Process and apparatus for creating artificial leaves and flowers

• US 6,322,740 B1
• Filed: 09/20/2000
• Issued: 11/27/2001
• Est. Priority Date: 10/27/1997
• Status: Expired due to Fees

• Current Assignee: NSI International, Inc.
• Original Assignee: Natural Science Industries, Ltd.
• Inventors: Glanz, Andrew, Hanson, Susan
• Primary Examiner(s): DAVIS, ROBERT B
• Application Number:
  US09/666,903
• Time in Patent Office: 433 Days
• Field of Search: 249/55, 249/96, 249/97, 249/117, 249/134, 264/279, 264/275, 206/575, 425/2, 425/112, 425/470
• US Class Current: 264/275
• CPC Class Codes: B29C 33/40 Plastics, e.g. foam or rubber
• CPC Class Codes: B29C 39/10 incorporating preformed parts or layers, e.g. casting around inserts or for coating articles coating a surface by casting in general B05D1/30, B29C39/126 takes precedence
• CPC Class Codes: B29C 39/26 Moulds or cores
• CPC Class Codes: B29C 69/001 a shaping technique combined with cutting, e.g. in parts or slices combined with rearranging and joining the cut parts for reinforced material B29C70/545; B29C49/4278, B29C51/268 take precedence

Abstract

A method and apparatus for the forming of artificial leaves and flower petals, especially for use as a craft item, includes a male form for forming an armature for the leaf or petal and a female mold for generating the leaf or petal body. A flexible wire is wrapped about the male form to form an armature with an extending stem. The armature is removed from the form and placed in the mold. The mold is then filled with a film-forming casting material, such as a polyvinyl acetate. Upon cure, the artificial leaf or petal is removed from the mold. The leaf or petal may be combined with other leaves or petals similarly formed to form an artificial floral arrangement.

Claims

1. A method for forming a decorative item, comprising the steps of forming a side wall of a male form in a desired outline by placing a plurality of pegs in a matrix of holes in a base member, wrapping a length of flexible wire about the side wall of the male form to form a peripheral armature of the desired outline;

removing said armature from the male form and inserting it into a female mold having a mold bottom adapted and arranged to support the armature;

filling said mold to the level of said armature with a casting compound;

allowing said casting compound to cure to a film-like consistency; and

removing the decorative item from the mold.

8. The method of claim 1, wherein said casting compound is a polyvinyl acetate.

9. The method of claim 1 comprising the further step of forming an open network of wires within the peripheral armature after removing the armature from the male form and prior to inserting the armature into the female mold.

12. The method of claim 1 further comprising the step of forming the female mold by placing a plurality of pegs in a matrix of holes in a base member.

2. An kit for forming decorative items, comprising:

a length of flexible wire capable of being formed into a peripheral armature of a desired outline and retaining the desired outline upon forming;

a male form comprising a base with a matrix of bores arrayed upon a top surface and a plurality of pegs located in selected ones of said bores, said pegs forming a side wall of a contour corresponding to the desired outline shape of the item to be formed, said wire being formed into said armature by wrapping about said side wall;

a female mold having a mold bottom to accept the armature; and

a casting compound for filling said mold within the periphery of the armature and curing to a film-like consistency.

3. The kit of claim 2, wherein said mold bottom includes an adhesive layer portion to removably adhere said mold bottom to said armature.

4. The apparatus of claim 3, wherein said mold is of polyethylene.

5. The kit of claim 2, wherein said casting compound is a polyvinyl acetate.

6. The kit of claim 2, wherein said wire is a coated wire, said casting compound being a polyvinyl acetate.

13. The kit of claim 2 wherein the female mold comprises a base with a plurality of bores arrayed upon a top surface and a plurality of pegs located in selected ones of said bores, said pegs forming a side wall extending upwardly to form a chamber to accept the armature, the side wall of the mold being adapted and arranged to abut the armature.

14. The kit of claim 13, wherein retaining means comprise heads of the pegs.

7. A method for forming an artificial leaf or petal, comprising the steps of wrapping a length of flexible wire about a side wall of a male form to form a peripheral leaf or petal-forming armature having an extending stem;

removing said armature from the male form and inserting it into a female mold having a mold bottom adapted and arranged to support the armature;

filling said mold to the level of said armature with a casting compound;

allowing said casting compound to cure to a film-like consistency; and

removing the artificial leaf or petal from the mold.

10. The method of claim 7 further comprises an initial step of forming the side wall of the male form by placing a plurality of pegs in a matrix of holes in a base member.

11. The method of claim 10, wherein said step of wrapping the wire about the side wall comprises positioning the wire against inwardly-directed portions of the pegs.