Patent Application
20070015650
NOT APPLICABLE
NOT APPLICABLE
NOT APPLICABLE
The invention relates generally to sheet processing equipment, and more specifically to systems and methods for folding sheets, statements, and/or inserts prior to mailing.
Transactional printers, mail houses, and financial institutions such as credit card companies mail literally millions of documents within the United States each week. For example, credit card customers can expect to receive a monthly statement summarizing their charges for the prior month, or longer. The credit card companies, or other parties that prepare the mailings for them, are constantly on the lookout for improvements in efficiency, speed, and cost savings. Even incremental improvements in processing speed or efficiency can produce large benefits due to the huge number of mailings.
Sheet processing modules such as spiral folders are useful for processing continuous webs of paper, and are frequently an important component of mail processing systems. Yet currently used spiral folder systems and methods often suffer from significant operational drawbacks. For example, excessive sagging may occur in the center of the folded sheet stack between the spirals. This is particularly true when atypically thin or flexible material is processed in the module. Such sagging can cause the sheet to become misaligned in the sheet processing module, and can lead to paper jams, damaged forms, and the like. These failures can be costly, due to hours of machine downtime and lost operator time. To address these issues, some have suggested shortening the form length of the folded sheet, however such solutions can result in the beater assembly colliding with the chute assembly, again leading to misalignment of the sheet. Relatedly, others have proposed adjusting the beater assembly timing, but this can cause problems when different forms are loaded in the folder module. What is more, in some cases these solutions are not effective due to operator error in adjusting the form length setting or the beater timing.
In light of the above, it would be desirable to provide improved sheet processing systems and methods, particularly for processing components such as folding assemblies. The present invention addresses such needs.
The present invention provides sheet processing methods and systems that can be used with customer documents such as invoices and the like. These techniques may be particularly useful in preventing or reducing the frequency of unwanted system failures. Advantageously, the present invention provides sheet folding systems for continuous web materials having highly reliable folding configurations for long-lasting operation times with minimal downtime due to paper jams and other problems associated with paper misalignment.
In a first aspect, the present invention provides a folder system for folding a continuous web of material. The system can include a spiral folder assembly having a first set of rotatable spirals and a second set of rotatable spirals, a chute assembly that alternates between a first position and a second position, the chute assembly configured to guide the continuous web toward the first set of spirals when in the first position and toward the second set of spirals when in the second position, a beater assembly having a first beater adapted to urge the continuous web against the first set of spirals to form a first fold in the web, and a second beater adapted to urge the continuous web against the second set of spirals to form a second fold in the web, and a conveyor assembly configured to receive and transport the folded continuous web as it exits the spiral folder assembly, the conveyor assembly providing a support disposed between a first vertical plane defined by the first set of spirals and a second vertical plane defined by the second set of spirals, the support adapted to modulate an amount of sagging in the continuous web as the web is suspended between the first set of spirals and the second set of spirals. In some embodiments, the conveyor assembly includes a plurality of support rollers coupled with a support frame, and a support belt circumferentially wrapped about the plurality of support rollers.
In related embodiments, the support can be defined by at least one of the plurality of support rollers. The plurality of support rollers may define a horizontal path that extends at least one half of a horizontal distance between the first vertical plane defined by the first set of spirals and the second vertical plane defined by the second set of spirals. In some embodiments, the conveyor assembly includes a plurality of support rollers that define a substantially horizontal plane, and a support belt circumferentially wrapped about the plurality of support rollers. The conveyor assembly may also include a ramp roller, a plurality of exit rollers, a ramp belt circumferentially wrapped about the ramp roller and at least one of the plurality of exit rollers, and an exit belt circumferentially wrapped about the plurality of exit rollers. The plurality of support rollers and the ramp roller can be coupled with a support frame, and the support can be defined by at least one of the plurality of support rollers and the ramp roller. In some embodiments, the conveyor assembly may include a drive belt coupled with the ramp roller and a drive means, and a transfer belt coupled with the ramp roller and a support roller adjacent to the ramp roller. In still further embodiments, the folder system can include a first stop bar configured to restrain movement of the continuous web when the web is urged against the first set of spirals by the first beater, and a second stop bar configured to restrain movement of the continuous web when the web is urged against the second set of spirals by the second beater.
