Method and apparatus for making curled decorative grass

Abstract

Curled decorative grass having a variety of configurations and methods for making such decorative grass is provided which, because of its increased bulk, can also be used as a packing material, an animal bedding, cat litter, mulch for soil and a media for plants. The curled decorative grass is produced by curling a substantially flat sheet of material and thereafter cutting the resulting curled sheet of material, or by cutting a pre-curled material.

1 . A method for producing curled decorative grass comprising the steps of:
 providing a sheet or web of material capable of having a curl imparted thereto;   drawing the sheet or web of material over at least one curl bar so as to produce a curled sheet or web of material, wherein the at least one curl bar is provided with a curling edge over which the sheet or web of material is drawn to form the curled sheet or web of material, and wherein an angle of a portion of the curling edge of the at least one curl bar relative to a direction of travel of the sheet or web of material is different from an angle of another portion of the curling edge of the curl bar relative to the direction of travel of the sheet or web of material;   slitting the curled sheet or web of material to provide a slit curled sheet or web of material containing a plurality of curled, side-by-side strips of material; and   cutting the slit curled sheet of material to provide curled decorative grass having at least one of a substantially clock spring configuration and a compression tension spring configuration.   
     
     
         2 . The method of  claim 1  wherein, in the step of drawing the sheet or web of material over at least one curl bar, the sheet or web of material is maintained under tension while drawn over the at least one curl bar to ensure proper angular disposition of the sheet or web of material over the at least one curl bar, and wherein, in the step of slitting the curled sheet or web of material, the curled sheet or web of material is maintained under tension while slitting the curled sheet or web of material. 
     
     
         3 . The method of  claim 1  further comprising the step of:
 passing the slit curled sheet or web of material through a restraining assembly prior to cutting the slit curled sheet or web of material so as to maintain the slit curled sheet or web of material in a substantially planar or flattened condition, thereby enhancing uniformity of the curled decorative grass.   
     
     
         4 . The method of  claim 1  wherein, in the step of providing a sheet or web of material, the sheet or web of material is selected from the group consisting of paper, polymeric film, laminated polymeric film, wax paper, paper having a shape-sustaining agent applied to at least one side thereof, paper having a lacquer applied to at least one side thereof, and combinations thereof. 
     
     
         5 . The method of  claim 1  wherein, in the step of providing a sheet or web of material, the sheet or web of material is provided with at least one of a printed pattern and an embossed pattern on at least a portion of one surface thereof such that at least a substantial portion of the curled decorative grass formed therefrom contains at least a portion of the printed pattern and/or embossed pattern. 
     
     
         6 . A method for producing curled decorative grass comprising the steps of:
 providing a sheet or web of material capable of having a curl imparted thereto;   drawing the sheet or web of material over at least one curl bar so as to produce a curled sheet or web of material, wherein the at least one curl bar is provided with a curling edge over which the sheet or web of material is drawn to form the curled sheet or web of material, and wherein an angle of a portion of the curling edge of the at least one curl bar relative to a direction of travel of the sheet or web of material is different from an angle of another portion of the curling edge of the curl bar relative to the direction of travel of the sheet or web of material; and   slitting the curled sheet or web of material to provide curled decorative grass having at least one of a substantially clock spring configuration and a compression tension spring configuration.   
     
     
         7 . The method of  claim 6  wherein, in the step of drawing the sheet or web of material over at least one curl bar, the sheet or web of material is maintained under tension while drawn over the at least one curl bar to ensure proper angular disposition of the sheet or web of material over the at least one curl bar, and wherein, in the step of slitting the curled sheet or web of material, the curled sheet or web of material is maintained under tension while slitting the curled sheet or web of material. 
     
     
         8 . The method of  claim 6  wherein, in the step of providing a sheet or web of material, the sheet or web of material is selected from the group consisting of paper, polymeric film, laminated polymeric film, wax paper, paper having a shape-sustaining agent applied to at least one side thereof, paper having a lacquer applied to at least one side thereof, and combinations thereof. 
     
     
         9 . The method of  claim 6  wherein, in the step of providing a sheet or web of material, the sheet or web of material is provided with at least one of a printed pattern and an embossed pattern on at least a portion of one surface thereof such that at least a substantial portion of the curled decorative grass formed therefrom contains at least a portion of the printed pattern and/or embossed pattern. 
     
     
         10 . The method of  claim 6  wherein, in the step of slitting the curled sheet or web of material, the curled decorative grass are attached via at least one attach point. 
     
     
         11 . A method for making curled decorative grass comprising the steps of:
 providing a plurality of strips of material; and   drawing the plurality of strips of material over at least one curl bar so as to produce a curled decorative grass having at least one of a substantially clock spring configuration and a compression tension spring configuration, wherein the at least one curl bar is provided with a curling edge, and wherein an angle of a portion of the curling edge of the at least one curl bar relative to a direction of travel of the plurality of strips of material is different from an angle of another portion of the curling edge of the curl bar relative to the direction of travel of the plurality of strips of material.   
     
     
         12 . The method of  claim 11  wherein, in the step of drawing the plurality of strips of material over at least one curl bar, the plurality of strips of material are maintained under tension while drawn over the at least one curl bar to ensure proper angular disposition of the plurality of strips of material over the at least one curl bar. 
     
     
         13 . The method of  claim 11  wherein the step of drawing the plurality of strips of material over at least one curl bar further comprises cutting the plurality of strips of material to provide curled decorative grass. 
     
     
         14 . The method of  claim 13  further comprising the step of:
 passing the plurality of strips of material through a restraining assembly after the plurality of strips of material are drawn over at least one curl bar and prior to cutting the plurality of strips of material so as to maintain the plurality of strips of material in a substantially planar or flattened condition, thereby enhancing uniformity of the curled decorative grass.   
     
     
         15 . The method of  claim 11  wherein, in the step of providing the plurality of strips of material, the plurality of strips of material are attached via at least one attach point. 
     
     
         16 . The method of  claim 11  wherein, in the step of providing a plurality of strips of material, the plurality of strips of material are selected from the group consisting of paper, polymeric film, laminated polymeric film, wax paper, paper having a shape-sustaining agent applied to at least one side thereof, paper having a lacquer applied to at least one side thereof, and combinations thereof. 
     
     
         17 . The method of  claim 11  wherein, in the step of providing a plurality of strips of material, the plurality of strips of material are provided with at least one of a printed pattern and an embossed pattern on at least a portion of one surface thereof.