Abstract:
A system and method for automatically producing folded and sealed printed products from form sheets includes a high-speed printer interconnected with a conveyor which directs form sheets from the outfeed of the printer to the infeed of a folder gluer. In an alternative embodiment for producing such products from a form web, the system and method includes a burster interconnected with a conveyor to separate the printed form web into form sheets. Means for controlling the system include jam detection means for sensing and stopping all system components in the event of a form jam. Means for communicating between the printer and conveyor align those elements without need for conventional hard wiring or mechanical fasteners. Means for communicating between the burster and conveyor includes a simple cable and cable connections.

Description:
BACKGROUND OF THE INVENTION 
     The present invention relates to an improved system and method for producing sealed printed products, in particular, for automatically printing, conveying, folding and sealing sheet materials for mailing. The present invention further relates to apparatus and control modifications to provide for automatically conveying and controlling printed materials in a folder/gluer. 
     In the production of folded and sealed printed products, such as mailers, checks, bills and the like, the products are typically printed on individual form sheets or on continuous form webs which are thereafter burst, and the printed form sheets or form webs stacked in a chute. Thereafter, the printed sheets or form webs are manually stacked at the infeed of a folder or folder/gluer. Wilson, U.S. Pat. No. 3,552,282 shows one such system. 
     As regards the folding of printed form sheets or form webs, interconnection of printing devices with folders has long been known, shown with respect to mimeograph machines by Smith, U.S. Pat. No. 2,807,463, blueprint machines by Funk, U.S. Pat. No. 3,961,781 and web printing presses by Vijuk, U.S. Pat. No. 4,616,815 and Bay, U.S. Pat. No. 4,705,496. Smith discloses a passive surface on which a mimeographed sheet is sent into a folder, while Funk discloses an inclinable belt conveyor. In the automatic handling of webs, Vijuk requires an intermediate stack to form before the form web is advanced for folding, while Bay inverts the web during transport along a feeding track or channel. 
     By contrast, the step of manually stacking sheets for folding and gluing typically continues. Lubotta et al, U.S. Pat. No. 4,668,211 discloses schematically, without more, that a printed blank may exit from a laser printer into a conventional folder and gluer. 
     Forms entering a conventional folder/gluer require proper registration to assure the correct application of adhesives, establishment of fold lines, and alignment of perforations. Such registration is not provided by simple interconnection of known systems. There remains, therefore, a need for development of both systems and means for automatically producing folded and sealed printed products which will automate the production of such products from initial infeed of forms to the final folded and glued product. 
     SUMMARY OF THE INVENTION 
     The present invention meets that need by providing a system in which a high-speed printer is interconnected with a folder/gluer to convey, fold and seal form sheets automatically. A conveyor attached at the infeed of the folder/gluer conveys form sheets from the outfeed of the high-speed printer, preferably a laser printer, to the infeed of the folder/gluer. The system further includes means for controlling the operation of the interconnected printer and folder/gluer. 
     The means for controlling includes first, second and third jam detection sensors located on the conveyor at the end nearest the printer, at the infeed of the folder/gluer, and at the outfeed of the folder/gluer. The sensors provide signals indicating the passage of forms through the folder/gluer. Means for signalling a form jam, preferably a printed circuit board, receives signals from the first, second and third sensors and generates a control signal to stop the printer, conveyor and folder/gluer in the event of a jam. 
     First means for communicating between the printer and conveyor are disposed on the high-speed printer and mate with second means for communicating disposed on the conveyor. The second means for communicating includes at least one docking pin and at least one light source, preferably, a light emitting diode. The first means for communicating includes at least one aperture matable with one of the docking pins, and at least one light sensor, such as a light sensitive transistor or a fiber optic cable attached to such a transistor, aligned with the light source. The light sensor is further connected to means for operating the high-speed printer. At least one of the light sources and light sensors are used to convey control signals to stop the printer in the event a jam is detected in the folder/gluer. 
