Method and apparatus for guiding webs in a web handling system

A web guide particularly adapted for mail handling systems is positioned between the mail handling system form feeder and separating device. The web guide provides a surface to guide and control the web during its travel between the feeder and separating device so as to avoid or minimize premature tearing of the web, particularly during web acceleration caused by the separating device.

FIELD OF THE INVENTION 
The present invention is directed to a method and apparatus for guiding 
webs in systems handling a continuum of travelling material and, in 
particular, to a web guide disposed between a mail handling form feeder 
and a separating device to avoid tearing of the web during mail 
processing. 
BACKGROUND ART 
Automated mail processing systems have been developed in the prior art to 
reduce the effort required on the part of the Post Office for processing 
mail. In one conventional mail processing system disclosed in U.S. Pat. 
No. 5,142,482, herein incorporated in its entirety by reference, a 
mainframe computer is provided which is in communication with a printer 
and a sheet feeder. The purpose of the connection between the computer and 
the printer is to provide data to the printer to cause the printing of 
names and addresses of mail recipients on address sheets or webs that are 
fed by the sheet feeder. Other data such as bills, account statements, 
late payment notices and the like could also be fed from the form or sheet 
feeder. The sheets may be in the form of a perforated web that is 
subsequently separated by a separating device typically referred to as a 
burster or cutter. Once the webs are separated into sheets, the sheets are 
fed to an inserter which places the sheets into envelopes and seals the 
envelopes for mailing. 
These types of mail handling systems are not without their disadvantages. 
Often times, webs being dispensed from the form or sheet feeder are not 
well controlled prior to entry into the cutter. The webs tend to whip 
around and can be subsequently torn at the perforation line prior to web 
entry into the separating device. This action can be caused or aggravated 
by acceleration of the separating device during a high-speed run. 
As such, a need has developed to provide an improved mail handling 
apparatus which overcomes the problem of loss of web travel control 
between the mail handling form feeder and the separating device or any 
other system handling a continuum of travelling material to be separated. 
In response to this need, the present invention provides a web guide which 
is positioned between the form feeder and a separating device to control 
the web travel during a run to avoid premature tearing of the web or other 
malfunction which may interrupt the continuity of the system. 
SUMMARY OF THE INVENTION 
Accordingly, it is a first object of the present invention to provide an 
improved mail handling apparatus. 
Another object of the present invention is to provide a mail handling 
apparatus which controls the travel of one or more webs exiting a form 
feeder and into a separating device. 
A still further object of the present invention is to provide a method for 
controlling the travel of one or more webs in a mail handling system by 
guiding the webs during travel between a form feeder and a separating 
device. 
Another object of the present invention is to provide a method and 
apparatus for guiding a web between the form feeder and the separating 
device in any system handling a continuum of a travelling web or the like. 
Other objects and advantages of the present invention will become apparent 
as a description thereof proceeds. 
In satisfaction of the foregoing objects and advantages, the present 
invention, in one embodiment, provides an improvement in a system 
apparatus having a form feeder and a separating device wherein at least 
one web is fed from the form feeder to the separating device during system 
operation. According to the present invention, a web guide is positioned 
between the form feeder and separating device, the web guide having a web 
guide surface to control or guide the travel of the web between the form 
feeder and separating device. 
Preferably, the web guide surface includes upstanding walls which are 
horizontally adjustable to accommodate different web heights. The web 
guide can also be vertically adjustable and angularly adjustable with 
respect to an axis of web travel to accommodate different web travel paths 
between a given form feeder and a separating device. 
The web guide could also include a vacuum-producing device which is capable 
of pulling a vacuum against the web to assist in guiding the web during 
its travel. The vacuum device could be controllable to accommodate 
different types and/or sizes of webs. 
More preferably, the web guide comprises a frame having an upstanding 
support extending therefrom and a pair of web guide decks extending 
laterally from the upstanding support. Each web guide deck can have a pair 
of guide walls with a web guide surface therebetween. The guide walls can 
be made horizontally adjustable to accommodate webs of varying widths. 
