CA1194517A - Fine tooth perforation of webs - Google Patents
Fine tooth perforation of websInfo
- Publication number
- CA1194517A CA1194517A CA000411348A CA411348A CA1194517A CA 1194517 A CA1194517 A CA 1194517A CA 000411348 A CA000411348 A CA 000411348A CA 411348 A CA411348 A CA 411348A CA 1194517 A CA1194517 A CA 1194517A
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- length
- perforation
- ties
- inches
- along
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- Perforating, Stamping-Out Or Severing By Means Other Than Cutting (AREA)
- Handling Of Sheets (AREA)
- Making Paper Articles (AREA)
Abstract
Fine Tooth Preparation of Webs ABSTRACT OF THE DISCLOSURE
A web or sheet of material. such as paper and an improved line of perforation therein. The line of perforation is made up of alternating cuts and ties with the ties having a length along the line of perforation of no more than about 0.010 inches and being present in sufficient number along the line of perforation to provide a burst strength of about 8-20 pounds per two lineal inches of length of the line of perforation. Separation of the web or sheet along the line of perforation reveals no appreciably visible breakage of the ties. Also disclosed is a perforating blade for making such lines of perforation.
A web or sheet of material. such as paper and an improved line of perforation therein. The line of perforation is made up of alternating cuts and ties with the ties having a length along the line of perforation of no more than about 0.010 inches and being present in sufficient number along the line of perforation to provide a burst strength of about 8-20 pounds per two lineal inches of length of the line of perforation. Separation of the web or sheet along the line of perforation reveals no appreciably visible breakage of the ties. Also disclosed is a perforating blade for making such lines of perforation.
Description
FINE TOOT~ PERFOR~TION OF WEBS
FIELD OF THE INVENTION
This invention relates to the provi.sion of fine perforations in webs, such as paper, and more specifically, to a perforating blade for providing such perforations and to a business form provided wi.th such perfoxations.
BACKGROUND ART
It has long been commonplace to provide webs, such as paper webs, or sheets with lines of weakness whereby one part of the web or sheet may be separated from another. In most cases, lines of perforations are utilized for this purpose~ The perforations are typically formed by a series of cuts extending through the web or sheet separated b~v ties, or unsevered portions of the web or sheet. Perforations heretofore used have ranged from rather coarse to so-called fine or "keen" perforations with the characterization being dependent upon the length of the tie along the line of perforation, and, to a lesser extent, the number of cuts per lineal inch of the line of perforationO In typical commercial practice, the finest perforation employed has a t.ie length in the range from about 0.02~-0.0~0 inches and frequentl.y, but not always, will be fo~md as a result of forming the perforations with a blade having seventeen teeth per inch with each tooth 25 having a cutting length of about 0.027 to 0.035 inches.
While such lines of perforation have functioned well for their intended purpose of allowing separation of webs along such lines, in many applications, they are not altogether acceptable. For example, and as is well 1. ~
known, in separating a business form along a line oE
perforation, the ties, during the process of being ruptured, and due to the fibrous nature of the paper, tend to pull outwardly of and extend past the straight cuts in the line oE perforation with the consequence that an unsightly edge results. The edge is ragged as a re-sult of the extended, ruptured ties and the relatively smooth cuts inbetween the ties. In cases where the forms are used for mass mailings or the like being processed on computer printers or tabulators, it is apparent to the recipient that the form is part of a mass mailing as opposed to a personal letter~
Consequently, to provide a more personalized appearance, business forms have been developed wherein an ordinary cut sheet business form, such as a letter-head, is "tipped on" to a paper carrier or web provided w~th control punch margins to facilitate computer pro-cessing. The carrier web is fed through the printer carrying with it the cut sheet letterhead which is then imprinted upon. Following the printing operation, the letterhead is removed from the carrier strip and stuffed into an envelope for mailing. The carrier strip is then discarded. Obviously, this procedure waste approximately one half of the paper involved in the business form, which wastage could be avoided iE the letterheads could be made up as continuous business forms with control punch margins and separated into individual form lengths with the control punch margins removed and still return -the appearance of a cut sheet. Furthermore, because of the nature of the paper used in some products, it is nec-essary to provide a punched perEoration as, for example, commonly used in postage stamps. ln some papers, and dependent upon the direction of the line of perforation, the fibers may not run parallel to or with the line of perforation. Consequently, strong fibers in a tie running across the line of perforation may cause the tearing of the tie to ~'wander" off of the line of per-foration and actually tear into the edge of the paper, again, resulting in an unsightly appearance. Consequently, punched perforations have been used in order to provide a large cut or hole into which -the tear may wander when a strong fiber or fibers are approached so that the tear, upon encountering the next tie, is automatically realigned on the line of perforation. Of course, punched hole perforations provide an even more unsightly edge than those encountered when separating a web or the like along a line of perforation formed of cuts and ties. Moreover, the equipment required to form punched hole type perforations is quite expensive and extremely costly to maintain.
The present inven-tion is directed -to overcoming one or more of the above problems.
SUMMARY OF THE INVENTION
It is an object of an aspec-t of the invention to provide a new and improvedline of perforation for use in webs. More specifically, it is~ an object of an aspect of the invention to provide a new and improved line of perforation that, when torn, results in edges that closely approximate the edge of so-called "cut sheets", and eliminates the need for the use of punched hole type perforations and the attendant equipment costs. It is an object of an aspect of the invention to provide a b:Lade for providing such lines of perforation.
According to one facet of the invention, there is provided a blade for perfora-ting webs or the li.ke which has a perforating edge defined by a series of tooth-like perforati.ng elements separated by notches.
The length of each of the majority of the perforating elements along the edge is no more than about 0.02 i.nches and the width of each notch between the cutting elements is no more than about 0..01 inches along the length of the edge.
According to another facet of the invention, there is provided a paper product, such as a busi.ness form, including at least one web or sheet of paper having a line of perforations formed by cuts through the paper separated by -ties, along which one part of the web may be separated from the remainder thereof. The invention contemplates the improvement wherein the ties have a length along the line of perforation of no more than 0.010 inches and wherein there are sufficient number of the ties along the line of perforation to provide a burst strength in the range of about 8-20 pounds per two lineal inches of length of the line of perforation. One part of the web or sheet may be separated from the remainder thereof along the line of perforation wi-thout appreciably visible breakage of the ties to provide a smooth edge resembling the cut edge of.a so-called "cut sheet " .
