Method and apparatus for making spiral garland

Information

  • Patent Grant
  • 6260342
  • Patent Number
    6,260,342
  • Date Filed
    Friday, November 19, 1999
    25 years ago
  • Date Issued
    Tuesday, July 17, 2001
    23 years ago
Abstract
A machine is provided for forming a decorative twisted spiral garland from at least one continuous ribbon web, and a pair of continuous wires. One or more ribbon webs are guided to the outside of a pair of elongated threaded rods which are respectively disposed on opposite sides of and generally parallel to a main axis. The rods form part of a loop frame which is rotated about the main axis to wind the ribbon webs around the rods in a series of continuous loops and draw the webs from supply reels, while the rods are simultaneously rotated about their own axes to advance the ribbon loops along the main axis. A wire supply rotates in synchronism with the loop frame, guiding a pair of wires into paths respectively on opposite sides of the ribbon loops and thence along the main axis between pinch rollers for pulling the wires longitudinally along the axis. The rotation of the wire supply twists the wires and the ribbon loops to form the garland. The final shape of the garland is determined by the amount of twist imparted to it, which can be controlled, in part, by collecting the garland in a rotating drum to partially “untwist” the garland. Filaments may also be guided from supply reels rotating with the loop frame into paths inside the loops, so as to be twisted with the ribbon loops, the twisting drawing the filaments to the axis in the finished garland.
Description




BACKGROUND OF THE INVENTION




The present invention relates to decorative garlands and, in particular, to techniques for forming such garlands.




Various types of decorative garlands, used for decorating Christmas trees, wreathes, and the like, have been heretofore provided. Generally, for purposes of mass production of such garlands specialized machinery is developed specific to each particular type of garland. Also, for many such garlands, the garland material must first be prepared in a specialized form for processing by the garland-making machinery. One such type of preparation involves the slitting of sheets of material to produce a desired effect in the finished garland, garlands of this type being disclosed, for example, in U.S. Pat. Nos. 3,484,329, 4,789,571 and 5,201,699.




SUMMARY OF THE INVENTION




It is a general object of the invention to provide a method of forming a novel type of decorative garland from standard supplies of commonly available materials, such as ribbons, wires and filament strands, which materials require no special processing or preparation before formation of the garland.




Another feature of the invention is the provision of a method of the type set forth, which is capable of forming a variety of different garland designs having different appearances, from the same starting materials.




In connection with the foregoing features, another feature of the invention is provision of an apparatus for performing a method of the type set forth.




More specifically, applicant has devised a novel garland design, details of which are disclosed in applicant's co-pending application Ser. No. 09/444,228, filed on even date herewith and entitled “Twisted Spiral Garland” (case 117). The garland is formed essentially by generating loops of ribbon and twisting the ribbon loops together with a pair of wires to produce a number of different unique garland designs, depending upon the amount of twist imparted to the materials. The present invention is directed to the method and apparatus for forming that garland.




Certain ones of these and other features of the invention may be attained by providing an apparatus for forming a decorative twisted spiral garland from at least one continuous ribbon web from a ribbon supply, and a pair of continuous wires from a wire supply, the apparatus comprising: structure establishing an axis, a loop frame including a pair of spaced elongated rods extending alongside the axis, ribbon guide mechanism for guiding the at least one ribbon web from the ribbon supply to the outside of the loop frame, a loop-forming drive assembly rotating at least one of the loop frame and the ribbon supply about the axis for wrapping the ribbon web around the loop frame to form a series of ribbon loops, a wire guide assembly for guiding the wires from the wire supply respectively into paths substantially parallel to the axis and outside of and respectively along opposite sides of the ribbon loops, a twist drive assembly for twisting the wires together in a spiral along the axis thereby to twist the ribbon loops, and a withdrawal mechanism engageable with the twisted wires and ribbon loops for advancing them along the axis simultaneously with forming of the loops and twisting of the wires to withdraw the loops from the loop frame and form an elongated twisted spiral garland.




Other features of the invention are attained by providing an apparatus of the type set forth which forms a garland including at least one filament guided along a path parallel to the main axis.




Still other features of the invention are attained by providing an apparatus of the type set forth, wherein the wire supply includes a ring coaxial with the main axis, and wherein wire supply reels are mounted on the ring for rotation respectively about parallel reel axes disposed on opposite sides of the main axis and defining a plane substantially perpendicular to the main axis, the twist drive assembly rotating the ring to twist the wires.




