Abstract:
The invention includes a combination of coupling clip structure and a plurality of binding elements for binding stacks of perforated sheets for delivery to an automated machine. The combination comprises at least two binding elements, and at least one coupling clip discrete from said at least two binding elements. At least one of the coupling clip or the binding element(s) comprises at least one recess, at least a portion of at least one said binding element being disposed in said recess in the coupling clip and/or at least a portion of the coupling clip being disposed in said recess in the binding element, the coupling clip coupling the at least two binding elements together in a predetermined adjacent spatial relationship. The coupling clip may be separated from the binding elements by the automated machine. The invention further includes a method of coupling a plurality of binding elements together with at least one coupling clip for delivery to an automated machine.

Description:
FIELD OF THE INVENTION  
       [0001]     The present invention relates to binding elements for holding a plurality of perforated sheets or the like, and more specifically the invention pertains to structure for coupling binding elements for use in automated binding processes.  
       BACKGROUND OF THE INVENTION  
       [0002]     Various types of binding elements have been utilized to bind a stack of perforated sheets or the like. Binding elements typically include a spine from which a plurality of fingers extends which may be assembled through perforations in a stack of sheets. This spine may be linear, with or without a longitudinally extending hinge. Alternately, the spine may be formed by sequential bending of a wire, as with wire comb or hanger type binding elements.  
         [0003]     Examples of such binding elements which are of a wire comb or hanger-type design are disclosed, for example, in U.S. Pat. No. 2,112,389 to Trussell and U.S. Pat. Nos. 4,832,370 and 4,873,858 to Jones, while machines for assembling such binders are disclosed in U.S. Pat. No. 4,031,585 to Adams, U.S. Pat. No. 4,398,856 to Archer et al., U.S. Pat. No. 4,525,117 to Jones, U.S. Pat. No. 4,934,890 to Flatt, and U.S. Pat. No. 5,370,489 to Bagroky. Other binding devices are disclosed, for example, in the following references: U.S. Pat. Nos. 2,089,881 and 2,363,848 to Emmer, U.S. Pat. No. 2,435,848 to Schade, U.S. Pat. No. 2,466,451 to Liebman, U.S. Pat. No. 4,607,970 to Heusenkveld, U.S. Pat. No. 4,904,103 to Im, U.S. Pat. No. 5,028,159 to Amrich et al., U.S. Pat. No. 4,369,013, Reexamination Certificate B1 4,369,013 and Re. 28,202 to Abildgaard et al. Machines for assembling plastic comb or finger binding elements are disclosed in patents such as U.S. Pat. Nos. 4,645,399 to Scharer, U.S. Pat. No. 4,900,211 to Vercillo, U.S. Pat. No. 5,090,859 to Nanos et al., and U.S. Pat. No. 5,464,312 to Hotkowski et al. The patents are included herein by reference.  
         [0004]     Due to the structure of such binding devices, which include elongated spines and fingers, the binding devices commonly become entangled when stored in a group. Thus, mechanical binding processes are considered to be either cumbersome and labor intensive, or complicated and expensive, requiring dedicated machines. Detangling the binding elements in order to assemble the element to a stack of sheets or lay the element into a binding machine can be a tedious and potentially time consuming process. Further, this tendency to become entangled may complicate or prevent the use of such binding devices in automated binding processes or machines wherein an automated feed is desirable. The time required to manually feed binding elements into a machine would be prohibitive to efficient, high-volume automated binding operations.  
         [0005]     Relatively low cost, manual, semi-automatic machines are commonly utilized in binding successive single documents by loading single elements by hand into such machines. In such manual arrangements, various issues present obstacles to efficient utilization. In such arrangements, one or more binding elements must be untangled from a box, exposing the operator to possible sharp corners and points, and then oriented and loaded by hand into a machine and/or another portion of the binding element.  