Such a line oE perforation, because of the short length of the ties, is not prone to wandering of the tear during separation and therefore may be utilized in applications heretofore requiri.ng punched hole perforations.
other aspects of the invention are as follows:
In a business form including at leas-t one weh or sheet of paper having a line of perforation therein formed by cuts through the paper separated by ties and by which part of the form may be separated from the remainder thereof, the improvement wherein said ties have a length along the line of perforation of about 0.010 inches, and said ClltS being in sufficient number to provide at least 50 ties per inch along the line of perforation so that said part may be separated from said remainder along said line of perforation withou-t appreciably visible breakage of said ties.
In a continuous business form including an elongated web of paper having at least one control punch margin extending along the length of the web and separated from the remainder of the web by a line of perforation by which the control punch margin may be separated from the remainder of the web, the improvement wherein said line of perforation is formed by alternating cuts extending through the paper and ties between the cuts, the ties each having a leng-th of abou-t 0.010 inches and said cuts being in sufficient number to provide at least 50 ties per inch of perforation length whereby said control punch margin may be separated from said remainder along an edge having the appearance of a cut edge rather than a perforated edge.
In a continuous business form including an elongated web of paper having ~ransverse lines of perfora-tion upon which the web rnay be separated to define individ-ual forrn lengths, the improvement wherein said lines of perforation are defined by cuts extending through the paper and alternating with ties having a length of 4a.
about 0.010 inches and the cu-ts being in sufficient number to provide at least 50 ties per i.nch of perfora-tion length such -tha-t the individual form lengths will have edges along said perforati.on lines that when separated will closely resemble cut edges rather than perforated edges and yet said form will have sufficient strength to prevent inadvertent partial or complete separation along said lines during manufacture.and/or subsequent use or processing~
A blade for perforating webs and having a perfor--ating edge defined by a-t least 50 tooth-like perforating elements per inch of edge length separated by notches the length of each of the majority of said elements along said edge being no more than 0.02 inches and the width of each notch between said elements being no more than 0.01 inches along the length of said edge.
A blade for perforating webs and having a perforating edge defined by a series of tooth-like perforating elements separated by notches, the wid-th of each notch between said elements being no more than 0.010 inches along the length of the edge, the length of each of the majority of said elements being no more than 0.010 inches, and wherein there are at least 50 of said elements per inch along the length of said edge.
A blade for perfora-ting webs and having a perforating edge defined by a series of tooth-]ike perforating elements separated by notches, -the width of each notch between said elements being no more than 0.008 inches along the lengt:h of the edge, the length of each of the majority of said elements being no more than 0.010 inches, and wherein there are at least 70 of said elements per inch along the length of said edge.
4b.
.~s~
O-ther objects and advantages of the invention will become apparent from the following specification taken in connection with the accompanying drawings.
4c.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a somewhat schematic view of the manufacture of a business form made according to the invention utilizing perforating blades made according to the invention;
FIG. 2 is a fragmentary view of the partial separation o~ a control punch margln from a business form along a line of perforation made according to -the in-vention utilizing a blade made according to the inven-tion;
FIG. 3 is a view similar to FIG. 2 but illustrat-ing a prior art product;
FIG. 4 is a fragmentary, considerably enlarged view of a perforating blade made according to the in-vention; and FIG. 5 is a view similar to FIG. 4 but showing a modified embodiment of the perforating blade.
BEST MODE FOR CARRYING OUT rrHE INVENTION
An exemplary er~odiment of a web product made according to the invention is illustrated in the process of manufacture in FIG. 1. As illustrated, a web of paper utilized in the manufacture of a continuous business form is shown. However, it is to be unders-tood that the principles of the invention may be u-tilized in o-ther -than continuous business forms, such as so-called unit sets or cut sheets, where lines of perfora-tion are re~uired therein. It is also to be unders-t:ood that -the .inven-tion may be employed in providing lines of perforation in webs of material o-ther than paper, as for example, plastic, and further, 5~
that the lines of perforation may also be useful in products where separation along the line of perforation is not required as, for example, in forming, under relatively close tolerances, aspirator holes in the wrappings for filters on cigarettes.
In FIG. 1, a continuous web of paper is desig nated 10 and along its longitudinal margins 12 is pro-vided with control punch openings 14 used for conventional purposes in both manufacture and processing. The web 10 is passing through manufacturing equipment in the direction of an arrow 16 and passes first to a perforating cylinder 18 operating in conjunction with an anvil cylinder 20 both of which revolve about respective rotational axes 22 and 24 in timed relation with the movement of web 10.
I'he perforating cylinder 18 carries one or more perforating blades 26 made according to -the invention which periodically come in contact with the web 10 to penetrate the same and bear against the anvil cylinder 20 to thereby form transverse lines of perforation 28 in the web. Other than the cutting edge on the blade 26, the equipment utilized is conventional, is set up in the conventional fashion according to known procedures, and is otherwise operated in a conventional way.
After leaving the perforating cylinder 18, the web 10 moves onwardly to a further anvil cylinder 30 located below the web. Above the web, a rotary shaft 32 mounts a pair of perfora-ting wheels, each designated 34. The perforating wheels 34 cooperate with the cylinder 30 so as to provide longi-tudinal lines of weakening 36 just inwardly of the margins 12 and the control punch openings 14 in -the web 10.
As is well known, after the business form thus provided is processed by a purchaser thereof, the control punch margins will be removed along the longitudinal lines of perforation 36 and the web will be separated along the transverse lines of perforation 28 to provide individual form lengths 40.
