Abstract: An on-demand exact registration form web perforating apparatus is simple yet effective, and can operate at high speed and has a long life. A form web is moved in a predetermined path past first and second rotatable continuous circumferential perforator wheels mounted on substantially stationary axes and spaced from each other along the predetermined path and in alignment with each other along the path. First and second anvil cylinders are spaced from each other along the path for cooperation with the wheels, each cylinder having an interrupted circumference including a raised portion and a depressed portion, and a movable axis about which the cylinder rotates.

Abstract: Multi-part business forms having speciality electronically imaged indicia are produced in a low-cost, high speed, low waste, and enhanced flexibility manner. While two part or four or more part forms may be produced, especially advantageous is the production of three part forms, such as airbills. After individual first, second and third parts are produced using conventional presses, the individual webs are separately fed to a collator and while fed to the collator are electronically imaged with speciality indicia, such as the name and address of the sender, airbill number, and—for the third part—a bar code. The webs are then collated on the collator, two business forms wide. A three part airbill produced includes first and second parts of carbonless paper stock having personalized first indicia electronically imaged on them, and a third part of carbonless label stock having the personalized indicia, and including bar code indicia, electronically imaged on it.

Abstract: A mailing envelope with a plurality of inserts is made by imaging variable color indicia on both faces of a paper substrate and imaging sense marks, and reply indicia, on at least one face of the substrate. The sense marks are used to properly align and slit the substrate web into a web of pre-determined width (removing the sense marks), and then label portions are flexographically printed on the first face of the web with magnetic ink. Adhesive and a release liner (e.g. using transfer tape) are applied to the second face of the web at the label portions and the labels are die cut from the label portions. The web is cut into sheets of predetermined length, each sheet including at least one set of labels, and the sheet is buckle folded to form a folded sheet with a plurality of panels in the sheet, at least one panel having a set of labels.

Abstract: A web of paper is printed with selective non-variable information and vastly different variable information on portions of the paper web which are ultimately separated into discrete documents. At least one ion deposition print unit and a number of flexographic print units are utilized, as well as a data source containing at least the variable information, and first and second computers. Data is read from the data source with the first computer and in response to the read data the ion deposition print unit is controlled with the first computer to print variable information on the paper web. Form lag commands are provided from the first computer to the second computer. In response to the lag commands the flexographic print units are independently controlled by the second computer to operatively engage and disengage the paper web and thereby print non-variable information from at least one of the flexographic units on each discrete document portion of the paper web.

Abstract: A dispensing mechanism dispenses labels having a pressure sensitive adhesive face and an adhesive release material coated face. A guide serves to guide the labels in web form along plasma-coated surfaces to a printer and then to a cutter mechanism for forming discrete labels and dispensing the labels. An open-cell foam sponge is provided for wiping the rotary cutter using silicone oil wicked into the wiper. A plate projects from the exit opening of the dispenser at an angle to the guide path to maintain the cut label on the dispenser plate. Additionally, a hub assembly is provided wherein the hub has a contact area in excess of 50% of the available contact area along the inside of the core mounting the label supply.

Abstract: A license plate decal is provided on a folded (e.g. Z-folded) business form which acts as a carrier for the decal. A cut out is formed in a panel of the mailer and a patch (such as a glassine patch) is adhesively secured at a peripheral portion to the mailer panel and a release coating is provided on at least a significant part of the central portion of the patch. The decal adhesive engages the release coating so that the decal and its associated pressure sensitive adhesive may be readily removed from the patch. The patch may be secured to the paper on either face thereof; if secured at the bottom face, the patch and decal can flex into the cutout to provide a minimum thickness when in a stack of mailer intermediates. Where the patch is secured at its top face, the maximum thickness of the patch and decal combination is preferably about 0.008 inches, which is significantly less than the thickness at the decal in prior art carriers.

Abstract: An on-demand exact registration form web perforating method is simple yet effective, and can operate at high speed and a long life. A form web is moved in a predetermined path past first and second rotatable continuous circumferential perforator wheels mounted on stationary axes and spaced from and in alignment with each other along the path. First and second anvil cylinders are spaced along the path for cooperation with the wheels, each cylinder having an interrupted circumference including a raised portion and a depressed portion, and an axis of rotation.

