U.S. patent application number 09/742265 was filed with the patent office on 2001-12-13 for decorations composed of polypropylene.
Invention is credited to Docherty, Edward.
Application Number | 20010051279 09/742265 |
Document ID | / |
Family ID | 26867109 |
Filed Date | 2001-12-13 |
United States Patent
Application |
20010051279 |
Kind Code |
A1 |
Docherty, Edward |
December 13, 2001 |
Decorations composed of polypropylene
Abstract
Artificial icicles, artificial Christmas trees, garlands,
ribbons and the like composed of non-flammable polypropylene
film.
Inventors: |
Docherty, Edward;
(Jacksonville, FL) |
Correspondence
Address: |
Law Office of Thomas C. Saitta, P.A.
Suite 203
6821 Southpoint Dr. North
Jacksonville
FL
32216
US
|
Family ID: |
26867109 |
Appl. No.: |
09/742265 |
Filed: |
December 20, 2000 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60171438 |
Dec 22, 1999 |
|
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Current U.S.
Class: |
428/461 ;
428/18 |
Current CPC
Class: |
C09K 21/14 20130101;
Y10T 428/31681 20150401; A47G 33/0863 20130101; Y10T 428/24917
20150115; Y10T 428/31692 20150401; Y10T 428/31678 20150401; B32B
15/08 20130101; A47G 33/06 20130101 |
Class at
Publication: |
428/461 ;
428/18 |
International
Class: |
B32B 015/08; A47G
033/06 |
Claims
I claim:
1. A decorative element adapted for use as an artificial icicle or
ribbon and comprising a thin, non-flammable, polypropylene film,
where the film is provided as an elongated narrow strip with a
thickness in the range about 0.5 mil and 5 mil, where the thickness
is chosen dependent on the desired stiffness of the strip.
2. The decorative element of claim 1, where said film comprises a
polypropylene core layer, a metal adhesion layer joined to said
core layer, and a non-heatsealable skin layer joined to said core
layer.
3. The decorative element of claim 2, further comprising a metal
foil layer joined to said metal adhesion layer.
4. A decorative element comprising a plural number of thin,
elongated, narrow, nonflammable, polypropylene strips and elongated
support means for said strips, where said support means maintain
the physical position and orientation of each of said strips
relative to each other.
5. The decorative element of claim 4, where said support means
comprise intertwined wires and said strips extend generally
perpendicularly from said wires.
6. The decorative element of claim 5, where said film comprises a
polypropylene core layer, a metal adhesion layer joined to said
core layer, and a non-heatsealable skin layer joined to said core
layer.
7. The decorative element of claim 6, further comprising a metal
foil layer joined to said metal adhesion layer.
8. A decorative element simulating a Christmas tree, said
decorative element comprising a vertical support member to simulate
a tree trunk, multiple generally horizontal support members
extending from said vertical support member to simulate tree
branches, and a plural number of thin, elongated, narrow,
non-flammable, polypropylene strips attached to said horizontal
support members.
9. The decorative element of claim 8, where said film comprises a
polypropylene core layer, a metal adhesion layer joined to said
core layer, and a non-heatsealable skin layer joined to said core
layer.
10. The decorative element of claim 9, further comprising a metal
foil layer joined to said metal adhesion layer.
Description
This application claims the benefit of U.S. Provisional Patent
Application Ser. No. 60/171,438 filed Dec. 22, 1999.
BACKGROUND OF THE INVENTION
[0001] This invention relates generally to the field of decorative
elements made of thin film or sheet polymers, and in particular to
such decorations such as garlands, ribbons, artificial icicles and
artificial Christmas trees where environmental considerations and
flammability concerns are important.
[0002] Many decorative elements used for holiday celebrations and
other special occasions are made from strips of thin plastic film
(typically 0.5 to 1.5 mils), either alone or in combination with
wire or other support means. Often the film is colored or
metallized by adding additional layers to the plastic film create a
foil with enhanced reflective properties. Examples of such
decorations include artificial icicles (long narrow strips of thin
silver-colored foil which are draped onto Christmas trees),
garlands (short narrow strips of thin foil or colored plastic
entwined with interlocking wires to create an elongated decorative
device which is draped onto or encircling Christmas trees or other
base articles), ribbons (long medium-width strips of thin foil or
colored plastic used to encircle items), and artificial Christmas
trees (decorative objects simulating a tree and having short narrow
strips of thin, green or other-colored, plastic or foil mounted
onto branch-like projections extending from a trunk-like central
member).
