System and method for folding a paper carrier with an attached card

Abstract

To provide systems and methods for folding paper carriers with attached cards.SOLUTION: Folder systems and related methods are provided for accurately and efficiently folding a paper carrier that has a card attached without bending or dislodging the card from the carrier. A movable fold chute 150 receives a part of the carrier with the card attached and allows the carrier to fold while protecting the card portion of the carrier. The fold chute moves between different positions which allow the carrier to enter and exit through folding rollers 101 to 103 along a generally straight paper path without forcing the cards around small radii, thereby preventing damage to the cards or causing them to separate from the carrier sheet.SELECTED DRAWING: Figure 3

Description

[Technical Field]

[0001] (Field) FIELD OF THE DISCLOSURE The present disclosure relates generally to a paper folder, and more particularly to a paper folder for folding a paper carrier having a rigid card attached thereto. [Background technology]

[0002] (background) Direct mail is an important tool for businesses to communicate with their customers. Many businesses need to distribute cards, such as payment cards, identification cards, or membership cards, to individuals through the mail. Cards may be personalized or combined with other inserts or mailer components, and the entire package must be addressed to the appropriate recipient, all of which makes preparing such mailers very labor-intensive and tedious.

[0003] Mail preparation and finishing systems increase efficiency by automating the printing, folding, and inserting processes. However, prior folder systems designed to fold only a few sheets of paper are ill-equipped to handle paper carriers with rigid cards attached. These systems have the potential to remove or damage cards, misfold carriers, or jam the machine. Summary of the Invention [Means for solving the problem]

[0004] (overview) The present disclosure addresses these and other problems by providing a folding device system and related methods for accurately and efficiently folding paper carriers with attached cards. The attached cards are stiffer than paper substrates and cannot pass through traditional folding devices. The disclosed system allows stiffer cards to be transported through the folding process without bending the cards or forcing them around very small radii, thereby preventing damage to the cards and separation of the cards from the carrier sheet.

[0005] The system of the present invention includes a movable folding chute that can be aligned with the folding nip to maintain a generally straight paper path into or out of the folding chute. The folding chute prevents the portion of the carrier with the card attached from being bent or compressed, allowing the carrier to fold around the attached card without disturbing the attached card. In a first position, the folding chute receives the front portion of the carrier, including the card, from the infeed nip formed by the interface of two rollers aligned with the folding chute so that the carrier moves along a straight path as it moves from the infeed nip into the folding chute. When the front portion of the carrier with the card attached is inside the folding chute, the carrier contacts a strain stop or other abutment member that stops the forward movement of the front portion while the rear portion of the carrier is still engaged with and advancing through the infeed nip. The folding chute moves or rotates to a second position, where the folding chute is aligned with the folding nip. A strain forms in the rear portion of the carrier, which is still advancing. The strain grows as the rear portion advances. The distorted portion of the carrier is captured in a folding nip aligned with the folding chute, which has moved to a second portion. The folding nip creates a fold in the distorted portion of the carrier and pulls the front portion, with the attached card, through the folding nip along a substantially straight paper path from the folding chute through the folding nip. The movement of the folding chute is generally timed with the rotation of the rollers that create the infeed nip and folding nip, which advances the paper carrier a suitable distance to allow the entire card-carrying portion of the paper carrier to enter the folding chute along the substantially straight paper path before the carrier moves sufficiently to distort the carrier.

[0006] In a particular aspect, the present invention relates to a method for folding a carrier having a card attached thereto. The method begins by providing a carrier having a first portion and a second portion, the first portion carrying a card. The first portion of the carrier is fed into an opening of a folding chute without bending the card. The folding chute is then repositioned to create a distortion in the second portion of the carrier. The distorted second portion of the carrier is then introduced into a folding nip aligned with the repositioned folding chute to create a fold in the second portion.

[0007] In a method embodiment, the step of feeding the first portion of the carrier into the opening of the folding chute is facilitated by rotating the first roller and the second roller to cause advancement of the carrier through an infeed nip formed at the interface between the first roller and the second roller. The method may further include, after the infeeding step, contacting the first portion with a strain stop associated with the folding chute. Contacting the first portion with the strain stop may stop advancement of the first portion relative to the second portion. The second portion of the carrier may continue advancement through the infeed nip after the first portion contacts the strain stop. Continued advancement through the infeed nip causes strain in the second portion to grow. The strain may then grow toward the folding nip until captured by the folding nip. In certain embodiments, the folding nip is formed at the interface between the second roller and the third roller. The first roller, the second roller, and the third roller may rotate at a constant speed throughout the method.

[0008] In embodiments, infeeding of the carrier into the folding chute is accomplished when the folding chute is aligned with the infeed nip so that the carrier enters the opening of the folding chute at an angle θ (θ is between 0 and 45 degrees, or, more specifically, between 0 and 30 degrees, between 0 and 20 degrees, between 0 and 10 degrees, or between 0 and 5 degrees, relative to the carrier path defined by the infeed nip). Repositioning the folding chute may involve rotating the folding chute to align the folding chute with the folding nip so that the carrier and the opening of the folding chute are at an angle θ, θ is between 0 and 45 degrees, or, more specifically, between 0 and 30 degrees, between 0 and 20 degrees, between 0 and 10 degrees, or between 0 and 5 degrees, relative to the carrier path defined by the folding nip.

[0009] A related aspect of the invention relates to a system for folding a carrier having cards attached thereto, the system including an infeed nip formed at the interface of a first roller and a second roller, a folding nip formed at the interface of the second roller and a third roller, and a movable folding chute with an opening, the movable folding chute configured to assume a first position in which the opening is aligned with the infeed nip and a second position in which the opening is aligned with the folding nip.

