Abstract:
A collating method, particularly for a continuous production line of mailing covers that makes it possible to simultaneously collate the documents to be folded and their envelope and fold them in order to obtain a mailing cover finished in a single pass. The method includes, during the collating step, that the documents ( 1 ) to be enclosed are stacked and then advanced at a predetermined pace (P). The envelope ( 2 ) is next stacked such that the envelope ( 2 ) at least partially covers the documents ( 1 ) and the envelope ( 2 ), which are offset and carried away at the predetermined pace (P) toward a folding area. The collating method is for use in production lines for mailing covers of the like.

Description:
[0001]    This is a national stage completion of PCT/FR20061002394 filed Oct. 25, 2006 which claims priority from French Application Serial No. 0510923 filed Oct. 26, 2005. 
     
    
     TECHNICAL REALM 
       [0002]    The present invention concerns a method for collating documents comprising at least a step of delivering the documents, a step of collating the documents by stacking and aligning them along at least one edge, and a step of evacuating the stacked documents, especially for production lines for creating mailing covers from a width of material such as paper or the like. 
         [0003]    The invention also concerns a document collating device comprising at least two superimposed conveyors that are parallel and adjacent, the space between them defining a trajectory for said documents that connects a delivery zone and an evacuation zone, and at least one alignment stop interposed on said trajectory to form a document collating zone, said alignment stop being connected to a drive means. 
       PRIOR ART 
       [0004]    Document collation devices are well known throughout the paper industry, for example, in machines used to manufacture mailing covers, Collating devices known in the art are designed to stack documents of essentially the same size that will be folded and inserted into a previously formed envelope, such as the devices described in Publications U.S. Pat. No. 6,796,558 and DE 103.35.418. Other devices are designed to collate documents differing in size, such as those described in publications DE 94.04.431 and U.S. Pat. No. 5,445,368. However, these devices require supply and/or collating zones dedicated to each document format, making the mechanism complex and expensive to manufacture. 
       DESCRIPTION OF THE INVENTION 
       [0005]    The present invention proposes a novel method of collating documents in response to the recent need for a more global method of continuously producing mailing covers, in which the documents to be inserted and the envelopes which will hold these documents are created simultaneously from a single width of paper in the order of mailing covers to be produced, which ensures the integrity of the mailing covers and reduces their unit cost by using a simple, economical, and reliable collating device. 
         [0006]    For this purpose the invention concerns a method of the type described, characterized in that during the collating step, a least one first type of document is stacked, this first type of document is advanced by a predetermined step, at least one second type of document is stacked at least partially covering the first type of document, and in that during the evacuation step, the combination formed of the first and second types of document that have been stacked and displaced is evacuated for said predetermined step. 
         [0007]    In a preferred embodiment, this method comprises a folding step following the evacuation step, in which the combination of documents is folded to form a rolled unit folded in such a way that one of the documents is outside the folded unit and creates an envelope surrounding the other type of document. 
         [0008]    The second type of document remains outside the rolled unit, for example, and preferably constitutes an open envelope. The first type of document is designed to remain inside the rolled unit, for example, and preferably constitutes the contents of the envelope that may be formed by a number n of documents. The second type of document constituting the envelope may be shorter in length than the first type of document. 
         [0009]    The parameters of the predetermined step may advantageously be determined by the length of the documents for collating. For example, it may be equal to ⅓ the length of the first type of document. 
         [0010]    In the preferred embodiment, prior to the collating step, the documents corresponding to the first type and those corresponding to the second type are detected and at least the collating step is controlled by a control unit on the basis of the data detected. 
         [0011]    This collating method is advantageously integrated with a more general method of using a continuous process to produce mailing covers from a width of blank or printed material, culminating in closed mailing covers. 
         [0012]    To achieve this, the invention further concerns a collating device of the type indicated characterized in that it comprises at least one control unit regulating at least the means driving said alignment stop in order to control advancement of at least a first type of document for a predetermined distance before at least one second type of document is stacked to at least partially cover the first type of document, and evaluating the combination formed of the first and second types of document stacked and displaced for said predetermined distance, said control unit being connected to a detector unit which identifies the first and the second types of document. 
     
    
     
       SUMMARY DESCRIPTION OF THE DRAWINGS 
         [0013]    The present invention and its advantages will be more readily apparent from the following description of one embodiment provided by way of non-limiting example, with reference to the attached drawings, in which: 
           [0014]      FIG. 1  is a perspective view of a collating device according to the invention; 
           [0015]      FIG. 2  is an enlarged detailed view in transverse cross-section of the device of  FIG. 1  taken along arrows II-II; 
           [0016]      FIG. 3  is a schematic of five steps in the collating method of the invention; 
           [0017]      FIGS. 4A-C  are schematic representations of the device of  FIG. 1  in a first operating step respectively seen from the side, from the top, and in detail; 
           [0018]      FIGS. 5A-C  through  FIGS. 10A-C  are similar to  FIGS. 4A-C  in different operating steps. 
       
