SIMULATED TREE BRANCH, CHRISTMAS TREE, AND METHOD OF MANUFACTURE

Description

PRIOR APPLICATION

This application is a continuation-in-part (CIP) of International Application under the Patent Cooperation Treaty (PCT) designating the United States, No. PCT/CN2024/103945, filed Jul. 5, 2024, which claims priority to Chinese Patent Application No. 202321771216.9, entitled “Simulated Branch and Christmas Tree,” filed with the China National Intellectual Property Administration on Jul. 6, 2023, the entirety of each of which is incorporated herein by reference.

TECHNICAL FIELD

The present disclosure relates to a simulated branch and a Christmas tree including such a simulated branch.

BACKGROUND

During the Christmas holiday season, it is a traditional custom around the world to use a Christmas tree for decoration. Traditional Christmas trees are real trees that are decorated. With the increase in environmental awareness in recent years, more and more artificial simulated Christmas trees have been used.

Simulated Christmas trees usually include a simulated trunk and simulated branches mounted on the simulated trunk. The simulated branch typically uses a metal inner core as support, and foliage is tied around the metal inner core. Tying the foliage requires dedicated tying machines or manual tying, and the process is complicated and costly.

In addition, because the metal inner core is usually straight and difficult to bend, simulated branches are difficult to form into curved, zigzag, or other non-linear shapes. Different simulated branches are also difficult to splice together to form complex shapes. The variability and scalability of design and manufacture are therefore poor, affecting the realism of the simulated Christmas tree.

Accordingly, in view of the problems of the prior art, a need exists for a new simulated branch and a Christmas tree including such a simulated branch.

SUMMARY OF THE DISCLOSURE

The present disclosure proposes a simulated branch, Christmas tree, and method for manufacturing them, which address at least the above problems through the following technical features and also bring other technical effects.

In one aspect of the present disclosure, a simulated branch is provided, comprising a first branch body which includes a first main body and a plurality of first insertion portions provided on the outer periphery of the first main body. The first main body and the plurality of first insertion portions are integrally injection-molded, and the first branch body does not include a metal inner core.

In some examples, the first main body further includes at least one linear segment, at least one zigzag segment, and/or at least one curved segment.

In some examples, the first branch body further includes at least one first sub-branch extending laterally from the first main body, and the first sub-branch is integrally injection-molded with the first main body.

In some examples, the simulated branch further includes foliage. An end portion of the foliage cooperates with at least one of the plurality of first insertion portions, so as to insert the foliage into the first insertion portion.

In some examples, one of the first insertion portion and the foliage end portion is a recess, and the other is a projection that matches the recess.

In some examples, one end of the first branch body is provided with a hook for connecting the simulated branch to a simulated trunk of a Christmas tree, and the hook is integrally injection-molded with the first main body.

In some examples, the simulated branch further includes another first branch body. An end portion of the other first branch body cooperates with at least one of the plurality of first insertion portions to insert the other first branch body into the first insertion portion, thereby connecting the other first branch body to the first branch body; or the end portion of the other first branch body cooperates with the other end of the first branch body to insert the other first branch body into the first branch body, thereby connecting the other first branch body to the first branch body.

In some examples, the simulated branch further includes a second branch body comprising a metal inner core and an outer layer surrounding the metal inner core, and the second branch body is connected to the first branch body.

In some examples, the outer layer is formed by tying rope, and the simulated branch further includes foliage that is tied and fixed to the second branch body by the rope.

In some examples, the outer layer is an outer sleeve fitted over the metal inner core, and the outer sleeve is provided with a plurality of mounting holes for inserting foliage.

In some examples, the outer layer is a second main body covering the metal inner core and a plurality of second insertion portions disposed on the outer periphery of the second main body, the second main body and the plurality of second insertion portions being integrally injection-molded.

In some examples, one end of the second branch body is provided with a hook for connecting the simulated branch to a simulated trunk of a Christmas tree.

In some examples, one end of the first branch body is provided with a first mounting portion, one end of the second branch body is provided with a second mounting portion that cooperates with the first mounting portion, and the first and second mounting portions cooperate to connect the first and second branch bodies.

In some examples, one of the first mounting portion and the second mounting portion is a projection, and the other is a recess that matches the projection.

In some examples, the simulated branch further includes a connecting member disposed between the first branch body and the second branch body, and one end of the connecting member cooperates with the first mounting portion, and the other end cooperates with the second mounting portion, so as to connect the first branch body and the second branch body.

In another aspect, the present disclosure further provides a Christmas tree, comprising a simulated trunk and the simulated branch described above, the simulated branch being mounted on the simulated trunk.

In yet another aspect, the present disclosure further provides a Christmas product comprising a simulated branch which includes a first branch body including a first main body and a plurality of first insertion portions disposed on the outer periphery of the first main body, the first main body and the plurality of first insertion portions being integrally injection-molded, and the first branch body not including a metal inner core.

In some examples, the Christmas product is a Christmas tree comprising a simulated trunk, and the simulated branch is mounted on the simulated trunk.

In some examples, the Christmas product is a Christmas wreath or a Christmas garland.