[0010] In embodiments, the movable folding chute includes a strain stop. The movable folding chute may be operatively associated with a motor that repeatedly repositions the movable folding chute between a first position and a second position. The infeed nip and the movable folding chute may define a first carrier path that is substantially straight when the movable folding chute is in the first position, and the movable folding chute and the folding nip may define a second carrier path that is substantially straight when the movable folding chute is in the second position. The first carrier path and the second carrier path may be substantially perpendicular to each other. The present invention provides, for example: (Item 1) 1. A method for folding a carrier having a card attached thereto, said method comprising: providing a carrier having a first portion and a second portion, the first portion comprising a card; feeding the first portion of the carrier into an opening of a folding chute without bending the card; repositioning the folding chute to create a distortion in the second portion of the carrier; capturing the distorted second portion of the carrier within a folding nip aligned with the repositioned folding chute to create a fold in the second portion; A method comprising: (Item 2) The method according to any preceding item, wherein the feeding step is facilitated by rotating a first roller and a second roller to cause the carrier to advance through an infeed nip formed at an interface between the first roller and the second roller. (Item 3) 10. The method of claim 1, further comprising contacting the first portion with a strain stop associated with the folding chute after the feeding step. (Item 4) 10. The method of claim 9, wherein contacting the first portion with the strain stop stops advancement of the first portion relative to the second portion. (Item 5) 10. The method of claim 9, wherein the second portion of the carrier continues to advance through the infeed nip after the first portion contacts the strain stop. (Item 6) 10. The method of claim 9, wherein the continued advancement through the infeed nip causes the strain in the second portion to grow. (Item 7) 10. The method of claim 1, wherein the strain grows toward the folding nip until the strain is taken up by the folding nip. (Item 8) 10. The method of claim 1, wherein the folding nip is formed at an interface between the second roller and a third roller. (Item 9) 2. The method of claim 1, wherein the first roller, the second roller, and the third roller rotate at a constant speed throughout the method. (Item 10) 10. The method of claim 9, wherein during the infeed step, the folding chute is aligned with the infeed nip so that the carrier enters the opening of the folding chute at an angle θ, θ being between 0 and 45 degrees relative to a carrier path defined by the infeed nip. (Item 11) 10. The method of claim 9, wherein repositioning comprises rotating the folding chute to align the folding chute with the folding nip such that the carrier exits the opening of the folding chute at an angle θ, θ being between 0 and 45 degrees relative to a carrier path defined by the folding nip. (Item 12) 1. A system for folding a carrier having a card attached thereto, said system comprising: an infeed nip formed at the interface of the first roller and the second roller; a folding nip formed at the interface of the second roller and a third roller; a movable folding chute having an opening, the movable folding chute configured to have a first position in which the opening is aligned with the infeed nip and a second position in which the opening is aligned with the folding nip; A system comprising: (Item 13) 10. The system of claim 1, wherein the movable folding chute includes a strain stop. (Item 14) 10. The system of claim 9, wherein the movable folding chute is operably associated with a motor configured to repeatedly reposition the movable folding chute between the first position and the second position. (Item 15) 2. The system of claim 1, wherein the infeed nip and the movable folding chute define a first carrier path that is substantially straight when the movable folding chute is in the first position. (Item 16) 2. The system of claim 1, wherein the movable folding chute and the folding nip define a second carrier path that is substantially straight when the movable folding chute is in the second position. (Item 17) 2. The system of claim 1, wherein the first carrier path and the second carrier path are substantially perpendicular to each other. (Summary) A folding system and related methods are provided for accurately and efficiently folding a paper carrier with an attached card without bending the card and removing the card from the carrier. A movable folding chute receives a portion of the carrier with the attached card and allows the carrier to fold while protecting the card portion of the carrier. The folding chute moves between different positions to allow the carrier to enter and exit through the folding rollers along a generally straight paper path without forcing the card around a small radius, thereby preventing damage to the card or separation of the card from the carrier sheet. [Brief explanation of the drawings]

[0011] BRIEF DESCRIPTION OF THE DRAWINGS Features and advantages of the claimed subject matter will become apparent from the following detailed description of the corresponding embodiments, which description should be considered in conjunction with the accompanying drawings.

[0012] [Figure 1] FIG. 1 shows an insertion device system.

[0013] [Figure 2-1] FIG. 2A shows a side view of the folding device.

[0014] [Figure 2-2] 2B-2E show the folding apparatus of FIG. 2A at various stages in performing the folding method on a paper carrier with a rigid card attached.

[0015] [Figure 3] FIG. 3 is a schematic diagram of a folding device.

[0016] [Figure 4] 4-6 show the process of folding the paper carrier using the folding tool. [Figure 5] 4-6 show the process of folding the paper carrier using the folding tool. [Figure 6] 4-6 show the process of folding the paper carrier using the folding tool.

[0017] [Figure 7] FIG. 7 shows a system that integrates multiple folders with their own paper paths.

[0018] [Figure 8] FIG. 8 illustrates a process for creating half folds in a paper carrier using a system with multiple folders.

[0019] [Figure 9] FIG. 9 illustrates a process for creating a C-fold in a paper carrier using a system with multiple folders.

[0020] [Figure 10] FIG. 10 illustrates a process for creating another configuration of C-folds in a paper carrier using a system having multiple folders.

