ORNAMENT PRODUCTION

Abstract: A method and apparatus is disclosed for producing an ornament for gift wrapping purposes and the like. The ornament has a basic member with a plurality of radially disposed conical elements, and these basic members may be combined to produce spheroidal or hemispheroidal ornaments having a plurality of radial cones or spikes. In the method, a flat circular blank (14) is formed with a plurality of radially disposed leaves (15). The leaves are wrapped around a conical form (20) and adhesively secured to form one of the basic members. The apparatus includes a winder (18) for wrapping the leaves around the conical form and positioning means (16) for holding the blank and locating each leaf on the form to be wrapped into a conical element by the winder.

Description: This invention relates to a method and apparatus for producing ornaments or decorations which may be used for wrapping gifts in a manner similar to ribbon-type bows or for any other purposes. The most common type of ornament used in the past for gift wrapping is the ribbon bow. Such bows can be hand made or machine made, and they can either be in the form of a random collection of ribbon loops and ribbon strands, or they can be made with uniform or symmetrical ribbon loops and strands. Either type is esthetically pleasing, but if the objective is the uniform type, it is generally considered to be desirable to have a regular pattern or a symmetrical shape with the various elements of the ornament made in predetermined uniform sizes and shapes. A difficulty with the prior art bow type ornaments is that they are too commonplace, especially the machine bows, since they tend to be so perfectly made that they look cheap. DE-A-329,597 discloses the use of disc-shaped blanks each formed with a plurality of leaves radially projecting from a central portion in order to manufacture artificial blossom stars. The leaves of each blank are simultaneously shaped into small conical elements by means of a plurality of hollow forms that are pushed radially towards the centre of the star while the blank is rigidly held by a star-shaped core including a plurality of conical core-forms. Winding of each leaf onto the core is achieved by axial translation of the hollow forms over the conical core-forms. It is an object of the present invention to overcome these disadvantages by producing a novel ornament having conically formed elements. According to one aspect of the invention, the method as described in the generic part of claim 1 comprises the additional steps of stacking the central parts of the blanks while disposing the conical elements projecting from the central part in a circumferential arrangement. Then compressing and connecting together the central parts to obtain the requested ornaments. The conical elements are made from each blank in that a conical form having a longitudinal axis is provided and the blanks are positioned at an angle with respect to the longitudinal axis suitable for pressing the central portion of at least one leaf of the blank against the conical form with the lateral portions of one leaf projecting away from the conical form on either side thereof. After that one of the projecting lateral portions is folded over the conical form and held there against. An adhesive material is applied to one of the lateral portions and the other is folded over this portion, thereby a firm conical element is formed, held solid together by the adhesive material. Then the conical form is removed from the conical element. According to another aspect of the invention, an apparatus for use in producing an ornament with features as disclosed in the characterising part of claim 6 is provided. Preferred embodiments of the invention will now be described, by way of example with reference to the accompanying drawings, in which: Figure 1 is a diagrammatic perspective view of a preferred embodiment of the apparatus of the present invention; Figure 2 is an exploded perspective view of the wrapping elements of the winder of the embodiment shown in Figure 1; Figure 3 is a perspective view of the first wrapping element viewed in the direction of arrow 3 of Figure 2; Figure 4 is an enlarged perspective view of the preferred embodiment showing a blank in position with one leaf ready to be wrapped around the conical form to form a conical element; Figures 5a to 5d are sectional views taken along lines 5-5 of Figure 4 showing sequential stages of a leaf being wrapped around the conical form; Figure 6 is a perspective view of a blank after one leaf has been formed with a conical element; Figure 7 is an exploded perspective view showing a plurality of disks prior to being assembled into an ornament as shown in Figures 8, 9 and 10; Figure 8 is a perspective view looking from above of an ornament produced by the method of the present invention; Figure 9 is a perspective view of the ornament shown in Figure 8 but viewed from below; and Figure 10 is an elevational view of the ornament shown in Figures 8 and 9. Referring to the drawings, in Figure 1 a preferred embodiment of an ornament winding apparatus is shown diagrammatically and is generally indicated by reference numeral 10. Figures 2 and 3 show details of the wrapping elements of winding apparatus 10. Figures 4 to 7 inclusive illustrate the operation of the winding