Patent Publication Number: US-6338770-B1

Title: Selective horizontal, continuous vertical, sealing action

Description:
BACKGROUND AND SUMMARY OF THE INVENTION 
     A wide variety of different types of equipment have been developed for sealing pressure activated adhesive (primarily pressure activated cohesive) business forms, and particularly mailer type business forms, such as shown in U.S. Pat. Nos. 5,174,493 and 5,201,464. The equipment developed includes edge sealing rolls which engage only the edge portions of the forms which contain the pressure activated cohesive, or steam roller type rollers which engage the entire forms (where inserts are not used), and often various types of turning mechanisms between sets of rolls so as to seal patterns of adhesive having different orientations. Typically such equipment applies a sealing force of at least 100 pounds per lineal inch, typically about 200 pounds per lineal inch. 
     In U.S. Pat. Nos. 5,938,880 and 5,944,946 a method and apparatus are disclosed that allow both the “horizontal” and “vertical” patterns of cohesive of mailer type business forms to be sealed in a single pass but without the crushing action provided by steam roll type equipment. While the method and apparatus in those patents is highly useful, it normally effects sealing of the same patterns of adhesive at a number of different locations, and is limited in its ability to adapt to different locations of the patterns of pressure sensitive cohesive on particular forms. 
     The method and apparatus according to the present invention allow the same advantages as the method and apparatus in U.S. Pat. Nos. 5,938,880 and 5,944,946 as far as being able to effectively seal both vertical and horizontal patterns of pressure activated adhesive in a single unidirectional path and without utilizing a steam roller action which can crush inserts or portions of the form between the patterns, but does so with greatly enhanced versatility, and also in a very cost effective manner. This enhanced versatility and cost effectiveness are provided by utilizing two different sets of rolls. The first set includes a first roll that is substantially continuous but a second roll which is non-round and has projection portions which are the only portions of the roll that can effectively seal with the first roll. The second roll is controlled by a stepper motor, in turn controlled by a microprocessor, so that a projection of the second roll can be brought into operative association with the first roll whenever desired, whether at a regular interval or irregular interval, in order to effectively seal a pressure activated adhesive pattern which is substantially parallel to the axes of rotation of the rolls. A second set of rolls, for sealing pressure activated adhesive patterns that are substantially perpendicular to the axes or rotation of the first set of rolls, is preferably provided substantially immediately adjacent the discharge from the first set of rolls, and includes a continuous roll and a pair of rolls that cooperate with the continuous roll (second and third rolls) and which are on a substantially common axis. The positions of the second and third rolls with respect to each other and the first roll may be adjusted so as to accommodate different widths of forms (spacings between the pressure activated cohesive patterns to be sealed by the second set of rolls). No further sealing equipment is necessary. 
     According to one aspect of the present invention there is provided a method of sealing a business form having pressure activated adhesive including a first pattern in a first dimension, and a second pattern in a second dimension substantially transverse to the first dimension, comprising: (a) Moving the form in a direction substantially parallel to the second dimension; and while practicing (a). (b) At only a first location, automatically applying at least about 100 pounds per lineal inch of pressure to the form at the second adhesive pattern to seal the form at the second adhesive pattern substantially without engaging any other portion of the form. And (c) at only a second location, spaced in the direction of movement of the form, automatically applying at least about 100 pounds per lineal inch of pressure to the form at the first adhesive pattern. 
     Typically (b) is practiced using a first set of rolls including a first substantially continuous roll having a length greater than the length of the second adhesive pattern, and a second roll having a non-round shape with at least one projection having a length greater than the length of the second adhesive pattern and comprising the only part of the second roll cooperating with the first roll to seal the first adhesive pattern. Also typically (c) is practiced using a second set of rolls including a first substantially continuous roll and a second substantially continuous roll, the second set of rolls aligned with the first adhesive pattern of the business form. 
     When the form comprises two first substantially parallel patterns of adhesive spaced from each other a first distance in the second dimension, then (c) is further practiced using a third roll of the second set rotatable about an axis substantially common with that of said second roll, and operatively spaced approximately the first distance from the second roll in the second dimension, so that the second and third rolls of the second set cooperate with the first roll of the second set to substantially simultaneously seal the two first patters of adhesive of the form. Where the form comprises two second substantially parallel patterns of adhesive spaced from each other a second distance in the first dimension, then (b) is further practiced to selectively rotate the first roll of the first set to come into contact with the form at both second patterns of adhesive to seal the form at both second patterns, but so as to substantially not come in contact with the form between the two second patterns of adhesive. When the form comprises a third second pattern of adhesive substantially parallel to both of the two second patterns of adhesive, disposed between the two second patterns in the first dimension, then (b) is further practiced to selectively rotate the first roll of the first set to come into contact with the form at all three of the second patterns of adhesive to seal the form at all three second patterns, but so as to substantially not come in contact with the form between the second patterns of adhesive. 
