CA1328168C

CA1328168C - Bow making machine and apparatus

Info

Publication number: CA1328168C
Application number: CA000584100A
Authority: CA
Inventors: Olaf Raiskums
Original assignee: OVATION GIFTS AND GREETINGS INC.
Current assignee: RAINBOW STAR PRODUCTS Inc; CHARAN GROUP (THE); Coopers & Lybrand Ltd; GREYVEST CAPITAL Inc; OVATION GIFTS AND GREETINGS Inc
Priority date: 1988-11-25
Filing date: 1988-11-25
Publication date: 1994-04-05
Anticipated expiration: 2011-04-05

Abstract

ABSTRACT OF THE DISCLOSURE

Apparatus and methods for producing bows with conical ornamental elements from a roll of sheet material. The sheet material is conveyed through a rotary die which produces a continuous blank with pairs of opposing leaves. The blank is then conveyed between sets of cone-forming assemblies which transform the leaves into the required conical elements. The resulting strip with paired conical elements is advanced towards a rotary cutting element which separates bow components, each bow component having an elongate central part and a pair of opposing conical elements. Each bow component is pushed onto a pronged collecting element which is indexed about its longitudinal axis with each bow component collected. This produces a set of bow components extending radially in various directions. The set of bow components is then stripped from the collecting element and stapled onto a cardboard backing member.

Description

1~2~168 FIELD ~E INVENl~ION
The invention relates to the production of bows for ornamentation of gifts.
BACKGRO~NP OF TEIE ~ENTIQ~
Prior U.S. Patent No. 4,661,197 of the present inventors describes a bow formed with a multiplicity of conical ornamental elements and having a generaUy hemispheric overall shape. Cone-forming assemblies are taught in the prior patent for transforming leaves associated with a sheet-like blank into the de~sired conical elements. These cone-fonning assemblies comprise a conical form and a winder or wrapping assembly which effectively wraps a planar leaf about the form. The blanks specifically illustrated therein are generaUy circular with radiaUy directed leaves. Once the leaves associated with a number of circular blanks are formed into conical elements, the blanks are stacked and stapled OlltO a backing member to provide an estheticaUy pleasing bow.
St l~y~TION
The present invention provides a bow construction which lends itself to faster and less expensive production and provides methods and apparatus which permit such manufacture. In particular, the apparatus and processes described herein lend themselves to production of bows from continuous sheet materials supplied, for example, in roll form.
In one aspect, the invention involves a bow formed with conical oznarnental elements and having a novel construction. The bow is 25 forrned from a multiplicity of bow components each having an elongate central portion and a pair of conical elements integrally formed with the central portion and extending from opposing ends of the central portion. The bow . ~ ~: . , .

13281~8 components are stacked along a predetermined axis, each bow components in the stack bçing rotated about the predetermined a~is relative to any immediately overlaid component. Means are provided for securing the set of bow components in their stacked and rotated relationship to the backing 5 member. The bow is preferably constituted by two distinct sets of bows, one set being secured to the backing member and the second set being secured onto the first set.
In another aspect, the invention provides a method for producing a bow which mvolves forming sheet material into a continuous strip having pairs of ornamental elements at predetermined intervals along the ;
length of the strip. The ornamental elements are preferably conical in form, but the method can be adapted for construction of bows with other types of ornaments. Each pair comprises one ornamental element extending laterally from one side edge of the ~trip and another ornamental element extending laterally from an oppos~ng side edge of the strip. An end portion of the strip ; `
is advanced in a predetermined direction towards a cutting position. The strip end portion is cut t~ separate a bow component having a central portion and a pair of ornamental ~lements e~tending from opposing ends of the central portion. The bow c~n~ponent is pierced by a collecting element, the collecting element being indexed through a predetermined angle about an axis with each bow component collect~d. The steps of advancing the strip, cutting the skip to produce a bow c~ppnent, piercing the resulting the bow component and indexing the collectin~ element are repeated until a set of bow components of predetermined numb~ i~ retained on the collecting element. Thereafter7 the 25 set of bow compopentS is s~ipped from the collecting element onto a backing member and fixed ~n the backing member.
In ~ r aspect, the invention provides a method of . . , , , , ~:. . ;
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~32~168 producing bows in which collecting and stripping operations are performed in a substantially contemporaneous manner The method involves forming sheet materials into a continuous strip having pairs of ornamental elements at predetermined intervals along the length of the strip. One of a plurality of 5 collecting elements is located at a collecting station and another at a stripping station. Backing members to receive sets of bow components are delivered at intervals to the collecting station. Individual bow components are ~ormed on the collecting element currently at the collecting station by advancing the strip towards to the collecting station until an end portion is in an ap~ropriate 10 cutting position, cutting the end portion of the strip to separate a bow component having a central portion and a pair of ornamental elements extending from opposing ends of the central portion, piercing the bow component with the collecting element currently at the collecting station, and indexing the collecting element through a predetermined angle about an axis 15 transverse to the direction of advancement of the strip The advancing, cutting, piercing and indexing steps are repeated until a predetermined number of bow components is formed on the collecting element At the stripping sta~on, a set of bow components on the collec~ng element curren~ at the stripping station is stnpped onto and fixed to a backing member The 20 collecting elements are repeatedly indexed in a predetermined sequence along a close circuit between the collecting position and the st~ipping position. Eachindexing ~nvolves replacing the collecting element currently at the collecting station with a collecting element reta~ning no set of bow components and replacing the collecting element currently at the stripping station with a 25 collecting element retaining a set of bow components With each indexing, the steps of fonning a set of bow components on the collecting element currently at the collecting station and the steps of s~ipping and fixing a set of ..: ~:. ,, ~ .

: :, - 13281~8 bows from the collecting element currently at the stripping station are repeated.
In another aspect9 the invention provides apparatus for producing a bow from sheet materials. The apparatus comprises means for forming sheet material into a continuous strip having pairs of ornamental elements at predetermined intervals along the length of the strip. Means are provided for cutting an end portion of the strip to produce bow components, each bow component comprising a central portion and a pair of ornamental elements extending from opposing ends of the central portion. A collecting element is provided which is shaped to pierce the central portion of each bow component and to retain each pierced bow component in a fixed angular relationship relative to the collecting element. Means are provided which pierce the central portion of each bow component with the collecting element, such means preferably being in the form of a pushing element which pushes each bow component onto a stationary collecting element. Means are provided for indexing the collecting element relative to each bow component about an axis of the collecting element such that a set of bow components in predetermined angularly spaced-apart relationship is eventually formed on the collecting element. Means are provided for str~pping the set of bow components onto a backing rnember and for fixing the bow components to the backing member in their predetermined angular relationship.
In another aspect, the invention provides apparatus for producing a bow from sheet materials in which the collecting of bow components and stripping of bow components onto a backing member can be performed substantially contemporaneously. Means are provided for forming sheet material into a continuous strip having a paired o~namental elements.

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.,, , -` ~328168 Means are provided for advancing an end portion of the strip to a collecting station where cutting means cut the strip to produce bow components. A
plurality of collecting elements are provided, each shaped to pierce the centralportion of a bow component and to maintain each pierced bow component in a S fixed angular relationship relative to the collecting element. Means are provided for indexing the plurality of collecting elements in a predetermined sequence in a closed circuit between the collecting station and a stripping station. Means are provided for repeatedly piercing and collecting ~e bow components produced by the cutt~ng means at the collecting station, including means for indexing the collecting element currently at the collecting station relative to each bow comp~nent about a collecting element axis such that the bow components are collected in a predetermined angularly spaced apart relationship. Means are provided for delivering backing members at intelvals to the st~ipping station ultimately to receive collected bow components.
Means are provided for str~pp~ng a set of bow components frorn the collecting element currently at the stripp~ng station onto a backing member.and for fixing the strip set of bow components thereto. The delively of backing members may be timed to permit two or more sets of bow components ~o be mounted one atop another to form a complete bow.
Various aspects of the invention will be more a~parent from a description of a preferred embodiment of bow-forming machinery below and will be more specifically defined in the appended claims.
DESCR~ON OF l'HE I)~WTNGS
'rhe invention will be better understood with the re~erence to drawings in which:
~Ig. 1 is a diagrammatic view of bow forming machinery embodying the invention;

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13281~8 ~lg. 2 is a fragmented perspective view of components of the machinery which convert a roll of sheet matenal into a continuous blank with paired leaves;
fig. 3 is a fragmented perspective view of a drive assembly associated with the components of fig. 2; , fig. 4 is a fragmented elevational view in partial cross-section of portions of a conveyor which transports the blank between two cone-forming assemblies;
fig. 5 is a fragmented side elevational view illustrating two sets of cone-forming assemblies;
fig. 6 is a cross-sectional view illustrating a track and bearing which support a slide associated with one set of cone-forming assemblies;
fig. 7 is a fragmented perspec~ve view of the one set of cone-forming assemblies;
~Ig. 8 is an enlarged side elevation in partial cross-section detailing the construction of a single cone-forming assembly;
fig. 9 is a fragmented perspective view illustra~ng machinery comp~n~nts which cut and collecting bow components, deliver backing members to receive bow component sets, and s~ip sets of bow components onto the backing members, fig. 10 is an enlarged fragmented perspective view p~oviding further detail regarding a bow component collecting station;
fig. 11 is a side elevational view illustrating drive and timing assemblies associated with ~e cutting and collecting of bow components;
fig. 12 is a pe~spective view illustrating how a set of bow components is stripped and stapled onto a ticket-like backing member;
~lg. 13 is a fragmented elevational view in partial cross-section ~328168 g illustrating the construction, mountmg and operation of a bow component collecting element;
fig. 14 is an extensively fragment elevational view illustrating various positions of an optical sensor and reflecting pin mounted on a plvotmg arm;
fig. 15 is a perspective view of the drive and timing assembly of fig. 11 with a general support frarne omitted;
fig. 16 is a perspective view illustrating how a strip formed with conical elements is advanced towards a cutting assernbly;
fig. 17 is a perspective view illustrating how an element for pushing bow components cut from the strip onto a pronged collecting element is guided for reciprocating rectilhlear r;lotion;
fig. 18 is a side cross-sectional view a drive assembly which produces the reciprocating rec~linear motion and which adjusts the stroke of the pushing element;
figs. l9a-19c are diagrammatic end views of wrapping elements associated with the cone-forming assembly of fig. 8 in vaIious stages of leaf wrapping;
fig. 20 is a perspective view of a bow produced by the machinery.
DE$CRIPI10N QF PREFE~ED EMB0DI~
The overall operation of preferred bow forrning machineIy 10 will be described with respect to the schematic representation of fig. 1. The starting material is a roll 12 of sheet material which travels along a path indicated with arrows. The sheet material is conveyed to a rotary die 14 to be forrned into a continuous blaTIk 16 with pa~red leaves extending from ., . . ~ , .
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opposing side edges of the blank 16. One pair of leaves 18 illustrated in fig.

2 is exemplary. The resulting scrap 20 is directed over a continuously-powered roller 22 and discarded. The blank 16 is then conveyed to two sets of cone-form~ng assemblies 24, 26 which transform the 5 leaves into conical ornamental elements. The resulting strip 28 has pai~ed conical elements at regular predetermined intervals along its length. A pair of conical elements 30, 32 shown in connection with certain strip advancing apparatus in fig. 16 is exemplary: one conical element 30 extends laterally from one side edge of the strip 28; the other conical element 32, from the 10 opposing side edge of the strip 28.

