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.

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.

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.