structural bark material passes through fiberglass mesh tape  21  into contact with pipes  17 ,  19 ,  20  and  24  and couplings  18  and  22 . The resin that forms resin layer  23  is in a putty-like form and may be applied by hand.  
         [0021]    Finally, referring to FIG. 4, individual foliage or leaves  25  are secured to the spine and lateral members of the pipe and coupling structure of foliage assembly  11 . Foliage  25  may simulate the leaves of deciduous trees or the thin narrow leaves, also called needles, of conifers. The leaves thus maybe artificial oak leaves, fur needles, redwood needles, pine needles, sruce needles and other types of foliage coverage, which are designed to be suitable for exterior conditions. Foliage varies from  4 ″ to  24 ″ in length and are made of a fabric with a flexible plastic stem, in the case of deciduous leaves. Conifer needles may be made entirely of a plastic material.  
         [0022]    To apply foliage  25  to the spine and lateral member os branch structure  11 , holes are first drilled at selected points in various pipes  17 ,  20 ,  24  and couplings  18 ,  22  . The holes preferably span 360 degrees relative to the axis of each member. Then glue is applied to an end of the foliage member  25  and the end is inserted into one of the holes.  
         [0023]    Resin layer  23  is cured in dry air at ambient temperature. Usually the temperature is kept above 60° F. The resin cures, but remains flexible. Consequently, foliage assembly  11  remains flexible so that it will move with wind movement..  
         [0024]    Referring to FIG. 6, a preferred hanger is shown for attaching foliage assembly  11  (FIG. 4) to a pole, such as a telecommunications tower (not shown). A steel angle bracket  27  is welded to a steel pipe  29 . Steel pipe  29  is inserted and glued into base plastic pipe  13 . Bracket  27  comprises a metal plate bent at 90 degrees. This results in a downward facing clip portion that is spaced from the end of steel pipe  29  by a clearance. Bracket  27  fits into a slot or a lug on a telecommunications pole (not shown). When installed, branch pipes  17  and  20  of the spine and lateral members will typically be in horizontal plane  16  (FIG. 7), which is perpendicular to the pole. The free ends  19   b  of end pipes  19  and the tip pipes  24  will be pointing upward at about a 30 degree angle.  
         [0025]    The foliage assembly may be used for exterior Christmas trees, landscaping, utilities, or telecommunication systems, as mentioned, to provide an aesthetic environment. The foliage assembly can also be attached to lamp posts, sign posts, or any other post or shaft, including flag poles.  
         [0026]    The present invention provides an attractive, simple, and relatively inexpensive way to construct an artificial foliage assembly. The foliage member is flexible so as to move with wind, yet has adequate strength due to the woven fiberglass tape..  
         [0027]    While the invention has been shown or described in only some of its forms, it should be apparent to those skilled in the art that it is not so limited, but is susceptible to various changes without departing from the scope of the invention.