The strip 28 is conveyed to a collecting station 36 where individual bow components are cut from the strip 28. S)ne bow component 38 illustrated in ~lg. 16 is exemplary and may be seen to comprise an elongate central portion 40 and an inte~ally connected pair of conical ornamental elements 42, 44 extending from opposing ends of the central portion 40. In this embodiment of the machinery 10, each bow component is collected substantially contemporaneously with its cutting on one of two pronged coUecting elements 42, 44. The collecting element 42 cullently at the collecting station 36 in ~Ig. 1 is indexed about its longitudinal axis relative to 20 each succeeding bow component cut from the strip 28 such that a set of components in angularly spaced-apart relationship is formed on the collecting element. The other collecting element 44 is ~urrently shown at a stripping station 50 in fig. 1.

The collecting element currently at the collecting station 36 is 25 then moved to the stripping station 50 where the set of bow components is stripped onto an elongate backing member formed of thin cardboard and stapled to the backing member. Although a sufficient number of bow '~ :

-` 13281 68 components might be formed in any given set to constitute a complete bow, it has been found preferable to form each bow from at leas~ two separate sets of bow components (thirteen components in each set), the second set being stripped onto the first set and stapled to the backing member. In this embodiment of the invention, one collecting element coUects bow components at the collecting station 36 whenever a set of bow components is being stripped from the other collecting element at the stripping station 50.
Ihere are a multiplicity of operations perfolmed by the machinery 10. To understand how these opera~ions are controlled and timed, the following brief overview of the control principles associated with the machinery 10 will be helpful. First, many of the actuators in this embodiment of the invention are pneumatic cylinders. Whether specifically mentioned or not, each of the pneumatic cylinders ls associated with a pair of magnetic sensors, one at either end of the pneumatic cylinder, which respond to the position of the associated piston. One sensor indicates when the cylinder is fully-contracted; the other indicates when the cylinder is fully-extended. As a general rule, the process steps and sub-steps actuated by the cylinders are completed with either a full-extension or a full~ontraction of each cylinder.
The signals generated by the associated sensors consequently indicate when such process steps and su~steps have been completed and are normally transmitted to a central controller 52 to time a sequence of operations. Most other operations are timed or controlled with optical sensors that project a beam of light and expect to receive a reflected beam. Exceptions to these types of control are noted in the description of operation below.
The manner in which the starting material is dispensed, die~ut and delivered to the two sets 24, 26 of cone-forming assemblies will be described with reference to fig. 2 1. The roll 12 of sheet material is mounted . , . . , ,, ~ .
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~32~168 on a powered supply roller 60 which is mounted for rotation in a conventional manner on a general support frame 62 associated with the machinery 10. The sheet material is conveyed to the rotary die 14 along a path defined by four free-wheeling rollers 64, 66, 68, 70. A slackened loop 72 is formed in the conveying path upstream of the dispensing roller 60 and downstream of the die 14 . For purposes of this specification and the appended claims, the term "upstream" should be understood as meaning in the direction of movement of the sheet material, blank or processed strip with conical elements, and "dovvnstream" should be und~rstood as meaning in a direction contrary to such direction of movement.
The slackened loop 72 is formed between t~vo of the free-wheeling rollers 68, 70 which are spaced apart horizontally by about two inches. The two rollers 68, 70 are vertically spaced as well, although this is not critical to the formation of the slackened loop 72. A weight 74 formed as a roller draws a Nn of the sheet material downwardly between the two free-wheeling rollers 68, 70 (as apparent in figs. 1 and 2) and between two vertical aluminum plates 76, 78 which ef~ectively isolate the loop 72. The weight 74 is simply loosely rested on the sheet material and has circumferential flanges encompassing the sides of the sheet mate~ial.
An optical detector or sensor 80 serves to detect when the slack in the loop 72 has reduced in resp~nse to conveying of the sheet material to the die 14 . The sensor 80 projects a beam 82 of light horizontally and through an aperture which is not apparent in the drawings but is located where the one alurninum plate 76 is shown fragmented in fig. 2. When the slack has reduced to a predetermined degree, namely, when the height of the bottom of the loop 72 is greater than the height of the optical sensor 80, the sensor 80 , , : - , .,; . . .

detects light reflected back from the other aluminum plate 78 and actuates a motor 84 associated wi~ the dispensing roller 60 to dispense more material.
The dispensed material is drawn into the loop 72, as dispensed, owing to the presence of the weight 74. Once the bottom of the slackened loop 72 extends 5 below the height of the optical sensor 80, intermpting and absorbing the beam 82, the sensor 80 discontinues the operation of the motor 84. It should be noted that this arrangement may be adversely affected by use of highly refle tive sheet material. Wi~h such materials3 it may be desirable to form an opening in the other aluminum plate 78 and to rely on non-reflection of the 10 sensor beam to indicate when slack has been reduced. Alternative sensing arrangements will be apparent.
The dispensing of the sheet material is largely independent of the subsequent convey~ng of the processed sheet material to var~ous stations in the machinery 10. One problem which arises in connection with the 15 conveying of the sheet material to different processing stations is a potential tearing of ~e strip 28 if conveyed and processed at different effective speeds.
This necessitates relative timing of conveying operations. Use of the slackened loop 72 effectively isolates the process of deliver~ng sheet rnaterialto the die 14 ~nd simplifies timing reguirements.
The rotary die 14 comprises a support frame 90 fixed to the general support frame 62 of the machinery 10 and consis~ing of two vertical parallel plates and a plurality of horizontal tie rods A cylindrical die member 92 is rnounted for rotation between the two plates, and a steel roller 94 presses the sheet material against the cylindrical die rnember 92. The roller 94is driven ~n a manner described more fully below, and the cylindrical die member 92 simply follows the roller 94. Care should be taken to ensure that the support frame 90 is sufficien~y robust that ~e roller 94 does not misalign .

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relative to the cylindrical die member 92 in response to torques applied dur~ng driving of the roller 94. Failure to maintain a proper parallel relationship between the cylindrical die member 92 and roller 94 can damage the rotary die 14 over a relatively short period of time.
The cylindrical die member 92 has two continuous projections 96,98 extending outwardly from its periphery. One projection 96 defines one side edge of the required strip 2~ and the leaves to be formed on that side.'~e other projection 98 defines the opposing side edge of the slrip 28 and the leaves to be formed on that opposing side edge. The resulting scrap 20 is simply directed over the top of the cy]indrical die member 92 and loosely over the scrap roller 22 which is con~nuously operated by a motor 23 to discard the scrap as produced.
A conveyor 100 guides the resulting blank 16 with paired leaves between the two sets 24, 26 of cone-forming assemblies. The conveyor 100 comprises a pair 102 of endless chains mounted in parallel relationship on paired sprocket wheels 104, 106 located at opposing ends of the cha~ns 102. The paired sprocket wheels 104 are driven; the other sprocket wheels 106 are simply idlers. The chains 102 have paired projections in side-by-side relationship such as the pair of projections 106 of fig. 7 extending transversely and outwardly from the chains. The horizontal spacing between each pa~r of projections corresponds to the width of the blank 16 between its opposing parallel side edge portions. The pitch of the paired projections (their relative spacing along the chains 102) corresponds to the spacing between the pa~red leaves along ~e blank 16. This arrangement p~rmits the paired projections to lodge behind successive pairs of leaves on the blanlc 16 in substantially the manner in which the palticular paired projections 106 lodge behind and push an exemplary pair of leaves 110~ 112.

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-~2~1~8 The upper runs of the chains 102 travel along a track 114 seen in cross-section in fig. 7. The track has a pair 116 of square longitudinal shoulders which support rollers formed with the paired chains 102 and a central longitudinal portion 118 which supports the centre of the blank 16. A
central guide plate 120, fixed to the general support frame 62 and marginally spaced from the upper runs of the chains 102, ensures that the blank 16 is held down while being conveyed between the cone-forming assemblies 24, 26. `
The pa~red sprocket wheels 104 of the conveyor 100 are fixed to a drive shaft 122 which is rotatably supported on the general support ~ame 62 as apparent in fig. 4. The supporting means include a sleeve 124 fixed to the general support frame 62 and a pair of bearmgs 126 which support the drive shaft 122 within the sleeve 124. A sprocketed drive wheel 128 is fixed to the drive shaft 122 adjacent its ~ear end surface to penn~t the shaft 122 to be rotated.
A circular timmg plate 130 ca~ying ten radially directed teeth (only one tooth 132 specifically indicated) is fixed to a rear end portion of the drive shaft 122. The circumferential spacing between the teeth coITesponds to the pitch of the paired projections of the chain 102 and consequen~y to the longitudinal spacing b~tween pa~red leaves of the blank 16. An optical sensor 134 mounted on the gene~al support frame 62 projects a beam 136 of light hori~ontally towards the teeth and detects light reflected from the teeth. The sensor 134 consequently provides an indica~on of the position of the leaves for purposes of application of an adhesive prior to cone-form~ng (as described more fully below). The tooth 132, which is typical, is separable from the timing plate 130 and has a large base fo~med with a , ~

circumferentially-dire ted slot. The tooth 132 is held to the tirning plate 130 by means of a bolt 142 extending through the slot and can be moved circumferential by loosening the bolt 142. The circumferential position of the teeth can consequently be varied to permit m~nor adjustment of the t~ming of the application of adhesive to the leaves. In practice, however, this is seldom done, and the releasable mounting of the teeth serves primarily to permit the teeth to be periodically removed and polished to ensure proper reflection of light back to the sensor 134.
The timing of die operation and the advancement of the resulting blank 16 by the conveyor 100 will be described with the reference to fig. 3. This illustrates the drive mechanism located behind the rotary die 14 and the conveyor 100. The primary driving means are a motor 144, an indexing table 146 with a toothed, circular periphery 148, and reduction gear 150 coupling ~e indexing table 146 to the motor 144. When actuated by the central controller 52, the motor 144 rotates a control shaft 152 through 360 degrees and indexes the table 146 through roughly 60 degrees, the gear ratios of the reduction gear be~ng selected to provide such relative measures of rotation. Motor operation is terminated by the central controUer 52 whenever ,, a cut~ff switch 154 is trip3ped by a cam 156 mounted on the control shaft lS2. A control arm 158 associated with ~e switch 154 carries a roller 160 which travels along the periphery of the carn 156. Accsrdingly, the control arm 158 can r~tate through only 360 degrees be~ore a cut-off signal is generated (as ~n the position illustrated in fig. 3). When such a signal is produced, the central controller 52 discontinues operation of the motor 144.
The indexing table 146 is mechanically coupled to both ~e rota~y die 14 and the conveyor 100. A drive chain 162 couples the periphery 148 of the indexing table 146 to a sprocket wheel 164 associated with the ~32~16~

roller 94 of rotary die 14 and also to the sprocket wheel 128 associated with the conveyor drive shaft 122. A displaceable idler sprocket wheel 166 mounted to the general support firame 62 permits drive chain 162 to be tightened in a conventional manner. The transmission ratios to the die sprocket wheel 164 and to the conveyor sprocket sprocket wheel 128 are selected such that, upon each 60 degree indexing of the table 146, the rotary die 14 cuts ten new pairs of leaves in the sheet material and the conveyor 100 advances ten pairs of leaves past the cone-form~ng assemblies 24, 2S. The die sprocket wheel 164 has in practice been formed with 68 sprockets whereas the conveyor sprocket wheel 128 has been ~ormed w~th 70 sprockets so that the rotary die 14 operates marginally faster than the conveyor 100.
This ensures that the blank 16 is not excessively tensioned and broken during transit from the rotary die 14 to the conveyor 100.
Prompt stopping of the motor 144 is very ~mportant and dynamic braking is used to that end. Delays in halting motor operation can cause dramatic increases ~n scrap produced in the cone-forming processes owing to misposition~ng of leaves. Although the rotary die 126 and conveyor 100 have been successfully operated by the inventors in the manner described aboYe, it may be preferable to trigger stopping of the motor 144 directly from the cut-off switch 154 to avoid delays in signal processing. Also, the cut-off position of the cam 156 might be more quickly detected with a fast-acting optical sensor rather than a mechanical cut-off switch. Use of serv~motors to drive the various components would potentially avoid such problems, although adding considerably to the cost of the machinery.
The con~folming process involves applying an adhesive adjacent on a downstream lateral portion of each leaf prior to the actual wrapping of the leaf about a conical form. The general object is to ensure that ;