According to the invention, each of the lines of perforation 28 and 36 is formed of alternating cuts extending through the web 10 shown at 42 in FIG. 2 which are separated by very small ties, shown at 44. ~s also seen in FIG. 2, wherein the line of perforation 36 is specifically illustrated and wherein the web 10 is par-tially severed thereon, the resulting edge 46 is quite smooth and upon normal visual inspection~ will have the appearance of the cut edge of a cut sheet product. While not illustrated in FIG. 2, the edges of the web, when severed on the lines of perforation 28 will have the same appearance. This results as, according to the invention, the length of each tie 44 along the line of perforation 28 20 or 36 is no greated than about 0.010 inches, and preferably, it is no greater than about 0.008 inches. In almost all types, grades and weights of paper, if the tie length is greater than 0.010 inches, the noticeable jagged edge typically associated with prior art lines of perforati.on, such as is illustrated in FIG. 3, begins to appear. In such a case, the prior art ties 48, due to the fibrous nature of the paper, tend to pull Ollt as the tear is formed resulting in a series of small stubs 50 extending from the edge 52 of the -tear. In some types of paper, the unde-sirable jagged edge appearance of the prior art willbecome apparent when the tie length exceeds 0.008 inches.
~hus, a -tie length of 0.010 inches will be satisfactory in some instances whereas a maxlmum tie length of 0.008 inches will provide a commercially satisfactory product in virtually every instance.
Of further concern in the manufacture of a product made according to the invention, is the fact that the lines of weakening 28 and 36 must not be made so weak as to allow inadverten-t rupture of the ties during manufacture and/or subsequent use or processing. For example, comp~lter printers typically jerk a business form being imprinted upon a relatively high frequency, accelerating the paper to advance a new line to the printing mechanism and then decelerating the same to allow prin-ting to be performed. If one of the lines 36, in whole or in part ruptures, feeding is impaired. Conversely, if one of the transverse lines 28 in whole or in part ruptures, there is provided an edge which may snag within the innards of the computer printer thereby causing a shutdown.
Moreover, as is well known, many continuous business forms are zig zag folded for packaging and ~hipment and such folding occurs on the transverse lines of weakening 28. The folding, of course, weakens some of the fibers with the consequence that if the lines 28 are made too weak, some breakage of the lines may be expected to occur in folding with the result that the loose edge, when the form is processed by a customer~
may snag within the innards of the printer.
On the other hand, it is undesirable to have the lines of weakening 28 and 36 provided with too great of streng-th otherwi.se the control punch margins and/or the bursting oE the web 10 into individual form lengths 40 cannot be reliably performed.
Thus, according to the invention, the ties 44 in the form made according to the lnvention are provided in sufficient number so that the line of perforation has a burst strenyth of about 8-20 pounds per two lineal inches of the length of the line of perforation, as meas~lred on a conventional perforation strength tester. Thus, the major considerations are maximum tie length and burst strength as outlined above. However, there remains a further consideration as well. ~ssuminy the ma-terial of a given web would allow the burst strength characteristics required to be met with ties appreciably smaller than 0.010 inches, it has been visually determined that where the length 15 of the cuts 42 begin to exceed 0.02 inches~ the ragged edge appearance of the prior art as shown in FIG. 3 begins to become noticeable, albeit considerably less pronounced than in prior art structures. This is particularly true where the majority of the cuts 42 have a length in excess of 0.02 inches. Conse~uently, it is highly desirable that there be a minimum of 33 cuts per lineal inch of each line of perforation 28 or 36.
In the case of somewhat finer perforations, but not -the finest contemplated according to the invention, it has been visually ascertained that an improvement in edge appearance obtains where the length of -the cuts and the ties are approximately the same. Given a maximum tie di-mension of 0.01 inches, and cuts of the same order, to achieve the uniformity in such a moderately fine line of perforation, there will preferably be at least 50 cuts per lineal inch of each line of perforation 28 or 36.
With even finer lines of perforation made accord-ing to the invention, which optimally include 70 or more cuts per lineal inch of the lines of perforation 28 or 36, there is no requirement that the ties and cuts have dimensions on the same order.
It should be recognized that the principles set forth immediately preceding are general, as opposed to exclusive, for, as will be seen hereinafter, there are exceptions thereto.
Turnin~ now to FIG. 4, the perforatin~ edge of the perforating blade 26 is shown in detail, considerably enlarged. It will be understood that the rotary perfora-ting blades or wheels 34 are identical to the perforating rule 26 with, of course, the exceptioll that their perfora-ting periphery is circular rather than linear. The blade 26 is preferably formed of conventional two or three point cutting rule such as "Sandvik" rule manufactured in Sweden and distributed in the Uniced States by the Disston Corporation of Philadelphia, Pennsylvania. The apex of the perforating edge is shown at 60, ma~ be beveled on one side onlyr beveled on both sides only, or double beveled on both sides as is conventional. There is provided a plurality of tooth-like perforatiny elements 62 separated from each other by notches 64. The length of each tooth 60 is designated L in ~IG. 4 while the depth of each notch 64 is shown at D. The width of each notch is shown at W
and for purposes of definition herein is that dimension of the notch extending along the line of perforation and which provides the length of each tie 44 along such line.
Thus~ the dimension "L" defines the length of each cu-t 42 while the dimension "W" defines the length of each tie 44.
10 .
At this point, it should be noted that the perforation lines 28 and 36 in a si.ngle form may not always be identical due to differing strength requirements either in manufacture or in subse~uent use in processing. For example, in the case of the manufacture of single ply business forms utilizing relatively positive folding apparatus such as jaw/tucker foldersr a typical value of L would be 0.006 inches while W would be 0.008 inchesO D
would be selected to be 0.014 inches; and the blade is used to form the transverse lines of perforation 28. The same dimensions may be utilized in conjunc-tion with the rotary perforating blades or wheels 34 in forming lines of per-foration such as the lines 36.
Where lower perforation strength is required, as, for example, when less positive folding apparatus is employed, a typical value of L might be 0.008 inches while W would have a value of 0.006 inches with D remaining at 0.014 inches. In the case of transverse lines of perfora-tion such as lines 28, and where the form is not intended to be folded on such a transverse line, a typical value of W can be 0.005 inches with L having a value of 0.008 inches. D may remain at 0.01~ inches.
Generally speaking, because there is no folding on the lines of perforation 36, they may be initially formed with lesser strength than -the lines 28. In such a case, L would have a value of 0.010 inches while W would have a value of 0.004 inches with D again remaining a-t 0.01~
inches for single ply forms. The resulting line of perfora-tion may also be utilized advantageously on interior, so-called "vertical perfs" in multiple ply forms as well as on the so-called "s-tub perf" on unit sets.
