Abstract: An envelope blank is conveyed through a folding mechanism that folds one or more flaps of the blank. In folding a side flap the leading edge of the blank adjacent to the score line follows in a helical path a convex face of a plowshare. The plowshare face applies at the leading edge of the blank adjacent to the score line a force which bends the side flap through an angle of 180° to a position where the flap is folded to overlap the blank. The folding of the flap is initiated by the convex face of the plowshare so that the flap folding forces are applied to the score line where the flap has the least resistance to bending. The folding forces are removed from the flap free edge which is supported to follow the movement of the flap leading edge.

Abstract: A stack of sheets or blanks are supported for individual high speed feeding from the bottom of the stack on a table positioned adjacent to a feed cylinder. An air blast from a pivotal nozzle deflects the leading edge of the bottom blank downwardly into engagement by suction force with the surface of the feed cylinder. Rotation of the feed cylinder separates the bottom blank from the stack. A plurality of rocker arms are then oscillated forwardly into the gap between the stack and the separated bottom blank. The rocker arms are independently, rotatably supported transverse to the leading edge of the stack. The position of the rocker arms is adjustable to support the stack as determined by the die cut configuration of the blanks. A fast cam actuates oscillation of centrally positioned rocker arms beneath the central portion of the stack leading edge with an accompanying blast of air between the bottom blank and the stack.

Abstract: A series of overlapping envelope blanks are fed into contact with a pull-out roll which engages and accelerates the first blank to separate it from the remaining blanks. From the pull-out roll, the separated blank is fed onto the surface of a rotary aligning wheel. A plurality of aligning pins extend from the surface of the wheel and are positioned in spaced relation around the wheel. The separated blank is fed into contact with the aligning pins forcing the blank with its trailing edge engaged with the pull-out segment to maintain the separated blank aligned on the surface of the wheel. Vacuum ports are positioned on the surface of the wheel adjacent to the aligning pins. The negative pressure from the vacuum ports secures the sheet to the surface of the wheel as the sheet is aligned into a preselected position on the wheel by contact with the pins.

Abstract: A leading edge of a leading blank in a series of overlapping envelope blanks is fed at a preselected speed into contact with a rotatably mounted backing roller. The backing roller is mounted in a frame and is selectively adjustable between a first position and a second position. A rotatably mounted segment roller is positioned opposite the backing roller. A pull-out segment is a secured to a radial portion of the backing roller. A plurality of longitudinal slots are provided in the surface of the pull-out segment and are selectively connected to a source of negative pressure. The segment roller is driven at a preselected speed greater than the speed of the series of overlapping blank. In a first mode of operation, the backing roller is adjusted to a first position in the frame so that upon rotation, the pull-out segment frictionally engages the leading edge of the leading blank, separating it from the series of overlapping blanks.

Abstract: A continuous web of sheet material is fed through the lip of a first pair of driven pull rolls around a series of idler rollers and through the nip of a second pair of driven pull rolls. The pairs of pull rolls are selectively rotated to exert a desired tension on the web in a tension zone formed between the pairs of rolls. One pair of pull rolls operates as feed rolls to advance a preselected length of the web to a rotating cutter mechanism so that envelope blanks of a selected length are cut from the web for each revolution of the cutter mechanism. The feed rolls are operated by a servo-controlled motor responsive to an operator initiated signal to adjust the feed length without interrupting the feed of the web to the cutter mechanism. The second pair of pull rolls operates as tension rolls and is servo-motor controlled to maintain a preselected tension on the web fed to the cutter mechanism.

Abstract: An envelope blank is conveyed by a transport system in an envelope making machine to a folding mechanism that folds one or more flaps of the blank. In folding a side flap, the leading edge of the blank adjacent to the score line is conveyed along a convex face of a plowshare. The plowshare face applies at the leading edge of the blank adjacent to the score line a force which bends the side flap through an angle of 180.degree. to a position where the flap is folded to overlap the blank. A crease is formed on the score line to permanently set the flap on the blank. The folding of the flap is initiated by the convex face of the plowshare. Extending from the upper edge of the plowshare face is a grid-like network of flexible rods mounted to follow the helical path of the plowshare face. The free edge portion of the flap is supported by the grid to follow the flap leading edge being folded by the plowshare.

Abstract: A continuous web of material is unwound from a roll by driven pull rolls that feed the web material to a printing unit in a feedline of an envelope making machine. The printing unit prints a selected one of the inside surface and the outside surface of the web before the web is cut and folded to form envelopes. The printing unit is supported by a base which is mounted for pivotal movement on a platform of a fixed frame member. The base is connected to the platform by a vertical pivot pin for movement through a 180.degree. between a first position for printing the inside surface of the web and a second position for printing the outside surface of the web. The base of the printer is locked to the platform in the selected one of the first and second positions to perform the desired printing operation. The web is fed between counter-rotating impression and plate cylinders rotatably mounted and driven on the printer base.

