Movable Fold Chute for Folding Carriers With Attached Cards
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Solution Overview
Problem
Existing folder systems are unable to efficiently fold paper carriers with attached rigid cards without damaging or dislodging the cards, often causing jams or misfolds.
Innovation Solution
A movable fold chute system that aligns with folding nips to maintain a straight paper path, allowing the carrier to be folded around the attached card without bending it, using a buckle stop to form a fold while the card remains undisturbed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If traditional buckle folders are used to fold paper carriers with attached rigid cards, then the folding process can be automated, but the rigid cards are damaged, dislodged, or cause machine jams
Solution Approach 1:
The folding process is divided into distinct stages: feeding stage where the card is protected, buckling stage where the paper folds around the card, and folding stage where the fold is completed. The fold chute is segmented into multiple positions (first position for feeding, second position for folding) to handle different stages separately, preventing card damage while maintaining automation.
Solution Approach 2:
The fold chute is made movable between at least two positions: a first position aligned with the feeding nip to receive the card-carrying portion, and a second position aligned with the folding nip to complete the fold. This dynamic repositioning allows the system to adapt the fold chute's location to match the folding nip, enabling automated folding without damaging rigid cards.
2Reliability
If the paper carrier is folded around the attached card, then the card remains protected and undisturbed, but the carrier cannot pass through traditional folders due to the rigid card
Solution Approach 1:
The movable fold chute acts as an intermediary component between the feeding nip and the folding nip. It receives the card-carrying portion in the first position, maintains a straight paper path to protect the card, then moves to the second position to align with the folding nip for completion. This intermediary structure enables folding of carriers with rigid cards without requiring traditional folder compatibility.
Solution Approach 2:
The fold chute transitions from a static structure to a dynamic one that operates in multiple positional dimensions. By moving between first and second positions along the paper path, it creates the necessary space and alignment to fold the carrier around the rigid card, a capability traditional static folders lack.
3Object-affected harmful factors
If the fold chute is positioned to receive the card-carrying portion, then the card is not bent or stressed, but the carrier cannot be folded without moving the fold chute
Solution Approach 1:
The fold chute is designed as a movable component that transitions between positions. In the first position, it receives the card-carrying portion with the card protected and unstressed. Then it moves to the second position to align with the folding nip, enabling the folding action. This dynamic positioning eliminates card bending while achieving the folding function.
Solution Approach 2:
The fold chute is positioned in the first position beforehand to receive and protect the card-carrying portion before the folding action occurs. This preliminary positioning ensures the card is not bent or stressed during the critical folding moment, and the chute then moves to complete the folding process.
Data Source
AI summary
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 receives a portion 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 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.