U.S. patent application number 09/935162 was filed with the patent office on 2002-01-03 for simple pressure seal units and methods.
This patent application is currently assigned to MOORE NORTH AMERICA, INC.. Invention is credited to Meyer, Richard C., Parker, Rebecca L..
Application Number | 20020000299 09/935162 |
Document ID | / |
Family ID | 23050459 |
Filed Date | 2002-01-03 |
United States Patent
Application |
20020000299 |
Kind Code |
A1 |
Parker, Rebecca L. ; et
al. |
January 3, 2002 |
Simple pressure seal units and methods
Abstract
A simplified pressure sealing apparatus for acting on business
forms having pressure activated cohesive to seal the cohesive has
only two or three pressure-seal rollers for effecting proper
sealing. The pressure seal rollers may receive a folded business
form substantially immediately from the output of a folder, or one
of the pressure-seal rollers may function to both assist in folding
the form, and then pressure sealing it. The form may be held in a
flip plate above the nip between first and second pressure-seal
rollers, or a separate set of idler nip wheels may hold the form in
position once it has passed completely through the sealing nip. In
either case the form may pass completely through the sealing nip
yet be moved through the sealing nip in the opposite direction, and
then diverted to a stack.
Inventors: |
Parker, Rebecca L.; (Grand
Island, NY) ; Meyer, Richard C.; (Alfred,
ME) |
Correspondence
Address: |
NIXON & VANDERHYE P.C.
8th Floor
1100 North Glebe Road
Arlington
VA
22201-4714
US
|
Assignee: |
MOORE NORTH AMERICA, INC.
|
Family ID: |
23050459 |
Appl. No.: |
09/935162 |
Filed: |
August 23, 2001 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
09935162 |
Aug 23, 2001 |
|
|
|
09274992 |
Mar 24, 1999 |
|
|
|
Current U.S.
Class: |
156/442.1 |
Current CPC
Class: |
Y10T 156/17 20150115;
B43M 5/047 20130101; Y10T 156/1051 20150115 |
Class at
Publication: |
156/442.1 |
International
Class: |
B43M 003/00 |
Claims
What is claimed is:
1. A pressure sealing apparatus for acting on business forms having
pressure activated cohesive to seal the cohesive, said apparatus
comprising: first and second pressure-seal rollers rotatable about
substantially parallel first and second axes of rotation,
respectively, and in operative association with each other so as to
define a nip which supplies sufficient pressure so as to activate
pressure activated cohesive on a business form passing through said
nip; drive means for driving at least one of said pressure-seal
rollers to effect movement of a business form completely through
said nip; and holding means for holding a business form having
pressure activated cohesive in a position distinct from said nip
but so that the business form will substantially automatically be
engaged by and pass through said nip upon operation of said drive
means.
2. Pressure sealing apparatus as recited in claim 1 wherein said
holding means comprises a primarily vertically disposed flip plate
positioned with respect to said nip so that the trailing edge of a
business form entering the flip plate will ultimately enter said
nip and become the leading edge of the business form.
3. Pressure sealing apparatus as recited in claim 1 wherein said
drive means comprises reversible drive means for driving at least
one of said pressure-seal rollers alternately clockwise and
counterclockwise, wherein said pressure-seal rollers consist
essentially of said first and second rollers, and wherein said
holding means comprises a pair of idler nip wheels.
4. Pressure sealing apparatus as recited in claim 3 wherein said
holding means further comprises a conveyor having a business
form-engaging conveying surface extending substantially transverse
to said pressure-seal rollers and substantially in alignment with
said nip and idler nip wheels.
5. Pressure sealing apparatus as recited in claim 4 wherein said
conveyor comprises a belt conveyor driven by a reversible drive and
positioned to assist in feeding a business form to be sealed into
said nip and into association with said idler nip wheels.
6. Pressure sealing apparatus as recited in claim 5 wherein said
pressure-seal roller axes are substantially vertical; and further
comprising a forms guide positioned in association with respect to
said belt conveyor to guide forms into contact with said belt
conveyor to be fed to said nip, said forms guide mounted on the
opposite side of said nip from said idler nip wheels.
7. Pressure sealing apparatus as recited in claim 6 further
comprising a forms deflector mounted with respect to said nip and
constructed so as to allow a business form within said forms guide
to pass through said nip into contact with said idler nip wheels,
but will deflect the business form away from the forms guide when
passing from said idler nip wheels through said nip.
8. Pressure sealing apparatus as recited in claim 6 wherein said
pressure-seal rollers each have a substantially continuous constant
diameter peripheral surface having a length sufficient to engage
substantially all the surface area of a business form face brought
into contact therewith.
9. Pressure sealing apparatus as recited in claim 2 wherein said
drive means comprises reversible drive means for driving at least
one of said pressure-seal rollers alternately clockwise and
counterclockwise, and wherein said pressure-seal rollers consist
essentially of said first and second rollers.
10. Pressure sealing apparatus as recited in claim 9 further
comprising a business form folder having a discharge disposed
substantially immediately adjacent said nip on the opposite side
thereof from said flip plate, so that folded business forms are fed
by said folder into said nip.
11. Pressure sealing apparatus as recited in claim 10 further
comprising a diverter positioned adjacent said folder discharge for
diverting sealed forms passing through said nip from said flip
plate away from said folder.
12. Pressure sealing apparatus as recited in claim 2 wherein said
pressure-seal rollers consist essentially of said first and second
rollers and a third roller rotatable about a third axis of rotation
substantially parallel to said first and second axes of rotation,
and in operative association with said first roller other so as to
define a second nip which supplies sufficient pressure so as to
activate pressure activated cohesive on a business form passing
through said second nip.
