Continuous business forms assembly with anti-tenting means

A continuous business forms assembly comprising a zig-zag folded stack of a multiplicity of superimposed, elongated plies of paper, including a plurality of intermediate plies. Each of the plies is provided with a longitudinally extending, control punch margin and the plies are held in assembled relation by longitudinally extending glue lines between adjacent plies adjacent the control punch margins. Individual form lengths in the assembly are defined by cross lines of weakening in the plies and the intermediate plies are completely severed in the area of at least the ones of the cross lines on which the assembly is folded and provided with reliefs thereat so that stresses caused by folding the assemblies into the stack are relieved to prevent tenting.

BACKGROUND OF THE INVENTION 
This invention relates to continuous business forms assemblies and, more 
specifically, to multiple-ply continuous business forms assemblies. 
Prior art of possible relevance includes U.S. Letters Pat. No. 2,907,585 to 
Sornberger issued Oct. 6, 1959. 
"Tenting" has long been a vexatious problem in the manufacture of 
multiple-ply, continuous business forms assemblies. Most typically, such 
assemblies are zig-zag folded in a stack at the end of the manufacturing 
process along transverse lines of weakening defining the individual forms 
in the assembly. The phenomena of tenting is so named, because when the 
stack is unfolded, at each fold line, a peaked structure will appear at 
the margin of the assembly where the various plies are positively secured 
together, as by glue, which structure somewhat crudely resembles a tent. A 
graphic illustration of such a "tent" appears in the drawings of the 
above-identified Sornberger patent. 
Tents occur because the various plies of the assembly move longitudinally 
relative to each other at the time they are initially folded into the 
zig-zag stack for any of a variety of reasons and are due to the fact that 
while the distance between the transverse lines of weakening on each ply 
is the same, the outermost ply at each fold lies in a path having a 
greater length about the fold than the path in which an innermost ply 
resides. This difference in length is analogous to the difference in 
length about a race track between inner and outermost lanes thereon. 
Typically, during manufacturing, the plies are secured together by glue 
which ultimately, positively holds the plies together. However, at the 
time of folding the assembly into the zig-zag stack, the glue will not 
have completely set up, allowing the relative movement causing the tent. 
Subsequently, the glue will set up, permanently incorporating the tent in 
the assembly. 
Tents interfere with subsequent processing as, for example, printing on the 
forms in high speed equipment, such as tabulators, computer printers, or 
the like and may, in fact, cause such equipment to stop. 
Tenting is aggravated by the number of plies in the assembly. Generally, 
through good manufacturing techniques, assemblies having four to six plies 
can be manufactured without tenting so extreme as to disrupt subsequent 
processing operations. However, when it is attempted to increase the 
number of plies over and above that amount, the tenting becomes so 
pronounced that commercially acceptable forms cannot be manufactured. 
Over the years, the prior art has tried a number of approaches to eliminate 
or minimize the tenting problem. The structure disclosed by Sornberger is 
indicative of one approach. However, it will be appreciated merely from a 
cursory review of the Sornberger patent that extremely complicated cutting 
operations and gluing operations are required. 
Theoretically, tenting could be eliminated in forms wherein so-called 
"cold" glues are employed if the assembly line was such as to allow 
complete drying of such glues prior to folding of the forms. As a 
practical matter, for most cold glues used in the business forms industry 
today, and at manufacturing speeds typically used, a drying area in an 
assembly line following a collator whereat the plies are assembled 
together would have to be so long as to be totally impractical. 
It has also been proposed that faster drying or so-called "hot" glues be 
employed. This approach, while used to some extent, is not totally 
satisfactory for the reason that most such hot glues dry to a greater 
thickness the the cold glues, with the result that the forms of the 
resulting assembly are considerably thicker than might be desired in the 
glued marginal areas and are quite stiff and thus difficult to handle. 
Thus, there is a real need for a simple, but effective, means for 
eliminating or minimizing tenting to eliminate difficulties in subsequent 
processing and/or the manufacture of multiple-ply, continuous business 
forms assemblies having a greater number of plies than can be manufactured 
according to present-day techniques. 
SUMMARY OF THE INVENTION 
It is the principal object of the invention to provide a new and improved 
multiple-ply, continuous business forms assembly. More specifically, it is 
an object of the invention to provide such an assembly which is relatively 
tent-free and therefore is easily processed on office forms handling 
equipment and which may be composed of an increased number of plies over 
present-day forms. 
An exemplary embodiment of the invention achieves the foregoing object in a 
continuous business forms assembly comprised of a multiplicity of 
superimposed, elongated plies of paper, including at least one 
intermediate ply. The plies are held in assembled relation by 
longitudinally extending glue lines between adjacent plies and individual 
form lengths in the assembly are delimited by cross lines of weakening in 
the several plies. The intermediate plies are completely severed and have 
notches at at least some of the cross lines of weakening. The upper and 
lower plies are at least partially unsevered above the notches and are 
severed between the notches. Tent-causing stresses are relieved, 
precluding the formation of tents when the assembly is folded into a 
zig-zag stack at the conclusion of manufacture. Inasmuch as the upper and 
lower plies in the assembly are not completely severed, feeding of the 
form through office forms handling equipment is facilitated. 
