An accumulator for business forms is easily inserted into, or removed from, a path of continuous format, zig-zag business forms being fed from one business form handling machine (such as a folder) to another (such as a mailing machine like an inserter). A barrier having drive belts on one face is movable from a position allowing forms to pass under it, to a barrier position in which the forms engage the barrier and are slowly driven up the barrier until they bend over by their own weight onto a shelf. The forms are also driven along a shelf into contact with a stop, and a stack of forms is formed on the shelf. By handling the forms in this way the forms are creased along the perforations between the continuous forms (making subsequent separation easier) and prevented from developing a curl.

In the production of business forms, there are many instances when it is 
desirable to process the forms in continuous format from a roll to a 
mailing machine, such as a mail inserting machine. In handling the forms 
in such a manner, it may be desirable to accumulate a quantity of forms so 
that one machine can be down, or running at a slow speed than another 
machine in the line, without adverse effects on the form production rate. 
One way that it has been suggested that the general objectives according to 
the invention could be achieved is the utilization of a random loop 
accumulator, such as shown in U.S. Pat. No. 4,928,940 or 5,104,107. 
However, in a random loop accumulator, the forms may set in a curl which 
makes further processing difficult, and additionally it can be difficult 
to determine (when too many forms have accumulated which could result in a 
catastrophic shut down of the equipment). 
According to the present invention, a business form handling machine, and a 
method of handling business forms, are provided which allow forms to be 
processed directly from a roll to mailing equipment, such as from a roll 
(such as a Moore 8600 roll feed) connected to a Siemens printer, a Moore 
8700 folder, and then a mailing machine (such as a Pitney-Bowes mail 
inserting machine). The stacker/accumulator according to the invention is 
typically provided between the folder and the inserter. The business forms 
are handled in such a way that they do not curl, but rather they first 
move vertically, and then are provided in a stack from which they can be 
taken. By handling the forms in this way, a crease is provided along the 
perforation line between continuous forms which makes subsequent bursting 
easier, and the forms do not develop a curl. The number of forms that have 
been stacked/accumulated also is easy to determine, and it is a simple 
matter to control operation of the preceding or following equipment (e.g., 
folder and inserter) depending upon the buildup of the forms in the stack. 
According to one aspect of the present invention, a method of accumulating 
business forms in continuous format in zig-zag configuration is provided. 
Each form has a leading edge and a trailing edge, the trailing edge of one 
form adjacent the leading edge of the next in the continuous zig-zag 
format (separated by perfs), and the forms travel in a first generally 
horizontal path. A shelf is utilized which is generally parallel to the 
first path and vertically spaced from it, as well as a barrier downstream 
of the shelf in the first path. The method comprises the following steps: 
(a) Placing the barrier in the first path; and then continuously. (b) 
Moving a leading edge of a first of the continuous format of forms in the 
first path into contact with the barrier. (c) Slowly driving the leading 
edge of the first form up the barrier until it bends over by its own 
weight into operative association with the shelf. (d) Slowly driving the 
first form along the shelf in a second generally horizontal path, 
essentially opposite the first path, to form the top form in a stack of 
forms on the shelf. And, (e) causing other forms to follow substantially 
the same path as the first form, to provide additional forms in a zig-zag 
stack on the shelf underneath the first form. 
Step (d) is typically practiced until the first form engages a stop, and 
there is also preferably the further step of slowly conveying the first 
form upwardly away from the shelf as step (e) is being practiced. There 
also is preferably the further step of sensing the height of the zig-zag 
stack of business forms on the shelf when it reaches a predetermined 
level; and arresting the feed of forms in the first path, in step (e), in 
response to the sensing of the predetermined level, and/or the further 
step of taking forms off the stack of business forms on the shelf. 