13. Pressure sealing apparatus as recited in claim 12 further
comprising a business form folder, including a first folder roller
rotatable about a fourth axis of rotation substantially parallel to
said third axis, and operatively positioned with respect to said
third pressure-seal roller and first and second fold plates so that
said third roller effects folding of a business form passing
between said third pressure-seal roller and said first folder
roller, and effects sealing of the business form when passing from
said second fold plate through said second nip.
14. Pressure sealing apparatus as recited in claim 13 wherein said
pressure-seal rollers are positioned with respect to each other so
that imaginary lines passing through said axes of rotation thereof
have substantially an L-shape.
15. Pressure sealing apparatus as recited in claim 13 wherein said
drive means drives said first pressure-seal roller substantially
continuously in a first direction of rotation.
16. Pressure sealing apparatus as recited in claim 13 wherein said
pressure seal rollers each have a substantially continuous constant
diameter peripheral surface having a length sufficient to engage
substantially all the surface area of a business form face brought
into contact therewith.
17. Pressure sealing apparatus as recited in claim 13 wherein said
business form folder consists essentially of said first folder
roller, a second folder roller on the opposite side of said first
folder roller from said third pressure-seal roller, said third
pressure-seal roller, said first and second fold plates, and a feed
table for feeding business forms to be folded into a nip between
said first and second folder rollers.
18. Pressure sealing apparatus as recited in claim 1 wherein said
pressure-seal rollers consist essentially of said first and second
rollers and a third roller rotatable about a third axis of rotation
substantially parallel to said first and second axes of rotation,
and in operative association with said first roller other so as to
define a second nip which supplies sufficient pressure so as to
activate pressure activated cohesive on a business form passing
through said second nip.
19. Pressure sealing apparatus as recited in claim 18 further
comprising a business form folder, including a first folder roller
rotatable about a fourth axis of rotation substantially parallel to
said third axis, and operatively positioned with respect to said
third pressure-seal roller and first and second fold plates so that
said third roller effects folding of a business form passing
between said third pressure-seal roller and said first folder
roller, and effects sealing of the business form when passing from
said second fold plate through said second nip.
20. Pressure sealing apparatus as recited in claim 18 wherein said
pressure-seal rollers are positioned with respect to each other so
that imaginary lines passing through said axes of rotation thereof
have substantially an L-shape.
21. Pressure sealing apparatus as recited in claim 18 wherein said
drive means drives said first pressure-seal roller substantially
continuously in a first direction of rotation, and wherein said
pressure-seal rollers each have a substantially continuous constant
diameter peripheral surface having a length sufficient to engage
substantially all the surface area of a business form face brought
into contact therewith.
22. Pressure sealing apparatus as recited in claim 18 wherein said
business form folder consists essentially of said first folder
roller, a second folder roller on the opposite side of said first
folder roller from said third pressure-seal roller, said third
pressure-seal roller, said first and second fold plates, and a feed
table for feeding business forms to be folded into a nip between
said first and second folder rollers.
23. A method of handling a business form having patterns of
pressure activated cohesive, using first and second fold rollers,
and first, second and third pressure-seal rollers, first and second
fold plates, and a holding device above the first and second
pressure-seal rollers, comprising substantially automatically: (a)
feeding a business form having patterns of pressure activated
cohesive between the first and second fold rollers and into the
first fold plate, to introduce a first fold therein; (b) feeding
the form from the first fold plate to between the first fold roller
and the third pressure-seal roller and then to the second fold
plate to introduce a second fold therein; (c) feeding the form from
the second fold plate to between the third and first pressure-seal
rollers to effect activation of pressure activated cohesive on the
form, and to the holding device above the first and second
pressure-seal rollers; and (d) feeding the form from the holding
device to between the first and second pressure-seal rollers to
effect activation of pressure activated cohesive on the form so
that the form is held in folded condition.
24. A method as recited in claim 23 wherein (a)-(d) are the only
operations for effecting folding of the business form and sealing
of the folded business form.
25. A method as recited in claim 23 further comprising (e), after
(d), diverting the form from between the first and second rollers
to a stack.
26. A method as recited in claim 23 further comprising spring
pressing the third and second pressure-seal rollers into contact
with the first pressure-seal roller to provide a sealing pressure
between both the third and first pressure-seal rollers, and first
and second pressure-seal rollers, of at least about 100
pounds/lineal inch.
27. A method as recited in claim 26 further comprising driving only
the first pressure-seal roller, the third and second pressure-seal
rollers being driven by engagement with the first pressure-seal
roller.
28. A method as recited in claim 23 wherein the pressure-seal
rollers each have a substantially continuous constant diameter
peripheral surface having a length sufficient to engage
substantially all surface area of a business form face brought into
contact therewith; and wherein (c) and (d) are practiced to apply a
pressure of at least about 100 pounds/lineal inch across
substantially the entire surface of the folded form.
29. A method of handling a business form having patterns of
pressure activated cohesive, using first and second pressure-seal
rollers defining a nip therebetween, and a holding device above the
nip between the first and second pressure-seal rollers, comprising
substantially automatically: (a) feeding a folded business form
having patterns of pressure activated cohesive from a folder into
the nip from below the nip; (b) driving one or both of the
pressure-seal rollers to move the form up through the nip into the
holding device while activating pressure activated cohesive on the
form; and (c) after the form has passed completely through the nip,
reversing the direction of rotation of the pressure-seal rollers to
move the form downwardly through the nip to effect activation of
pressure activated cohesive on the form so that the form is held in
folded condition.
30. A method as recited in claim 29 further comprising (d)
diverting the form away from the folder as the form is passed
downwardly during the practice of (c).
31. A method as recited in claim 30 wherein (d) is practiced by
moving a diverter automatically in response to reversing the
direction of rotation of the pressure-seal rollers.
