Abstract:
A quarter folder comprising an input conveyer for receiving a shingled stream of half folded signatures, an aligning section for aligning the signatures, a folding section for folding the shingled stream to thereby form a quarter folded shingled stream, a singulating section to separate the shingled signatures into individual folded signatures and a re-shingling section. The quarter folder of the present invention can operate at a high speed and receive copies directly from a press.

Description:
FIELD OF THE INVENTION  
       [0001]     The present invention relates to a folding apparatus and more particularly, relates to a quarter folder for signatures.  
       BACKGROUND OF THE INVENTION  
       [0002]     The folding of paper signatures or like objects is known in the art. Generally, such folders operate at a relatively slow throughput compared to the speed of the press from which the signatures come. In view of this limitation, either the press speed is slowed down to meet that of the folding apparatus or alternatively, a plurality of the folder machines for a single press is required.  
         [0003]     Presses conventionally include folding units which bring out multiple sheet single folded assemblies in an overlapped running shingle. The assemblies are called signatures and their folded edges are called spines. The signatures in a running shingle usually move with the spines as the leading edge and with each signature set back slightly from the one which precedes it so that it travels in a shingled relationship. The single folded signature is often called a half folded signature and it often is desirable to fold the same to become a quarter folded signature. By cutting the original spine edge, a quarter folded signature may be turned into a booklet where each page is one-quarter of the original sheet of paper.  
         [0004]     Generally, the quarter folding is done on an individual signature. This operation presents an inherent limitation on the speed at which it can be done since each sheet must be individually handled and then quarter-folded.  
       SUMMARY OF THE INVENTION  
       [0005]     It is an object of the present invention to provide a folder for signatures which can operate at a high through-put.  
         [0006]     It is a further object of the present invention to provide a mobile inline quarter folder which is able to keep up with the printing speed of a relatively fast web press.  
         [0007]     According to one aspect of the present invention, there is provided a folder comprising an input conveyor for receiving a shingled stream of signatures, means for aligning the shingled stream of signatures, means for folding the shingled stream of signatures to form a folded stream of shingled signatures, means for singulating the folded stream of shingled signatures into individual folded signatures, means for re-shingling the individual folded shingled signatures into a stream.  
         [0008]     According to a further aspect of the present invention, there is provided a method for folding signatures, the method comprising the steps of providing a line of shingled signatures, aligning the shingled signatures, folding the shingled signatures, singulating the folded shingled signatures and re-shingling the singulated signatures to form shingled folded signatures.  
         [0009]     The apparatus of the present invention includes a number of different stations which operate together to provide an inline folder which can operate at high speeds. As utilized herein, the word signatures is used to designate any paper which is to be folded. In a preferred embodiment, the apparatus of the present invention is used as a quarter folder—i.e. it takes an already folded signature and further folds the same. However, it will be understood that the present invention can also be used for performing a half folded signature. The description of the preferred embodiment will generally relate to the quarter folder configuration.  
         [0010]     The first station preferably includes a crusher roller which is designed to reinforce the original half fold on the signature as well as to eliminate any air pockets to ensure proper handling of the signature throughout the apparatus. The crusher roller is preferably provided with a quick release for security purposes.  
         [0011]     The first station in a preferred embodiment also comes with a drop down air-actuated conveyor which works when a make-ready switch is turned off. In the off position, copies entering the machine are immediately diverted downwards under the machine where they may be placed into a scrap bin or alternatively, fall onto a separate conveyor which carries the product away from the machine. When the pressman is ready to commence the quarter folding operation, the make-ready switch is turned on and copies are immediately allowed to proceed to the subsequent stations. Incorporated with the drop down conveyor are sensors to detect signatures which are sufficiently out of line so as to pose a problem for further processing. When such signatures are detected, the conveyor will immediately drop down.  
         [0012]     The second station comprises an aligning station wherein there is provided a high-speed belt jogger which will accurately position the copies entering therein. The jogger includes a slightly elastic belt which is entrained about rollers. At least some of the rollers are of a non-circular configuration so as to provide a vibratory action to the stream of shingled signatures.  
         [0013]     In preferred embodiments, a tensioning arrangement is provided for the belting forming the jogger to ensure that the belt as it passes over the non-circular roller is not slipping and provides constant vibration. Furthermore, the rollers for the belt preferably are provided with a double crown arrangement to prevent the belts from derailing.  