Abstract: A printing apparatus includes an inker roll, a plate cylinder and an impression cylinder mounted for rotation about parallel axes. The inker roll is selectively displaced into engagement and disengagement with the plate cylinder to transfer ink to the plate cylinder and to a substrate about the impression cylinder. The inker roll is moved to transfer ink only during printing cycles and is out of engagement with the plate cylinder during non-printing cycles. A doctor blade engages the inker roll along a diameter thereof passing through the pivotal axis of the inker roll and its axis of rotation and on the side of the axis of rotation remote from its pivotal axis.

Abstract: A mailing envelope with a plurality of inserts is made by imaging variable color indicia on both faces of a paper substrate and imaging sense marks, and reply indicia, on at least one face of the substrate. The sense marks are used to properly align and slit the substrate web into a web of pre-determined width (removing the sense marks), and then label portions are flexographically printed on the first face of the web with magnetic ink. Adhesive and a release liner (e.g. using transfer tape) are applied to the second face of the web at the label portions and the labels are die cut from the label portions. The web is cut into sheets of predetermined length, each sheet including at least one set of labels, and the sheet is buckle folded to form a folded sheet with a plurality of panels in the sheet, at least one panel having a set of labels.

Abstract: A moving web is either perforated or cut using a knife cylinder having at least one blade, and an anvil cylinder having at least one raised anvil surface, and preferably a plurality (e.g. about 22) of alternating substantially uniform raised surfaces and depressions. The knife cylinder is substantially continuously rotated, and the anvil cylinder is substantially continuously rotated by a servo motor, which also positively controls the position of the anvil cylinder with respect to the knife cylinder to selectively either effect perforation or cutting of the web, or no perforation or cutting. Position controlling is typically accomplished by substantially constantly and instantly indexing the anvil cylinder in a reverse direction. Sensors may be utilized for sensing the locations of the knife and anvil cylinders and providing that information to a computer controller to facilitate indexing.

Abstract: Multi-part business forms having speciality electronically imaged indicia are produced in a low-cost, high speed, low waste, and enhanced flexibility method. While two part or four or more part forms may be produced, especially advantageous is the production of three part forms, such as airbills. After individual first, second and third parts are produced using conventional presses, the individual webs are separately fed to a collator and while fed to the collator are electronically imaged with speciality indicia, such as the name and address of the sender, airbill number, and--for the third part--a bar code. The webs are then collated on the collator, two business forms wide. A three part airbill produced includes first and second parts of carbonless paper stock having personalized first indicia electronically imaged on them, and a third part of carbonless label stock having the personalized indicia, and including bar code indicia, electronically imaged on it.

Abstract: A plurality of interconnected envelope blanks are formed from an envelope web of paper. Die cut windows are also formed in each envelope blank of the interconnected web and transparent window patches are adhesively secured over the die cut window. A plurality of inserts from insert webs of paper are formed and may be variably imaged. The inserts are collected and disposed on the interconnected envelope blanks with address information registering through the window. The interconnected blanks and web form with inserts applied are severed to form discrete envelope blanks and later folded and glued to form complete mailers.

Abstract: A stuffed mailing envelope is formed from webs of paper. A plurality of insert sheets are constructed from webs of insert paper by variably imaging the insert webs, and then intelligently aligning them and cutting them into aligned sheets, and then folding the aligned sheets to produce a formed insert. A plurality of interconnected envelope blanks are formed from an envelope web of paper, and a plurality of insert sheets (including the formed insert) are collected and placed on each of the envelope blanks while they are interconnected in web form. Then, while conveying the interconnected envelope blanks in web form, the blanks are severed from each other and are formed around the inserts to produce a final mailing envelope containing a plurality of insert sheets. The envelope blank typically has two parallel minor flaps and two parallel major flaps.

Abstract: A serrated rotary die having a minimum die cutback angle .theta., wherein ##EQU1## where CL DIST is the centerline distance between punch and die axes of rotation, ##EQU2## MD is a die internal diameter at the die teeth roots, and HT is the height of the die over midpoint.