In another embodiment, the present invention provides a method for folding a continuous web of material. The method can include directing the continuous web of material with a chute assembly that alternates between a first position and a second position, guiding the continuous web toward a first set of rotatable spirals of a spiral folder assembly when the chute assembly is in the first position, guiding the continuous web toward a second set of rotatable spirals of the spiral folder assembly when the chute assembly is in the second position, urging the continuous web against the first set of spirals with a first beater of a beater assembly to form a first fold in the web, and urging the continuous web against the second set of spirals with a second beater of the beater assembly to form a second fold in the web, advancing the folded continuous web from the spiral folder assembly toward a conveyor assembly, and supporting the folded continuous web with a support of the conveyor assembly to modulate an amount of sagging in the continuous web as the web is suspended between the first set of spirals and the second set of spirals. In some embodiments, the method includes transporting the folded continuous web with the conveyor assembly by rotating a support belt circumferentially wrapped about a plurality of support rollers. The method may also include supporting the folded continuous web with at least one of the plurality of support rollers as the web is suspended between the first set of spirals and the second set of spirals.
In related embodiments, the plurality of support rollers may define a horizontal path that extends at least one half of a horizontal distance between a first vertical plane defined by the first set of spirals and a second vertical plane defined by the second set of spirals. The method may also include transporting the folded continuous web with the conveyor assembly in a downstream direction from the support rollers by rotating a ramp belt circumferentially wrapped about a ramp roller and at least one of a plurality of exit rollers. In some embodiments, the method may include advancing the folded continuous web from the spiral folder assembly onto a support belt circumferentially wrapped about a plurality of support rollers, the plurality of support rollers that define a substantially horizontal plane, rotating the support belt to advance the folded continuous web from the support belt onto a ramp belt circumferentially wrapped about a ramp roller and at least one of a plurality of exit rollers, and rotating the ramp belt to advance the folded continuous web from the ramp belt onto an exit belt circumferentially wrapped about the plurality of exit rollers.
The method may also include activating a drive means to rotate the ramp roller, and rotating a support roller adjacent to the ramp roller via a transfer belt coupled with the ramp roller and the support roller adjacent to the ramp roller. In some embodiments, the method includes restraining movement of the continuous web with a first stop bar when the web is urged against the first set of spirals by the first beater, and restraining movement of the continuous web with a second stop bar when the web is urged against the second set of spirals by the second beater. In related embodiments, the continuous web may include a sheet having a plurality of perforations, and the method may include folding the sheet along each of the plurality of perforations.
In yet another aspect, the present invention provides a method of constructing a folder system for folding a continuous web of material. The method may include coupling a system frame with a spiral folder assembly having a first set of rotatable spirals and a second set of rotatable spirals, coupling the system frame with a chute assembly that alternates between a first position and a second position, the chute assembly configured to guide the continuous web toward the first set of spirals when in the first position and toward the second set of spirals when in the second position, coupling the system frame with a beater assembly having a first beater adapted to urge the continuous web against the first set of spirals to form a first fold in the web, and a second beater adapted to urge the continuous web against the second set of spirals to form a second fold in the web, and coupling the system frame with a conveyor assembly configured to receive and transport the folded continuous web as it exits the spiral folder assembly, the conveyor assembly providing a support disposed between a first vertical plane defined by the first set of spirals and a second vertical plane defined by the second set of spirals, the support adapted to modulate an amount of sagging in the continuous web as the web is suspended between the first set of spirals and the second set of spirals. In a related embodiment, the method of constructing the conveyor assembly can include coupling a plurality of support rollers with a support frame, and circumferentially wrapping a support belt about the plurality of support rollers, the plurality of support rollers defining a horizontal path that extends at least one half of a horizontal distance between a first vertical plane defined by the first set of spirals and a second vertical plane defined by the second set of spirals. In some embodiments, the method can include coupling a plurality of support rollers with a support frame, and circumferentially wrapping a support belt about the plurality of support rollers, coupling a ramp roller with the support frame, coupling a plurality of exit rollers with the system frame, circumferentially wrapping a ramp belt about the ramp roller and at least one of the plurality of exit rollers, and circumferentially wrapping an exit belt about the plurality of exit rollers. In related embodiments, the method can include coupling the system frame with a first stop bar configured to restrain movement of the continuous web when it is urged against the first set of spirals, and a second stop bar configured to restrain movement of the continuous web when it is urged against the second set of spirals.
FIGS. 5A-F illustrate spiral folder configurations according to various embodiments of the present invention.