         [0014]     A third station comprises a section for pinning the signatures and forming the pre-folding configuration. Wings of the paper entering the third section are guided to prevent subsequent problems with the handling of the signatures. In this section, the signatures are formed and folded into the desired configuration and each copy is scored to ensure a clean final fold.  
         [0015]     The fourth station is operative to finish the fold which forms the new spine of the signatures. In this regard, spring steel is used immediately after the creasing wheel to ensure a satisfactory fold. The bottom section of the folder is open so that the signature can now move without any friction on the sides which would otherwise create an uneven quarter folded copy.  
         [0016]     In the fifth station, the copies are turned through 90° so that they are in a desirable horizontal position for the subsequent operations. The arrangement is such that the subsequent high-speed section does not prematurely pull the copies out ahead of time.  
         [0017]     The sixth station is a singulating station which individually separates a stream of signatures in preparation for the re-shingling operation.  
         [0018]     The seventh station is a re-shingling operation and provides a catching and braking system which re-shingles each copy to be the same distance apart as when the signatures first entered the apparatus. Preferably, the section also has a drop down conveyor of the type discussed with respect to the first station. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0019]     Having thus generally described the invention, reference will be made to the accompanying drawings illustrating embodiments thereof, in which:  
         [0020]      FIG. 1  is a top plan view illustrating the sequence of operation for the transformation of a half fold signature into a quarter fold signature;  
         [0021]      FIG. 2  is a side elevational view thereof;  
         [0022]      FIG. 3  is a top plan view of the apparatus;  
         [0023]      FIGS. 3A and 3B  are top plan views of the front and rear portions of  FIG. 3 ;  
         [0024]      FIGS. 4A and 4B  are side elevational views thereof;  
         [0025]      FIG. 5  is a top plan view of one of the belts in a jogger section of the apparatus;  
         [0026]      FIG. 6  is a view taken along the lines  6 - 6  of  FIG. 5 ;  
         [0027]      FIG. 7  is a top plan view of the former section of the apparatus;  
         [0028]      FIG. 8  is a sectional view taken along the lines  8 - 8  of the  FIG. 7 ;  
         [0029]      FIG. 9  is a cross sectional view taken along the lines  9 - 9  of  FIG. 7 ;  
         [0030]      FIG. 10  is an expanded top plan view of the turning of the quarter folded signatures through 90 degrees; and  
         [0031]      FIG. 11  is a side elevational view thereof. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0032]     Referring to the drawings in greater detail and by reference characters thereto, there is illustrated in  FIG. 3A  the first portion of a quarter folder apparatus which is generally designated by reference numeral  10 .  
         [0033]     Quarter folder apparatus  10  is designed to receive a plurality of half fold signatures  12  coming from any suitable source of the same, including a printing press. Half fold signatures  12  are delivered to a conveyor section generally designated by reference numeral  14  and which conveyor section  14  includes a first roll  16 , a second roll  18 , and a third roll  20 . A plurality of drive belts  22  are entrained about first rolls  16  and  18 , with other drive belts  24  being entrained about second roll  18  and third roll  20 . Mounted above first roll  16  is a crusher roll  26  which is designed to reinforce the crease forming the spine of half fold signatures  12 . As may be seen in  FIG. 4A , a pneumatic cylinder  28  is mounted to a frame post  32  and to a bracket  30  on which third roll  20  is journalled. Thus, the conveyor can be moved from a normal operational position to a drop down position (as shown in dotted lines) wherein any signatures there are discharged into a container  34  situated therebelow.  
         [0034]     The subsequent section of apparatus  10  is a jogger section and to which reference will now be had. The jogger includes a plurality of rolls  46  about which belts  48  are entrained. The aligning of the signatures is accomplished by having a pair of end rolls  38  about which a jogger belt  44  is entrained. As will be seen in  FIGS. 5 and 6 , there is also provided a plurality of hexagonal rolls  40  to impart a vibratory action to jogger belt  44 . There are also a plurality of pressure rolls  42  which are designed to maintain pressure on jogger belt  44  such that a good vibratory action is achieved without any slippage of the belt  44 . The jogger belts converge in a downstream direction.  