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each conical element retains its form once the wrapping process is complete.
To that end, a pair of hot-melt dispensers 168, 17û are provided, one associated with each of the sets 24, 26 of cone-forming assemblies. The dispenser 168 associated with the ~lrst set 24 is positioned immediately downstream and above and to the side of the blank 16 where the filrst set 24 operates on the leaves. The second dispenser 170 is similarly positioned with respect to the second set 26 of cone-forming assemblies above and to an opposing side of the blank 16 to apply adhesive to the leaves appearing at that side. Each of the dispensers 168, 170 is electrically-actuated to eject a liquidadhesive and closed with a biasing spring. The duration of ejection will typically be about 2.5 milliseconds. To enhance the speed of operation it may desirable to provide dispensers 168, 170 in which both ejection and shut-off are electrically controlled to avoid the delays inherent in use of a biasing spring.
The adhesive is applied to the leaves during ~e advancing of the blank 16 by the conveyor 100. As mentioned above, the teeth associated with the tim~ng plate 130 interrupt and reflect the beam 136 of light generated by the associated optical sensor 134. Each signal so produced by ~e sensor ;

134 is ~ansmitted to ~e central controller 52 which actuates bo~ dispensers 168, 170 to eject liquid adhesive onto ~e two leaves then Immediately below and registered with ~e outlets of the dispensers 168, 170. Accordingly, liquid adhesive is de~osited on each of the ten leaves presented to each of the sets of conforming-form~ng assemblies with each advancing of the blank 16.

The two sets of cone-forming assemblies 24, 26 are substantially identical in confilguration and operation. They comprise the ;, same number of cone-forming assemblies, namely, ten. The first set 24 ~ ~2~6~

operates exclusively on leaves extending from one lateral side of blank 16; the second set 26 operates exclusively on the leaves extending ~rom the opposing side the blank 16. The sets 24, 26 of con~forrning assemblies are operated substantially contemporaneously.
~ne cone-fonning assembly 166 of the first set 24 is typical and is detailed in fig. 7. The cone-forming assembly 166 comprises a conical form 174 and a winder assembly 172 adapted to wind a leaf about the form ;
174. The winder assembly 172 comprises two separate male and female wrapping elements 178, 180 which together define a conical bed 182. With each pçriodic advancing of the blank 16, a fresh leaf is positioned over the bed 182, such as the leaf 112 shown over the winder assembly 172. A
pneumatic cylmder 184 is then actuated to advance the conical form 174 axially to press the leaf against the bed 182, and suction is applied along a conduit 186 tothe interior of the conical form 174 and ultimately to an opening 188 formed in the upper exterior of the form 174. The negative pressure at the opening 188 is used to hold portions of the leaf 112 to the conical form 174 during initial phases of the wrapping process.
The movement o~the wrapping elements 178, 180 to effect the wrapping of the leaf 112 is apparent from the series of end views of ~e wrapping elements provided in figs. l9a-19c. In these views, a cun~ed arrow adjacent one of the wrapping elements 178, 180 indicates the direction in which the element is about to be ~otated to arrive at the orientation in a succeeding drawing. The degree measurement adjacent the alrow indicates the extent of such rotation. The home position of the wrapping elements is 2~ shown in fig. 19a.
The male wrapping element 180 is f~st rotated upwardly and through about 180 degrees in a first direction until it engages the female - ~

~328~6~

wrapping element 178. This step wraps one lateral portion 190 of the leaf 112 about the form and over the vacwum opening 188 where the leaf portion is held. A leading sharpened edge 192 of the male wrapping element 180 crimps a portion 194 of the one lateral leaf portion 190 to one side of the vacuum opening 188 in a conforming recess 196 formed in the ~emale wrapping element 178. The cnmped portion 194 and other lateral leaf portion 198 then extend in a roughly radial manner ~rom between the wrapping elements 178, 180 as in fig. l9b.
The male wrapping element 180 is then driven in an o~posite direction through about 540 degrees. During this rotation, the male wrapping element 180 initial departs from the female wrapping element 178 and then re-engages and drives the female wrapping element 180 through about 360 degrees thereby wrapping and adhering the other lateral leaf portion 198 (which bears a drop 200 of adhesive deposited by the dispenser 168) over the crimped portion 194 and the one lateral leaf portion 190. The resulting o~ientation (which corresponds to the home position) is illustrated in filg. l9c.
The female wrapping element 178 is then rotated in a re ~erse direction ~rough 360 degrees. The female wrapping element 178 in~tially separates from the male uTapping element 180 and thereafter re~ngages and drives the male wrapping element 180 to home position, essentially to the same orientation apparent in fig. l9c. The purpose of ~is additional 360 de~ee rotation is to restore a pneumatic cy]inder operating the male wrapping element 180 to a particular home position which is intermediate its fully~xtended and fully-contracted states, as described more fully below.
2S Air under pressure is then applied to the interior of the conical form 174, and the conical form 174 is retracted leaving a fully assembled conical element.
The manner in which the two wrapping elements 178, 180 are . . ~
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driven to produce such a wrapping operation will now be described. Theexemplary winder assembly 172 may be seen to comprise an outer cylindrical shaft 202 connected to the female wrapping element 178 and an inner shaft 204 connected to the male wrapping element 180. The outer cylindrical shaft 202 is mounted with bearings 206 in a winder support structure 208 for rotation about its longitudinal axis. The inner shaft 204 is rotatably mounted within the outer cylindrical shaft 202 for rotation about the same axis. A pair of gears 210,212 are keyed to the exterior surfaces of the two shafts 182, 2V4. These gears 210, 212 are meshed with two identical drive mechanisms 214, 216.
The drive mechanism 214 associated with the cylindrical shaft 202 eomprises an elongate toothed rack 218. This track 218 is attached to an upper surface of an elongate brass wear member 220. The wear member 220 15 is supported for horizontal sliding movement by a pair of horizontally spaced-apart bearings mounted to the support structure 208, such as the bearing 222. Another brass strip 224 is ~Ixed to one side edge of the rack 218. The rack 218 is displaced by a pneumatic cyl~nder 226 which has magnetic sensors 228,230 at opposing ends to detect extremes in the stroke 20 of the cylinder 226. A full extension or full con~action of the pneumatic cylinder 226 corresponds to ~40 degrees of rotation of the female wrapping member 178. The drive mechanism 216 associated with the male wrapping elements 180 element similarly comprises a second toothed rack 232 meshed with the associated gear 212 and driven by a second pneumatic cylinder 234.
The cylinder 234 also has sensors 236, 238 at opposing ends to indicate fully-extended and fully-con~acted cylinder states. A full extension or full contraction of the pneumatic cylinder 225 corresponds to 360 degrees of ~ . , .

" 132~16~

rotation of the female wrapping member 178. When the racks 218, 232 are installed, the various winder assemblies must be differently oriented so that, as they are progressively engaged with the racks 218, 232, all winder assemblies can ultimately be located simultaneously in their home positions.
The starting or home position of the first and second pneumatic cylinders 226, 234 is apparent in fig. 8. In the home position, the cylinder 226 which operates the female wrapping element 178 is fully-contracted while the cylinde~ 234 which operates the male wrapping element 180 is extended about 1/3 of its stroke from its fully-contracted state towards its fully-extended state. To produce the vvrapping operation described above, the second pneumatic cylinder 234 is contracted ~rom its home position to its fully contracted state (producing the imtial 180 degree rotation of the male wrapping element 180 towards the female wrapping element 178~. Completion of this sub-step is indicated by the sensor 238.
The controller 52 then initiates a full extension of the second pneumatic cylinder 234, producing an initial 180 degree rotation of the male wrapping element 180 in a contrary direction away ~m the female wrapping element 178 and then the further 360 degree rotation during which the male wrapping element 180drives the female wrapping element 178 (the first pneumatic cylinder 226 idling and following during this process~. The wrapping of both lateral leaf portions is then complete, and completion of ~is step is ~ndicated by the senor238. The con~oller 52 then causes a full contraction of the f~t cylinder 226 which produces the required 360 degree rotation of the female wrapping element 178 towards its home position. The second cylinder 234 idles and follows during this process, permitting the female wrapping element 178 after about 180 degrees of rotation to drive the male wrapping element ~;
180 back to its home state and to drive the male wrapping element back to its ;............. : .,: . :
.
.. ' ~
- ~ --, . ~

132~168 home position (one-third extended). Completion OI this step is indicated to the controller 52 by the sensor 230.
The cone-form~ng assemblies of the first set 24 are operated contemporaneously in the same manner as the exemplary cone-form~ng 5 assembly 166. The set 24 comprises ten conical forms in parallel relationship as apparent in fig. 5. These are mounted on a slide 240 which is support by two parallel spaced-apart tracks (such as the track 242 apparent in side view in fig. 5 and in transverse cross-section in fig. 6) fixed to the general support ~rame by bearings meshed with the tracks (such as the bearing 244 meshed 10 with ~e ~ack 242). When actuated~ the pneumatic cylinder 184 advances the slide 240 thereby extending the ten conical fonns through openings ~only one opening 246 indicated) in the central guide plate 120 towards the conical beds associated with the various winder assemblies of the first set 24. The winding elements constituting the conical beds are then operated 15 simultaneously by actuating the pneumatic cylinders 226, 234 in the manner described above with respect to ~e single con~forming assembly 166.
The operation of the con~fonn~ng assemblies 24 and the production and advancing of the blank 16 are timed as follows. The indexmg table 146 is actuated ~e~eby causing the rotary die 14 to cut ten pa~rs of ~0 leaves and causing the conveyor 100 to convey ten fresh pails of leaves to the conical beds. The cut~ff switch 154 associated wi~ the indexing table 146 indicates that the cutting and advancing steps are complete. The cen~al contr~ller 52 responds to the cut~ff switch 154 by actuating the pneumatic cylinder 184 which displaces the slide 240 and engages the conical forms with 25 the associated conical beds. Negative pressure is also applied to the intenors of the conical forms. A magnetic sensor 248 at the end of the pneumatic cylinder 184 indicates that the pneumatic cylinder 184 is fully extended and .. ~ . .
. : , . . . . . ................... . .
- .
,- .: , ~

