GB2342591A

GB2342591A - Christmas cracker manufacture

Info

Publication number: GB2342591A
Application number: GB9822380A
Authority: GB
Inventors: Michael Hilary Burke
Original assignee: Durell R & D Ltd
Current assignee: Durell R & D Ltd
Priority date: 1998-10-09
Filing date: 1998-10-14
Publication date: 2000-04-19
Anticipated expiration: 2018-10-14
Also published as: IES80730B2; GB9822380D0; IES980835A2; GB2342591B

Abstract

A method and apparatus for manufacturing a Christmas cracker in which from a feeder station (2), decorative paper (6) and cardboard (7) are treated and led together through a gluing station (4). Then a snap is laid on the glue, on the cardboard (7) and decorative paper (6) which forms a composite sheet, which is then divided into discrete sheets (44). Then a novelty (45) is laid on each sheet and the sheet rolled to form a cylinder. Further rolling causing a twist to be formed on either side of the cardboard to form the rest of the cracker (48).

Description

"Christmas Cracker Manufacture" Introduction The present invention relates to a continuous method and apparatus for manufacturing a plurality of Christmas crackers.

Such Christmas crackers generally comprise a novelty, a roll of cardboard in the form of a cylinder surrounding the novelty, a snap comprising an elongate strip of material incorporating intermediate its ends an explosive material at a weakened portion thereof and in which the explosive material is activated when the strip is pulled apart to break the snap, a roll of decorative paper projecting beyond both ends of the cylinder and having a neck portion adjacent each end of the cylinder to close the cylinder to prevent the novelty falling out and the free ends forming a pair of open-mouthed pulling handles.

Christmas crackers are traditionally made by hand and there are various problems with this. Firstly, there is a lack of consistency in sizes, there is a lack in consistency in general overall appearance and then very often, the novelties fall out, particularly when the crackers have been carelessly made. The problem, however, with trying to form such a Christmas cracker by a machine is the sheer complexity of the operations required and the need to handle the paper and the various components separately. Further, since the novelties are themselves of irregular size and shape, this further adds to the problem. Additionally, the paper is relatively light, particularly the decorative paper, thus the handling of it causes problems. The present invention is directed towards providing a method of manufacturing a plurality of Christmas crackers effectively on a continuous basis and to providing an apparatus for carrying out such a process.

Statements of Invention According to the invention, there is provided a continuous method of manufacturing a plurality of Christmas crackers of the type comprising a novelty, a roll of cardboard in the form of a cylinder surrounding the novelty, a snap comprising an elongate strip of material incorporating intermediate its ends an explosive material at a weakened portion thereof and in which the explosive material is activated when the strip is pulled apart to break the snap, a roll of decorative paper projecting beyond both ends of the cylinder and having a neck portion adjacent each end of the cylinder to close the cylinder to prevent the novelty falling out, and the free ends forming a pair of open-mouthed pulling handles, the decorative paper having an inner surface and an outer decorative surface in which the following steps are performed not necessarily sequentially: leading decorative paper from a roll of paper beneath a gluing head; applying glue to the inner surface of the paper; leading cardboard from a roll of cardboard beneath a gluing head; applying glue to the cardboard; laying the snap on the inner surface of the paper; cutting the cardboard transversely from the roll; forming the cardboard into a cylinder; delivering the novelty to the cardboard to be surrounded by the cylinder; cutting the decorative paper into discrete decorative sheets; rolling the decorative paper to surround the novelty and the cylinder; forming the necks in the decorative paper; and removing the cracker.

This is much less labour intensive and produces a product of higher quality than heretofore.

Ideally, the method comprises the sequential steps of: leading decorative paper from a reel beneath the glue head; leading cardboard from a separate reel onto the inner surface of the decorative paper to contact it and form a composite sheet therewith; leading the composite sheet to a glue head; applying glue to the exposed surface of the cardboard for the snap; applying glue to the cardboard longitudinally spaced from the glue for the snap thereof to form a raised stop; laying a snap on the cardboard; cutting the composite sheet into discrete composite sheets; placing a novelty on the discrete composite sheet; rolling the discrete composite sheet around itself till an exposed edge of the cardboard sheet connects against the stop to prevent further rolling and twisting the ends relative to the central portion to form the neck.

