U.S. patent number 3,809,410 [Application Number 05/115,448] was granted by the patent office on 1974-05-07 for continuous card form.
This patent grant is currently assigned to International Business Machines Corporation. Invention is credited to Oliver D. Johnson, Kenneth B. Maynard.
United States Patent |
3,809,410 |
Johnson , et al. |
May 7, 1974 |
CONTINUOUS CARD FORM
Abstract
Improved folding during manufacture of continuous forms and
refolding during runs through a high-speed printer are obtained by
a fold score comprising a series of perforations extending across
the detachable marginal strips and transversely aligned with, and
preferably the same size as, the groups of perforations
constituting the ties between the break-out cards and intervening
medial strips. Especially in a two-card wide form, the structural
strength of each medial strip adjacent a fold score line is
suitably reduced, such as by a slot, to prevent toggle-like
stiffening at the fold line, and consequent stacking jams, such as
can occur during refolding of the form upon sudden stops following
a high-speed line skip in a printer. In grain long forms, the
overlapping plies providing the medial strip are heat sealed only
at selected areas rather than along the entire strip to reduce
medial strip shrinkage and further improve ease of stacking.
Inventors: |
Johnson; Oliver D. (E.
Brunswick, NJ), Maynard; Kenneth B. (Belle Mead, NJ) |
Assignee: |
International Business Machines
Corporation (Armonk, NY)
|
Family
ID: |
22361469 |
Appl.
No.: |
05/115,448 |
Filed: |
February 16, 1971 |
Current U.S.
Class: |
281/5;
493/410 |
Current CPC
Class: |
B41L
1/326 (20130101); G06K 19/04 (20130101) |
Current International
Class: |
B41L
1/00 (20060101); B41L 1/32 (20060101); G06K
19/04 (20060101); B42d 019/00 () |
Field of
Search: |
;281/5
;282/3B,12R,12A,12B,11.5,11.5A ;293/62 ;229/69 ;93/1R ;270/61F |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
Primary Examiner: Schnall; Jerome
Attorney, Agent or Firm: Otto, Jr.; Henry E.
Claims
1. A continuous card form of the type wherein a series of machine
processable breakout tabulating cards are detachably connected to
marginal strips containing uniformly spaced pin-feed holes and also
detachably connected to narrow medial strip portions extending
across the form and separating successive cards, and wherein cuts
and ties define respective lines of separation of each marginal
strip from the cards, and a plurality of groups of perforations and
of intervening slits that extend tangentially from the outermost
perforations of each group to those of the next group constitute
respective other lines of separation of each medial strip portion
from the cards extending between each of said marginal strips to
the other, said other lines of separation being arranged in pairs
extending across the form, each of said pairs defining one of said
medial strip portions, characterized in that at each spaced
preselected location along the form where the form is to be folded,
each marginal strip is provided with a fold score consisting solely
of respective sets of additional perforations transversely aligned
with a corresponding set of the first-mentioned perforations and
formed simultaneously therewith, and
two additional slits are provided which are cut simultaneously with
the intervening slits and extend tangentially from the respective
outermost perforation of each of such corresponding sets into the
respective marginal strips tangentially to the innermost additional
perforation aligned with such corresponding set, whereby the form
at each such location will fold along a continuous straight fold
line coincident with the center line of all the transversely
aligned perforations at said location, and will initially fold with
equal facility in either direction but, once folded, have a memory
facilitating refolding in the same direction, and
the form comprises a series of at least two parts detachably
connected to each other by lines of weakness along their respective
short edges between the marginal strips as well as detachably
connected to common medial strips, and
each medial strip that is adjacent to a fold score is conditioned
to reduce its structural strength, at least at and slightly to
either side of each point where it is intersected by an imaginary
longitudinal projection of such lines of weakness, thereby to
preclude toggle-like stiffening or
2. A continuous card form according to claim 1, further
characterized in that
said additional perforations are of the same size as the
first-mentioned perforations and extend across substantially the
entire width of the
3. A continuous card form according to claim 1, further
characterized in that
each medial strip which is adjacent a fold score has at least one
rectangular slot therein having its long dimension extending
parallel to the fold line to reduce its structural strength,
thereby to preclude
4. A continuous card form according to claim 1, further
characterized in that
said sets of additional perforations are transversely aligned with
the perforations defining the leading long edge of the medial strip
during the
5. A continuous card form according to claim 1, wherein
