Patent ID: 7029001

Claim:
A method of forming a business form product of multiple substrates, said method comprising the steps of: (a) feeding a first continuous substrate web along a longitudinal path; (b) feeding a second continuous substrate web along the path; (c) aligning the first and second webs in an edge-to-edge relationship to form a seam therebetween, wherein the seam extends along and is at least generally parallel to the path; and (d) applying a continuous streamer of tape to the webs over and along the seam to retain the webs in said edge-to-edge relationship to thereby form a common continuous sheet, said longitudinal path being defined in a rotary press, step (d) including the step of feeding the aligned webs and the streamer of tape through a nip roller to apply the tape over and along the seam, step (c) including the steps of aligning at least one of the webs with a mechanical guide prior to feeding the at least one web through the nip roller, said mechanical guide including a shaft and at least one collar that engages one edge of the at least one web to thereby align said at least one web in said edge-to-edge relationship with the other web, said at least one web being within at least about one-one-hundredths of an inch from said other web when in said edge-to-edge relationship, said mechanical guide being positioned upstream of the nip roller and located within one foot of web length from the nip roller, said at least one web being at least in part formed from magnetic material, step (c) further including the step of feeding the at least one web through an idler roller prior to feeding the at least one web through said mechanical guide, said idler roller being positioned at least four feet of web length from the mechanical guide.