# Patent

## Title
Method for folding material fed from a continuous band into

## Abstract

This is a continuation of co-pending application Ser. No. 07/651,664, now U.S. Pat. No. 5,091,226 filed on Feb. 6, 1991.

## Background
The present invention is directed generally to a decorative garland. More particularly, the invention is directed to a decorative garland constructed from a cut film web having a center web portion with widely spaced traversely cut sections forming loops upon longitudinal folding of the web. The web further includes a border web portion with narrowly spaced traversely cut sections forming a fine cut, tinsel-like appearance near the wire spine holding the film web.

Previous decorative garland typically has a uniform, finely cut tinsel appearance or consists of a longitudinal string of bows or loops. Garland thus has not been constructed from a web of cut film to produce a product of varying decorative appearance. In addition, it has been extremely difficult to produce decorative garland using wider film web sections for the loop type of elements or wide cut tinsel elements. The supporting wire spin can crush and distort wider strips of loops or tinsel elements, creating an unattractive appearance for the garland, and it is also difficult to stuff any substantial amount of film web into the wire spine having wide strips for the loops or tinsel elements.

It is therefore an object of the invention to provide an improved decorative garland and method of manufacture.

It is another object of the invention to provide a novel decorative garland having at least two different film web texture features.

It is a further object of the invention to provide an improved decorative garland constructed from a cut film web having widely spaced transverse cuts in a center web portion and narrowly spaced transverse cuts in a border web portion.

It is an additional object of the invention to provide a novel decorative garland constructed from a film web folded longitudinally along a line through a center web portion.

It is yet another object of the invention to provide an improved decorative garland having a wire spine twisted along a folded border web portion of a cut film web and forming a spiralled plurality of wide cut loops extending from the wire spine and a plurality of narrow cut tinsel-like elements nearest the wire spine.

It is still a further object of the invention to provide a novel cut film web having a center web portion and border web portion with different widths of transversely cut sections for forming decorative garland.

It is yet an additional object of the invention to provide an improved decorative garland having a mixture of a variable width cut film web held by a spirally wound wire spine.

It is still another object of the invention to provide a novel decorative garland comprised of a spirally wound wire spine holding a narrowly cut border web portion, allowing the wider cut center web portion to form undistorted loops extending from the wire spine.

It is yet a further object of the invention to provide an improved garland having a high density of web loops and/or tinsel-like elements by virtue of wrapping the wire around a crushable, narrowly cut border web portion.

Other objects, features and advantages of the present invention will be readily apparent from the following description of the preferred embodiments thereof, taken in conjuction with the accompanying drawings described below wherein like elements have like numerals throughout the several views.

FIG. 1 illustrates the feeding of raw web material to a cutting device for forming a cut film web;

FIG. 2 shows the folding of the cut film web and the use of wires to receive and hold the cut film web along a longitudinal line within the narrowly spaced cut, border web portion; and

FIG. 3A illustrates the spinning and twisting of the garland product to obtain the desired wire spine twist; FIG. 3B shows a close view of the garland and wire spine region used for stuffing the cut film web and achieving the spiral arrangement of loops formed; and FIG. 3C shows a web with asymmetrical cut widths for the center and border web portions.

A decorative garland constructed in accordance with the invention is shown generally at 10 in FIG. 3B. The structure of the decorative garland (hereinafter "garland 10"), can best be understood by reference to FIGS. 1-3 showing various stages on manufacture. A source web (not shown) of material, such as conventional plastic, nylon, nylon, cloth fabric and the like, are precut to a desired width "W" for a starting web 12 shown in FIG. 1. This starting web 12 is drawn by feed rollers 14 for selective cutting by a cutting means, such as a rotary cutter 16 and an associated cutting bar 18. In order to generate the desired cutting pattern, the rotary cutter 16 has spaced cutting edges 20 extending the desired length "L" to form a border web portion 22 having narrowly spaced cuts 24, transversely disposed along cut film web 26. Note the cutting bar 18 interacts with the rotary cutter 16 to complete the cutting process, and includes at least one notch 28 to leave a continuous uncut web strip 30. The uncut web strip 30 is needed to maintain the necessary rigidity and support to enable processing of the cut film web 26.