[0021] [Figure 11]FIG. 11 illustrates a process for creating a Z-fold in a paper carrier using a system with multiple folders.

[0022] [Figure 12] FIG. 12 illustrates a process for creating a quarter fold in a paper carrier using a system with multiple folders.

[0023] [Figure 13] FIG. 13 illustrates a process for creating another four-fold configuration on a paper carrier using a system with multiple folders.

[0024] [Figure 14A] FIG. 14A is a perspective view of a folded carrier with a card attached, of the type produced by the folding system disclosed herein.

[0025] [Figure 14B] FIG. 14B is an end view of the carrier with the card attached and folded, ready for insertion into the envelope.

[0026] [Figure 15] FIG. 15 shows a system architecture for use in the present invention.

[0027] For a complete understanding of the present disclosure, reference should be made to the following detailed description, including the appended claims, in connection with the above-described drawings. While the present disclosure will be described in connection with exemplary embodiments, it is not intended that the disclosure be limited to the particular embodiments described therein. Various omissions and substitutions of equivalents are contemplated as the circumstances suggest or render expedient. DETAILED DESCRIPTION OF THE INVENTION

[0028] (Detailed explanation) The folder system of the present disclosure uses a movable folding chute to receive a portion of the carrier with a card attached so that another portion of the carrier can be folded while preventing the card from being bent or removed. Movement of the folding chute aligns the carrier with different folding nips so that the carrier can enter and exit the folding chute along a generally straight paper path.

[0029] The folding systems disclosed herein can be integrated into larger mail processing and inserter systems that can attach cards to carriers and then insert the carriers into envelopes. Inserter systems are automated or semi-automated machines that prepare paper mailers and can include document production modules, document handling applications, and finishing applications. Some exemplary inserter systems are EPIC TM Insertion System and RIVAL TM insertion systems, both of which are available from BlueCrest Inc. (Danbury, CT).

[0030] FIG. 1 shows a schematic diagram of an inserter system 10 integrating a folder 12 of the invention. The inserter system 10 has several modules for accomplishing different tasks in the mail preparation process. The modules are controlled by a computer and controller (not shown), as described in more detail below. The illustrative inserter system 10 and other compatible inserters may include different combinations and configurations of the various modules.

[0031] Documents are fed into system 10 for processing by document feeder 14. In different embodiments, the documents may be preprinted or blank. Optionally, information may be printed on the documents in print module 11. The documents may be, for example, invoices or financial statements, and may be provided by document feeder 14 as individual cut sheets or cut from a spool using a web cutter (not shown).

[0032] The document then moves to an attachment module 16, where cards are attached to the document, which may be referred to as a carrier. The card attachment module 16 may be configured to read information about the carrier, take cards from a stack of pre-punched cards, and attach the cards to the carrier at one or more locations. The carrier then enters the folding device 12, where it is folded. The folding device 12 folds the carrier with the attached cards, as will be described in more detail below.

[0033] The folded carriers then move to a buffer 18, which holds the carriers for subsequent processing. The carriers then move to a chassis 20, where inserts from multiple feeder modules 22 can be added to the carriers. The carriers then enter an insertion area 24, where the finished carriers are stuffed into envelopes provided by an envelope hopper 26, and the envelopes are sealed. The stuffed and sealed envelopes then enter an outsort module 28 to optionally divert defective envelopes from the production stream into a reject bin (not shown). Defective envelopes may have, for example, improperly assembled carriers and / or removed or damaged cards, and / or may be improperly sealed.

[0034] The properly assembled and sealed envelopes then enter a weighing and printing area 30 where indicia, such as postage indicia and / or address information, are applied using a printer 32 to form the finished mailpiece. Finally, the finished mailpiece is placed on a conveyor 34.

[0035] System 10 may be monitored and controlled via a user interface 19, which may be physically attached to the system or may be remote. User interface 19 may be a touch screen or other similar input device. User interface 19 may display parameters and operating status of various modules and allow a user to control functions or one or more modules and switch between jobs as needed. Operation of the user interface in relation to the system may be described in more detail below with reference to FIG. 15.

[0036] Other systems utilizing more or fewer components and / or different arrangements of components may also be used. It should also be understood that the improvements described herein may be used in stand-alone folders and that the folder need not be part of a larger document production system. The folder 12 of the present invention may enable high quality folds to be consistently achieved for cards attached and carriers having a range of thicknesses without manual adjustments and without degradation of the cards, carriers, or combinations thereof.

[0037] In direct mail, it is desirable to prepare mailers containing folded paper carriers with cards attached. Typically, to process such mailers, a paper carrier is prepared with the desired information printed on it, and a card is attached. The card is often made of a material that is stiffer than the paper carrier, such as thicker paper, cardboard, plastic, metal, or a polymeric material. The carrier with the attached card must then be folded and optionally combined with one or more other inserts before being inserted into an envelope for mailing. However, traditional strain-resist folding devices cannot accommodate paper carriers with stiff cards attached.