     In an alternative embodiment, the high-speed printer is a high-speed laser printer for printing form webs, and includes a burster to separate the form web into individual sheets before discharge onto the conveyor. In the event of a form jam, the control signal also stops the burster. In this embodiment the printer may be connected in line with the burster, or separated so that form webs are manually stacked at the infeed of the burster. Regardless, in the alternative embodiment the burster is positioned between the printer and conveyor, and interfaces with the conveyor. 
     Further, in the alternative embodiment, a third means for communicating between the burster and conveyor is disposed on the burster. While third means for communicating may be identical to first means for communicating, it is preferred to provide instead only a first cable connection for controlling the burster in the event of a jam. Second means for communicating thus further includes a second cable connection for receiving control signals, and control signals are relayed to the burster by an interface cable interconnected between the first and second cable connections of second and third means for communicating. Where the printer and burster are connected for automatically feeding the form web to the burster, the control signal is further relayed from the burster to stop the printer. 
     In a further aspect of the present invention, a method is provided for automatically printing, conveying, folding and gluing form sheets into sealed, folded printed products, including steps of sensing for jam detection. Alternatively, the method is adapted for automatic production of sealed, folded printed products from a form web. 
     It is thus an object of the present invention to provide a completely automatic system for printing, conveying, folding and gluing form sheets and form webs into sealed, folded and printed products. 
     It is an object of the present invention to provide an automatic system for bursting, conveying, folding and gluing form sheets from a printed form web into sealed, folded and printed products. 
     It is another object of the present invention to provide a means for controlling wherein all elements of the system may be stopped in the event of a form jam in the folder/gluer. 
     A further object of the present invention is to provide for interconnection of components with mating means for communicating through which the system components may be aligned and control signals passed without need for conventional connections and hardwiring. 
     Yet another object of the present invention is to provide a method for automatically printing, conveying, folding and gluing form sheets into sealed, folded and printed products. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a schematic perspective view of the system of the present invention. 
     FIG. 2 is a schematic perspective end view of the conveyor and infeed of the folder/gluer in the system of present invention. 
     FIG. 3 is a schematic perspective view of the outfeed of the folder/gluer of the present invention. 
     FIG. 4 is an exploded perspective view of the conveyor of FIG. 2, partially cut away to show the means for driving the conveyor rollers, and further showing the second means for communicating between the printer and the conveyor. 
     FIG. 5 is a partial perspective view of the first means for communicating between the printer and conveyor disposed on the high speed printer at its interface with the conveyor of the present invention. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     Referring to FIG. 1, in accordance with the present invention, a system 10 for automatically printing, conveying, folding and sealing form sheets 12 from form webs 14 is shown. Such a system is particularly suited for preparing mailers, checks, bills and the like, but may also be used in other applications requiring the printing, folding and sealing of form sheets or other sheet materials. 
     The system 10 of the present invention, as shown in FIG. 1, includes the alternative embodiment of a high-speed printer 16 for printing form webs 14, a burster 18, and a folder/gluer 20. It is understood that the system 10 could include simply a high-speed printer 16&#39; into which form sheets 12 are fed for printing. Shown in FIG. 1, a conveyor 22 attached at the infeed of folder/gluer 20 conveys printed form sheets 12 from the outfeed of burster 18 to the infeed of folder/gluer 20 for folding and gluing. System 10 further includes means for controlling 50 the operation of the system components. 
     Printer 16 is a high-speed printer for continuous form webs, preferably a laser printer, such as an IBM 3800 series. Printer 16&#39; is a high-speed printer for form sheets, preferably a laser printer, such as a Xerox 9700 series printer. High-speed printers 16, 16&#39; print at least one side of a form web 14 or form sheet 12, respectively. As shown in FIG. 1, printer 16 is adapted for receiving and printing a form web 14, and is combined with burster 18 which separates form web 14 into individual form sheets 12. Printer 16 may be connected in-line with burster 18 for automatic transfer of printed form web 14 to burster 18 in a manner known in the art, or may be separated so that a printed form web 14 is manually stacked at the infeed of burster 18. Individual form sheets 12 are discharged from burster 18 onto conveyor 22 along a first direction of form movement, as indicated in FIG. 1. 