In yet another aspect, the present disclosure further provides a method for manufacturing a simulated branch, comprising: providing a mold having an inner surface corresponding to the outer surface of the simulated branch; placing multiple ejector pins at multiple locations inside the mold; softening a moldable first material; injecting the softened first material into the mold to form a first main body of elongated shape and a plurality of first insertion holes corresponding to the positions of the ejector pins; reducing the temperature of the first material inside the mold after injection; and removing the first main body and the multiple ejector pins from the mold.

A number of advantages will become apparent from this disclosure.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention may be more completely understood in consideration of the following detailed description of various embodiments of the invention in connection with the accompanying drawings.

FIG. 1 illustrates a front view of a first branch body according to at least one embodiment of the present disclosure.

FIG. 2 is a perspective view diagram illustrating the first branch body of FIG. 1.

FIG. 3 is another perspective view diagram illustrating the first branch body of FIG. 1.

FIG. 4 is a front view diagram illustrating a first branch body according to at least one embodiment of the present disclosure.

FIG. 5 is a front view diagram illustrating a first branch body according to another embodiment of the present disclosure.

FIG. 6 is a perspective view diagram illustrating a first branch body according to yet another embodiment of the present disclosure.

FIG. 7 is a front view diagram illustrating a simulated branch according to at least one embodiment of the present disclosure.

FIG. 8 illustrates a side view of the simulated branch of FIG. 7.

FIG. 9 is a partial sectional view diagram of the embodiment of FIG. 7, illustrating the installation state of foliage inserted into a first insertion portion.

FIG. 10 is a schematic view diagram illustrating a simulated branch according to at least one embodiment of the present disclosure.

FIG. 11 is a partial sectional view illustrating the embodiment of FIG. 10, illustrating the mating relationship between the first mounting portion and the second mounting portion.

FIG. 12 is a partial view diagram illustrating the embodiment of FIG. 10, illustrating the metal inner core, tying rope, and hook of the second branch body.

FIG. 13 is a schematic view diagram illustrating a simulated branch according to at least one embodiment of the present disclosure, in which foliage has been tied to the second branch body.

FIG. 14 is a side view illustrating of the embodiment of FIG. 13.

FIG. 15 is a schematic view diagram illustrating a simulated branch according to another embodiment of the present disclosure.

FIG. 16 is a schematic view diagram illustrating the embodiment of FIG. 15 after foliage has been installed.

FIG. 17 is a schematic view diagram illustrating a simulated branch according to yet another embodiment of the present disclosure.

FIG. 18 is a partial view diagram illustrating the embodiment of FIG. 17, illustrating an outer sleeve fitted over the metal inner core and mounting holes.

FIG. 19 is a schematic view diagram illustrating the embodiment of FIG. 17 after foliage has been installed.

FIG. 20 is a schematic view diagram illustrating simulated foliage according to at least one embodiment of the present disclosure.

FIG. 21 is a schematic view diagram illustrating simulated foliage according to at least one embodiment of the present disclosure, illustrating an example in which multiple other first branch bodies are mounted on the first branch body.

FIG. 22 is a flow diagram illustrating a method for manufacturing a simulated branch according to at least one embodiment of the present disclosure.

While the invention is amenable to various modifications and alternative forms, specifics thereof have been shown by way of example in the drawings and will be described in detail. It should be understood, however, that the intention is not to limit the invention to the particular embodiments described. On the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the scope of the invention as defined by the appended claims.

DETAILED DESCRIPTION

While the invention is amenable to various modifications and alternative forms, specifics thereof have been shown by way of example in the drawings and will be described in detail. It should be understood, however, that the intention is not to limit the invention to the particular embodiments described. On the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention as defined by the appended claims.

In the following description, certain specific details are set forth in order to provide a thorough understanding of various disclosed embodiments. However, one skilled in the relevant art will recognize that embodiments may be practiced without one or more of these specific details, or with other methods, components, materials, etc.

Reference throughout this specification to “an embodiment,” “one embodiment,” “one implementation,” “one aspect,” or “an implementation” means that a particular feature, structure or characteristic described in connection with the implementation is included in at least one implementation. Thus, the appearances of the phrases “in one implementation”, “in an implementation,” “in one aspect,” “in an example,” “in an embodiment,” or the like, in various places throughout this specification are not necessarily all referring to the same implementation. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner in one or more implementations.

Unless the context requires otherwise, throughout the specification and claims that follow, the word “comprising” or “comprises” is synonymous with “including” or “includes” and is inclusive or open-ended (i.e., does not exclude additional, unrecited elements or method acts).

As used in this specification and the appended claims, the singular forms “a,” “an,” and “the” include plural referents unless the content clearly dictates otherwise. It should also be noted that the term “or” is generally employed in its inclusive-or sense (i.e., “and/or”), unless an exclusive-or interpretation is expressly and unambiguously set forth.

Approximations such as “about,” “approximately,” “substantially,” “near,” “proximate,” “essentially,” or the like, when used in connection with a relationship or a state value, are to be interpreted as clear and definite, with an ascribed meaning equal to the absolute relationship or exact value as stated, with a permissible tolerance or variation that does not depart from the structure, form, fit, or function of the thing described, unless a different and definite meaning is provided expressly or contextually.

The headings and Abstract of the Disclosure provided herein are for convenience only and do not interpret the scope or meaning of the embodiments.