apparatus, and Figures 8 to 10 show a typical ornament 12 which may be produced using the method and apparatus of the present invention. As mentioned above, Figure 1 is a diagrammatic representation of winding apparatus 10, and it shows a blank 14 retained in position by a fixed positioning device 16. Blank 14 has a plurality of flat radially disposed leaves 15, some of which are only shown in phantom for the purposes of illustration. A winder assembly 18 and a conical form 20 are shown mounted in a frame 22. In a production version of winding apparatus 10, there would be multiple sets of winder assemblies 18 and conical forms 20 and multiple positioning devices 16 that move between the sets of winder assembly 18 and conical form 20 with the blank 14 being rotated and indexed to operate successively on each leaf 15 of blank 14. However, for the purposes of illustration, winding apparatus 10 has been shown as a single unit for the purposes of simplification in the present specification. In any event, the apparatus shown in Figure 1 would work perfectly well and it is not necessary to have multiple sets of the apparatus for the purposes of the present invention. Referring in particular to Figures 1 to 3, the conical form 20 is longitudinally slideably mounted in a bearing 24 in frame 22, so that conical form 20 moves in a reciprocating motion as indicated by arrow 26. Conical form 20 is connected to an actuator indicated by reference numeral 28 through a conventional clevis 30, so that the actuator 28 reciprocates conical form 20 into and out of engagement with winder assembly 18. Conical form 20 has a longitudinal internal passage 32 communicating with openings 34 adjacent to the distal end of form 20. A flexible supply hose 36 is connected to conical form 20 to communicate with internal passage 32 and vacuum or air pressure as required is supplied to internal passage 32, as indicated by respective arrows 38, 40. The vacuum is supplied to conical form 20 to help the leaves 15 adhere to the form in operation of the apparatus, and pressure is applied to the internal passage through tube 36 of conical form 20 to release the leaves 15 from the form after they have been formed into conical elements as will be described further below. The winder assembly 18 is rotatably mounted in a bearing 42 in frame 22, and suitable retaining rings (not shown) are provided to prevent longitudinal movement of the members of the winder assembly 18. Winder assembly 18 includes a first internal wrapping element 44 and a second outer concentric wrapping element 46, and wrapping elements 44, 46 rotate relative to each other about a common axis. This axis is a coincident with the longitudinal axis of conical form 20 in the preferred embodiment but it does not have to be as discussed further below. First and second wrapping elements 44, 46 are driven by respective gear trains 48, 50, but second wrapping element 46 could just be frictionally mounted in frame 22 so that it is driven by the first wrapping element 44 as discussed below as well. Referring in particular to Figures 2 and 3, first wrapping element 44 has a conical bed 52 which mates with the conical end portion of conical form 20 when the two are brought together. Consequently, conical bed 52 is in a lower quadrant of first wrapping element 44 as shown in the drawings. A longitudinal knife edge 54 is formed along one side of conical bed 52, the purpose of which will be described below. Second wrapping element 46 also has a conical bed 56 in a lower quadrant thereof which mates with the conical end portion of conical form 20. Conical bed 56 has one bevelled longitudinal edge 58 which mates with or accommodates the knife edge 54 of first wrapping element 44 when the two wrapping elements are rotated together so that the knife edge 54 fits into the bevelled edge 58. When the two wrapping elements 44, 46 are positioned as shown in Figure 1, the two conical beds 52, 56 are in registration to form a combined conical bed to receive a leaf 15 of the blank 14. The positioning device 16 includes a vacuum head 60 mounted on a hollow shaft 62 retained in a bearing 64, so that vacuum head 60 is rotatably mounted in frame 22. The vacuum head 60 has a plurality of openings 66 in the upper surface thereof in communication with the hollow shaft 62, so that when vacuum is applied to hollow shaft 62 as indicated by arrow 68, a suction is applied to the central portion 70 of blank 14 to retain the blank in position with one leaf 15 positoned over the conical beds of the wrapping elements 44, 46. A suitable drive and indexing mechanism (not shown) is connected to vacuum head 60 to rotate the blank and position each leaf 15 seriatim over the conical beds of the wrapping elements. Vacuum head 60 is orientated obliquely relative to the axis of conical form 20 and winder assembly 18, so that as blank 14 is rotated by vacuum head 60 with conical form 20 separated from winder assembly 18 as shown in Figure 1, the leaves 15 can pass above wrapping elements 44, 46 to be positioned over the conical beds 52, 56. Also, the longitudinal central axis of vacuum head 60 intersects with the longitudinal axis of conical form 20 and winder assembly 18 in the preferred embodiment. The operation of winding apparatus 10 and the method of producing an ornament using this apparatus according