Abstract: A stack of sheets or blanks for feeding one by one from the bottom of the stack by a feeding mechanism is supported for high speed feeding to subsequent stations. A feed cylinder rotatably supported beneath the leading edge of the stack includes a suction device. An intermediate portion of the blank leading edge is drawn by the suction device downwardly toward an opening in the periphery of the feed cylinder. Continued rotation of the feed cylinder further bends the blank. For blanks of large size and having a leading edge with an irregular contour the blank leading edge intermediate portion extends forwardly from edge lateral portions. Positioned in spaced relation along the interior of the feed cylinder are a plurality of air manifolds having outlets directed at selected angles upon the lateral portions of the blank leading edge. The manifolds are connected to a source of pressurized air which is directed in a sweeping motion upon the blank leading edge lateral portions upon rotation of the feed cylinder.

Abstract: Finished envelopes are conveyed in a feed line of an envelope forming machine aligned in spaced apart relation to a spiral delivery mechanism that transfers the envelopes on edge to the surface of a delivery table. A conveyor on the delivery table sequentially advances the envelopes in a stacked relation from a receiving end portion to a discharge end portion where a predetermined quantity of stacked envelopes are periodically removed from the table as envelopes are added to the stack at the receiving end portion of the table. The envelopes are maintained in a compact stack by a stop member which is normally biased toward the receiving end portion of the table by an actuator mechanism. The stop member exerts pressure on the stack as it advances upon the addition of envelopes from the receiving end portion to the discharge end portion.

Abstract: A continuous web of sheet material is fed through the nip of a first pair of driven pull rolls around a series of idler rollers and through the nip of a second pair of driven pull rolls. The pairs of pull rolls are selectively rotated to exert a desired tension on the web in a tension zone formed between the pairs of rolls. One pair of pull rolls operates as feed rolls to advance a preselected length of the web to a rotating cutter mechanism so that envelope blanks of a selected length are cut from the web for each revolution of the cutter mechanism. The feed rolls are operated by a servo-controlled motor responsive to an operator initiated signal to adjust the feed length without interrupting the feed of the web to the cutter mechanism. The second pair of pull rolls operates as tension rolls and is servo-motor controlled to maintain a preselected tension on the web fed to the cutter mechanism.

Abstract: A pair of pull rolls unwind web material from a roll and advance the web at a preselected linear feed rate to a web cutting mechanism. The pull rolls are rotated at a preselected speed to generate the desired linear speed rate for cutting the web at selected intervals to produce blanks of a preselected length. The feed rolls are driven by a servo-motor which is operated by a controller that is microprocessor controlled. The controller is electrically connected to an encoder that is drivingly connected to a rotating knife cylinder of the web cutting mechanism. A selected length of blank to be cut from the web is inputted by the operator through a keypad to transmit a corresponding signal to the controller. In addition, the controller receives a signal from the servo-motor that drives the pull rolls, which signal is representative of the rate of rotation of the pull rolls.

Abstract: An envelope blank forming machine for forming generally rectangular booklet envelope blanks and generally diagonal envelope blanks on the same machine includes a pair of removable turnbars, adjustable pull rolls and an adjustable cutoff device. Preselected adjustment of these components provides a generally rectangular blank or a generally diagonally shaped blank. Retractable trim devices are provided in cutting relation with the blank when diagonal blanks are being formed. Seal flap cutters and first and second flap cutters are provided to form the booklet seal flap and bottom flap on the booklet envelope blank. These cutters are removed and replaced with seal flap corner cutters, bottom flap corner cutters and diagonal trim cutters when generally diagonal envelope blanks are being formed.

Abstract: An envelope forming apparatus has a vacuum table with apertures through which a vacuum is applied onto the surface of the vacuum table. A series of parallel endless belts move across the vacuum table and transport an envelope blank across the vacuum table. The vacuum through the apertures in the vacuum table holds the blank on the belts as they move across the vacuum table and as the blank is folded by a plowshare folder located relative to the vacuum table. Alternatively, a single wide belt with apertures may be substituted for the series of parallel belts.

Abstract: An envelope making machine includes a printer for printing material on the envelope blanks as they are being formed into envelopes in the machine. The printer has printing modules which include an impression cylinder, a plate or type cylinder, an anilox roll and a fountain roll. The fountain roll is positioned adjacent to and rotates in a direction opposite to the anilox roll and upon rotation transfers a film of ink to the surface of the anilox roll. A distributor or doctor blade is positioned below the anilox roll and has a blade edge portion that is approximately in juxtaposition with a lower quadrant of the anilox roll and faces the direction of rotation of the anilox roll to control and distribute the film of ink on the surface of the anilox roll. An adjustment device is provided to adjust the thickness of the film of ink on the anilox roll. The adjustment device is operable to make adjustments in the ink film thickness while the machine is operating.