     The folding and gluing operations of folder/gluer 20 are conventional, as known in the art, and may be performed on a base unit such as a model 404 folder/gluer manufactured by Baumfolder, Inc., Sidney, Ohio. While the model 404 gluer/folder is a buckle chute folder which performs two folds, any number of folding and gluing apparatuses known in the art may be used. Folder/gluer 20 is capable of operating at or above the maximum output rate of printers 16, 16&#39;. 
     Conveyor 22, further shown in FIGS. 2 and 4, receives form sheets 12 on conveyor surface 24 and conveys them in a second direction of form movement towards the infeed of folder/gluer 20 as shown in FIG. 2. As shown in FIGS. 1 and 2, the change in direction aligns the longitudinal axis of form sheets 12 in the second direction of motion, which is preferred for folding. As best shown in FIG. 4, conveyor surface 24 includes means for receiving 26, including a generally flat area 28 on which form sheets 12 may slide and springs 30 which may be adjustably positioned, as shown, to control form sheets 12. Conveyor surface 24 further includes means for advancing 32 and means for aligning 34 form sheets 12. 
     Means for advancing 32 includes skewed rollers 36 and ball rollers 38. Ball rollers 38 are rotatably kept in fence 40, and are positioned opposite skewed rollers 36. Skewed rollers 36 urge form sheets 12 towards fence 40, and form sheets 12 are nipped between ball rollers 38 and skewed rollers 36 to advance by friction towards the infeed of folder/gluer 20. Heavier or lighter ball rollers 38 may be used to speed or slow the advance of form sheets 12. 
     Shown in FIGS. 2 and 4, means for aligning 34 comprises fence 40, which may be adjustably positioned across conveyor surface 24 by gross and fine means for adjusting 42 and 44, respectively. Such adjustment permits form sheet 12 to be aligned as desired with respect to perforation knives in folder/gluer 20, or to adapt conveyor 22 to receive and convey form sheets 12 of different sizes. As shown in FIG. 4, skewed rollers 36 are driven by motor 46 and belt 48 in a manner known in the art. 
     System 10 further includes means for controlling 50, which includes jam detection means for sensing the travel of a form sheet 12 through folder/gluer 20. Jam detection means includes first, second and third sensors 52, 54 and 56, respectively, positioned at the infeed of conveyor 22 (as shown in FIGS. 2 and 4), at the infeed of folder/gluer 20 (as shown in FIG. 2), and at the outfeed of folder/gluer 20 (as shown in FIG. 3), respectively. Jam detection means further includes means for signalling a form jam, such as circuit means 58, shown in FIG. 1, for receiving signals from sensors 52, 54 and 56 and for signalling system components to stop in the event of a form jam. Each of first, second and third sensors 52, 54 and 56 generate signals to indicate passage of a form sheet 12, and circuit means 58 receives and processes the signals to determine if a form sheet 12 has jammed. 
     In operation, first sensor 52 determines if a form sheet 12 passes over within a given time. If the form is delayed, first sensor 52 signals circuit means 58 that there is a form jam. Second sensor 54 likewise determines if a form sheet 12 passes over within a given time, and if delayed, second sensor signals circuit means 58 that there is a form jam. Third sensor 56 senses the discharge of a form sheet 12 at the outfeed of folder/gluer 20. Unless third sensor 56 detects the discharge of a folded, sealed form sheet before sensor 54 detects infeed of the next following form sheet 12, circuit means 58 generates a stop signal, indicating a form jam. 
     In the event of a form jam, circuit means 58 generates a control signal to stop printer 16&#39;, or alternatively, burster 18 (and printer 16, if connected), conveyor 22 and folder/gluer 20. First, second and third sensors 52, 54 and 56 are preferably photo-eye proximity sensors, and circuit means 58 is preferably a printed circuit board designed as known in the art to receive and process sensor signals and to generate a stop signal, as needed. Other aspects of means for controlling 50 are conventional, as known in the art. 