[0038] The folding system disclosed herein allows carriers with attached cards to be folded using a unique configuration of rollers and a movable folding chute. An example of a folding device employing a movable folding chute is shown in FIG. 2A . Folding device 100 includes a folding cluster consisting of folding roller 101, folding roller 102, and folding roller 103. Folding roller 101 and folding roller 102 are aligned to form an infeed nip 112 at the interface therebetween. Folding roller 102 and folding roller 103 are similarly aligned to form a folding nip 114 at the interface therebetween. A paper carrier (not shown) enters folding device 100 at paper inlet 119 between drive roller 122 and drive roller 123. Drive roller 126, together with drive roller 122, is operatively connected by drive belt 133 to guide the paper along paper path 140. Paper path 140 is defined by the interface between drive belt 133 and drive belt 134. Drive belt 133 is driven by drive motor 138, which rotates in a counterclockwise direction to advance drive belt 133. Paper guide 162 is positioned to direct a piece of paper from a paper path 140 defined at the interface of drive belts 133 and 134 into infeed nip 112. As discussed further below with respect to FIGS. 8-13 , if a fold cluster is intended to be bypassed, paper guide 162 may instead direct the paper to bypass infeed nip 112. The entire path along which the paper travels from paper inlet 119 into infeed nip 112 maintains the paper in a generally linear orientation, meaning that the paper does not bend around any small radius that could cause an attached card to be removed or bent. For example, a generally linear orientation may be defined as not bending around a radius smaller than, e.g., 10 cm, 100 cm, or 1000 cm, or the like.

[0039] As described above, infeed nip 112 is formed between folding roller 101 and folding roller 102. To advance paper through infeed nip 112, folding roller 101 rotates in a counterclockwise direction, and folding roller 102 rotates in a clockwise direction. Folding roller 101 and folding roller 102 have surfaces that grip paper between them due to surface friction and roller orientation. The folding rollers may be adjustable to provide different levels of grip or to have greater clearance for paper and carriers of different thicknesses. The folding rollers grip the paper in such a way that the paper does not slide against the roller surface, but rather is advanced by the rotation of the roller. When the paper is between the rollers, the paper is engaged by the roller to prevent slippage.

[0040] 2A, a piece of paper moving from paper path 140 through infeed nip 112 moves in a direction substantially perpendicular to the axis formed between folding rollers 101 and 102. Thus, infeed nip 112 does not cause the paper carrier moving therethrough to buckle appreciably as it advances through infeed nip 112.

[0041] The folding chute 150 can be downstream of the infeed nip 112. The folding chute 150 is a receptacle with a lumen sized and shaped to receive the paper carrier. The folding chute 150 has an opening (not shown) at or near its proximal end, adjacent and downstream from the infeed nip 112, through which the paper carrier can enter the lumen as it advances out of the infeed nip 112. The folding chute 150 also has a strain stop (not shown) within the lumen, configured to contact a portion of the paper carrier and stop its further advancement into the lumen. The strain stop can simply be the distal end of the lumen, or it can be one or more bumpers or friction members within the lumen configured to contact the paper carrier. As discussed below with respect to Figures 8-13, the strain stop can be adjusted to accommodate different sizes of paper or different folding configurations. Folding chute 150 is configured to pivot about a point near its proximal end such that distal end 152 of folding chute 150 swings back and forth in an arcuate manner indicated by arrow 171. Rotation or pivoting of folding chute 150 allows folding chute 150 to assume at least a first position (shown in FIG. 2B) and a second position (shown in FIG. 2D). As described below, in operation, folding chute 150 continuously pivots back and forth to allow folding of subsequent carriers having cards attached thereto.

[0042] Folding chute 150 is connected to a chute arm 182 operatively associated with a chute motor 185. Chute motor 185 drives chute gear 183 with a chute belt 184. Chute arm 182 includes a rigid shaft 186 and one or more rotatable or articulatable hinges 189. As chute gear 183 rotates, chute arm 182 moves folding chute 150 back and forth. The range of motion of chute arm 182 and folding chute 150 is shown in FIGS. 2B-2E . While folding chute 150 is depicted in FIG. 2A as having a vertical orientation, it should be understood that folding chute 150 is movable and therefore operable to assume different positions relative to the folding rollers, including the first and second positions described above, and all positions therebetween.

[0043] 2B-2E show paper carrier 190 with card 191 attached as it moves through folder 100. 2B-2E are shown in cross section to show a portion of paper 190 and the position of card 191 within folding chute 150. In FIG. 2B, paper carrier 190 with card 191 enters folder chute 150. The entry angle θ between the paper path in infeed nip 112 and the angle of folding chute 150 is depicted in dashed lines and is small, e.g., less than about 40 degrees, less than about 35 degrees, less than about 30 degrees, less than about 25 degrees, less than about 20 degrees, less than about 15 degrees, less than about 10 degrees, less than about 5 degrees, or less than about 1 degree, to avoid damage to card 191 as it enters folding chute 150. As shown in FIG. 2C , when the majority of the card portion of carrier 190 is outside infeed nip 112, folding chute 150 moves counterclockwise. When the leading edge of carrier 190 reaches the strain stop (not shown), folding chute 150 should be in a nearly vertical orientation, and document skew 195 is just beginning to form. At this point, card 191 is within folding chute 150 and is protected. As shown in FIG. 2D , if skew 195 continues to form, folding chute 150 moves past the center, preparing the card to be aligned for exit through folding nip 114. Similar to entry angle θ, exit angle θ1 is also low to prevent damage to the card as it exits folding chute 150. As shown in FIG. 2E , folder carrier 190 completes its first fold and emerges from folding nip 114. As explained in more detail below, the process can be repeated again in another fold cluster to create the final C- or Z-fold.

[0044] 3-6 show a schematic depiction of the coordinated movement of the folding chutes throughout the folding process.

[0045] FIG. 3 shows a schematic diagram of folding apparatus 100 having folding rollers 101-103 and folding chute 150 operably connected to gear 183 driven by a motor (not shown). Paper travels from left to right, as indicated by arrow 142. The paper descends first paper path 144 and can be directed by paper guides (not shown) into either fold path 145 or bypass path 146. If the carrier is intended to be folded, the paper guide directs the carrier into fold path 145, where it is folded in the manner described above and sent through exit path 147. If the carrier is not intended to be folded, the paper guide directs the carrier into the bypass path. Folded and unfolded carriers descend path 148 for further downstream processing.

