U.S. patent application number 10/839880 was filed with the patent office on 2005-05-12 for system and method for producing personalized imaged material.
This patent application is currently assigned to Solar Communications, Inc.. Invention is credited to Hudetz, Peter R..
Application Number | 20050097866 10/839880 |
Document ID | / |
Family ID | 34437425 |
Filed Date | 2005-05-12 |
United States Patent
Application |
20050097866 |
Kind Code |
A1 |
Hudetz, Peter R. |
May 12, 2005 |
System and method for producing personalized imaged material
Abstract
A system and method for producing personalized imaged material
includes selectively gathering stock sheets and assembling the
stock sheets into designated sets of sheets, or in an alternative
method, sequentially feeding the stock sheets. The stock sheets in
each designated set of sheets are sequentially processed to image
personalized information onto the stock sheets. The personalized
sheets are sequentially presented for finishing, which can include
associating an additional item with the personalized sheets.
Processing is carried out by collators, feeding systems, and
variable data imaging systems, and finishing systems. Operational
control is provided by a control system that includes a data
structure containing user information and recipient profile
information. An operations controller executes job requests for a
particular user and accesses recipient profiles to image
personalized information onto the stock sheets. The system and
method are useful for direct marketing, invoicing, document
preparation, preparation of personalized books, and the like.
Inventors: |
Hudetz, Peter R.;
(Naperville, IL) |
Correspondence
Address: |
BRINKS HOFER GILSON & LIONE
P.O. BOX 10395
CHICAGO
IL
60610
US
|
Assignee: |
Solar Communications, Inc.
|
Family ID: |
34437425 |
Appl. No.: |
10/839880 |
Filed: |
May 4, 2004 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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10839880 |
May 4, 2004 |
|
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10712291 |
Nov 12, 2003 |
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Current U.S.
Class: |
53/474 |
Current CPC
Class: |
B41J 13/103 20130101;
B41J 11/50 20130101; B65H 2301/4311 20130101; B41J 13/08 20130101;
B65H 39/043 20130101; B41J 11/0085 20130101 |
Class at
Publication: |
053/474 |
International
Class: |
B65B 061/20 |
Claims
1. A method for producing personalized imaged material comprising:
(a) selectively ejecting predetermined stock sheets from a
plurality of sheet feeders; (b) sequentially processing the stock
sheets to image personalized information onto the stock sheets to
form personalized sheets; and (c) sequentially finishing the
personalized sheets.
2. The method of claim 1, wherein sequentially finishing the
personalized sheets comprises packaging the personalized sheets
with one or more additional items.
3. The method of claim 2, wherein packaging the personalized sheets
comprises providing a package and associating an object with the
package.
4. The method of claim 3, wherein associating an object with the
package comprises inserting the object into the package.
5. The method of claim 3, wherein associating an object with the
package comprises attaching the object to the package.
6. The method of claim 3, wherein associating an object with the
package comprises attaching the object to at least one of the
personalized sheets.
7. The method of claim 3, wherein associating an object with the
package comprises associating an object selected from the group
consisting of product samples, vouchers, and marketing aids.
8. The method of claim 1, wherein sequentially finishing the
personalized sheets comprises: (a) folding the personalized sheets
to form a folded package; and (b) sealing the folded package.
9. The method of claim 8 further comprising imaging personalized
indicia on an outer surface of the folded package.
10. The method of claim 1 wherein selectively ejecting
predetermined stock sheets comprises: (a) providing a multi-bin
collator, wherein each bin contains stock sheets having
predetermined indicia thereon; and (b) activating selected bins in
response to control signals from a control system and feeding the
stock sheets from the selected bins onto a conveyance device,
wherein the conveyance device sequentially delivers the stock
sheets to the imaging system.
11. The method of claim 10 further comprising scanning the package
for verification and aligning the package prior to imaging.
12. The method of claim 1, wherein sequentially finishing the
personalized sheets comprises inserting each of the personalized
sheets into a package.
13. A method for producing personalized printed material
comprising: (a) selectively gathering stock sheets and assembling
the stock sheets into designated sets of sheets; (b) sequentially
processing the stock sheets in each designated set of sheets to
image personalized information onto the stock sheets; (c)
re-gathering the stock sheets into the designated sets of sheets;
and (d) packaging the designated sets of sheets with additional
items.
14. The method of claim 13, wherein packaging the designated sets
of sheets with additional items comprises associating an object
with the designated sheets.
15. The method of claim 14, wherein associating an object with the
designated sheets comprises providing a package and inserting the
object into the package.
16. The method of claim 14, wherein associating an object with the
package comprises attaching the object to the package.
17. The method of claim 14, wherein associating an object with the
package comprises attaching the object to the personalized
sheet.
18. The method of claim 14, wherein associating an object with the
package comprises associating an object selected from the group
consisting of product samples, vouchers, and marketing aids.
19. The method of claim 14, wherein associating an object with the
package comprises inserting a personalized sheet into a
package.