said medial strip is in part defined by over-lapping adhered long
edge portions of adjacent grain long cards, and
each medial strip which is adjacent a fold score has a plurality of
preselected areas spaced along its length where the overlapping
medial-strip-constituting portions are unadhered, thereby to reduce
the structural strength of such medial strip along the fold score
and to minimize strip shrinkage to preclude toggle-like stiffening
or kinking of
6. A continuous card form according to claim 1, wherein
said medial strip is in part defined by over-lapping long edge
portions of adjacent grain long cards, and
at least one slot is provided having at least one of its long
edges
7. A grain long continuous card form according to claim 6,
wherein
each slot is relatively long and narrow and cuts through only a
single ply portion of the medial strip immediately adjacent said
overlapping long
8. A continuous card form according to claim 6, wherein
the overlapping edge portions of the medial strip are adhered only
at transversely spaced areas including those between longitudinally
aligned sets of perforations in order to reduce medial strip
shrinkage and
9. A continuous card form according to claim 1, further
characterized in that
the form is a grain short continuous card form having a single ply
medial strip, and
said sets of additional perforations are transversely aligned with
the perforations defining the leading long edge of the medial strip
during the initial zigzag folding of the form, and
at least one slot is provided extending transversely of the form
and disposed between the opposing sets of slits defining the
leading and
10. A continuous form according to claim 1 characterized in
that
the said cards are "grain long" and
said medial strips extend parallel to the grain and are defined by
overlapping portions between the upper and lower ends of the
respective said at least two parts.
Description
This invention relates to continuous form stationery, and more
particularly to a continuous form comprising a series of break-out
tabulating cards with means providing initial folding with equal
facility in either direction and refolding in the same direction
without stiffening or kinking during runs through a highspeed
printer or the like.
BACKGROUND OF THE INVENTION
For many years continuous card forms have been made according to
the teachings of U. S. Pat. No. 2,700,556, assigned to the assignee
of the present invention. In these forms, the fold score in the
side marginal strips consists of a line of short cuts extending
transversely in alignment with a line of slits that constitute the
long edges of the break-out card. These slits extend between groups
of transversely aligned perforations; i.e., each group generally
consists of four perforations, and the slits extend tangentially to
said perforations and cut tangentially into the outermost
perforations in each group. These perforations are intentionally
offset from the slits and recessed within the card edges so that
the small tufts of paper fiber that remain when the ties are broken
will not impair processing of the cards through data processing
equipment.
With this arrangement, the form does not fold along a straight
line. The form tries to fold along a line coincident with the
center line of the perforations until it reaches the marginal
strips; then it shifts slightly to a line coincident with that of
the short cuts. This is not as aesthetically pleasing and precise
as having a truly straight fold line. The short cuts are cut along
the same line as the slits so they can be formed in the same
operation. To shift the line of short cuts slightly into alignment
with the center line of the perforations in an attempt to provide a
truly straight fold line would require either a more expensive tool
or an additional sequential cutting operation. But, most important,
since the short cuts are made with beveled cutting blades, forms
cannot be folded in either direction with equal facility along just
any score line. To facilitate folding with minimal effort, short
cuts have to be made alternately from the back and front of the
form; if the score is made repeatedly from the same side, the bevel
of the cutting blade will aid folding in one direction and hinder
folding in the opposite direction. It follows, then, that with fold
scores consisting of short cuts, folded stacks must have an odd
number, e.g., three, cards between each fold, when the score is
made from alternate sides to avoid folding difficulties.
Attempts to increase productivity by increasing folding speed
during manufacture of continuous card forms, and/or attempts to
refold the forms as they are processed through high-speed printers
or the like, have produced additional problems. For example, at
high printer speeds when only a few lines are printed on each card,
sudden stops following high-speed long-distance line skipping have
resulted in kinking or undesired stiffening of the form during
refolding, especially in the case of wide breakout tabulating card
forms having offset scores. To overcome this problem dummy lines of
printing could be inserted to reduce the distance of highspeed
skipping; but, obviously, this prevents optimum operation and
throughput.