This method according to the invention allows for the formation of extremely tight neck portions preventing all possibility of loss of a novelty or its removal for example by children prior to use.

Preferably, the cardboard is scored transversely prior to application of the decorative paper to facilitate subsequent rolling, preferably the scoring is so arranged as to form two spaced-apart weakened portions adjacent a cut edge of a discrete composite sheet, the scoring may be formed by cutting to form a series of in-line short slits.

In this method according to the invention, there is performed the steps of: moving a pair of rollers to contact the inner surface of the decorative sheet forming the composite sheet adjacent its ends and spaced-apart from each other; rotating the rollers to roll the ends of the composite sheet around the rollers; causing the rollers to grip the ends of the composite sheet to give a further rotation relative the central portion containing the novelty to form the twist; and retracting the rollers: additionally a vacuum may be applied to each roller to cause the decorative paper of the composite sheet to adhere thereto.

Another method of carrying out the invention comprises the sequential steps of: feeding decorative paper from a reel with its inner surface exposed; cutting the paper into discrete decorative sheets; lifting a discrete decorative sheet onto a conveyor; moving the discrete decorative sheet by the conveyor beneath a gluing head; applying glue to the discrete decorative sheet; laying a snap on each discrete decorative sheet; laying a cylinder of cardboard containing a novelty on the discrete decorative sheet; rolling the discrete decorative sheet around the cylinder; crimping the discrete decorative sheet at each end of the cylinder to form the neck; and in which separately, the sequential step are performed of making the cylinder and inserting the novelty by: cutting the cardboard into strips; rolling the cardboard to form a cylinder; applying glue to the interior of the cylinder; drying the glue; and inserting the novelty into the cylinder.

In some instances with this latter method, the additional step before applying the glue to the discrete decorative sheet is performed of: placing a label face down beneath the discrete decorative sheet; and applying the label to the discrete decorative sheet and the label may be applied by: piercing the discrete decorative sheet and the label to form some holes; at the glue application stage, applying glue over the holes; and pressing the label and discrete decorative sheet together. Preferably, the method of inserting the novelty into the cylinder comprises: carrying the novelty and cylinder together so that they are aligned; and pushing the novelty into the cylinder.

Ideally, the decorative paper is lead from more than one reel on top of each other whereby the discrete decorative sheets are alternatively stacked.

This allows crackers with different decorative paper to be delivered sequentially from the machine obviating the need for a"pick and mix"operation where it is desired to place different coloured crackers in the one box.

The rolling may comprise the steps of: moving a pair of rollers to contact the inner surface of the discrete decorative sheet adjacent its ends and spaced-apart from each other; rotating the rollers to rotate the ends of the discrete decorative sheet around the rollers; and retracting the rollers and in which the neck is formed by applying a plate having a V-shaped notch cut therein to the rolled discrete decorative sheet adjacent each end of the cylinder.

Additionally, the invention provides apparatus for use in the method comprising reel supports, cutters, gluing heads and conveyors, which further comprises: a reel for carrying the decorative paper and a separate reel for carrying cardboard so arranged as to cause the cardboard to lie intermediate the side edges of a strip of decorative paper to form a composite sheet therewith; a pair of spaced-apart hollow rollers having air inlets on the cylindrical surface thereof; means for rotating the rollers; means for moving the rollers in and out across the conveyor to contact the decorative paper; and a vacuum source connected to the interior of each roller.

In this apparatus means may be provided for cutting a line of transverse spaced-apart slits in the cardboard prior to forming the composite sheet.

The apparatus may also comprise: a novelty container having a clamshell door and mounted on a ram for movement up and down relative to the conveyor; means for opening the clamshell door; and a delivery tube for novelties having an outlet for delivery of a novelty to the novelty container.

