Inserting apparatus and method using a snap-and-burst technique

Abstract

Apparatus uses a burster method to bow a continuous web of inserts and thereafter separates the forwardmost insert from the continuous web. A pair of feed rollers advances the forwardmost insert along a predetermined path toward a pair of burst rollers. Upon receipt of the forwardmost insert, the burst rollers first operate at a decreased relative speed with respect to the advancing speed of the web, thereby bowing the continuous web of inserts. The burst rollers then operate at an increased relative speed with respect to the feed rollers, thereby separating the forwardmost insert.

What is claimed is:  
     
         1 . A method for separating inserts from a continuous web of inserts being connected to each other by a weakened web portion with a bursting apparatus comprising a plurality of rotatable burst rollers and insert sensing means, said method comprising the steps of: 
 (a) advancing the continuous web along an insert path toward a predetermined dispensing location, said insert path extending between said plurality of rotatable burst rollers;    (b) sensing the presence of at least one of the inserts at a sensing position with the insert sensing means;    (c) advancing the continuous web after sensing at least one of the inserts at the sensing position;    (d) bowing the portion of the continuous web that is immediately upstream of said opposed burst rollers; and    (e) bursting the forwardmost insert from the next insert in the continuous web along the weakened web portion by operating said plurality of rotatable burst rollers.    
     
     
         2 . A bursting apparatus capable of performing the method described in    claim 1   , said apparatus further comprising: 
 support means for connection to said plurality of rotatable burst rollers;    a plurality of rotatable feed rollers connected to said support means, said plurality of feed rollers defining a feed roller bight to receive the inserts;    a feed roller drive connected to at least one of said plurality of feed rollers to rotate said feed rollers;    a burst roller drive connected to at least one of said plurality of burst rollers to rotate said burst rollers; and    a controller;    wherein said plurality of rotatable burst rollers is connected to said support means, and wherein said plurality of burst rollers defines a burst roller bight, and wherein said plurality of burst rollers are spaced from said plurality of feed rollers and are oriented to direct the inserts from said feed roller bight to said burst roller bight; and    wherein the controller controls said feed roller drive and said burst roller drive by providing control signals to activate and deactivate said feed roller drive and said burst roller drive in response to signals comprising sensing signals from said insert sensing means, said sensing signal indicative of the presence of or the absence of an insert at a sensing position.    
     
     
         3 . The apparatus as described in    claim 2    wherein the weakened web portions are perforated lines.  
     
     
         4 . The apparatus as described in    claim 2    wherein the sensor comprises a photoelectric sensor.  
     
     
         5 . The apparatus as described in    claim 2    wherein the sensor generates a signal indicative of the presence of an insert at said sensing position.  
     
     
         6 . The method of claim I wherein said bursting apparatus further comprises: 
 support means for connection to said plurality of rotatable burst rollers;    a plurality of rotatable feed rollers connected to said support means, said plurality of feed rollers defining a feed roller bight to receive the inserts;    a feed roller drive connected to at least one of said plurality of feed rollers to rotate said feed rollers;    a burst roller drive connected to at least one of said plurality of burst rollers to rotate said burst rollers; and    a controller;    wherein said plurality of rotatable burst rollers is connected to said support means, and wherein said plurality of burst rollers defines a burst roller bight, and wherein said plurality of burst rollers are spaced from said plurality of feed rollers and are oriented to direct the inserts from said feed roller bight to said burst roller bight.    
     
     
         7 . The method of    claim 6    wherein said controller controls said feed roller drive and said burst roller drive by providing control signals to activate and deactivate said feed roller drive and said burst roller drive in response to signals comprising sensing signals from said insert sensing means, said sensing signal indicative of the presence of or the absence of an insert at a sensing position.