Other features of the invention are attained by providing a method of forming a decorative twisted spiral garland from at least one continuous ribbon web from a ribbon supply and a pair of continuous wires from a wire supply, the method comprising: wrapping the at least one ribbon web from the ribbon supply around a loop frame to form a series of ribbon loops about an axis, guiding the wires from the wire supply respectively into paths extending substantially parallel to the axis and outside of and respectively along opposite sides of the ribbon loops, twisting the wires together in a spiral along the axis thereby to twist the ribbon loops, and advancing the twisted wires and ribbon loops along the axis to withdraw the loops from the loop frame and form an elongated twisted spiral garland.




The invention consists of certain novel features and a combination of parts hereinafter fully described, illustrated in the accompanying drawings, and particularly pointed out in the appended claims, it being understood that various changes in the details may be made without departing from the spirit, or sacrificing any of the advantages of the present invention.











BRIEF DESCRIPTION OF THE DRAWINGS




For the purpose of facilitating an understanding of the invention, there is illustrated in the accompanying drawings a preferred embodiment thereof, from an inspection of which, when considered in connection with the following description, the invention, its construction and operation, and many of its advantages should be readily understood and appreciated.





FIG. 1

is a side elevational view of garland-forming machine constructed in accordance with and embodying features of the present invention and including a forming station and a garland collecting station;





FIG. 2

is an enlarged end elevational view of the garland-forming station of the machine of

FIG. 1

, as viewed from the right-hand end thereof;





FIG. 3

is an enlarged end elevational view of the garland-forming station of the machine of

FIG. 1

, as viewed from the left-hand end thereof;





FIG. 4

is a further enlarged, fragmentary view in vertical section taken along the line


4





4


in

FIG. 3

;





FIG. 5

is a further enlargement of a portion of

FIG. 4

;





FIG. 6

is a further enlarged, fragmentary sectional view, taken generally along the line


6





6


in

FIG. 4

;





FIG. 7

is a further enlarged, fragmentary view in horizontal section, taken generally along the line


7





7


in

FIG. 5

;





FIG. 8

is a view similar to

FIG. 7

, illustrating formation of the ribbon loops and the finished garland;





FIG. 9

is a further enlarged sectional view taken generally along the line


9





9


in

FIG. 8

;





FIG. 10

is a further enlarged, fragmentary, sectional view taken generally along the line


10





10


in

FIG. 8

;





FIG. 11

is a further enlarged, fragmentary, sectional view of the central portion of

FIG. 10

;





FIG. 12

is a side elevational view of a length of finished garland produced by the machine of

FIG. 1

; and





FIG. 13

is an end elevational view of the garland of FIG.


12


.











DESCRIPTION OF THE PREFERRED EMBODIMENT




Referring to

FIG. 1

, there is illustrated a machine, generally designated by the numeral


15


, constructed in accordance with embodying features of the present invention, for forming the decorative spiral garland of

FIGS. 12 and 13

, the details of which garland are further described in the aforementioned co-pending U.S. patent application Ser. No. 09/444,228. The machine


15


has two basic portions, including a forming station


20


and a collecting station


130


, which may be mounted on separate frames.




As was indicated above,

FIG. 1

shows what will hereinafter will be referred to as the front side of the machine


15


, the opposite side (the left-hand side of

FIG. 3

) being hereinafter referred to as the rear side. Also, for purposes of discussion, the opposite ends of the machine


15


or any portion thereof will be referred to as “left-hand” and “right-hand” ends, as viewed in FIG.


1


.




Referring also to

FIGS. 2-4

, the forming station


20


has a base frame


21


including a pair of upstanding front posts


22


, respectively provided at their lower ends with adjustable feet


23


. The posts


22


are connected at their lower ends by a lower side beam


24


, and are also respectively connected to rearwardly extending end beams


25


substantially perpendicular to the side beam


24


, the end beams


25


being provided at their rear ends with adjustable feet


26


. The posts


22


are connected intermediate their ends by a side beam


27


. Upstanding from the lower end beams


25


intermediate their ends are a pair of rear posts


28


respectively joined by diagonal struts


29


to the rear ends of the lower end beams


25


. The posts


28


are interconnected intermediate their ends by a side beam


30


and at their upper ends by an angle iron beam


31


. A rectangular mounting plate


32


is fixed to the right-hand one of the posts


28


adjacent to its upper end. The posts


22


and


28


, at the left-hand end of the frame


21


, are interconnected by horizontal end beams


33


and


34


(FIG.


3


), while the posts


22


and


28


at the right-hand of the frame


21


are interconnected by beams


35


and


36


(FIG.


2


). The frame


21


also carries three rectangular corner plates


37


at the junctures of the beams


35


and


36


with the posts


22


and


28


(FIG.