A preferred embodiment of the invention contemplates that each of the plies 
be provided with longitudinally extending control punch margins and that 
the longitudinally extending glue lines be adjacent the control margins. 
In order to maintain the control punch margins of the upper and lower 
plies continuous, the control punch margins of the upper and lower plies 
are made wider than the control punch margins of the intermediates plies 
so that a slit extending through all of the control punch margins to sever 
the intermediate plies need not completely sever the control punch margins 
of the upper and lower plies. Alternately, the edges of the control punch 
margins of the intermediate plies are provided with inwardly directed, 
wedge-shaped cutouts at the transverse lines of weakening to achieve the 
same result. 
In one type of form made according to the invention, the intermediate plies 
are provided with die cuts which are centrally located and aligned with 
the lines of weakening and the severing of the intermediate plies extends 
from their edges to the die cuts. 
In a preferred embodiment, the assembly is folded into a zig-zag stack on 
certain of the lines of weakening and the severing of the intermediate 
plies is made only at such lines of weakening to facilitate refolding of 
the form after handling by office processing equipment. 
In a highly preferred embodiment of the invention, one of the notches is 
located at the intersection of the cross lines of weakening and a 
longitudinal line of weakening separating the control punch margins from 
the remainder of the associated plies. Such a notch is disposed only in 
the intermediate plies and severing is accomplished by slitting all plies 
with the slit extending just to the edges of the notch. As a consequence, 
the upper and lower plies are not completely severed to facilitate 
feeding. 
Other objects and advantages will become apparent from the following 
specification taken in connection with the accompanying drawings.

DESCRIPTION OF THE PREFERRED EMBODIMENTS 
An exemplary embodiment of a multiple-ply, continuous business forms 
assembly made according to the invention is illustrated in the drawings as 
being of the type disclosed in the commonly assigned U.S. Letters Pat. No. 
3,104,799 issued Sept. 24, 1963 to Steidinger. However, as will appear 
more fully hereinafter, it is to be understood that the usefulness of the 
invention is not limited to such forms and will find equal utility in 
other types of forms as, for example, the multiple-ply, continuous 
business forms assembly disclosed in the commonly assigned U.S. Letters 
Pat. No. 3,092,401 issued June 4, 1963 To Steidinger. 
The multiple-ply, continuous business forms assembly is folded into a 
zig-zag stack, generally designated 10, along transverse lines of 
weakening 12 extending through the plies of the form. As illustrated, the 
assembly is folded on every other cross lines of weakening 12 but those 
skilled in the art will recognize that, depending upon form length, the 
assembly may be folded on every such line 12, every second line 12, or 
every third line 12, etc. 
As best seen in FIG. 2, the assembly includes an upper ply 14 and a lower 
ply 16 and plural intermediate plies 18. According to the invention, there 
may be twelve or more of the plies 14, 16 and 18. Each of the intermediate 
plies 18 is provided with a series of notches in the form of die cuts 20 
centrally located in the panel in the manner disclosed in the first 
identified Steidinger patent. The die cuts 20 are aligned with the lines 
of weakening 12 and glue lines 22 extending transverse to the length of 
the assembly disposed on each side of each line of weakening 12 secure the 
upper and lower plies 14 and 16 together to partially define a stuffed, 
sealed envelope wherein the intermediate plies 18 are inserts and/or 
return envelopes. 
Each of the longitudinally extending margins of the various plies is 
provided with a control punch margin 30 including a plurality of pin feed 
holes 32 by which the assembly may be fed through a computer-printer, a 
deleaver, or the like. Each control punch margin 30 is separated from the 
central portion of the associated ply by longitudinally extending lines of 
weakening 34 so that, after processing has been completed, the margins 30 
may be removed. 
One side of the assembly is provided with an additional longitudinal line 
of weakening 36 which is spaced inwardly of the line of weakening 34 and 
acts as a tear strip whereby the sealed envelopes may be opened and the 
insert material, or intermediate plies 18 removed. In the area between the 
lines of weakening 34 and 36, longitudinally extending glue lines 38 
secure the plies together. Depending upon the particular type of form 
being manufactured, the lines 38 may appear on one or both sides of the 
assembly. Typically, the glue employed in the forming of the lines 38 will 
be a so-called "cold" glue for the reason that the same dries to form a 
thinner glue line than so-called "hot" glues and results in a less stiff 
form. 