The invention provides another apparatus for use in the method of the general type comprising real supports, cutters, gluing heads, and conveyors in which there is provided a plurality of reels for different forms of decorative paper arranged side by side so as to lead the different sheets of decorative paper on top of one another, and in which the means for applying the snaps comprises: a conveyor mounted above a main conveyor carrying a discrete decorative sheet; said conveyor comprising a belt in the form of a plurality of upstanding channels in side by side transverse configuration across the conveyor to hold one snap in each channel, the conveyor being operated in sequence with the main conveyor to move incrementally and drop a snap onto a discrete decorative sheet as it passes below and preferably this apparatus includes: a reel feeding the cardboard onto a table; a gripper for bearing down on the cardboard on the table to move the cardboard in incremental steps across the table; a transverse cutter mounted on the table; a gripper on the side of the transverse cutter remote from the reel for moving a cut piece of cardboard to a cylinder having an elongate mouth in the cylindrical wall thereof for reception of a sheet of cardboard; pusher means for moving the now formed cylinder into a conveyor, said conveyor having a plurality of cylindrical guides forming a conveyor belt into which a cylinder can be pushed; and an associated gluing head for spraying adhesive on the interior of the cardboard adjacent an exposed edge thereof to secure the cardboard to itself; and drying means for drying the adhesive.

Detailed Description of the Invention The invention will be more clearly understood from the following description of some embodiments thereof, given by way of example only, with reference to the accompanying drawings, in which: Fig. 1 is a perspective view of an apparatus for manufacturing a Christmas cracker according to the invention which also illustrates the formation of the cracker as it goes through the machine; Fig. 2 is a perspective view of portion of the apparatus removed of Fig. 1 with many parts; Figs. 3 to 6 are perspective views of another portion of the apparatus in different use positions with various other parts removed; Fig. 7 is a still further perspective view of part of the apparatus ; Fig. 8 is a perspective view of part of the apparatus illustrated in Fig. 7 with a further part added; Fig. 9 is a perspective view of portion of an alternative construction of apparatus according to the invention; Fig. 10 is a perspective view of portion of the apparatus of Fig. 9; Fig. 11 is a perspective view of another portion of the apparatus of Fig. 9; Fig. 12 is a further perspective view of part of the apparatus; Fig. 13 (a) to (e) is a side diagrammatic view illustrating part of the operation of the apparatus of Fig. 9; and Fig. 14 (a) and (b) are further diagrammatic views of this operation.

Referring to the drawings and initially to Figs. 1 to 8 inclusive, there is provided an apparatus for manufacturing a Christmas cracker indicated generally by the reference numeral 1. In the various embodiments of the invention described and illustrated, many of the parts have been removed for clarity, since to show all the parts would have been very confusing.

The terms"upstream""downstream""forwardly"and "rearwardly"are used in the sense of the trawl of the paper, cardboard and formed crackers through the apparatus.

Essentially, the apparatus comprises a feeder portion indicated generally by the reference numeral 2, a cardboard treating mechanism indicated generally by the reference numeral 3, a gluing station indicated generally by the reference numeral 4 and an assembly portion indicated generally by the reference numeral 5.

Decorative paper is identified by the reference numeral 6 and cardboard by the numeral 7. Effectively, the apparatus 1 has a feeder conveyor 8 to progress the decorative paper 6 and cardboard 7 through the feeder portion 2 to the cardboard treating mechanism 3, through the gluing station 4 and to the assembly portion 5. To avoid complexity, most of this is not shown. A take-off conveyor 9 is provided on the side of the assembly portion 5 remote from the feeder portion 2.

Referring particularly to Fig. 2 the feeder portion 2 comprises a reel 10 for cardboard 7 and a reel 11 for decorative paper 6. The cardboard treating mechanism 3 has a series of rollers and a cutter roller 12. The gluing station 4 comprises three glue heads 13 and a spaced-apart forwardly arranged glue head 14, all of which can be clearly seen in Fig. 2. Containers 15 are provided for snaps.

Referring now to Figs. 3 to 7, there is illustrated some of the assembly portion 5 comprising a pair of air motors 20 having pneumatic rams 21 on which are mounted rotatable hollow rollers 22, each having air inlets 24 connected to a vacuum pump (not shown). Mounted behind the rollers 22, that is to say,"upstream"having regard to the progression through the machine, is a cutter 25 and mounted intermediate the cutter 25 and the rollers 22 is a novelty placement device having a clamshell door 26 mounted on a ram 27. Opposite the ram 27 is a delivery tube 28. In front of the rollers 27 and on the opposite side to the delivery tube 28 namely upstream is a curved plate 30 mounted on a ram 31. Fully formed crackers are identified by the reference numeral 48.

Referring to Fig. 8, there is illustrated mounted on the side of the apparatus 1 a conveyor 35 having a belt forming a plurality of novelty containing recesses 36 which travels between an entrance hole 37 of the delivery tube 28 and a pneumatic ram 39.