2


). At the left-hand end of the machine


15


, the posts


22


and


28


are also joined by large rectangular mounting plate


38


(FIG.


3


).




Respectively upstanding from the beams


27


and


30


intermediate their ends are posts


39


, interconnected at their upper ends by a cross beam


39




a


(FIG.


4


). Mounted on the cross beam


39




a


intermediate its ends is a bearing


40


, in which is journalled one end of a tubular main shaft


41


, which extends horizontally and is connected at its opposite end to a tubular extension


42


which is journalled in a bearing


43


mounted on the end beam


33


. The main shaft


41


has a longitudinal axis which defines a main axis “X” of the machine


15


(see FIGS.


4


and


7


). Disposed within the distal end of the extension


42


is a bearing


44


, in which is journalled one end of an inner shaft


45


, the opposite end of which is journalled in a bearing block


46


fixed to the right-hand end of the main shaft


41


, as can best be seen in

FIG. 4

, so that the shafts


41


and


45


are coaxial. Formed through the main shaft


41


are a pair of diametrically opposed rear openings


47


and a pair of diametrically opposed front openings


48


, for a purpose to be explained more fully below.




The forming station


20


also includes a loop frame, generally designated by the numeral


50


, carried by the bearing block


46


. More specifically, referring to

FIGS. 5 and 7

, the loop frame


50


includes a first angle bracket


51


fixed to the bearing block


46


and having a flange


52


projecting therefrom and carrying a bearing block


53


, in which is journalled an elongated, externally screw-threaded rod


54


. Mounted on the bearing block


46


on the opposite side of the main axis from the angle bracket


51


is an angle bracket


55


, having a flange


56


on which is mounted a bearing block


57


in which is journalled a second screw-threaded rod


58


. The rods


54


and


58


are respectively disposed on opposite sides of the main axis “X” and extend generally parallel thereto, although preferably the rods are slightly inclined to the main axis so that they converge slightly toward their distal or right-hand ends, as can best be seen in FIG.


7


.




The forming station


20


also includes a filament supply


60


which is mounted on the main shaft


41


for providing one or more strands of filament, such as monofilament fiber. More specifically, referring in particular to

FIG. 4

, the filament supply


60


includes a pair of mounting brackets


61


respectively projecting radially outwardly from diametrically opposed locations adjacent to the left-hand end of the main shaft


41


. The mounting brackets


61


respectively carry sets of bushings


62


in which are received spindles or shafts


63


on which monofilament spools


64


respectively freely rotate, the spindles


63


preferably being disposed substantially parallel to the main axis “X”. Monofilament strands


65


from the spools


64


are respectively passed through guide tubes


66


, which are fitted through the openings


47


and


48


in the main shaft


41


to clear the bearing


40


, and then continue to exit ends


67


adjacent to the left-hand ends of the rods


54


and


58


. Preferably, the guide tubes


66


substantially define a plane which includes the main axis “X” and is substantially perpendicular to the plane defined by the rods


54


and


58


. However, the exit ends


67


are preferably bent out of the plane, one toward the rod


54


and one toward the rod


58


, as can best be seen in

FIGS. 5 and 7

.




The forming station


20


also includes a wire assembly, generally designated by the numeral


70


, which includes a circular support ring


71


disposed substantially coaxial with the main axis “X” and having a cylindrical flange


72


and an annular flange


73


. The flange


73


is provided with a guide edge


74


, generally V-shaped in transverse cross-section (

FIG. 5

) disposed for guiding engagement in the grooves of a plurality of grooved support rollers


75


, the shafts of which are respectively mounted on the mounting plate


32


and the corner plates


37


(see FIG.


2


). Preferably, four of the rollers


75


are provided at equiangularly spaced-apart locations for stably supporting the ring


71


for rotation about the main axis.




Spanning the ring


71


and fixed to the annular flange


73


thereof along parallel chords of the ring


71


are a pair of support bars


78


and


79


for supporting a wire supply, generally designated by the numeral


80


. Referring in particular to

FIGS. 4-7

, the wire supply


80


includes two pairs of blocks


81


, respectively supported on the support bars


78


and


79


adjacent to one end thereof, and two pairs of blocks


82


, respectively supported on the support bars


78


and


79


adjacent to the opposite ends thereof. Two shafts or spindles


83


are respectively mounted in the blocks


81


and


82


, so that they are disposed at opposite sides of the main axis and define a plane substantially perpendicular to the main axis. The shafts


83


respectively rotatably support two spools


84


of wires


85


, which are guided over a wire guide assembly which includes a pair of diametrically opposed brackets


86


.