     In the preferred embodiment (a)-(c) are practiced so as to first move the form into operative association with the first set of rolls, and then into operative association with the second set of rolls. The invention also further comprises adjusting the positions of the second and third rolls of the second set with respect to each other along the common axis, to accommodate forms having different spacings between the second patterns of adhesive. The adjustment may be accomplished using any conventional mechanism or technique. 
     According to another aspect of the present invention a sealing apparatus is provided. The sealing apparatus comprises or consists of the following components: A first set of rolls comprising a first substantially continuous roll, and a second roll having a non-round shape with at least one projection, the first and second rolls mounted and positioned for rotation about substantially parallel axes and so that at a first position the at least one projection comes into operative association with the first roll to perform a sealing action, but the second roll besides the at least one projection not coming into operative association with the first roll, and at a second position the at least one projection is not in operative association with the first roll. A stepper motor operatively connected to the second roll of the first set so as to effect rotation thereof to move the at least one projection between the first and second positions. And a second set of rolls including a first substantially continuous roll having a first length and a second substantially continuous roll having a second length less than about half of the first length, the first and second rolls of the second set mounted and positioned for rotation about substantially parallel axes which are also parallel to the axes of the rolls of the first set of rolls. 
     Preferably the first set of rolls has a discharge which discharges material being sealed thereby in a first direction; and the second set of rolls is positioned substantially immediately adjacent the first set of rolls discharge in the first direction to receive material discharged from the discharge between the first and second rolls of the second set. Preferably the second set of rolls comprises the third roll substantially concentric with the second roll and rotatable about a substantially common axis, the third roll spaced from the second roll along the substantially common axis. 
     In order to provide a minimal amount of material while still having optimum operability, the second roll of the first set preferably has a configuration that in end view simulates an airplane propeller so that the at least one projection comprises first and second projections angularly spaced from each other about 180 degrees. Preferably the second roll of the first set is positioned above the first roll of the first set, and the first and second rolls are rotatable about substantially horizontal axes. Also, the stepper motor is typically connected to a microprocessor which controls the stepper motor. 
     In the normal use, the first and second sets of rolls are positioned and mounted so as to receive therebetween business forms having pressure activated adhesive, and the sets of rolls are capable of applying at least about 100 pounds of pressure per lineal inch to business forms disposed between the first and second rolls of each of the first and second sets of rolls. 
     According to yet another aspect of the present invention a set of pressure applying rolls per se is provided. The set of rolls comprises: A first substantially continuous roll rotatable about a first axis. A second non-round roll having a configuration that in end view substantially simulates an airplane propeller, including at least first and second projections angularly spaced from each other, and rotatable about a second axis substantially parallel to the first axis. The first and second rolls mounted and positioned so that at a first position one of the projections comes into operative association with the first roll to perform a sealing action, but the second roll besides the projections not coming into operative association with the first roll, and at a second position the projections are not in operative association with the first roll. And the second roll positioned above the first roll, and the first and second axes comprising substantially horizontal axes. 
     The first set of rolls also preferably comprises a stepper motor operatively connected to the second roll so as to effect rotation thereof to move the projections between the first and second positions. The second non-round roll may have exactly two projections angularly spaced from each other about 180°. 
     It is the primary object of the present invention to provide for the simple, versatile, and cost effective sealing of business forms having pressure activated adhesive, and apparatus for that purpose. This and other objects of the invention will become clear from an inspection of the detailed description of the invention and from the appended claims. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is an end view, looking in on the first set of rolls, of an exemplary sealing apparatus according to the present invention for practicing the exemplary method according to the invention; 
     FIG. 2 is a side view of the sealing apparatus of FIG. 1; 
     FIG. 3 is a top view of the sealing apparatus of FIGS. 1 and 2; 
     FIG. 4 is a side view of another exemplary configuration of the top roll of the first set of rolls of the sealing apparatus according to the invention; 
     FIG. 5 is a top plan schematic view showing a business form having various pressure activated cohesive patterns associated therewith and with the overlaying portions of the form cut away for clarity of illustration; and 
     FIG. 6 is a schematic cross-sectional view taken along lines  6 — 6  of the form of FIG. 5 with the components greatly exaggerated in size for clarity of illustration, and adhesive patterns illustrated by Xs. 