to the present invention will now be described with particular reference to Figures 4 to 6. Firstly a blank 14 is formed and this is a planar, circular blank of flexible material such as paper or plastic and it has a plurality of flat radially disposed leaves 15. In the preferred embodiment, leaves 15 are spaced apart slightly and are conical in plan view, each having a narrow neck portion 72 adjacent to the central portion 70 of the blank. Each leaf 15 also has a wider distal end portion 74 and respective first and second side portions 76, 78. First side portion 76 has a tab 80, the purpose of which will be described further below. Blank 14 is then placed on vacuum head 60, and the vacuum head is rotated until one leaf 15 is positioned over the conical beds, 52, 56 of winder assembly 18. Conical form 20 is then advanced in the direction of arrow 82 in Figure 4 until the conical end portion of conical form 20 engages leaf 15 and presses same into the conical beds of wrapping elements 44, 46. Vacuum is then applied through supply hose 36 and leaf 15 is wrapped around conical form 20 to produce a conical element 84 as shown in Figure 6. The wrapping of a leaf 15 into a conical element 84 is best illustrated by Figures 5a to 5d. Figure 5a shows winder assembly 18 in the positon shown in Figures 1 and 4 with wrapping elements 44, 46 in the starting positon. Wrapping element 44 is then rotated counterclockwise as seen in Figure 5 by gear train 48 causing the first side portion 76 of leaf 15 to be wrapped around conical form 20. Wrapping element 44 is continued to be rotated to the position shown in Figure 5b whereupon knife edge 54 tucks or crimps the tab 80 of first side portion 76 under the second side portion 78. This helps retain the first side portion wrapped on conical form 20 as the wrapping operation continues. Also, the vacuum applied to conical form 20 through openings 66 creates a suction to help hold the first side portion 76 in position. The direction of rotation of first wrapping element 44 is then reversed and wrapping element 44 is rotated clockwise until it engages second wrapping element 46. Both wrapping elements 44, 46 then continue to rotate clockwise as indicated in Figure 5c causing second side portion 78 to be wrapped around conical form 20 overlapping the first side portion 76 as illustrated in Figure 5c. Wrapping elements 44, 46 then continue the clockwise rotation as illustrated in Figure 5d to complete conical element 84, and the rotation continues further until the wrapping elements 44, 46 again end up in the starting position shown in Figures 1 and 4. When the wrapping elements 44, 46 are in the position shown in Figure 5b and just prior to second side portion 78 being wrapped around first side portion 78 a shot of adhesive is applied to second side portion 76 in the location indicated by arrow 86 in Figure 5b. This adhesive is applied by an adhesive spray or applicator 88 positioned as shown in Figure 4. Any suitable adhesive may be used depending upon the material used for blank 14. After the conical element 84 has been formed on conical form 20 as in Figure 5d, the conical form 20 is retracted or separated from the conical element. To facilitate this separation, the vacuum previously applied to conical form 20 through supply hose 36 is discontinued and replaced by positive air pressure to help release the conical element from conical form 20. Vacuum head 60 is then rotated to bring the next leaf 15 into position and the procedure is repeated to make a second conical element 84. The method is continued until a disk 90 is produced as shown in Figure 7 with a conical element 84 formed on each leaf. Disk 90 having a plurality of radially arranged conical elements may itself be used as a decoration or ornament, or a plurality of disks 90 may be combined to form an ornament 12 as shown in Figures 8 to 10. Ornament 12 is made by stacking a plurality, such as seven, disks 90 in a vertical arrangement as shown in Figure 7 and compressing the centre portions of the stack of disks and connecting them together with a fastener such as a staple 92. If desired, a self-adhesive backing 94 can be placed beneath the stack of disks 90 prior to stapling them together so that ornament 12 is provided with an adhesive base as shown in Figure 9 for attaching the ornament to another object. The ornament shown in Figures 8 to 10 is produced by stacking the disks 90 as in Figure 7 such that the conical elements 84 of alternating disks are staggered as shown in Figure 7. This produces an ornament 12 which is symmetrical with evenly spaced radially orientated projecting conical elements 84. It will be appreciated that leaves 15 are centered on the conical form 20 prior to being wrapped into a conical element 84 in the preferred embodiment, and that the first and second side portions 76, 78 are wrapped transversely around conical form 20. The side portions 76, 78 are wrapped symmetrically around conical form 20, so that the axes of the conical elements are radially orientated in disk 90. The conical elements are also radially orientated in the ornament shown in Figures 8 to 10. If desired, two of the ornaments shown in Figures 8 to 10 can be put back to back to produce a spheroidal ornament rather than an hemispheroidal ornament as shown in Figures 8 to 10. This can also be done