[0046] FIG. 4 shows paper carrier 190 entering folder 100. A front portion 193 of the carrier, to which a stiff card 191 or other stiff object is attached, enters the folder before a rear portion 194 of the carrier. Folding chute 150 is in a first position where it is substantially aligned with the paper path of the paper moving through infeed nip 112. In this orientation, folding chute 150 is approximately perpendicular to an axis represented by dashed line 119 between folding rollers 101 and 102, or is at an angle θ or less from a perpendicular to axis 119. In embodiments, angle θ is approximately 40 degrees, 35 degrees, 30 degrees, 25 degrees, 20 degrees, 15 degrees, 10 degrees, 5 degrees, or 1 degree or less. The timing of the movement of folding chute 150 is configured so that folding chute 150 is in the first position when the paper carrier is emerging from folding nip 112.

[0047] When the folding chute 150 is in the first position, the front portion 193 of the paper carrier 190 with the card 191 attached thereto can advance through the infeed nip 112 and enter the lumen of the folding chute 150 without bending. When the card 191 is entirely inside the folding chute 150, the folding chute 150 rotates counterclockwise from the position of the folding chute 150 shown in FIG. 4 to the vertical position of the folding chute 150 shown in FIG. 5. The front portion 193 of the paper carrier 190 contacts a strain stop (not shown) while the rear portion 194 of the paper carrier 190 is still engaged with and advancing through the infeed nip 112. Contact with the strain stop stops the front portion 193 of the paper carrier 190, and continued advancement of the rear portion 194 through the infeed nip 112 causes a strain 195 to form. Contact with the strain stop occurs as folding chute 150 rotates in a counterclockwise manner, causing strain 195 to form downstream toward folding nip 114, which is at the interface between folding roller 102 and folding roller 103. As folding chute 150 continues to rotate in a counterclockwise manner, infeed nip 112 continues to advance the rear portion of carrier 190, causing strain 195 to grow toward folding nip 114. Because front portion 193 of carrier 190, with card 191 attached, is contained within folding chute 150 during strain formation, card 191 remains flat and undisturbed.

[0048] 6, the growing strain 195 contacts folding rollers 102 and 103 and is trapped within the folding nip 114 causing a fold 196 to form in the rear portion of carrier 190. Once the fold is made, the front portion 193 of the carrier is pulled out of the folding chute 150, which is by this time substantially aligned with the folding nip 114 such that the card 191 is not bent and the card and carrier exit along a substantially straight path and are advanced through the folding nip 114. Carrier 190 with attached card 191 exits the folding chute 150 at an angle substantially perpendicular to axis 118 between rollers 102 and 103. Substantially orthogonal includes an angle θ1 from a perpendicular to the axis 118, where the angle θ1 is less than about 35 degrees, less than about 30 degrees, less than about 25 degrees, less than about 20 degrees, less than about 15 degrees, less than about 10 degrees, less than about 5 degrees, or less than about 1 degree.

[0049] The carrier with the card now attached and folded moves down exit path 147, and the process can be repeated for another carrier. The chute motor (not shown) continues to rotate chute gear 183, which causes chute arm 182 to rotate folding chute 150 back in a clockwise direction, causing folding chute 150 to once again assume the first position where it can receive another carrier from infeed nip 112. The process repeats for additional carriers as needed.

[0050] The system of the present invention encompasses various combinations and configurations of folding devices that can create various folds in the carrier with the card attached. Multiple folding devices can be arranged one after the other to create a series of folds in the carrier. The folding devices can accommodate half folds, C-folds, Z-folds, and quarter folds, each of which can be configured with cards placed in a different fold of the carrier. Other folding configurations are possible, as can be envisioned by one of ordinary skill in the art based on the disclosure herein.

[0051] An exemplary arrangement of folding devices in the folding system of the present invention is shown in FIG. 7. The paper path includes a first folding station 710 and a second folding station 720 downstream from the first folding station 710. The first folding station 710 includes one folding device 100 as described above. The second folding station 720 includes an upper folding device 721 and a lower folding device 722, each of which is substantially similar to the folding device 100 described above. Paper guides (not shown) direct a strip of paper moving from left to right into the various folding and bypass paths. The first paper guide associated with the first folding station 710 directs the paper into either folding path 145 to create a fold or bypass path 146 to avoid creating a fold. At the second folding station, the paper guides may direct the paper either into upper folder 721 via fold path 745 or into lower folder 722 via fold path 755, depending on the type of fold desired, or alternatively, the paper guides may guide the paper into bypass path 746 to avoid making a fold at second folding station 720. As shown in FIG. 7 , paper carrier 190 bypasses both folding stations via bypass path 146 and bypass path 746. This represents a "through path" where no folds are made.

[0052] Some non-limiting examples of fold configurations that can be formed with the disclosed system are shown in Figures 8-13. As described with respect to specific fold paths described below, strain stops in the folding chute 150 associated with each folding device can be adjusted, as can the timing of the folding chute's movement and roller speeds, to control the precise location of the fold in the paper. For example, a folding cluster may create a fold down the center of the paper to create two halves, or a folding cluster may create a fold in a third or quarter of the paper.