20. A method for producing personalized printed material
comprising: (a) selectively gathering stock sheets and assembling
the stock sheets into designated sets of sheets; (b) sequentially
processing each stock sheet into a feeding system (c) imaging
personalized information onto the stock sheets; (c) re-gathering
the stock sheets into the designated sets of sheets; and (d)
presenting the designated sets of sheets for final processing.
21. The method of claim 20, wherein sequentially processing each
stock sheet into a feeding system comprises transporting the
designated sets of sheets from a collator to the feeding system,
and wherein the feeding system operates at a rate of about 1 to
about 50 times faster than the transport rate of the collator.
22. The method of claim 21, wherein the feeding system comprises a
re-feeder system.
23. The method of claim 21, wherein the feeding system comprises a
rotary feed system.
24. The method of claim 20, wherein selectively gathering stock
sheets comprises: (a) providing a multi-station collator; and (b)
activating selected bins in response to control signals from a
control system.
25. The method of claim 24, wherein imaging personalized
information comprises transferring the stock sheets from the
multi-station collator to an imaging system.
26. The method of claim 25, wherein the designated sets of sheets
have a varying number of stock sheets, and wherein the operating
speeds of multi-station collator, the feeding system, and the
imaging system are synchronized such that the stock sheets are
processed at substantially constant throughput rate.
27. A method for producing personalized imaged material comprising:
(a) selectively ejecting predetermined stock sheets from a
plurality of sheet feeders to form a sequential order of stock
sheets, wherein each stock sheet contains specified indicia
thereon; (b) sequentially processing the stock sheets to image
personalized information onto the stock sheets to form personalized
sheets; and (c) associating an additional item with each
personalized sheet, wherein a feature of the additional item is
related to one or both of the specified indicia or the personalized
information.
28. The method of claim 27 further comprising: (a) folding the
personalized sheets to form a folded package containing the
additional item; (b) sealing the folded package; and (c) imaging
personalized indicia on an outer surface of the folded package.
29. The method of claim 27 further comprising: (a) imaging
personalized indicia on an inner surface of the personalized
sheets; (b) folding the personalized sheets to form a folded
package containing the additional item; and (b) sealing the folded
package.
30. The method of claim 27 wherein selectively ejecting
predetermined stock sheets comprises: (a) providing a multi-bin
collator, wherein each bin contains stock sheets; and (b)
activating selected bins in response to control signals from a
control system and feeding the stock sheets from the selected bins
onto a conveyance device, wherein the conveyance device delivers
the stock sheets to the imaging system in the sequential order.
31. A method for producing personalized imaged material comprising:
(a) providing a multi-bin collator, wherein each bin contains stock
sheets having predetermined indicia thereon; (b) activating
selected bins in response to control signals from a control system
and feeding one or more stock sheets from the selected bins onto a
conveyance device; (c) sequentially processing the stock sheets to
image personalized information onto the stock sheets to form
personalized sheets; and (d) sequentially finishing the
personalized sheets.
32. The method of claim 31, wherein the stock sheets comprise
sheets having predetermined indicia selected from the group
consisting of marketing information, advertising information,
invoice information, and event information.
33. The method of claim 31, wherein the stock sheets comprise
sheets having advertising information thereon, and wherein
personalized information comprises coupon information.
34. The method of claim 31, wherein the stock sheets comprise
sheets having invoice information thereon, and wherein personalized
information comprises usage and billing amounts.
35. The method of claim 31, wherein the stock sheets comprise
sheets having event information thereon, and wherein personalized
information comprises seating and ticket price information.
Description
RELATED APPLICATION
[0001] This application is a continuation-in-part of
commonly-assigned, co-pending patent application Ser. No.
10/712,291, filed Nov. 12, 2003, the subject matter of which is
incorporated by reference herein.
TECHNICAL FIELD
[0002] The present invention relates, generally, to collation and
selective insertion of imaged material, and more particularly, to
systems and methods for dynamic insertion and custom finishing of
printed material.
BACKGROUND
[0003] With the advent of computer technology, a wide variety of
processing and handling system are now available to produce
customized printed material. High volume production of selectively
inserted printed material and packaging of the printed material can
now be performed by computer-controlled equipment. Large volume
production of advertising materials, account statements, and bulk
mailing can be carried out using high-volume collation and
packaging systems. For example, bulk mailing systems can place
several enclosures or inserts into packages intended for mailing to
selected recipients. The packages typically include common items
that are sent to all recipients and additional items inserted into
the package for selected recipients. The creation of mailing
packages containing individualized inserts can only be realized on
a cost-effective basis through the use of automated, high-speed
equipment.
[0004] The preparation of individualized packages of printed
material requires the use of scanning technology for product
quality control. Typically, selective insertion systems employ
machine readable indicia printed on control documents to ensure the
proper printed materials are enclosed within a designated package.
In one such system, selected inserts are placed into billing
statements under the control of an integrated system controller.
The controller directs selective insertion of enclosures into the
billing statements. The system controller directs the inserter to
selectively include inserts with the billing statement according to
instructions from a data processor.