    
    
     ILLUSTRATIONS OF THE INVENTION AND BEST WAY OF ACHIEVING THE INVENTION 
       [0019]      FIG. 1  illustrates a collating device  10  for documents  1 ,  2  according to the invention followed by a folding device  20 , both devices  10 ,  20  being supported by the same chassis  30 , which is partially shown. This chassis comprises, in a known manner which is not shown, a footed structure that is carinated and equipped with a means for driving the moving parts, at least one control unit for the drive means, etc. Obviously the two collating and folding devices  10  and  20  may be separated and each supported by a different chassis. 
         [0020]    Said collating device  10  comprises, in known manner, two conveyors  11 ,  12  superimposed in parallel and adjacent one another to define a trajectory T for circulation of documents  1 ,  2  in the direction of arrow F, between an intake zone and an evacuation zone, passing through a collating zone. This trajectory T is preferably situated in a horizontal plane, but may also be in a slightly inclined plane. In the example shown, each conveyor  11 ,  12  is formed of four drive belts  13  distributed at regular intervals along an expanse that at least covers the expanse of documents  1 ,  2 . This is not a limitation on the number of drive belts  13 , which may vary according to the width of the documents  1 ,  2  to be collated. These drive belts  13  are guided by drive rollers  14 , preferably grooved, located in the intake and evacuation zones, and connected to a drive means, not shown, of any known type such as a reduction motor, for example, with a gear train, notched belt, or chain transmission, etc. Drive belts  13  for the two conveyors  11 ,  12  are obviously arranged facing each other in order to use friction for driving documents  1 ,  2  in the direction of arrow F. 
         [0021]    Collating device  10  also comprises in known manner an alignment stop  15  interposed in the trajectory T of documents  1 ,  2  to define the collating zone between the two conveyors  11 ,  12 . In the example shown this alignment stop  15  is formed of two pairs of drive wheels  16  contacting a generatrix passing through circulation trajectory T of documents  1 ,  2 , These two pairs of drive wheels  16  are inserted between the four pairs of drive belts  13  symmetrically in relation to the median plane of collating device  10  in order to balance the drive force applied to documents  1 ,  2 . They are rotated by drive means, not shown, of any known type such as servomotors, for example, that cause them to stop in order to collate documents  1 ,  2  by stacking them with their edges aligned and abutting drive wheels  16  and cause them to rotate in order to drive stacked documents  1 ,  2  toward the evacuation zone. These drive means control drive wheels  16  during an intermediate collating step in order to make stacked documents  1  advance for a predetermined distance P, the parameters of which are determined according to the length of documents  1 ,  2  to be collated using the collation process described below. 
         [0022]    This collating device  10  also comprises in its collating zone, in a known manner, at least one deflector  17  or lifting device located upstream of alignment stop  15  for shifting documents  1 ,  2  upward or downward relative to trajectory T defined by conveyors  11 ,  12  so as to stack documents  1 ,  2  at the top or at the bottom. In the example shown, collating device  10  comprises four deflectors  17 , two of which are integrated within conveyor  11  located below and two of which are integrated in conveyor  12  situated above the trajectory T of documents  1 ,  2 . Each deflector  17  is formed of four discs  18  located opposite the four corresponding drive belts  13 , said discs  18  being supported by an axle  19  mounted on chassis  30 . This axle  13  may be fixed or it may rotate freely. It can also be regulated to adjust the height of discs  18  relative to trajectory T of documents  1 ,  2 . Discs  18  comprise a deep peripheral groove  18 ′ defining two lateral walls used to guide drive belts  13  in translation. In this example the two lower deflectors  17  are slightly raised relative to trajectory T of documents  1 ,  2  to lift them and create a stack of documents  1 ,  2  below (see  FIG. 2 ). Obviously, other types of deflectors or lifting devices can be used, such as, for example, inclined ramps interposed between belts  13 . 
         [0023]    Folding device  20  comprises in known manner several pairs of parallel drive cylinders  21 - 24  combined with at least two folding pockets  25 ,  26  adjustable in depth. These cylinders are driven in rotation by a drive means, not shown, of any known type that allows them to be regulated according to the length of documents  1 ,  2  and the depth of the folds to be made. The number of folding pockets  25 ,  26  may vary according to the number of folds to be made, as may the number of pairs of cylinders. 
         [0024]    Documents  1 ,  2  to be collated, in the example shown in  FIG. 31  are a first document type  1 , for example sheets of A4 paper to be inserted into an envelope and a second document type  2  which will form the envelope, for example, a 110×220 mm envelope. Obviously these examples are not limiting and any other format for documents  1  and envelope  2  may be used. According to the novel method for the continuous production of mailing covers briefly described in the introduction, said documents  1 ,  2  are printed one after the other in the order of insertion from a single width of material, for example, paper. They are then cut apart, separated by a predetermined interval and then moved along to collating and folding devices  10  and  20 . Next, the flaps of envelope  2  are glued and creased to close the mailing cover, which is ready for mailing. Said  FIG. 3  provides an illustration in five steps of the collation method for documents  1 , represented by the light gray areas, and envelopes  2 , represented by the darker gray areas, with the solid line at the right extremity representing alignment stop  15  on collating device  10  and arrow F representing the direction in which documents  1 ,  2  circulate continuously in this device: 