in one step by stacking the disks 90 appropriately as in Figure 7 prior to compressing the centre portions and attaching the disks together. Having described preferred embodiments of the invention, it will be appreciated that various modifications may be made to the apparatus and methods described. For example, the number of leaves in each blank can be varied as well as the shape of each leaf. Different numbers of disks 90 can be used to form ornaments and they can be coupled together in different ways as will be appreciated by persons skilled in the art. Further, conical element 20 could be positioned differently so that the longitudinal axis of the conical element is not coincident with the axis of the winder assembly 18. This would result in conical elements 84 being in an askew arrangement which may be desirable to produce different looking ornaments. Also as mentioned above, it is not necessary to independently drive the second wrapping element 46. As will be apparent from Figures 5a to 5d, if second wrapping element 46 is rotatably but frictionally held in frame 22, the first wrapping element 44 will engage and drive the second wrapping element 46 by itself. However, the independent drive means for each of the wrapping elements, 44, 46 is preferred. Finally, it is not necessary to have the first side portion 76 crimped or tucked under the second side portion 78 of leaf 15 by knife edge 54, because the vacuum of suction applied to conical element 20 should be sufficient to retain the first side portion in position while the second side portion 78 is wrapped around it to complete the conical element 84. From the above, it will be appreciated that the method and apparatus of the present invention produces a unique and esthetically pleasing ornament made of a plurality of uniformly shaped conical elements that may be combined in various arrangements as desired.

Claims: A method of producing an ornament (12) comprising a plurality of circumferentially arranged conical elements (84), said method comprising the step of (a) making said plurality of conical elements (84) from a plurality of planar blanks (14) made of flexible material each of said blanks having a central part (70) and at least one leaf (15) projecting from said central part, said at least one leaf (15) having a central portion (72) and lateral portions (76, 78) extending from said central portion; characterised in that said method comprises the additional steps of: (b) stacking the central parts (70) of said blanks (14) while disposing the conical elements (84) projecting from said central parts in a circumferential arrangement; and (c) compressing and connecting together said central parts (70) to obtain the requested ornament (fig. 7); wherein step (a) of said method is carried out as follows to make one or more of said conical elements (84) from each blank (14): providing a conical form (20) having a longitudinal axis; positioning said blank (14) at an angle with respect to said longitudinal axis suitable for pressing the central portion of one of said at least one leaf (15) of said blank against said conical form (20) with the lateral portions (76, 78) of said one leaf (15) projecting away from said conical form, on either side thereof; folding one of said projecting lateral portions (76) over said conical form (20) and holding said one lateral portion there against; applying an adhesive material to at least one of said lateral portions (76); folding the other of said projecting lateral portions (78) over the said one portion (76) with said adhesive material therebetween, whereby to form a firm conical element (84) held solid by said adhesive material; and removing said conical form (20) from said conical element (84). A method as claimed in claim 1, wherein step (a) comprises the additional step of applying a vacuum pressure to hold said one lateral portion (76) of said one leaf (15) against said conical form (20) while said other lateral portion (78) is being folded thereon and thereafter applying a positive pressure thereto to release said conical element (84) from said conical form (20). A method as claimed in claim 1, including tucking the side edge of said one lateral portion (76) under said other lateral portion (78) for retaining said one lateral portion in position while folding said other lateral portion over said one lateral portion. A method as claimed in claim 1, 2 or 3, wherein use is made in step (a) of blanks (14) whose leaves (15) have an identical essential trapezoidal shape whereby folding of said lateral portions (76, 78) around said conical form (20) in the said overlapping relation produces conical elements (84) having radially oriented axes. A method as claimed in claim 1, 2 or 3, wherein use is made in step (a) of circular blanks (14) each having a number of leaves (15) radially projecting from the central part (70) thereof and wherein said step (a) comprises the additional steps of rotating the blank (14) being processed after each of said leaves (15) has been formed into a conical element (84) and proceeding with the remaining successive leaves to form like conical elements around the central part (70) of said blank (14). An apparatus (10) for use in producing an ornament (12) comprising a plurality of circumferentially arranged conical elements (84), said apparatus being designed to