[0005] Selective insertion systems are also used to place inserts
into bulk mailing items, such as advertising mailers and
advertising inserts within newspapers. In one such system,
newspapers are collated with materials that vary depending upon the
product interest of selected newspaper subscribers. In addition to
placing selective inserts within the newspaper, the system also
prints indicia identifying the selected subscriber on a jacket of
the newspaper.
[0006] High-speed, computer-controlled processing equipment is also
used for permit and pre-sort bulk mailing for delivery to the U.S.
Postal Service. Scanning equipment is used to pre-sort bulk
mailings and to inspect and verify that mail pieces have been
properly pre-sorted and proper postage applied. Such systems
include stacking structures for accommodating a plurality of like
stationery items. Printing systems are used to print various parts
of information stored by a computer system on selected stationery
items from the stacking structure. Identification marks are placed
on the stationery items for use by the U.S. Postal Service for
marking and identifying pre-sorted letters.
[0007] Automated systems have also been developed that validate the
sequence and package completeness of output from a high-speed
printer. The equipment can add covers and inserts and, if required,
bind the printed material together in a variety of ways and place
the printed material in a package. The systems are configured to
assemble a variety of documents, such as insurance policies,
contracts, instructional materials, parts and repair manuals, and
business reports of various types. For example, the system can
place particular clauses within insurance policies that are to be
selectively mailed to policy holders residing in a particular
state. The automated printing and assembly equipment thus enables
large volume distribution of insurance policies and other documents
that contain particular information relevant to selected
recipients.
[0008] Although computer controlled systems have enabled
development of high-volume printed material handling systems,
systems and methods have yet to be developed to address the
particular need for individualized finished printed material.
Further, advancements in system configuration are necessary to
fully realize the potential of advanced printing and handling
systems. Accordingly, a need existed for systems and methods to
address a wide variety of applications for personalized printed
material and finishing of the printed material.
SUMMARY
[0009] In an embodiment of the invention, a method for producing
personalized imaged material includes selectively ejecting
predetermined stock sheets from a plurality of sheet feeders. The
stock sheets are sequentially processed to image personalized
information onto the stock sheets to form personalized sheets and
the personalized sheets are sequentially finished.
[0010] In another embodiment of the invention, a method for
producing personalized printed material includes selectively
gathering stock sheets and assembling the stock sheets into
designated sets of sheets. The stock sheets in each designated set
of sheets are sequentially processed to image personalized
information onto the stock sheets. The stock sheets are then
re-gathered into the designated sets of sheets and packaged with
additional items.
[0011] In yet another embodiment of the invention, a method for
producing personalized printed material includes selectively
gathering stock sheets and assembling the stock sheets into
designated sets of sheets. Each stock sheet is sequentially
processed into a feeding system and personalized information is
imaged onto the stock sheets. The stock sheets are re-gathered into
the designated sets of sheets presented for final processing.
[0012] In still another embodiment of the invention, a method for
producing personalized imaged material includes selectively
ejecting predetermined stock sheets from a plurality of sheet
feeders to form a sequential order of stock sheets. Each stock
sheet contains specified indicia thereon. The stock sheets are
sequentially processed to image personalized information onto the
stock sheets to form personalized sheets. Each personalized sheet
is associated with an additional item, where a feature of the
additional item is related to one or both of the specified indicia
or the personalized information.
[0013] In a further embodiment of the invention, a method for
producing personalized imaged material includes providing a
multi-bin collator, where each bin contains stock sheets having
predetermined indicia thereon. Selected bins are activated in
response to control signals from a control system and one or more
stock sheets are fed from the selected bins onto a conveyance
device. The stock sheets are sequentially processed to image
personalized information onto the stock sheets to form personalized
sheets and the personalized sheets are sequentially finished.