Each web guide deck can also be vertically adjustable with respect to the 
upstanding support to accommodate form feeders dispensing webs at varying 
heights. The decks can be angularly adjustable with respect to the web 
guide surface or web longitudinal axis to accommodate different angles of 
dispensing from the form feeder or feeding to the separating device. 
The vacuum device is preferably a fan with the fan inlet arranged in 
communication with the web guide surface so that the fan inlet provides 
the desired suction. 
In another aspect of the invention, a method of controlling the travel of 
at least one web exiting a form feeder and entering the separating device 
of a system treating a continuum of material such as a mail handling 
system comprises the steps of providing at least one web being dispensed 
from the form feeder and guiding the web during its travel between the 
form feeder and the separating device to avoid web tearing during web 
travel. During the guiding step, a vacuum could be applied to the web to 
further assist in maintaining control over the web during its travel. The 
guiding step could also include vertical, horizontal and/or angular 
adjustment to accommodate webs travelling in different orientations and/or 
directions from the form feeder or to the separating device. The vacuum 
can also be controlled to accommodate webs of different sizes and/or types 
.

DESCRIPTION OF THE PREFERRED EMBODIMENTS 
With reference now to FIG. 1, the inventive web guide device is generally 
designated by the reference numeral 10 and is shown disposed between a 
form feeder 3 and a cutter 5 of a conventional mail handling system. The 
form feeder 3 dispenses a pair of webs 7 and 9 to the cutter 5, the cutter 
5 tearing the webs 7 and 9 at perforations thereof to form sheets for 
insertion into a given envelope. The form feeder 3 and cutter 5 are 
conventional apparatus in mail handling systems and do not require further 
detailed description for understanding of the invention. Although a cutter 
is depicted, any device that can separate the webs such as a burster, a 
laser cutter, a sheeting device or the like can be used as a separating 
device downstream of the web guide. 
The web guide 10 is disposed between the form feeder 3 and the cutter 5 so 
as to guide the webs 7 and 9 and to prevent either web tangling, web loss 
of control during web travel or premature tearing of the web prior to 
entry into the cutter 5. The web guide can be positioned at any point 
between the form feeder 3 and cutter 5 so long as adequate support is 
provided to the webs 7 and 9 during their travel. Preferably, the web 
guide 10 has a tape measuring device 4 to assist in positioning the web 
guide between the form feeder 3 and the cutter 5. The tape measuring 
device 4 is mounted within the web guide 10 and can be pulled out 
similarly to a conventional tape measure for web guide positioning. 
Referring now to FIG. 2, the web guide 10 includes a frame 11 which is 
comprised of legs 12, a base 13 and an upstanding support 17. Extending 
laterally from a side of the upstanding support 17 are a pair of decks 19. 
Each deck 19 provides a web guiding surface 21 thereon to support the webs 
during their travel to the cutter 5. 
In the embodiment depicted in FIG. 2, each deck 19 includes a pair of guide 
walls 23 which guide the webs 7 and 9 along their respective edges during 
web travel. 
The guide walls 23 can be made horizontally adjustable by means of the pegs 
27 riding in the slots 29 in the deck 19. Of course, other ways or means 
could be used to provide the horizontal adjustment of the guide walls 23 
as would be known in the art. It should also be understood that the guide 
walls 23 could be fixed or the decks 19 alone could be used merely to 
support the underside of the webs 7 and 9 without any guide walls, if so 
desired. 
The decks 19 could also include gradations 29 on the surface thereof to 
facilitate setting the guide walls in a given position to accommodate 
standard width webs. 
In another aspect of the invention, vacuum devices 25 can be provided in 
each deck 19. The vacuum devices 25 are preferably fans with inlets 31 
arranged in the web guiding surface 21. In FIG. 2, a pair of vacuum 
devices 25 are shown for each deck 19 but the number can vary depending on 
the size of the deck and given application in a particular mail handling 
system. 