         [0006]     Relatively high cost, automated machines likewise present challenges that have yet to be successfully overcome. For example, elements may be presented to automated machines in cassettes, which are typically formed of plastic, or attached to a backing with an adhesive or mechanical coupler. Such presentation methods result in excessive volumes of waste that must be stored and ultimately discarded. Additionally, the use of adhesive in such coupling can make the coupling vulnerable to atmospheric factors, causing the adhesive to loosen or lose its holding properties. Various other methods have been proposed for coupling binding elements together for packing, shipping, or feeding to an automated process. Such arrangements are disclosed, for example, in P.C.T. Application PCT/US0106362, filed Feb. 28, 2001, based upon U.S. Provisional Application 60/188372, which likewise are assigned to the assignee of the present application and is hereby incorporated by reference in its entirety. At least a portion of these arrangements have not been commonly utilized, however. While some types of binding elements may be preformed and delivered to the automated binding machine on spools, spools are generally quite large, bulky, weighty and cumbersome, and still require the use of separating paper to prevent tangling. Additionally, they typically require skilled operator set up. Accordingly, there still exists a need for alternate or additional arrangements that may be successfully and economically automated at a relatively low cost and with minimal associated waste.  
       BRIEF SUMMARY OF THE INVENTION  
       [0007]     The invention provides a clip-type coupling structure for coupling a plurality of binding elements to provide a combination of binding elements and coupling clips that is particularly suitable for packaging and shipment, as well as usage in automated binding processes, and various methods of utilizing the same. In accordance with the invention, a separately formed coupling clip is provided that releasably engages at least two binding elements to temporarily couple the binding elements to maintain their respective relative positions. A plurality of binding elements in this form may be provided either as discrete sheets, or as a continuous sheet which is rolled up, for example, for storage, shipping, or feeding to an automated binding process. In use, the coupling clip is separated from the binding elements to allow separate usage of the binding elements.  
         [0008]     The coupling clip may be of any appropriate design. The coupling clip preferably includes a plurality of legs that partially surround a portion of at least two adjacently disposed binding elements. In the currently preferred embodiment, two pairs of legs are provided, the pairs of legs being coupled by a base element. Each pair of legs is adapted to surround any appropriate portions of the binding elements, e.g., spine to spine, spine to finger, or finger to finger. It is envisioned that alternate designs may be utilized. For example, a design with three such legs may be utilized wherein one leg is common holds the pair of binding elements, or a base with two legs may be utilized. The base and legs may be of any appropriate design or length so long as the clip temporarily couples the binding elements.  
         [0009]     Preferably, the design is such that the application of an external force to coupling clip causes release of one or more of the coupled binding elements. This may be accomplished by including one or more portions that flex to allow the separation of the legs, or example. In one embodiment, two pairs of legs are provided to couple two adjacent binding elements, an inwardly disposed leg and an outwardly disposed leg. The inwardly disposed legs may be formed on a portion of the base section wherein application of a force to that base section cause the legs to flex slightly apart from one another, releasing the coupled binding elements. In an alternate embodiment, the base includes flanges that extend from the sides of the coupling clip such that application of a force to a flange causes the adjacent outwardly disposed leg to flex outward from the adjacent portion of the coupling clip holding the binding element. The coupling clip may thus elastically flex to allow the coupling or decoupling of the binding elements. Alternately, the coupling clip may be designed to move between at least two discrete positions, clamping and unclamping positions.  
         [0010]     In utilizing such coupling clips, one or more may be utilized to couple binding elements in a given spatial relationship. For example, one, two, three or more such coupling clips may be utilized to couple a pair of binding elements. Additionally, this same or a different number of such coupling clips may be utilized to couple one of the pair of binding elements to a third binding element, and onward to a plurality of binding elements to create a continuous length of binding elements.  
