Simple pressure seal methods

Information

  • Patent Grant
  • 6312544
  • Patent Number
    6,312,544
  • Date Filed
    Monday, November 27, 2000
    24 years ago
  • Date Issued
    Tuesday, November 6, 2001
    23 years ago
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.
Description




BACKGROUND AND SUMMARY OF THE INVENTION




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”® 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.




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.




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.




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.




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.




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.




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.




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.




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.




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.




The invention also relates to 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. 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.




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.




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 there between, 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.




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.




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.




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 guiding substantially downward movement of the folded form while the form is in a substantially vertical plane.




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





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;





FIG. 2

is a top perspective view of just the pressure-seal roller assembly of the apparatus of either

FIG. 1A

or

FIG. 1B

;





FIG. 3

is a view like that of

FIG. 1A

only for another embodiment of apparatus according to the present invention;





FIG. 4

is a view like that of

FIG. 2

for the pressure-seal roller assembly of the

FIG. 3

embodiment;





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





FIG. 6

is a rear schematic view of the apparatus of FIG.


5


.











DETAILED DESCRIPTION OF THE DRAWINGS




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.


1


A. 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. 1A

, 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


.




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


.




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.




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


A). 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


.




The pressure sealing apparatus


10


also comprises a holding means for holding a business form


17


having pressure activated cohesive 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.




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


.




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.




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


.




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


.




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


.




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.




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


.





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.


1


B 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


80


is provided associated with the infeed tray


48


, which wheel


80


is driven by the roller


12


through a feed drive belt


81


.




Another 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


”.




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


.




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.




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


.




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


.




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


.




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


.





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


”.




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.




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)


230


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.




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


.




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


.




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.




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


230


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.




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.




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.




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.



Claims
  • 1. 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.
  • 2. A method as recited in claim 1 further comprising (d) diverting the form away from the folder as the form is passed downwardly during the practice of (c).
  • 3. A method as recited in claim 2 wherein (d) is practiced by moving a diverter automatically in response to reversing the direction of rotation of the pressure-seal rollers.
  • 4. A method as recited in claim 1 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.
Parent Case Info

This is a divisional of application Ser. No. 09/274,992, filed Mar. 24, 1999, now pending.

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891277 Markoe Jun 1908
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4428794 Hayskar et al. Jan 1984
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4701233 Beck et al. Oct 1987
4875965 Marzullo Oct 1989
4918128 Sakai Apr 1990
4924652 Krasuski et al. May 1990
5098511 Barnes Mar 1992
5133828 Jacques Jul 1992
5201464 File Apr 1993
5258045 Yamashita Nov 1993
5427851 Mehta Jun 1995
5772841 Lindsay Jun 1998
5814183 Miller Sep 1998
5865925 Lindsay Feb 1999
5968308 Lindsay Oct 1999
6024682 Mandel et al. Feb 2000