Paper folder utilizing sheet inversion to develop auxiliary fold types

A method and apparatus for folding inserts by inverting the insert sheet after the first fold is made and reintroducing the folded insert sheet into a first buckle chute from the opposite end. The second fold is then made in a second buckle chute which results in either a bottom address or a middle address appearing on the folded insert in a manner that the address will appear through the window of the envelope.

FIELD OF THE INVENTION

The invention relates generally to sheet folding and inserting machines and more particularly to a method for folding and transporting paper such that a specific region of the paper can be positioned in the window of a receiving envelope.

BACKGROUND OF THE INVENTION

Sheet folding machines have long been well known and have enjoyed great commercial success in a variety of document processing applications, particularly those associated with the preparation of mail in which one or a plurality of sheets are folded in a variety of configurations before being inserted into envelopes in an envelope inserting machine. Briefly, folding machines of this character comprise one or a pair of buckle chutes and a plurality of sets of feeding and folding rollers. In a typical arrangement, sheets are fed into the folding mechanism and directed into a first buckle chute by a first pair of feeding rollers until the lead edge of the sheet strikes a stop, after which the portion of the sheet adjacent to the entrance of the buckle chute buckles to form a new lead edge, which then passes through the next pair of feeding rollers which creases the new lead edge, thereby forming a first fold in the sheet. The new lead edge is then directed into a second buckle chute until it strikes a stop, which causes the portion of the sheet adjacent to the entrance of the second buckle chute to buckle and form still another new lead edge, and this new lead edge then passes through still another pair of feeding rollers which again creases the lead edge, thereby forming a second fold in the sheet. The tri-folded sheet is then fed through a discharge path from the folding machine.

Typically, inserter systems prepare mail pieces by gathering collations of documents on a conveyor. The collations are then transported on the conveyor to an insertion station where they are automatically stuffed into envelopes. After being stuffed with the collations, the envelopes are removed from the insertion station for further processing. Such further processing may include automated closing and sealing the envelope flap, weighing the envelope, applying postage to the envelope, and finally sorting and stacking the envelopes.

Often times the address of the recipient appears on the folded insert, which is then inserted into a windowed envelope. Sometimes the recipient's address appears on the top ⅓ panel of the document. In these cases the conventional two buckle chute folder may be configured to fold the document in a “C” or “Z” fold so that the recipient's address will appear through the window of the envelope. The above fold types accommodate the customer needs of certain users. The recipient's address may also appear on different portions of the folded insert, for instance, the bottom portion or middle portion of the folded insert. Bottom addressing and middle addressing of inserts normally require folders with opposite buckle chute arrangements, positioned both above and below the folder paper path. Such arrangements normally results in a folder with a minimum of three buckle chutes to accomplish all the basic fold types, i.e., top address C-fold, and the auxiliary fold types, middle address C fold and bottom address Z fold.

A disadvantage of the prior art is that three buckle chutes are required to perform the basic fold types for bottom and middle addressing of inserts. Another disadvantage of the prior art is that one of the three buckle chutes must be positioned to oppose the other two buckle chutes, making it difficult to transport material past the folder either above or below without folding the material or intersecting the mechanical assembly of the buckle chute.

SUMMARY OF THE INVENTION

This invention incorporates a folder into an insertion system that overcomes the disadvantages of the prior art by inverting the insert sheet after the first fold is made and reintroducing the folded insert sheet into the first buckle chute from the opposite end. The second fold is then made in the second buckle chute which results in either a bottom address or a middle address appearing on the folded insert in a manner that the address will appear through the window of the envelope.

An advantage of the foregoing is that all of the basic fold types may be accomplished in an insertion system without the need to incorporate an opposing buckle chute. Thus, the space on one side of the folder paper path may be used for other mail processing functions. The capability to perform specific fold functions may also be decoupled from the basic folder which enables greater flexibility in the build and sale of the folder system.

DETAILED DESCRIPTION OF THE PRESENT INVENTION

In describing the present invention, reference is made to the drawings, wherein similar reference numerals inFIGS. 1-7designate similar elements in the various views.