The present invention will find application in a wide variety of web processing environments. The systems and methods disclosed herein are useful for preventing, inhibiting, or otherwise addressing excessive or unwanted sag in sheet-like materials as they are advanced through processing systems. For example, the present invention can effectively process lightweight grades of paper (16 lb) with a large distance between perforations (14 in.) which may otherwise exhibit unwanted sag when processed using currently known systems. Advantageously, the present techniques can prevent or inhibit the exit side of a folded stack from pulling away from the stops during stack processing, and can also prevent or inhibit placement of the perforated line behind the exit beaters, both of which may occur with other known approaches for dealing with excessive sag. Relatedly, the present invention is also useful for preventing the beaters from colliding with the swing chute, and for preventing the entrance side of the folded stack from buckling against the entrance stops, which are drawbacks of present systems when they are adjusted to a different form length setting in an attempt to deal with excessive sag. Relatedly, the present invention is useful for preventing timing problems when different forms are loaded, which occurs, for example, when the exit beater timing is adjusted to help catch the perforated line.
The instant invention can provide greater support to a folded stack when compared to known systems. The instant invention can also help to maintain the perforated lines or folds closer to the folder stops. It can reduce the need to adjust form length setting and beater timing, the time needed to set-up the folder module, and the amount of damaged forms due to paper jams.
Turning now to the figures,
When the folded web 104 leaves the spiral folder assembly 110, it falls to rest on one or more rotating ramp belts 164 of ramp arrangement 160, which are wrapped circumferentially about a ramp roller 162 and an exit roller 172. As seen from this perspective, ramp belt 164 rotates in a counter-clockwise direction, illustrated by arrow 164a. Typically, rotation of exit roller 172′ is driven by a drive chain 177 which is coupled with a drive motor 175 via a drive sprocket 176. Drive motor 175 can be any of a variety of motors, such as those marketed by Zero-Max, Inc. of Plymouth, Minn. Rotation of exit roller 172′ causes exit belt to circumferentially rotate about exit rollers 172, 172′. One of the exit rollers 172 is coupled with ramp roller via ramp belt 164. Rotating ramp belt 164 operates to advance the folded web 104 from spiral folder assembly 110 toward one or more rotating exit belts 174 of exit arrangement 170. As seen from this perspective, exit belt 174, which is wrapped circumferentially about a plurality of exit rollers 172, 172′, rotates in a counter-clockwise direction, illustrated by arrow 174a. Typically, exit belt 174 of conveyor assembly 140 acts to advance the folded web 104 toward another downstream processing location as indicated by arrow 104a.
As noted previously, the present invention can prevent or inhibit the folded stack from pulling away from stops 206 and/or 208, such that web folds/perforations are kept close to or at stops 206, 208. Often, beater timing involves a leading edge of beater 232, 234 being disposed about 0.75 inches from its respective stop 206, 208, so beater 232, 234 will have ample time to force the perforated line to collapse and create a fold. Accordingly, the present invention can inhibit or prevent the perforations and/or folds from being placed at inappropriate locations relative to beaters 232 and/or 234 during web processing. For example, without the necessary support at the lower center of the folded stack, the sagging will shorten the overall horizontal distance between the perforated lines at spirals 212 and perforated lines at spirals 214. If the perforated lines are not close enough to stops 206, 208, then beater 232, 234 may not be able to effectively collapse the perforated line to cause a fold. In known systems, such as those shown in
During the web processing operation, web 204 can be continuously advanced through chute assembly 220 as it swings back and forth between position 2A and position 2B, and spirals 212 and 214 can be rotated about their own individual axes so that spiral blades 213 and 215 operate to advance the paper folds in a downward direction. This process effectively creates an accordion-type fold or fan fold in web 204. When the folded web 204 leaves the spiral folder assembly 210, it can be supported by a support 251 defined at least in part by a support assembly 250 of conveyor assembly 240. Support assembly 250 can include one or more support rollers 252, 252′ and one or more support belts 254, where support belts 254 are wrapped circumferentially about one or more support rollers 252, 252′. In some embodiments, support belts 254 are about 1.5 inches wide and about 0.0625 inches thick, and support rollers 252 are made of aluminum. Often, support 251 will be disposed between a first vertical plane 280 defined by first set of spirals 212 and a second vertical plane 290 defined by second set of spirals 214. Support 251 can be configured so as to prevent or reduce sagging of continuous web 204 as it is suspended between first set of spirals 212 and second set of spirals 214. It is appreciated that the position or orientation of support 251 can be configured in any of a variety of ways. By setting the orientation of various components of conveyor assembly 240, an operator can modulate or adjust the amount of sagging present in folded web 204. In some cases, the conveyor assembly 240 configuration will be a pre-set configuration, based on parameters such as spiral blade depth, web thickness, distance between folds or perforations in the web, and the like. Factors such as these are further discussed below in reference to FIGS. 5A-F.