[0053] FIG. 8 illustrates a process for creating half-folds using the disclosed folding apparatus. For simplicity, paper carrier 190 is shown without a card attached, although it should be understood that a card may generally be attached to the carrier as described above. Paper carrier 190 is directed into folding apparatus 100 at first folding station 710 by paper guides (not shown). Folding chute 150 and strain stop (not shown) are configured to allow a predetermined length of paper carrier 190 to enter folding chute 150 such that strain 195 is formed at the midpoint of the length of paper carrier 190, thereby creating a half-folded carrier when the strained portion is captured in folding nip 114. A completed half-folded carrier 890 is shown moving between first folding station 710 and second folding station 720. Because no further folds are desired, a second paper guide (not shown) directs the half-folded carrier 890 to bypass the second folding station 720 via the bypass path 746. In the embodiment shown in FIG. 8, a half fold is made so that the bottom surface of the paper carrier is on the outside of the folded carrier. In another configuration, a half fold is made so that the top surface of the paper carrier is on the outside of the folded carrier. This can be done by bypassing the first folding station 710 and directing the carrier to the lower folder 722 to create the half fold.

[0054] 9-11 show various tri-fold configurations. To fold a piece of paper in thirds, two folds are required. The first fold can be made about one-third of the way down the length of the piece of paper, and the second fold can be made about two-thirds down. Tri-folds include a C-fold, where both folds are made in the same direction, and a Z-fold, where two folds are made in opposite directions.

[0055] FIG. 9 illustrates a process for creating a C-fold using the disclosed folding system. A paper carrier 190 is directed into a first folding cluster, where a fold is made approximately one-third of the length of the carrier by the methods described herein. The folded carrier 990 is then directed into one of the folders 721 or 722 of the second folding station 720 to make a second fold, completing the C-fold configuration. The first configuration of C-folds ("C-fold up") can be created by the process shown in FIG. 9. To create a distortion 195 in the carrier, the carrier is fed into the folding chute 150 until approximately one-third of the carrier is in the folding chute. The front portion 193 of the carrier 190 comprises approximately one-third of the carrier, and the rear portion 194 of the carrier comprises approximately two-thirds of the carrier. The partially folded carrier 990 is then directed into the upper folder 721 of the second folding station 720 to make a second fold, completing the C-fold. A completed C-fold carrier 995 is shown downstream of the second folding station 720.

[0056] A different configuration of the C-fold ("C-fold down") can be made by the process shown in Figure 10. In this configuration, two-thirds of the carrier enters the folding chute 150, so the first fold is made further down the length of the carrier 190. The second fold is then made by orienting the carrier into the lower folder 722 of the second folding station 720. This results in a differently oriented C-fold than that made in Figure 9. Such a different configuration may be desired based on where the cards are attached to the carrier.

[0057] When cards are mounted in the middle section of a tri-fold carrier, a "C-fold down" configuration should be used, whereby the middle section is inside the respective folding chute 150 during each fold. When cards are mounted in the front section, a "C-fold up" configuration should be used.

[0058] FIG. 11 shows a process for making Z-folds. The "Z-fold" process begins identically to the "C-fold" process described above, except that instead of being directed into the upper folder 721 for the second fold, the carrier is directed into the lower folder 722. A carrier 1190 is shown folded into folder 722. A completed Z-folded carrier 1195 is shown downstream of the second folding station 720. Differently configured Z-folds can be made using the first step of the "C-fold" process described above, directing the carrier into the upper folder 721 to complete the second fold.

[0059] Figures 12 and 13 show the process for creating quarter-folds. Carrier 190 enters first folding station 710 and is folded in half using the same process as shown in Figure 8 to create half-folds. However, instead of bypassing second folding station 720, the half-folded carrier is then directed to either upper folder 721 as in Figure 12 or lower folder 722 as in Figure 13. In both Figures 12 and 13, the half-folded carrier is folded in half again by the second folding station to create quarter-folded carrier 1295 and carrier 1395.

[0060] Those skilled in the art will understand the various configurations for producing C-folds and Z-folds, as well as half-folds and quarter-folds, depending on the intended location of the attached card and the orientation of the printing on the top and bottom surfaces of the carrier, and will be able to design an appropriate folding scheme using the systems disclosed herein. The different folding schemes described with respect to the folding schemes shown in Figures 8-13 depend on the location of the strain stops, the speed of the rollers and folding chutes, and the orientation of the paper guides to direct the carrier into the folding device or bypass path.

[0061] FIG. 14A shows a perspective view of a sample completed carrier package 115 formed by a folded carrier 113 with a card 128 attached at location 130. FIG. 14B shows an end view of the folded carrier package 115. The folded carrier 113 is folded into a Z-fold. The cardholder's name and address and / or other account information 106 may be printed on one of three panels 108, 109, 110 of the carrier 113. The three panels are defined by two fold lines 116, 117 created by a folding tool as described above. The information 106 may be printed, for example, by the printing module 11 shown in FIG. 1. The printer module may also print a barcode 120 on another panel, such as end panel 109, representing information about the account, such as the account number and the number of cards attached to the carrier 113. In other configurations of the folded carrier, it may be desirable to print the information 106 or barcode information 120 in other selected locations on the carrier 113 .

[0062] Card 128 generally has the account number and account holder's name printed on the card, and the same information encoded in a magnetic stripe on the back of card 128. Additional information, such as the number of cards attached to the carrier, may also be included in the bar code. In addition, the back of the card has the account number and account name encoded in a bar code printed on the back of the card. This information is checked for proper encoding, and if the code is incorrect or does not match the encoded information on the carrier to which it is to be attached, card 128 is passed through a card reject bin.