11 .
In ~che foregoing examples, the value of D is given as 0.014 inches. This value is selected as it enables the blades to cut rela-tively heavy stock, such as tabulator cards, as well as thinner webs or sheets thereby providing greater blade versatility. However, where such versatility is not required, D may be selected to have a value of approximately twice the tota]. thickness of the paper to be perforated and, in general, should not be less than about 0.005 inches greater than the total thickness of the paper to be perforated. Nonetheless~ in instances where scoring of the ties is desirable for the purpose of weakening them to achieve a desired burst strength, or for other purposes, D May have a value less than the total thickness of the paper to be perforated.
The foregoing dimensions are achieved by ap-propriately forming the notches 64. One method of forming the notches to have the requisite dimensions is the use of conventional, wire type, electron discharge machining pro-cesses. Ho~ever, it is believed that the notches 64 could likewise be formed utilizing laser cutting principles.
Turning now to FIG. 5, a rule useful in forming the lines of perforation in mul-tiple ply forms is il-lustrated. The rule illustrated in EIG. 5 includes two types of teeth, the first being designated 70 and the second being deslgnated 72. The various teeth are separated by notches 74 and the same approach to dimensions mentioned in connection with the description of FIG. 4 is employed.
In particular, the cutting dimension of the teeth 70, or L is 0.010 inches for the teeth 70 while W, or the tie dimension, will be 0.008 inches. The depth of the notches 7~, or D, will be approximately 0.025 inches for a four 5~
ply business foxm and should yenerally be 0.005 inches grea-ter than the total thickness to be perforated.
The length of L dimension of the tooth 72 is 0.032 inches and one of the teeth 72 is provided along the perforating edge every 0.255 inches, representing an excep-tion to the preferred maximum tooth length of 0.020 inches. The purpose of this exception is to provide greater strength to the perforating edge.
Because the depth of the notches 74 must necessarily be greater to cut through multiple plies of paper, the teeth 70 are more prone to be deformed under the pressure encountered when they contact the anvil cylinder 20 (FIG.
1). Consequently, wider teeth such as the tooth 72 are provided at intervals such as those mentioned above to increase resistance of the perforating edge to deformation.
For the same reason, the L dimension of the teeth 70 is increased somewhat over that employed for the teeth 62.
Another exception to the general rule of tooth lengths not exceeding 0.020 inches will be found where perforation blades are utilized in die cutting. For ex-ample, die cuts will typically have round or squared corners and to form the corners properly, i-t may be necessary to greatly exceed a cut length of 0.020 lnches at such corners.
Moreover, in some instances, where the forms are provided with both the lines of perEoration 28 and 36, that part of the lines of perforation 28 within the control punch mar-gin, which will be separated Erom the form in any event, may be provided w:ith cuts longer than 0.020 inches as well as ties having a greater dimension than 0.010 inches, since neither will afEect the appearance of the Einished form.
Other examples of specialized applications wherein the preferred dimensions may be exceeded will be appreciated by those skilled in the art.
From the foregoing, it will be appreciated that a perforation blade made according to the invention provides lines of perforation in webs, such as paper webs or sheets, that, when severed, result in edges of the finished product that closely resemble the edges of cut sheet products. Con-sequently, a more personalized and/or cleaner appearing business form results. Moreover, in the case of mass mailings or the like, the carrier strip may be discarded en-tirely providing a paper savings of up to 50%.
Further, there will be a savings in the manufactur-ing operation since the carrier strip need not be formed nor is it necessary to perform the step of tipping cut sheets onto a carrier web. The customer of the form may process the same more economically since he no longer is required to dispose of the carrier web.
The elimination of the carrier web reduces the thickness of a given number of individual form lengths there-by minimizing bulk in both storage and transportation. In the same vein, the weight of the carrier web is eliminated lowering transportation costs.
It will also be appreciated that because of the extremely short length of -the ties 44, even the presence of extremely strong fibers in paper, which fibers are not extending generally parallel to the line of perforation, will not cause the tear to wander. Consequently, perfora-tions of the type disclosed herein may be substituted for punched hole type perforations heretofore required in 1'1 .
many applica-tions, thereby avoiding the need for the purchase of specialized equipment to form such perfora-tions and the extensive mai.ntenance associated therewith.
FIELD OF THE INVENTION
This invention relates to the provi.sion of fine perforations in webs, such as paper, and more specifically, to a perforating blade for providing such perforations and to a business form provided wi.th such perfoxations.
BACKGROUND ART
It has long been commonplace to provide webs, such as paper webs, or sheets with lines of weakness whereby one part of the web or sheet may be separated from another. In most cases, lines of perforations are utilized for this purpose~ The perforations are typically formed by a series of cuts extending through the web or sheet separated b~v ties, or unsevered portions of the web or sheet. Perforations heretofore used have ranged from rather coarse to so-called fine or "keen" perforations with the characterization being dependent upon the length of the tie along the line of perforation, and, to a lesser extent, the number of cuts per lineal inch of the line of perforationO In typical commercial practice, the finest perforation employed has a t.ie length in the range from about 0.02~-0.0~0 inches and frequentl.y, but not always, will be fo~md as a result of forming the perforations with a blade having seventeen teeth per inch with each tooth 25 having a cutting length of about 0.027 to 0.035 inches.
