Abstract: This invention provides a system and method for aligning, feeding, trimming, slitting, rotating, cross-slitting and stacking sheets, each containing one or more discrete page images thereon that allows for greater automation of the overall process so that reduced or no manual intervention is required to generate completed book stacks or “blocks” from a stream or stack of printed sheets. Sheets are fed to a first, upstream trimming station to remove margin edges and optionally separate the sheets relative to the discrete page images. The sheets are then rotated 90 degrees and fed to a second, downstream trimming station that trims the right-angle edges and optionally separates the sheets into a final group of full-bleed pages, removing margins and gutter strips. The sheets are fed to a stacking assembly to be tacked in page order and any rejected, defective sheets or stacks are removed from the order.

Abstract: This invention provides a slitter assembly with automated adjustment of slitter elements that allows for driven rotation of elements on the associated drive shaft during operation while enabling the elements to be moved freely along the drive shaft during setup and subsequently secured to the shaft free of lateral movement. This ensures that adjustment of the slitter elements is accurate, repeatable and reliable. In an illustrative embodiment, the slitter elements each comprise a pair of coaxial members including a blade member and a locking member. The blade member contains a slitter blade and overlies the locking member which is nested therewith. The locking member directly engages the drive shaft surface with a wedge assembly structure. The members are spring-loaded with respect to each other so that the two surfaces are normally biased to cam together and exert a hoop stress on the drive shaft.

Abstract: This invention provides a system and method for aligning, feeding, trimming, slitting, rotating, cross-slitting and stacking sheets, each containing one or more discrete page images thereon that allows for greater automation of the overall process so that reduced or no manual intervention is required to generate completed book stacks or “blocks” from a stream or stack of printed sheets. Sheets are fed to a first, upstream trimming station to remove margin edges and optionally separate the sheets relative to the discrete page images. The sheets are then rotated 90 degrees and fed to a second, downstream trimming station that trims the right-angle edges and optionally separates the sheets into a final group of full-bleed pages, removing margins and gutter strips. The sheets are feed to a stacking assembly to be tacked in page order and any rejected, defective sheets or stacks are removed from the order.

Abstract: A system and method for rotating sheets receiving cut sheets from a source and providing them to a utilization device. The rotator continually engages sheets with at least one drive component throughout the transport and rotation process. The rotator includes a transport mechanism having a plurality of nip roller pairs along the length of a feed table. The nip rollers (nips) can be selectively engaged with, and disengaged from, the driven rollers using discrete actuators. This allows for feed velocity differentials when entering and exiting the rotator feed table, and also for clearance during sheet rotation. A rotator disk assembly is centered on the table between, and comprises a driven rotator disk and an overriding, freely rotating pressure disk. When sheets enter or pass through the rotator section, the pressure disk is raised to provide a clearance for sheets to pass.

Abstract: This invention provides a system and method for separating, folding, stacking and transporting a continuous web that allows stacks of web that are relatively large (four-feet-high or more) to be generated at high speed directly beneath the folding mechanism and to be transferred as complete, discrete stacks to downstream locations and stack utilization devices without interrupting the ongoing, upstream stack-folding and stack-formation process. A zigzag folded web passes by a pair of opposing front and rear compression plate assemblies, with fingers that are extended to selectively project into the folding area, onto a stack supported by a vertically moving supporting mechanism. The supporting mechanism cycles between an ever-lower position in which upper, loose pages of the folded web pass by plate fingers (when retracted) and an upper position in which the stack engages and presses upwardly against the now-extended plate fingers to compress the stack.

Abstract: This invention provides a system and method for aligning, feeding, trimming, slitting, rotating, cross-slitting and stacking sheets, each containing one or more discrete page images thereon that allows for greater automation of the overall process so that reduced or no manual intervention is required to generate completed book stacks or “blocks” from a stream or stack of printed sheets. Sheets are fed downstream on a feed surface, trimmed at a first, upstream trimming station to remove margin edges and optionally separate the sheets relative to the discrete page images. The sheets are then rotated 90 degrees and fed to a second, downstream trimming station that trims the right-angle edges and optionally separates the sheets into a final group of full-bleed pages, removing margins and gutter strips. The sheets are feed to a stacking assembly to be tacked in page order and any rejected, defective sheets or stacks are removed from the order.

