Folder pocket divider and method of construction

Abstract

Installable and removable inserts for pocket folders and their method of manufacturer are shown and described. Inserts have spaced part divider panels which are anchored to a base plate or form a base plate. In one embodiment, a single plate divider also forms the base and one upright divider while another element with two dividers is bonded to the base. In another embodiment two separate upright dividers are bonded together at a common upright wall and the pair is then bonded to a base. Other embodiments are disclosed.

Claims

1. A method of forming a unitary web material into a divider system for insertion into a pocket folder, comprising the steps of: a. cutting a blank of web material defining right and left edges and a center dividing line therebetween thereby defining left and right divider panels; b. forming first fold lines in said web material spaced from and parallel with said center dividing line on both left and right divider panels; c. forming second fold lines in said web material spaced from and parallel with said second fold line, on both left and right divider panels and thereby defining a portion between said first and second fold line and defining a foot region between first fold lines on right and left panels; d. folding said web material on said first and second fold lines to fold said portion onto foot region and adhering said portion to said region on both left and right panels; e. folding said second fold line to permit said left and right panels to be generally oriented orthogonally to said foot portion.

2. A method of forming a unitary web material into a divider system for insertion into a pocket folder, comprising the steps of: a. cutting a blank of web material into a unitary sheet, having right and left edges and a center dividing line therebetween thereby defining left and right divider panels and a central foot panel; b. upwardly folding said divider panels vertically with respect to the foot panel, thereby defining first fold lines at the intersection between the divider and foot panel; c. inwardly folding said foot panel along a second fold line spaced from but parallel to the first fold line to create an overlapping portion between said first and second fold lines and adhering said overlapping panel to said foot panel thereby creating a double web portion; d. upwardly folding said on both left and right divider panels at said second fold line, thereby defining a pair of upright divider panels with a spaced therebetween, all made from a unitary web.

3. The method of claim 2 wherein said step of adhering includes gluing.

4. The method of claim 3 wherein folding includes first scoring and then folding.

5. The method of claim 4, wherein scoring including scoring a center fold line and a scoring a line on either side of the central fold line.

6. The method of claim 5 wherein the scores on either side of the central fold line score are sharper than the central fold line score.

Description

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

(1) FIG. 1 is a perspective view of a pocket folder.

(2) FIG. 2 is a perspective view of pocket folder showing dividers and papers.

(3) FIG. 3 is a top plan view of the sidewalls and bottom of the pocket folder.

(4) FIG. 4 is a perspective view of left and right gussets for the pocket folder.

(5) FIG. 5 is a perspective view of an insert unit for a pocket folder.

(6) FIG. 6 is a front plan view of FIG. 5.

(7) FIG. 7 is a close up fragmentary view of a portion of FIG. 5.

(8) FIG. 8 is a top plan view of a second embodiment of one portion of the insert unit.

(9) FIG. 9 is a perspective view of an embodiment with 3 element divider with a board base.

(10) FIG. 10 is a side view of FIG. 9.

(11) FIG. 11 is a close up fragmentary view of a portion of FIG. 9.

(12) FIG. 12 is a top plan view of one portion of a 3 element insert unit.

(13) FIG. 12A is a top plan view of a base plate before installation in FIG. 9.

(14) FIG. 13 is close up fragmentary exploded view of 2 portions separated before back to back bonding.

(15) FIG. 14 is a perspective view of a further embodiment of a three element divider unit.

(16) FIG. 15 is a side plan view of FIG. 14.

(17) FIG. 16 is a close up fragmentary perspective view of the embodiment in FIG. 14 before bonding along fold lines to illustrate overlapping layers.

(18) FIG. 17 is a side plan view of FIG. 14.

(19) FIG. 18 is an end plan view of FIG. 17.

(20) FIG. 19 is a top plan view of a base plate before installation in FIG. 14.

(21) FIG. 20 is a perspective view of a 3 element divider without a separate base board.

(22) FIGS. 20a/20b illustrate an end view of a divider to create a gap with the outer walls first in the unfolded position (FIG. 20a) and then the folded position (FIG. 20b).

(23) FIG. 21 is a side view of FIG. 20.

(24) FIG. 22 is a close up fragmentary view of part of FIG. 20 before bonding to a base portion.

(25) FIG. 23 is a plan view of an element for first and second dividers in a three divider system, unfolded.

(26) FIG. 24 is a close up fragmentary view of an element in a folded state.