32. A method as recited in claim 29 wherein the pressure-seal
rollers each have a substantially continuous constant diameter
peripheral surface having a length sufficient to engage
substantially all surface area of a business form face brought into
contact therewith; and wherein (b) and (c) are practiced to apply a
pressure of at least about 100 pounds/lineal inch across
substantially the entire surface of the folded form.
33. A method of handling a business form having patterns of
pressure activated cohesive, using first and second pressure-seal
rollers rotatable about substantially vertical axes and defining a
nip therebetween, and a holding device on a second side of the nip
opposite a first side, comprising substantially automatically: (a)
feeding a folded business form having patterns of pressure
activated cohesive to a first position on the first side of the
nip; (b) moving the form substantially horizontally into the nip;
(c) driving one or both of the pressure-seal rollers to move the
form substantially horizontally through the nip into contact with
the holding device while activating pressure activated cohesive on
the form; and (d) after the form has passed completely through the
nip, reversing the direction of rotation of the pressure-seal
rollers to move the form back toward the first side of the nip
through the nip to effect activation of pressure activated cohesive
on the form so that the form is held in folded condition.
34. A method as recited in claim 33 further comprising (e)
automatically diverting the form away from the first position
during the practice of (d).
35. A method as recited in claim 34 wherein (a) is practiced by
effecting guided substantially downward movement of the folded form
while the form is in a substantially vertical plane.
36. A pressure sealing apparatus comprising: pressure-seal rollers
consisting essentially of first and second pressure-seal rollers
rotatable about substantially parallel first and second axes of
rotation, respectively, and in operative association with each
other so as to define a first nip; and a third pressure-seal roller
rotatable about a third axis of rotation substantially parallel to
said first and second axes of rotation, and in operative
association with said first roller so as to define a second nip;
wherein said pressure-seal rollers are positioned with respect to
each other so that imaginary lines passing through said axes of
rotation thereof have substantially an L-shape; holding means
located above said first nip for holding a folded sheet; and drive
means for driving at least one of said rollers to effect movement
of a folded sheet through said nips.
Description
BACKGROUND AND SUMMARY OF THE INVENTION
[0001] Business forms, particularly mailer type business forms,
having pressure sensitive cohesive (such as the type shown in U.S.
Pat. Nos. 4,918,128 and 5,427,851 and sold commercially by Toppan
Forms Ltd. of Japan under the trade designation TN-124), are
becoming increasingly popular because of the significant advantages
associated with the use of pressure activated cohesive as opposed
to heat activated adhesive or rewettable adhesive. One of many
examples of business forms utilizing this pressure activated
cohesive is shown in U.S. Pat. No. 5,201,464 (the disclosure of
which is hereby incorporated by reference herein). A wide variety
of different types of pressure sealing equipment, such as that sold
by Moore North America, Inc. under the trademark
"SpeediSealer".RTM. has been developed for utilization with such
forms, typically such equipment having at least two sets of in-line
pairs of pressure-seal rollers to apply a sealing force of at least
about 100 pounds per lineal inch to effect proper sealing of folded
forms, having the cohesive thereon. Much of this equipment is
expensive, however, and particularly the pressure-seal rollers
themselves can be very expensive. Therefore, there has been a
desire to reduce the complexity and expense of such equipment
particularly for low or mid-volume installations.
[0002] One prior art pressure seal piece of equipment that is
greatly simplified, using only two pressure-seal rollers in
association with a reversible motor, is disclosed in U.S. Pat. No.
5,133,828 (the disclosure of which is hereby incorporated by
reference herein). While that equipment is very useful, it is
impractical to automate, the forms do not pass completely through
the nip between pressure-seal rolls before they are reversed during
normal operation and therefore sometimes one edge of the form may
not be sealed as securely as desired, and the sealer is distinct
from the folding equipment for folding business form intermediates
(such as in U.S. Pat. No. 5,201,464) into folded business forms
(e.g. mailers). According to the present invention an apparatus and
method are provided which allow for automation, or at least
semi-automatic operation, of simplified pressure seal equipment,
pass the forms completely through the nip between pressure seal
rollers during operation, may be placed immediately at the output
(or near the output) of the folder, and in one embodiment even
comprise part of the folder so that one of the pressure-seal
rollers functions both to effect folding and sealing. Despite these
advantages, the apparatus according to the invention comprises only
two rollers, or in the embodiment where a portion of the
conventional folder has been eliminated only three pressure-seal
rollers, so that the equipment is simple and relatively
inexpensive.
[0003] According to one aspect of the present invention a pressure
sealing apparatus for acting on business forms having pressure
activated cohesive, to seal the cohesive, is provided. The
apparatus comprises: First and second pressure-seal rollers
rotatable about substantially parallel first and second axes of
rotation, respectively, and in operative association with each
other so as to define a nip which supplies sufficient pressure so
as to activate pressure activated cohesive on a business form
passing through the nip. Drive means for driving at least one of
the pressure-seal rollers to effect movement of a business form
completely through the nip. And holding means for holding a
business form having pressure activated cohesive in a position
distinct from the nip but so that the business form will
substantially automatically be engaged by and pass through the nip
upon operation of the drive means.
[0004] In one embodiment the holding means may comprise a primarily
vertically disposed chute positioned with respect to the nip so
that a business form within the chute and not within the nip will
be biased at least partly by gravity toward or into contact with
one of the pressure-seal rollers or the nip.
[0005] In one embodiment using a chute, the drive means comprises
reversible drive means (such as a reversible electric motor or any
other conventional type of drive) for driving at least one of the
pressure-seal rollers alternatively clockwise and counterclockwise,
and the pressure-seal rollers consist essentially of (only) first
and second rollers. The apparatus may further comprise a business
form folder having a discharge disposed substantially immediately
below the nip on the opposite side thereof from the chute, so that
folded business forms are fed by the folder into the nip.