         [0011]     Alternately, a single coupling clip may couple more than two binding elements in a given spatial relationship. As with a coupling clip that couples only two binding elements in a given spatial relationship, a plurality of such coupling clips that couple more than two binding elements in a given spatial relationship may be utilized along the length of the plurality of binding elements to be coupled. In one such embodiment, the coupling clip is in the form of a carrier strip that couples three or more binding elements in a given special relationship, the carrier strip including a plurality of such individual coupling arrangements for coupling to the binding elements.  
         [0012]     Thus, the coupling clip arrangement provides an economical means by which a plurality of binding strips may be coupled in a given spatial relationship for storage, shipping or feeding to an automated process. Such an automated process may include a means by which a force is applied to the coupling clip or the binding element to separate the binding element from the clip. The coupling clip may ten be dropped into a collection container for disposal or reuse. The coupling clip does not damage or interfere with the use or final appearance of the coupled binding elements.  
         [0013]     The coupling clip may be economically manufactured using conventional molding techniques.  
         [0014]     These and other objects and advantages of the invention will be apparent to those skilled in the art upon reading the following detailed description and upon reference to the drawings. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0015]      FIG. 1  is a perspective view of a binding element of the prior art.  
         [0016]      FIG. 2  is a front elevational view of a coupling clip constructed in accordance with teachings of the invention for coupling a plurality of binding elements.  
         [0017]      FIG. 3  is a front elevational view of the coupling clip of  FIG. 2  engaged with a plurality of binding elements, the binding elements being shown in cross-section.  
         [0018]      FIG. 4  is a front elevational view of an alternate embodiment of the coupling clip constructed in accordance with teachings of the invention.  
         [0019]      FIG. 5  is a front elevational view another alternate embodiment of the coupling clip constructed in accordance with teachings of the invention.  
         [0020]      FIG. 6  is a front elevational view another alternate embodiment of the coupling clip constructed in accordance with teachings of the invention.  
         [0021]      FIG. 7  is a front elevational view of another embodiment of the coupling clip constructed in accordance with teachings of the inventions.  
         [0022]      FIG. 8  is a front elevational view of another embodiment of the coupling clip constructed in accordance with teachings of the inventions.  
         [0023]      FIG. 9  is a front elevational view of the coupling clip and binding elements of  FIGS. 2 and 3  wherein a force is applied to separate the coupling clip and binding elements.  
         [0024]      FIG. 10  is a perspective view of a plurality of binding elements of the prior art coupled together by a plurality of coupling clips constructed in accordance with teachings of the invention.  
         [0025]      FIG. 11  is a side view of a plurality of binding elements being fed to an automated binding machine.  
         [0026]      FIG. 12  is a front elevational view another alternate embodiment of the coupling clip constructed in accordance with teachings of the invention.  
         [0027]      FIG. 13  is a side elevational view of another alternate embodiment of the coupling clip constructed in accordance with teachings of the invention.  
         [0028]      FIG. 14  is a side elevational view of another alternate embodiment of the coupling clip constructed in accordance with teachings of the invention. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0029]     Turning now to the drawings, there is shown in  FIG. 1 a  binding element  30  constructed according to the teachings of the prior art. The binding element  30  includes a spine  32  from which a plurality of fingers  34  extends. The fingers  34  of the illustrated binding element  30  include two portions  34   a,    34   b  that meet to form a closed finger loop, as will be appreciated by those of skill in the art. It will further be appreciated that the illustrated binding element  30  is merely representative of binding elements of the prior art, and is not intended to limit the scope of the present invention. The present invention is equally applicable to binding elements of alternate design, such as, for example, those various types of binding elements mentioned in the Background of the Invention section of this disclosure. Moreover, the binding element may be of substantially any design, and may be of substantially any length.  