What is more, the present invention contemplates a wide variety of different configurations for any of the system components, including, but not limited to, spiral folder assembly 210, chute assembly 220, assembly 230, and conveyor assembly 240. For example, conveyor assembly 240 often includes one or more support rollers 252, 252′, although in some embodiments a support roller may not be present. Ramp roller 262 may be adapted so as to provide achieve a desired effect of the invention, in the absence of a support roller 252, 252′. Relatedly, an operator may configure support arrangement 250, ramp arrangement 262, and exit arrangement 240 with any desired combination or belts and rollers. As noted previously, such configurations will often provide support 251 so as to reduce or inhibit an amount of sagging present in continuous web 204 as it is suspended or otherwise processed through first set of spirals 212 and second set of spirals 214. In some embodiments, support 251 is disposed along a horizontal plane defined by bottom ends 216 and 218, respectively, of spiral blades 213 and 215. Support 251 may be present in any of a variety of orientations and/or locations at or near this plane, so long as it provides the desired effect on the sag in continuous web 204. In many embodiments, continuous web 204 is processed along a cascade-like web processing path defined by conveyor assembly 240.
As seen from the perspective shown in
When the folded web 304 leaves the spiral folder assembly 310, it can be supported by a support 351 defined at least in part by a support assembly 350 of conveyor assembly 340. Support assembly 350 can include one or more support rollers 352 and one or more support belts 354, where support belts 354 are wrapped circumferentially about one or more support rollers 352. Support assembly 350 may also include a transfer belt 358 wrapped circumferentially about a ramp roller 362 and a support roller 352, configured to transmit rotational force from ramp roller 362 to support roller 352. In some embodiments, transfer belt 358 is made of urethane, and is about 0.5 inches wide and about 0.0625 inches thick.
As seen from the perspective shown in
As seen from the perspective shown in
As illustrated in FIGS. 5A-F, the configuration of certain system components may depend on not only the nature of the material being processed but also the nature of other components in the system. As seen in
In some embodiments, the width of the continuous web (e.g. width sc of web 504c shown in
There are a variety of ways in which folds and/or perforations in the continuous web may engage the spiral blades. For example, as shown in
In many instances conveyor assembly 540a will be configured to inhibit sagging that occurs perpendicular to the direction in which web 504a travels through the system, as shown in
In some embodiments, dimension D is about 2 inches. In some embodiments, dimension D is within a range between about 1 inch and about 3 inches. In other embodiments, dimension D is within a range between about 0.5 inches and about 3.5 inches. In some embodiments, dimension E is about 4.875 inches. In some embodiments, dimension E is within a range between about 3.875 inches and about 5.875 inches. In other embodiments, dimension E within a range between about 2.875 inches and about 6.875 inches. In some embodiments, dimensions F and G are about 3 inches. In some embodiments, dimensions F and G are within a range between about 2 inches and about 4 inches. In other embodiments, dimensions F and G are within a range between about 1 inch and about 5 inches. In some embodiments, dimension H is about 8 inches. In some embodiments, dimension H is within a range between about 6 inches and about 10 inches. In other embodiments, dimension H is within a range between about 4 inches and about 12 inches. In some embodiments, dimension I is about 2 inches. In some embodiments, dimension I is within a range between about 1 inch and about 3 inches. In other embodiments, dimension I is within a range between about 0.5 inches and about 3.5 inches.
Systems of the present invention often include two end plates 653 for supporting ramp rollers, support rollers, or both. In some embodiments, the distance between end plates 653 is about 20 inches. In some embodiments, the distance between end plates 653 is within a range between about 15 inches and about 25 inches. In other embodiments, the distance between end plates 653 is within a range between about 10 inches and about 30 inches. It is appreciated that end plate 653 can be manufactured from any of a variety of suitable materials. In some embodiments, end plate 653 is made of aluminum, and is about 0.25 inches thick.
While the above provides a full and complete disclosure of certain embodiments of the present invention, various modifications, alternate constructions and equivalents may be employed as desired. Therefore, the above description and illustrations should not be construed as limiting the invention, which is defined by the appended claims.