[0006] The apparatus may still further comprise a diverter
positioned adjacent the folder discharge for diverting sealed forms
passing through the nip from the chute away from the folder.
[0007] In another embodiment using the substantially vertical
chute, the pressure-seal rollers consist essentially of (only) the
first and second rollers and a third roller rotatable about a third
axis of rotation substantially parallel to the first and second
axes of rotation, and in operative association with the first
roller so as to define a second nip which supplies sufficient
pressure so as to activate pressure activated cohesive on a
business form passing through the second nip. This embodiment may
further comprise a business form folder, including a first folder
roller rotatable about a fourth axis of rotation substantially
parallel to the third axis, and operatively positioned with respect
to the third pressure-seal roller and first and second fold plates
so that the third roller effects folding of a business form passing
between the third pressure-seal roller and the first folder roller,
and effects sealing of the business form when passing from the
second fold plate through the second nip. In the embodiment the
business form folder may consist essentially of (only) the first
folder roller, a second folder roller on the opposite side of the
first folder roller from the third pressure-seal roller, the third
pressure-seal roller, the first and second fold plates, and a feed
table for feeding business forms to be folded into a nip between
the first and second folder rollers.
[0008] The pressure-seal rollers may be positioned with respect to
each other so that imaginary lines passing through the axes of
rotation thereof have substantially an L-shape. The drive means
(such as a conventional electric motor, or any other conventional
type of drive) may drive the pressure-seal roller continuously in a
first direction of rotation. While the rollers may provide only
edge seal, in a preferred embodiment the pressure-seal rollers each
have a substantially continuous constant diameter peripheral
surface having a length sufficient to engage substantially all
surface area of a business form face brought into contact
therewith.
[0009] The holding means may take a wide variety of other forms
aside from the vertically disposed chute, and/or the vertically
disposed chute may have spring leafs, elastic portions, or other
elements associated therewith for properly retaining the form. For
example, the holding means may comprise spring leaves spring
pressed into engagement with each other, or any other suitable
conventional device for properly holding a business form or sheet
of paper in a releasable manner in a particular location. For
example, the holding means may comprise a pair of idler nip
rollers, particularly where the drive means comprises reversible
drive means for driving at least one of the pressure-seal rollers
alternately clockwise and counterclockwise, wherein the
pressure-seal rollers consist essentially of the first and second
rollers. The holding means may further comprise a conveyor having a
business form-engaging conveying surface extending substantially
transverse to the pressure-seal rollers and substantially in
alignment with the nip and idler nip wheels. For example, the
conveyor may comprise a belt conveyor driven by a reversible drive
and positioned to assist in feeding a business form to be sealed
into the nip and into association with the idler nip wheels. In
this embodiment typically the pressure-seal roller axes are
substantially vertical; and the structure further comprises a forms
guide positioned in association with respect to the belt conveyor
to guide forms into contact with the belt conveyor to be fed to the
nip, the forms guide mounted on the opposite side of the nip from
the idler nip wheels. The apparatus may further comprise a forms
deflector mounted with respect to the nip and constructed so as to
allow a business form within the forms guide to pass through the
nip into contact with the idler nip wheels, but will deflect the
business form away from the forms guide when passing from the idler
nip wheels through the nip. In this embodiment too while the
rollers may comprise edge seal rollers, preferably the
pressure-seal rollers each have a substantially continuous constant
diameter peripheral surface having a length sufficient to engage
substantially all surface area of a business form face brought into
contact therewith.
[0010] According to another aspect of the present invention a
pressure-seal apparatus is provided comprising the following
components: Pressure-seal rollers consisting essentially of first
and second pressure-seal rollers rotatable about substantially
parallel first and second axes of rotation, respectively, and in
operative association with each other so as to define a first nip;
and a third pressure-seal roller rotatable about a third axis of
rotation substantially parallel to the first and second axes of
rotation, and in operative association with the first roller so as
to define a second nip. The pressure-seal rollers are positioned
with respect to each other so that imaginary lines passing through
the axes of rotation thereof have substantially an L-shape. Holding
means located above the first nip for holding a folded sheet after
it has passed through the second nip in such a manner that the
trailing edge of the folded sheet is forced to follow the surface
of the first roller as it rotates, thereby introducing the trailing
edge into the first nip, where it becomes the leading edge of the
folded sheet. And drive means for driving at least one of the
rollers to effect movement of a folded sheet through the nips.
[0011] The invention also relates to method of handling a business
form having patterns of pressure activated cohesive, using first
and second fold rollers, and first, second and third pressure-seal
rollers, first and second fold plates, and a holding device above
the first and second pressure-seal rollers. The method may comprise
substantially automatically: (a) Feeding a business form (e.g. an
unfolded intermediate) between the first and second fold rollers
and into the first fold plate, to introduce a first fold therein.
(b) Feeding the form from the first fold plate to between the first
fold roller and the third pressure-seal roller and then to the
second fold plate to introduce a second fold therein. (c) Feeding
the form from the second fold plate to between the third and first
pressure-seal rollers to effect activation of pressure activated
cohesive on the form, and to the holding device above the first and
second pressure-seal rollers. And (d) feeding the form from the
holding device to between the first and second pressure-seal
rollers to effect activation of pressure activated cohesive on the
form so that the form is held in folded condition. The folding may
be C-fold, Z-fold, or a double fold, eccentric or uniform.
[0012] In the method, (a)-(d) may be the only operations necessary
for effective folding of the business form and sealing of the
folded business form. The method may further comprise (e), after
(d), diverting the form from between the first and second rollers
to a stack. The method may also further comprise spring pressing
the third and second pressure-seal rollers into contact with the
first pressure-seal roller to provide a sealing pressure between
both the third and first pressure-seal rollers, and first and
second pressure-seal rollers, of at least about 100 pounds/lineal
inch. Also, the method may further comprise driving only the first
pressure-seal roller, the third and second pressure-seal rollers
being driven by engagement with the first pressure-seal roller. In
the practice of the method the pressure-seal rollers may each have
a substantially continuous constant diameter peripheral surface
having a length sufficient to engage substantially all surface area
of a business form face brought into contact therewith; and (c) and
(d) may be practiced to apply a pressure of at least about 100
(e.g. 100-200) pounds/lineal inch across substantially the entire
surface of the folded form.