         [0025]    Step 1: alignment stop  15  is stopped and retains a first document  1 ; 
         [0026]    Step 2: alignment stop  15  is stopped and retains a second document  1  which is stacked on top of or beneath the first document  1 ; 
         [0027]    Step 3: alignment stop  15  moves and takes with it the two stacked documents  1  for a predetermined distance P, for example, about ⅓ the length of the documents, or approximately 95 mm for A4 format documents; 
         [0028]    Step 4: alignment stop  15  is stopped and retains envelope  2 ; 
         [0029]    Step 5: alignment stop  15  moves and evacuates the stack formed by the two documents  1  and envelope  2  towards folding device  20 . 
         [0030]    Possible Industrial Applications: 
         [0031]    The different steps in this collating method are detailed in  FIGS. 4 through 10  illustrating the collating and folding devices  10  and  20 . 
         [0032]      FIGS. 4A-C  correspond to step 1 of  FIG. 3 : alignment stop  15  is stopped, a first document  1  driven by conveyors  11 ,  12  is blocked against it in the collating zone and a second document  1  arrives in collating device  10 .  FIG. 4C  shows the detail A of  FIG. 4A  enlarged to depict the slightly raised position of lower left deflector  17  and its effect on first document  1  which is slightly raised relative to lower conveyor  11  in order to receive second document  1  which follows beneath it, driven by conveyors  11 ,  12 . 
         [0033]      FIGS. 5A-C  correspond to step 3 in  FIG. 3 : alignment stop  15  is moving to displace the first and second documents  1  for a predetermined distance P towards folding device  20 .  FIG. 5C  shows the detail B of  FIG. 5A  enlarged to depict the slightly raised position of lower right deflector  17  and its effect on the stack formed by the first and second documents  1  that are slightly raised relative to lower conveyor  11  in order to receive envelope  2  which follows beneath them, driven by conveyors  11 ,  12 . 
         [0034]      FIGS. 6A-C  correspond to step 4 of  FIG. 3 : alignment stop  15  is stopped and envelope  2  driven by conveyors  11 ,  12  is stacked below documents  1  that are blocked and displaced by a predetermined distance P, as shown in  FIG. 6C  showing the detail B of  FIG. 6A . 
         [0035]      FIGS. 7A-B  correspond to step 5 of  FIG. 3 : alignment stop  15  is moving to evacuate the stack formed by documents  1  and envelope  2  toward folding device  20 . 
         [0036]    In  FIGS. 8A-C , the stack consisting of documents  1  and envelope  2  is directed toward first pocket  25  of folding device  20  by a first pair of drive cylinders  21  to form a first fold, during which procedure the displaced portion of documents  1 , approximately the first one-third of their length, is folded over the second third, between drive cylinders  21 ,  22  as illustrated by  FIG. 8C  showing the detail C of  FIG. 8A . 
         [0037]      FIGS. 9A-C  illustrate the formation of the second fold, during which the first fold, previously directed toward second pocket  26  on folding device  20  by a second pair of drive cylinders  22 , is directed between drive cylinders  22  and  23 , folding the second one-third of documents  1  over the third one-third, while simultaneously folding the first half of envelope  2 , as shown in  FIG. 9C  which depicts the detail D of  FIG. 9A . 
         [0038]      FIGS. 10A-C  illustrate the resulting rolled packet in which documents  1 , having been folded twice, are located inside envelope  2 , having been folded once, with the lateral flaps and the closing flap of envelope  2  remaining open. This rolled packet is evacuated by a fourth pair of drive cylinders  24  as illustrated in  FIG. 10C  showing the detail E of  FIG. 10A , towards the mailing cover finishing zone (not shown) in which the lateral flaps are glued and folded to the back of envelope  2  and then the closing flap is also glued and folded to the back of envelope  2 , closing the mailing cover. 
         [0039]    Collating and folding devices  10  and  20  are regulated by a control unit (not shown) governed by detectors (not shown) which identify the type of documents  1 ,  2  entering collating unit  10 , either documents  1  forming the envelope contents, or the envelope  2  itself, in order to control guide wheels  16  for alignment stop  15  as a consequence and in conformity with the cycle of the collating method described above. These detectors may consist of any known type of sensor: touch, optical, ultrasound, infrared wave, camera, etc., and are capable of detecting the beginning and end of each type of document  1 ,  2 , reading bar codes, and so forth. 
         [0040]    The description makes it clear that this invention achieves its stated goals: e.g., by specifically regulating alignment stop  15 , it allows different types of documents  1 ,  2 , to be collated, particularly documents of different lengths, in order to form a mailing cover in a single operation, and ensures the integrity of the contents and the envelope since the different types of documents  1 ,  2  each follow a unique trajectory T, eliminating any risk of error. 
         [0041]    The present invention is not limited to the exemplary embodiment described, but extends to any modification and variation obvious to a person skilled in the art while remaining within the scope of protection defined in the attached claims.