SUMMARY OF THE INVENTION
Applicants have discovered that disadvantages and problems of the
type above described can be overcome by providing a continuous card
form employing a fold score consisting solely of a series of
uniformly spaced perforations transversely aligned with and
preferably the same size as the perforations along the madial
strip. This economically provides a truly straight fold line
coincident with the common center line of all of the transversely
aligned perforations. This type of fold score can always be cut
from one side of the form concurrently with the cutting of the
perforations inset from the long edges of the break-out card. This
fold score also has a memory facilitating refolding in the same
direction as the initial fold. By using this type of fold score and
reducing the inherent structural strength of the medial strip
especially in areas generally longitudinally aligned with lines of
weakness between adjacent cards of a multiple-card width form or
between card and stub portions, kinking and consequent failure to
stack properly during refolding have been eliminated. Structural
strength of the medial strip may be reduced in several ways. In the
case of either a grain long or grain short continuous card form,
cut a slot in preselected areas of the medial strip adjacent the
fold line; and/or in the case of grain long forms, bond the
overlying medial-strip-defining edges of the form only at
transversely spaced preselected areas (rather than along the entire
length of the medial strip as heretofore).
Other objects and advantages will become apparent from the
following more detailed description of the invention and from the
accompanying drawings, wherein:
FIG. 1 is a fragmentary plan view of a grain long continuous card
form according to one embodiment of the invention;
FIGS. 2 and 3 are fragmentary views, to enlarged scale, of
different portions of the form of FIG. 1;
FIG. 4 is a sectional view taken along the line 4--4 of FIG. 1,
with thickness exaggerated for clarity;
FIG. 5 is a sectional view taken along line 5--5 of FIG. 3;
FIG. 6 is a fragmentary plan view comparable to that of FIG. 2 but
of a prior art continuous card form with a widely used conventional
fold score;
FIGS. 7A and 7B are sectional views to enlarged scale taken along
the line 7--7 of FIG. 6 denoting condition of the holding tie
respectively before and after folding of the prior art form;
FIGS. 8A, 8B, and 8C are sectional views to enlarged scale taken
along the line 8--8 of FIG. 6 denoting, respectively, the position
of the card edge of the prior art form before folding, and two
positions the card edge may assume relative to the medial strip
edge after folding;
FIG. 9 is a side elevational view of the delivery section of a
printer, schematically showing the sequence of positions assumed by
a continuous form during refolding in proper manner;
FIG. 10 is a view, like FIG. 9, but showing improper refolding ue
to toggle-like stiffening of the form along the score line, such as
can occur when sudden stops follow high-speed long-distance line
skips in a high-speed printer.
FIGS. 11 and 12 are views, generally like FIG. 3, but showing other
embodiments of the invention as applied to grain long continuous
card forms; and
FIGS. 13 and 14 are views, comparable to those in FIGS. 1 and 3,
illustrating a grain short continuous card form according to still
another embodiment of the invention.
DESCRIPTION
As illustrated in FIG. 1, the invention is shown embodied in a
grain long continuous tabulating card form 10 comprising a series
of pairs of side-by-side arranged "grain long" cards 11, 12.
"Grain" means the direction in which the paper is run through a
paper machine during its manufacture, there being a greater
orientation of fibers in the direction of travel. "Grain long"
means that the grain runs in the long direction of the cards 11, 12
(see FIG. 1); whereas "grain short" means the grain runs in the
short direction (see FIG. 13). The cards 11, 12 of each pair are
detachably connected along their adjacent short ends by lines of
weakness defined by cuts, such as 13, 14, extending longitudinally
in laterally spaced and longitudinally staggered relation to
provide short holding ties 15 between the ends of the cuts. The
cards 11, 12 are detachably connected along their remote short ends
to respective marginal strips 16, 17 by a series of cutouts 18 (see
FIG. 2). These cutouts have inturned angular end portions 19, 20
that terminate in longitudinally aligned but slightly spaced short
slits 21, 22, respectively, that are thus laterally offset slightly
from the interior edge 23 of the central part of each cutout 18;
the spaces between slits 21, 22 thus serve as holding ties 24. As
illustrated, cards 11, 12 have three rounded corners 25, and a
single angled corner cut 26 at their upper left corners. Marginal
strips 16, 17 have uniformly spaced pinfeed holes 27 for receiving
the forms tractor pins (not shown) that advance the form through a
high-speed printer.