[0013] According to yet another aspect of the invention there is
provided a method of handling a business form having patterns of
pressure activated cohesive, using first and second pressure-seal
rollers defining a nip therebetween, and a holding device above the
nip between the first and second pressure-seal rollers, comprising
substantially automatically: (a) Feeding a folded business form
from a folder into the nip from below the nip. (b) Driving one or
both of the pressure-seal rollers to move the form up through the
nip into the holding device while activating pressure activated
cohesive on the form. And (c) after the form has passed completely
through the nip, reversing the direction of rotation of the
pressure-seal rollers to move the form downwardly through the nip
to effect activation of pressure activated cohesive on the form so
that the form is held in folded condition.
[0014] In this aspect of the invention, the method may further
comprise (d) diverting the form away from the folder as the form is
passed downwardly during the practice of (c). In fact (d) may be
practiced by moving a diverter automatically in response to
reversing the direction of rotation of the pressure-seal rollers.
In the practice of the method the pressure-seal rollers may each
have a substantially continuous constant diameter peripheral
surface having a length sufficient to engage substantially all
surface area of a business form face brought into contact
therewith; and (b) and (c) may be practiced to apply a pressure of
at least about 100 pounds/lineal inch across substantially the
entire surface of the folded form.
[0015] According to still another aspect of the invention there is
provided a method of handling a business form having patterns of
pressure activated cohesive, using first and second pressure-seal
rollers rotatable about substantially vertical axes and defining a
nip therebetween, and a holding device on a second side of the nip
opposite a first side, comprising substantially automatically: (a)
Feeding a folded business form to a first position on the first
side of the nip. (b) Moving the form substantially horizontally
into the nip. (c) Driving one or both of the pressure-seal rollers
to move the form substantially horizontally through the nip into
contact with the holding device while activating pressure activated
cohesive on the form. And (d) after the form has passed completely
through the nip, reversing the direction of rotation of the
pressure-seal rollers to move the form back toward the first side
of the nip through the nip to effect activation of pressure
activated cohesive on the form so that the form is held in folded
condition.
[0016] In this aspect of the method, there may further comprise (e)
automatically diverting the form away from the first position
during the practice of (d). Also, (a) may be practiced by effecting
guided substantially downward movement of the folded form while the
form is in a substantially vertical plane.
[0017] It is the primary object of the present invention to provide
a simple yet effective method and apparatus for substantially
automatically sealing, or folding and then sealing, business forms
having pressure activated cohesive. This and other objects of the
invention will become clear from an inspection of the detailed
description of the invention, and from the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIGS. 1A and B are side schematic views of first and second
embodiments of apparatus according to the present invention, for
both folding and then sealing business forms having pressure
activated cohesive;
[0019] FIG. 2 is a top perspective view of just the pressure-seal
roller assembly of the apparatus of either FIG. 1A or FIG. 1B;
[0020] FIG. 3 is a view like that of FIG. 1A only for another
embodiment of apparatus according to the present invention;
[0021] FIG. 4 is a view like that of FIG. 2 for the pressure-seal
roller assembly of the FIG. 3 embodiment;
[0022] FIG. 5 is a top perspective view of a third embodiment of
apparatus for sealing business forms having pressure activated
cohesive, according to the invention; and
[0023] FIG. 6 is a rear schematic view of the apparatus of FIG.
5.
DETAILED DESCRIPTION OF THE DRAWINGS
[0024] The pressure sealing apparatus embodiment of FIG. 1A is
shown generally by reference numeral 10, and is in association with
part of a conventional folder, shown generally by reference numeral
11 in FIG. 1A. In the embodiment of FIG. 1A the pressure sealing
apparatus 10 comprises first, 12, and second, 13, pressure-seal
rollers rotatable about substantially parallel first and second
axes (see FIG. 2) 14, 15, respectively. The rollers 12, 13 are
mounted in operative association with each other so as to define a
first nip 16 which supplies sufficient pressure so as to activate
pressure activated cohesive on a business form 17 (a stack of forms
17 after folding being illustrated at 18 in FIG. 1, and a stack of
unfolded intermediates that are folded and sealed to make the
business form 17 being shown at 19 in FIG. 1A) that passes through
the nip 16.
[0025] The rollers 12, 13 may be mounted in the position
illustrated in FIGS. 1A and 2 in a conventional manner including by
mounting blocks, 20, 21 for the roller 12, and 22, 23 for the
roller 13 (see FIG. 2). The rollers 12, 13 may be mounted so that
there is a slight (and perhaps adjustable) gap between them. In the
embodiment actually illustrated, however, conventional die spring
assemblies 24, 25 are provided in association with the blocks 22,
23 to bias the roller 13 into contact with the roller 12, to
provide a force sufficient to supply a pressure of at least about
100 (e.g. 100-200) pounds per lineal inch to a form 17 passing
through the nip 16.
[0026] In the embodiment illustrated in FIGS. 1A and 2, the rollers
12, 13 each have a substantially continuous constant diameter
peripheral surface 26, 27, respectively (see FIG. 2), having a
length sufficient to engage substantially all surface area of a
business form 17 brought into contact therewith. Alternatively, the
surfaces 26, 27 may be interrupted with rubber belts and grooves,
may be segmented, or may only provide peripheral sealing (such as
the rollers actually illustrated in U.S. Pat. No. 5,133,828). The
rollers 12, 13 are preferably solid, but may be hollow metal tubes
with pressed-in end caps.
