Patent Publication Number: US-5294100-A

Title: Method and apparatus for securing plural printed material with peelable tabs

Description:
BACKGROUND OF THE INVENTION 
     I. Field of the Invention 
     This invention relates generally to the formation of plural printed documents in stacked relationship for handling and mailing. More particularly, the invention pertains to a method and apparatus for securing stacked plural printed documents by utilizing adhesive tabs which wrap around the sides of the stacked plural printed documents and glue beads interposed among the stacked plural printed documents for maintaining the integrity of the stack during handling and mailing. 
     II. Background of the Invention 
     Magazines printed for distribution via the United States Postal Service (USPS) are typically addressed at the facility where the individual components are collated and bound to produce the magazine. The postage represents a significant portion of the overall production cost. The USPS regulations include a number of options which allow the publisher to reduce postage costs. These reductions are the driving force behind the magazine packaging which occurs at the printing plant. One such option relates to so called &#34;firm packages&#34; in which a plurality of documents such as magazines, catalogs, etc. are to be delivered to a single address. 
     In a typical magazine production process the magazine signatures are collated and then bound together. The complete magazines are then addressed either inline with the collating and binding machinery or offline on an independent mail labeling line. After the magazines are labeled, they are stacked and then bound into packages. The package forming operation typically employs machinery which cross-ties and/or shrinkwraps the stack of magazines. 
     The formation of the packages is the point in the process when most of the postage cost reduction options are available. In the simplest case, the packages would be formed into constant size stacks with the address labels for the magazines in no particular order. This leaves the entire sorting effort to the post office and results in no discount. The discounts occur when the magazines are presorted according to the USPS regulations. The current practice results in varying size packages which include magazines that are destined for a particular city or zip code destination. At the finest presort level, magazines which are destined for the same address are packaged together. Such packages are referred to as &#34;firm packages&#34; by USPS definition. However, due to limitations with the existing packaging methods of cross-tying or shrink wrapping, small-count firm packages are not typically produced. 
     The usual minimum package size per USPS regulations is six magazines for second class mail, although USPS regulations can be met with smaller &#34;firm&#34; packages. The existing packaging equipment is only capable of forming packages of six or more at typical line speeds. The formation of firm packages of two to five magazines requires a maximum cycle rate which exceeds the current state of the art for stacking, cross-tying, and shrink wrapping equipment. Small-count packages also pose a problem for cross-tying or shrink wrapping because the small stack tends to curl up as the shrink wrap or cross-tie straps are applied. 
     In some instances, small-count firm packages are produced by slowing down the binding line. This results in cost increases for labor and binding line utilization, which quickly can negate any postage cost avoidance. The problem of curling is still present at the lower speeds. 
     An alternative application for the formation of packages occurs when a publisher wishes to mail some or all of their magazines with a renewal card, bill, advertising or editorial supplements referred to as &#34;allowable enclosures&#34; or &#34;onserts&#34;. In this case a wrapper, envelope or polybag is used to contain the magazine onserts and the magazine. Polybags are typically applied offline because the polybagging process is slower than typical line speeds and it does not allow intermittent application of the polybag. 
     Therefore what is needed is a method and apparatus which can operate at typical line speed to form small-count firm packages and does not cause curling of the items to be packaged. The present invention forms packages, by the automated application of tabs, which are applied to opposite sides of a stack of plural printed documents. The tabs wrap around opposed edges of the stack and contact the top and bottom book in the stack. The tabs are held in place by a peelable adhesive. Small beads of peelable adhesive may also be placed between the magazines or onserts in the stack to prevent skewing or slipping of the magazines or onserts during handling and/or mailing. 