BRIEF DESCRIPTION OF THE DRAWING
[0014] FIG. 1a is a front view of an exemplary pre-printed sheet
that may be used as a stock sheet in accordance with the
invention;
[0015] FIG. 1b is a front view of the stock sheet illustrated in
FIG. 1a having personalized information printed thereon;
[0016] FIG. 2a is a front view of an insert sheet that may be used
as an addressing vehicle in accordance with the invention;
[0017] FIG. 2b is a front view of the insert sheet illustrated in
FIG. 2 having personalized information printed thereon in
accordance with the invention;
[0018] FIG. 3a is a schematic block diagram of a control system
arranged in accordance with the invention;
[0019] FIG. 3b is a schematic block diagram of a general
information file structure in accordance with the invention;
[0020] FIG. 3c is a schematic block diagram of customer data files
in accordance with the invention;
[0021] FIG. 4a is a schematic diagram of two exemplary collation
systems arranged in accordance with the invention;
[0022] FIG. 4b is a schematic diagram of a re-feeder, an imaging
system, and a re-gathering system arranged in accordance with the
invention;
[0023] FIG. 4c is a top view of the schematic diagram illustrated
in FIG. 4b and including additional components of a packaging
system arranged in accordance with the invention;
[0024] FIG. 4d is a schematic diagram of an insertion and imaging
system arranged in accordance with the invention;
[0025] FIG. 5 is a flow diagram illustrating a process control
sequence for a single-lane machine in accordance with the
invention;
[0026] FIG. 6 illustrates another embodiment of a process control
sequence for a single-lane machine in accordance with the
invention;
[0027] FIG. 7 illustrates a process control sequence for a
single-lane machine arranged in accordance with a further
embodiment of the invention;
[0028] FIG. 8 is a schematic top view of a dual-lane machine
arranged in accordance with one embodiment of the invention;
[0029] FIG. 9 is a schematic top view of a dual-lane machine
arranged in accordance with another embodiment of the
invention;
[0030] FIG. 10 is a flow diagram of a process control sequence for
a dual-lane machine in accordance with the invention;
[0031] FIG. 11 illustrates a process control sequence for a
dual-lane machine in accordance with another embodiment of the
invention;
[0032] FIG. 12 is a schematic diagram of a sequential collation and
imaging system arranged in accordance with another embodiment of
the invention;
[0033] FIG. 13 is a schematic diagram of a finishing system
including a folding, labeling, and imaging system arranged in
accordance with one embodiment the invention;
[0034] FIG. 14 is a top view illustrating the folding, labeling,
and imaging operation carried out by the finishing system
illustrated in FIG. 13;
[0035] FIG. 15 is a schematic diagram of a finishing system
arranged in accordance with one embodiment the invention for
associating an object with a package or with a personalized sheet;
and
[0036] FIGS. 16a-16c are top views illustrating a sequential
imaging and finishing process in accordance with an embodiment of
the invention.
[0037] It will be appreciated that for simplicity and clarity of
illustration, machine elements shown in the Figures have not
necessarily been drawn to scale. For example, the dimensions of
some of the elements are exaggerated relative to others for
clarity. Further, where considered appropriate, reference numerals
have been repeated among the Figures to indicate corresponding
elements.
DETAILED DESCRIPTION
[0038] The present invention provides a system and method for
low-cost, high-volume production of personalized printed materials.
A computerized processing system enables a wide range of imaged
materials to be automatically processed and packaged for delivery
to recipients. The system and method of the invention can be
utilized to address numerous applications including, but not
limited to, direct marketing, invoice preparation, customized
documentation preparation, and the like. The computer control
processing system enables the storage of large quantities of
information concerning various aspects of the recipients of the
personalized imaged materials. The computerized control system also
enables storage of user information that can be selectively coupled
with recipient information to provide personalized imaged materials
to selected recipients based on user criteria and recipient data
files.
[0039] As will become apparent from the following description, the
various embodiments of the invention are designed with maximum
flexibility to enable the use of the system for a wide variety of
applications and the preparation of small and large volume imaged
material production. Although the exemplary embodiments of the
invention described below generally relate to direct marketing,
those skilled in the art will appreciate that the system and method
of the invention can equally be applied to a wide variety of
different imaged materials.
[0040] Shown in FIG. 1a is a front view of a pre-printed sheet 20.
In the illustrative embodiment, pre-printed sheet 20 includes
indicia 22 showing the source of the pre-printed sheet, in this
instance Solar Communications, Inc., the assignee of the present
invention and a coupon blank 24. In accordance with the invention,
pre-printed sheet 20 can be one of many such pre-printed sheets
having a variety of coupon blanks and different provider indicia.
The provider indicia can vary in a number of ways including
different products, different advertising information, and
different providers, which may be divisions of a single business
entity or different business entities. As used herein, the term
"indicia" is intended to apply to all forms of imaged information
including identifying marks, printed text, graphic elements, and
the like.
[0041] FIG. 1b is a front view of pre-printed sheet 20 after
processing in the system of the invention to image personalized
information thereon. In accordance with one aspect of the
invention, pre-printed sheet 20 has been subjected to an imaging
process to place customized indicia 26 and 28 on coupon blank 24.
As a result of the imaging process, coupon blank 24 now includes a
particular value, shown as indicia 26, and a barcode, shown as
indicia 28, for identification and tracking purposes. By processing
pre-printed sheet 20 through the imaging system of the invention, a
stock sheet has been processed to place personalized information
onto the stock sheet. In accordance with the invention, numerous
additional customized or personalized indicia can be imaged onto
pre-printed sheet 20. For example, specific products, additional
pricing information, and the like, could also be imaged on
pre-printed sheet 20.
[0042] A front view of an exemplary insert sheet 30 is illustrated
in FIG. 2a. Insert sheet 30 includes provider indicia 32. Insert
sheet 30 can be one of a number of different inserts, including an
addressing insert for mailing purposes, a special insert
identifying additional products or services, and the like. In the
aspect of the invention where insert sheet 30 functions as an
addressing vehicle, personalized information in the form of a
recipient address 34 is placed on insert sheet 30, as illustrated
in FIG. 2b. Additionally, further provider information 36 can also
be imaged onto insert sheet 30 prior to packaging. Those skilled in
the art will appreciate that numerous additional indicia can also
be imaged onto insert sheet 30 including additional provider
information, package opening incentives, and the like.