To make the objectives, technical solutions, and advantages of the present disclosure clearer, the technical solutions of the embodiments of the present disclosure will be clearly and completely described below in conjunction with the accompanying drawings of the specific embodiments. The same reference numerals represent the same components in the drawings. It should be understood that the described embodiments are only some embodiments of the present disclosure, and not all of them. Based on the embodiments described in the present disclosure, other embodiments obtained by those skilled in the art without creative work shall fall within the protection scope of the present disclosure.

Unless otherwise defined, technical terms or scientific terms used herein shall have the usual meaning understood by a person of ordinary skill in the field to which the present disclosure belongs. The terms “first,” “second,” and similar terms used in the specification and claims of the present disclosure do not indicate any order, quantity, or importance, but are merely used to distinguish different components. Likewise, terms such as “a” or “an” do not necessarily indicate a limitation in number. Terms such as “including” or “comprising” indicate that the elements or objects appearing before the term cover the elements or objects listed after the term and their equivalents, without excluding other elements or objects. Terms such as “connected” or “coupled” are not limited to physical or mechanical connections but can include electrical connections, whether direct or indirect. “Upper,” “lower,” “left,” “right” and the like are only for indicating relative positional relationships, and when the absolute position of the object being described changes, those relative positional relationships may also change accordingly.

There is room for improvement in existing simulated Christmas trees. Simulated Christmas trees generally include a simulated trunk and simulated branches mounted on the simulated trunk. Simulated branches generally use a metal inner core as support, and foliage is tied outside the metal inner core. Tying the foliage requires dedicated tying machines or manual tying, and the process is complicated and costly. Furthermore, because the metal inner core is usually straight and difficult to bend, simulated branches cannot readily be made into curved, zigzag, or other non-linear shapes. Different simulated branches are also difficult to splice together to form complex shapes. The variability and scalability of design and manufacture are poor, affecting the realism of simulated Christmas trees.

In addition, as people's aesthetic standards increase, the requirements for the visual appeal of simulated Christmas trees are also rising, and new requirements have been put forward for the shape of simulated Christmas trees. For example, a requirement may be to restore the appearance of a real Christmas tree. Another example is that for simulated Christmas trees with large tree girth and dense tree shape, the larger the tree girth, the more the number of branch bifurcations required, and sometimes further bifurcations are needed within the bifurcations. However, existing simulated Christmas trees are difficult to achieve such effects due to their high cost and poor scalability.

It should be noted that the “metal inner core” referred to herein means a strip-shaped support member made of metal material such as copper, aluminum, iron, etc., and in an insert-molding process, a metal insert in the form of a screw, pin, nail, fixing pin, etc., added to the mold is also considered a “metal inner core.” The provision of the metal inner core can make the structure of the branch more firm and stable. The cross-section of the metal inner core may be circular, triangular, square, pentagonal, hexagonal, and so on. The metal inner core may have tying rope wound around it to fix foliage, or may have a flexible outer sleeve fitted over it, or an outer layer may be injection-molded on its outer surface. The surface of the metal inner core may be smooth, and the smooth surface can ensure smooth flow of the injection material during injection molding. The surface of the metal inner core may also be textured with grooves or protruding ribs, and such a rough surface can make the injection material bond more firmly and tightly with the metal inner core.

Generally speaking, a metal inner core is not bendable by human force or is difficult to bend by human force, and must be bent using specialized bending machines. Therefore, simulated branches made of metal inner cores are usually strip-shaped or straight-shaped. This differs from real trees, whose branches are not necessarily straight but have certain bends or curves. Therefore, simulated branches with metal inner cores have lower aesthetic appeal and realism. In other words, even if the metal inner core can bend or be bent, the bending and bent shapes are limited.

In view of the defects of the prior art, the present disclosure proposes a simulated branch and a Christmas tree including such a simulated branch. The simulated branch does not include a metal inner core, and the branch body and insertion portions are integrally formed by injection molding. By virtue of injection-molding technology, the branch body can be formed into various shapes, including but not limited to linear, zigzag, curved, or combinations thereof. Therefore, various Christmas tree shapes can be simulated, and the compatibility and aesthetic appeal are high.

Preferred embodiments of the simulated branch and Christmas tree of the present disclosure will be described below in conjunction with the drawings.

Another aspect of the disclosure provides a simulated branch defined by a first branch body having a first main body and a plurality of first insertion portions disposed along the outer periphery of the first main body, the first main body and the first insertion portions being formed integrally by injection molding, with the first branch body absent a metal inner core.

In optional embodiments, the first main body is molded with at least one linear segment and at least one zigzag or curved segment, and may further include at least one first sub-branch laterally extending from the first main body that is itself integrally injection-molded. To facilitate tool-less attachment and modularity, foliage elements are configured with projection/recess interfaces that engage the first insertion portions, and, in a distinct variant, the branch includes a first hook at one end that is integrally injection-molded with the first main body for direct connection to a simulated trunk. In still other modular configurations, additional first branch bodies are insertable into the first insertion portions or mate with the opposite end of the first branch body to create larger or more complex assemblies. The simulated branch may also be combined with a second branch body that includes a metal inner core and an outer layer, where novelty-oriented variants of the outer layer include an outer sleeve with mounting holes or a second main body with integrally injection-molded second insertion portions; the first and second branch bodies may be joined via cooperating mounting portions that employ projection/recess engagement and, if desired, a connecting member disposed between them.