         [0035]     Subsequently, the half folded signatures pass to a forming and folding section. In this section, there are provided a pair of lower end rolls  52 ,  54  about which a small diameter belt  58  is entrained. Between lower end rolls . 52 ,  54  there are also provided a plurality of support rolls  56 .  
         [0036]     There is also provided a pair of top end rolls  60  and  62  along with a plurality of top support rolls  64  which are pressure adjustable. A relatively narrow top belt  66  is entrained about the rolls.  
         [0037]     At the entrance to the forming and folding section, there are provided a pair of guide bars  68  and  70  ( FIG. 9 ), one being situated on each side of the apparatus. Each of the guide bars is designed to gently guide the ends of the half folded signatures with the guiding surface being convex in configuration as may be seen in  FIG. 9 .  
         [0038]     Situated further downstream are a second pair of guiding members  72 ,  73 . A pair of spring steel members  74 ,  76  are arranged to finalize the fold in the signatures. Immediately preceding spring steel members  74 ,  76  is a creasing roll  78  designed to impart a sharp crease in the signatures. At the next section, there are provided a pair of belt mounting assemblies  80 ,  80 ′. A belt  88  is entrained a roll in belt mounting assembly  80  thereabout as well as a roll  82  at the other end thereof. Mounted intermediate the rolls is a guide roller  84 . As may be seen in  FIG. 3 , a pneumatic cylinder  86  is provided for moving belt mounting assembly  80  is provided.  
         [0039]     As shown be seen in  FIG. 3 , belts  88 ,  88 ′ are twisted such that they take the signatures from a vertical direction to 90° to a horizontal direction. During all this time, the belts maintain a secure grip on the spine of the signatures.  
         [0040]     Following the folding operation, the signatures are fed to a singulating mechanism which comprises an upper conveyor  92  and a lower conveyor  102 . Upper conveyor  92  comprises a pair of end rolls  94  about which belts  100  are entrained. Mounted centrally between end rolls  94 ,  96  is a pressure roll  98 .  
         [0041]     Lower conveyor  102  includes end rolls  104 ,  106  about which belts  108  are entrained.  
         [0042]     The above arrangement is such that as signatures are fed, a nip is created between belts  100 ,  108  by means of pressure roll  98 . This section is running at a substantially higher speed than the previous section and a single signature is withdrawn from the shingled stream. In this regard, the spacing is such that the next signature is securely retained by the preceding section.  
         [0043]     The re-shingling section comprises an upper conveyor  110  which includes a pair of end rolls  112 ,  114  and adjustable pressure rolls  116 ,  118  with belts  126  entrained thereabout. A lower conveyor  120  comprises a pair of end rolls  122 ,  124  having belts  128  entrained thereabout. As may be seen from  FIG. 4B , there is also provided a pneumatic cylinder  130  mounted on bracket  132  of the frame and a bracket  134  of lower conveyor  120 . Thus, the conveyor can be dropped down or lowered to deposit undesired product in container  136 .  
         [0044]     As the signatures are travelling at an extremely high rate of speed as they exit the singulating section, the geometry of the upper conveyor  110  and lower conveyor  120  is important. As may be seen, lower conveyor  120  has a slight upward angle while there is a convergence between belts  122 ,  124  to guide the singulated shingles. Preferably, the lower conveyor is at an angle of between 4° and 6° with respect to the horizontal.  
         [0045]     Referring to  FIGS. 1 and 2 , the operation of the machine on the signatures is illustrated. As designated by reference numeral  12 , originally the signatures enter as half fold signatures and typically slightly misaligned. The signatures then go through the crusher roll and the jogger section as illustrated in reference numeral  202  where they are aligned and flattened. As shown by reference numeral  204 , as they exit the aligned or jogging section, they are in a proper shingled position. Subsequently, as indicated by reference numeral  206 , the signatures have their wings guided downwardly until, as they pass through the end of the forming section, they are as shown by reference numeral  208  with a final folding being indicated by arrows  210 .  
         [0046]     As indicated by reference numeral  212 , the shingles are then rotated through 90° to lie flat as indicated by reference numeral  214  where they pass to be singulated as indicated by reference numeral  216 .  
         [0047]     It will be understood that the above described embodiment is for purposes of illustration only and that changes and modifications may be made thereto without departing from the spirit and scope of the invention.