[0043] A computer control system for preparing personalized printed
material in accordance with the invention is illustrated in FIG.
3a. The control system includes a data structure 38 that is
interfaced to an operations controller 40. Data structure 38
includes an information database that includes a wide variety of
provider and recipient information. The provider information can
include source identification information, brand information,
specific product information, market pricing, and discount
information, and the like. The information database can also
include recipient information, such as identification, product
preferences, store preferences, geographic location, and the like.
In another aspect of the invention, information database 42 can
include information relating to additional applications of the
invention, such as invoicing, custom document preparation,
preparation of personalized books, and the like. Where the provider
is, for example, a service company, such as a utility company, the
provider information can include regional rate information, billing
code information, invoice routing information, and the like. The
recipient information could include annual usage information,
special fees or rate information, rate discount information, and
the like. Further, where the provider is a book publisher or
distributor, the recipient information could include, for example,
names for insertion into personalized books, such as, for example,
children's books, and the like.
[0044] In accordance with the invention, the assembled information
in information database 42 is organized into general information
files 44 and specific information files 46. FIG. 3b illustrates an
example of the file organization within general information files
42. The file database includes user profile data 48 and various
topic category files 50. The content of user profile data 48 will
depend upon the particular business activity of the user, in
addition to the number and type of user locations, the particular
products or services offered by the user, and the like. Topic
category 50 can include particular product information, such as
product type, product brand, general pricing information, such as
discounts, and the like.
[0045] Specific information files 46 can include numerous data
relating to specific recipients of the personalized printed
materials. As illustrated in FIG. 3c, the recipient data files can
include identification information, specific pricing applying to a
specified recipient or groups of recipients, product preferences
for individual recipients and groups of recipients, store
preferences of individual recipients, geographic location of
particular recipients, and the like.
[0046] Those skilled in the art will appreciate that the
architecture of data structure 38 described above is but one of
many different possible architectures of a data structure for the
present invention. Depending upon the particular application of the
present invention, data structure 38 can have additional
information files from those described above. For example,
additional information files can include regulatory information,
statutory information, and the like. In accordance with the
invention, as illustrated in FIG. 3a, operations controller 40 is
interfaced with a variety of processing systems used in the
production of personalized imaged material.
[0047] Operations controller 40 provides command and control
instructions to one or more collators 52, refeeders 54, imaging
systems 56, inserters 58, and finishing systems 60. Operations
controller 40 responds to commands to provide personalized printed
materials intended for particular recipients as requested by
specific users.
[0048] A system manager 62 responds to input instructions from
operations personnel and instructs operations controller 40 to
prepare sets of personalized printed material using particular data
files maintained in data structure 38. System manager 62 initiates
and maintains all of the data files within data structure 38 and,
accordingly, maintains an awareness of the status of all data files
in data structure 38.
[0049] Those skilled in the art will appreciate that the functions
of system manager 62 and operations controller 40 can be carried
out by electronic devices, such as microprocessors,
microcontrollers, and the like. Further, the databases maintained
in data structure 38 can be stored in hard memory devices, such as
dynamic-random-access-memory (DRAM), static-random-access-memory
(SRAM), on-board memory structures, and the like. System operators
can enter command instructions to system manager 62 and data into
data structure 38 through any of a number of different input/out
devices, such as computer terminals, voice-activated systems,
scanning devices, and the like.
[0050] Upon receiving instructions in the form of a job request
from system manager 62, operations controller 40 matches the job
request information with user profile data 48 and topic category
files 50 with one or more recipient data files in specific
information files 46. Once the user information and recipient
information is matched, operations controller 40 relays command
signals to the various operating equipment to produce the requested
personalized printed material.
[0051] FIGS. 4a-4d illustrate one embodiment of a single-lane
machine for practicing the present invention. The various
components making up the single-lane machine include a collator 70,
a re-feeder 72, an imaging system 74, a re-gathering system 76, and
a finishing system 78. The single-lane machine can also include an
insertion system 80 and a second imaging system 82.
[0052] In accordance with the invention, collator 70 can be one of
several different types of collators. Two exemplary collators are
schematically illustrated in FIG. 4a. A vacuum and rotary feed
collator 84 includes a bin 86 that gravity feeds stock sheets 88 to
a rotary feed device 90. Rotary feed device 90 in conjunction with
a belt 92 sequentially feeds stock sheets 88 onto the spaces
between conveyor lugs 94. Conveyor lugs 94 are distributed along
conveyor system 96. As conveyor system 96 moves in a lateral
direction from left to right, rotary feed device 84 feeds stock
sheets 88 onto the space between conveyor lugs 94 in response to
commands received from operations controller 40 through a system
relay 98. System relay 98 activates rotary feed device 84 in
response to instructions from operations controller 40 and returns
operational status information to operations controller 40.
