Improvements in or relating to artificial vegetation

This invention relates to artificial vegetation.

The improved simulation by artificial vegetation of natural vegetation has long been an aim of those in the industry. Initially vegetation was prepared by injection moulding of a plastic material and the resulting products were, by present day standards, inferior. More modern techniques use a woven fabric such a silk or a polyester fabric and a far more realistic simulation of natural vegetation has been achieved. Indeed solely from the point of view of appearance it is now often quite difficult to distinguish natural vegetation from artificial vegetation.

The touch or feel of vegetation made from fabrics does however leave much to be desired and it is therefore an object of the present invention to provide artificial vegetation having an improved simulation of the feel of natural vegetation or at least to provide the public with a useful choice.

Accordingly the present invention consists in artificial vegetation formed at least in part from expanded polythene foam, preferably expanded polythene foam sheet.

Preferably the artificial vegetation is formed by cutting the polyethylene foam into two dimensional, shaped pieces then heat setting the pieces to obtain the required three dimensional shape.

Preferably wires are enclosed between two layers of expanded polythene foam before heat-setting.

Preferably colour is applied after heat setting and a resin is applied to the foam to promote absorbtion of colour by the foam.

Preferably the pieces are covered with a suitably absorbant substance before assembly to prevent them from sticking to each other.

Thus the present invention involves the formation of artificial vegetation, particularly flowers and leaves from expanded polyethylene foam. Expanded polyethylene foam, particularly expanded polyethylene foam sheet has been found to be particularly advantageous when used in the formation of artificial vegetation as it gives the vegetation a thickness, resilience and surface texture more similar to that of natural vegetation than other products available on the market. The use of expanded polyethylene foam for this purpose is surprising as it is usually used only for packaging.

Such packaging materials have not in the past been considered to be useful in the manufacture of artificial flowers.

A further advantage of using polyethylene foam is that it can be formed into artificial vegetation by conventional methods and equipment. As special procedures and equipment are not required, the use of expanded polyethylene foam is also very cost effective.

A typical method of forming artificial vegetation from polyethylene foam begins with the cutting of shaped pieces in two-dimensions from the foam which is suitably though not necessarily of a thickness of no less than about 0.5mm. For some vegetation, however, blocks of expanded polyethylene may be required. If wires or any other objects are required to be inset into the foam, these can be inset after cutting. For example, some leaves and large flower petals may require a wire or wires so that their positions can be changed in the finished article or to provide an authentic looking rib or vein in the petal or leaf. The wire or other objects may be enclosed between two or more shaped pieces of polyethylene foam. The next step is to heat set the pieces to give them a three dimensional shape; to curve or bend the pieces themselves and also to give the surface of the pieces texture as desired. Further, heat setting seals any inset objects into the foam or between two sheets of foam.

After the desired shape is obtained, the pieces are coloured. It is preferable to coat the pieces with a resin or the like to assist in the absorbtion of pigments by the expanded polyethylene foam. Colour may be sprayed, painted, printed, or in any other suitable fashion, applied to the pieces.

After colouring a coating of an absorbant substance for example a powder such as talcum powder or chalk powder, or a resin, may be applied to assist in preventing the pieces from sticking to each other. The powder may also reduce any residual tackiness in the pieces which would detract from the overall feel of the resulting product.

After the pieces have been prepared in the above fashion they are then assembled (if necessary) in the desired arrangement and secured in any conventional manner, for example by wires.

Some parts of the artificial vegetation may be formed by wrapping a support, such as wire, plastic or the like in the expanded polyethylene foam sheet, which upon heat setting would remain in position around the support. Stems and stamens for example may be suitably formed in this way.

The above describes a preferred embodiment of the present invention, variations and modifications of which may be made as will be understood by persons skilled in the art to which this invention relates. For example, a number of layers of foam sheet may be used to build up a certain piece of the vegetation and in this case very thin foam sheet (ie. less than 0.5mm) could be used.