A recessed section 32 of length "M" in the rotary cutter 16 allows formation of a center web portion 34 having a widely spaced transverse cut (e.g., of width "N" in FIG. 1). That is, the cutting edges 20 are recessed along M to prevent cutting the web 12. Therefore, the wider web portions 34 are formed by using selected cutting teeth, such as tooth 36, to cut across the full width of the web 12, except for the region of the uncut web 30.

The resulting cut film web 26 is then fed to a folding and stuffing station 38 shown in FIG. 2. The cut film web 26 is folded longitudinally along a line through the center web portion 34 using folding means. An example of such a folding means is shown in FIG. 2 wherein a curved rod 40 flips the edge of the cut film web 26. The web 26 can then engage a "V" shaped guide device 42 which gathers or completes the fold of both of the border web portions 22 in a back to back manner.

Draw rolls 43 pull the folded web 44 at the same linear speed of travel as the feed rolls 14. These draw rolls 43 include means for holding the folded web 44, including wire grooves 46 for guiding a front wire 48 and a rear wire 50 into engagement with the folded web 44. The wires 48 and 50 are preferably metered out at a rate of travel of approximately one-sixth the rate of linear travel of the folded web 44. These two wires 48 and 50 are then twisted about the narrow cut border web portions 22 to form a wire spine 52 (see FIG. 3B) enabling the support and compaction, or stuffing, of the folded web 44 by the wire spine 52 without crushing or crinkling of the wider center web portion 34. In addition, this speed differential between the wires and web enables forming a garland 10 having a high density of loops 56 and of narrowly cut border web portions 22 along the length of the wire spine 52. In fact, due to the crushable nature of the narrowly cut portions 22, the wire spine 52 can retain a substantial amount of web material compared to trying to compact wider cut web material. This high density stuffing further results in the narrowly cut, or closely spaced cut, tinsel-like border web portions 22 appearing as a distinctive tinsel-like decorative element. These tinsel-like elements are radially disposed near the wire spine 52, and the bow-like loops 56 are disposed further from the wire spine 52 (see FIG. 3B).

The twisting process is best illustrated in FIG. 3A wherein the draw rolls 43 engage the folded web 44 with the wires 48 and 50 in the manner described hereinbefore. A rotating bushing assembly 58 centers and aids in twisting unfinished web 26, resulting in forming the finished garland 10 just below the draw rolls 43 in region 60. The assembly 58 also directs the garland 10 to a rotating drum 62. In the drum 62 a centrifugal force is generated and is transmitted upward to the region 60 of the web 26, causing the twisting of the wires 48 and 50 to form the helically wound wire spine 52. The resulting finished garland 10 is also collected in the rotating drum 62. The rate of linear travel for the folded web 44, the infeed rate of the wires 48 and 50 and the rotational rate of the rotating drum 62 can be used, alone, or together, to control the pitch of the wire spine winding and the density of the folded web 44 along the wire spine 52.

In other embodiments more than two wires can also be used and more than one type or number of the starting webs 12 (different color, different transverse cut spacing or even longitudinal cuts) could be used to take advantage of the features of the invention.

In another form of the invention shown in FIG. 3C, a cut film web 68 can include widely spaced transverse cut sections 70 and a transversely adjacent web portions 72 and 73 having narrowly spaced transverse cut sections 74. This asymmetric cut pattern with varying widths of transverse cut spacings will enable forming a garland having a different appearance than shown in FIG. 3B.