(27) FIG. 25 is a plan view of a third element which works with the element in FIG. 23.

(28) FIG. 26 is a close up fragmentary view of a portion of FIG. 20 before bonding.

(29) FIG. 27 is an end schematic view of three scoring tools.

(30) FIG. 28 is view like FIG. 27 applied to a sheet to be scored.

(31) FIG. 29 is a close up fragmentary view of a portion of FIG. 28.

DETAILED DESCRIPTION

(32) This disclosure describes file folder, sometimes known as a pocket, and a removable divider system, and method of manufacturer and assembly. The removable divider system may be used with containers other than a file or pocket, such as a box or filing cabinet. For simplicity we will refer to all containers as a pocket. The divider may be removable or affixed permanently.

(33) A method of manufacturer is also disclosed by the drawings and description.

(34) Pocket 10 in FIGS. 1-6 show a unitary blank with a front extension panel 12, first panel 14a and second panel 14b. The extension panel 12 extending laterally from the second panel 14a along fold lines 20 which are formed of a plurality of zig zag/accordion fold lines which provide for expansion. It is also possible to construct this pocket without the accordion folds and be merely flat, without expansion capability. Extension panel 12 extends from panel 14a/b along fold lines 20, panel 12 which becomes the front panel when folded, includes a pair of flaps 30, 32 which complete the folder when the flaps are adhered to the back panel. Hap 30 is an extension of the front panel along the longitudinal edge and 32 is an extension along the lateral edge along fold lines 34, 26.

(35) In order to insure that there will be tab/writing space 40, visible at the top (distal) edge of each panel, it is preferably to offset/cut away a portion of panel 12 at its top tab edge 42. This offset 43 (shown in broken lines as an option) provides exposure of the tab section 40 of panel 14a by being shorter than panel 14b.

(36) In FIG. 4, the left and right sidewalls 120 (identical) can be seen. These sidewalls are affixed to the folded portions 30/32 of the panels 14a/b. The gusset 120 comprises a material which is repeatedly folded on top of itself in a well-known manner. The folded gusset 120 has an accordion-like expansion capability of zig zag folds 120 which permits the pocket 10 to gradually expand as it is filled with items to be stored.

(37) The insert unit 200 is shown in FIGS. 5-9 and partially visible in FIG. 2. It can be constructed in multiple ways, but the preferred construction is that it is a unitary element which is emplaced in the pocket and can be removed as desired.

(38) In FIG. 5, unit 200 is shown to have two spaced apart vertical walls 202/204 which are joined at their bottom by connector portion 206. The connector is formed differently in different embodiments.

(39) The embodiment shown in FIG. 6 is formed of a single unitary structure but may have extra optional score and fold lines which allow for user adjustment of the gap between panels. Insert unit 200 is formed from a single piece of stock, preferably a cardboard or semi rigid material typical of file folder stock. A series of fold line scores are formed in the connector portion 206. Between the scores, are regions 206a, 206b, 206c on either side of the floor portion 206d. The scores therefore are symmetrical about the floor 206d.

(40) In this embodiment, the stock is folded between 206b and 206c with portions 206b/206c glued/affixed to portion 206d. This occurs on both sides of 206c. The result is that two flanges/feet are created by the span of 206b/206c affixed to 206d. When inserted into the pocket, these feet provide stability and inhibit movement of the unit within the pocket especially when the pocket is filled with papers which thereby press the feet into the bottom of the pocket. It is also possible for the feet to be glued to the pocket or held in by a removable adhesive system such as Velcro or releasable glue.

(41) Notice that the both portions 206a and 206b overlie 206c/206d in this embodiment. This is so that the score between the portions 206a/206b can be folded upwardly on both sides so that the span of the foot is reduced by the width of 206a according to user needs. This feature, of extra score and fold lines can also be incorporated in all embodiments to provide easy user adjustment of the panel spacing, at least with respect to the panels which face the sidewalls of the pocket folder. If the desired width of the pocket is W1 then the portions 206b/206c are folded up. If the desired width of the pocket is W2, then portions 206a/206b are allowed to remain flat or orthogonal to panels 202/204. Thus, in this embodiment, the width of the foot is adjustable. It is within the scope of this invention to provide additional score lines parallel with those shown to provide additional foot width adjustment.

(42) Likewise, in an alternate embodiment, portions 206a (or 206b) may be eliminated if no adjustment is desired.