~ 32~16~ :

that the conical forms are in an operative position relative to the beds. The pneumatic cylinders 226, 234 are then operated in the rnanner described above to complete the wrapping of the ten leaves about the conical forms. The sensor 230 of the pneumatic cylinder 226 indicates that the wrapping operation is complete. The controller 52 then causes air under pressure to be applied to each of the conical forrns and causes the pneumatic cylinder 184 to retract the slide 240 and the var~ous conical forms. The second set 26 o~
cone-forming assemblies is operated simultaneously with the first set 24 in the sarne general manner.
The resulting strip 28 with paired conical elements is advanced to the collecting station 36 along a horizontal supporting surface 250, as apparent in figs. 10, 15 and 18. At the collecting station 36, the advancing end portion 2S2 of ~e strip 28 is cut transversely to produce individual bow components. The mechanism for advancing the strip 28 towards a cutting position comprises two pushing elements 260, 262. The pushing elements 250, 262 have elongate body portions 264, 266 and forked upper portions 268, 270, respectively, the ~orks being spaced sufficiently to locate on either side of the strip 2~ nediately behind a pair of conical elements. A pa~r of parallel elongate slots 272, 274 are formed in the supporting surface 250 to pennit the ~orked po,rtions 268, 270 to ~avel through and along the horizontal support surface 2~
The ~lmting and driving of one push~ng element 260 is typical. Two shafts 2~6, 278 are rotatably mounted to the general support frame 62 in parallel ~.latlonship. A pair of disks 280, 282 are ~lxed to the shafts 276, 278 for ~4tation with the respective shafts. The body portion 264 of the pushing elen~nt 260 is pinned eccentrically to both disks 280, 282 at ~ ' ~'' : '' .
` .~ , , ~ ;
.... ~.
- , 24 1328~6~

equal radii from the relevant rotational axes. Sprocketed pulleys 284, 286 are fixed to opposite ends of the shafts 276, 278 to permit the sha~ts 276, 278 to be driven. With each complete rotation of the shafts 276, 278, ~he forked portion 268 rises through the slots 272,274 in the horizontal supporting 5 surface 250, advances the strip 28 laterally a distance equal to the spacing between two pairs of conical elements, and then drops below the horizontal supporting surface 250. The othe~ pushing element 262 is mounted to the general support frame 62 m a similar manner by means of two disks 288, 290 and two shafts 292, 294 associated with sprocketed pulleys 296, 298.
A common sprocketed belt 300 joins and simultaneously drives the four sprocketed pulleys 284, 286, 296, 298 thereby synchronizmg the operation of the two pushing elements 260, 262. A sliding sprocketed idler pulley 302 permits tension in the belt 300 to be adjusted in a conventional manner. One shaft 276 carries a major sprocketed drive pulley 304 which is coupled to an electric motor 306by means of a sprocketed pulley 308 fixed to the motor shaft and a sp~ocketed drive belt 310 connecting the two pulleys 308, 312. A sliding sprocketed idler pulley 312 permits tension in the belt 310 to be adjusted in a conventional manner. The motion of the two pushing elements 260,262 is ~med such that one descends below 20 the horizontal suppor~dng surface 250 ~thereby ceasing pushing) as the other ascends through the hori~ontal supporting sur~ace 250 (thereby commencing pushing). For a brief instant during this transition, both elements 260, 262 are pushing. The general object is to provide a continuous advancing action and to prevent the s~ip 28 from slipping in a downstream direction.
The cuttmg operation is pe~oImed by a rotary cutting element 320 comprising a disk 322 and a blade 324 extending radially from the periphery of the disk 322. The cutting element 320 is mounted to the general .
.. :, . . : -- . . .
.. .
~: : '' , ~ .. .. .

support structure for rotation in a conventional manner. The advancing strip 28 is held down adjacent to the cutting element 320 by an overhanging structure 326 spaced a small distance above the horizontal support surface.
As the end portion 252 of the s~ip 28 approaches the cutting position, air under pressure is supplied through a conduit 328 and ejected through a nozzle 330 formed in the overhanging structure 326 to prevent the end portion 252 from curling upwardly when otherwise engaged by a pushing element described more fully below.
The rotaIy cutting element 320 is driven together with the two pushing elements 260, 262 and their relative operation is synchronized. The rotary cutting element 320 is driven by a gear mechanism which comprises two meshed bevel gears 338, 340. One bevel gear 340 is mounted on a drive shaft 342 together with a sprocketed drive pulley 344, and is operated by the same sprocketed belt 310 which provides motive power to the two pushing elements 260,262 associated with ~e advancing mechanism. The transmission ratios are selected such that the cut~ng blade 324 rotates once with each complete cycle of vne pushmg element. Accordingly, one bow component is cut from the strip 28 with each advancing of ~e strip by each of the pushing elements 260, 262. Appropriate ~ansmission ratio can be set by selecting the size of the sprocketed drive pulleys in an conventional manner. : ' The relative ~ning of the advancing and cutting operations can be adjusted by loosening the drive belts 300, 310 and locating the two pushing elements 260, 262 and the rota~ cutting element 320by hand in predetermined orientations and then ensuring that ~e drive belts 300, 310 are properly engaged with the respective pulleys.
In this particular embodirnent of the invention, collection of the bow components forrned by the rotaly cutting element 320 involves the , ,~, , : ' :: . , .

132816~

operation of a pushing element 34B formed with a cross-bar 350. This cross-bar 350 pushes each bow components substantially contemporaneously with the cutting of the bow component onto one of the collecting elements 46, 48 curren~y at the collecting station 36. Although not illustrated, it should benoted that the pushing element 348 has a central opening in the cross-bar 350 which receives the prongs of the collecting elements 46, 48. This opening may be ~llled with a foamed plastic to provide support for the bow components during the piercing operation and yet accomm~date ~e prongæ.
The pushing element 348 is mounted on an elongate drive assembly illustrated in fig. 17 and comprising two push rods 352, 354 joined by a pivot pin 356. The upper push rod 352 is guided for vertical movement within a longitudinal groove 358 formed in steel block 360 fixed to the general frarne 62 and is retained therein by a closure plate 362 bolted to the bloclc 360. This arrangement guides movement of the pushing element 348 along the axis of the collecting element currently at the collecting sta~on 36, transv~rse to the direction in which the strip end portion 252 is being advanced. The lower push rod 354 is coupled eccentrically to a rotaly member 364 with a pivot pin 366.
The rotary member 364 is mounted by two bearings 368 in the interior of a support shucture 370 ~or rotation about a horizontal axis. It is rotated by the motor 306 through a sprocket pulley 372 mounted on the rotary member 364, a sprocket pulley 374 mounted on the motor shaft, and a sprocketed drive belt 376 connecting the two sprocket wheels 372,374. The pushing element 348 is consequently moved in a reciprocating fashion along the transverse axis against each bow component thereby causing the bow component to be pierced by the collecting element.

132~16~

The stroke of the pushing element 348 is progressively shortened in roughly one-eighth inch increments during collection of each bow component of a set. The general object is to ensure that the bow components are not tightly packed when pushed onto the collecting element, 5 as this detracts drastically from the quality of the finished product. To thatend, a threaded shaft 378 is mounted to the rotary member 364 in part by a pair of beanngs 380 which permit rotation of the threaded shaft 378 about its longitudinal axis, perpendicular to the horizontal rotational axis of the rotary -member 364. A first bevel gear 382 is keyed to the exterior of the threaded shaft 378, and a second bevel gear 384 is meshed with the first bevel gear 382. The second bevel gear 384 is keyed onto a drive shaft 386 which is supported in the interior of the rotary member 364 by two bearmgs 388 for rotation about the horizontal rotation axis of the rotary member 364. This drive shaft 386 is normally maintained stationary during collection of the set 15 of bow components. Rotation of the rotary member 364 conse~uently produces a rotation of the threaded shaft 378 about its longitudinal axis and a simultaneous rotation of the threaded shaft 378 with the rotary member 364 about the horizontal rotational axis of the rotary member 364. A threaded follower 390 is meshed with the threaded shaft 378 such that rotation of the 20 threaded shaft 378 about its longitudinal axis causes displacement of the follower 390 ax~ally along the shaft 37~. The pivot pin 366 eccentrically coupling the lower push rod 354 to the rotaly member 364 is fixed to the follower 390. Accordingly, with each rotation of the rota~y member 364, the follower 390 travels along the threaded shaft 378 towards the horizontal ;
25 rotation axis by a distance corresponding to the pitch of ~e shaft threads. The stroke of the pushing element 348 is consequently shortened by a corresponding amount as each bow component is collected.

:; , , :: -:
., ~ ~ . .

132~16~

The stroke of the pushing element 348 is reset to a predetermined value once a set of thirteen bow components has been formed on a collecting element. A separate resetting motor 392 is provided for such purposes. The resetting motor 392 is coupled to the threaded shaft 378 by a 5 linkage which includes the drive shaft 386 mounted in the interior of the rotary member 364 and the pair of bevel gears. A sprocketed pulley 394 is attached to the drive shaft 386 and coupled by a sp~ocketed belt 396 to the resetting motor 392 to perrnit rotation of the drive shaft 386. When the i resetting motor 392 is actuated, the drive sha~t 386 is rotated thereby causing 10 the threaded shaft 378 to rotat about its longitudinal axis in a direction opposite to that occasioned by normal rotation of the rotary member 364.
Tbis causes the follower 390 to travel away from the ho~zontal rotational axis of tbe rotary member 364, effectively increasing ~e stroke of the pushing element 348.
The process of resetting the stroke of the pushing element 348 is stopped when ~e stroke acquires a predetermined value by a mechanism illustrated in figs. 11, 14 and 17. The mechanism comprises a plate-l~ce pivot arm 398 having one end portion connected by a pivot pin 400 t~ the general support frame 62. The opposing free end portion 402 of the a~n 398 20 is formed with an upwardly projecting s~ucture defining a concave par~-circular edge 4W which can be engaged by the bottom of the lower push rod. The free arm end portion 402 has a horizontal projection which supports a vertically-oriented reflecting pin 406. An optical sensor 408 is mounted on the exterior of the general support frame 62 and directs a beam 410 of light 25 horizontally in the general direction of Ihe reflecting pin 406. A solenoid 412 is mounted to ~e general support frame 62 and positioned such that a shaft 414 associated with the solenoid 412 deflects the aIm 398 downwardly , .
' ', :~ , ' - ~

-` ~32816~

completely free of the lower push rod ~to avoid clanging durmg the collecting process). The position of the reflective pin 406 when the arm 398 is so deflected is indicated in stippled outline at 416 in fig.14. A biasing spring 418 acting between the general suppolt frame 62 and the arm 398 tends to draw the free arm end portion 402 upwardly. When a complete set of bows has been collected at the collecting element currently at the collecting station36, the solenoid 412 is deactivated by the central controller 52 allowing the arm 398 to swing upwardly. This engages the bottom of ~e lower push rod with the part~ircular edge 404 and orients the reflecting pin 406 in substantially the position indicated in stippled outline at 420 in fig. 14. The resetting motor 392 is then actuated to displace the follower 390 away from the rotational axis of the rotary member 364, and the arm 398 pivots downwardly with the attendant downward movement of the lower push rod.
The exact position of the lower push rod relative to the arm 398 is not cxitical as it engages the part-circular edge 404 defined in the arm 398. When the arm 398 has been pushed down un~l the reflecting pin 406 no longer interrupts the sensor beam 410 as in the orientation indicated in solid outline in fig. 14, ~e sensor 408 sends a signal to the controller 52 indicating that the stroke of the pushing element has been reset to a ~edetennined value. The central contro~ler 52 then deactivates the resetting motor 392 and acthates the solenoid 412 to push the arm 398 downwardly in preparation for the collection of the next set of bow components. The reflecting pin 406 may be threaded onto horizontal projection suppor~ng the pin to perrnit adjustment of the reset value of the stroke.

The timing of the operatioDs at ~e collecting station 36 will be described with reference to figs. 11 and 1~. First, the operation of the .: - . :

.