[0027] The apparatus 10 also comprises drive means for driving at
least one of the rollers 12, 13 to effect movement of a business
form completely through the nip 16. While the drive means may
comprise any suitable conventional drive, such as any type of
conventional motor with associated gears, pulleys, chains,
sprockets, belts, or the like, in the embodiment illustrated in
FIGS. 1A and 2 the first roller 12 is driven by an electric motor
30 which is connected to the shaft 31 (see FIG. 2) of the roller 12
defining the axis 14 by a belt or chain 32 (see FIG. 1A) and
associated pulleys or sprockets. The motor 30 need not be
reversible, and preferably substantially continuously rotates the
roller 12 in the clockwise direction (as illustrated in FIG. 1).
Because of the engagement of the peripheral surfaces 26, 27 of the
rollers 12, 13, rotation of the roller 12 effects rotation of the
roller 13 in a counterclockwise direction. Alternatively, the
rollers 12, 13 may be connected together by gears, or a separate
drive in sync with the motor 30 may be provided for the roller
13.
[0028] The pressure sealing apparatus 10 also comprises a holding
means for holding a business form 17 having pressure activated
adhesive in a position distinct from the nip 16 but so that the
business form 17 will substantially automatically be engaged by and
pass through the nip 16 upon operation of the drive means 30, 31,
32, etc. While the holding means may comprise any suitable clamping
or holding mechanism for holding a form or document in a particular
position, in the embodiment illustrated in FIG. 1A, the holding
means comprises a primarily vertical flip plate 34 mounted above
the nip 16, and positioned with respect to the nip 16 so that the
trailing edge of a business form 17 entering the flip plate 34,
after passing through the nip 37 (e.g. substantially completely in
the flip plate 34) will be forced to follow the peripheral surface
26 of roller 12 until it enters the nip 16, thus becoming the
leading edge of form 17. In the embodiment illustrated the flip
plate 34 may be made out of sheet metal or plastic, and is
substantially the same as a conventional fold plate in a buckle
folder, and typically is adjustable to have an effective interior
length between about 3.6 and 5.5 inches.
[0029] In the embodiment illustrated in FIG. 1A, the pressure seal
apparatus 10 consists essentially of, in addition to the elements
previously described, a third pressure-seal roller 35 which
preferably is substantially the same as the rollers 12, 13 and is
rotatable about a third axis 36 (see FIG. 2) substantially parallel
to the axes 14, 15 and in operative association with the first
roller 12 so as to define a second nip 37 which supplies sufficient
pressure so as to activate pressure activated cohesive on a
business form 17 passing through the second nip 37. While the third
roller 35 may have any suitable conventional relationship with the
first roller 12 (as described above for the rollers 12, 13), in the
embodiment illustrated in the drawings the roller 35 is mounted by
the blocks 38, 39 and has conventional spring biasing
means/elements 40, 41 for biasing the roller 35 peripheral surface
42 into contact with the surface 26 of the roller 12. Rotation of
the roller 12 in a clockwise direction thus effects rotation of the
roller 35 in a counterclockwise direction, and a pressure of at
least about 100 pounds per lineal inch is applied to the form 17 by
the rollers 35, 12 passing through the second nip 37.
[0030] As is readily seen in FIGS. 1A and 2, the axes 36, 14, 15
are on the apices of a right triangle, or, looking at it another
way, the imaginary lines 43 passing through the axes 36, 14 and 14,
15, respectively (see FIG. 2) are substantially L-shaped. The
roller 35 may also have any suitable configuration, but preferably
is comparable to the configuration of the rollers 12, 13, e.g. in
the embodiment illustrated in FIG. 2 having a substantially
continuous peripheral surface.
[0031] By feeding a folded form 17 first between the second nip 37,
then into the flip plate 34, and then through the first nip 16,
after passing through the first nip 16, the form 17 is deflected by
the diverter 44 to the stack 18, e.g. in a sheet metal stacking bin
45.
[0032] Not only does the pressure seal apparatus 10 have one less
roller than most conventional pressure seal apparatus, it
cooperates with the otherwise conventional folder 11 so as to
eliminate two conventional fold rollers in the folder 11.
[0033] The folder 11 in the structure of FIG. 1A consists
essentially of a first conventional folder roller 46 rotatable
about an axis substantially parallel to the axis 36, and a second
conventional fold roller 47 cooperating with the first roller 46 on
one side thereof, the first fold roller 46 cooperating with the
third pressure-seal roller 35 and positioned with respect thereto
to effect folding. The folder 11 further consists essentially of a
feed table 48 for feeding the business forms from the stack 19 into
a nip 49 between the fold rollers 46, 47; and a first conventional
fold (or flip) plate 50, and a second conventional fold (or flip)
plate 51. The elements 48, 49, 50, and 51 are positioned in a
similar manner to that in a conventional buckle folder except that
since the roller 46 cooperates with the roller 35 the second fold
plate 51 is positioned so as to receive the form during folding
from the first fold plate 50, and then to direct the folded form
into the second nip 37.