         [0030]     In accordance with aspects of the invention, there is provided a coupling clip for coupling a plurality of binding elements in a given spatial relationship, and a combination of one or more coupling clips with a plurality of binding elements. An embodiment of such a coupling clip  40  is shown in  FIG. 2 . The clip  40  includes a base portion  42  and a coupling portion  44  for receiving a portion of each of at least a pair of binding elements to couple them together. The coupling portion  44  includes preferably includes at least one leg that forms a recess  48  for receiving a portion of one or more binding elements. In the illustrated embodiment, two pairs of such legs  50 ,  52 ,  54 ,  56  are provided. As shown in  FIG. 3 , the spines of respective binding elements  58 ,  60  are received in the recesses  48  between the legs  50 ,  52  and  54 ,  56  of the pairs to maintain the binding elements in a given spatial relationship. It will be appreciated by those of skill in the art that alternate portions of the binding elements  58 ,  60  may be disposed the recesses  48 . For example, the fingers may be disposed in the recesses, or the finger of one binding element and the spine of another binding element may be disposed in the respective recesses.  
         [0031]     It will further be appreciated by those of skill in the art that the coupling portion  44  may be alternately designed. For example, three, rather than four such legs  62 ,  64 ,  66  may be provided, as shown in  FIG. 4 . In this embodiment, a single central leg  64  supports both binding elements  58 ,  60 , the remaining two legs  62 ,  66  each supporting a respective binding element  58 ,  60 . In another alternate embodiment, only two such legs  68 ,  70  are provided, the binding elements  58 ,  60  being disposed between a respective one of said legs  68 ,  70  and the base portion  72 , as shown in  FIG. 5 . Alternately, portions of both binding elements  58 ,  60  may be disposed in a single recess  74  as shown in  FIG. 6 . It will be appreciated that numerous alternate designs may be provided within the scope of the invention utilizing an alternate number of legs and structures. It will be appreciated by those of skill in the art, however, that it is preferable that the binding elements be parallelly disposed, as shown for example in  FIG. 3 , in order to facilitate compact and efficient packing, as shown in  FIG. 10 .  
         [0032]     Returning now to  FIGS. 2 and 3 , in order to maintain the spines  58 ,  60  in the recess(es)  48 , the binding elements  58 ,  60  may be press-fit or snap-locked in position. Such a snap-locked design is shown, for example, in  FIG. 2 , wherein a protrusion  76  is provided that inhibits the movement of the binding elements  58 ,  60  from the respective recesses  48 . In this embodiment, the protrusion  76  is disposed along inner legs  52 ,  54 , although such a protrusion may be alternately disposed or additional protrusions provided.  
         [0033]     Also as shown in  FIG. 2 , the fingers  50 ,  52 ,  54 ,  56  may include structure that facilitates assembly of the binding elements  58 ,  60  into the coupling clip  30 . For example, the fingers  50 ,  52 ,  54 ,  56  may be provided with ramped surfaces  80 ,  82  that guide the binding element  58 ,  60  into the adjacent recess  48 .  
         [0034]     According to an important aspect of the invention, the binding elements  58 ,  60  may be readily released from the clip  40 , preferably by the application of an outside force to the coupling clip  40 . In this way, the coupling clip  40  may be separated from the binding elements  58 ,  60  without damaging the binding elements  58 ,  60  so that they may be readily utilized in a manual or automated binding process. In the embodiment of  FIGS. 2 and 3 , the base portion  42  comprises a force-receiving section  84 , the inner legs  52 ,  54  extending from the force-receiving section  84 . It will be appreciated by those of skill in the art that relative geometry of the force-receiving section  84  and the remaining portion of the base section  42  and fingers  50 ,  56  are such that a force applied to the force-receiving section  84 , as shown in  FIG. 9 , will result in a bending or arching of the coupling clip  40  such that the inner fingers  52 ,  54  move toward each other, that is, away from the outer fingers  50 ,  56  such that the binding elements  58 ,  60  disposed in the recesses  48  are free to pass out of the recesses  48 . More preferably, the force-receiving section  84  comprises an area of weakness  86  that concentrates the stress of a force applied thereto such that a localized bending occurs at that portion of the force-receiving section  84 , as may likewise be seen in  FIG. 9 .  