Each of the brackets


86


has a cross bar


87


which extends perpendicular to the main axis “X” and is provided at its opposite ends with attachment flanges


88


, respectively fixed to adjacent ones of the blocks


81


(or


82


). Each cross bar


87


carries, intermediate its ends, a depending clevis bracket


89


, which projects inwardly toward the main axis, the brackets


89


respectively rotatably supporting wire guide wheels


90


. More specifically, each of the guide wheels


90


has a shaft


91


disposed in complementary openings in the arms of the associated clevis bracket


89


, the opposite ends of the shafts


91


being secured in place by suitable clips


92


(FIG.


7


). Each guide wheel


90


has a circumferential groove


93


for receiving and positively guiding the associated wire


85


. More specifically, referring to

FIG. 5

, each wire


85


is guided from the outer side of its associated spool


84


and over the outer side of an associated guide wheel


90


, wrapping part way around the wheel


90


and then back between the wheels


90


along the main axis “X” and toward the ring


71


.




The forming station


20


also includes a ribbon supply


95


, which includes two spools


96


and


96


A of ribbon, respectively mounted for rotation about shafts or spindles


97


and


97


A mounted on the base frame


21


, as on the beams


36


and


35


. The spools


96


and


96


A may carry different types of ribbon, such as different colors, different materials, or the like, or the same type of ribbon, the ribbon webs


99


and


99


A respectively being guided through a guide mechanism


100


to the loop frame


50


. Referring in particular to

FIGS. 5 and 6

, the guide mechanism


100


includes a pair of horizontal support bars


101


and


101


A, preferably angle irons, spanning the posts


22


and


28


at vertically spaced locations adjacent to the wire assembly


70


. Respectively mounted on the support bars


101


and


101


A are a pair of guide brackets


102


and


102


A, each being a generally Z-shaped bar, and respectively having guide slots


103


and


103


A in the distal ends thereof. The guide mechanism


100


also includes a pair of dancer frames


104


and


104


A, which are of identical construction. The dancer frames


104


and


104


A respectively have pivot shafts


105


and


105


A, which are rotatably mounted in suitable bearings carried by the support bars


101


and


101


A, respectively. The dancer frames


104


and


104


A rotatably carry at their opposite ends pulleys


106


,


107


, and


106


A,


107


A, and are also provided with anchor pins


108


,


108


A, which are respectively connected to inner ends of helical tension springs


109


,


109


A, the outer ends of which are respectively anchored on the posts


22


and


28


.




In use, the ribbon webs


99


and


99


A are respectively guided through the dancer frames


104


and


104


A and the guide slots


103


and


103


A to the loop frame


50


in the same manner, but from opposite sides of the main axis “X”. Referring, by way of example, to the ribbon web


99


, as viewed in

FIG. 6

, it first passes counterclockwise around the pulley


106


and then clockwise around the pulley


107


, back under the pulley


106


and then through the slot


103


from the outside to the inside thereof, and thence to the loop frame


50


. It will be appreciated that the dancer frames


104


and


104




a


take up slack in the webs


99


and


99


A.




Referring in particular to

FIGS. 1-5

, the forming station


20


also includes a drive assembly, generally designated by the numeral


110


, including a main motor


111


mounted by means of a suitable mounting bracket


112


on the base frame


21


. The motor


111


drives an output shaft


113


, which is journalled in bearings


114


and


115


and extends substantially parallel to the main axis “X.” The shaft


113


carries a pulley


116


, which is coupled by a drive belt


117


to the cylindrical flange


72


of the support ring


71


of the wire assembly


70


, for rotating same about the main axis in the direction of the arrows in

FIGS. 2 and 6

. The shaft


113


also carries a pulley


118


, which is coupled by a belt


119


to a pulley


120


mounted on the rear extension


42


of the main shaft


41


for effecting rotation thereof (see

FIG. 4

) in the direction of the arrow in FIG.


3


. The sizes of the several pulleys are selected so that the support ring


71


and the main shaft


41


rotate in synchronism, so that the orientation of the loop frame


50


relative to the wire supply guide wheels


90


remains fixed. In this regard the belts


117


and


119


are timing belts and the pulleys


116


,


118


and


120


and the flange


72


are appropriately toothed (not shown).




The forming station


20


also includes a drive motor


121


mounted by means of a suitable bracket on the mounting plate


38


and having a shaft


123


with a pulley


124


coupled by a belt


125


to a pulley


126


fixed to the inner shaft


45


, for effecting rotation thereof relative to the main shaft


41


. Referring in particular to

FIGS. 5 and 7

, the inner shaft


45


also carries two pulleys


127


, respectively coupled by drive belts


128


to pulleys


129


, which are respectively carried by the rear ends of the loop frame rods


54


and


58


for effecting rotation of the rods


54


and


58


about their longitudinal axes in the direction of the arrows in FIG.