    
    
     DETAILED DESCRIPTION OF THE DRAWINGS 
     FIGS. 1 through 3 illustrate an exemplary embodiment of a sealing apparatus according to the present invention, particularly useful in the practice of the method of sealing a business form having pressure activated adhesive. The business forms with which the sealing apparatus  10  of FIGS. 1 through 3 is used are preferably those sold by Moore North America, Inc. under trademark “Sealermate®” having pressure activated adhesive (cohesive), such as exemplified by U.S. Pat. Nos. 5,174,493 and 5,201,464, the disclosures of which are hereby incorporated by reference herein. 
     The apparatus  10  comprises a first set of rolls  11  and a second set of rolls  12 . Forms are fed into association with the apparatus  10  substantially in the direction  13  seen in FIGS. 2 and 3, which is substantially perpendicular to the axes of rotation of the rollers of the sets  11 ,  12  as hereinafter described. 
     A first set of rolls  11 , as seen in all of FIGS. 1 through 3, preferably comprises a first substantially continuous roll  14 , a conventional round roll having a shaft  15  which defines an axis of rotation  16  about which the roll  14  rotates. The round exterior surface  17  of the roll  14  is typically hard and substantially unyielding, such as made of steel, and is capable, when cooperating with the second, upper, roll  18  of the first set  11 , of applying a sealing force to a business form moving in the path  13  of at least about 100 pounds per lineal inch, e.g. about 200 pounds per lineal inch. 
     The second, upper, roll  18  of the first set  11  has a non-round configuration. While two exemplary configurations thereof are illustrated in FIGS. 1 through 3 on one hand, and FIG. 4 on the other (roll  18 ′ in FIG.  4 ), a wide variety of other configurations also may be provided. The construction of the roll  18  in FIGS. 1 through 3 is the preferred construction, however, because that has a minimal amount of material which not only reduces the cost of the roll, but since it has a minimal amount of material that contacts the form reduces the pressure necessary to cause a suitable seal. Also the construction illustrated in FIGS. 1 through 3 has less weight than most other constructions, so that the roll is very responsive, and a smaller stepper motor (as hereinafter described)  19  (see FIG. 1) may be used to effect rotation thereof. 
     The configuration of the roll  18  in FIGS. 1 through 3 is, in end view, one that substantially simulates an airplane propeller having at least first and second projections  20 ,  21  that are substantially uniformly extending from a central shaft  22  which is substantially parallel to the shaft  15  so that the roll  18  is rotatable about an axis of rotation  23  substantially parallel to the axis  16 , and substantially perpendicular to the path  13 . While in the preferred embodiment shown two projections  20 ,  21  are provided, angularly spaced from each other approximately 180°, it is to be understood that three or even more projections could be provided, and preferably uniformly angularly spaced from each other around the shaft  22 . 
     The shafts  15 ,  22  are mounted by suitable conventional bearings or the like (which may have a conventional adjustment mechanism for adjusting the spacing between the rolls  14 ,  18 ) so that the distal portions  24  of the projections  20 ,  21 , when in closest proximity to the surface  17  of the first roll  14 , are slightly spaced from each other, the spacing between approximately equal to the thickness of the folded business form to be handled thereby. However, the rolls may be spring pressed together so that the projection distal portions  24  actually touch the surface  17 , but that is not preferred, rather a uniform, though adjustable, spacing is always provided between the projection distal portions  24  and the surface  17 . 
     The conventional stepper motor  19  is preferably controlled by a conventional microprocessor, such as illustrated schematically at  26  in FIG.  1 . The control, and control circuitry, supplied by the conventional microprocessor  26  can be very similar to that of a conventional rotary cutter. A sensor (such as an optical sensor)  27  (see FIGS. 1 and 2) is preferably provided to sense the leading edge of the form moving in the path  13  into the nip between the rolls  14 ,  18  of the first set  1   1 , such sensing by the sensor  27  triggering an operation of the conventional stepper motor  19  to rotate the roll  18  so as to bring one of the distal portions  24  of the projection  20 ,  21  into operative contact with a portion of the business form having a pressure activated adhesive pattern substantially parallel to the axes  16 ,  23  so that sealing thereof is effected at the nip between the rolls  18 ,  14 . 