According to another aspect of the present invention a business form 
handling machine operatively connected between first and second other 
business form handling machines, such as between a folder and an inserter, 
is -provided. The machine according to the invention comprises: A business 
form conveyance surface extending in a first plane, and relatively 
stationary. First and second side elements disposed on opposite sides of 
the conveyance surface. A forms accumulating backstop; and, means for 
mounting the backstop to the side elements for movement between first and 
second positive positions, the first position one in which the backstop is 
generally parallel to the conveyance surface and spaced a substantial 
distance therefrom so that business forms may be conveyed on the 
conveyance surface between the conveyance surface and the backstop, and 
the second position one in which the backstop is generally perpendicular 
to the conveyance surface so that business forms on the conveyance surface 
will be conveyed into contact with the backstop. The backstop typically 
has a first face, and further comprises a plurality of first conveying 
elements disposed on the first face for conveying business forms engaging 
the first face away from the conveying surface. Shelf means are also 
provided as well as means for mounting the shelf means adjacent the 
backstop and defining a shelf plane generally parallel to the conveying 
surface and spaced a substantial distance therefrom, but closer to the 
conveying surface than the most remote portion of the backstop conveying 
elements when the backstop is in the second position. The mounting means 
for the shelf means may include the side elements. 
There also is preferably provided second conveying elements on the shelf 
means for conveying business forms along the shelf means away from the 
backstop, as well as stopping means associated with the shelf means for 
stopping the movement of the business forms when they reach a 
predetermined position. Also, third conveying elements may be associated 
with the stopping means for conveying business forms upwardly from the 
shelf means. A motor is typically mounted to the side elements, and drive 
means interconnect the motor and the first, second and third conveying 
means so that the motor powers the conveying means. 
The first, second and third conveying means typically comprise belts having 
outstanding ribs, which ribs engage a surface of each business form and 
effect driving thereof, and pulleys receiving the belts. The conveying 
surface may comprise a generally horizontal table with conveyor belt means 
associated therewith, and the first other business form handling machine 
may comprise a folder, with the second machine comprising a mailing 
machine such as an inserter. Also, there is preferably provided means for 
sensing when forms have accumulated on the shelf means more than a 
predetermined amount, and controlling one or both of the first and second 
other business form handling machines to prevent further buildup of forms 
on the shelf. A cart may mount the conveying surface and the side 
elements, and also mount the first other business machine, with an 
electrical connection extending from the sensing means to the cart and the 
first other business form handling machine. 
It is a primary object of the present invention to provide for the 
effective accumulation and stacking of business forms, typically in a 
business form handling system for handling continuous business forms 
including other equipment, such as a printer, folder, roll takeoff and 
inserter. This and other objects of the invention will become apparent 
from an inspection of the detailed description of the invention and from 
the appended claims.

DETAILED DESCRIPTION OF THE DRAWINGS 
The invention relates to a business form handling machine 10 operatively 
connected between first and second other business form handling machines 
11, 12. The machine 11 immediately "upstream" of the machine 10 according 
to the invention, preferably comprises a folder such as a Moore 8700 
folder, while the downstream machine 12 comprises a use device, typically 
a mailing machine such as a Pitney Bowes inserter. Upstream of the folder 
11 there also is typically provided a printer, such as a Siemens printer, 
and a roll feed, such as a Moore 8600 roll feed. The machine 10 according 
to the invention is designed to handle up to 18 inch wide forms and 81/2 
inches by 12 inches in length. 
The basic components of the machine 10 comprise a business form conveyance 
surface 13, such as a table which extends in a first plane and which is 
relatively stationary. Preferably conveyor belts 14 are provided on the 
top of the table 13 to convey forms in a first generally horizontal 
direction 15 away from the folder 11. First and second side elements, such 
as the sidewalls/plates 16, 17, are disposed on opposite sides of the 
conveyance surface 13. A forms accumulating backstop, shown generally at 
18, is mounted to the side elements 16, 17. 
Preferably the backstop 18 is mounted to the side elements 16, 17 by 
mounting means which provide for movement between first and second 
positive (that is, locked) positions in which the backstop is fixed. The 
first position, as shown in FIG. 2, is one in which the backstop 18 is 
generally parallel to the conveyance surface 13 and spaced a substantial 
distance therefrom (above it) so that business forms may be conveyed on 
the conveyance surface 13 between the conveyance surface 13 and the 
backstop 18 (under the backstop 18). The second position--illustrated in 
FIG. 1--is one in which the backstop 18 is generally perpendicular to the 
conveyance surface 13 forming a barrier, so that business forms on the 
conveyance surface 13 will be conveyed into contact with the backstop 18. 