In operation, cardboard 7 is led from the reel 10 to the cardboard treating mechanism 3 where the cardboard 7 is scored transversely with interrupted slits identified by the reference numeral 40 in Fig. 1 to form fold-lines to allow it to be easily rolled. The decorative paper 6 is led over other rollers so that the cardboard 7 lies on top of the decorative paper 6 forming a composite sheet as they are led through the gluing station 4 where the gluing heads 13 deposit upstanding portions of glue adjacent where the cardboard will eventually be cut and the gluing head 14 deposits a central glue portion 42 for a snap. As the composite sheet proceeds through the apparatus 1, snaps 43 (see Fig. 1) are removed from the containers 15 and placed on the central glue portion 42 and secured thereto. Subsequently, by air dryers, deliberately not shown, the glue is dried so that the three free upstanding portions of glue 41 now form a hard transverse stop. The composite sheet is then brought to the cutter 25 where a transverse cut is made dividing the composite sheet of decorative paper and cardboard into a short discrete sheets 44 (see Fig. 1).

Referring particularly to Figs. 3 to 6 the curved plate 30 is pushed by the ram 31 over the discrete sheet.

Novelties only shown and identified by the reference numeral 45 in Figs. 1,4 and 5 are delivered along the conveyor 35 to adjacent the ram 39 where a novelty is pushed by the ram 39 into the entrance 37 of the tube 28 where it is delivered to the clamshell door 26. The clamshell door 26 is then lowered by the ram 27 and opens so that the novelty is placed on the cardboard 7 as can be seen in Fig. 4. Simultaneously, the clamshell door 26 lifts and the ram 31 moves the plate 30 beneath the clamshell door 26. The rollers 22 move inwards and when pushed fully inwards, vacuum is applied to the rollers 22 through the inlets 24. The rollers 22 are rotated causing the cut paper and cardboard to be rolled up into the curved plate 30. The stops formed by the dried glue portions 41 prevent further rotation of the cardboard. There is further rotation of the rollers 22 to further twist the paper 6 to form the neck 46 of the cracker 48.

The ram 31 is retracted pulling the plate 30 containing a cracker 48 onto the conveyor 9.

Referring to Figs. 9 to 14, there is illustrated an alternative apparatus according to the present invention, only salient portions of which are illustrated as in this embodiment, many details are omitted and indeed only those details are shown that are significantly different to those of the embodiment of Figs. 1 to 8.

The apparatus is indicated generally by the reference numeral 50 and comprises a feeder portion indicated generally by the reference numeral 51, a label fixing station 52, a gluing station indicated generally by the reference numeral 53, a snap delivery station indicated generally by the reference numeral 54, a tube forming station indicated generally by the reference numeral 55 and finally, an assembly station indicated generally by the reference numeral 56.

The feeder portion 51 comprises a plurality of reels 60 on each of which is mounted decorative paper 6 which reels 60 are arranged to feed together through rollers 61 to a cutter 62 downstream of which is a vacuum operated sheet lifter 63 above a conveyor 65 which feeds a crease forming wheel 66.

The conveyor 65 has an open work belt to allow access from below. A sheet locating device for the conveyor 65 is provided by a pair of pusher lugs 70 mounted on a short auxiliary conveyor (not shown) beneath the conveyor 65 and retractable stops 71. The lugs 70 can be seen in Fig. 10 projecting through the conveyor 65.

The conveyor 65 then feeds the label fixing station 52.

The label fixing station 52 comprises a combined punch and gluing head 75 having a plurality of hollow label piercing punches having side exits (not shown) for depositing glue on paper 6. The label fixing station 52 also has a magazine 76 for labels which magazine 76 is mounted beneath the conveyor 65. An associated presser plate 77 is mounted directly above the magazine 76 and the conveyor 65 on a ram 78.

The gluing station 53 comprises four transversely arranged gluing heads 80 downstream of which is the snap delivery station 54 which is best shown in Fig. 12.

The snap delivery station 54 comprises a conveyor belt 90 mounted between a pair of drums 91,92. The conveyor belt 90 comprises a plurality of transversely arranged separate compartments each one of which can carry a snap. A shield 93 is mounted spaced-apart from the conveyor belt 90 around the pulley 91 so as to lie beneath the pulley 91 and retain snaps within the belt 90 until the snap is carried beneath, ~the pulley 91 for deposit on the conveyor belt 65.