~32~6~

pushing elements 260, 262 is mechanically synchronized with the advancing and cutting operations in the manner described above. The object is to ensure that the cutting of a bow component commences after the central portion of the bow component has been pierced by the collecting element currently at the 5 collecting station 36, the prongs associated with the collecting element serving to hold the bow component in place durmg the cutting operation. Second, the operations at the collecting station 36 are timed by a tirning wheel 424 mounted on the drive shaft associated with the principal motor 306.
The direction of rotation of the timing wheel 424 is clockwise in fig. 11. The timing wheel 424 is cut to define three radially~irected edges:
a leading edge 426 extending between innerrnost and outermost radii of the timing plate; a f-rst trailing edge 428 starting at an mtermediate radius of thetim~ng wheel 424 and terminat~ng at an outermost radius; a second trailing edge 430 star~ng at an innermost radius of the timing wheel 424 and terminating at the intermediate radius. First and second op~cal sensors 432, ;
434 are mounted on the general SUppOIt frame 62 and projects two beams of light horizontally at radii commensurate respecthrely with the radial spans of first and second trailing edges 428, 430. -The second optical sensor 434 effectively counts the bow 20 components being collected on the collecting element currently at the collecting station 36. Whenever the leading edge 426 of the fiming wheel 424 interrupts and reflects the beam of the second sensor 434, the second sensor 434 produces a signal effectively indicating that a bow component has been colle ted. The position of the t~ming wheel 424 on the motor shaft is selected 25 such that the signal is generated substantially when the pushing element 348 is at the lowest point in its stroke. This signal indicates to the controller 52 that the collecting element currently at the collecting station 36 may be indexed (as ~32~168 described more fully below). The same signal is also tallied by the central controller 52 until a tally of thirteen is reached, indicating collection of a full set of bow components, and the controller 52 then terminates the operat;on of the principal drive motor. It should be noted that the expanse of disk 450 between the leading edge 426 and the second trailing edge 430 is provided to permit the controller 52 sufficient time to poll the second optical sensor 434 and obtain the relevant signal.
The expanse of disk 450 between the leading edge 426 and the first trailing edge 428 represents a star~ng or home region for co~unencement of collection operations. This is detected by the first optical sensor 432 when the leading edge 426 interrupts and reflects the sensor's beam. When the home region is achieved after a count of thirteçn bow components, the controllçr 52 interchanges the collecting elements 46, 48, actuates the resetting motor 392 to reset the stroke of the pushing element 348, and initiates another cycle of bow component cutting and collection. The purpose of providing such a home region is to accornrnodate delays in halting the operation of the drive motor 310. In palticular, the mechanism for limiting 1he resetting ~f the stroke of the pushing element 348 requires the pushing element 348 to be near the bottom of its stroke (within the part~ircular edge 404 of the pivoting arm 398 described above). If there is an overshooting of the home region when the motor 310 is being stopped, the controller ~2 slowly reverses the drive motor 310 until the home region is achieved (indicated by reflection of the beam produced by the first optical sensor 432. An a]ternative to such operation would be to replace the driven rnotor 310 with a servo-motor which can be more readily controlled.
It should be noted that the central controller 52 compares the rate of production of the strip 16 with the rate of co~ection of bow ., - - , ~L328168 components and operates the rotary die 14 and the sets 24, 26 Qf cone-forming assemblies so as to ensure that the strip 16 is produced at an appropriate rate. A loose run of the strip 16 tas apparent in fig. 1) should be maintained between the sets 24, 26 of cone-forming assemblies and the advancing mechanism to ensure that the collecting station 36 is always adequately supplied and that no break in the strip 16 occurs. `
As previously mentioned, there are two collecting elements 46, 48 in this embodiment of the machinery 10. These collecting elements 46, 48 are supported from a horizontal platform 440. The pla~orm 440 is mounted to the top of a vertically-oriented cylindrical shaft 442 which is supported forrotation about its vertical longitudinal axis with appropriate bearings (not illustrated) mounted in a support block 444. The motive means for producing rotation is a pneumatic cylinder M6. I~e cylinder 446 is coupled to the cylindrical shaft 442 in a manner analogous to that in which the pneumatic cylinders 220, 226 are coupled to the individual winder assemblies, and consequently has not been illustrated. Basically, a toothed rack is attached to one end of the piston rod associated wi~h the pneumatic cylind~r ~6, and the rack is meshed wi~ a gear fixed to the cylindrical shaft 442. When the pneumatic cylinder 446 is extended fully, the cylindrical shaft 442 rotates through 180 degrees in a first direction thereby interchanging the two collecting elements 46, 48 at the stripping and collecting stations. When the cylinder 446 is fully contracted, the cylindrical sup~ort rotates back through 180 degrees, once again interchanging ~e two collecting elements 46, 4B.
Magnetic sensors (not illustrated) at opposing ends OI the pneumatic cylinder 446 indicate when ~e fully-contracted and fully~xtended states of the cylinder 446, and consequently provide the controller 52 with signals ;, ~ , ; . . .
:. ..
, ~ ~

1328~

identifying which of the collecting elements 46, 48 is currendy at the collecting station 36 and which is currently at the stripping station 50. This is significant since, in this embodiment of the invention, the two collecting elements 46, 48 are of different lengths and dedicated to collecting two 5 distinct sets of bow components. It will be appreciated that the two collecting elements 46, 48 are indexed through a predetermined, albeit limited, closed circuit which in this particular embodiment of the invention comprises only the stripping and collecting stations. One collecting element bearing no leaves is positioned with each indexing at the collecting station 36, while the other 10 collecting element (which was previously formed with leaves) is then positioned at the stripping station 50. Additional collecting elements might be introduced and indexed through more stations in variants of the system described herein, but this would not appear to enhance operations.
The collecting element 48 shown at the stripping station 50 in figs. 12 and 13 is typical. It comprises two prongs 448 tapered and pointed to p~nit pierc~ng of ~e central portion of each bow component cut from ~e strip 28. The prongs 448 are fixed in substan~ally par~llel relationship to a supporting disk 450 associated with the colleeting element 48. Since two prongs 448 are used, the angular relationship of each bow component relative 20 to the longitudinal axis of the collecting element 48 is fixed when pierced.
The collecting element 48 is mounted to the horizontal platfolm 440 for rotation about a longitudinal c~llecting element axis. The mounting means comprise a drive shaft 452 which ~lts into a passage 454 extending vertically through the horizontal support platform 440. The ends of the 25 passage 454 are expanded radially to define seating surfaces fo~ two bearings456. These bearings 4$6 support the dlive shaft 452 for rotation about its vertical longitudinal axis. An upper end portion of the shaft 452 has a .

~32~:L6`~

shoulder 4S8 which bears against the upper surface of the horizontal support platform 440. A lower end portion of the shaft 452 is formed with a circular recess that receives a C~lip 460 to complete its retention to the horizontal support platform 440. The disk 450 of the collecting element 48 is sirnply bolted to the lower end of the drive sha~t 452 for rotation therewith. A
sprocketed pulley 462 is fixed to an upper end of the shaft 452 and is coupled :~
by a toothed belt 464 to another sprocketed pulley 466 associated with a stepper motor 468. The stepper motor 468 is ultimately controlled by the central controller 52 which causes the collecting element 48 to be indexed in ~`
predetermined angular increments about its longitudinal axis with each bow component collerted.
Each collecting element is associated with similar stripping members. The stripping member 470 associated with the collecting element ~;
48 currently shown at the stripping station 50 in figs. 12 and 13 is mounted at one end of an elongate shaft 472. A longitudinal passage is formed centrally through the drive shaft 452, and the elongate shaft 472 supporting the stripping member 470 is mounted for vertical sliding movement within the passage 474 and through an aligned clearance hole of the disk 450 associated with the collecting element 48. The stripping member 470 is a disk-shaped element with a pair of apertures which receive the prongs 448 of the collecting element 48 and which pennit displacement of the stripping member 470 between a retracted position at one upper end of the prongs 448 and an advanced position at an opposing lower end of the prongs 448. An upper end of the shaft 472 supportirlg the stripping member 470 is ~ead and receives an elongate internally threaded head 480. A biasing spring 492 mounted about the shaft 472 acts between the top of the sprocketed drive pulley 462 and the head 480. The spring 492 applies an upward resilient restonng foIce . ' ', ~ ~ ' .

~3~8168 to the shaft 472 which tends to return the stripping member 470 to its retractedposition. It should be noted that the mounting of the shaft 472 permits rotation of the stripping member 470 with the collecting element 48 during indexing about the axis of the collecting element 48.
A pneumatic cylinder 494 with a driving element 496 is positioned at the collecting station 36. The pneurnatic cylinder 494is supported by an arm extending from the general support ~rame 62. When the pneumatic cylinder 494 is fully retracted, the driving element 496 is positioned a predeterm~ned distance, for example, above the head 480 associated with the collecting element cuIrently at the stripping station 50, asapparent in fig. 13. As apparent in figs. 12, the pneumatic cylinder 494 can be actuated by the controller S2 to drive the element 496 against, for example, the head 480 ta displace the stripping member 470 f~om its retracted position to its advanced position thereby pushing a collected set of bow components from ~e collecting element onto a backing member (such as the set of bow components 498 being str~pped onto an upper face of the backing member 500 in ~lg. 12). It should be noted that the driving element 49Ç is screw threaded onto a threaded portion of the piston rod associated with the pneumatic cylind~ 494 to perm~t adiustment OI the clearance between the driving element 496 and the head 480. This pe~nits adjustment of the range of moving of lhe s~ipping element, and in particular, pe~n~ts adjustment of the advanced ~sition to c~incide with the ends of the prongs 448.
The two collecting elements 46, 48 are substantially identical except that the prongs of the collecting element 48 shown at the stripping station 50 in figs. 12 and 13 are about 1/4 inch shorter and have tips positioned about 1/4 inch higher than those associated with the other .- .

,~ ` ' ' ' ' .

:
` ` ~ 3 ~ 8 collecting element 4S. The head 480 associated with the shorter collecting element 48 is also adjusted to be about 1/4 inch lower than the head associated with the longer collecting element 46. The longer collecting element 46 is devoted en~irely to collecting the first set of thirteen bow components to be 5 applied to each backing member; the shorter collecting element 48 is devoted entirely to collecting the second set of thirteen bow components to be stacked onto the first set. In this embodiment of the invention, the bac~cing members delivered to the collecting station 36 are maintained at a single height during the stripp~ng operations. The purpose of this arrangement is consequently to 10 accommodate the thickness of the central portions of the first set of bow components when fixed to a backing member. One alternative would be to , adjust the vertical position of the stapling mechanism and the vertical positionof the backing member during stapling operations prior to each interchangement of collecting elements 46, 48.
15Bow components a~e stripped in the angular relationship in which they have been collected onto an upper face of the backing member currently at ~e stripping statiotl 50. They are then fixed in the particular angular relatianship to the backing member by an air-powered stapler 510.
The stapler 510 is part of a stapling assembly 512 mounted on a horizontal 20 platform 514 which is vertically displaceable by a pair of pneumatic cylinders 516 between a retracted (lowered) position and an advanced (raised) position.
Full contraction of the cylinders 516 corresponds to the retracted position;
full extension of the cylinders 516 corresponds to the advanced position ~n which a staple ejec~ing port is positioned immediately against the lower 25 opposing surface of the backing member. Magnetic sensors (not illustrated) associated wi~ opposing ends of these cylinders 516 indicate to the controller 52 ~e retracted and advanced s~ates.

:' , . .

~ . -.

132816~ .