In a related aspect, a Christmas tree comprises a simulated trunk and at least one simulated branch mounted on the trunk, the simulated branch including the integrally injection-molded first main body and peripheral first insertion portions of claim 1, with the first branch body formed without a metal inner core. In preferred embodiments aimed at reducing parts count and assembly labor while improving aesthetics, the simulated branch includes a first hook integrally injection-molded with the first main body for direct mounting to the simulated trunk. For scalable tree architectures and richer silhouettes, the tree may employ branches that incorporate laterally molded sub-branches, linear/zigzag/curved segmenting for realistic geometry, and projection/recess interfaces that accept foliage or couple additional first branch bodies. The tree may also include branches that are hybridized with a second branch body carrying a metal inner core and a novelty-oriented outer layer such as an outer sleeve with mounting holes or a second main body with integrally injection-molded second insertion portions, joined to the first branch body via cooperating mounting portions and, in some embodiments, a connecting member.

A related aspect is directed to a method that forms the simulated branch by providing a mold whose inner surface corresponds to the branch's outer surface, positioning ejector pins at locations that correspond to the first insertion portions around a first main body, softening a moldable material, injecting the softened material to integrally injection-mold the first main body and the first insertion portions defined by the pins, cooling the molded article, and demolding to remove both the simulated branch and the pins, without inserting a metal inner core into the mold. Optional formation steps include molding the first main body with linear and zigzag or curved segments, integrally molding a first sub-branch laterally from the first main body, and integrally molding a first hook at one end for direct trunk connection. In hybrid production, the method may further form a second branch body by either fitting an outer sleeve over a metal inner core and forming mounting holes in the sleeve, or injection-molding a second main body over the core together with integrally molded second insertion portions at its periphery; the method may also form cooperating mounting portions on the first and second branch bodies, including projection/recess features configured to mate for reliable connection. These process-level options prioritize integral formation of functional interfaces and geometries, contrasting with prior art processes that add wires, fasteners, or hooks post-molding rather than creating them in-mold.

Compared with the embodiments shown in the drawings, possible embodiments within the protection scope of the present disclosure may have fewer components, components not shown in the drawings, different components, different arrangements of components, or different connections of components. In addition, without departing from the concept of the present disclosure, two or more components shown in the drawings may be implemented as a single component, or a single component shown in the drawings may be implemented as multiple separate components.

As shown in FIGS. 1 to 9, a simulated branch according to at least one embodiment of the present disclosure includes a first branch body 1 and foliage 2 connected to the first branch body 1. After assembly of the first branch body 1 and the foliage 2 into a simulated branch, the simulated branch is connected to the simulated trunk of a Christmas tree. Optionally, the simulated branch may further include multiple first branch bodies 1, 3, 3′, and another first branch body 3, 3′ may be connected to the first branch body 1 to form a rich branch shape. For example, the simulated branch may further include a second branch body 4 having a metal inner core 41, and the second branch body 4 is connected to the first branch body 1 to enhance the adaptability and compatibility of the simulated branch of the present disclosure. The preferred example of the first branch body 1 will be described first with reference to FIGS. 1 to 6.

As shown in FIGS. 1 to 6, the first branch body 1 includes a first main body 11 and a plurality of first insertion portions 12 disposed on the outer periphery of the first main body 11. The first main body 11 and the plurality of first insertion portions 12 are integrally injection-molded, and the first branch body 1 does not include a metal inner core.

Since the first branch body 1 does not include a metal inner core and is formed by injection molding, its shape and size can be customized to better simulate the shape of real branches. For example, the first main body 11 may include at least one linear segment, at least one zigzag segment, and/or at least one curved segment. As shown in FIG. 1, the first main body 11 includes a linear segment 111 and a zigzag segment 112. Alternatively, the first main body 11 may include multiple linear segments, multiple zigzag segments, and/or multiple curved segments, or any combination thereof, to meet requirements for various irregular shapes.

The first insertion portion 12 is integrally formed with the first main body 11 and may be configured to extend outward from the outer periphery of the first main body 11. The extension direction of the first insertion portion 12 is consistent with the extension direction of the foliage 2, so that the foliage 2 can be inserted into the first insertion portion 12. That is, the extension direction of the first insertion portion 12 also determines the unfolding direction of the foliage 2. Optionally, the angle between the extension direction of the foliage 2 and the first branch body 1 may be within 60 degrees, within 70 degrees, within 80 degrees, or within 90 degrees.

The sectional view of FIG. 9 shows the installation state of the foliage 2 inserted into the first insertion portion 12. The foliage end portion 20 of the foliage 2 may cooperate with at least one of the plurality of first insertion portions 12 to insert the foliage 2 into the first insertion portion 12. As shown in FIG. 9, the foliage end portion 20 is inserted into the first insertion portion 12 along the extension direction of the first insertion portion 12. The foliage end portion 20 may fit tightly with the first insertion portion 12, or may be bonded using an adhesive. The length of the first insertion portion 12 may be set so that the foliage end portion 20 can be fully inserted.

One of the first insertion portion 12 and the foliage end portion 20 is a recess, and the other is a projection that matches the recess. For example, in this embodiment, the first insertion portion is a first insertion hole, and the foliage end portion 20 is a post that matches the first insertion hole 12, or vice-versa.