[0003] It is the most common current practice to make these
decorative elements from a polyvinyl chloride (PVC) polymer. PVC is
typically produced by an oxyhydrochlorination process. The
electrolysis of brine provides chlorine and caustic soda, and the
chlorine is reacted with ethylene to produce ethylene dichloride,
which is dehydrohalongenated to yield vinyl chloride monomer.
Approximately 9.8 billion pounds are produced annually, with most
commercial PVC made up of homopolymers and a small amount of
copolymers. It has a high blending capability with plasticizers,
stabilizers and other additives.
[0004] Unfortunately, PVC suffers from serious drawbacks with
regard to health and the environment. Many credible studies have
shown that exposure to PVC causes a number of medical conditions
and diseases, including numbing/poor circulation in the fingers,
and severe damage or cancer of the liver, lungs, skin and blood.
This is mainly due to the use of pthalates as an additive to soften
the PVC. The pthalates leach from the PVC rather easily over time
and exposure. Companies such as Visa, Nike, Lego, Brio, Mattel and
Toys-R-Us have announced severe restrictions or outright bans on
production of certain toys and other items from PVC. The
international environmental protection organization Greenpeace
continues to promote a call for a total ban on the use of PVC in
production.
[0005] Furthermore, while PVC is considered flame-resistant, since
it does not ignite until a temperature of about 1500 degrees C. is
reached, it does present problems in situations likely to be
encountered in the home. PVC will not ignite at low temperatures,
but PVC film such as used in holiday decorations will char when
contacted by a flame. This charring releases toxic gases and smoke
into the air.
[0006] It is an object of this invention to provide decorative
elements composed of an environmentally safe and non-carcinogenic
polymer, to wit, polypropylene (PP), of the type which is
designated as non-flammable under the standards of the Federal
Hazardous Substance Act, which can be formed into thin films of a
transparent, colored or metallized nature. The thin film PP is
formed into decorative elements such as artificial icicles,
artificial Christmas trees, garlands, ribbons, etc.
SUMMARY OF THE INVENTION
[0007] The invention comprises decorative elements composed
entirely of thin film plastic or composed of thin film plastic and
support elements, structured to create artificial icicles,
artificial Christmas trees, garlands, ribbons and the like, where
the polymer used in construction is polypropylene due to its
beneficial environmental characteristics. The polypropylene is of
the type which is considered non-flammable under 16 CFR 1500.44 of
the Federal Hazardous Substances Act. The decorative elements
typically range in thickness from about 0.5 mil up to 5 mil, with
the thicker films being less susceptible to undesired crimping or
creasing. The film may be metallized for aesthetics and combined
with other film layers or components.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 is a side view of a polypropylene film having a core
layer, a metal adhesion layer, a metal foil layer and a skin
layer.
[0009] FIG. 2 is an end view of a garland.
[0010] FIG. 3 is partial view of an artificial Christmas tree
showing the vertical and horizontal support members.
DETAILED DESCRIPTION OF THE INVENTION
[0011] The invention comprises in general decorative elements,
which include but are not limited to artificial icicles 60,
artificial Christmas trees 50, garlands 40, ribbons and the like,
where the decorative elements are composed primarily or
substantially of polypropylene (PP) polymer film material 20. The
PP material is present in thin film form, typically approximately
0.5 to 5 mils in thickness, depending on the desired physical and
structural properties, and is presented in relatively narrow
elongated form, such that the overall length is greater than the
width, and very much greater than the thickness. The PP film 20 may
be transparent, opaque, colored or metallized by adding layers to
create a reflective foil.