[0053] In accordance with one embodiment of the invention, a number
of rotary feed systems 84 are positioned above and laterally
distributed along conveyor system 96. Each of the rotary feed
systems supplies a stock sheet from its bin onto select spaces on
conveyor system 96. After a select space has passed beneath several
rotary feed systems 84, a designated set of sheets 100 is assembled
on a select space of conveyor system 96. The make-up of designated
set 100 depends upon the particular activation sequence of rotary
feed system 84 as conveyor system 96 moves in a generally left to
right direction. Those skilled in the art will recognize that
rotary feed systems 84 could also be positioned along side of
conveyor system 96 and feed stock sheets either at a right angle to
the direction of motion of conveyor system 96 or in the same
direction of motion. As described above, operations controller 40
responds to commands from operations personnel and uses information
in data structure 38 to initiate activation signals to the various
rotary feed systems of the collator.
[0054] A friction feed collator 102 is also illustrated in FIG. 4a.
Friction feed collator 102 includes a bin 104 containing stock
sheets 88. A friction belt 106 grabs stock sheets that are released
from bin 104 and feeds the stock sheets through a feed conveyor
system 108 onto the spaces between conveyor lugs 94. In similarity
to rotary feed collator 84, friction feed collator 102 includes a
number of friction feed systems positioned above and laterally
distributed along conveyor system 96. Each friction feed system is
equipped with a system relay 110 that receives instructions from
operations controller 40 and sends operation status information
back to operations controller 40. Those skilled in the art will
recognize that friction feed systems could also be positioned along
side of conveyor system 96 and feed stock sheets either at a right
angle to the direction of motion of conveyor system 96 or in the
same direction of motion.
[0055] Collator 70 can deliver a varying number of stock sheets
into the space between lugs 94 on conveyer system 96. In this
method, the feed device delivers multiple copies of the stock
sheets in its bin into the same space on conveyor system 96.
Accordingly, a designated set of sheets at a specific location on
conveyer system 96 can have a number of sheets from the same bin.
Collator 70 can also delivery multiple sheets from more than one
bin into the same space on conveyor system 96. Thus, the make up of
a designated set of sheets can also include multiple sheets from
several bins. The ability to feed multiple sheets from the same bin
is advantageous, for example, in the case where a designated set of
sheets include admission tickets to an event, such as a sporting
event, or fine arts event, or the like.
[0056] Conveyor system 96 transfers designated set 100 to a pick-up
system 112. As illustrated in FIG. 4b, pick-up system 112 is a
component of re-feeder 72. Re-feeder 72 also includes a bin 114 and
friction feed belt 116. Designated sets 100 are loaded into bin 114
and individual stock sheets are sequentially fed by friction feed
belt 116 through transfer system 118 and into aligning system 120.
Re-feeder 72 sequentially feeds stock sheets into aligning system
120 upon commands received through a system relay 122 from
operations controller 40.
[0057] In accordance with one embodiment of the invention,
re-feeder 72 is configured to operate at transfer rates
substantially greater than the operational rate of collator 70. In
a preferred embodiment of the invention, re-feeder 72 operates at a
rate that ranges from about the same rate as collator 70 (about a 1
to 1 operating speed ratio) to about 2 to about 50 times faster
than collator 70. The high operating speed of re-feeder 72 ensures
that designated sets 100 transferred from collator 70 can be
sequentially processed at a rate that will accommodate the large
number of stock sheets 88 contained within each designated set
100.
[0058] Those skilled in the art will recognize that other types of
feeding systems can be used to assemble the designated sets of
sheets prior to imaging. For example, a continuous rotary feed
system can be used to collect the sets of sheets from the collator
and sequentially deliver the individual sheets to aligning system
120. Further, an operator can manually collect the sets of sheets
and deliver the sets of sheets to aligning system 120. Accordingly,
the present invention contemplates human intervention where
necessary or where cost effective to provide interfacing between
operating systems.
[0059] Regardless of the method used to collect the designated sets
of sheets, aligning system 120 aligns each stock sheet 88 to
position each stock sheet at a proper orientation for imaging by
imaging system 74. Once aligned by alignment system 120, stock
sheets 88 are transferred to a vacuum belt 124 in imaging system
74. As each stock sheet 88 is transferred to vacuum belt 124, a
scanning device 126 scans the stock sheet for a code or other
graphic indicia to ensure that the correct stock sheet will be
presented to imaging system 74. Scanning device 126 sends optical
signals to a digital signal converter 128 that relays scan
information to operations controller 40. Operations controller 40
verifies that the stock sheet 88 is a proper member of designated
set 100 prior to imaging personalized indicia onto stock sheet 88
by imaging system 74. If scanning device 126 detects an incorrect
sheet, imaging system 74 diverts the entire set of sheets from
which the incorrect sheet originated to a waste bin (not shown) and
operations controller 40 reorders the set of sheets containing the
incorrect sheet.
[0060] While the foregoing processing sequence envisions that all
of the stock sheets will be imaged with personalized information,
the present invention also contemplates processes in which not all
of the sheets in a set of sheets are imaged. In some cases it may
not be desirable to image personalized information on each sheet
within a set of sheets. For example, cover and end sheets within a
set may have a different format than the remaining sheets within a
set. Accordingly, it is within the scope of the present invention
that certain ones of designated set 100 are transferred through
imaging system 74 without being imaged.