The first insertion holes 12 may be arranged along the circumferential direction within a 0-degree to 180-degree angular range around the first main body 11, such as at 0 degrees, 30 degrees, 45 degrees, 60 degrees, 90 degrees, 120 degrees, 135 degrees, 150 degrees, or 180 degrees. Therefore, all the foliage 2 may be disposed on one side of the first branch body 1. In addition, in the longitudinal direction, the circumferential angles of two adjacent insertion holes 12 differ, and the circumferential angles of the first insertion holes 12 may repeat periodically in the longitudinal direction.

Referring to FIG. 2, one end 10 of the first branch body 1 may be provided with a first mounting portion 18 for connecting to a second branch body 4. The connection between the first branch body 1 and the second branch body 4 will be described later in detail.

Referring to FIGS. 4 and 5, optionally, the first branch body 1 may further include at least one first sub-branch 13 extending laterally from the first main body 11, and the first sub-branch 13 may be integrally injection-molded with the first main body 11. Exemplarily, the angle between the first sub-branch 13 and the first main body 11 may be less than or equal to 90 degrees. Alternatively, the angle may be greater than 90 degrees. The present disclosure imposes no limitation on the number or extension direction of the first sub-branches 13. FIGS. 4 and 5 illustrate two examples, respectively including one and two first sub-branches 13. The present disclosure is not limited thereto; a person skilled in the art may provide more than two sub-branches 13. Their positions and extension angles in both the longitudinal and circumferential directions may be adjusted and varied based on actual needs. In addition, because an integral injection-molding process is used, the shape of the first sub-branch 13 may also be diverse and may include multiple linear segments, multiple zigzag segments, and/or multiple curved segments, or any combination thereof, to meet requirements for various irregular shapes.

Optionally, one end 10 of the first branch body 1 may further be provided with a first hook 17 for connecting the simulated branch to a simulated trunk of a Christmas tree. The first hook 17 may be hook-shaped or ring-shaped for hanging the first branch body 1 on the simulated trunk of the Christmas tree. Optionally, the first hook 17 may be integrally injection-molded with the first main body 11, eliminating the additional bending step required for forming a hook in the existing metal inner core, avoiding the need for machine or manual bending.

Moreover, in terms of environmental protection, integrally injection-molding the first hook 17 with the first main body 11 also has benefits. Existing simulated branch hooks require straightening of the metal inner core using machines, followed by machine bending to form the hook. To prevent rust, the hooks must also be immersed in paint or anti-rust oil, which contains hazardous chemicals, such as banana oil and other solvents harmful to the human body and the environment and flammable and non-environmentally friendly. In contrast, the present disclosure proposes integrally injection-molding the hook with the first main body, eliminating such cumbersome steps and removing the need for such environmentally harmful and hazardous treatments. The product is environmentally friendly, harmless, and fire-resistant.

In summary, the integrally injection-molded simulated branch proposed in the present disclosure does not contain a metal inner core, has high design flexibility, can be formed into any irregular shape, and can be molded independently to produce a complete Christmas tree or used with existing technologies to assemble a finished Christmas tree. It is the latest innovation in the industry. It can fully replicate the actual shape and size of real trees to produce simulated Christmas trees identical in shape and size. Beyond Christmas trees, the simulated branch proposed in the present disclosure can also be directly injection-molded into various Christmas products, such as Christmas wreaths and Christmas garlands. Therefore, the simulated effect is strong, flexibility is high, cost is low, and aesthetics are improved.

In addition to the above embodiments, the simulated branch proposed in the present disclosure also has high scalability and can be spliced with various existing simulated branches to manufacture aesthetically advanced Christmas trees in a cost-effective manner. The end portion of the branch can adopt an integrally injection-molded first branch body, while the base portion can still use an existing simulated branch. In addition, the simulated branch proposed herein may also be spliced using multiple first branch bodies. In summary, simulated branches based on the present disclosure can be used to make products across different price ranges, covering low-end, mid-low-end, mid-high-end, and high-end Christmas trees.

Examples of simulated branches according to various embodiments of the present disclosure will be described below with reference to FIGS. 10 to 19. For simplicity, identical reference numerals denote the same or similar components or features. The following description will mainly address the differences among the multiple examples and will simplify or omit identical features.

According to at least one embodiment of the present disclosure, the simulated branch further includes a second branch body 4. The second branch body 4 includes a metal inner core 41 and an outer layer 42 surrounding the metal inner core 41. The second branch body 4 is connected to the first branch body 1. In contrast to the first branch body 1, the second branch body 4 includes a metal inner core 41.

FIGS. 10 to 14 illustrate one example of the second branch body 4. In this example, the outer layer 42 of the second branch body 4 is formed by tying rope 421, and the foliage 2 is tied and fixed to the second branch body 4 by the rope 421, as shown in FIGS. 13 and 14. In this example, one end 40 of the second branch body 4 is provided with a second hook 45 for connecting the simulated branch to the simulated trunk of a Christmas tree. The function and purpose of the second hook 45 are similar to those of the first hook 17 and will not be repeated here.

The tying rope 421 may wrap most of the surface of the metal inner core 41, and a portion of the metal inner core 41 may remain exposed. The exposed portion is bent to form the second hook 45.