As mentioned previously, such glues, under current manufacturing 
techniques, cannot fully dry prior to the folding of the assembly into the 
zig-zag stack 10 and thus account for tenting in conventional forms. 
According to the present invention, the tendency to tent is eliminated by 
completely severing the intermediate plies 18 at at least some of the 
cross lines of weakening 12 in the vicinity of the glue lines 38. In the 
case of assemblies, such as that illustrated in the drawings, the severing 
will be complete and generally extend from the edge of the intermediate 
plies through the control punch margins to intersect the end of the die 
cut 20. 
In the embodiment illustrated in FIGS. 1-3, such a slit is in part defined 
by notches in the form of an aperture 42 in the intermediate plies 18 only 
lying on the intersection of the longitudinal lines of weakening 34 and a 
corresponding cross line of weakening 12, a cut 44 extending through all 
plies to one end of the aperture 42 and to the end of the die cut 20, and 
a cut 48 extending through all plies and having a length so as to extend 
from an edge of the aperture 42 to the edge of the intermediate plies 18. 
As a consequence of this construction, the intermediate plies 18 are 
completely severed at each such cross line of weakening 12 whereat the 
aforementioned structure is provided. At the same time, the upper and 
lower plies 14 and 16 remain continuous in their control punch margins 30, 
as illustrated by the lack of cuts at areas 50 and 52, as best illustrated 
in FIG. 3. As a result of such continuity, portions of the control punch 
margins 30 of the upper and lower plies 14 and 16 cannot fold upon 
themselves to provide tongues or the like which could interfere with 
processing of the forms on office equipment. 
In forms of the type illustrated in the Figures, it is preferable that the 
severing be only at those cross lines of weakening 12 which are folded 
when the assembly is folded into a zig-zag stack. In other words, for 
forms of the type illustrated in FIG. 2, it is preferred that there be 
severing of the intermediate plies only at the cross lines 12 whereat the 
assembly is to be folded. Such a preferred construction has optimal 
refolding characteristics. Of course, where forms of the type illustrated 
in FIG. 2 are folded into a zig-zag stack on each cross line of weakening, 
then, of course, it is necessary that the severing structures be placed at 
each such cross line of weakening. 
A modified embodiment is illustrated in FIG. 4 and structure identical to 
that in the embodiment illustrated in FIGS. 1-3 has been given like 
reference numerals. 
In the embodiment of FIG. 4, the control punch margins 30 of the 
intermediate plies have the same width as the control punch margins of the 
upper and lower plies. However, at the transverse lines of weakening 12 
whereat the assembly is to be folded into a zig-zag stack, the 
intermediate plies are provided with an inwardly directed, wedge-shaped 
notch or cutout 70. The cut 48 has a length to extend from the adjacent 
side of the aperture 42 to the apex of the cutout 70. Thus, the 
intermediate plies are completely severed by the cuts 44 and 48, the 
aperture 42, and the cutout 70. At the same time, the upper and lower 
plies remain joined in the areas 50 and 52 to ensure that the control 
punch margins of the upper and lower plies remain continuous to facilitate 
good feeding characteristics. 
The complete severing of the intermediate plies at some of the cross lines 
of weakening minimizes or eliminates the stresses in the glued areas of 
the form caused by folding the same in a zig-zag stack, which stresses are 
responsible for tenting. The preferred structure employing the aperture 42 
and two slits enables all plies to remain continuous through the collating 
process after which the slits 44 and 48 may be formed to completely sever 
the interior plies at the desired location without completely severing the 
control punch margin of the upper and lower plies to thereby assure good 
feeding characteristics in office equipment. 
FIGS. 5 and 6 illustrate the phenomena, in somewhat exaggerated fashion, by 
which tent-causing stresses are minimized. In particular, they illustrate 
the configuration of the parts at the notches and at the slit, and 
particularly, the configuration of the upper and lower plies 14 and 16 
when the assembly is folded in the areas where such plies are continuous, 
that is, about the notches. For simplicity of illustration, the 
illustration shows the configuration at the notch or aperture 42 in the 
interior plies 18 rather than at the notches formed by the die cuts 20, 
since the former illustrates the severest case. 
As illustrated in FIGS. 5 and 6, the upper ply 14 is continuous, that is, 
unsevered, in the area 80 which is about the aperture 42. As a 
consequence, the nose-like formation in the area 80, due to folding 
stresses, will collapse into the notch 42. The lower ply 16 has a similar 
continuous area 82 which is somewhat irregularly deformed within the 
aperture 42 by reason of compression forces applied thereagainst by the 
collapsing of the upper ply 14. 
Of course, the configuration will be just the opposite of that illustrated 
at the folds on either side of that illustrated in FIGS. 5 and 6. 
To some extent, adjacent the edges 84 of the continuous portion 80, the 
paper of which the ply 14 is formed will stretch, as illustrated. 