7


. This rotation of the threaded rods


54


and


58


, together with the slight convergence thereof, facilitates advancing loops of the ribbon webs


99


and


99


A into the guide wheels


90


and their subsequent removal from the loop frame


50


, as will be explained more fully below.




Referring to

FIG. 1

, the collecting station


130


is disposed adjacent to the right-hand end of the forming station


20


and there is disposed thereat a collection assembly


131


mounted on a frame


132


. The frame


32


may be discrete from the base frame


21


and includes a mounting bracket


133


supporting a withdrawal motor


134


, which is coupled through suitable gear reduction and drive linkage for rotating a pair of pinch rollers


135


about axes disposed substantially perpendicular to the main axis “X” and on opposite sides thereof. An inclined support


136


supports a guide spool


137


, which is rotated about an axis parallel to the axes of the pinch rollers


135


by a drive chain


138


. Disposed beneath the guide spool


137


is the open upper end of a guide tube


140


journalled in a bearing


141


on the frame


132


for rotation about a substantially vertical axis in the direction of the arrow in FIG.


1


. The guide tube


140


has an elbow


142


at its lower end and is coupled at its upper end by a drive belt


143


to a pulley


144


on the output shaft of a suitable gear reducer


145


driven by a motor


146


supported on the frame


132


for rotating the guide tube


140


. Disposed beneath the guide tube


140


and the elbow


142


thereof is a collection drum


150


having a vertical shaft


151


depending therefrom journalled in a bearing


152


on the frame


132


and carrying a pulley


153


. The pulley


153


is coupled by a belt


154


to a pulley


155


at the output of a suitable gear reducer


156


of a drive motor


157


, which may be mounted on or adjacent to the frame


132


for effecting rotation of the drum


150


about the axis of the shaft


151


, which is preferably substantially coaxial with the guide tube


140


.




Referring now to

FIGS. 5-8

, the setup of the machine


15


for operation will be described. Initially, the drive assembly


110


may be manually adjusted so as to bring the loop frame


50


into the position illustrated in the drawings, with the threaded rods


54


and


58


disposed in a substantially horizontal plane. The wires


85


are then respectively threaded around and between the guide wheels


90


in the manner illustrated in

FIGS. 5 and 7

and then pulled sufficiently to the right, in the direction of the large arrows in

FIG. 1

, so as to be gripped between the pinch rollers


135


. Similarly, the filaments


65


are respectively pulled along opposite sides of the guide wheels


90


and pulled out sufficiently to be gripped between the pinch rollers


135


. Then the leading end of the ribbon web


99


A is threaded through the associated portion of the guide mechanism


100


as described above, and then passed over the tops of the rods


54


and


58


, then back under the rods


58


and


54


and then back over the rods


54


and


58


to form one and a half turns or coils of loops


170


A. The loops


170


A are arranged in a helical spiral such that the adjacent lengths of each loop extending across the tops of the rods


54


and


58


are spaced apart a pitch distance substantially equal to the width of the ribbon web


99


A. While the manual wrapping of one and a half turns is illustrated, additional turns could be manually wrapped until the leading end of the ribbon web


99


A reaches the guide wheels


90


, at which point it is pinched between those wheels to hold it in place. Then the other ribbon web


99


, after having been passed through the guide mechanism


100


as described above, is passed beneath the rods


58


and


54


, then back over the rods


54


and


58


in the gap between the coils of the loops


170


A, and then back beneath the rods


58


and


54


to form essentially one and a half turns of the loop


170


. Again, the manual wrapping may continue until the leading end of the web


99


reaches the guide wheels


90


and is then pinched therebetween to hold it in place. At this point, the leading ends of the ribbon loops


170


,


170


A are disposed between the guide wheels


90


, surrounding the filaments


65


and disposed between the wires


85


, as can best be seen in

FIGS. 10 and 11

, and the machine


15


is ready for operation.




Preferably, there is provided a suitable control mechanism (not shown) such that all of the motors of the machine


15


can be started substantially simultaneously. The main motor


111


will rotate the wire assembly


70


and the main shaft


41


in synchronism. The rotation of the wire assembly


70


twists the wires


85


about each other and, because they are disposed along the outside of the ribbon loops


170


,


170


A, simultaneously twists those loops as they exit the guide wheels


90


and the rods


54


and


58


. The twisted ribbon loops, along with wires


85


and the filament


65


, are pulled along the main axis “X” by the action of the pinch rollers


135


. The twisting of the ribbon loops


170


and


170


A also twists the filaments


60


and


65


and pulls them in toward the main axis “X”. The twisting of the wires


85


, the filaments


65


and the ribbon loops


170


,


170


A forms the assembled parts into a spiral garland


175


.