Abstract: An envelope blank forming machine for forming generally rectangular booklet envelope blanks and generally diagonal envelope blanks on the same machine includes a pair of removable turnbars, adjustable pull rolls and an adjustable cutoff device. Preselected adjustment of these components provides a generally rectangular blank or a generally diagonally shaped blank. Retractable trim devices are provided in cutting relation with the blank when diagonal blanks are being formed. Seal flap cutters and first and second flap cutters are provided to form the booklet seal flap and bottom flap on the booklet envelope blank. These cutters are removed and replaced with seal flap corner cutters, bottom flap corner cutters and diagonal trim cutters when generally diagonal envelope blanks are being formed.

Abstract: Apparatus for severing window patches from a web of patch material includes a mechanism for applying adhesive to selective portions of the web, a pair of cooperating rolls to feed the web to the adhesive applying mechanism, a vacuum roll engaging successive window patches with adhesive, a severing mechanism cutting successive window patches of a pre-selected length from the web in spaced relation to a portion of the web engaged to the surface of the vacuum roll, a vacuum conveyor positioned between the adhesive applying mechanism and the severing mechanism to advance the web along a path from the adhesive applying mechanism toward the severing mechanism, a discharging end portion of the vacuum conveyor being spaced from the severing mechanism. The vacuum conveyor is constructed and arranged to transport the web from the adhesive applying mechanism, a pre-selected distance through the vacuum roll before the web is transferred to the vacuum roll and from the latter to the severing mechanism.

Abstract: A paper web is unwound and conveyed through an envelope making machine where a side flap cutting device forms side flaps in the side edges of the web. Scorer rollers form longitudinal scores in the side flaps and the side flaps are thereafter folded along the score lines. Other scorer rollers form transverse score lines for the top and bottom flaps of the envelope. Envelope blanks having the folded side flaps are thereafter severed from the web and separated from each other. After the blanks are severed from the web, gum is applied to the upper surface of the side flaps of the severed envelope blanks and the bottom flap is folded into overlying relation with the folded side flaps to form the pocket in the envelope. The so formed envelopes are thereafter collated into overlying relation with the edges of the top flap exposed. Gum is applied to the top flaps and dried. The top flap is then folded into overlying relation with the bottom flap.

Abstract: A transfer cylinder is rotatably mounted in a machine frame and is positioned in spaced parallel relation with a rotatable delivery cylinder. A side fold cylinder is positioned intermediate the transfer and delivery cylinders. The transfer cylinder conveys the envelope blank onto the periphery of the side fold cylinder. Rotation of the side fold cylinder with the envelope blank retained thereon folds the side flap and advances the folded envelope into engagement with the delivery cylinder. A gumming cylinder having an adhesive applicator portion is positioned adjacent the delivery cylinder and is operable to apply a strip of adhesive to the exposed bottom flap of the envelope blank as the blank is transferred from the delivery cylinder to the gumming cylinder. A selected amount of the adhesive is transferred from a reservoir by a roller to the surface of the adhesive applicator. The gumming cylinder rotates in timed relation to the delivery cylinder and in an opposite direction.

Abstract: A drive shaft of the gumming and folding section of an envelope machine rotates at a preselected speed and is drivingly connected through meshing gears to the input shaft of a variable speed drive mechanism. The input shaft is connected to an output shaft through a differential transmission so that the output shaft is driven at a preselected ratio relative to the speed of the input shaft. The output shaft is drivingly connected to a web feeding apparatus that conveys a continuous web of material from a supply roll at a preselected speed. Thus, the web feeding apparatus is driven at a predetermined ratio relative to the speed of the drive shaft. A web cutting apparatus is drivingly connected to the input shaft so that a cut off knife is rotated at a fixed speed relative to the drive shaft to cut the continuous web at preselected intervals to form envelope blanks having a bottom flap connected to a closure flap.

Abstract: A pair of rotatable cutter mechanisms are positioned on opposite sides of a moving web and are arranged upon rotation of the cutter shafts to cut notches in the side edges of the moving web. The cutter shafts are rotatably driven by a drive mechanism that includes a pair of endless timing belts connected to the cutter shafts. One of the timing belts is reeved about a drive pulley that is non-rotatably connected to a helical gear. The main drive shaft has a helical gear that meshes with the helical gear connected to the pulley. The pair of timing belts are drivingly connected to each other by means of a pair of meshing helical gears connected to separate pulleys associated with the respective timing belts. Phase adjustment of both of the cutter mechanisms is accomplished by axially moving the helical gears connected to the pulley and main drive shaft while the helical gears remain in meshing relation with each other.