The cut film web 68 shown in FIG. 3C can be processed in a similar manner as shown in FIGS. 1-3A to produce however a somewhat appearing garland. The appearance of the resulting garland would depend upon the selected location where the wires 48 and 50 were engaged with the cut film web 68. For example, if the wires 48 and 50 were engaged along line 76 shown in FIG. 3C, the resulting garland would generally still include loop shapes, such as the loops 56 in FIG. 3B. However, the tinsel-like features of narrowly cut sections 74 will appear not only very near the wire spine 52 (as in FIG. 3B), but will also appear radially further out from the wire spine 52 near the radial extension of the loops 54. Other such decorative features can be generated by selecting different widths for the starting web 12 over which wide and narrow transverse cutting is carried out.

While preferred embodiments of the invention have been shown and described, it will be clear to those skilled in the art that various changes and modifications can be made without departing from the invention in its broader aspects as set forth in the claims provided hereinafter.

## Claims

1. A method of making a decorative garland, comprising the steps of: cutting being selectively performed by cutting means to generate a cut pattern with said starting web film material having an uncut longitudinal web strip near each said longitudinal edge to maintain support of said cut pattern of said starting web film material and said cut pattern comprised of a shorter transverse length of cut web film material on one side of each said uncut web strip and a longer transverse length of cut web film material on the other side of said uncut web strip; but web film material and along a single fold line about in the middle of said web film material to form a plurality of loops from said cut web film material; and plurality of loops extending radially outward from said wirelike spine, said wirelike spine further twisted about said cut web film material such that said shorter transverse length of cut web film material is disposed radially closer said wirelike spine than the ends of said loops.

2. The method as defined in claim 1 wherein said wirelike spine is applied to said folded cut form of said starting web film material with said shorter transverse length of said cut web film material being compacted or stuffed along the length of said wirelike spine thereby retaining a high density of said cut web film material along said wirelike spine.

3. The method as defined in claim 1 wherein said cut form of said starting web film material includes substantially equal width cuts longitudinally for said shorter and longer transverse lengths of said starting web film material.

4. The method as defined in claim 1 wherein said step of longitudinal folding results in a plurality of transverse cut strips of said starting web film material being folded against each other to form a plurality of said loops disposed in a helical pattern about said spine.

5. The method as defined in claim 1 wherein said cut form of starting web film material includes different longitudinal width transverse cuts of said starting web film material.

6. A method of making a decorative garland, comprising the steps of: sides of said starting web film material and with at least a portion of the cut part of said starting web film material stopping short of each of the longitudinal sides of said starting web film material and further forming shorter transverse length cuts of border web film material portions adjacent the longitudinal sides of said web film material; between the longitudinal sides of said cut web film material such that a plurality of loops are formed and said shorter transverse length cuts of border web material are disposed face on each other after folding; and folded cut web film material by twisting said wirelike spine about said folded cut web film material such that loops are formed on one side of said wirelike spine and the shorter transverse length cuts of border web material which are extensions of each said loop form open ended portions of said cut web film material radially closer to said wire spine compared to the radial end of each said loop, said twisted wirelike spine causing formation of a helically twisted array of loops along the length of said spine and further compacting said cut web film material along the length of said wirelike spine to retain a high density of said cut web film material along said wirelike spine.

7. A method of forming a decorative garland having a plurality of loops, comprising the steps of: material with substantially equal longitudinal width cuts and said web film material including a longer transverse length cut portion and with a shorter transverse length cut portion being positioned adjacent the longitudinal borders of said web film material, said longer and shorter transverse length cut portions separated by an uncut longitudinal web strip for providing support for said web film material; material; web film material using a wirelike spine to hold said folded cut web by twisting said spine about said folded cut web film material causing formation of said loops in a helically twisted array along the length of said spine and each of said shorter transverse length cut portions being disposed radially nearest said wire spine relative to said loops; and spine thereby retaining a high density of said cut web film material along said wirelike spine.

8. The method as defined in claim 7 wherein at least one of a rate of linear travel for said folded cut web film material and an infeed rate of said wirelike spine can be varied to control the level of said high density of said cut web film material along said wirelike spine.