As seen in FIGS. 3 through 5, the backstop 18 may be mounted for pivotal 
movement about one shaft element 20 (also seen in FIG. 6) which passes 
through, and is journalled in, the second side element 17, and a pin 21 
(see FIGS. 1, 3, and 4 in particular) which has one position into which it 
is biased in which the backstop 18 is locked in position (FIG. 3), and a 
second position which can be moved against the bias, which allows the 
backstop 18 to be rotated about the axis 22 defined by shaft element 20 
and pin 21 between the FIG. 1 and 2 positions. The pin 21 is mounted for 
reciprocal movement in the direction of the arrows 23 in FIG. 3 by a 
collar 24 which surrounds the pin 21 and is stationary with respect to the 
first side element 16. The pin 21 has a shoulder 25 formed on it, with a 
coil spring 26 acting between the collar 24 and the shoulder 25 to 
normally bias the pin to the locking position illustrated in FIGS. 1 and 
3. In the locking position a rectangular, or other non-round, portion 27 
of the pin 21 is received within a similarly shaped opening 28 (see FIG. 
4) in the backstop 18 sidewall 29, thereby preventing pivotal movement of 
the backstop 18. The same pin 21 non-round portion 27 is received in a 
similar non-round opening 30 in the first side element 16. 
When the pin 21 is moved away from the backstop 18 in the direction of the 
arrows 23 of FIG. 3 against the spring 26 bias, eventually a round portion 
31 thereof will come into association with the opening 28 and will allow 
the backstop 18 to be pivoted between the positions of FIGS. 1 and 2. Once 
pin 21 is released into the new position into which the barrier 18 has 
been pivoted, which is 90.degree. from the other position, the pin 21 is 
released and the spring 26 pressure forces the non-round portion 27 into 
engagement with the opening 28 in the backstop 18, locking it in place. 
The top face 33 of the backstop 18 as seen in FIG. 2 is flat, however, the 
opposite face 34--which is the barrier forming face--seen in FIG. 5 has a 
plurality of first conveying elements 36 disposed on it for conveying 
business forms which engage the face 34 away from the conveyance surface 
15. The conveying elements 36, as illustrated in FIG. 5, preferably 
comprise a plurality of belts 38, e.g., of rubber, which have outstanding 
ribs 39 which are designed to engage a surface of the business form and 
effect driving thereof. The belts 38 are mounted on pulleys 40, which in 
turn are mounted on shafts 41 (see FIG. 5) extending between the sidewalls 
29, 42 of the backstop 18. A drive mechanism 43 for those pulleys 40 and 
belts 38 is provided by the drive pulley 44 connected to the shaft 20 as 
seen in FIG. 5, which in turn is connected to a gear 46. As seen in FIG. 
6, the gear 46 is connected to drive means 47 to effect driving thereof, 
the drive means 47 ultimately being connected to the motor 48 which is 
mounted on the second side element 17. The drive elements 36 are moved 
very slowly so that the forms only inch upwardly. 
As seen in FIGS. 1, 2, and 6, the machine 10 also comprises shelf means 50 
adjacent the backstop 18 and defining a shelf plane generally parallel to 
the conveyance surface 13 and spaced a substantial distance 52 from it 
(that is, vertically above--see FIG. 9). However, the shelf means 50 is 
closer to the conveyance surface 13 than the most remote portion (top 
portion 53 in FIG. 9) of the backstop conveying elements 36. The shelf 
means 50 are also preferably mounted by the side plates/elements 16, 17, 
and by arms 54 mounted to the interior thereof (see FIG. 1 in particular). 
The shelf means 50 preferably include second conveying elements 57 for 
conveying business forms along the shelf means 50 away from the backstop 
18. The second conveying elements 57 preferably comprise the ribbed belts 
58 mounted on the pulleys 59 and driven by the same drive means 47 as the 
conveying elements 36 on the backstop 18. The second conveying elements 57 
convey the forms until they contact the stop means 60, which may be formed 
by the plate 61 (FIGS. 1 and 2 in particular) which also preferably has 
third conveying elements 62 associated therewith. The third conveying 
elements 62 are like the first and second conveying means 36, 57, and are 
designed to engage and slowly move business forms upwardly away from the 
shelf 50 plane. The common drive means 47, driven by the motor 48, drive 
all of the first, second, and third conveying means, all being driven very 
slowly. 