Abstract: A system and method for rotating sheets receiving cut sheets from a source and providing them to a utilization device. The rotator continually engages sheets with at least one drive component throughout the transport and rotation process. The rotator includes a transport mechanism having a plurality of nip roller pairs along the length of a feed table. The nip rollers (nips) can be selectively engaged with, and disengaged from, the driven rollers using discrete actuators. This allows for feed velocity differentials when entering and exiting the rotator feed table, and also for clearance during sheet rotation. A rotator disk assembly is centered on the table between, and comprises a driven rotator disk and an overriding, freely rotating pressure disk. When sheets enter or pass through the rotator section, the pressure disk is raised to provide a clearance for sheets to pass.

Abstract: This invention provides a system and method for printing continuous web and feeding ink to printing pens (or cartridges) that employs an array of interleaved ink-jet pens that are arranged to receive bulk ink through a manifold. The manifold and pens are mounted on a fixed array suspended over the web feed path. The manifold includes a plurality of self-sealing quick-disconnect couplings that each serve a discrete ink-jet pen. The pens lay down ink in a registered manner across the full width of the web. The pens are organized into two parallel, multi-pen arrays that are each diagonally oriented with respect to the feed direction. The feed path allows for duplex printing with a second web-side's array located on a lower level of the device, generally beneath the first-side's array. Duplex printing is facilitated due to its inherent length of the feed path. The printed part of the web is free of contact over predetermined lengths that ensure sufficient time for the drying of ink.

Abstract: This invention provides a system and method for separating, folding, stacking and transporting a continuous web that allows stacks of web that are relatively large (four-feet-high or more) to be generated at high speed directly beneath the folding mechanism and to be transferred as complete, discrete stacks to downstream locations and stack utilization devices without interrupting the ongoing, upstream stack-folding and stack-formation process. A zigzag folded web passes by a pair of opposing front and rear compression plate assemblies, with fingers that are extended to selectively project into the folding area, onto a stack supported by a vertically moving supporting mechanism. The supporting mechanism cycles between an ever-lower position in which upper, loose pages of the folded web pass by plate fingers (when retracted) and an upper position in which the stack engages and presses upwardly against the now-extended plate fingers to compress the stack.

Abstract: An apparatus for adjusting a swing arc and centering of a swinging director chute during separating, folding, stacking and transporting a continuous web that allows stacks of web that are relatively large (four-feet-high or more) to be generated at high speed directly beneath the folding mechanism and to be transferred as complete, discrete stacks to downstream locations and stack utilization devices without interrupting the ongoing, upstream stack-folding and stack-formation process. The apparatus includes a lever arm, interconnected with the swinging director chute, and a connecting rod having a first pivot end and a second pivot end. The first pivot end is adjustable movable along the lever arm. A drive arm connected to the second pivot end includes a lead screw. The lead screw can be operatively connected to an index wheel having a plurality of directed posts and a movable pawl that advances the index wheel.

Abstract: A system and method for cutting continuous web that provides a simplified and direct feed path during loading, and thereafter a more-complex serpentine feed path at an infeed unit for reliable infeed of the web, arranged as either a free loop or a moderately tensioned configuration. Downstream, an indexing drive intermittently pauses the web for the cutter knife to operate. The indexing drive and infeed unit's drive are synchronized by a controller to produce a small horizontally disposed buffer loop therebetween. The buffer loop is maintained within a predetermined range using a sensor, operatively with the controller, that measures the location of the end of the loop, modulating the drives to maintain the buffer loop's (returning) end within a predetermined location about the sensor's sensing field. The system includes an adjustment drive motor for moving a plurality of edge guide sets toward and away from each other in synchronization.

Abstract: This invention provides a system and method for separating, folding, stacking and transporting a continuous web that allows stacks of web that are relatively large (four-feet-high or more) to be generated at high speed directly beneath the folding mechanism and to be transferred as complete, discrete stacks to downstream locations and stack utilization devices without interrupting the ongoing, upstream stack-folding and stack-formation process. A zigzag folded web passes by a pair of opposing front and rear compression plate assemblies, with fingers that are extended to selectively project into the folding area, onto a stack supported by a vertically moving supporting mechanism. The supporting mechanism cycles between an ever-lower position in which upper, loose pages of the folded web pass by plate fingers (when retracted) and an upper position in which the stack engages and presses upwardly against the now-extended plate fingers to compress the stack.

Abstract: A system and method for utilizing web that is free of tractor pin feed holes comprises the driving of the web along a predetermined path within the utilization device. A web guide is provided in an upstream location from a utilization device element. The guide engages width-wise edges of the web and forms the web into a trough to stiffen the web. A drive roller and a follower roller impinge upon opposing sides of the web and rotate to drive the web through the guide. The drive roller is located adjacent to the guide according to a preferred embodiment. A registration controller is utilized to synchronize the movement of the web with the operation of the utilization device element. The controller includes a drive controller that controls the speed of either the drive roller or the utilization device element to maintain the web and the utilization device element in appropriate synchronization.