The cards 11, 12 of each pair are detachably connected to the cards
of an adjacent pair by medial strips 28. As best shown in FIGS.
2-5, these strips 28 are defined by upper and lower overlapping
edge portions U and L, respectively, which have facing stripes S of
heat-setting adhesive by which said portions are adhered to each
other to create the continuous card form. Each card 11, 12 is
detachably connected to the adjacent medial strips 28 by a
plurality of groups of transversely aligned perforations 29
identical in size and number and uniformly spaced from each other;
and a series of slits 30 that cut tangentially into and extend
tangentially from the outermost perforation of one group into the
outermost perforation of the adjacent group. The spaces between the
perforations of each group thus constitute holding ties 31 that
hold the form together until it is burst to break out the
individual cards 11, 12 from the medial strips 28 and marginal
strips 16, 17. The form as thus far described is substantially
identical with that of the prior art.
According to the invention, and as shown in FIGS. 1 to 3, the
improved form 10 has a series of uniformly spaced additional
perforations 32 extending across the marginal strips 16, 17 in
precise transverse alignment with the perforations 29 and cut
concurrently therewith in a single operation. The fold score
perforations 32 preferably are of the same diameter as perforations
29. The slits 30 that extend into the marginal strip cut
tangentially into the innermost of the perforations 32. These
perforations 32, 29 cooperate to provide a fold line (see FIG. 2)
that is perfectly straight and coincident with the center line of
all the transversely aligned perforations 32, 29.
Form 10 also has an elongated slot 34 (FIG. 3) cut from the medial
strip 28 immediately adjacent the card edge between two sets of
adjacent perforations 29. This slot preferably extends across and
to each side of an imaginary projection of the line of weakness
defined by the cuts 13, 14 and ties 15; and the slot (see FIG. 5)
has been found adequate for its intended functions even though
formed by removal of cardstock only from the lower portion L of the
medial strip 28. This slot is provided to significantly reduce the
structural strength of the medial strip 28, thereby positively to
insure that the "three-up" continuous card form 10 will assume the
proper sequence of positions, illustrated as a, b, c, d in FIG. 9,
for proper zigzag refolding on a stack 41 after leaving the tractor
feed rolls 42, 43 in the delivery section of a printer 44. Note
that fold line 33 moves progressively downward and outward to one
side successively to the positions a, b, c, and d, while the next
fold line 133 moves into proper position for progressive downward
and outward movement to the opposite side of the stack.
In FIG. 6 there is illustrated a grain long continuous card form
10' of the conventional prior art type disclosed in U. S. Pat. No.
2,700,556. Instead of perforations like 32, form 10' employs short
cuts 100 transversely aligned with and cut concurrently with slits
30' that extend tangentially from perforations 29'. These cuts 100
constitute a fold score which is made at every medial strip
irrespective of where the form is to be initially folded and later
refolded. As heretofore noted, if a form 10' is to be stacked
"three-up," i.e., with three pairs of cards 11', 12' between folds,
the beveled knife blades cut alternately from first the front, then
the back of the form 10' at each successive medial strip; but even
if this is done, the form will fold along an irregular line 101.
This irregular fold line 101 coincides with the center line of the
aligned perforations 29' until it reaches the marginal strips 16',
17'; then it shifts slightly to coincide with the line of short
cuts 100. Also, in the form 10' of the prior art, the superposed
stripes S' of heat sealing adhesive are adhered along the entire
length of the medial strip 28'; and, except for the slits 30' and
perforations 29' that define the line of separation between the
cards and medial strip, the medial strip remains intact and
structurally strong. As a result, certain problems have been
encountered which are inexpensively and successfully overcome in
the improved continuous card form 10.