More specifically, referring to

FIGS. 12 and 13

, the twisting action tends to take each loop


170


,


170


A and eventually fold it in half, with each loop


170


forming two adjacent half loops


177


and each loop


170


A forming two adjacent half loops


179


, the half loops


177


of ribbon web


99


forming a first helix or spiral


176


, and the half loops


179


of the other ribbon


99


A forming a second helix or spiral


178


. There results an essentially double-helix configuration of the type illustrated in FIG.


12


. During the twisting process, the filaments


65


as a result of the folding of the loops into half loops, wind up in the finished garland


175


along the main axis “X” and help to maintain the creases in the loop folds.




The operation of the pinch rollers


135


serves to continuously withdraw the garland


175


from the forming station


20


, the pinching action of the rollers serving to stop the twist of the wires


85


. Thus, it will be appreciated that the rate of rotation of the pinch rollers


135


controls the rate at which the product is withdrawn from the forming station


20


. The pinch rollers


135


feed the finished garland


175


, around the guide spool


137


and then downwardly into the guide


140


, the rotation of which lays the garland


175


into continuous coil loops


160


in the bottom of the drum


150


. The drum


150


may be removably mounted on the shaft


151


, so that when it is full the garland


175


can be cut and a full drum


150


removed and replaced with an empty drum.




It has been found that, when the operational speeds of the various moving parts of the forming station


20


are set for optimal operation of the machine, this may result in the garland


175


being slightly overtwisted as it exits the forming station


20


, resulting in a spiral with a very large pitch and a somewhat flattened appearance, as indicated at


173


in

FIGS. 1 and 8

. This may be adjusted at the collecting station


130


. More specifically, the guide


140


and the drum


150


are both rotated in the direction of the arrow in

FIG. 1

, at relative speeds selected to impart a slight reverse twist to the garland


175


, this untwisting reducing the pitch of, or tightening the spiral as it exits the guide spool


137


.




The pitch or tightness of the double helices of the spiral garland


175


is controlled in part by the rate of rotation of the pinch rollers


135


and their spacing from the forming station


20


, relative to the twist rate of the wires


85


imparted by the wire assembly


70


, and in part by the amount of reverse twist imparted by the rotation of the drum


150


. It is a significant aspect of the method of the invention that the amount of twist imparted to the ribbons and wires can be adjusted so as to result in a variety of different shapes and appearances of finished garland, examples of which are illustrated in the aforementioned copending application Ser. No. 09/444,228. While this adjustability is limited in the machine


15


, as explained above, in accordance with the method of the present invention greater adjustability could be achieved with other apparatus.




While, for purposes of illustration, a garland


175


comprising two ribbon webs and two mono-filaments has been shown, it will be appreciated that the present machine and method are operable for producing finished garlands using only a single ribbon web and either a single filament or no filament at all. Also, strands of other material, such as yarn, could be used in place of the monofilament. It will be appreciated that, if only a single ribbon web is used, there will result a spiral garland comprising only a single helix of folded half loops. Also, while in the illustrated embodiment the ribbon loops


170


,


170


A are arranged on the loop frame


50


with a pitch substantially equal to the width of the ribbon webs, the loops could be arranged with a greater or lesser pitch, resulting in spaces between adjacent loops or overlapping of the loops, resulting in different appearances of the finished garland.




The speed of rotation of the rods


54


and


58


is not critical but should be sufficiently high that the ribbon loops are fed into the guide rollers


90


at a rate at least as great as the rate at which the wires


85


are being pulled from the forming station


20


by the pinch rollers


135


.




It would also be possible to utilize more than two ribbons, in which case the ribbon webs would preferably be guided to the loop frame


50


from locations equiangularly spaced about the main axis.




In the preferred embodiment, the ribbon loops


170


,


170


A are formed by rotating the loop frame


50


relative to the ribbon supply


95


. However, it will be appreciated that the same effect could be achieved by holding the loop frame


50


fixed and rotating the ribbon supply


95


about the main axis. Similarly, while, in the preferred embodiment, the wire twist is effected by rotating the entire wire assembly


70


, a similar result could be achieved by holding the wire assembly


70


fixed and imparting twist to the wires by utilizing a rotating withdrawal mechanism in place of the pinch rollers


135


. Also, while particular rotation directions have been described, they could all be reversed and produce a garland with substantially the same appearance as the garland


175


. However, in that case the direction of the threads on the rods


54


and


58


should also preferably be reversed.