         [0035]     Alternate arrangements may be provided whereby the coupling clip releases the coupled binding elements upon application of an external force. Returning to  FIG. 4 , for example, the force-receiving portion may be in the form of a pair of force-receiving arms  92 ,  94  extending from the base  96  substantially adjacent the outer legs  62 ,  66 . In this embodiment, areas of reduced thickness  98  cause the outer legs  62 ,  66  to flex outward when a force is exerted on the arms  92 ,  94 , releasing the binding elements  58 ,  60 . A similar arrangement is shown, for example, in  FIG. 7 . Alternately, such force-receiving arms  100 ,  102  may extend outward directly from the outer legs  68 ,  70 , as shown in  FIG. 5 . In this way, the legs  68 ,  70  would bend or flex outward, again, releasing the binding elements  58 ,  60 . It will be appreciated by those of skill in the art that alternate arrangements or combinations of these arrangements may likewise be utilized.  
         [0036]     A plurality of such coupling elements may be utilized to chain three or more binding elements together to create a sheet of coupled binding elements. As shown in  FIG. 10 , for example, a coupling clip  40  of  FIG. 2  may be used to couple together two adjacently disposed binding elements  110 ,  112 . A further coupling clip  114  may be utilized to couple a third binding element to one of the first pair binding elements ( 112 , for example, as illustrated). A third binding clip may then be utilized to couple a fourth binding element to the chain of binding elements, etc., to create a chain of binding elements of any desired length for storage, packaging, shipment or delivery to an automated binding process, as shown in  FIG. 1 . In the case of such an automated binding process, a separating force may be applied, as indicated above, for example, to separate the coupled binding elements either before, during, or after the binding process. Thus, the invention further includes an automated arrangement that includes such a coupled plurality of binding elements, and a process for delivering and separating a coupled plurality of binding elements.  
         [0037]     In another embodiment of the invention, a plurality of such coupling clips is formed as a single unit  122 , as shown for example in  FIG. 12 . It will be appreciated that, as with the chained plurality of binding elements, the binding elements may be released from the coupling clip array  122  by application of appropriate sequentially applied forces.  
         [0038]     It will be appreciated by those of skill in the art that the coupling clip may alternately include a protrusion that is received in a recess in a binding element. As shown in  FIG. 13 , in a simple embodiment of such a coupling clip  150 , the coupling clip  150  comprises a pair of protrusions  152  that may be received in bores in respective binding elements to be coupled (not shown). The body  151  and the protrusions  152  therefrom may be of any desired cross-sections. It will be noted that the transition  153  from the protrusions  152  to the body  151  provide a ledge or sorts to facilitate maintaining the respective positions of the adjacent binding elements.  
         [0039]     Alternately, the coupling clip  156  may include a combination of recess(es)  158  and protrusion(s)  160 , such as shown in  FIG. 14 . In this way, the recess  158  may receive a portion of a binding element (not shown), while the protrusion  160  may be received in a bore or other recess in a binding element to be adjacently coupled (not shown). It will thus be appreciated that a wide variety of structural combinations is envisioned under the invention.  
         [0040]     The coupling clips may be formed of any appropriate material by known fabrication methods, such as, for example, stamping or injection molding. They may be formed of any appropriate material, such as, for example, wood, metal, or plastic. After use, they may either be scrapped, or reused.  
         [0041]     While this invention has been described with an emphasis upon preferred embodiments, variations of the preferred embodiments can be used, and it is intended that the invention can be practiced otherwise than as specifically described herein. Accordingly, this invention includes all modifications encompassed within the spirit and scope of the invention as defined by the following claims. For example, various aspects of the invention may be practiced simultaneously, such as a plurality of binding elements with stacking structures, flexible connectors and runners disposed in a cartridge.  
         [0042]     All of the references cited herein, including patents, patent applications, and publications, are hereby incorporated in their entireties by reference.