In use, each fan (blades not shown) pulls a vacuum an inlet 31 to apply a 
downward force on the web as it travels on the guide surface 21. With this 
downward force, the web is maintained more securely along the guide 
surface 21 during its travel between form feeder 3 and the cutter 5. 
Fan speed control 33 can be provided on the support 17, one control for 
each deck 19. The fan speed control 33 can control the speed of the fan 
and resulting vacuum to apply different degrees of downward force on a 
given web. For example, a heavier gauge web would require a higher 
downward force and a higher fan speed. Similarly, lighter gauge webs would 
require less of a vacuum to maintain the web in contact with the guide 
surface 21 during its travel. 
With reference now to FIG. 3, the decks 19 can be both vertically and 
angularly adjustable with respect to either the axis of the web during its 
travel or the support 17. 
The upper deck 19 shown in FIG. 3 is depicted in cross-hatch in a vertical 
adjustment, the vertical adjustment designated by the letter A. A channel 
35 could be provided in the support 17 to allow the deck 19 to move up and 
down. The actual mechanism for vertical adjustment between the deck 19 and 
support 17 could be any known mechanism in the art. For example, the deck 
19 could be mounted to a rack which is movable within the support 17 
either by manual force, a crank or the like. Any other means could also be 
utilized to provide the vertical adjustment. 
The lower rack 19 shown in cross hatch in FIG. 3 is depicted with an 
angular adjustment, the angular adjustment designated by the letter B. In 
this mode, the rack 19 could rotate about a pivot point (not shown) where 
the rack is movably mounted to the support 17. This pivotal arrangement 
could take the form of a pin upon which the rack is mounted for pivotal 
movement, the pin extending laterally from the support 17. The pin could 
also travel vertically for the vertical adjustment described above. Again, 
other means of angular adjustment as would be recognized by those skilled 
in the art could be utilized with the inventive web guide. 
Although two racks are depicted in FIGS. 1-3, the inventive web guide 10 
could have one or more than two racks as would be necessary with a given 
mail handling system. Each rack could be either fixed or adapted for one 
or more of the angular, horizontal and vertical adjustments described 
above. Likewise, the vacuum devices could be provided on one of a 
plurality of rack or all racks, if desired. 
The racks 19 could also include position locking mechanisms to ensure that 
the racks remain in a given orientation after adjustment for a given web. 
With the inventive web guide, the gyrations of a web when being dispensed 
from a form feeder are controlled so that the web perforations are 
presented at their strongest attitude to the cutter 5. Much higher 
accelerations can be tolerated without tearing of the webs. 
With the vertical, horizontal and angular adjustment capability of the web 
guide, various size materials can be guided. Further flexibility is 
provided when using the vacuum devices. 
When using at least two racks, the racks would extend laterally from a 
given support. If one rack were to be used, a single support could be used 
which could be positioned either laterally of the rack or therebeneath. 
Other configurations and shapes of the racks 19 and frame 11 could also be 
utilized to provide the guiding of the web. 
In the method aspect of the invention, the travel of the web exiting the 
form feeder is controlled by the guiding surfaces of the guide device 10 
to avoid web gyration, premature perforation of the webs or other problems 
which may be caused if the webs tend to whip out of control during 
operation of the mail handling system. The web guide provides particular 
control when the angular, vertical and/or horizontal adjustment is used 
for a given web. Even more control is provided when the vacuum devices are 
utilized to apply the downward force onto the web for controlled travel. 
Although a mail handling system using a cutter is exemplified in FIG. 1, 
any system handling a continuum of work can utilize the inventive web 
guide for work support. 
As such, an invention has been disclosed in terms of preferred embodiments 
thereof which fulfill each and everyone of the objects of the present 
invention as set forth hereinabove and provides a new and improved web 
guide for a mail handling system. 
Of course, various changes, modifications and alterations from the 
teachings of the present invention may be contemplated from those skilled 
in the art without departing from the intended spirit and scope thereof. 
Accordingly, it is intended that the present invention only be limited by 
the terms of the appending claims.