From the foregoing, it can be seen that there has been provided a method and apparatus for forming a unique, continuous, spiral garland from a pair of wires and one or more ribbon webs, the garland also optionally including one or more filaments, the unique shape of the finished garland being effected by forming the ribbon web into continuous loops and twisting the loops by twisting the wires. The method and apparatus is capable of producing a wide variety of finished garland shapes by varying the number of ribbon webs used, the pitch of the ribbon loops and the extent of twist imparted thereto.




While particular embodiments of the present invention have been shown and described, it will be apparent to those skilled in the art that changes and modifications may be made without departing from the invention in its broader aspects. Therefore, the aim in the appended claims is to cover all such changes and modifications as fall within the true spirit and scope of the invention. The matter set forth in the foregoing description and accompanying drawings is offered by way of illustration only and not as a limitation. The actual scope of the invention is intended to be defined in the following claims, when viewed in their proper perspective based on the prior art.



Claims
  • 1. An apparatus for forming a decorative twisted spiral garland from at least one continuous ribbon web from a ribbon supply, and a pair of continuous wires from a wire supply, the apparatus comprising:structure establishing an axis, a loop frame including a pair of spaced elongated rods extending alongside the axis, ribbon guide mechanism for guiding the at least one ribbon strip from the ribbon supply to the outside of the loop frame, a loop-forming drive assembly rotating at least one of the loop frame and the ribbon supply about the axis for wrapping the ribbon strip around the loop frame to form a series of ribbon loops, a wire guide assembly for guiding the wires from the wire supply respectively into paths substantially parallel to the axis and outside of and respectively along opposite sides of the ribbon loops, a twist drive assembly for twisting the wires together in a spiral along the axis thereby to twist the ribbon loops, and a withdrawal mechanism engageable with the twisted wires and ribbon loops for advancing them along the axis simultaneously with forming of the loops and twisting of the wires to withdraw the loops from the loop frame and form an elongated twisted spiral garland.
  • 2. The apparatus of claim 1, wherein each of said rods is externally threaded.
  • 3. The apparatus of claim 2, wherein each of said rods has a longitudinal axis, and further comprising rod drive mechanism coupled to said rods for effecting rotation thereof respectively about their longitudinal axes.
  • 4. The apparatus of claim 3, wherein said rods have distal ends disposed adjacent to said wire guide assembly said rods converging slightly toward their distal ends.
  • 5. The apparatus of claim 1, wherein the ribbon supply includes plural ribbon webs respectively guided from locations angularly spaced about said axis.
  • 6. The apparatus of claim 5, wherein said ribbon supply includes two ribbon webs guided from opposite sides of said axis.
  • 7. The apparatus of claim 1, wherein said loop frame drive assembly includes means for rotating the loop frame about said axis relative to the ribbon supply.
  • 8. The apparatus of claim 7, wherein said twist drive assembly includes means for rotating said wire guide assembly about said axis.
  • 9. The apparatus of claim 8, wherein said loop frame and said wire guide assembly are rotated in synchronism.
  • 10. The apparatus of claim 1, wherein said withdrawal mechanism includes a pair of pinch rollers between which said twisted spiral garland is guided.
  • 11. The apparatus of claim 1, and further comprising collection apparatus disposed adjacent to said withdrawal mechanism for collecting the continuous twisted spiral garland.
  • 12. The apparatus of claim 11, wherein said collection apparatus includes a drum rotating in a direction and at a speed so as to partially untwist the garland.
  • 13. An apparatus for forming a decorative twisted spiral garland from at least one continuous ribbon web from a ribbon supply, at least one filament from a filament supply, and a pair of continuous wires from a wire supply, the apparatus comprising:structure establishing an axis, a loop frame including a pair of spaced elongated rods extending alongside the axis, ribbon guide mechanism for guiding the at least one ribbon strip from the ribbon supply to the outside of the loop frame, a loop-forming drive assembly rotating at least one of the loop frame and the ribbon supply about the axis for wrapping the ribbon strip around the loop frame to form a series of ribbon loops, a filament guide mechanism for guiding the at least one filament from the filament supply into a filament path inside the ribbon loops, a wire guide assembly for guiding the wires from the wire supply respectively into paths substantially parallel to the axis and outside of and respectively along opposite sides of the ribbon loops, a twist drive assembly for twisting the wires together in a spiral along the axis thereby to twist the ribbon loops and the at least one filament, and a withdrawal mechanism engageable with the twisted wires and ribbon loops and at least one filament for advancing them along the axis simultaneously with forming of the loops and twisting of the wires to withdraw the loops from the loop frame and form an elongated twisted spiral garland.