FIG. 11 specifically illustrates one example of the connection between the first branch body 1 and the second branch body 4. This connection method is also applicable to the first and second branch bodies in other examples. As shown in FIG. 11, one end 10 of the first branch body 1 is provided with the first mounting portion 18, and the other end 40′ of the second branch body 4 is provided with a second mounting portion 46 that cooperates with the first mounting portion 18. The first mounting portion 18 and the second mounting portion 46 cooperate to connect the first branch body 1 and the second branch body 4. Specifically, the first mounting portion 18 is a recess, such as a recess hole structure, and the second mounting portion 46 is a projection that cooperates with the recess, such as a columnar projection structure.

Alternatively, the recessed/protruding relationship of the first mounting portion 18 and the second mounting portion 46 may be reversed. For example, FIG. 20 illustrates an example in which the first mounting portion 18 is a projection, and correspondingly, the second mounting portion 46 may be a recess that cooperates with the projection.

In an embodiment not shown, the first branch body 1 and the second branch body 4 may also be connected via a connecting member. The connecting member is disposed between the first branch body 1 and the second branch body 4, and one end of the connecting member cooperates with the first mounting portion 18, while the other end cooperates with the second mounting portion 46, thereby connecting the two branch bodies.

The example shown in FIGS. 10 to 14 is suitable for low-end or mid-low-end products. By splicing the first branch body 4 without a metal inner core and with high design tolerance with the second branch body 4 with a metal inner core, the end portion of the branch, which uses the first branch body 4, can be made into various complex shapes. This reduces labor costs and enables the manufacture of low-cost Christmas trees with improved aesthetics.

FIGS. 15 to 16 illustrate another example of the second branch body 4. In this example, the second branch body 4 adopts a structure of a metal inner core plus a covered outer layer. Specifically, the outer layer 42 is a second main body 43 that covers the metal inner core 41, and multiple second insertion portions 44 are arranged on the outer periphery of the second main body 43. The second main body 43 and the plurality of second insertion portions 44 are integrally injection-molded. The second insertion portions 44 may have features similar to the first insertion portions 12, which will not be repeated here.

The example illustrated in FIGS. 15 to 16 is suitable for mid-high-end or high-end products. It has high compatibility and does not require manual or machine tying of rope. Instead, the outer layer is produced by integral injection molding, reducing labor and machine costs and improving production capacity. The shape effects can be diversified, greatly improving production capability compared to the prior art.

FIGS. 17 to 19 illustrate yet another example of the second branch body 4. In this example, the outer layer 42 is an outer sleeve 422 fitted over the metal inner core 41, and the outer sleeve 422 is provided with a plurality of mounting holes 423 for inserting foliage 2. FIG. 19 shows foliage 2 inserted respectively into the first branch body 1 and the second branch body 4.

The example illustrated in FIGS. 17 to 19 is suitable for mid-end products. It has high realism, improved aesthetics, high production capacity, high compatibility, and flexible design.

It should be noted that to achieve better simulated effects, the surfaces of the first main body 11, first sub-branch 13, outer sleeve 422, and second main body 43 may all be provided with bark-like textures.

Additionally, the simulated branch of the present disclosure may also be assembled from multiple first branch bodies 1, 3, 3′, which provides high flexibility. FIG. 21 exemplifies such an example. As shown in FIG. 21, the simulated branch may include multiple other first branch bodies 3, 3′. The branch end portion 30 of the other first branch bodies 3, 3′ cooperates with at least one of the plurality of first insertion holes 12 or cooperates with the other end 10′ of the first branch body, thereby connecting the other first branch body 3, 3′ to the first branch body 1.

As shown again in FIG. 21, the branch end portion 30 of another first branch body 3′ cooperates with the other end 10′ of the first branch body 1, for example, by means of a projection-and-recess engagement. The branch end portions 30 of two other first branch bodies 3 are respectively inserted into two first insertion holes 12. This approach greatly improves the scalability of the simulated branch. Furthermore, this approach permits large simulated branches to be split into smaller simulated branches for assembly. That is, longitudinal or lateral extensions can be achieved, greatly increasing practicality compared to existing simulated branches.

In another aspect, the present disclosure further provides a Christmas tree comprising a simulated trunk and the simulated branches described above, the simulated branches being mounted on the simulated trunk.

In yet another aspect, the present disclosure further provides a Christmas product including the simulated branches described above. Specifically, the Christmas product may be a Christmas tree, a Christmas wreath, or a Christmas garland.

In yet another aspect, as shown in FIG. 22, the present disclosure further provides a method for manufacturing a simulated branch, comprising the following operations:

• • S1: providing a mold having an inner surface corresponding to the outer surface of the simulated branch;
  • S2: placing multiple ejector pins at multiple positions inside the mold;
  • S3: softening a moldable first material;
  • S4: injecting the softened first material into the mold to form a first main body of elongated shape and a plurality of first insertion holes corresponding to the positions of the ejector pins;
  • S5: after injection, lowering the temperature of the first material inside the mold; and
  • S6: removing the first main body and the multiple ejector pins from the mold.

Optionally, the mold in step S1 may be machined by a CNC machining center based on three-dimensional software design drawings. Further, the machined mold may be trimmed, and bark-like textures on the branch may be carved manually.

Unlike existing injection-molding processes, the manufacturing method proposed in the present disclosure does not include the step of incorporating a metal inner core into the mold.

During the injection-molding process, the raw material is softened using an injection-molding machine, which can inject the material into the mold to perform injection molding of the simulated branch.