While such lines of perforation have functioned well for their intended purpose of allowing separation of webs along such lines, in many applications, they are not altogether acceptable. For example, and as is well 1. ~
known, in separating a business form along a line oE
perforation, the ties, during the process of being ruptured, and due to the fibrous nature of the paper, tend to pull outwardly of and extend past the straight cuts in the line oE perforation with the consequence that an unsightly edge results. The edge is ragged as a re-sult of the extended, ruptured ties and the relatively smooth cuts inbetween the ties. In cases where the forms are used for mass mailings or the like being processed on computer printers or tabulators, it is apparent to the recipient that the form is part of a mass mailing as opposed to a personal letter~
Consequently, to provide a more personalized appearance, business forms have been developed wherein an ordinary cut sheet business form, such as a letter-head, is "tipped on" to a paper carrier or web provided w~th control punch margins to facilitate computer pro-cessing. The carrier web is fed through the printer carrying with it the cut sheet letterhead which is then imprinted upon. Following the printing operation, the letterhead is removed from the carrier strip and stuffed into an envelope for mailing. The carrier strip is then discarded. Obviously, this procedure waste approximately one half of the paper involved in the business form, which wastage could be avoided iE the letterheads could be made up as continuous business forms with control punch margins and separated into individual form lengths with the control punch margins removed and still return -the appearance of a cut sheet. Furthermore, because of the nature of the paper used in some products, it is nec-essary to provide a punched perEoration as, for example, commonly used in postage stamps. ln some papers, and dependent upon the direction of the line of perforation, the fibers may not run parallel to or with the line of perforation. Consequently, strong fibers in a tie running across the line of perforation may cause the tearing of the tie to ~'wander" off of the line of per-foration and actually tear into the edge of the paper, again, resulting in an unsightly appearance. Consequently, punched perforations have been used in order to provide a large cut or hole into which -the tear may wander when a strong fiber or fibers are approached so that the tear, upon encountering the next tie, is automatically realigned on the line of perforation. Of course, punched hole perforations provide an even more unsightly edge than those encountered when separating a web or the like along a line of perforation formed of cuts and ties. Moreover, the equipment required to form punched hole type perforations is quite expensive and extremely costly to maintain.
The present inven-tion is directed -to overcoming one or more of the above problems.
SUMMARY OF THE INVENTION
It is an object of an aspec-t of the invention to provide a new and improvedline of perforation for use in webs. More specifically, it is~ an object of an aspect of the invention to provide a new and improved line of perforation that, when torn, results in edges that closely approximate the edge of so-called "cut sheets", and eliminates the need for the use of punched hole type perforations and the attendant equipment costs. It is an object of an aspect of the invention to provide a b:Lade for providing such lines of perforation.
According to one facet of the invention, there is provided a blade for perfora-ting webs or the li.ke which has a perforating edge defined by a series of tooth-like perforati.ng elements separated by notches.
The length of each of the majority of the perforating elements along the edge is no more than about 0.02 i.nches and the width of each notch between the cutting elements is no more than about 0..01 inches along the length of the edge.
According to another facet of the invention, there is provided a paper product, such as a busi.ness form, including at least one web or sheet of paper having a line of perforations formed by cuts through the paper separated by -ties, along which one part of the web may be separated from the remainder thereof. The invention contemplates the improvement wherein the ties have a length along the line of perforation of no more than 0.010 inches and wherein there are sufficient number of the ties along the line of perforation to provide a burst strength in the range of about 8-20 pounds per two lineal inches of length of the line of perforation. One part of the web or sheet may be separated from the remainder thereof along the line of perforation wi-thout appreciably visible breakage of the ties to provide a smooth edge resembling the cut edge of.a so-called "cut sheet " .
Such a line oE perforation, because of the short length of the ties, is not prone to wandering of the tear during separation and therefore may be utilized in applications heretofore requiri.ng punched hole perforations.
other aspects of the invention are as follows:
In a business form including at leas-t one weh or sheet of paper having a line of perforation therein formed by cuts through the paper separated by ties and by which part of the form may be separated from the remainder thereof, the improvement wherein said ties have a length along the line of perforation of about 0.010 inches, and said ClltS being in sufficient number to provide at least 50 ties per inch along the line of perforation so that said part may be separated from said remainder along said line of perforation withou-t appreciably visible breakage of said ties.
In a continuous business form including an elongated web of paper having at least one control punch margin extending along the length of the web and separated from the remainder of the web by a line of perforation by which the control punch margin may be separated from the remainder of the web, the improvement wherein said line of perforation is formed by alternating cuts extending through the paper and ties between the cuts, the ties each having a leng-th of abou-t 0.010 inches and said cuts being in sufficient number to provide at least 50 ties per inch of perforation length whereby said control punch margin may be separated from said remainder along an edge having the appearance of a cut edge rather than a perforated edge.
In a continuous business form including an elongated web of paper having ~ransverse lines of perfora-tion upon which the web rnay be separated to define individ-ual forrn lengths, the improvement wherein said lines of perforation are defined by cuts extending through the paper and alternating with ties having a length of 4a.
about 0.010 inches and the cu-ts being in sufficient number to provide at least 50 ties per i.nch of perfora-tion length such -tha-t the individual form lengths will have edges along said perforati.on lines that when separated will closely resemble cut edges rather than perforated edges and yet said form will have sufficient strength to prevent inadvertent partial or complete separation along said lines during manufacture.and/or subsequent use or processing~
A blade for perforating webs and having a perfor--ating edge defined by a-t least 50 tooth-like perforating elements per inch of edge length separated by notches the length of each of the majority of said elements along said edge being no more than 0.02 inches and the width of each notch between said elements being no more than 0.01 inches along the length of said edge.
A blade for perforating webs and having a perforating edge defined by a series of tooth-like perforating elements separated by notches, the wid-th of each notch between said elements being no more than 0.010 inches along the length of the edge, the length of each of the majority of said elements being no more than 0.010 inches, and wherein there are at least 50 of said elements per inch along the length of said edge.
A blade for perfora-ting webs and having a perforating edge defined by a series of tooth-]ike perforating elements separated by notches, -the width of each notch between said elements being no more than 0.008 inches along the lengt:h of the edge, the length of each of the majority of said elements being no more than 0.010 inches, and wherein there are at least 70 of said elements per inch along the length of said edge.
4b.
.~s~
O-ther objects and advantages of the invention will become apparent from the following specification taken in connection with the accompanying drawings.
4c.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a somewhat schematic view of the manufacture of a business form made according to the invention utilizing perforating blades made according to the invention;
FIG. 2 is a fragmentary view of the partial separation o~ a control punch margln from a business form along a line of perforation made according to -the in-vention utilizing a blade made according to the inven-tion;
FIG. 3 is a view similar to FIG. 2 but illustrat-ing a prior art product;
FIG. 4 is a fragmentary, considerably enlarged view of a perforating blade made according to the in-vention; and FIG. 5 is a view similar to FIG. 4 but showing a modified embodiment of the perforating blade.