     System 10 further includes first, second and third means for communicating between conveyor 22 and printer 16&#39; or burster 18. High-speed printer 16&#39; includes first means for communicating 60 between printer 16&#39; and conveyor 22. First means for communicating 60 interfaces with second means for communicating 62 which is disposed on conveyor 22. First and second means for communicating 60, 62 align and interconnect printer 16&#39; and conveyor 22, and pass system control signals therebetween without conventional mechanical attachment or hardwiring. 
     As shown in FIG. 4, second means for communicating 62 includes at least one docking pin 64 and at least one light source 66, preferably a light-emitting diode. Shown in FIG. 5, first means for communicating 60 includes at least one aperture 68, preferably with a bushing, matable with docking pin 64, and at least one light sensor 70 aligned with light source 66. Light sensor 70 may be, for example, a light sensitive transistor, fiber optic cable or other arrangement, which is connected to means for operating printer 16&#39;. At least one docking pin 64 and aperture 68 are provided to insure and maintain alignment of light source 66 and light sensor 70. Control signals, such as a stop signal from circuit means 58, may be relayed across the interface between conveyor 22 and printer 16&#39; by light source 66 and light sensor 70. 
     In the alternative embodiment shown in FIG. 1, a third means for communicating 72 between conveyor 22 and burster 18 is provided at burster 18 to interface with second means for communicating 62. While third means for communicating 72 may be identical to first means for communicating 60, it is preferred for third means for communicating 72 to comprise only a first cable connection 74 to receive control signals to stop burster 18 in the event of a form jam. Second means for communicating 62 thus further includes a second cable connection 76 for sending control signals. Control signals are relayed to burster 18 by interface cable 78 interconnected between first and second cable connections 74, 76. Where printer 16 and burster 18 are connected for automatically feeding form web 14 to burster 18, control signals are further relayed from burster 18 to stop printer 16. 
     Finally, system 10 may include a conventional stacking device 80 on which sealed and folded printed products are stacked or shingled, as shown in FIG. 1. Materials used to construct the various apparatuses are typical of those known in the art. 
     In a further aspect of the present invention, a method is provided comprising: providing at least one form sheet 12 to a high-speed printer 16&#39;; printing form sheet 12 on at least one side; discharging form sheet 12 in a first direction of form movement to infeed conveyor 22 of folder/gluer 20; conveying form sheet 12 in a second direction generally 90 degrees to the first direction of form movement; and aligning form sheet 12 for infeed to folder/gluer 20. The method further includes sensing form sheet 12 at the end of conveyor 22 closest to printer 16&#39; with first sensor 52; sensing form sheet 12 at the infeed of folder/gluer 20 with second sensor 54; folding and gluing form sheet 12; and sensing the discharge of form sheet 12 from folder/gluer 20 with a third sensor 56. Finally, the method includes stacking the sealed, folded printed form sheets on a stacking device 80. The steps of sensing the form sheet 12 with the first, second and third sensors 52, 54 and 56 include signalling passage of the form sheet 12 to a means for signalling a form jam, circuit means 58, which in the event of a form jam, further triggers the step of signalling high-speed printer 16&#39;, conveyor 22 and folder/gluer 20 to stop. 
     Alternatively, the method eliminates printer 16&#39; and begins with the step of providing a printed form web 14 to the infeed of burster 18; and bursting an individual form sheet 12 from form web 14. Additionally, those steps may be preceded by the steps of providing a form web 14 to printer 16; printing form web 14 on at least one side; and conveying form web 14 to the infeed of burster 18. These steps occur before the step of discharging form sheet 12 to infeed conveyor 22. 
     While certain representative embodiments and details have been shown for purposes of illustrating the invention, it will be apparent to those skilled in the art that various changes in the apparatus, method and article disclosed herein may be made without departing form the scope of the invention, which is defined in the appended claims.