[0061] In accordance with the inventive process, vacuum belt 124
positions stock sheet 88 within the imaging field of an imaging
device 130. Imaging device 130 can be one of a number of different
imaging devices including a variable data imaging system, a laser
printer, an ink jet printer, and the like. In a preferred
embodiment of the invention, imaging device 130 is a solvent-based
ink jet system that can image stock sheets at a conveyor speed of
about 500 to about 1000 linear feet per minute. Imaging system 130
is preferably a system configured to image stock sheets 88 from a
position immediately above the stock sheets. Alternatively, imaging
system 130 can also image stock sheets 88 from a position
immediately below the stock sheets. In accordance with the
invention, imaging device 130 also includes an imaging control
system 131 and vacuum system 132 that provides vacuum pressure for
vacuum belt 124.
[0062] Preferably, re-feeder 72 and imaging system 74 operate at a
speed that is consistent with the demand for individually
processing the stock sheets within a designated set 100 that
contains a maximum number of stock sheets. At such an operating
speed, the number of stock sheets in each designated set can vary,
while the linear speed of vacuum belt 124 remains constant. For
example, where a designated set 100 contains three stock sheets and
another designated set 100 contains seven stock sheets, operations
controller 40 will instruct re-feeder 72 to skip four feeds, plus a
number for buffer purposes when processing the three-sheet
designated set. Operations controller 40 also instructs refeeder 72
to skip a certain number for buffer purposes when processing the
designated set containing seven stock sheets. The insertion of
buffers when processing designated sets 100 having different
numbers of stock sheets allows time, if needed, for the
re-gathering of the designated sets and transferring the designated
sets to final processing. The number of buffer positions depends on
the overall operating speed of the single-lane machine.
[0063] Those skilled in the art will recognize that a wide variety
of personalized indicia can be imaged onto the stock sheets by
imaging system 74. The type of information can vary depending upon
the nature of the material being imaged. For example, in the case
of invoice preparation, the personalized information can include
usage of services, such as utility services including, electricity,
water, and the like, and for communications services, such as
television, telephone, internet services, and the like. In addition
to advertising mailers, the as described above the stock sheets can
include admission tickets to various events. In this case, there
can be multiple tickets for a given event date and imaging system
74 can image each ticket for a given date with seat number, ticket
price, and the like. Accordingly, it is within the scope of the
present invention that all such printed materials be processed by
the system and method of the invention.
[0064] After stock sheets 88 are imaged to contain personalized
information, they are transferred to re-gathering system 76 and
reassembled into the original designated sets initially prepared by
collator 70. Where needed for final processing purposes,
re-gathering system 76 can include a rotary indexing device 134
that delivers re-gathered designated sets 100 to a conveyor 136.
Stations 138 within rotary indexing device 134 rotate into
alignment with vacuum belt 124 and receive personalized sheets 89
from imaging system 74. Alternatively, another type of indexing and
turn over device, such as a belt system and the like can also be
used. In yet another alternative, re-gathering system does not
include a turn over device. Those skilled in the art will
appreciate that the re-gathering system illustrated in FIGS. 4b-4d
is one of many different possible equipment configurations for
re-gathering the sheets processed by imaging system 74.
[0065] In an alternative embodiment, collator 70, re-feeder 72,
imaging system 74, and re-gathering system 76 can all operate at
variable transfer rates. These systems can be independently
controlled by, for example, servo motors that are electronically
linked to operations controller 40. Operations controller 40
monitors the numbers of sheets in the sets and the operating speed
of each operating system. By varying the operating speeds through
an interlinked control system, a relatively constant throughput can
be obtained where the number of sheets in consecutive sets varies.
In synchronizing the operating speeds, one system can be instructed
to operate at a higher transfer rate than an adjacent system, and
visa versa. The use of electronically-linked, machine speed
controls can be broadly employed to synchronize the collator
operating speed and the various interface components and processing
components in the finishing operations. Accordingly, an interlinked
operating speed control system that independently varies the
transfer rates of the various process systems is contemplated by
the present invention.
[0066] Once re-gathered and indexed, the designated sets of
personalized sheets 101 can be transferred to a number of finishing
operations. Those skilled in the art will appreciate that numerous
types of finishing procedures can be carried out to organize the
designated sets of sheets into a user specified format. For
example, the designated sets of sheets can be bound together or
attached using some other physical attachment means, such as clips,
pins, staples, glue, and the like. Also the designated sets of
sheets can be packaged by overwrapping, or shrink wrapping, or the
like. Additionally, the designated sets of sheets can be inserted
into an envelope suitable for mailing with the U.S. Postal Service
or another document delivery service. In the machine embodiment
illustrated in FIGS. 4a-4d, the single-lane machine is arranged to
insert index sets of sheets 101 into envelopes 140.
[0067] As described above, the single-lane machine can also include
insertion system 80 and second imaging system 82. Insertion system
80 includes a bin 142 that contains insert sheets 144. Insert
sheets 144 can be any of a number of different types of sheets
having a variety of information imaged thereon. In the embodiment
of the invention described with reference to FIGS. 1 and 2, insert
sheets 144 are intended to provide address information for
particular recipients in addition to user information.
