Moore Business Forms, Inc.

Michael S Kalisiak

John E Traise

Eugene E Mietlicki

Rebecca L Parker

Richard S Downing

John Van De Ven

David G Wagner

Daniel F Pustelnik

A vertical pressure sealing assembly is disclosed for sealing four edges of a business form. The assembly defines a business form path in a single vertical plane. The assembly includes two sealing modules each having a frame to support upper and lower sealing wheels. The sealing wheels are aligned with the outer edges of the business form. Each sealing module includes a first and second pair of upper/lower sealing wheels on each side of the module frame. The first frame is positioned vertically above and offset from the second sealing module. The second sealing module is orthogonal to the first module. A form chute between the two sealing modules is positioned immediately below the first sealing module and adjacent the second sealing module. Conveyor belts and drive wheels are used to move the business form through the vertical pressure sealing assembly.

Vertical pressure sealer apparatus

An integrated system is provided for folding, inserting, pressure sealing, delivering, and optionally separating into different jobs, mailer type business forms. A common housing mounted by wheels supports in, or on, it: a folder for folding paper sheets with pressure activated adhesive to form to form pre-mailers; an inserter for receipt of pre-mailers from the folder and for placing insert sheets into the pre-mailers; a conventional pressure sealer module for pressure sealing pre-mailers to form mailer type business forms; and a delivery device for delivering stacked forms horizontally out of a bottom portion of the housing. A separator modification of the delivery device may be provided for receipt of sealed mailers to separate the mailers into different stacked groups. Typically the forms move generally downwardly during processing. The inserter includes a pair of reversible vacuum drums which grasp a folded paper sheet and move it apart to receive a substantially linearly driven insert. The separator includes parallel belt conveyor assemblies which can be reciprocated in a horizontal direction perpendicular to a stacking direction.

Integrated compact folder/sealer/inserter

A system and method for pressure sealing business forms provide for maximum utilization of floor space and ease of control by an operator. First and second pressure sealing devices, each having upper and lower sets of rollers forming nips for sealing business forms only along strips of pressure sensitive adhesive, are mounted one above the other. A common drive is provided for the drive rollers of each set, for each sealing device. Tape conveyors assist in conveying the forms through the first sealer, around a horizontal axis large diameter drum, and from the large diameter drum through a second sealer, the forms moving in the opposite direction to the one they moved in through the first sealer when going through the second sealer. A rotator is provided between the drum and the second sealer for changing the orientation of the forms about 90.degree.. The forms are fed to the first sealer by an infeed conveyor/deshingler, and are removed from the second sealer by an outfeed conveyor/stacker.

Stacked pressure seal method

Business forms having machine readable elements, such as zipcodes, are separated into discrete groups by laterally shifting one end of a carriage onto which the forms travel from forms handling equipment. The carriage has a first end which is oscillated in a generally horizontal plane by an eccentric and arm driven by a stepper motor in response to sensing of the zipcodes by an optical scanner. A second end of the carriage is mounted for only limited oscillatory movement. A number of endless conveyor tapes are associated with the carriage, extending around a first grooved roller mounted at the first end of the carriage, and around a driven second grooved roller mounted on a frame distinct from the carriage adjacent the second end of the carriage. The tapes are circular in cross-section and disposed at an angle of between about 2.degree.-5.degree. with respect to the direction of movement of the forms in the maximum shift position, and discharge the forms onto a conveyor belt downstream of the second end of the carriage. Lateral shifting of the first end of the carriage, about one inch either side of center, takes place each time the sensor detects a zipcode change in response to the zipcode change, controlling the stepper motor and the motor driving the conveyor tapes through a CPU.

Forms separating conveyance

Apparatus is provided for preventing a sheet drooping during sheet feeding in a first direction in a generally horizontal plane where a sheet is not entirely supported by a conveyor. A rod is mounted below the plane, having at least one collar with a support pin extending radially outwardly from the collar making an engagement angle of about 55-85 with respect to a second plane parallel to the horizontal plane and passing through the rod. The position of the support pin with respect to the rod may be readily adjusted, both the angle with respect to the second plane, and along the rod. Adjustment of the position of the collar with respect to the rod, in both modes, may be provided by a screw threaded fastener extending in a screw threaded bore intersecting the rod, and about 90.degree. circumferentially spaced from the support pin. The support pin may have a truncated cone end with a rounded tip at the end for engaging a sheet. Also the position of the rod with respect to a feeding conveyor may be adjusted, as by using notched side plates that the rod fits in and is stabilized in so that it does not rotate with respect to the side plate.

Delivering and stacking short grain forms

Continuous forms (e.g. computer paper with individual sheets separated by perforations) of one job are automatically folded and separated from the forms of the next job. Detectable marks are printed within a window onto the first form of one job, or the last of another, in a first mode, or the forms are counted in a second mode. The marks within the window are sensed by an LED sensor, which feeds information to a computer (microprocessor) control. The computer control effects operation of a cutting blade to sever the last form of one job from the first form of the next. The forms are automatically folded in a festooning action by a Bunch folder. Hall effect sensors are mounted for cooperation with notched discs on the same shaft as beaters of the Bunch folder, and function as end of travel limit switches for the folder swing chute, to provide relevant data to the microprocessor for proper operation of the cutting blade.

Job separator control

Sheets, such as business forms, are turned so that their orientation is changed from landscape to portrait mode, or vice versa. Simple apparatus effects sheet rotation, and includes a conveyance surface on which a sheet travels in a first direction, first and second rollers for engaging the sheet traveling on the conveyance surface, and first and second drives (e.g., D.C. stepper motors) for driving the first and second rollers independently of each other. A sensor senses the position of the sheet just downstream of the rollers, and a controller (computer)--in response to the sensor--controls the speed and direction of rotation of the motors so that one roller rotates with a given tangential speed in a first direction of rotation, while the other roller rotates at that same speed in an opposite direction of rotation.

Rotation of a document through a finite angle

The skew angle of a sheet (e.g., business form or other document) is detected by providing two sensors spaced from each other a known distance along a straight line perpendicular to the direction of conveyance of the sheet. If there is a skew, the distance travelled by the sheet leading edge between sensings by the sensors is determined, and the skew angle calculated from its tangent. First and second independent drive rollers under the sheet are driven in opposite directions of rotation to compensate for the skew angle. The rollers preferably act in conjunction with a controller (computer) to not only reorient the sheet to compensate for the skew, but also to rotate the document through a significant angle (e.g., 90.degree.) to give the sheet a second orientation different from its initial orientation (e.g., from portrait to landscape).

Compensation for skewing of documents during a rotation through a finite

Stacked table top pressure sealer system

Apparatus and methods are provided for ensuring predetermined lengthwise registration of interstacked form parts forming a unitary form. The form includes a continuous web comprised of longitudinally adjacent forms, each having a pair of transversely adjacent form parts. Each form part has a registration mark identifying the form parts as parts of a first form. Each registration mark has discrete portions including a count portion which specifically identifies the form parts as part of a predetermined form of a predetermined plurality of forms. When the form parts are interstacked, the registration marks are sensed to determine the accurate transverse alignment of the interstacked form parts and provide an error signal in response to a sensed lack of registration of the corresponding form parts.

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North Tonawanda, NY, United States of America

Michael S Kalisiak