Abstract: A system and method for detecting and diverting sections of web having splices on a continuous web is provided. A splice detector is located adjacent a source of continuous web, typically a roll. The movement of the web from the roll is tracked, and the relative location of the splice within the web stream is noted by a controller. Downstream, a web utilization device is provided with a movement detector also connected to the controller. Movement of the splice-containing section through utilization device is tracked so that the splice-containing section is not processed by the utilization device, or is reprocessed on a non-splice-containing section. A cutter is also provided with a movement detector, also connected to the controller. Movement of the web from the utilization device to the cutter is tracked and the section containing the web is cut. A diversion mechanism can be used to remove the cut section of web containing the splice so that it does not appear in the final stream of finished cut sheets.

Abstract: An apparatus for selectively streaming and merging side-by-side sheets is provided. In general, sheets enter in a side-by-side orientation onto an input feed surface and are directed selectively upwardly or downwardly onto overlying upper and lower feed surfaces by a diverter assembly having two diverter sides. The diverter sides can be independently moved to direct sheets upwardly or downwardly. The upper feed surface and lower feed surface have opposing edge guides. The upper feed surface and lower feed surface can be moved with respect to each other so that the edge guides are placed one sheet width apart or more than two sheet widths apart. By orienting the two diverter halves, and setting the desired distance between the upper and lower edge guides, sheets can pass along each of the upper and lower surfaces in a side-by-side streamed or over-lapping merge orientation.

Abstract: A system and method for utilizing web that is free of tractor pin feed holes comprises the driving of the web along a predetermined path within the utilization device. A web guide is provided in an upstream location from a utilization device element. The guide engages width-wise edges of the web and forms the web into a trough to stiffen the web. A drive roller and a follower roller impinge upon opposing sides of the web and rotate to drive the web through the guide. The drive roller is located adjacent to the guide according to a preferred embodiment. A registration controller is utilized to synchronize the movement of the web with the operation of the utilization device element. The controller includes a drive controller that controls the speed of either the drive roller or the utilization device element to maintain the web and the utilization device element in appropriate synchronization.

Abstract: A device for feeding web material to a printer that is adapted to accept web from an external roll, adequately align the web with the printer and properly tension the web as it passes through the printer. The infeed device includes a pair of parallel guide rods spaced sufficiently apart to allow passage of the web there between. A pair of edge guides, attached to the parallel guide rods define the web path there through. A spring-loaded pressure pad acts in combination with a smooth metal shoe to tension the web. Further tension is applied to the web as it passes a curved smooth metal surface, just prior to entering the printer. The infeed device allows a wide variety of web materials and web thicknesses to be tensioned and fed into the printer.

Abstract: A system for stacking continuous folded forms or web coming from a folder and separator and moving to a conveyor. A table is positioned adjacent and in line with the conveyor and in a position for receiving a horizontally-extending stack of folded forms disposed on the table top. The table is a tiltable table and is able to be tilted from a substantially-horizontal position to a substantially-vertical position to likewise move the stack from a horizontal to a vertical stack position. A cart is movable to a position adjacent to the tilted table for receiving from the table the vertical stack for support on the cart. The cart can include a plurality of storage locations that can each be provided with a stack.

Abstract: A system and method for utilizing a continuous pinless web that is free of tractor pin feed holes within a utilization device that is originally adapted to feed web having tractor pin feed hole strips along its widthwise edges is provided. The utilization device can comprise an IBM high-volume laser printer having an image transfer drum synchronized to a pair of tractor pin feed drive units. A drive roller is operatively connected to the lower pin feed unit according to a preferred embodiment. A registration controller is utilized to synchronize the movement of the web with the operation of the utilization device element using a differential and a separate registration motor. The image transfer drum and drive roller are each synchronized to a central drive motor that generates pulses via an encoder. The pulses track the movement of the image transfer drum. A mark sensor reads marks on the web to synchronize actual movement of the web with the image transfer drum using the registration motor.

Abstract: The invention is a stapler and staple guide assembly for same. The stapler provides automated stapling for stacks of sheet material regardless of stack thickness. In a first embodiment two staple guides load individual sheets or small stacks of sheets onto a staple with the staple supported in a base. The staple is then cut to an appropriate height and cinched. In another embodiment, numerous split guides may be cascaded to increase staple loading speed. Other improvements to a stapling process include dimpling sheets of material and/or pre-drilling sheets of material to simplify loading sheets onto a staple.