The stapler 510 has a trigger 518 which is operated by a horizontally~riented pneumatic cylinder 520 with a relatively short stroke.
The piston rod of the pneumatic cylinder 520 is terminated witb a conical actuating element 522. In a retracted position, the conical actuating element S22 is positioned immediately adjacent tbe trigger 518, but the trigger 518 is not depressed. When the pneumatic cylinder 520 is extended, a portion of the conical actuating element 522 with a larger cross-section engages and depresses the trigger 518 thereby causing ejection of a staple. Magnetic sensors (not illustrated) associated with the trigger controlling cylinder 520 1~) indicate fully~ontracted and fully-extended states of the cylinder 520corresponding to activation and deactivation of the stapler 510. '~
The stapling assembly 512 includes a rubber suction cup 524 which is mounted on a rigid suction line 526. The suction cup 524 is positioned to engage the lower face of a backing member delivered to the ``
stripping station 50 when the stapling assembly 512 is raised. The cup 524 has a central aperture 528 through which negative pressure is applied to the :, bottom face of the backing member to hold the bacldng member securing during the stripping and stapling ope~adons. A nozzle 530 is mounted on and receives pressur~zed air flows from a conduit 532 fixed to the stapling ' ' assembly 512. When such p~essurized air flows are applied to the nozzle 530, and suction is no longer applied to the suction cup 524, a finished bow seated on the suction cup 524 is blown away from machinery, as to a ~eceptacle.
Bacl~ng members are delivered at intervals to the stripping station 50. These backing members are f~rmed as a continuous roll 540 and mounted on a reel 542 which rotates with a shaft 544 rotatably mounted on the general support frame 62. They are dravwn from the reel 542 by a movable ,., . , .~ ... ..

, ~3281~8 jaw 546 comprising a large rectangular slide 548, a U-shaped jaw member S50 which is fixed to the top of the slide 548 and through which the backing members are extended, and a squat vertically-oriented pneumatic cylinder (not illustrated) which is mounted within the slide 548 and which has a piston rod term~nated with a circular pad whose diameter is smaller than the width of the backing members. The pad can be extended vertically through an upper surface of the slide 548 to clamp a backing member between the pad and the interior surface of the U-shaped jaw member 550. The slide 548 is bearing-mounted to a horizontal track 552 and can be moved between a retracted position (solid in fig. 9) and an advanced position (stippled in fig. 9) prox~mate to a stationary jaw 5S4. A pneumatic cylinder 556 is mounted to the track 552 for such purposes and operably connected to the slide 548. The stationary jaw ~54 is substantially identical to the movable jaw 546. It comprises a U-shaped jaw member 55~ mounted on top of a support block ;
560 and a verlically-oriented pneumatic cylinder mounted with the support block 560 and operable to press a backing member against the U-shaped jaw member 558. All pneumatic cylindcr asso iated with the backing member delive~y system have pairs of magnetic sensors at opposing ends thereof to indicate fully extended and contracted states, which correspond to the comple~on of the vanous process steps actuated by the cylinders.
To advance a new backing member to the stripping station 50, the stationaly jaw S54 is released and a signal is ~ansmitted to the controller 52 to indicate that the associated pneumatic clarnping cylinder has fully contracted. The con~oller 52 then actuates the clamping cylinder of the movable jaw 546. Upon receipt of a signal from the clamping cylinder that the clamping has been initiated, the controller 52 actuates the slide cylinder ~.

~32~16~ :

556 which slides the movable jaw 546 in a clamped state towards the ;
stationary jaw 554. This advances a backing member along a parallel pair of channeled guides 562 extending between the movable and stationary jaws and mounted for sliding movement relative to the movable jaw 546. The magnetic 5 sensors associated with the pneumatic cylinder 556 indicate to the controller 52 when this advancing operation is complete. The stationary jaw 554 is then actuated by the controller 52 to clamp the bacldng member advanced through the stationary jaw 554, the controller 52 being signaled by sensors associated with the clamping cylindçr of the stationary jaw 554 that such clamping has 10 been initiated. The movable jaw S46 is then released, and up~n receipt of sensor signals indicating such release, the controller 52 causes the slide cylinder 556 to retract the movable jaw 546. The controller 52 receives a signal from the sensors associated with the slide cylinder ~56 (now fully contracted) indicating when the retraction is complete.
Once anew backing member has been advanced to the stripping station 50, the controller 52 causes the stapling assembly 512 to be displaced from its retracted position to its advanced position. The suction cup 524 then engages the lower face of the backing member. When so gripped by ':
the suction cup 5~4, the backing member is cut from the roll 540 by a blade 564 which is momentarily advanced by a pneumatic cylinder 566 along a track 568 and then retr~cted to a rest position. The advancing of the stapling assembly 512, application of suction to the cup 524, and the cuffing operation are once again timed by sensors at opposing ends of the relevant pneumatic cylinders and providing signals to the controller 52 to indicate the sequence of25 events occurring.
An optical sensor 170 positioned downstr~am of the movable jaw 546 responds to dark patches printed on the backing members. These 13281~8 patches are positioned to indicate that the backing members are being properly advanced. In particular, registration of a dark patch with optical sensor 570 indicates to the controller 52 that a backing member advanced to the stationary jaw 554 is properly positioned for cutting and separation from the roller. An ;~
5 alternative which may be more reliable is to allow the optical sensor to sightthrough a hole normally provided in a backing member to perrnit a finished bow to be hung in a conventional manner from a retail display rack.
The stripping and stapling processes are controlled by the central controller 52 in a cyclic fashion. It will be assumed that the shorter 10 collecting element is currently at the stripping station S0 and that a bow has just been completed. The controller 52 actuates a compressed air flow through the nozzle 530 to eject the ~mished bow from the stapling assembly 512. The controller 52 then causes the stapling assembly 512 to be displaced to its retracted position to permit delivery of a new backing member. The 15 magnetic sensors associated with cylinders 516 supporting the stapling assembly 512 indicates when the retraction is complete. Ihe controller 52 then actuates the bacldng member delivery system to deliver a new backing member to the stripping station 50 in the manner described above. l`he sensors associated with the backing member deliver system indicate when this 20 operation is complete. The con~ller 52 then actuates the pneumatic cylinders 516 supporting the stapling assembly 512 to place the stapler 510 immediately against the bott~m of the backing element to engage the suction cup 524 with the baclcing member. When the sensors associated with pneumatic cylinders 516 indicate that the stapling assembly 512 has been fully advanced, the 25 controller 52 actuates the suction line 526 to grip the backing member with the suction cup 524. It also actuates the pneumatic cylinder S66 associated with the blade 564 to sever the backing member from the roll 540.

`:

~ 3 2 ~ 8 The controller 52 then initiates the interchangement of the two collecting elements 46, 48. The central controller 52 is signalled when the collecting element are interchanged and the longer collecting element 46 with a 5 set of bow components is positioned at the stripping station 50. The requisitesignal is provided by the magnetic sensors associated with the pneumatic cylinder 446 which rotates the cylindrical shaft 442 supporting the collecting elements 46, 48 and associated stepper motors. Another optical sensor 572 is fixed to the general support frame and directs a beam of light horizontally 10 towards the head associated wi~ the collecting element 4~ currently at the collecting station 36. The signal generated by reflection of the beam signals the controller 52 that the par~icular collecting element is properly oriented for collection and that the stripping element has not failed for some reason to return to its retracted position.
The con~roller 5~ then astuates the cylinder 494 operating the driving element 496 to strip the set of bow components frorn the longer collecting element A6 onto the backing member. Magnetic sensors associated wi~ the driving cylinder 494 indicate to the controller 52 when the stripping member has been fu~ly advanced. The central controller 52 then actuates ~e trigger controlling ~linder 520 to extend ~ereby tiiggering the stapler 510 and driving a staple ~rwgh the backing member and ~rough the stripped set of bow component~? It should be noted that during the stapling, the driving cylinder 494 is maintained fully extended (analogous to fig. 12) so that the stripping member s~ s not only to maintain the set of bow components against the backing mer~ber but also serves as a necessary anvil to bend the legs of the driven staple ~gainst the backing member. The sensors associated with the triggering ~yl~nd~r 520 indicate when the cylinder 520 has been fully , ~ 3 2 ~

extended and the controller 52 then causes the triggering cylinder 520 to be retracted.
The con~roller 52 then awaits completion of the collection of bows components on the short collecting element 48 which is the at the 5 collecting station 36. The timing wheel 424 and the pivoting arm ultimately generate signals indicating that the timing wheel 424 is at its home position and that the resetting of the stroke of the push~ng element 348 is complete.
The controller 52 then actuates the pneumatic cylinder 446 which rotates the platform 440 supporting the collçcting elements 46, 48, effectively placing the 10 shorter collectmg element 48 at the stripping station 50 with a second set ofbows. The magnetic sensors associated with the pneumatic cylinder 446 indicate when the interchangemenL of collecting elements 46, 48 is complete.
The controller 52 then repeats the stnpping and stapling steps described immediately above with the shorter collec~ng element 48. Since a complete 15 bow has now been formed, the control cycle is repeated.
The overall process of fonning bows will now be described in general detail. The sheet material dispensing assembly, the rotary die 14 and the cone-forming assemblies 24, 26 are operated at regular intervals to produce a continuous strip 28 of sheet matenal having the required paired 20 conical elements.
A first set of bow components is formed on the collecting element 46 with the longer set of prongs. This is done by continuously advancing the strip 28 towards the collecting station 36 and a cutt~ng position relative to the rotaly cutt~ng element and repeatedly cut~ng the strip end 25 portion 252, piercing the central portion of the component with the collecting element, cutting the end portion 252 of the strip 28 to separate a bow component, and indexing the collecting element 46 through a pr~determined ~` : ~

43 ~ 32~8 angle about its axis after each component is cut and pierced. A set of bow components previously collected on the shorter collecting element 48 now at the stripping station 50 is substantially contemporaneously stripped onto a backing member to complete a bow then in process at the stripping station 50 and the central portions of the stripped set of bow components are stapled to the backing member. The finished bow is removed with a burst of compressed air; the stapling assembly 512 is lowered to permit a new backing member to be delivered to the stIipping station 50; and the stapling assembly 512 is once again raised to an operative position in which the new backing member is supported by the suction cup S24.
The pair of collecting elements 46, 48 are then indexed between the collecting and stripping stations, placing the longer collecting element 46 at the stripping station 50 with a first set of bow components for the new backing member and placing the shorter collecting element 48 at the 15 collecting station 36 with no bow components. The steps associated with foTming a set of bow components and the steps associated with stripping and fixing bow components to a backing member are ~en repeated at the respective stations.
The pair of collecting components 46, 48 are once again interchanged. The shorter collecting element 48 is then at the stripping station50 with a second set of bow components for the bow in process at the stripping station 50. The longer collecting element 46 is then at the collectingstation 36 awaiting formation of a f~st set of bow components for a new backing member to be delivered to the stripping station 50 once the bow in process at the stripping station ~0 is complete. One cycle is of operation is now complete. Ihe processes as described above are then repeated to provide continuous bow production.

. ~;, : :

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` 13281~8 44 ;

The central controller 52 is constituted principally by a p~ogrammable logic controller (PLC). A number of functions are prefeMbly perforrned mdependent of the PLC to simplify programming. The dispensing of sheet material, for example, is controlled directly in response to the optical sensor 80 associated with the slackened loop 72 thereby requiring no intervention by the central con~oller 52. The operation of the die 14 and conveyor 100 requires only an actuating signal from the PLC and response by the PLC to the signal generated by the cut~ff switch 154. I'he operation of the adhesive dispensers 168, 170 can be controlled by a separate timing board in response solely to the optical sensor llB and timing plate 116. The programming of the PLC to implement the remaining functions in response to the various sensors will be readily apparent to a skilled programmer.
A bow 574 produced accord~ng to the above process and mounted on a backing member 576 is illustrated in ~Ig. 6. Although it closely resembles the bow described in prior U.S. patent No. 4,661,197, it is constructed exclusively of bow components consisting of an elongate central portion and a pair of conical elements integrally formed at opposing ends of the central portioll. The bow components are stacked along a vertical central axis with each bow component rotated relative to any ~Imediately overla~d bow component by a predetenn~ned angle.
During the production of the bow 574, the stepper motors index their respective collecting elements 46, 48 in increments indicated in thetable below. The home position or orientation at the collecting station 36 of the two prongs of each collecting element is initially a plane parallel to the direction of movement of the s~ip end portion 252 towards the rotary cutting element 320 and containing the vertical longitudinal axis of the collec~ng . . .