     SUMMARY OF THE INVENTION 
     The present invention is a method and apparatus for securing small-count firm packages without disrupting the operation of an automated magazine binding production line normally producing large-count stacks. While the invention is being described in the context of a magazine publishing application, it may also be adapted to other printed documents. As the magazines are conveyed through a conventional trimming station, past a labeler head and towards the portion of the line which forms and secures large-count stacks, those magazines required for small-count stacks (firm packages) are diverted to an adjacent parallel line incorporating the present invention. Once diverted, the magazines are conveyed to a short-count stacker. Just prior to being assembled into a stack, a hot-melt release glue applicator selectively tacks a peelable glue bead(s) onto a cover of each magazine to be stacked, except for the top one in the stack. The magazines are then stacked, via the stacker, and conveyed to a tabbing station. 
     The tabbing station has a first and second transfer belt conveyor between which lies opposed tab applicators. Each tab applicator has a source of tab substrate material which feeds up through two stepper motor driven tab feed wheels. The feed wheels draw the tab substrate material up until the desired length necessary for the particular firm package being assembled is reached. The tab substrate material is then cut to form a tab and the tab held in place by a vacuum shoe. A second hot-melt glue applicator applies the peelable glue onto the ends of the tab. The vacuum shoe rotates the tab and, with a properly timed blast of air, forces the ends of each tab against the top and bottom surface of the stack. The stack may then pass through a mechanical plow arrangement which completes the fold of the tabs onto the top or bottom surfaces of the stack. The stack then passes through upper and lower nip rollers for firmly securing the adhesive tabs to the package and the glue beads between each magazine to the opposing cover surfaces. The firm packages are then conveyed to the main lines sorting and mail stations where they are merged with the larger stacks in the original sequence. 
     In the alternative embodiment, the present invention remains inline upstream of the standard stacking and tying equipment and is directed to an onserting operation. The stacking station in the alternative embodiment consists of an onserting operation in which supplemental printed documents are deposited onto magazines as they move along a conveyor line. The onserts are secured to the magazines by the tabbing process and then the tabbed group is labeled and stacked in the conventional manner. 
     OBJECTS 
     The primary object of the present invention is to provide a method and apparatus for producing small-count packages at typical magazine binding line speeds. 
     Another object of the present invention is to provide a method and apparatus which eliminates curling of the stacked printed material in the small-count package. 
     Yet another object of the present invention is to provide a method and apparatus for securing onserts and &#34;allowable enclosures&#34; to printed materials with tabs instead of using an envelope, polybag, or paperwrap. 
     Still another object of the present invention is to provide a method and apparatus for forming and securing short-count packages which are less expensive than enveloping or polybagging. 
     Another object of the present invention is to provide a method and apparatus for forming and securing a &#34;firm package&#34;, or onserts which are more acceptable to publishers sensitive to the negative environmental image associated with polybagging. 
     Still another object of the present invention is to provide a method and apparatus which allows intermittent operation of the packing forming process during continuous operation of the line incorporating the present invention. 
     Another object of the present invention is to provide a new method and apparatus for forming a small-count firm package which meets the USPS domestic mail manual regulations. 
     Another object is to provide a packaging concept which is compatible with USPS automated sorting equipment and the associated automation discounts as an alternative to polybagging which is excluded from current automation proposals. 
    
    
     DESCRIPTION OF THE DRAWINGS 
     These and other objects of the present invention will become more readily apparent from the following detailed description taken in conjunction with the accompanying drawings in which: 
     FIG. 1 is a schematic of a magazine saddle binding production line incorporating the present invention; 
     FIG. 2 is a schematic of an adhesive binding production line for magazines incorporating the alternative embodiment present invention; 
     FIG. 3 is a plan view of a tab of the present invention; 
     FIG. 4 is an end view of a secured, small-count firm package; 
     FIG. 5 is a plan view of the tabbing station of the present invention; and 
     FIG. 6 is a side view of the tabbing station of the present invention. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     The present invention comprises an apparatus and method for securing plural printed documents such as plural magazines or magazines and onserts in stacked relationship for handling and mailing. Typically, the plural printed documents are six or fewer magazines per stack, thereby forming a small-count firm packages, such as that term is used in Issue Number 14, dated May 15, 1992 of USPS Domestic Mail Regulations, or an onsert(s) on a magazine. The present invention may preferably be incorporated as an optional stacking and securing line in parallel arrangement with the typical stacking and securing line of an automated magazine binding production lines geared towards large-count stacks, which are typically secured by cross-tying and/or polybagging. FIGS. 1 and 2 are schematics which show two typical types of automated magazine binding production lines which include the invention. 