It has been found that when a form like the "three-up" prior art
continuous card form 10' shown in FIG. 6 is processed through a
high-speed, e.g., 2,000 lines per minute, printer, there are
conditions under which improper refolding and misstacking will
occur; e.g., when sudden stops follow high-speed long-distance line
skips. These conditions frequently cause the fold line 101 to swing
past center; i.e., as viewed in FIG. 10, to swing initially left of
center to the position shown in a', rather than right of center.
This over-center toggle-like stiffening or kinking causes fold line
101 to become locked past center. As a result, form 10' starts to
fold along the closest downstream card edge score W and
irreversibly initiates a misstacking sequence, wherein fold line
101 and card edge score W move downward and rightward successively
to the positions shown in a', b', c'. Meanwhile, card edge score V
upstream of the locked-over-center fold line 101 buckles and folds
as shown in b' and c'. It is now impossible for the next fold line
101' to reach the left edge of stack 41', even if the form does
eventually buckle or fold along line 101. From this instant on, the
disarray will become progressively worse, requiring shutdown of the
printer to alleviate the stacking jam.
The reason why the over-center locking action occurred along fold
line 101 can best be understood by reference to FIGS. 6, 7, and 8.
In form 10', the cuts 100 in combination with the perforations 29'
provide the irregular fold line 101. Before initial folding of the
form along line 101, the holding ties 102 between perforations 29'
and the slits 30' assume the positions shown in FIGS. 7A and 8A,
respectively. Folding causes the holding ties 102 to shrink to the
extent indicated at 103 due to stresses imposed on the card fibers.
During subsequent refolding, if the card edge 104 along slit 30'
swings so as to overlap the lower portion L' of medial strip 28',
as illustrated in FIG. 8B, form 10' will fold along line 101 and
stack properly. However, if edge 104 butts against medial strip
28', as illustrated in FIG. 8C, the overcenter toggle-like locking
action shown in FIG. 10 will occur and prevent refolding.
It has been determined by actual test that this over-center locking
action is prevented by significantly reducing the strength of the
medial strip at least at one critical area along its length.
As illustrated in FIGS. 1 to 5, elongated slot 34 is a cut about
0.030 inch wide and extending from one group of perforations 29 to
the adjacent group. Where, as illustrated, the portions U, L of the
medial strip 28 do not completely overlap, it is sufficient that
the slot 34 be cut through only one of the portions, e.g., lower
portion L, of the medial strip, which desirably minimizes the
cutting force required. By having one edge of slot 34 aligned with
slit 30, the slot can be cut at the same time as and with the same
tool that cuts the slit. This slot permits the medial strip to
collapse and deflect toward the middle of the slot and thus destroy
the "beam effect" that enabled the fold line to lock over
center.
In the double-width form 10 illustrated, the critical area was
found to be adjacent the center line of the web, at and to each
side of the line of weakness separating the cards 11, 12. In forms
of other construction, the critical areas generally are aligned
with longitudinal lines of weakness because the form has the
greatest tendency to curl there transversely and thereby stiffen
into a beam that is rigid in a longitudinal direction. Hence, in a
form comprising a full size tabulating card with a short detachable
stub portion, the critical area in the medial strip would generally
be longitudinally aligned with the line of weakness separating card
and stub, irrespective of their relation to the center line of the
web. With forms of different design or printers operating at even
higher speeds, it may be necessary or desirable to remove the
over-center locking possibility from each section by a series of
slots across the entire width of the form; e.g., from each group of
perforations 29 to the adjacent group, essentially replacing all
slits 30 with slots 34.
The ease of stacking is further improved by reducing the amount of
medial strip shrinkage. This shrinkage occurs when the cards are
heated along the medial strips 2 to effect bonding of the
superposed stripes S of heat sealing adhesive. The heat causes the
medial strip to shrink and permanently become shorter in length
than the body of the card 11 or 12 to which it is attached by the
holding ties 31. This, in turn, places a greater stress on the
holding ties, increases the bending of the card form in the
transverse direction and creates a tendency for the form to fold at
a point such as W or V (FIG. 10) which is downstream or upstream of
the fold score line 101.