[0012] PP is universally recognized as an environmentally safe
material, and does not present any of the problems associated with
PVC, especially in regard to the health and cancer hazards. It is
non-irritating, non-carcinogenic, non-mutagenic, with no oral,
dermal or inhalatory problems. It is also a more economical
product. PP differs from the simple polymer ethylene through the
mere addition of a methyl group attached to every other carbon
atom, thus stiffening the polymer chain. PP's stiffer chain gives
it a higher melting temperature and tensile strength, with a
melting point for the homopolymer at about 330 degrees F. PP is
very easily tailored for specific applications. It has a high heat
of combustion, making it ideal for applications near light
bulbs.
[0013] PP is synthesized by placing propylene monomer under
controlled conditions of heat and pressure in the presence of
organo-metallic, stereospecific catalysts of the Ziegler-Natta
type. Stereochemcial configurations of either isotactic,
syndiotactic or atatic may be achieved. Vapor phase and slurry
processing are mainly used. Molecular weight, molecular weight
distribution, stereospecificity and additives influence the
physical and processing properties of PP. Stabilization packages,
antioxidants, ultraviolet inhibitors and other additives are
usually incorporated during processing.
[0014] In general PP film is considered non-flammable, however
certain PP films containing additives may be flammable. PP film
suitable for use in the invention therefore, is of the type which
is defined as non-flammable under the testing procedure of 16 CFR
1500.44 of the Federal Hazardous Substances Act, such that it does
not ignite and burn at a rate greater than 0.1 inches along its
major axis.
[0015] For artificial icicles 60, the PP thin film 20 is presented
as having a metallized foil layer 24 which is very narrow relative
to its length. There is no added support structure, the icicles 60
being draped onto other objects, such as the branches of a
Christmas tree. Thin films in the range of 0.5 to 1.5 mil in
thickness are suitable for this application. For garlands 40, the
PP film 20 may be of any color or foil presentation, and comprises
lengths not as exaggerated relative to width as for the icicles 60,
but again having a relatively narrow width. The strips of PP film
20 are entwined amongst or otherwise attached to transversely
extending support members 30, such as intertwined wires 31, such
that the PP strips 20 extend generally perpendicularly in all
directions from the support means 30. Because it is desired that
the PP thin film strips 20 extend in all directions, the film 20
must be relatively stiff to counter gravity effects, and therefore
film thicknesses of up to about 5 mil may be utilized for this
application. The support means 30 maintain the physical position
and orientation of the individual PP strips 20 relative to each
other, and the strips 20 are oriented in different directions to
give the garland 40 a cylindrical appearance. Ribbons are formed of
long narrow strips 20 of PP, with the width to length ration not as
extreme as for the icicles 60 or garland 40. As with garlands 40,
any color or foil may be utilized. The film 20 thickness is chosen
based on the desired degree of stiffness of the ribbon. For
artificial Christmas trees 50, support means 30 comprising a
vertical member 33 to simulate a trunk and generally horizontal
members 32 extending radially from the vertical member 33 to
simulate branches are provided. Green-colored PP, or any other
color or foil if design considerations are to take precedent over
simulated authenticity, are provided in a configuration which will
approximate the configuration of natural pine needles. The PP
strips 20, relatively narrow and short, are attached to the
branch-like support elements 32 by entwining or any other suitable
fastening means, including adhesive. Stiffness is of paramount
importance in this application, so thicker films of up to about 5
mil will be utilized.
[0016] A suitable polypropylene film 20 for use in the applications
described above, for example, is a biaxially oriented PP film 20
which comprises a PP core layer 21 having on one side a metal
adhesion layer 22 for attachment of a decorative metal foil layer
24 and on the other side a skin layer 23 which is non-heatsealable,
such as a multilayer PP film sold under the brand POLIBAK. This
film composition provides for good metal adhesion if desired, is
dimensionally stable in changing climatic conditions, is superior
in handling during vacuum metallization processing and has very
good overall machinability. For the thicker films, cast PP film may
be utilized.
[0017] It is understood that certain equivalents and substitutions
for elements set forth above may be obvious to those skilled in the
art, and thus the true scope and definition of the invention is to
be as set forth in the following claims.
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