Abstract: This invention overcomes the disadvantages of the prior art by providing a system and method for inserting contents into envelopes that generally reduces the number of operative device components, locates all components in a readily and accessible location, reduces the number of adjustments needed to change envelope size and contents size, provides an efficient and aesthetically pleasing design, allows for a highly flexible arrangement of backup hoppers to primary hoppers for feeding envelope contents and otherwise affords a substantial number of improvements over currently available envelope inserters.

Abstract: This invention provides an inkjet print engine in combination with a conventional lithographic printing press so as to allow variable information to be applied to the fed sheets. Such information can include, but is not limited to, address information for mailing and/or special messages to the recipient. The system and method locates an inkjet printing head (single-color or multi-color) with respect to one of a number of locations along the print path. More particularly, the inkjet head can be located on a transverse carriage with movement is controlled by a conventional print head controller. The controller also addresses the formation of print at the head in conjunction with the movement of the carriage and also with respect to the movement of the sheet through the printing press. The locations at which the inkjet assembly can be located include the upstream or downstream blanket or plate rollers, the sheet in the region of the impression roller, the infeed region or the outfeed region.

Abstract: This invention overcomes the disadvantages of the prior art by providing a system and method for inserting contents into envelopes that generally reduces the number of operative device components, locates all components in a readily and accessible location, reduces the number of adjustments needed to change envelope size and contents size, provides an efficient and aesthetically pleasing design, allows for a highly flexible arrangement of backup hoppers to primary hoppers for feeding envelope contents and otherwise affords a substantial number of improvements over currently available envelope inserters.

Abstract: An improved hopper and singulating/feed assembly for a utilization device, such as an inserter, that feeds sheet-like materials from a hopper feed stack that reduces the various geometrical and physical problems that lead to jams, misfeeds and failures to properly singulate the stack is provided. A hopper reduces the pressure on the bottom sheets of the stack by providing a parallel wedge structure at the stack base. This wedge structure also helps to drive bottom sheets successively forward toward a front face so as to further break frictional and adhesive contact between sheets at the bottom of the stack. Hopper side guides with integral angled shelves engage front side edges of the stack and allow easier singulation of respective bottom sheets. Likewise a fixed sucker block assembly, which seats a suction cup in a rotating base with a surrounding planar block face and an integral fulcrum edge improves the separation of the bottom sheet from the overlying stack.

Abstract: A system and method for storing and dispensing a stack of materials to a feed station of the utilization device that is adapted to feed stacks of the materials is provided. The materials, typically sheets or envelopes, are provided in a predetermined orientation in a stack in a container having a dispensing end or other opening. To dispense, the container is positioned with respect to the feed station and a release on the container is operated using a predetermined motion. The release enables the contents of the container, in stack form, to be transferred to the feed station free of any operator intervention with the contents of the stack. The dispensing end/opening can be shoulders on a container that are moved out of interfering contact with the stack when the stack is placed over upright guides on the feed station.

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 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 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 storing and dispensing a stack of materials to a feed station of the utilization device that is adapted to feed stacks of the materials is provided. The materials, typically sheets or envelopes, are provided in a predetermined orientation in a stack in a container having a dispensing end or other opening. To dispense, the container is positioned with respect to the feed station and a release on the container is operated using a predetermined motion. The release enables the contents of the container, in stack form, to be transferred to the feed station free of any operator intervention with the contents of the stack. The dispensing end/opening can be shoulders on a container that are moved out of interfering contact with the stack when the stack is placed over upright guides on the feed station.

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 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.

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 incorporating, in the production of a continuous stream of images, by an image transfer device upon a moving web, post-production operations upon the web at various locations. Locations of a web, having a plurality of images placed thereon, output from an image transfer device are tracked. Specific operations at various locations upon the web are performed by a post-production device as the web passes through it. The web is directed from the image transfer device to the post-production device. In response to the tracking of locations upon the web, the point when a location has entered the post-production device is determined. In response to this determination, the post-production device is commanded to perform its specific operation at a connect location.

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.

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 method and apparatus for sorting books of sheets in which individual books are generated in succession is provided. This process entails the stacking of cut sheets that form a completed book in an offset arrangement relative to adjacent books. Each offset stacked book is removed from the other books by applying a lifting force between the lowest book in the stack and the next book in the stack while the lowest book in the stack is allowed to bend away from the next highest book in the stack. The bend forms a space, tunnel or separator entrance opportunity into which a projection or other separator structure is directed. The lowest book is lowered onto a conveyor and moved away from the stack. The process continues for each successive next-highest book in the stack. A support mechanism is provided to maintain the lowest book at a selected elevation as the projection moves inwardly. The support moves away concurrently to deposit the lowest book on the conveyor.

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 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.