BEST MODE FOR CARRYING OUT rrHE INVENTION
An exemplary er~odiment of a web product made according to the invention is illustrated in the process of manufacture in FIG. 1. As illustrated, a web of paper utilized in the manufacture of a continuous business form is shown. However, it is to be unders-tood that the principles of the invention may be u-tilized in o-ther -than continuous business forms, such as so-called unit sets or cut sheets, where lines of perfora-tion are re~uired therein. It is also to be unders-t:ood that -the .inven-tion may be employed in providing lines of perforation in webs of material o-ther than paper, as for example, plastic, and further, 5~
that the lines of perforation may also be useful in products where separation along the line of perforation is not required as, for example, in forming, under relatively close tolerances, aspirator holes in the wrappings for filters on cigarettes.
In FIG. 1, a continuous web of paper is desig nated 10 and along its longitudinal margins 12 is pro-vided with control punch openings 14 used for conventional purposes in both manufacture and processing. The web 10 is passing through manufacturing equipment in the direction of an arrow 16 and passes first to a perforating cylinder 18 operating in conjunction with an anvil cylinder 20 both of which revolve about respective rotational axes 22 and 24 in timed relation with the movement of web 10.
I'he perforating cylinder 18 carries one or more perforating blades 26 made according to -the invention which periodically come in contact with the web 10 to penetrate the same and bear against the anvil cylinder 20 to thereby form transverse lines of perforation 28 in the web. Other than the cutting edge on the blade 26, the equipment utilized is conventional, is set up in the conventional fashion according to known procedures, and is otherwise operated in a conventional way.
After leaving the perforating cylinder 18, the web 10 moves onwardly to a further anvil cylinder 30 located below the web. Above the web, a rotary shaft 32 mounts a pair of perfora-ting wheels, each designated 34. The perforating wheels 34 cooperate with the cylinder 30 so as to provide longi-tudinal lines of weakening 36 just inwardly of the margins 12 and the control punch openings 14 in -the web 10.
As is well known, after the business form thus provided is processed by a purchaser thereof, the control punch margins will be removed along the longitudinal lines of perforation 36 and the web will be separated along the transverse lines of perforation 28 to provide individual form lengths 40.
According to the invention, each of the lines of perforation 28 and 36 is formed of alternating cuts extending through the web 10 shown at 42 in FIG. 2 which are separated by very small ties, shown at 44. ~s also seen in FIG. 2, wherein the line of perforation 36 is specifically illustrated and wherein the web 10 is par-tially severed thereon, the resulting edge 46 is quite smooth and upon normal visual inspection~ will have the appearance of the cut edge of a cut sheet product. While not illustrated in FIG. 2, the edges of the web, when severed on the lines of perforation 28 will have the same appearance. This results as, according to the invention, the length of each tie 44 along the line of perforation 28 20 or 36 is no greated than about 0.010 inches, and preferably, it is no greater than about 0.008 inches. In almost all types, grades and weights of paper, if the tie length is greater than 0.010 inches, the noticeable jagged edge typically associated with prior art lines of perforati.on, such as is illustrated in FIG. 3, begins to appear. In such a case, the prior art ties 48, due to the fibrous nature of the paper, tend to pull Ollt as the tear is formed resulting in a series of small stubs 50 extending from the edge 52 of the -tear. In some types of paper, the unde-sirable jagged edge appearance of the prior art willbecome apparent when the tie length exceeds 0.008 inches.
~hus, a -tie length of 0.010 inches will be satisfactory in some instances whereas a maxlmum tie length of 0.008 inches will provide a commercially satisfactory product in virtually every instance.
Of further concern in the manufacture of a product made according to the invention, is the fact that the lines of weakening 28 and 36 must not be made so weak as to allow inadverten-t rupture of the ties during manufacture and/or subsequent use or processing. For example, comp~lter printers typically jerk a business form being imprinted upon a relatively high frequency, accelerating the paper to advance a new line to the printing mechanism and then decelerating the same to allow prin-ting to be performed. If one of the lines 36, in whole or in part ruptures, feeding is impaired. Conversely, if one of the transverse lines 28 in whole or in part ruptures, there is provided an edge which may snag within the innards of the computer printer thereby causing a shutdown.
Moreover, as is well known, many continuous business forms are zig zag folded for packaging and ~hipment and such folding occurs on the transverse lines of weakening 28. The folding, of course, weakens some of the fibers with the consequence that if the lines 28 are made too weak, some breakage of the lines may be expected to occur in folding with the result that the loose edge, when the form is processed by a customer~
may snag within the innards of the printer.
On the other hand, it is undesirable to have the lines of weakening 28 and 36 provided with too great of streng-th otherwi.se the control punch margins and/or the bursting oE the web 10 into individual form lengths 40 cannot be reliably performed.
Thus, according to the invention, the ties 44 in the form made according to the lnvention are provided in sufficient number so that the line of perforation has a burst strenyth of about 8-20 pounds per two lineal inches of the length of the line of perforation, as meas~lred on a conventional perforation strength tester. Thus, the major considerations are maximum tie length and burst strength as outlined above. However, there remains a further consideration as well. ~ssuminy the ma-terial of a given web would allow the burst strength characteristics required to be met with ties appreciably smaller than 0.010 inches, it has been visually determined that where the length 15 of the cuts 42 begin to exceed 0.02 inches~ the ragged edge appearance of the prior art as shown in FIG. 3 begins to become noticeable, albeit considerably less pronounced than in prior art structures. This is particularly true where the majority of the cuts 42 have a length in excess of 0.02 inches. Conse~uently, it is highly desirable that there be a minimum of 33 cuts per lineal inch of each line of perforation 28 or 36.
In the case of somewhat finer perforations, but not -the finest contemplated according to the invention, it has been visually ascertained that an improvement in edge appearance obtains where the length of -the cuts and the ties are approximately the same. Given a maximum tie di-mension of 0.01 inches, and cuts of the same order, to achieve the uniformity in such a moderately fine line of perforation, there will preferably be at least 50 cuts per lineal inch of each line of perforation 28 or 36.
With even finer lines of perforation made accord-ing to the invention, which optimally include 70 or more cuts per lineal inch of the lines of perforation 28 or 36, there is no requirement that the ties and cuts have dimensions on the same order.