     FIG. 1 shows a conventional magazine binding production line indicated generally by numeral 10 and having a standard saddle stitcher 12, such as an A. M. Sheridan SP 855 saddle stitcher. The printed pages or signatures are bound at the standard saddle stitcher 12 into magazines. The magazines are then conveyed via conveyor 13 through a standard page trimmer 14, such as a HT 15 trimmer, and then past a standard labeler head 15, such as a Cheshire 539 or a standard ink jet printer such as the Video Jet 9416, which applies an address label under control of a system computer (not shown). 
     The next portion of the line contains stacking and securing means. It is here that the present invention is incorporated. Typically, the signatures are conveyed through to a standard stacking arrangement, such as a RIMA RS-12 counter stacker, designated generally 18, for forming large-count stacks of six or more magazines. The cross-tying process is next where the large-count stacks are tied in one direction at a first OVAL JP-80 tier 19, then are oriented via bump turn conveyor 21 so second OVAL JP-80 tier 23 ties the stack in a direction perpendicular to the first tie. 
     The present invention allows small-count stacks to be formed by diverting quantities of magazines from the main conveyor line to a parallel production line, designated generally as 20, operating at the same throughput as the main production line. The parallel production line 20 of the present invention forms and secures small-count stacks. This parallel production line then rejoins the main production line at 22 for the sorting and mailing portions of a typical magazine binding production line. 
     FIG. 2 shows an alternative embodiment of the present invention as applied to a typical adhesive binding production line, designated generally as 24. It includes an onserter apparatus 26. The onserter is located between the trimmer 28 and stacking portion of the line designated generally as 30. As mentioned above, the onserter 26 functions to position a bill, renewal notice, advertising or editorial supplement on top of each individual magazine or, in the case of a demographic system, on selected magazines in the stream which are to be routed to a particular subscriber or customer. The onserter line will also include a tabber station 32 that will secure this type of small-count package. After the onserts have been secured to the magazine, the composite is conveyed past labeling station 29 and toward the stacking and securing portion of the line. This portion of the line can include two parallel lines, one line for stacking large-count stacks and one line for small-count stacks which utilizes the present invention for the preparation of &#34;firm&#34; packages. 
     Referring again to FIG. 1, the apparatus comprising the present invention is found in a parallel line to the main production, and includes a diverter 33, a 90° turn conveyor 34, a reject divert station 34a, shuttle pocket 35, a stacking station 38, a tabbing station 40, and a second conveyor 42 for transferring the assembled and tabbed stacks to the sorter table on the main line. FIG. 3 shows a resulting small-count firm package 44 secured by tabs 46 and 48. FIG. 4 shows a typical tab 45 for securing the small-count package. 
     The apparatus comprising the present invention is connected to the main production line 10 by a conventional diverter 33 such as RIMA stacker infeed divert gate, and a 90° turn conveyor 34 allowing a predetermined number of printed documents to be extracted from the main production line 10 to the parallel line 20 of the present invention. Downstream from the 90° conveyor 34 is a first glue applicator 36. The first glue applicator is preferably a hot melt glue gun such as the Nordson Model H-20 which will apply hot melt releasable glue bead such as H. B. Fuller HM 2703 or pressure sensitive glue bead to the cover surface of selected magazines at a predetermined location thereon. 
     The 90° turn conveyor 34 leads to stacking station 38. The stacking station 38 orients a predetermined number of the magazines into a stacked relationship. The stacking station 38 preferably includes an ultra high speed short-count stacker. The stacker preferably should have a maximum stack capability of about 21/2&#34; and a nominal maximum stacker cycle rate of 150 stacks per minute. This will ensure that the parallel line of the present invention runs the same throughput as the main production line. 