It has been found by actual test that medial strip shrinkage can be
substantially eliminated by heating only preselected areas of the
medial strip 28 so that the superposed strips S of heat sealing
adhesive will bond only at said areas. As illustrated in FIG. 3,
these areas preferably are longitudinally aligned with cuts 13, 14
as denoted at 150 and aligned with the opposed sets of perforations
29 as denoted at 151. For ease of manufacture, it is preferable
that the adhesive be applied as stripes S extending the full length
of the medial strips but that it be bonded only at the preselected
areas 150, 151; this may be accomplished readily be recessing the
otherwise solid heater bar (not shown) at those locations where
bonding is not desired. Of course, if preferred, the adhesive could
be selectively applied only to the preselected areas. Stripes S may
also be bonded at 153.
Other embodiments of the invention are illustrated in FIGS. 11 to
14.
FIG. 11 shows a grain long continuous card form 110 without rounded
corners or slash cuts. A slot 134 in the lower portion of the
medial strip 128 has one edge aligned with slits 130 and extending
longitudinally from the perforations 129 transversely of the line
of the cuts 113, 114.
In FIG. 12 grain long form 110' has a series of slots 134' that are
substantially larger than slots 134 and are cut through both plies
of the medial strip 128'. Both (rather than only one) of the edges
of the slots extend tangentially between adjacent sets of
perforations 129'; and these slots are provided across the form
except at the marginal strips (not shown) so as to leave unslotted
essentially only the areas 151' extending longitudinally between
opposed sets of perforations 129'.
In the cards 110, 110', fold score perforations (not shown, but
similar to perforations 32 of FIGS. 1-5) are provided in the
marginal strips in precise transverse alignment with perforations
129, 129' to provide the straight fold line 133, 133',
respectively.
FIGS. 13 and 14 illustrate a grain short continuous card form 210
in which the medial strip 228 is constituted, in conventional
manner, by only a single continuous ply or web of cardstock
appropriately provided with slits 230 and sets of perforations 229.
However, according to the invention, perforations 232 are provided
in the marginal strips 216, 217 precisely transversely aligned with
perforations 229 at selected longitudinal points where folding is
desired. One elongated slot 234 (or if desired, a plurality of
slots 234) is cut out from the medial strip 228. Since the medial
strip 228 is merely a single ply, there is, of course, no heat
sealing.
The fold score perforations, e.g., 32, 232, may be aligned with
either the leading or trailing long edge of the medial strip.
However, it has been found preferable to provide the fold score
perforations along that edge of the medial strip which is the
leading edge when the forms are initially folded. This may or may
not be the leading edge of the card during subsequent refolding, as
during a run through a printer; however, during each refolding, it
is also preferable that the fold score perforations be at the
leading edge of the medial strip.
It is to be understood that the slots 34, 134, 134' or 234, and/or
the unadhered areas between 150, 151, and/or other types of
structural weakening may be employed with each medial strip 28,
128, 128' or 228, rather than with only those adjacent a fold line
33, 133, 133' or 233, as no harm is done by weakening each medial
strip.
With the improved forms herein disclosed, fold score perforations,
e.g., 32, are provided in the marginal strips only where folding
(or refolding) is desired; thus, for a three-up form, where folding
is desired only after each series of three cards, fold perforations
will be provided only at every third medial strip. Since the form
with punched hole perforations will fold with equal facility from
either side, all fold perforations may be made from the same side,
facilitating manufacture; also, they may be made at any desired
interval according to whether one-up, two-up, three-up, four-up or
six-up forms are preferred.
Moreover, the fold score perforations provide a fold score line 33,
133, 133' or 233 of more uniform strength than that obtained with
the cuts 100 of FIG. 6. They also provide holding ties, e.g., 53 or
253, between the fold score perforations that cause negligible
breaking and/or weakening of the cardstock immediately adjacent
said perforations. In contrast, the slit cuts 100 often partially
broke the holding ties because of the bevel of the cutting blade
and/or dullness of its cutting edge. The shearing-type cutting
tools that provide the fold score perforations last longer than the
tools used to make the slit cuts 100; this facilitates initial
folding at the time of manufacture, and assures greater throughput
and reduced maintenance time.
While the invention has been particularly shown and described with
reference to preferred embodiments thereof, it will be understood
by those skilled in the art that the foregoing and other changes in
form and details may be made therein without departing from the
spirit and scope of the invention.
* * * * *