It should be recognized that the principles set forth immediately preceding are general, as opposed to exclusive, for, as will be seen hereinafter, there are exceptions thereto.
Turnin~ now to FIG. 4, the perforatin~ edge of the perforating blade 26 is shown in detail, considerably enlarged. It will be understood that the rotary perfora-ting blades or wheels 34 are identical to the perforating rule 26 with, of course, the exceptioll that their perfora-ting periphery is circular rather than linear. The blade 26 is preferably formed of conventional two or three point cutting rule such as "Sandvik" rule manufactured in Sweden and distributed in the Uniced States by the Disston Corporation of Philadelphia, Pennsylvania. The apex of the perforating edge is shown at 60, ma~ be beveled on one side onlyr beveled on both sides only, or double beveled on both sides as is conventional. There is provided a plurality of tooth-like perforatiny elements 62 separated from each other by notches 64. The length of each tooth 60 is designated L in ~IG. 4 while the depth of each notch 64 is shown at D. The width of each notch is shown at W
and for purposes of definition herein is that dimension of the notch extending along the line of perforation and which provides the length of each tie 44 along such line.
Thus~ the dimension "L" defines the length of each cu-t 42 while the dimension "W" defines the length of each tie 44.
10 .
At this point, it should be noted that the perforation lines 28 and 36 in a si.ngle form may not always be identical due to differing strength requirements either in manufacture or in subse~uent use in processing. For example, in the case of the manufacture of single ply business forms utilizing relatively positive folding apparatus such as jaw/tucker foldersr a typical value of L would be 0.006 inches while W would be 0.008 inchesO D
would be selected to be 0.014 inches; and the blade is used to form the transverse lines of perforation 28. The same dimensions may be utilized in conjunc-tion with the rotary perforating blades or wheels 34 in forming lines of per-foration such as the lines 36.
Where lower perforation strength is required, as, for example, when less positive folding apparatus is employed, a typical value of L might be 0.008 inches while W would have a value of 0.006 inches with D remaining at 0.014 inches. In the case of transverse lines of perfora-tion such as lines 28, and where the form is not intended to be folded on such a transverse line, a typical value of W can be 0.005 inches with L having a value of 0.008 inches. D may remain at 0.01~ inches.
Generally speaking, because there is no folding on the lines of perforation 36, they may be initially formed with lesser strength than -the lines 28. In such a case, L would have a value of 0.010 inches while W would have a value of 0.004 inches with D again remaining a-t 0.01~
inches for single ply forms. The resulting line of perfora-tion may also be utilized advantageously on interior, so-called "vertical perfs" in multiple ply forms as well as on the so-called "s-tub perf" on unit sets.
11 .
In ~che foregoing examples, the value of D is given as 0.014 inches. This value is selected as it enables the blades to cut rela-tively heavy stock, such as tabulator cards, as well as thinner webs or sheets thereby providing greater blade versatility. However, where such versatility is not required, D may be selected to have a value of approximately twice the tota]. thickness of the paper to be perforated and, in general, should not be less than about 0.005 inches greater than the total thickness of the paper to be perforated. Nonetheless~ in instances where scoring of the ties is desirable for the purpose of weakening them to achieve a desired burst strength, or for other purposes, D May have a value less than the total thickness of the paper to be perforated.
The foregoing dimensions are achieved by ap-propriately forming the notches 64. One method of forming the notches to have the requisite dimensions is the use of conventional, wire type, electron discharge machining pro-cesses. Ho~ever, it is believed that the notches 64 could likewise be formed utilizing laser cutting principles.
Turning now to FIG. 5, a rule useful in forming the lines of perforation in mul-tiple ply forms is il-lustrated. The rule illustrated in EIG. 5 includes two types of teeth, the first being designated 70 and the second being deslgnated 72. The various teeth are separated by notches 74 and the same approach to dimensions mentioned in connection with the description of FIG. 4 is employed.
In particular, the cutting dimension of the teeth 70, or L is 0.010 inches for the teeth 70 while W, or the tie dimension, will be 0.008 inches. The depth of the notches 7~, or D, will be approximately 0.025 inches for a four 5~
ply business foxm and should yenerally be 0.005 inches grea-ter than the total thickness to be perforated.
The length of L dimension of the tooth 72 is 0.032 inches and one of the teeth 72 is provided along the perforating edge every 0.255 inches, representing an excep-tion to the preferred maximum tooth length of 0.020 inches. The purpose of this exception is to provide greater strength to the perforating edge.
Because the depth of the notches 74 must necessarily be greater to cut through multiple plies of paper, the teeth 70 are more prone to be deformed under the pressure encountered when they contact the anvil cylinder 20 (FIG.
1). Consequently, wider teeth such as the tooth 72 are provided at intervals such as those mentioned above to increase resistance of the perforating edge to deformation.
For the same reason, the L dimension of the teeth 70 is increased somewhat over that employed for the teeth 62.
Another exception to the general rule of tooth lengths not exceeding 0.020 inches will be found where perforation blades are utilized in die cutting. For ex-ample, die cuts will typically have round or squared corners and to form the corners properly, i-t may be necessary to greatly exceed a cut length of 0.020 lnches at such corners.
Moreover, in some instances, where the forms are provided with both the lines of perEoration 28 and 36, that part of the lines of perforation 28 within the control punch mar-gin, which will be separated Erom the form in any event, may be provided w:ith cuts longer than 0.020 inches as well as ties having a greater dimension than 0.010 inches, since neither will afEect the appearance of the Einished form.
Other examples of specialized applications wherein the preferred dimensions may be exceeded will be appreciated by those skilled in the art.
From the foregoing, it will be appreciated that a perforation blade made according to the invention provides lines of perforation in webs, such as paper webs or sheets, that, when severed, result in edges of the finished product that closely resemble the edges of cut sheet products. Con-sequently, a more personalized and/or cleaner appearing business form results. Moreover, in the case of mass mailings or the like, the carrier strip may be discarded en-tirely providing a paper savings of up to 50%.
Further, there will be a savings in the manufactur-ing operation since the carrier strip need not be formed nor is it necessary to perform the step of tipping cut sheets onto a carrier web. The customer of the form may process the same more economically since he no longer is required to dispose of the carrier web.