[0034] In operation of the apparatus 10, 11, in the method of
handling a business form having patterns of pressure activated
cohesive, according to the present invention, first the business
form from the stack 19 is fed between the first and second fold
rolls 46, 47, into the first fold plate 50, to introduce a first
fold therein, as is conventional. Then the form is fed from the
first fold plate to between the first fold roller 46 and the
pressure-seal roller 35 and then into the second fold plate 51 to
introduce a second fold therein, as is conventional (except that in
the conventional folder a second set of rollers like the rollers
46, 47 is provided between the fold plates 50, 51 instead of the
third pressure-seal roller 35 cooperating with the first fold
roller 46, according to the invention). Then the form is fed from
the second fold plate 51 to the nip 37, as is conventional (except
that in the conventional folder the additional aforementioned
second set of rollers would be provided instead of pressure-seal
rollers 35, 12 to perform this fold), passage of the folded form 17
through the nip 37 effecting actuation of the pressure activated
cohesive thereon. Then the folded form 17 passes to the flip plate
34 constructed as a conventional fold plate, and positioned above
the nip 16. Then the trailing edge of form 17 follows the
peripheral surface 26 of roller 12 as it turns clockwise, and thus
the trailing edge of form 17 is pulled down into the nip 16 and
becomes the leading edge of the form 17. The nip 16 between rollers
12, 13 effects activation of the pressure activated cohesive
thereon so that the form 17 is held in a folded condition. The
above described steps are the only operations necessary to effect
folding of the form 17 and sealing thereof.
[0035] When passing through the first nip 16, the form 17 is
diverted by the diverter 44 into the stack 18 in the stacking bin
45. In the embodiment illustrated the rollers 35, 13 are spring
biased into contact with the roller 12 so that driving only the
first roller 12, with the drive means 30-32, also drives the
rollers 13, 35 by engagement of the peripheral surfaces 26, 27, 42
thereof. At each of the second nip 37 and the first nip 16, a
pressure of at least about 100 pounds per lineal inch is applied to
the form 17 to effect sealing thereof. In the embodiment
illustrated in the drawings, a pressure seal is provided by the
constant diameter peripheral surfaces 26, 27, 42 over substantially
the entire surface of the form 17 when fed through the nips 37,
16.
[0036] FIG. 1B is a side schematic view of a second embodiment of
apparatus according to the present invention that is substantially
the same as the FIG. 1A embodiment except for the relative
positions of the components. All of the components in FIG. 1B that
are the same as those in FIG. 1A are shown by the same reference
numeral. The major differences between the FIG. 1B and the FIG. 1A
embodiments are: The positions of the outfeed bin 45 and the motor
30 are swapped, the bin 45 faces left instead of right, and the
motor 30 is repositioned. That is, the motor 30 in the FIG. 1B
embodiment, compared to the FIG. 1A embodiment, is moved to a
position under the second roller 13. The angles of the various
parts are slightly different compared to those in the FIG. 1A
embodiment (e.g. although the flip plate 34 is still above the nip
16 it does not make as steep an angle leading into the nip 16).
Also a separate feed nip wheel 60 is provided associated with the
infeed tray 48, which wheel 60 is driven by the motor 30 through a
nip feed drive belt 61.
[0037] The second embodiment according to the present invention is
illustrated in FIGS. 3 and 4. In this embodiment components
comparable to those in the FIGS. 1A and 2 embodiment are shown by
the same reference numeral only preceded by a "1".
[0038] In the FIGS. 3 and 4 embodiment, the pressure seal apparatus
consists essentially of first and second rollers 112, 113, shown
having the same configuration, including with substantially
continuous constant diameter peripheral surfaces 126, 127 thereof
(see FIG. 4), although it is to be understood that any conventional
configuration of the rollers may be provided as described above
with respect to the rollers 12, 13. In this embodiment too,
mounting blocks 120-123 are utilized, as well as conventional
spring biasing devices 124, 125.
[0039] In the FIGS. 3 and 4 embodiments, the holding means, in the
form of the chute 134, is similar to that in FIG. 1, except that
the chute 134 is almost completely vertical, and need not be a
fold/flip plate, and may be stationarily (but removably) mounted
substantially immediately vertically above the nip 116. Also, in
the FIGS. 3 and 4 embodiment the motor 130 is a reversible motor
for driving at least one of the rollers 112, 113 (in the embodiment
illustrated just the first roller 112) alternatively clockwise and
counterclockwise, or any other suitable reversible drive means may
be provided in place of the reversible motor 130, shaft 131, and
belt or chains 132 with conventional pulleys or sprockets. Also, in
the FIGS. 3 and 4 embodiment, the diverter 144 may be a
substantially tear-drop shape bar or similar element that is
automatically moved from the rightmost position in FIG. 3 which
guides the form into the nip 116 from the bottom, to the leftmost
position illustrated in FIG. 3, which diverts the form 17 from the
nip 116 as it is moving downwardly toward the stacking bin 145. The
pivotal movement of the bar 144 may be automatic when the rollers
112, 113 are reversed, as by utilizing a stepper motor, cam,
solenoid, or any other suitable conventional structure.
[0040] The folder 111 illustrated in FIG. 3 is entirely
conventional except for the juxtaposition thereof in association
with the pressure seal apparatus 110. It includes the conventional
feed table 148, first and second fold rollers 146, 147, first and
second fold plates 150, 151, respectively, and third and fourth
fold rollers 55, 56, the third fold roller 55 cooperating with both
the first fold roller 146 and the fourth fold roller 56.
[0041] In the method of operation of the folding and sealing
procedure utilizing the apparatus 110, 111 in FIGS. 3 and 4, the
business forms 17 from the stack 19 (an intermediate construction
at that time) are fed one at a time between the rollers 146, 147 up
to the first fold plate 150, then from the first fold plate 150
between the rollers 146, 55 into the second fold plate 151 to
introduce the second fold therein, and then from the second fold
plate 151 to between the rollers 55, 56, which drive the folded
form 17 from the folder 111 up to the nip 116, approaching it from
below. The folding action provided by the folder 111 is entirely
conventional, except for the third and fourth fold rollers 55, 56
discharging the folded form 17 substantially immediately into the
nip 116. Note that the diverter bar 144 is in the rightmost
position illustrated in FIG. 3 as the folded form 17 is being fed
up into the nip 116.