- ~ , :
- ., , 132~68 element. The headings "First Set" atld "5econd Set" indicate the two sets of bow components used to form a bow according to the processes described above, in the order in which they are fixed to a backing member (that ;s, the second set is uppermost). ~he numbers under ~ese headings identify bow 5 components in the order in which they are collected on each collecting elementand consequently their vertical order from top to bottom as located on the backing member 576. The numbers under the heading "Index Angle" indicate relative angular indexing in degrees between successive bow components in a common direction, ~e ~lrst such entry in each column being relative to the 10 common plane containing the home position of the prongs of both collecting elements at the collecting station S0. Although precise figures are provided below, it will be appreciated that such preclse angular increments will not be achieved in practice. Variations of a few degrees with each indexing are acceptable.
First Set ~ndex Angle Second Set Index Angle 22.5 1 4~
2 67.5 2 90 4- ~5 4 90 67.5 ~ 67.5 9 67.5 9 67.5 12 90 12 67.5 13 45 13 22.5 These indexing inc,rements also defime the angular relationship in a common direction about a ver~cal central axis between each par~cular bow component and any immediately supe~acent bow component. With respect the first bow components in each set, ~e index angle represents the angle by which each o~

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- .: .
- . - . , .
.. .. .

13~8:l~8 these components is rotated in the common direction relative to a plane containing the vertical axis. A principal object of this angular relationship above is to ensure ~at bow components will be forced upwardly by underlieing bow components to provide an overall hemispheric appearance.

5 The angular increments above were determined empirically. In any alternative indexing arrangement, considerable care must be exercised in selecting the increments if an esthetically pleasing, hemispheric bow is to result.
It will appreciated that particular embodiments of the invention have been described and that modifications may be made therein without 10 depar~ing ~rom the spirit of the invention or necessarily departing from the scope of ~e appended claims.

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Claims

1. Apparatus for producing a bow from sheet materials, comprising:
means for forming the sheet material into a continuous strip having pairs of ornamental elements at predetermined intervals along the length of the strip, each pair comprising one ornamental element extending laterally from one side edge of the strip and another ornamental element extending laterally from an opposing side edge of the strip;
cutting means for cutting an end portion of the strip to produce bow components, each bow component having a central portion and a pair of ornamental elements extending from opposing ends of the central portion;
a collecting element shaped to pierce the central portion of each bow component and to retain each pierced bow component in a fixed angular relationship relative to the collecting element;
collecting means for piercing the central portions of each bow component with the collecting element;
indexing means for indexing the collecting element relative to each bow component about an axis of the collecting element such that a set of bow components in predetermined angularly spaced-apart relationship is retained on the collecting element when a predetermined number of bow components have been pierced by the collecting element;
stripping means for stripping the set of bow components from the collecting element onto a backing member; and, fixing means for fixing the set of bow components to the backing member in the predetermined angularly spaced-apart relationship.

2. The apparatus of claim 1 in which:

the apparatus comprises means for advancing the end portion of the strip in a predetermined direction towards a collecting station;
the collecting means comprise a pushing element located at the collecting station, means for guiding movement of the pushing element along the axis of the collecting element, the axis being oriented transverse to the predetermined direction, and motive means for moving the pushing element in reciprocating fashion along the transverse axis against each bow component thereby pushing the bow component onto the collecting element;
the apparatus comprises timing means for timing the operation of the advancing means, the cutting means and the motive means such that the pushing element pushes each bow component onto the collecting element substantially contemporaneously with the cutting of the bow component from the end portion of the strip by the cutting means.

3. The apparatus of claim 2 in which the motive means comprise means for adjusting the stroke of the pushing element during collection of the set of bow components on the collecting element, the stroke adjustment means shortening the stroke of the pushing element by a predetermined amount each time a bow component of the set is pushed onto the collecting element.

4. The apparatus of claim 3 comprising means for automatically resetting the stroke of the collecting element to a predetermined value when a predetermined number of bow components have been collected on the collecting element.

5. The apparatus of claim 2 in which the motive means comprise a motor and a linkage coupling the motor to the pushing element, the linkage comprising:
a rotary member rotated about a predetermined rotational axis by the motor;

a threaded shaft having a longitudinal axis oriented transverse to the rotational axis;
means connecting the threaded shaft to the rotary member such that rotation of the rotary member produces a rotation of the threaded shaft about its longitudinal axis and a simultaneous rotation of the threaded shaft with the rotary member about the rotational axis of the rotary member;
a threaded follower meshed with the threaded shaft such that rotation of the threaded shaft causes displacement of the follower axially alongthe threaded shaft;
an elongate drive assembly having one end portion attached to the pushing element and having an opposing end portion;
means connecting the opposing end portion of the drive assembly to the follower at a position offset radially from the rotational axis such that rotation of the rotary member produces a rectilinear movement of the pushing element along the axis of the collecting element and such that rotation of the threaded shaft about its longitudinal axis progressively shortens the stroke of the pushing element.

6. The apparatus of claim 5 comprising another motor for resetting the stroke of the pushing element to a predetermined value, the linkage comprising:
a drive shaft having a longitudinal axis;
means mounting the drive shaft within the rotary member for rotation about the longitudinal axis; of the drive shaft;
means coupling the drive shaft to the threaded shaft such that the threaded shaft rotates about its longitudinal axis with rotation of the drive shaft;

means coupling the drive shaft to the motor for rotation by the motor.

7. The apparatus of claim 1 in which the means for forming the sheet material into the strip comprise:
sheet dispensing means for dispensing sheet material;
a die;
sheet conveying means for conveying the dispensed sheet material to the die;
means for operating the die to form the sheet material into a continuous blank having pairs of leaves;
a plurality of cone-forming assemblies;
blank conveying means for conveying the blank from the die to the cone forming assemblies;
means for operating the cone forming assemblies to form the leaves into conical ornamental elements thereby to form the strip.

8. The apparatus of claim 7 in which the sheet dispensing means comprise:
means for receiving and rotatably supporting a reel of the sheet material;
means for forming a slackened loop of the sheet material downstream of the die and upstream of the reel;
detecting means for detecting when the slack in the loop has reduced to a predetermined degree in response to conveying of the sheet material to the die; and, means for rotating the reel to dispense the sheet material from the reel whenever the slack has reduced at least to the predetermined degree thereby increasing the slack in the loop.

9. The apparatus of claim 8 in which:
the means for forming the slackened loop comprise a pair of rollers in horizontally spaced-apart relationship and each shaped to guide the sheet material and comprise a weight drawing the sheet material downwardly between the two rollers to define the slackened loop;
the detecting means comprise an optical detector positioned a predetermined distance below the pair of rollers and responsive to the height ofthe slackened loop.

10. The apparatus of claim 7 in which:
the plurality of cone-forming assemblies comprises a first set of conforming assemblies and a second set of cone-forming assemblies, the first and second sets of cone forming assemblies comprising the same predetermined number of cone-forming assemblies;
the blank conveying means direct the blank along a predetermined path between the first and second sets of cone forming assemblies, the first set of cone-forming assemblies being positioned to a firstside of the predetermined path and the second set of cone-forming assemblies is positioned to an opposing second side of the predetermined path, the first set of cone forming assemblies being positioned downstream of the second set of cone forming assemblies;
the apparatus comprises timing means for actuating the blank conveying means to advance the blank periodically by a distance corresponding to the number of cone-forming assemblies in each of the first and second assemblies and for engaging the first set of cone-forming assemblies upon each advancing of the blank with leaves positioned on the second side of the predetermined path and simultaneously engaging the second set of cone-forming assemblies with leaves positioned on the first side of the predetermined path.

11. The apparatus of claim 10 comprising:
a pair of liquid-adhesive dispensers, a first of the pair of dispensers having an outlet positioned downstream of the first set of cone forming assemblies and above and to the second side of the predetermined path, the second of the pair of dispensers having an outlet positioned downstream of the second set of cone forming assemblies and above and to the first side of the blank;
means for detecting when each of the leaves registers vertically with the outlet of one of the pair of dispensers with each periodic advancing ofthe blank and for actuating the dispensers to eject liquid adhesive from the dispenser outlets onto the registered leaves.

12. The apparatus of claim 1 in which the stripping means comprise:
a stripping member mounted on the collecting element;
means guiding the stripping member for movement between a retracted position at one end of the collecting element and an advanced positionat an opposing end of the collecting element;
controllable means for moving the stripping member between the advanced and retracted positions.

13. The apparatus of claim 12 in which:
the collecting member comprises a plurality of prongs;
the stripping member has apertures which receive the plurality of prongs and which permit axial displacement of the stripping member along the prongs between the advanced and retracted positions;
the stripping member guiding means means permit indexing of the stripping member with the collecting element.

14. The apparatus of claim 13 in which:
the stripping member guiding means include a shaft attached to the stripping member;
the controllable means for moving the stripping member comprise drive means for displacing the shaft axially when the drive means are actuated in a first direction thereby advance the stripping member to the advanced position and a biasing spring applying a force to the shaft in a seconddirection opposite to the first direction thereby restoring the stripping memberto the retracted position when the drive means are not actuated.

15. The apparatus of claim 12 in which the fixing means comprise a stapler for driving a staple through the backing member and the set of bow components stripped onto the backing member, the means for moving the stripping member being adapted to maintain the stripping member in the advanced position during the driving of the staple such that the legs of the staple against the stripping element to bend the legs.

16. Apparatus for producing a bow from sheet materials, comprising:
means for forming the sheet material into a continuous strip having pairs of conical ornamental elements at predetermined intervals along the length of the strip, each pair comprising one ornamental element extending laterally from one side edge of the strip and another ornamental element extending laterally from an opposing side edge of the strip;
means for advancing an end portion of the strip to a collecting station;
cutting means at the collecting station for cutting the end portion of the strip to produce bow components, each bow component having a central portion and a pair of ornamental elements extending from opposing ends of the central portion;
a plurality of collecting elements each shaped to pierce the central portion of a bow component and to retain each pierced bow component in a fixed angular relationship relative to the collecting element;
means for indexing the plurality of collecting elements in a predetermined sequence in a closed circuit between the collecting station and a stripping station, each indexing comprising replacing the collecting element currently at the collecting station with another collecting element which retains no set of bow components and replacing the collecting element currently at the stripping station with a collecting element retaining a set of bow components;
collecting means for forming a set of bow components on the collecting element currently at the collecting station by repeatedly piercing the central portion of the bow components produced by the cutting means, the collecting means including means for indexing the collecting element currently at the collecting station relative to each bow component about an axis of the collecting element such that the bow components of the set are in a predetermined angularly spaced-apart relationship;
means for delivering backing members at predetermined intervals to the stripping station;
means for stripping a set of bow components from the collecting element currently at the stripping station onto a backing member currently at the stripping station;
means for fixing the central portions of the stripped set of bow components to the backing member currently at the stripping station.

17. The apparatus of claim 16 in which the stripping means comprise:

a plurality of stripping members, each stripping member being associated with a different one of the collecting elements;
means associated with each collecting element for guiding the associated stripping member for movement between a retracted position at one end of the collecting element and an advanced position at an opposing end of the collecting element, movement of the stopping member from the retracted position to the advanced position serving to strip bow components from the associated collecting element.