The machine 10 also comprises sensing means for sensing when forms have 
accumulated on the shelf means more than a predetermined amount. The 
sensing means are shown only schematically at 64 in FIG. 6, but may 
comprise photoelectric means, or any other common type of position sensor 
for business forms. The sensing means 64, which may be adjustable in 
height from the top of the shelf 50, sense the predetermined height of a 
stack of forms (66 in FIG. 10) on the shelf 50. When the predetermined 
stack height is sensed, the sensing means 64 may operate to control one or 
both of the folder 11 and inserter 12 so as to reduce the height of the 
stack 66 on the shelf. FIG. 6 shows an electrical connection 67 going from 
the sensing means 64 (and from the motor 48) to the folder 11, and shows 
the machine 10 mounted as an extension of the folder 11 on the same cart 
68. 
The particular manner in which the forms are accumulated and stacked 
according to the invention, fed from the folder 11 in a first path 70, 
which is a generally horizontal direction, best seen with respect to FIGS. 
7 through 10 which show the continuous progress of representative ones of 
the forms as they are continuously fed from the folder 11 toward the 
backstop 18, and then up away from the backstop 18 to stack on the shelf. 
Note in FIGS. 7 through 10 that the business forms are in continuous 
format and zig-zag configuration, each form 71 having a leading edge 72 
and a trailing edge 73 (FIG. 8), the trailing edge of one form adjacent 
the leading edge of the next in the continuous zig-zag format (a 
perforation line being between them). The action on the business forms 
will be described with respect to a "first form" 71 seen in FIGS. 7 
through 10, but the action on the rest of the forms is very similar, the 
forms stacking up both as they are being conveyed upwardly, and then later 
on as they bend over under their own weight (FIG. 9) onto the shelf 50 and 
form the horizontal stack 66 on the shelf 50. 
The method according to the invention, which can be seen with respect to 
FIGS. 7 through 10, comprises the steps of placing the barrier 18 
(backstop) in the first path 70 of conveyance of the forms, and then 
continuously practicing the other steps. The other steps include moving 
the leading edge 72 of the first 71 of the continuous formatted forms in 
the first path 70 into contact with the barrier 18, either by the 
conveying belts 14 on the conveyance table 13, or by the natural action of 
the folder 11. Then there is the step of slowly driving the leading edge 
72 of the first form 71 of the barrier 18 (utilizing the first conveying 
elements 36, particularly the ribs 39 on the belts) until it bends over by 
its own weight (see FIG. 9) into operative association with the shelf 50. 
The forms are slowly driven along the shelf 50 in a second generally 
horizontal path 75, essentially opposite the first path, and the first 
form 71 forms the top of a stack 66 of forms on the shelf 50 (see FIG. 
10). The forms are continuously fed in this manner to provide additional 
forms in a zig-zag stack on the shelf 50 underneath the first form 71 
(again see FIG. 10). Ultimately, the forms are taken off the stack 66, 
first form 71 first (that is top form first) to the use device 12, such as 
a Pitney Bowes mail inserter machine. 
Note that as the forms are being conveyed in the second path 75 they engage 
a stop plate 61, and then are also preferably slowly conveyed upwardly 
from the shelf 50 along the stop 60 by the third conveying elements 62. 
There also is the step of sensing the height of the zig-zag stack on the 
shelf (FIG. 10) and, when it reaches a predetermined level, arresting the 
feed of forms in the first path 70 in response to the sensing of the 
predetermined level, as by shutting down the folder 11. Alternatively, or 
in addition, the forms may be removed from the stack 66 utilizing the use 
device 12. 
Because the forms are handled in the manner illustrated in FIGS. 7 through 
10, first being moved vertically upwardly in a vertical stack (FIG. 8), 
and then into a horizontal stack (FIG. 10), the forms have a crease formed 
along the edges thereof (the perforations) which facilitates further 
handling and bursting. Also, the forms do not set in a curl position, 
which can happen in a random loop accumulator. Also, the machine 10 
according to the present invention includes its own motor 48, and is 
conveniently mounted on a folder 11 or the like, and when the backstop 18 
is moved to the position illustrated in FIG. 2, the forms may be readily 
conveyed by the conveyor belts 14 on the table 13 directly to another 
machine 12 downstream of the folder 11, such as a burster or the like. 
It will thus be seen that according to the present invention an 
advantageous method and business form handling machine have been provided. 
While the invention has been illustrated in what is presently conceived to 
be the most practical and preferred embodiment, 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 structures and methods.