The creation of the insertion hole in the first main body is accomplished through step S2, in which ejector pins are inserted at the desired insertion hole locations during injection-molding, thereby reserving insertion hole spaces during molding and completing the formation of the insertion holes for the simulated branch.

Steps S5 and S6 involve cooling and demolding. After injection, the molded simulated branch is cooled and removed from the mold. The first main body and the multiple ejector pins are removed from the mold for subsequent use. Water cooling may be used to assist in lowering the temperature during cooling and demolding.

Additional Notes and Examples

Example 1 is a simulated branch comprising: a first branch body including a first main body and a plurality of first insertion portions disposed along an outer periphery of the first main body; wherein the first main body and the plurality of first insertion portions are integrally injection molded; and wherein the first branch body is without a metal inner core.

In Example 2, the subject matter of Example 1 includes, wherein the first main body includes at least one linear segment, and at least one zigzag or curved segment.

In Example 3, the subject matter of Examples 1-2 includes, wherein the first branch body further includes at least one first sub branch extending laterally from the first main body, the first sub branch being integrally injection molded with the first main body.

In Example 4, the subject matter of Examples 1-3 includes, foliage having an end portion formed to cooperate with at least one of the plurality of first insertion portions to insert the foliage into the at least one first insertion portion.

In Example 5, the subject matter of Example 4 includes, wherein one of the first insertion portion and the foliage end portion is a recess and the other is a projection formed to mate with the recess.

In Example 6, the subject matter of Examples 1-5 includes, a first hook at one end of the first branch body, the first hook being formed to connect the simulated branch to a simulated trunk of a Christmas tree, and the first hook being integrally injection molded with the first main body.

In Example 7, the subject matter of Examples 1-6 includes, another first branch body, wherein an end portion of the other first branch body is formed to cooperate with at least one of the plurality of first insertion portions to insert the other first branch body into the at least one first insertion portion and thereby connect the other first branch body to the first branch body.

In Example 8, the subject matter of Examples 1-7 includes, another first branch body, wherein an end portion of the other first branch body is formed to mate with an opposite end of the first branch body to insert the other first branch body into the first branch body and thereby connect the other first branch body to the first branch body.

In Example 9, the subject matter of Examples 1-8 includes, a second branch body connected to the first branch body, the second branch body including a metal inner core and an outer layer surrounding the metal inner core.

In Example 10, the subject matter of Example 9 includes, wherein the outer layer comprises tying rope, and the simulated branch further comprises foliage tied and fixed to the second branch body by the tying rope.

In Example 11, the subject matter of Examples 9-10 includes, wherein the outer layer comprises an outer sleeve fitted over the metal inner core, the outer sleeve having a plurality of mounting holes formed to receive foliage.

In Example 12, the subject matter of Examples 9-11 includes, wherein the outer layer comprises a second main body covering the metal inner core and a plurality of second insertion portions disposed along an outer periphery of the second main body, the second main body and the plurality of second insertion portions being integrally injection molded.

In Example 13, the subject matter of Examples 9-12 includes, wherein one end of the second branch body includes a second hook formed to connect the simulated branch to a simulated trunk of a Christmas tree.

In Example 14, the subject matter of Examples 9-13 includes, a first mounting portion at one end of the first branch body and a second mounting portion at one end of the second branch body, the second mounting portion being formed to cooperate with the first mounting portion to connect the first branch body with the second branch body.

In Example 15, the subject matter of Example 14 includes, wherein one of the first mounting portion and the second mounting portion is a projection and the other is a recess formed to mate with the projection.

In Example 16, the subject matter of Examples 14-15 includes, a connecting member disposed between the first branch body and the second branch body, wherein a first end of the connecting member is formed to cooperate with the first mounting portion and a second end of the connecting member is formed to cooperate with the second mounting portion to connect the first branch body with the second branch body.

Example 17 is a Christmas tree comprising a simulated trunk and at least one simulated branch, the simulated branch including: a first branch body including a first main body and a plurality of first insertion portions disposed along an outer periphery of the first main body; wherein the first main body and the plurality of first insertion portions are integrally injection molded; and wherein the first branch body is without a metal inner core.

In Example 18, the subject matter of Example 17 includes, wherein the simulated branch includes a first hook at one end of the first branch body, the first hook being formed to connect the simulated branch to the simulated trunk, and wherein the first hook is integrally injection molded with the first main body.

In Example 19, the subject matter of Examples 17-18 includes, wherein the first main body includes at least one linear segment and at least one zigzag or curved segment.

In Example 20, the subject matter of Examples 17-19 includes, wherein the first branch body further includes at least one first sub branch extending laterally from the first main body, the first sub branch being integrally injection molded with the first main body.

In Example 21, the subject matter of Examples 17-20 includes, foliage having an end portion formed to cooperate with at least one of the plurality of first insertion portions to insert the foliage into the at least one first insertion portion.

In Example 22, the subject matter of Example 21 includes, wherein one of the first insertion portion and the foliage end portion is a recess and the other is a projection formed to mate with the recess.

In Example 23, the subject matter of Examples 17-22 includes, another first branch body, wherein an end portion of the other first branch body is formed to cooperate with at least one of the plurality of first insertion portions to insert the other first branch body into the at least one first insertion portion and thereby connect the other first branch body to the first branch body.