  • 14. The apparatus of claim 13, wherein the filament supply includes two filaments respectively guided from opposite sides of said axis.
  • 15. The apparatus of claim 14, wherein said twist drive assembly includes means for rotating said wire guide assembly about said axis.
  • 16. The apparatus of claim 15, wherein the filament supply is coupled to said loop-forming drive assembly for rotation of the filament supply synchronously with the loop frame.
  • 17. The apparatus of claim 13, wherein the ribbon supply includes plural ribbon webs respectively guided from locations angularly spaced about said axis.
  • 18. An apparatus for forming a decorative twisted spiral garland from at least one continuous ribbon web guided from a ribbon supply, and a pair of continuous wires from a wire supply, the apparatus comprising:structure establishing a main axis, a loop frame including a pair of spaced elongated rods extending alongside the main axis, ribbon guide mechanism for guiding the at least one ribbon strip from the ribbon supply to the outside of the loop frame, a loop-forming drive assembly rotating at least one of the loop frame and the ribbon supply about the main axis for wrapping the ribbon strip around the loop frame to form a series of ribbon loops, the wire supply including a ring coaxial with the main axis and a pair of wire supply reels mounted on said ring for rotation respectively about parallel reel axes disposed on opposite sides of the main axis and defining a plane substantially perpendicular to the main axis, a wire guide assembly for guiding the wires from the wire supply reels respectively into paths substantially parallel to the main axis and outside of and respectively along opposite sides of the ribbon loops, a twist mechanism coupled to the ring for rotating it about the main axis for twisting the wires together in a spiral along the main axis thereby to twist the ribbon loops, and a withdrawal mechanism engageable with the twisted wires and ribbon loops for advancing them along the main axis simultaneously with forming of the loops and twisting of the wires to withdraw the loops from the loop frame and form an elongated twisted spiral garland.
  • 19. The apparatus of claim 18, wherein said wire supply includes support mechanism for supporting said ring externally thereof.
  • 20. The apparatus of claim 19, wherein said support mechanism includes a plurality of rollers equiangularly spaced about said main axis and engaging an outer surface of said ring.
  • 21. The apparatus of claim 18, wherein said twist mechanism includes a drive belt engageable with an outer surface of the ring for rotating it about the main axis.
  • 22. The apparatus of claim 21, further comprising means coupling said twist mechanism with said loop-forming drive assembly for rotating the ring and the loop frame in synchronism.
  • 23. A method of forming a decorative twisted spiral garland from at least one continuous ribbon web from a ribbon supply and a pair of continuous wires from a wire supply, the method comprising:wrapping the at least one ribbon web from the ribbon supply around a loop frame to form a series of ribbon loops about an axis, guiding the wires from the wire supply respectively into paths extending substantially parallel to the axis and outside of and respectively along opposite sides of the ribbon loops, twisting the wires together in a spiral along the axis thereby to twist the ribbon loops, and simultaneously with forming of the ribbon loops and twisting of the wires, advancing the twisted wires and ribbon loops along the axis to withdraw the loops from the loop frame and form an elongated twisted spiral garland.
  • 24. The method of claim 23, wherein the wrapping includes wrapping two ribbons around the loop frame from opposite sides thereof.
  • 25. The method of claim 23, wherein the wrapping includes rotating the loop frame so as to draw the ribbon web from the ribbon supply and wrap it around the loop frame.
  • 26. The method of claim 25, wherein the wires are twisted at the same rate as the rotation of the loop frame.
  • 27. The method of claim 23, and further including guiding at least one filament from a filament supply into a filament path inside the ribbon loops.
  • 28. The method of claim 23, and further comprising collecting the formed twisted spiral garland.
  • 29. The method of claim 28, wherein the collecting includes the arranging the continuous twisted spiral garland in coils.
  • 30. The method of claim 28, wherein the collecting includes partially untwisting the garland.
US Referenced Citations (16)
Number Name Date Kind
RE. 35897 Protz, Jr. Sep 1998
60013 King Nov 1866
1994926 Schlegel Mar 1935
2304281 Riley Dec 1942
2851715 Goodloe Sep 1958
3453170 Jason Jul 1969
3484329 Boisse Dec 1969
3732679 Sohr May 1973
3832841 Cole Sep 1974
4148178 Raschle Apr 1979
4575472 Lefferts Mar 1986
4789571 Kinderman et al. Dec 1988
4957784 Ripamonti Sep 1990
5183442 Lefferts Feb 1993
5201699 Protz, Jr. Apr 1993
5589238 Ruff Dec 1996