The elimination of the carrier web reduces the thickness of a given number of individual form lengths there-by minimizing bulk in both storage and transportation. In the same vein, the weight of the carrier web is eliminated lowering transportation costs.
It will also be appreciated that because of the extremely short length of -the ties 44, even the presence of extremely strong fibers in paper, which fibers are not extending generally parallel to the line of perforation, will not cause the tear to wander. Consequently, perfora-tions of the type disclosed herein may be substituted for punched hole type perforations heretofore required in 1'1 .
many applica-tions, thereby avoiding the need for the purchase of specialized equipment to form such perfora-tions and the extensive mai.ntenance associated therewith.
Claims (16)
1. In a business form including at least one web or sheet of paper having a line of perforation therein formed by cuts through the paper separated by ties and by which part of the form may be separated from the remainder thereof, the improvement wherein said ties have a length along the line of perforation of about 0.010 inches, and said cuts being in sufficient number to provide at least 50 ties per inch along the line of perforation so that said part may be separated from said remainder along said line of perforation without appreciably visible breakage of said ties.
2. The business form of claim 1 wherein said form is a single sheet or web in thickness.
3. The business form of claim 1 wherein said cuts have approximately the same length along said line of perforation.
4. The business form of claim 1 wherein said cuts have a length on the same order as the length of said ties along said line of perforation.
5. The business form of claim 1 wherein said line of perforation is straight.
6. In a continuous business form including an elongated web of paper having at least one control punch margin extending along the length of the web and separated from the remainder of the web by a line of perforation by which the control punch margin may be separated from the remainder of the web, the improvement wherein said line of perforation is formed by alternating cuts extending through the paper and ties between the cuts, the 16.
ties each having a length of about 0.010 inches and said cuts being in sufficient number to provide at least 50 ties per inch of perforation length whereby said control punch margin may be separated from said remainder along an edge having the appearance of a cut edge rather than a perforated edge.
ties each having a length of about 0.010 inches and said cuts being in sufficient number to provide at least 50 ties per inch of perforation length whereby said control punch margin may be separated from said remainder along an edge having the appearance of a cut edge rather than a perforated edge.
7. The business form of claim 6 wherein said ties have a length of 0.008 inches or less.
8. In a continuous business form including an elongated web of paper having transverse lines of perfora-tion upon which the web may be separated to define individ-ual form lengths, the improvement wherein said lines of perforation are defined by cuts extending through the paper and alternating with ties having a length of about 0.010 inches and the cuts being in sufficient number to provide at least 50 ties per inch of perforation length such that the individual form lengths will have edges along said perforation lines that when separated will closely resemble cut edges rather than perforated edges and yet said form will have sufficient strength to prevent inadvertent partial or complete separation along said lines during manufacture and/or subsequent use or processing.
9. The continuous business form of claim 8 wherein said form has at least one control punch margin extending along the length of said web and separated from the remainder of the web by a longitudinal line of perforation, defined by alternating cuts through the paper separated by ties each having a length of about 0.010 inches, said cuts having a length to provide at least 50 ties per inch of perforation length, whereby when said web is separated on said transverse lines and said control punch margin is removed along said longitudinal line, each said individual 17.
form length will have the appearance of a cut sheet.
form length will have the appearance of a cut sheet.
10. The business form of claim 9 wherein said ties have a length of about 0.008 inches and there are sufficient cuts to provide at least about 70 ties per inch of said lines.
11. A blade for perforating webs and having a perfor-ating edge defined by at least 50 tooth-like perforating elements per inch of edge length separated by notches the length of each of the majority of said elements along said edge being no more than 0.02 inches and the width of each notch between said elements being no more than 0.01 inches along the length of said edge.
12. The blade of claim 11 wherein said blade is a rule.
13. The blade of claim 11 wherein said blade is a wheel.
14. The blade of claim 11 wherein the depth of each notch is at least 0.005 inches greater than the thickness of the web or webs to be perforated.
15. A blade for perforating webs and having a perfor-ating edge defined by a series of tooth-like perforating elements separated by notches the width of each notch between said elements being no more than 0.010 inches along the length of the edge the length of each of the majority of said elements being no more than 0.010 inches and wherein there are at least 50 of said elements per inch along the length of said edge.
16. A blade for perforating webs and having a perfor-ating edge defined by a series of tooth-like perforating elements separated by notches the width of each notch between said elements being no more than 0.008 inches along the length of the edge the length of each of the 18.
majority of said elements being no more than 0.010 inches, and wherein there are at least 70 of said elements per inch along the length of said edge.
19.
majority of said elements being no more than 0.010 inches, and wherein there are at least 70 of said elements per inch along the length of said edge.
19.
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US30240181A | 1981-09-15 | 1981-09-15 | |
US302,401 | 1981-09-15 |
Publications (1)
Publication Number | Publication Date |
---|---|
CA1194517A true CA1194517A (en) | 1985-10-01 |
Family
ID=23167594
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
CA000411348A Expired CA1194517A (en) | 1981-09-15 | 1982-09-14 | Fine tooth perforation of webs |
Country Status (2)
Country | Link |
---|---|
JP (1) | JPS58114900A (en) |
CA (1) | CA1194517A (en) |
Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US5005758A (en) * | 1985-12-16 | 1991-04-09 | Eastman Kodak Company | Envelope constructed for ink jet printing |
US5537905A (en) * | 1994-09-08 | 1996-07-23 | Zimmer Industries, Inc. | Nicked cutting rule |
-
1982
- 1982-09-14 CA CA000411348A patent/CA1194517A/en not_active Expired
- 1982-09-16 JP JP16153082A patent/JPS58114900A/en active Granted
Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US5005758A (en) * | 1985-12-16 | 1991-04-09 | Eastman Kodak Company | Envelope constructed for ink jet printing |
US5537905A (en) * | 1994-09-08 | 1996-07-23 | Zimmer Industries, Inc. | Nicked cutting rule |
Also Published As
Publication number | Publication date |
---|---|
JPS58114900A (en) | 1983-07-08 |
JPH0212717B2 (en) | 1990-03-26 |
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