     Except when one of the distal portions of a projection  20 ,  21  is in operative association with the surface  17  of the roll  14 , the roll  18  is never in sealing position with respect to the business form moving in the path  13 . For example, if the roll  18  is rotated more than a few degrees from the operative position illustrated in FIGS. 1 through 3, it is in an inoperative position wherein no sealing, or other effect, on the business form is provided by the first set of rolls  11 . For example, if the roll  18  is rotated 90° from the position illustrated in FIG. 2, there clearly is no interaction between the roll  18  and the business form moving in the path  13 . 
     The shaft  22  and projections  20 ,  21  also preferably are of metal or other hard material, and are capable, with the roll  14 , of applying a pressure of at least 100 pounds per lineal inch to a form at the nip between the rolls  14 ,  18  when the roll  18  is in the position illustrated in FIGS. 1 through 3. While the airplane propeller simulating -configuration illustrated in FIGS. 1 through 3 has many advantages, it is to be understood that other configurations could also be provided such as the elliptical configuration illustrated at  18 ′ in FIG. 4, or a conventional round roll may be provided which has bumps forming projections at various locations therealong with the bumps spaced far enough from the surface of the round roll so that the surface of the round roll never operatively engages a business form fed in the nip between the rolls  18 ,  14 . Other conventional constructions of label rolls may also be provided. 
     The length  29  (see FIG. 1) of the rolls  14 ,  18  may be substantially the same, and in one preferred embodiment for handling a wide variety of different types of business forms, such as mailer type business forms, the length  29  is about 11 inches. 
     The second set of rolls  12 , visible in FIGS. 2 and 3, includes a first substantially continuous bottom roll  31 , and a second substantially continuous upper roll  32 . As seen in FIG. 3, the first roll  31  has a length  33  which is substantially the same as the length  29 , e.g. about 11 inches. However, the second roll  32  has a length  34  which is less than half the length  33 , e.g. about 2 inches. The rolls  31  and  32  are mounted and positioned (e.g. by conventional bearings) so that they are rotatable about substantially parallel axes, which axes are substantially parallel to the axes  16 ,  23 . For example, as schematically illustrated in FIGS. 2 and 3, the first roll  31  is mounted by a shaft  35  while the second roll  32  is mounted by a shaft  36 . While the rolls  31 ,  32  could be spring pressed together, preferably the rolls  31 ,  32  are also positively mounted so that there is a slight spacing between the peripheries  37 ,  38  thereof so that at the nip  39  therebetween there is a spacing approximately equal to the thickness of a folded business form to be sealed thereby. Preferably both of the rolls  31 ,  32  are made of metal, such as steel, and have a substantially unyielding peripheral surface  37 ,  38 . 
     The position of the roll  32  with respect to the roll  31  is adjustable, as indicated by the arrows  40  in FIG. 3, along the axis of rotation thereof defined by the shaft  36 . Adjustment in the dimension  40  may be accomplished utilizing any suitable conventional equipment for that purpose. 
     The length  34  of the roll  32  is designed so as to seal only edge portions of a form passing through the nip  39 , and not to provide a steam roller type action. In the preferred embodiment of the invention the set  12  also comprises a third roll  41  which is substantially identical to the roll  32  except positioned on the opposite edge of the first roll  31  from the second roll  32 , and is rotatable about a shaft  42  which has a substantially common axis with the shaft  36 . The second roll  41  is also adjustable in the dimension  40  utilizing conventional equipment, and when both the rolls  32 ,  41  are active they seal side edges of a form passing through the nip  39  at the same time. If desired, one or both of the rolls  32 ,  41  may be mounted on a mechanism that allows the roll  32 ,  41  to be moved away from the roll  31  into an inoperative position. The adjustment in the dimension  40  preferably accommodates forms having spacings in the dimension  40  between pressure activated cohesive patterns of between about 5-11 inches. 
     In the preferred embodiment illustrated in the drawings, preferably a second set of rolls are positioned substantially immediately adjacent the discharge from the first set of rolls  11 . That is, the spacing (best seen in FIG. 2) between the sets  11 ,  12  is no more than the distance necessary to allow the roll  18  to clear the roll  32 . 
     The rolls  14 ,  31 ,  32  can be powered—as indicated schematically by the motors  45 ,  46  in FIGS. 1 and 3, or by gear trains instead of or in addition to the motors, controlled by the microprocessor control  26 . However, preferably a separate drive as shown schematically at  47  in FIG.  2 —is provided to transport the forms in the path  13  through the sets of rolls  11 ,  12 , and then to some other location downstream of the rolls  12 . The drive  47 , which is illustrated only schematically because it is conventional, may comprise conventional rollers, conveyor belts, or the like. The drive  47  also may be controlled by the microprocessor  26 . 