It will be appreciated from a consideration of FIG. 6 that if the 
continuous portions 80 and 82 of the plies 14 and 16, respectiely, were 
severed at their midpoint and the plies straightened to a planar 
configuration, the ends resulting from such severing would fall in a plane 
encompassing the slits 44 and 48. Thus, it will be appreciated that the 
outermost ply of the fold does not travel a greater distance about the 
fold than the innermost ply when the form is made according to the 
invention. As a consequence, the cause of tenting is eliminated. 
FIGS. 7 and 8 illustrate the application of the invention to continuous 
forms of the type disclosed in the second identified Steidinger patent. 
Where like elements are concerned, reference numerals identical to those 
used previously are employed. 
At those lines of weakening 12 whereat the form is to be folded, a series 
of notches 90 extend through the intermediate plies 18 longitudinally on 
both sides of such fold line, as best seen in FIG. 8; and one notch 90' 
straddles the line of weakening 34 at each such line of weakening 12 
whereat folding occurs. At the same time, slits 92 extend through all 
plies in the assembly between the notches 90 so as to completely sever the 
interior plies at the lines of weakening 12 upon which the assembly is to 
be folded. Areas 94 of both the plies 14 and 16 remain unsevered about the 
notches 90 so that the form remains continuous. 
As a consequence of the foregoing, when folded at the lines of weakening 12 
including the notches 90, a configuration very similar to that illustrated 
in FIG. 5 and 6 will be formed. 
In the embodiment illustrated in FIG. 7, the marginal edges 96 of the 
intermediate plies 18 are located inwardly of the marginal edges 98 of the 
upper and lower plies 14 and 16, enabling the margins of the upper and 
lower plies 14 and 16 to be continuous, as illustrated at 100, at their 
outermost extremity in the same fashion as described in connection with 
the embodiment shown in FIGS. 2 and 3. 
On the other hand, in the embodiment illustrated in FIG. 8, the marginal 
edges of all plies are in the same plane and an endmost one 102 of the 
notches 90 intersects the marginal edges of the intermediate plies 18 to 
again enable the marginal edges of the upper and lower plies 14 and 16 to 
be continuous in the area marked 104. Thus, the endmost one 102 of the 
notches 90 acts in the same fashion as the cutout 70 shown in the 
embodiment illustrated in FIG. 4. 
The plies 14, 16 and 18 of the continuous forms shown in FIGS. 7 and 8 
typically will be glued together by glue lines (not shown) in the manner 
disclosed by Steidinger in U.S. Pat. No. 3,092,401. 
From the foregoing, it will be appreciated that a variety of geometric 
shapes can be employed in forming the notches. No limitation to any 
particular shape is intended, it merely being sufficient that the width of 
the notch, that is, its dimension extending longitudinally of the 
continuous form, be sufficient so as to enable the collapse of the 
continuous portions of the upper and lower plies to be received therein. 
While the invention has been described in connection with single-width 
forms, those skilled in the art will readily appreciate its applicability 
to so-called "two-wide" forms. 
The invention permits the fabrication of continuous business forms 
assemblies having a greater number of plies, without tenting, using cold 
glues which are liquid at room temperature whereby the frequently less 
desirable hot glues (glues in a solid state at room temperature) are not 
required. 
The invention also permits an increase in the manufacturing speed over that 
used in the fabrication of assemblies by conventional techniques. 
Frequently, six-ply forms manufactured conventionally are run through the 
processing equipment at a linear speed that is only 65-70% of the linear 
speed at which three-ply forms are made, in part, to permit the glue to 
partially set to minimize tenting. Through the use of the anti-tenting 
structure of the invention, six-ply forms made according to the invention 
can be run through the manufacturing equipment at the same linear speed as 
conventional three-ply forms and some 40-50% or greater speeds than those 
employed in the manufacture of conventional six-ply forms. 
Moreover, inasmuch as tenting difficulties in prior art forms have 
generally precluded the use of relatively heavy weights of paper, the 
present invention, through its elimination of the stresses causing 
tenting, permits more extensive use of such heavier paper weights in 
continuous forms assemblies. 
A further benefit of the invention resides in the fact that forms made 
according to the invention, when zig-zag folded, lie flatter so that, for 
a shipping or storage container of a given size, all other things being 
equal, a greater number of form lengths made according to the present 
invention can be received therein than if the forms were made 
conventionally. Storage requirements are, accordingly, minimized and 
shipping labor reduced in that a given number of forms will occupy a 
lesser number of cartons and thereby reduce handling expense. 
Thus, use of the invention not only eliminates tenting and the resultant 
problems in processing forms by the purchaser thereof, but allows the 
manufacture of forms with a greater number of plies and/or with heavier 
paper than can be made conventionally. The invention permits substantial 
increases in processing speeds, thereby producing a commensurate increase 
in production capacity and further decreases storage and/or shipping 
expense.