Manufacturing container or tube from paper; or other manufacturi – Bending – Folding
Reexamination Certificate
2001-02-01
2003-09-02
Rada, Rinaldi I. (Department: 3721)
Manufacturing container or tube from paper; or other manufacturi
Bending
Folding
C493S405000, C493S418000, C493S448000, C493S450000
Reexamination Certificate
active
06612974
ABSTRACT:
FIELD OF THE INVENTION
The present invention relates generally to an adjustable folding station, and more particularly to a method and apparatus for folding cards of different sizes, shapes, and styles.
DESCRIPTION OF THE PRIOR ART
Social expression cards or greeting cards are manufactured and sold in a variety of sizes, shapes, and styles to provide consumers a wide selection. These cards are most popular during holidays and special occasions such as Christmas, Valentine's Day, birthday, anniversary, and the like. As can be expected, the card industry is and will continue to be a very lucrative and thriving industry.
During the manufacturing process, cards can be folded in different styles. For example,
FIGS. 1-3
illustrate various folds that are common in the industry.
FIG. 1
illustrates an example of a regular fold of a card. As illustrated, a card
2
is evenly divided along a score line
4
to form two panels
6
a,
6
b.
A regular fold occurs when the panel
6
b
is folded over the panel
6
a
(or vice versa) along the score line
4
. The score line
4
can be creased or indented prior to folding one panel over the other. The regular fold is one of the most commonly used folds in the card industry.
Next,
FIG. 2
illustrates an example of a gate fold of a card. As illustrated, a card
12
is evenly divided along a pair of score lines
14
a,
14
b
to form three panels
16
a,
16
b,
16
c.
A gate fold occurs when the first outer panel
16
c
is first folded over the center panel
16
b
along the score line
14
b.
Thereafter, the second outer panel
16
a
is folded over panels
16
b,
16
c
along the other score line
14
a
. Again, the score lines
14
a,
14
b
can be creased or indented prior to folding the panels over each other.
Alternatively, the card can be folded using a Z-fold method. A Z-fold occurs when the panels
16
b,
16
c
are first folded over the panel
16
a
along the score line
14
a
. Thereafter, the panel
16
c
is back folded over panels
16
b,
16
a
along the score line
14
b
to complete the Z-fold.
FIG. 3
illustrates a side view of the Z-fold of the card
22
.
Conventional folding stations that are used in the industry for folding cards will now be described. One conventional folding station is known as a buckle folder. A buckle folder pinches a creased card between two rollers and forces an end of the card against a stop. As the card continues to move against the stop, the card begins to buckle. The mechanical weakness provided by the crease allows the card to buckle at a predetermined point or the score line. As the card buckles outward, a nip roller grabs the card at the score line and completes the fold. Another conventional folding station is a belt folder, which uses a variety of rods and guides to move a panel of the card into its folded position as the card is pulled along by a series of opposing belts.
Although the conventional folding stations described above are widely used and accepted in the card industry, problems remain. For instance, conventional folding stations are not well suited to handle cards with different dimensions and styles. In other words, conventional folding stations are not flexible enough to fold cards of different sizes and shapes and cannot fold them using different folding techniques. Accordingly, there is a great need for an adjustable apparatus for folding cards of different sizes, shapes, and styles.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide an adjustable folding station for folding cards of different sizes, shapes, and styles.
It is another object of the present invention to provide a method and apparatus that can fold cards of different sizes, shapes and styles with minimal adjustments.
It is yet another object of the present invention to provide a method and apparatus implementing an adjustable vacuum bed and individually controlled vacuum suction cups for folding cards of different sizes.
It is another object of the present invention to provide a method and apparatus implementing separately actuated gates for folding cards of different styles.
These and other objects of the present invention are obtained by providing a card folding station having an adjustable vacuum bed and moveable gates. The vacuum bed includes at least two sections that are mounted for horizontal movement back and forth with respect to each other to accommodate cards of different widths. Each section of the vacuum bed includes multiple suction cups, each of which is individually connected to a vacuum supply. The vacuum supply independently controls each suction cup so that vacuum can be applied to selected or all suction cups such that cards of different lengths can be accommodated. The movable gates are pivotally mounted with respect to the vacuum bed and operated by motors to pivot 180 degrees from open to closed positions. During operation, a card (or cards) is placed on the vacuum bed and held therein as one or both gates are sequentially actuated to fold the card.
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Durand Paul
Hallmark Cards Incorporated
Rada Rinaldi I.
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