Referring now specifically to Figs. 9 and 11 the tube forming station 55 comprises a reel holder 100 for a reel of cardboard 7 which reel holder 100 feeds through rollers 101 to a cutter 102 transversely mounted across a table 103. Mounted on one side of the table 103 is a ram 104 carrying a pusher plate blade 105. Opposite to the ram 104 and pusher blade 105 is a stationary arcuate plate which has a pusher ram 107 associated therewith.

A conveyor, indicated generally by the reference numeral 110, comprising a plurality of clamshell doors 111 is provided. The conveyor 110 travels between the arcuate place 106 to feed the assembly station 56 via a gluing head 112. A novelty carrying conveyor (not shown) similar to the conveyor 35 with an associated ram is mounted adjacent the conveyor 110 to insert a novelty into a formed tube of cardboard. However, to show this would increase the complexity of the drawings without adding anything to the description.

Referring specifically to Fig. 12 the assembly station 56 comprises a support roller 120 driven by a belt 121 by a motor 122. A pair of spaced-apart clamps 123 and crimping plates, namely upper crimping plates 124 and lower crimping plates 125 are all mounted on an assembly (not shown) which raises and lowers the clamps 123 and the crimping plates 124 so that they move towards and away from each other and opens and shuts the clamps 123 in conventional manner. A takeoff conveyor 130 is provided.

In operation, decorative paper 6 is fed from one or more of the reels 60 so that they lie one on top of the other when they are delivered to the cutter 62 where they are cut into a stack of discrete decorative sheets which are then lifted one at a time by the sheet lifter 63 onto the conveyor 65. The sheet is then passed to the crease former 66 which is simply a wheel which puts a crease in each separate discrete decorative sheet to add certain rigidity and strength thereto.

After having had a crease made in each discrete decorative sheet the paper moves along the conveyor 65 and the lugs 70 move to project up through the conveyor 65 and engage against a sheet. The sheet then is moved by the lugs 70 against the stops 71 so as to correctly align the sheet of paper on the conveyor to ensure that as the conveyor 65 starts and stops, it will hereinafter be correctly aligned with the various pieces of equipment used. The stops 71 are then raised and the sheet of paper progresses to the label fixing station 52.

Then if it is desired to place a label on the sheet the combined punch and gluing head 75 first pierces the decorative paper 6 and then deposits glue onto the decorative paper 6 through the holes in its punches. The paper 6 is then moved to above the magazine 76 and below the presser plate 77 where the presser plate 77 will force the sheet of decorative paper 6 against a label in the magazine 76 and the glue which will have permeated through the holes pierced in the decorative paper will contact the label and will be secured thereto. Labels are not always affixed to the paper.

Then the discrete decorative sheet is moved to the gluing station 53 where the necessary glue is applied. The sheet is then delivered under to the snap delivery station 54 where a snap is dropped onto each discrete decorative sheet by the conveyor belt 90 out beyond the shield 93 as can be seen clearly in Fig. 12.

Then the discrete decorative sheet carrying a snap is delivered to the assembly station 56.

Before describing the assembly operation it is necessary to describe how tubes of cardboard are formed. Referring now to Fig. 11 cardboard 6 is led to the rollers 101 onto the table 103 where it is cut into short lengths by the cutter 102. As the cardboard 6 is pushed under the cutter 102 and a sheet cut, the pusher blade 105 pushes the sheet of cardboard 7 across the table 103 into the arcuate plate 106 so that it is curled around. The novelty is loaded and then the pusher ram 107 pushes the formed roll of cardboard into one of the sockets containing the novelty of the conveyor 110 and it is then brought around the conveyor 110 until glue is applied thereto at the gluing head 112.

Referring now specifically to Figs. 12,13 and 14 and more particularly to Figs. 13 and 14, in the assembly station 56 a clam shell door 111 carrying a tube of cardboard is lowered down toward the support roller 120 and simultaneously a sheet of paper 6 is delivered by the conveyor 65 onto the rotating roller 120 (Fig. 13 (a)).