     FIGS. 5 and 6 schematically illustrate an exemplary form that may be sealed utilizing the apparatus of FIGS. 1 through 3. The form is shown generally by reference numeral  50  and includes at least a first pattern  51  of pressure activated adhesive (cohesive) in a first dimension  52 , substantially perpendicular to the direction  13  and substantially parallel to the axes  16 ,  23 . In the embodiment illustrated in FIG. 5 there is also a second pattern of pressure activated cohesive  53  in the dimension  52 , and a third pattern  54 , the patterns  51 ,  53 ,  54  being substantially parallel to each other. The patterns  51 ,  53 ,  54  may be substantially continuous strips of cohesive, as indicated by the patterns  51 ,  53 , or may be discontinuous strips, such as shown at  54 , made up of a plurality of spaced boxes, dots, or other configurations of adhesive. However, the patterns  51 ,  53 ,  54  are not restricted to strips, but may be any suitable conventional type of pattern used with pressure activated cohesive. 
     The form  50  also comprises one or more patterns of pressure activated cohesive  55 ,  56  parallel to the direction  13  and substantially transverse to the dimension  52 . The patterns  55 ,  56  are adjacent the side edges  57  of the form  50  and substantially perpendicular to the leading edge  58  of the form  50 , and may be of any conventional pattern type as described above with respect to the patterns  51 ,  53 ,  54 . 
     FIG. 5 shows a bottom surface  60  of the form  50 , with the top surface or surfaces  61  cut away so as to illustrate the patterns of cohesive, and is only exemplary. It is to be understood that any type of conventional pressure seal form may be utilized including V-fold, double parallel eccentric C-fold, C-fold, Z-fold and eccentric Z-fold, with or without built-in reply envelopes, and with or without inserts. FIG. 6 is a schematic cross-sectional view along line  6 — 6  of FIG. 5 of a Z-fold form, having an intermediate paper ply  62  between the top and bottom plies  61 ,  60 , respectively, with the cohesive patterns shown schematically by Xs. 
     In the practice of the method of the present invention the first procedure is (a) moving the form  50  in the direction  13  (such as by using the conventional drive  47 ), and while (a) is being practiced: (b) at only a fist location (that is the first set of rolls  11  in the preferred embodiment), automatically applying at least about 100 pounds per lineal inch of pressure to the form at the second adhesive pattern or patterns  51 ,  53 ,  54  to seal the form at the second adhesive patterns  51 ,  53 ,  54  substantially without engaging any other portion of the form; and (c) at only a second location (e.g. 12 in the preferred embodiment), automatically applying at least about 100 pounds per lineal inch of pressure to the form at the first adhesive pattern or patterns  55 ,  56  to seal the form at the first adhesive patterns  55 ,  56  substantially without engaging any other portion of the form. Preferably (a)-(c) are practiced so as to first move the form  50  into operative association with the first set of rolls  11  so that sealing takes place at each of the patterns  51 ,  54 , and  53 , and then into contact with the second set of rolls  12  where sealing takes place at the patterns  55 ,  56  using the rolls  32 ,  41 , respectively. To seal at the patterns  51 ,  54 ,  53  after the sensor  27  senses the leading edge  58  of the form  50 , and knowing (based upon information input into the microprocessor  26 ) where the patterns  51 ,  54 ,  53  will be with respect to that leading  58 , the microprocessor  26  controls the stepper motor  19  so as to rotate the roll  18  to bring a distal portion  24  of each of the projections  20 ,  21  into operative association with the surface  17  of the roll  14  at each of the patterns  51 ,  54 ,  53  to apply the appropriate pressure to the form  50  thereat. 
     Depending upon the configuration of the form it may be only have one of the patterns  51 ,  53 ,  54  and only one of the patterns  55 ,  56 , or may have additional patterns aside from those illustrated in FIG. 5, and it may have inserts. In any event, however, the construction and construction of the roll sets  11 , 12  may readily accommodate the positions of the patterns, and their spacing as by adjusting the positions between the rolls  32 ,  41  in the dimension  40 , and operating the roll  18  with the stepper motor  19 . 
     It will thus be seen that according to the present invention a versatile, cost effective, and advantageous method and apparatus are provided for sealing business forms having pressure activated adhesive, or the like. While the invention has been herein shown and described in what is presently conceived to be the most practical and preferred embodiment thereof it will be apparent to those of ordinary skill in the art that many modifications may be made thereof within the scope of the invention, which scope is to be accorded the broadest interpretation of the appended claims so as to encompass all equivalent methods and apparatus.