     The tabbing station 40, is located immediately downstream of the stacking station 38. Referring to FIGS. 5 and 6, the tabbing station 40 has two longitudinally disposed transfer belts 56 and 58 on either side of the tabbing area which is designated generally as 60. Between the first or upstream transfer belt 56 and the tabbing area 60 on a first side of the tabbing area is a first drive roller 62a with a cooperating adjustable roller 64a. A corresponding first drive roller 62b with a cooperating adjustable roller 64b is located between the second transfer belt 58 and the tabbing area 60 is a second drive roller one is shown in FIGS. 5 and 6 as 65, 65 with a cooperating adjustable roller 66a. The adjustable rollers 64a and 64b pivot about shaft 68a and 68b, respectively, and adjustable rollers 66a and 66b pivot about shafts 70a and 70b. This allows for variations in the height of the stack. FIG. 6 shows the positions of the adjustable rollers 64b and 66b in solid line for stack 99 broken line for the case when a single magazine with one or more onserts passes through the tabbing station. 
     As seen in FIG. 5, on either side of the tabbing area 60 are two identical tab feed devices 72 and 74. Each of the tab feed devices, as shown by tab feed 72, has a reel 75 loaded with an elongated strip of tab substrate material 76. This tab substrate material is preferably high tear paper or a fiber reinforced paper tape. The tab substrate material 76 in each tab feed device is threaded through a tab advancer 78 which is operatively connected to a stepping motor 79. Each of the tab advancers 78 consists of two cooperating punch rollers 80 and 82. Each tab feed device also has a tab cutter 84 and 86, respectively, which is disposed adjacent each source of tab substrate material for cutting the tab substrate material to form a tab of a predetermined length. Each tab cutter has a blade 88a and 88b at the end of swing arm 90a and 90b. 
     Also forming a part of each of the tabbing devices 72 and 74 is tab adhesive applicator, one being shown at 91 in FIG. 6, is located adjacent each tab cutter. The two applicators may comprise any suitable adhesive applicator such as a hot melt glue gun, Nordson H20 or equivalent which can selectively apply a peelable or other releasable glue onto the tab substrate material. The applicator can conveniently be either located below the tab cutter or above the tab cutter and must be able to apply beads of adhesive to the opposed portions of the tab as shown by numerals 114 and 116 in FIG. 4. 
     Each tab feed device also has a tab transfer means, which is preferably a tab feed vacuum wheel shown as 92 and 94 in FIG. 5. The vacuum wheels contains a vacuum manifold for drawing a vacuum on the tab to hold the tab during its positioning and an air jet for blasting air in order to transfer the tab to the stack to be tabbed. 
     The tabbing area 60 can also include a mechanical plow arrangement located at 96 although it is not necessary. The mechanical plow arrangement consists of a plow folding board which will fold the tab over the remaining side and surface of the stacked magazines after it has been airblasted onto the stack. This mechanical plow arrangement is located upstream of the second power roller 65 and corresponding adjustable roller 66. The second conveyor 42 located between the main production line 10 and at the tabbing station 40 transports the sidetracked tabbed firm packages back to the main production line. 
     In the alternative arrangement found in the production line shown in FIG. 2, the present invention includes glue applicator 25, a stacking station consisting, like first glue applicator 36 of the first embodiment, of an onserter 26 and a tabbing station 32. Glue applicator 25 may be any glue applicator which will deposit a releasable glue bead on a top surface of each magazine to receive an onsert. The onserter 26 is any conventional onserter such as a Sitma model 675 which places an onsert on the top of a magazine. The tabbing station 32 has the same features as tabbing station 40 discussed above. 