[0042] One or both of the rollers 112, 113 (just the roller 112 in
the embodiment illustrated in FIGS. 3 and 4) are driven to move the
form 17 up and completely through the nip 116 into the holding
device/chute 134, while activating the pressure activated cohesive
on the form. After the form 17 has passed completely through the
nip 116, the direction of rotation of the rollers 112, 113 is
reversed, by reversing the reversible motor 130, to move the form
117 (which is already biased by gravity toward and/or into contact
with one of the rollers 112, 113 or the nip 116), and the form 17
is powered through the nip 116 downwardly, deflected by the
diverter 144 in the leftmost position illustrated in FIG. 3 so that
the folded and now sealed (so that it is held in a folded
condition) form 17 is deposited in the stacking bin 145.
[0043] The reversing of the motor 130 may be accomplished on a time
basis, or by utilizing conventional sensors of any suitable type
(such as optical sensors) which sense, for example, when the form
is passing through the rollers 55, 56, when it is completely
through the nip 116 going upwardly, etc. The motor 130 drives the
roll 112 counterclockwise when the form 17 is being moved upwardly
through the nip 116, and clockwise when being moved downwardly
through the nip 116.
[0044] FIGS. 5 and 6 illustrate another pressure seal apparatus
according to the present invention. In the FIGS. 5 and 6 embodiment
components comparable to those in the FIGS. 1 through 4 embodiments
are shown by the same two digit reference numeral only preceded by
a "2".
[0045] In the FIGS. 5 and 6 embodiment the axes 214, 215 are
preferably substantially vertical, rather than the preferably
substantially horizontal axes in the FIGS. 1 through 4 embodiments.
The motor 230 is reversible and is part of the conventional drive
means for driving the first roller 212. The folder 211 is located
above the pressure seal apparatus 210, and not immediately in
association therewith.
[0046] In the FIGS. 5 and 6 embodiment, the holding means 234 (best
seen in FIG. 6) comprises first and second idler nip rollers 60
rotatable about substantially vertical axes. The holding means also
preferably comprises a conveyor, such as the conveyor belt 62
driven by a reversible motor (or any other suitable drive device)
63 by rotating the shaft 64 of one of the rollers 65 engaging the
belt 62. The conveyor 62 also feeds the form 17 to the nip 216.
Alternatively, some other conveyance apparatus for feeding the form
17 to the nip 216 may be provided, and the nip wheels 60 could be
powered.
[0047] The pressure seal apparatus further preferably comprises a
forms guide, shown generally by reference numeral 67, for guiding a
form 17 having a substantially upright configuration when deposited
by the folder 211 onto the conveyor belt 62. The forms guide 67 may
comprise a pair of top-to-bottom converging (as seen in FIG. 5)
plates 68, 69 open at the bottom and top, with the bottom just
slightly above the conveyor belt 62.
[0048] The sealing apparatus 210 also preferably comprises a forms
deflector 71 mounted with respect to the nip 216 and constructed so
as to allow a business form 17 within the forms guide 67 to pass
through the nip 216 into contact with the nip wheels 60, but
deflecting the form 17 away from the forms guide 67 when the sealed
mailer 17 passes from the idler nip wheels 60 back through the nip
216.
[0049] The form 17 illustrated in FIG. 5 has a portion of the top
face thereof cut away so as to illustrate, schematically, a pattern
(in this case strip) of pressure activated cohesive 72 thereon.
[0050] In the method of handling a business form 17 having patterns
of cohesive 72 thereon utilizing the apparatus 210 of FIGS. 5 and
6, a folded business form 17 from folder 211 is fed to a first
position on the first side (the side illustrated in FIG. 5) of the
nip 216, as by being guided by the forms guide 67 into contact with
the conveyor belt 62 while the form 17 is in a substantially
vertical plane, as illustrated in FIG. 5. Then the form 17 is moved
substantially horizontally into the nip 216, as by at least an
initial movement with the conveyor belt 62 being rotated by the
reversible drive 63 so that the top surface thereof moves toward
the nip 216. Then one or both of the pressure-seal rollers 212, 213
is/are driven to move the form 17 substantially horizontally
through the nip 216 into contact with the holding device, such as
the idler nip wheels 234/60, while activating the pressure
activated cohesive 72 on the form 17. Then, after the form 17 has
passed completely through the nip 216, the direction of rotation of
the pressure-seal rollers 212, 213 is reversed (e.g. by reversing
the motor 230) and the direction of rotation of the conveyor belt
62 is reversed (e.g. by reversing the motor 63) to move the form
back toward the first side of the nip 216, through the nip 216, to
effect activation of the pressure activated cohesive 72 on the form
so that the form 17 is held in the folded condition illustrated in
FIG. 5. During the movement back from the holding device 234, 60
through the nip 216, the deflector 71 deflects the form 17 away
from the forms guide 67, and onto another apparatus such as a
stacking bin, conveyor, or any other suitable conventional device,
or it may be moved by the operator by hand.
[0051] In the FIGS. 5 and 6 embodiment, the reversing action of the
motor 230 and the drive 63 may be accomplished by any suitable
devices, such as the conventional means described above with
respect to the FIGS. 3 and 4 embodiment.
[0052] It will thus be seen that according to the present invention
a very effective apparatus and method have been provided for
pressure sealing, and typically also folding, business forms, such
as mailer type business forms, having pressure activated cohesive
thereon, and in a substantially automatic (automatic or at least
semi-automatic) manner, and in such a way that the forms are passed
completely through the nip each time a sealing action/pass is
practiced; yet the apparatus and method are simple and relatively
inexpensive.
[0053] While the invention has been herein shown and described in
what is presently conceived to be the most practical and preferred
embodiment thereof, it will be apparent to those of ordinary skill
in the art that many modifications may be made thereof within the
scope of the invention, which scope is to be accorded the broadest
interpretation of the appended claims so as to encompass all
equivalent apparatus and methods.
* * * * *