The clamshell door 111 opens to deposit the roll of cardboard onto the paper 6 (Fig. 13 (b)) and the paper 6 is pushed by the roller 120 into the clamshell door around the tube of cardboard (Fig. 13 (c)). When the paper is wrapped fully around the tube of cardboard (Fig. 13 (d)) the clamshell door 111 then partially closes but still allows the support roller 120 to remain in contact with the paper. The clamps 123 (Fig. 14 (a)) and the upper crimping plates 124 are lowered and the lower crimping plates 125 are raised. The support roller 120 continues to rotate what is now a tube of paper with the tube of cardboard inside it. The upper and lower crimping plates 124,125 engage the tube of paper to form the crimps as can be clearly seen in Fig. 14 (b) thus forming the open mouthed pulling handles. The clamps 123 and the crimping plates 124,125 are retracted and the formed cracker identified by the reference numeral 140 falls onto the conveyor 130.

Claims

CLAIMS 1. A continuous method of manufacturing a plurality of Christmas crackers of the type comprising a novelty, a roll of cardboard in the form of a cylinder surrounding the novelty, a snap comprising an elongate strip of material incorporating intermediate its ends an explosive material at a weakened portion thereof and in which the explosive material is activated when the strip is pulled apart to break the snap, a roll of decorative paper projecting beyond both ends of the cylinder and having a neck portion adjacent each end of the cylinder to close the cylinder to prevent the novelty falling out, and the free ends forming a pair of open-mouthed pulling handles, the decorative paper having an inner surface and an outer decorative surface in which the following steps are performed not necessarily sequentially: leading decorative paper from a roll of paper beneath a gluing head; applying glue to the inner surface of the paper; leading cardboard from a roll of cardboard beneath a gluing head; applying glue to the cardboard; laying the snap on the inner surface of the paper; cutting the cardboard transversely from the roll; forming the cardboard into a cylinder; delivering the novelty to the cardboard to be surrounded by the cylinder; cutting the decorative paper into discrete decorative sheets; rolling the decorative paper to surround the novelty and the cylinder; forming the necks in the decorative paper; and removing the cracker.
2. A method of manufacturing a Christmas cracker as claimed in claim 1 comprising the sequential steps of: leading decorative paper from a reel beneath the glue head; leading cardboard from a separate reel onto the inner surface of the decorative paper to contact it and form a composite sheet therewith; leading the composite sheet to a glue head; applying glue to the exposed surface of the cardboard for the snap; applying glue to the cardboard longitudinally spaced from the glue for the snap thereof to form a raised stop; laying a snap on the cardboard; cutting the composite sheet into discrete composite sheets; placing a novelty on the discrete composite sheet; rolling the discrete composite sheet around itself till an exposed edge of the cardboard sheet connects against the stop to prevent further rolling and twisting the ends relative to the central portion to form the neck.
3. A method of manufacturing a Christmas cracker as claimed in claim 2, in which the cardboard is scored transversely prior to application of the decorative paper to facilitate subsequent rolling.
4. A method of manufacturing a Christmas cracker as claimed in claim 3 in which the scoring is so arranged as to form two spaced-apart weakened portions adjacent a cut edge of a discrete composite sheet.
5. A method as claimed in claim 3 or 4, in which the scoring is formed by cutting to form a series of in line short slits.
6. A method of manufacturing a Christmas cracker as claimed in any of claims 2 to 5, comprising the steps of: moving a pair of rollers to contact the inner surface of the decorative sheet forming the composite sheet adjacent its ends and spaced apart from each other; rotating the rollers to roll the ends of the composite sheet around the rollers; causing the rollers to grip the ends of the composite sheet to give a further rotation relative the central portion containing the novelty to form the twist; and retracting the rollers.
7. A method of manufacturing a Christmas cracker as claimed in claim 6 in which a vacuum is applied to each roller to cause the decorative paper of the composite sheet to adhere thereto.
8. A method of manufacturing a Christmas cracker as claimed in claim 1, comprising the sequential steps of: feeding decorative paper from a reel with its inner surface exposed; cutting the paper into discrete decorative sheets; lifting a discrete decorative sheet onto a conveyor; moving the discrete decorative sheet by the conveyor beneath a gluing head; applying glue to the discrete decorative sheet; laying a snap on each discrete decorative sheet; laying a cylinder of cardboard containing a novelty on the discrete decorative sheet; rolling the discrete decorative sheet around the cylinder; crimping the discrete decorative sheet at each end of the cylinder to form the neck; and in which separately, the sequential step are performed of making the cylinder and inserting the novelty by: cutting the cardboard into strips; rolling the cardboard to form a cylinder; applying glue to the interior of the cylinder; drying the glue; and inserting the novelty into the cylinder.