[0063] The card may be attached to the carrier 113, for example at location 130 or location 132, or elsewhere, by an adhesive label 143. One side of the adhesive label 143 is attached to the card with a heat-activated adhesive, such as a releasable adhesive. The other side of the label is attached to the carrier with a permanent adhesive.

[0064] As described above and as will be apparent to those skilled in the art, roller speeds, folding chute motor speeds, and paper guide orientations combine to determine the particular folding configuration of a paper carrier moving through the folding system disclosed herein. The operation and function of the various moving parts are driven by motors and controlled by one or more computer processors operable to execute instructions. Various parameters may be controlled or monitored from a display device, as described below.

[0065] As mentioned above, aspects of the disclosure described herein, such as the speed and control of rollers, folding chutes, and paper guides, and the monitoring and control of various parameters, may be performed using any type of computing device, such as a computer or programmable logic controller (PLC), including a processor, such as a central processing unit, or any combination of computing devices, each device performing at least a portion of a process or method. In some embodiments, the systems and methods disclosed herein may be performed on a handheld device, such as a smart tablet, smartphone, or a dedicated device produced for the system.

[0066] 1 is operatively associated with a processor configured to control the operation of the mail insertion system, including the folding equipment. The user interface may employ software, hardware, firmware, hardwiring, or any combination thereof. The features that perform the functions may also be physically located in various locations, including being distributed such that some of the functions are performed in different physical locations (e.g., folding or inserting equipment in one room and a host workstation in another room or in a separate building, e.g., with a wireless or wired connection).

[0067] Processors suitable for executing a computer program include, for example, both general-purpose and special-purpose microprocessors, and any one or more processors of any kind of digital computer. Generally, a processor receives instructions and data from a read-only memory or a random-access memory, or both. The elements of a computer are a processor for executing instructions and one or more memory devices for storing instructions and data. Generally, a computer also includes one or more non-transitory mass storage devices for storing data, such as magnetic disks, magneto-optical disks, or optical disks, or is operatively coupled to receive or transmit data therefrom, or both. Information carriers suitable for embodying computer program instructions and data include all forms of non-volatile memory, including, for example, semiconductor memory devices (e.g., EPROMs, EEPROMs, solid-state drives (SSDs), and flash memory devices), magnetic disks (e.g., internal hard disks or removable disks), magneto-optical disks, and optical disks (e.g., CD and DVD disks). The processor and memory may be supplemented by, or integrated into, special-purpose logic circuitry.

[0068] To provide for user interaction, the systems described herein may be implemented in a computer having I / O devices, such as a CRT, LCD, LED, or projection device for displaying information to a user, and input or output devices, such as a keyboard and pointing device (e.g., a mouse or trackball), by which the user may provide input to the computer. Other types of devices may also be used to provide for user interaction. For example, feedback provided to the user may be any form of sensory feedback (e.g., visual feedback, auditory feedback, or tactile feedback), and input from the user may be received in any form, including acoustic, speech, or tactile input.

[0069] The subject matter described herein may be implemented in a computing system that includes back-end components (e.g., data servers), middleware components (e.g., application servers), or front-end components (e.g., client computers having a graphical user interface or web browser through which a user may interact with an implementation of the subject matter described herein), or any combination of such back-end, middleware, and front-end components. The components of the system may be interconnected through a network by any form or medium of digital data communication, such as, for example, a communications network. Examples of communications networks include cellular networks (e.g., 3G or 4G), local area networks (LANs), and wide area networks (WANs) such as, for example, the Internet.

[0070] The subject matter described herein may be implemented as one or more computer program products, such as one or more computer programs tangibly embodied in an information carrier (e.g., in a non-transitory computer-readable medium) for execution by or control of the operation of a data processing device (e.g., a programmable processor, a computer, or multiple computers). Computer programs (also known as programs, software, software applications, apps, macros, or code) may be written in any form of programming language, including compiled or interpreted languages (e.g., C, C++, Perl), and computer programs may be deployed in any form, including as stand-alone programs or as modules, components, subroutines, or other units suitable for use in a computing environment. The systems and methods of the present invention may include instructions written in any suitable programming language known to those skilled in the art, including, but not limited to, C, C++, Perl, Java, ActiveX, HTML5, Visual Basic, or JavaScript.

[0071] A computer program does not necessarily correspond to a file. A program may be stored in a file or portion of a file that holds other programs or data, in a single file dedicated to the program, or in multiple linked files (e.g., a file storing one or more modules, subprograms, or portions of code). A computer program may be deployed to be executed on one computer, or on multiple computers at one location, or on multiple computers distributed across multiple locations and interconnected by a communications network.

[0072] A file may be, for example, a digital file stored on a hard drive, SSD, CD, or other tangible, non-transitory medium. A file may be sent from one device to another over a network (e.g., as a packet sent from a server to a client, e.g., through a Network Interface Card, modem, wireless card, or the like).

[0073] Writing to a file according to embodiments of the present invention involves transforming a tangible, non-transitory computer-readable medium, for example, by adding, removing, or rearranging particles (e.g., having a net charge or dipole moment into a pattern of magnetization by a read / write head) so that the pattern represents a new array of information about a physical phenomenon of interest that is desired and useful to the user. In some embodiments, writing involves the physical transformation of material in a tangible, non-transitory computer-readable medium (e.g., having particular optical properties, such as burning a CD-ROM, from which an optical read / write device can subsequently read the new and useful array of information). In some embodiments, writing to a file involves transforming a physical flash memory device, such as a NAND flash memory device, and storing information by transforming physical elements within an array of memory cells made from floating-gate transistors. Methods of writing files are well known to those skilled in the art and can be invoked manually or automatically, for example, by a program or by a save command in software or a write command in a programming language.