make one or more of said conical elements (84) from a planar blank (14) having a central part (70) and at least one leaf (15) projecting from said central part, said at least one leaf (15) having a central portion and side portion (76, 78) extending from said central portion, characterised in that said apparatus (10) comprises: a conical form (20) having a longitudinal axis; a winder assembly (18) having means (44, 46) defining a conical bed (52, 56) extending essentially along said longitudinal axis; positioning means (16) for releasably holding said blank (14) at an angle with respect to said longitudinal axis and with one of said at least one blank leaf (15) being positioned over said conical bed (52, 56) of said winder assembly (18); means (28) for moving said conical form in a reciprocating rectilinear motion (26) along said longitudinal axis, said conical form (20) being movable between an active position, wherein said form (20) presses said central portion of said one leaf (15) into said conical bed (52, 56) with said side portions (76, 78) of said one leaf (15) bending outwardly of said conical bed (52, 56) on either side thereof, and a retracted position wherein said conical form (20) is located away from said conical bed (52, 56) and said leaf (15) wherein; means (48, 50) for rotating said conical bed (52, 56) about said longitudinal axis when said conical form (20) is in said active position, said means (48, 50) rotating said conical bed first in one direction to apply one of said leaf side portions (76) over said conical form (20) and then in reverse direction to apply the other side portion (78) over said conical form (20) in overlapping relation with said one side portion (76), whereby to form a conical element (84); means (32, 34, 36) for holding said one leaf (15) against said conical form (20) during rotation of said conical bed (52, 56) and subsequently for releasing said leaf (15) from said conical form (20); means (88) for applying an adhesive material to at least one of said side portions (76) to retain said conical element (84) in conical configuration. An apparatus as claimed in claim 6, wherein said winder assembly (18) includes a first wrapping element (44) and a second wrapping element (46) each wrapping element (44, 46) having a conical bed portion (52, 56), said bed portions cooperating together to form said conical bed; wherein said second wrapping element (46) is mounted on a support frame (22) for rotation about said longitudinal axis; and wherein said means (48, 50) for rotating said conical bed is operably connected to said first wrapping element (44) so that rotation of said first element (44), in one direction, wraps one of said leaf side portions (76) about said conical form (20) and subsequent rotation of said first element (44) in reverse direction drives said second element (46) to wrap the other leaf side portion (78) over said first portion (76). An apparatus as claimed in claim 6, wherein said winder assembly (18) includes a first wrapping element (44) and a second wrapping element (46), each wrapping element (44, 46) having a conical bed portion (52, 56); said bed portions cooperating together to form said conical bed; and wherein said means (48, 50) for rotating said conical bed is operably coupled to each wrapping element for rotating each wrapping element independently about said conical form (20) successively in reverse directions, said wrapping elements (44, 46) thereby consecutively wrapping said leaf side portions (52, 56) over said conical form (20) and over one another. An apparatus as claimed in claim 6, 7 or 8, wherein said conical form (20) has an internal passage (32) between the ends thereof and said holding and releasing means comprise vacuum applying and positive pressure applying means (36) operatively connected to said passage and suitable to cause said one leaf (15) to adhere to and be released from said conical form (20). An apparatus as claimed in claim 7 or 8, wherein said conical bed portion (56) of said second wrapping element (46) has one bevelled longitudinal edge (58) and wherein said conical bed portion (52) of said first wrapping element (44) has one longitudinal knife edge (54) adapted to mate with said bevelled edge (58) to crimp one side (76) of said leaf side portions under the opposite side portion (78) of said one leaf (15) upon rotation of said wrapping elements. An apparatus as claimed in claim 6, 7 or 8, wherein said planar blank (14) has a central part (70) and a plurality of leaves (15) radially projecting from said central part and wherein said positioning means (16) includes: a rotatable vacuum head (60) for retaining said central part (70) of said blank, said vacuum head (60) being oriented obliquely relative to said longitudinal axis for holding one leaf (15) of said blank (12) at a time over said conical bed, said vacuum head (60) having a central axis intersecting said longitudinal axis of said conical form (20); and means for rotating the vacuum head 60 for positioning each of the blank leaves (15) successively over said conical bed (52, 56) for the formation of a same number of conical elements (84).

Inventors: MANCEL, JAMES D., RAINSKUMS, OLAF B.
Applicants: RAINBOW STAR LICENSING S.A.
Application year: 1986
Main classification: D04D7
IPC codes: B31F5, A41G1, B31F7, D04D7, D04D9, B31F1