18. The apparatus of claim 17 in which:
each collecting element comprises a plurality of prongs;
each stripping member has apertures which receive the plurality of prongs of the associated collecting element and which permit axial displacement of the stripping member along the prongs of the associated collecting element;
the stripping member guiding means associated with each collecting element permit indexing of the associated stripping member with the collecting element.

19. The apparatus of claim 17 in which the stripping means comprise a plurality of springs, each of the springs being associated with a different one of the stripping members and acting to restore the associated stripping member to its retracted position.

20. The apparatus of claim 17 in which the stripping means comprise controllable drive means located at the stripping station for driving the stripping member of the collecting element currently at the stripping station to the advanced position

21. The apparatus of claim 17 in which the fixing means comprise a stapler located at the stripping station for driving a staple through the backing member and the set of bow components stripped onto the backing member, the means for moving the stripping member being adapted to maintain the stripping member in the advanced position during the driving of the staple such that the legs of the staple are driven against against the stripping element to bend the legs.

22. A method for use in producing a bow, comprising:
A. forming a continuous strip of sheet material having pairs of ornamental elements at predetermined intervals along the length of the strip, each pair comprising one ornamental element extending laterally from one side edge ofthe strip and another ornamental extending laterally from an opposing side edge of the strip;
B . advancing an end portion of the strip in a first predetermined direction until the end portion of the strip is at a predetermined cutting position;
C . cutting the exposed end portion of the strip to separate a bow component having a central portion and a pair of ornamental elements extending from opposing ends of the central portion;
D. piercing the central portion of the bow component with a collecting element such that bow component is retained on the collecting element;
E. indexing the collecting element through a predetermined angle about an axis transverse to the predetermined direction after the cutting and piercing;
F. repeating steps B - E until a first set of bow components of predetermined number is retained on the collecting element;
G. stripping the first set of bow components from the collecting element onto a backing member and fixing the first set of bow components to the backing member.

23. The method of claim 22 in which step C comprises holding the collecting element stationary and pushing the bow component along the transverseaxis onto the collecting element.

24. The method of claim 23 further comprising:
repeating steps B - E to form a second set of bow components of predetermined number on a collecting element;
stripping the second set of bow components from the collecting element on which the second set of bow components is retained onto the first setof bow components and fixing the second set of bow components to the backing member.

25. The method of claim 24 in which the pushing of the bow components of the first and second sets onto a collecting element comprises pushing each bow components of each set a successively shorter distance along the associated collecting element such that each succeeding bow components of each set is spaced a predetermined distance on the collecting element from a preceding bow component.

26. The method of claim 25 in which the fixing of the first and second sets of components to the backing member comprises stapling.

27. The method of claim 22 in which the forming of the strip comprises:
dispensing sheet material;
conveying the sheet material to a die and operating the die to form the sheet material into a continuous blank having pairs of leaves;
conveying the blank to cone forming assemblies and operating the cone forming assemblies to form the leaves into conical ornamental elements thereby to form the strip.

28. The method of claim 27 in which the dispensing of the sheet material comprises:
mounting a supply of the sheet material on a reel;
forming a slackened loop of the sheet material downstream of the die and upstream of the reel;
detecting when the slack in the loop has reduced to a predetermined degree in response to the conveying of the sheet material to the die;
and, rotating the reel to dispense the sheet material from the reel whenever the slack has reduced at least to the predetermined degree.

29. The method of claim 27 in which the step of conveying the blank to the cone forming assemblies and operating the cone forming assemblies comprises:
directing the blank between a first set of cone forming assemblies positioned to a first side of the blank and a second set of cone forming assemblies positioned to an opposing second side of the blank, the first set of cone forming assemblies being positioned downstream of the second set of cone forming assemblies, the first and second sets of cone forming assemblies comprising an equal number of cone-forming assemblies;
advancing the blank periodically by a distance corresponding to the number of cone-forming assemblies in each of the first and second assemblies;
engaging the first set of cone-forming assemblies upon each advancing of the blank with leaves positioned on the second side of the blank and simultaneously engaging the second set of cone-forming assemblies with leaves positioned on the first side of the blank.

30. The method of claim 29 comprising applying a liquid adhesive to leaves of the blank contemporaneously with each periodic advancing of the blank,the applying of the liquid adhesive comprising:
supplying liquid adhesive to a pair of dispensers, a first of the pair of dispensers having an outlet positioned downstream of the first set of cone forming assemblies and above and to the second side of the blank, the second of the pair of dispensers having an outlet positioned downstream of the second set of cone forming assemblies and above and to the first side of the blank;
detecting when each of the leaves registers vertically with the outlet of one of the pair of dispensers and ejecting liquid adhesive from the dispenser outlets onto the registered leaves.

31. The method of claim 22 in which step G comprises:
moving the collecting element from a collecting position in which the collecting element is aligned with the transverse axis to a stripping position spaced from the transverse axis;
positioning the backing member at one end of the collecting element at least when the collecting element is in the stripping position;
advancing a stripping member from a retracted position along the collecting element to an advanced position proximate to the backing member to push the first set of bow components onto one face of the positioned backing member.

32. The method of claim 31 in which step G comprises:
advancing a stapler into proximity with an opposing face of the positioned backing member;
holding the stripping element in the advanced position thereby retaining the first set of bow components against the one face of the positionedbacking member;
operating the stapler to drive a staple through the backing member and the first set of bow components and to drive the legs of the staple against the stripping element to bend the legs.

33. A method of producing bows, comprising:
A. forming a continuous strip of sheet material having pairs of conical ornamental elements at predetermined intervals along the length of the strip, each pair comprising one ornamental element extending laterally from one side edge ofthe strip and another ornamental extending laterally from an opposing side edge of the strip;
B. locating one of a plurality of collecting elements at a collecting position and another of the plurality of collecting elements at a stripping position;
C. providing backing members at predetermined intervals at the collecting position;
D. forming a set of bow components on the collecting element currently at the collecting position by i. advancing the strip in a first predetermined direction towards the collecting position until an end portion of the strip is in a predetermined cutting position;
ii. cutting the end portion of the strip when in the cutting position to separate a bow component having a central portion and a pair of ornamental elements extending from opposing ends of the central portion;
iii. piercing the central portion of the bow component with the collecting element currently at the collecting position such that bow component is retained on the collecting element currently at the collecting position;
iv. indexing the collecting element currently at the collecting position through a predetermined angle about an axis transverse to the predetermined direction after the cutting and piercing;
v. repeating steps i - iv until a set of bow components of predetermined number is formed on the collecting element currently at the collecting position;
E. stripping a set of bow components from the collecting element currently at the stripping position onto a backing member currently at the stripping position and fixing the central portions of each of the stripped set of bow components to the backing member, the stripping and fixing being done substantially contemporaneously with the forming of the set of bow components on the collecting element currently at the collecting position;
F . repeatedly indexing the plurality of collecting elements in apredetermined sequence along a closed circuit between the collecting position and the stripping position, each indexing comprising replacing the collecting element currently at the collecting position with another collecting element which retains no set of bow components and replacing the collecting element currently at the stripping position with a collecting element retaining a set of bow components;
and, G. repeating steps D and E with each indexing.

34. The method of claim 33 comprising for each backing member provided at the collecting position:
stripping a first set of bow components from one of the collecting element onto the backing member and fixing the first set of bow components to the backing member;
stripping a second set of bow components from another of the collecting elements onto the first set of bow components and fixing the second set of bow components to the backing member;
replacing the backing member after both the first and second sets of bows have been fixed to the backing member with another backing member.

35. The method of claim 34 in which the stripping and fixing of each of the first and second sets of bow components to each backing member provided at the stripping position, comprises:
advancing a stripping member from a retracted position along the collecting element on which the set of bow components is retained to an advancedposition proximate to the backing member thereby pushing the set of bow components onto one face of the backing member;
maintaining the stripping member in the advanced position thereby retaining the first set of bow components against the one face of the positionedbacking member;
placing a stapler into proximity with an opposing face of the backing member;
operating the stapler to drive a staple through the backing member and the set of bow components and to bend the legs of the staple against the stripping element.

36. The method of claim 33 in which the forming of the strip comprises:
dispensing sheet material;
conveying the sheet material to a die and operating the die to form the sheet material into a continuous blank having pairs of leaves;
conveying the blank to cone forming assemblies and operating the cone forming assemblies to form the leaves into conical ornamental elements thereby to form the strip.

37. The method of claim 36 in which the dispensing of the sheet material comprises:
mounting a supply of the sheet material on a reel;
forming a slackened loop of the sheet material downstream of the die and upstream of the reel;
detecting when the slack in the loop has reduced to a predetermined degree in response to the conveying of the sheet material to the die;
and, rotating the reel to dispense the sheet material whenever the slack has reduced at least to the predetermined degree.

38. The method of claim 36 in which the step of conveying the blank to the cone forming assemblies and operating the cone forming assemblies comprises:
directing the blank between a first set of cone forming assemblies positioned to a first side of the blank and a second set of cone forming assemblies positioned to an opposing second side of the blank, the first set of cone forming assemblies being positioned downstream of the second set of cone forming assemblies, the first and second sets of cone forming assemblies comprising an equal number of cone-forming assemblies, advancing the blank periodically by a distance corresponding to the number of cone-forming assemblies in each of the first and second assemblies;
engaging the first set of cone-forming assemblies upon each advancing of the blank with leaves positioned on the second side of the blank and simultaneously engaging the second set of cone-forming assemblies with leaves positioned on the first side of the blank.

39. The method of claim 38 comprising applying a liquid adhesive to leaves of the blank contemporaneously with each periodic advancing of the blank, the applying of the liquid adhesive comprising:
supplying liquid adhesive to a pair of dispensers, a first of the pair of dispensers having an outlet positioned downstream of the first set of cone forming assemblies and above and to the second side of the blank, the second of the pair of dispensers having an outlet positioned downstream of the second set of cone forming assemblies and above and to the first side of the blank;
detecting when each of the leaves registers vertically with the outlet of one of the pair of dispensers and ejecting liquid adhesive from the dispenser outlets onto the registered leaves.

40. A bow comprising:
a backing member;
a first set of substantially identical bow components, each of the bow components consisting of an elongate central portion and a pair of conical elements integrally formed with the central portion and extending from axially opposing ends of the central portion, the bow components being stacked along a predetermined axis, each of the bow components immediately overlaying another of the bow components in the stack being rotated about the predetermined axis relative to the other overlaid bow component;
a second set of bow components, each of the second set of bow components consisting of an elongate central portion and a pair of conical elements integrally formed with the central portion and extending from axially opposing ends of the central portion, the second set of bow components being stacked along the predetermined axis, each of the second set of bow components immediately overlaying another of the second set of bow components in the stack being rotated about the predetermined axis relative to the other overlaid bow component;

means securing the first set of bow components in stacked and relatively rotated relationship to the backing member; and means securing the second set of components to the backing member and centrally within the first set of components wherein each of the first and second sets consists solely of thirteen bow components and in which the bow components are oriented in a predetermined angular relationship defined substantially according to the following table:

First Set Index Angle Second Set Index Angle 1 22.5 1 45 2 67.5 2 90 67.5 5 67.5 9 67.5 9 67.5 12 90 12 67.5 13 45 13 22.5 where, the numbers 1 through 13 indicate the first through thirteenth bow components of each set in vertical order from top to bottom; the index angle indicated for the second through thirteenth bow components of each set represents the angle through which each bow component is rotated in a common direction about the predetermined axis relative to an immediately superjacent bow component of the set; and the index angle associated with each of the first bow components represents the angle through which each of the first bow components is rotated in the common direction about the predetermined axis relative to a plane containing the predetermined axis.