     MODE OF OPERATION 
     The present invention is incorporated into the automated main magazine binding production line 10 and will receive predetermined select magazines for forming small-count packages as explained below. In the typical automated microcomputer controlled magazine production binding line 10, the collated group of signatures, one is shown at 11, in FIG. 1, or a perfect binding line 24, as shown in FIG. 2, to a standard trimmer 14 for trimming the signatures so that the edges of the magazines will be regular. The trimmed magazines or other printed documents, are then conveyed thru a labeling station and then to either the stacking station 18 on the main production line 10 or diverted to the apparatus of the present invention on the parallel line 20. The magazines not diverted continue through a stacking station 18 and are cross-tied or shrink wrapped or removed to an off-line process. These non-diverted magazines then continue to a sorting and mailing station 100. 
     When small-count firm packages are to be formed, the computer control channels the requisite magazines from production line shown in FIG. 1, by means of diverting mechanism 33 and 90° turn conveyor 34. The magazines are conveyed through the first glue station 36. The glue station contains a glue applicator which applies a spot or bead of preferably peelable or releasable glue on the top surfaces of the magazines, except on the magazine which will be on the top of the stack. The predetermined number of magazines then enter the stacking station 38 where a stacker will stack the predetermined number into a small-count stack of six or fewer magazines. The glue beads are now disposed between the magazines to help secure the stack. 
     The stacked magazines are now conveyed to the tabbing station 40. Two stepping motors, also controlled by the main computer, drive the tab feed cooperating punch rollers 80 and 82 drawing up the tab substrate material to the necessary length for securing the stacked magazines. Once the desired length is reached, the tab substrate material is cut by the tab cutters 84 and 86 to form the tab. The adhesive is also applied to the tab after the tab is cut, depending upon whether the first and second tab adhesive applicators are located above or below the tab cutter. These adhesive applicators preferably apply the glue on the portion of the tab which will be facing the top and bottoms surfaces of the stacked magazines. FIG. 4 shows tab 45 partially broken away with adhesive coated areas 112 and 114. 
     When the tabbed substrate material is fed up through the tab feed 72 and 74 on both sides, a vacuum is drawn on the tab by vacuum wheels 92 and 94. When the tab substrate material is cut, the tab remains in its position. Vacuum wheels 92 and 94 rotate approximately 45 degrees placing the tabs adjacent opposing sides of the stack, at which time an air jet transfers the tabs against the opposed side edges of the stack. The air jet forces the ends of the tab to adhere to the top and bottom surface. The stack is then conveyed through the mechanical plow 96 which completes the fold of the tabs onto the top and bottom of the stack. The stack is then conveyed through rollers 64a, 64b, 66a and 66b which presses the tabs to the top and bottom surfaces to more firmly bond the tabs to the top and bottom magazines. The glue beads located between the magazines are also pressed to further secure the stack and prevent skewing of the stack. The now secured stack, one is shown at 99, is conveyed back to the main production line 10 where it can be sent to the sorting station 100. 
     Both the conventionally produced large stacks and the smaller stacks produced by this invention are tracked thru their respective processes by the tabbing line computer controller. At the merge point 22 the arriving stacks are gated such that the original stack sequence is regained. 
     The process is similar when the invention is associated with an automated magazine production line utilizing an onserter shown in FIG. 2. After the trimming station 28, the magazine is passed through a first glue station 25 where a hot melt adhesive glue bead may be tacked to the upper surface of the magazine. The magazine is then conveyed to the onserter 26 where the onsert is positioned on the top surface of the magazine and the glue bead is now located between the magazine and onsert. The magazine is then sent to the tabbing station 32 and the process of applying the tabs described above is the same. Once the onsert is secured to the magazine by the tabs, it is then conveyed past a labeling station 33 to the stacking portion of the magazine binding line where it can enter either the main line stacking station or be diverted to the present invention if it is to form a small-count package. 
     It is understood that the above disclosure and presently preferred embodiment is to be taken as illustrative of the invention. The invention may be readily adapted to secure a variety of plural printed documents in stacked relationship. Furthermore, it is to be understood that those skilled in the art be capable of making modifications.