Referring now to the drawings in detail and more particularly toFIG. 1the folder system10is shown with document11entering folder20through transport nip12and undergoing fold formation in the first fold roller cluster13. Document11enters folder20with the printed face of document11facing down and the recipients address at the leading edge of document11. The document11is advanced into the first buckle chute14by a distance equal to ⅓ of the length of document11prior to the formation of the first fold of document11. The foregoing describes the process of forming the first fold of document11.

Document11upon entering folder entrance nip12may be selectively transported to folder20(a primary folder path) or folder bypass path40through the articulation of the entrance gate44. It should be obvious to one skilled in the art that entrance gate44may be pivoted axis45, such that document11would be transported to the folder bypass path40which would prevent the formation of folds in document11. Thus, folding system10provides the option to not fold document11.

FIGS. 2-7illustrate the progression of the document through the fold system paper path withFIG. 7showing a fully formed bottom address z-fold exiting the folder.

Also shown in each Fig. is a paper path that by-passes the fold system. The foregoing paper path system can not readily be realized in a system having opposing buckle chutes.

FIG. 2illustrates the second step in the formation of a bottom address Z fold. Document11has advanced from first fold roller cluster13to fold cluster16and the leading edge of document11has entered buckle chute17and is approaching smart nip18.

FIG. 3illustrates the third step in the formation of a bottom address Z fold. Document11has been driven by smart nip18in a direction “A” through buckle chute17and has entered inverter entry nip31.

FIG. 4illustrates the fourth step in the formation of a bottom address Z fold. Document11has been transported by entry nip31to inversion nips32which upon receiving document11and driving the trailing edge of document11past the inversion point35have then reversed the direction of travel of document11and have transported document11to inverter exit nip33. The path from nip31to nips32and33is a second inversion path. Note that the current leading of document11was the trailing edge of document11as shown inFIGS. 1-3.

FIG. 5illustrates the fifth step in the formation of a bottom address Z fold. Document11has been driven by inverter exit nip33to smart nip15which has received document11and transported document11to first fold roller cluster13. Document11is shown spanning smart nip15, first fold roller cluster13, and fold cluster16with the unfolded edge of documents1advancing towards buckle chute17.

FIG. 6illustrates the sixth step in the formation of a bottom address Z fold. Document11is shown during the process of the second fold formation in fold cluster16. Smart nip18has received the unfolded edge of document11and transported document11in direction “A” until document11has entered buckle chute17by the length desired for the second fold. Smart nip18has then reversed the direction of document11, driving document11in direction “B” towards fold cluster16which forms the second fold of document11.

FIG. 7illustrates the fully formed bottom address Z fold of document11exiting the folder20via folder exit nip19.

FIG. 8is a drawing of document11showing three fold panels and three possible address locations. Document11has panels50,51and52. Panels50,51and52are respectively ⅓ the length of document11. It would be obvious to one skilled in the art that the operator of folder20may select specific length for panels50,51and52and these lengths may be produced by folder20by control of the motion of smart nips15and18. The address of the recipient of document11may be placed on any of the panels50,51and52and the choice of placement is at the discretion of the operator of folder system10. Thus, it is desirable to have a folder system that is capable of transforming document11into a folded document when the address is located in spaces53,54or55. Thereby, allowing the insertion of document11into an envelope with the correct orientation and the exposure of the recipient address in a window envelope.

The advancing of the document into the first buckle chute by a distance equal to ⅔ of the length of the document and executing the paper path processes described inFIGS. 2-7will result in the formation of a middle address C fold.

Two documents may be processed in the paper paths described inFIGS. 2-7such that the document is introduced to the paper path as the first document is advanced to the document inverter30. Through careful selection of the paper path length and the timing of the introduction of subsequent documents it is possible to maintain sustained processing and increase the through put of the documents in the paper path.

The above specification describes a new and improved method for method for folding and transporting paper such that a specific region of the paper can be positioned in the window of a receiving envelope. It is realized that the above description may indicate to those skilled in the art additional ways in which the principles of this invention may be used without departing from the spirit. Therefore, it is intended that this invention be limited only by the scope of the appended claims.