In Example 24, the subject matter of Examples 17-23 includes, another first branch body, wherein an end portion of the other first branch body is formed to mate with an opposite end of the first branch body to insert the other first branch body into the first branch body and thereby connect the other first branch body to the first branch body.

In Example 25, the subject matter of Examples 17-24 includes, a second branch body connected to the first branch body, the second branch body including a metal inner core and an outer layer surrounding the metal inner core.

In Example 26, the subject matter of Example 25 includes, wherein the outer layer comprises tying rope, and the foliage is tied and fixed to the second branch body by the tying rope.

In Example 27, the subject matter of Examples 25-26 includes, wherein the outer layer comprises an outer sleeve fitted over the metal inner core, the outer sleeve having a plurality of mounting holes formed to receive foliage.

In Example 28, the subject matter of Examples 25-27 includes, wherein the outer layer comprises a second main body covering the metal inner core and a plurality of second insertion portions disposed along an outer periphery of the second main body, the second main body and the plurality of second insertion portions being integrally injection molded.

In Example 29, the subject matter of Examples 25-28 includes, wherein one end of the second branch body includes a second hook formed to connect the simulated branch to the simulated trunk.

In Example 30, the subject matter of Examples 25-29 includes, a first mounting portion at one end of the first branch body and a second mounting portion at one end of the second branch body, the second mounting portion being formed to cooperate with the first mounting portion to connect the first branch body with the second branch body.

In Example 31, the subject matter of Example 30 includes, wherein one of the first mounting portion and the second mounting portion is a projection and the other is a recess formed to mate with the projection.

In Example 32, the subject matter of Examples 30-31 includes, a connecting member disposed between the first branch body and the second branch body, wherein a first end of the connecting member is formed to cooperate with the first mounting portion and a second end of the connecting member is formed to cooperate with the second mounting portion to connect the first branch body with the second branch body.

Example 33 is a method of manufacturing a simulated branch comprising: providing a mold having an inner surface corresponding to an outer surface of the simulated branch; positioning a plurality of ejector pins at respective locations within the mold corresponding to first insertion portions along an outer periphery of a first main body; softening a moldable first material; injecting the softened first material into the mold to integrally injection-mold the first main body and a plurality of first insertion portions defined by the ejector pins; cooling the first material within the mold to solidify the simulated branch; and demolding by removing the simulated branch and the plurality of ejector pins from the mold; wherein the method is performed without inserting a metal inner core into the mold.

In Example 33, the subject matter of Example 33 includes, wherein injecting the softened first material into the mold includes forming the first main body with at least one linear segment and at least one zigzag or curved segment.

In Example 35, the subject matter of Examples 33-33 includes, wherein injecting the softened first material into the mold includes forming at least one first sub-branch extending laterally from the first main body and integrally injection-molding the first sub-branch with the first main body.

In Example 36, the subject matter of Examples 33-35 includes, wherein injecting the softened first material into the mold includes forming a first hook at one end of the first branch body, the first hook being integrally injection-molded with the first main body.

In Example 37, the subject matter of Examples 33-36 includes, providing a metal inner core and forming an outer layer surrounding the metal inner core to produce a second branch body.

In Example 37, the subject matter of Example 37 includes, fitting an outer sleeve over the metal inner core to form the outer layer and forming a plurality of mounting holes in the outer sleeve configured to receive foliage.

In Example 39, the subject matter of Examples 37-37 includes, injection-molding a second main body over the metal inner core and integrally injection-molding a plurality of second insertion portions along an outer periphery of the second main body to form the outer layer.

In Example 40, the subject matter of Examples 37-39 includes, forming a second hook at one end of the second branch body.

In Example 41, the subject matter of Examples 37-40 includes, forming a first mounting portion at one end of the first branch body and forming a second mounting portion at one end of the second branch body.

In Example 41, the subject matter of Example 41 includes, forming respective projection and recess features on the first mounting portion and the second mounting portion configured to mate with one another.

The embodiments above are intended to be illustrative and not limiting. Additional embodiments are within each claim that does not expressly exclude such subject matter. In addition, although aspects of the present invention have been described with reference to particular embodiments, those skilled in the art will recognize that changes may be made in form and detail without departing from the scope of the invention, as defined by the claims.

Persons of ordinary skill in the relevant arts will recognize that the invention may comprise fewer features than illustrated in any individual embodiment described above. The embodiments described herein are not meant to be an exhaustive presentation of the ways in which the various features of the invention may be combined. Accordingly, the embodiments are not mutually exclusive combinations of features; rather, the invention may comprise a combination of different individual features selected from different individual embodiments, as will be understood by persons of ordinary skill in the art.

Any incorporation by reference of documents above is limited such that no subject matter is incorporated that is contrary to the explicit disclosure herein. Any incorporation by reference of documents above is further limited such that no claims that are included in the documents are incorporated by reference into the claims of the present Application. The claims of any of the documents are, however, incorporated as part of the disclosure herein, unless specifically excluded. Any incorporation by reference of documents above is yet further limited such that any definitions provided in the documents apply only to the incorporated subject matter, and not to any of the subject matter directly present herein.

For purposes of interpreting the claims for the present invention, it is expressly intended that the provisions of 35 U.S.C. § 112(f) are not to be invoked unless the specific terms “means for” or “step for” are recited in a claim.