9. A method of manufacturing a Christmas cracker as claimed in claim 8, in which the additional step before applying the glue to the discrete decorative sheet is performed of: placing a label face down beneath the discrete decorative sheet; and applying the label to the discrete decorative sheet.
10. A method of manufacturing a Christmas cracker as claimed in claim 9, in which there is performed the steps of: piercing the discrete decorative sheet and the label to form some holes; at the glue application stage, applying glue over the holes; and pressing the label and discrete decorative sheet together.
11. A method of manufacturing a Christmas cracker as claimed in any of claims 8 to 10 in which the method of inserting the novelty into the cylinder comprises: carrying the novelty and cylinder together so that they are aligned; and pushing the novelty into the cylinder.
12. A method of manufacturing a Christmas cracker as claimed in any of claims 8 to 11 in which the decorative paper is lead from more than one reel on top of each other whereby the discrete decorative sheets are alternatively stacked.
13. A method of manufacturing a Christmas cracker as claimed in any of claims 8 to 12 in which the rolling comprises the steps of moving a pair of rollers to contact the inner surface of the discrete decorative sheet adjacent its ends and spaced-apart from each other; rotating the rollers to rotate the ends of the discrete decorative sheet around the rollers; and retracting the rollers and in which the neck is formed by applying a plate having a V-shaped notch cut therein to the rolled discrete decorative sheet adjacent each end of the cylinder.
14. Apparatus for use in the method as claimed in any of claims 1 to 7 comprising reel supports, cutters, gluing heads and conveyors, which further comprises : a reel for carrying the decorative paper and a separate reel for carrying cardboard so arranged as to cause the cardboard to lie intermediate the side edges of a strip of decorative paper to form a composite sheet therewith; a pair of spaced-apart hollow rollers having air inlets on the cylindrical surface thereof; means for rotating the rollers; means for moving the rollers in and out across the conveyor to contact the decorative paper; and a vacuum source connected to the interior of each roller.
15. Apparatus as claimed in claim 14, in which means are provided for cutting a line of transverse spaced apart slits in the cardboard prior to forming the composite sheet.
16. Apparatus as claimed in claim 14 or 15, comprising: a novelty container having a clamshell door and mounted on a ram for movement up and down relative to the conveyor; means for opening the clamshell door; and a delivery tube for novelties having an outlet for delivery of a novelty to the novelty container.
17. Apparatus for use in the method as claimed in claims 8 to 13 inclusive of the general type comprising real supports, cutters, gluing heads, and conveyors in which there is provided a plurality of reels for different forms of decorative paper arranged side by side so as to lead the different sheets of decorative paper on top of one another, and in which the means for applying the snaps comprises: a conveyor mounted above a main conveyor carrying a discrete decorative sheet; said conveyor comprising a belt in the form of a plurality of upstanding channels in side by side transverse configuration across the conveyor to hold one snap in each channel, the conveyor being operated in sequence with the main conveyor to move incrementally and drop a snap onto a discrete decorative sheet as it passes below.
18. Apparatus as claimed in claim 17, in which there is provided: a reel feeding the cardboard onto a table; a gripper for bearing down on the cardboard on the table to move the cardboard in incremental steps across the table; a transverse cutter mounted on the table; a gripper on the side of the transverse cutter remote from the reel for moving a cut piece of cardboard to a cylinder having an elongate mouth in the cylindrical wall thereof for reception of a sheet of cardboard; pusher means for moving the now formed cylinder into a conveyor, said conveyor having a plurality of cylindrical guides forming a conveyor belt into which a cylinder can be pushed ; and an associated gluing head for spraying adhesive on the interior of the cardboard adjacent an exposed edge thereof to secure the cardboard to itself; and drying means for drying the adhesive.
19. A continuous method of manufacturing a plurality of Christmas crackers substantially as described herein.
20. Apparatus for use in the method of manufacturing a plurality of Christmas crackers substantially as described herein with reference to the accompanying drawings.
21. A Christmas cracker manufactured in accordance with the method of any of claims 1 to 13 and 19.
22. A Christmas cracker in accordance with the apparatus of claims 14 to 18 and 20.