[0074] Suitable computing devices typically include mass memory, at least one graphical user interface, and at least one display device, and typically include communication between devices. Mass memory exemplifies a type of computer-readable medium, i.e., computer storage media. Computer storage media can include volatile, nonvolatile, removable, or non-removable media implemented in any method or technology for storage of information, such as computer-readable instructions, data structures, program modules, or other data. Examples of computer storage media include RAM, ROM, EEPROM, flash memory or other memory technology, CD-ROM, digital versatile disks (DVDs) or other optical storage, magnetic cassettes, magnetic tape, magnetic disk storage or other magnetic storage devices, radio frequency identification tags or chips, or any other medium that can be used to store desired information and that can be accessed by a computing device.

[0075] Where one skilled in the art would recognize that this is necessary or optimal for carrying out the methods of the present invention, a computer system or machine employed in an embodiment of the present invention may include one or more processors (e.g., a central processing unit (CPU), a graphics processing unit (GPU), or both), a main memory, and a static memory, which communicate with each other via a bus.

[0076] In the exemplary embodiment shown in FIG. 15 , system 600 may include a computer 649 (e.g., a laptop, desktop, or tablet). Computer 649 may be configured to communicate over network 609. Computer 649 includes one or more processors 659 and memory 663, as well as input / output mechanisms 654. Where the methods of the present invention employ a client / server architecture, operations of the methods of the present invention may be performed using a server 613, which includes one or more of a processor 621 and memory 629 that can retrieve data, instructions, etc., or provide results via an interface module 625 or as a file 617. Server 613 may be engaged over network 609 through computer 649 or terminal 667, or server 613 may be directly connected to terminal 667, which includes one or more processors 675 and memory 679, as well as input / output mechanisms 671.

[0077] System 600 or a machine according to an exemplary embodiment of the invention may further include a video display unit (e.g., a liquid crystal display (LCD) or a cathode ray tube (CRT)) at any of I / O 649, I / O 637, or I / O 671. A computer system or machine according to some embodiments may include an alphanumeric input device (e.g., a keyboard), a cursor control device (e.g., a mouse), a disk drive unit, a signal generating device (e.g., a speaker), a touch screen, an accelerometer, a microphone, a cellular radio frequency antenna, and a network interface device, which may be, for example, a network interface card (NIC), a Wi-Fi card, or a cellular modem.

[0078] Memory 663, memory 679, or memory 629 according to exemplary embodiments of the present invention may include a machine-readable medium having stored thereon one or more sets of instructions (e.g., software) that embody any one or more of the methods or functions described herein. The software may also reside, completely or at least partially, within main memory and / or the processor during execution of the software by the computer system, the main memory and the processor also comprising machine-readable media. The software may further be transmitted or received over a network via a network interface device.

[0079] References throughout this specification to "one embodiment" or "an embodiment" mean that a particular feature, structure, or characteristic described in connection with an embodiment is included in at least one embodiment. Thus, the appearances of the phrase "in one embodiment" or "in an embodiment" in various places throughout this specification do not necessarily all refer to the same embodiment. Furthermore, particular features, structures, or characteristics may be combined in any suitable manner in one or more embodiments.

[0080] The terms and expressions employed herein are used as terms of description and not of limitation, and in the use of such terms and expressions there is no intention to exclude any equivalents of the features (or portions thereof) shown and described, recognizing that various modifications are possible within the scope of the claims. Accordingly, the claims are intended to cover all such equivalents.

Claims

1. 1. A method for folding a carrier having a card attached thereto, said method comprising: providing a carrier having a first portion and a second portion, the first portion comprising a card; feeding the first portion of the carrier into an opening of a folding chute without bending the card; repositioning the folding chute to create a distortion in the second portion of the carrier; capturing the distorted second portion of the carrier within a folding nip aligned with the repositioned folding chute to create a fold in the second portion; A method comprising:

2. 10. The method of claim 1, wherein the infeeding step is facilitated by rotating a first roller and a second roller to cause advancement of the carrier through an infeed nip formed at an interface between the first roller and the second roller.

3. The method of claim 2 , further comprising contacting the first portion with a strain stop associated with the folding chute after the feeding step.

4. The method of claim 3 , wherein contacting the first portion with the strain stop stops advancement of the first portion relative to the second portion.

5. The method of claim 4 , wherein the second portion of the carrier continues to advance through the infeed nip after the first portion contacts the strain stop.

6. The method of claim 5 , wherein the continued advancement through the infeed nip causes the strain in the second portion to grow.

7. The method of claim 6 , wherein the strain grows toward the folding nip until the strain is taken up by the folding nip.

8. The method of claim 2 , wherein the folding nip is formed at an interface between the second roller and a third roller.

9. The method of claim 8 , wherein the first roller, the second roller, and the third roller rotate at a constant speed throughout the method.

10. 3. The method of claim 2, wherein during the infeeding step, the folding chute is aligned with the infeed nip so that the carrier enters the opening in the folding chute at an angle θ, θ being between 0 and 45 degrees relative to a carrier path defined by the infeed nip.

11. 11. The method of claim 10, wherein repositioning comprises rotating the folding chute to align the folding chute with the folding nip so that the carrier exits the opening in the folding chute at an angle θ, θ being between 0 and 45 degrees relative to a carrier path defined by the folding nip.

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