(43) FIGS. 7 and 8 illustrate a simplified structure with fewer scores and folds. Panels 202/204 are scored and folded to create a region 206a which is scored and folded onto floor section 206, which can be of varied width according to need. Region 206a and 206b are bonded/glued to form the structure of FIG. 5.

(44) FIGS. 9-12A illustrate alternate embodiments which have more than 2 divider elements. Three elements are shown, but additional elements are possible by replication of structures shown and described.

(45) FIG. 9 illustrates a divider with a base 206 with three divider panels 202, 203 and 204. In this embodiment panel 203 is actually a double walled panel which results from scoring a pair of folder units 302/304 (FIG. 12) having faces 304\6/308/310/312 and bonding common abutting faces 308/310 or 306/312 as shown in FIG. 13 before bonding, and in FIG. 11 after bonding. In this embodiment, the middle divider panel with double thickness. It will be appreciated that any number of additional folder units 302 can be added to increase the number of dividers.

(46) To form the base for this embodiment is a separate element 206 which is then bonded to the floor sections 320 (typically horizontal portions) of the folder units.

(47) FIGS. 14-19 illustrate a further embodiment of a divider with three panels as in the previous embodiment but where there are no double walled portions. In this embodiment, each divider has a upright portion 402, 404, 406, a scored and folded line 410 and a region 412 folded generally 90 degrees of the upright portion as shown if FIG. 18. Tabs are 414 are shown in their respective 1.sup.st, 2.sup.nd and 3.sup.rd regions as known in the art for tabbed dividers. More, less or no tabs can be provided.

(48) FIG. 16 illustrates how the panels 402 404 406 are applied to the base 206 and bonded thereto. The final assembly is shown in FIG. 14.

(49) FIGS. 20-26 illustrate a further embodiment where there is no separate bottom element but it is integral to parts of one of the divider units.

(50) FIGS. 23-24 illustrate the construction of this 2 part embodiment. Folder section 302 and 303 having panels 306, 308, 309 and 310 are scored and folded along score lines shown. Section 302 forms two divider panels 306 and 308 with a bottom 308a which will ultimately be bonded to portion 310 of divider 303. Folder section 303 includes a divider panel 309 and also forms the base 303b (corresponding to base 206 in other embodiments).

(51) The assembly is shown if FIGS. 20 and 22. Section 303 is folded twice as score lines 350 and then again at 352 creating a narrow strip 302a corresponding to the width between divider panels 308 and 309. As seen in FIG. 22 the first fold 303a is folded and then bonded to base 303b to establish the first divider panel 303 and simultaneously the base 303b which receives the second panel unit 302 thereon and spaced from panel 309 to create a gap between plane sections. FIGS. 20a-20b illustrate this gap more clearly in folded (FIG. 20b) and unfolded (FIG. 20a) positions.

(52) The scoring of material is illustrated in FIGS. 27-29. In the preferred embodiment, longitudinal scoring and folding is accomplished by tools 510, 512 and 514 shown in their end view. From above, they would appear has longitudinal bars with the tips as shown in the figures. Where a score is desired, the point tip 520 is preferred with a preferred tip angle of approximately 52 degrees. Where a rounded corner is desired, a score bar 512 with a rounded tip 522 is employed. The preferred radius of the rounded tip is approximately 0.042 inch (1.06 mm). All scores on all material are preferably accomplished at the same time by adjusting the spacing between score bars. To make scores and folds in a single unitary sheet in one stroke, the fold scoring/folding tool has sharp pointed tips located above fold lines and rounded tips above locations needed only score lines.

(53) The method of manufacturer is to cut a single unitary blank and score an assemble the blank in accordance with the structure shown and bond elements also as shown. Unitary means that the material is a continuous web, not joined from separate pieces. The preferred cut pattern is as follows: a back panel with first and second sides having bottom edges and separated by a central fold line, the first side including a foldable extension panel which extends beyond the bottom edge. The extension forms the front panel of a foldable pocket and has lateral flaps.

(54) The above description and its applications as set forth herein is illustrative and is not intended to limit the scope of the invention. Variations and modifications of the embodiments disclosed herein are possible and practical alternatives to and equivalents of the various elements of the embodiments would be understood to those of ordinary skill in the art upon study of this patent document. These and other variations and modifications of the embodiments disclosed herein may be made without departing from the scope and spirit of the invention.