[0068] Upon receiving control signals from operations controller
40, system relay 146 commands insertion system 80 to transfer an
insert sheet 144 from bin 142 through transport system 148 to
second imaging system 82. Second imaging system 82 includes an
imaging device 150 that receives image control commands from
operations controller 40 through imaging control system 152. Second
imaging system 82 also includes an alignment system 154 to properly
align insert sheets 144 within the imaging field of imaging device
150. In similarity with imaging device 130, imaging device 150 can
be a variable field imaging system, or printing system, such as a
laser printer or an inkjet printer, or the like. In a preferred
embodiment of the invention, imaging device 150 is an inkjet
printing system.
[0069] Once personalized information has been imaged onto insert
sheet 144, the second imaging system 82 transfers the insert sheet
to a selected station within rotary indexing 134. As a result of
the operation of insertion system 80 and second imaging system 82,
designated sets of sheets 101 each contain an insert providing
address information to selected recipients.
[0070] Although the single-lane machine described above has been
set forth with respect to particular machine components, those
skilled in the art will appreciate that numerous different
mechanisms exist for performing the various operations described
above. For example, in addition to rotary indexing systems, other
types of vertical stacking indexing systems and lateral stacking
indexing systems could also be used. Further, in addition to the
rotary feed and friction feed collators described above, a swing
arm collator could also be used to prepare designated sets of
sheets for delivery to the re-feeding system. Further, the
single-lane machine described above can include additional sensing
devices and electronic control and relay systems to send
information to the operations controller and to receive
instructions from the operations controller. Additionally, although
the single-lane machine described above has been illustrated with
reference to conveyor belt systems for transferring the stock
sheets and designated sets of sheets, other types of conveyance
mechanisms can also be used. For example, rollers, air bearing
systems, vibrating systems, and the like.
[0071] Although the machine described and illustrated above sets
forth an embodiment in which all machine components are linked
together, those skilled in the art will appreciate that the system
can be assembled as individual components. For example, a human
operator or a mechanical transfer system can provide an interface
between the various machine components. In an alternative
embodiment, the collator can feed sets of sheets to a collection
area and a human operator or a mechanical transfer system can
deliver the sets of sheets to the re-feeder. Further, the sets of
documents from the re-gathering system can be transported to the
finishing system by a human operator or a mechanical transfer
system.
[0072] Those skilled in the art will appreciate that the machine
system described above can be operated under a number of different
control programs. The following description sets forth several
different program control sequences that can be used for the
machine system described above. In accordance with the invention,
the following program control sequences can also be employed to
operate machine systems that differ from those described above.
[0073] One embodiment of a process control sequence for a
single-lane machine arranged in accordance with the invention is
illustrated in FIG. 5. The control sequence begins by reading
database information from data structure 38 into operations
controller 40 at step 160. Re-feeder 72 is programmed for a maximum
number of inserts at step 162. The various bins of collator 70 are
activated by commands from operations controller 40 at step 164.
Information regarding the number of inserts or stock sheets to be
included in a designated set is relayed to re-feeder 72 at step
166. Scanning device 126 is instructed to scan each sheet for
verification at step 168. Imaging control system 131 upon receiving
instructions from operations controller 40 prints personalized
information on the sheet at step 180. At step 182 an optional
drying procedure is carried out cure the imaged sheet. The optional
drying system can reside in proximity to vacuum belt 124 at a
position downstream from imaging device 130. Re-gathering system 76
is instructed to index, collect and re-collate the printed sheets
into the original sets of sheets at step 184. If needed, the
re-collated sets of sheets can be turned over or otherwise
positioned for final processing at step 186. Final processing as
described above is carried out at step 188.
[0074] An additional embodiment of a process control sequence for
the single-lane machine described above is illustrated in FIG. 6.
The processing sequence illustrated in FIG. 6 is intended for use
with a variable speed re-gathering system. The process sequence is
similar to that illustrated in FIG. 5 with the exception that the
re-feeder is not programmed for a maximum number of inserts. Steps
190 and 192 are similar to steps 160 and 164 in the process
sequence described above. At step 194, operations controller 40
sends instructions to re-feeder 72 for the required number of
sheets for each designated set. Steps 196, 198, and 200 are similar
to steps 168, 180, and 182 described above. At step 202, the number
of stock sheets in each designated set is relayed by operations
controller 40 to re-gathering system 76. Electronic control within
re-gathering system 76 adjusts the speed of rotary indexing system
134 according to the number of sheets required in each set. Steps
204 and 206 are similar to steps 186 and 188 described above.
[0075] FIG. 7 illustrates a process control sequence for the
single-lane machine described above in the embodiment in which the
single-lane machine includes an insertion system 80 and second
imaging system 82. Steps 208-224 are similar to steps 160-186
described above. At step 226, operations controller 40 instructs
insertion system 80 and second imaging system 82 to provide a
personalized insert sheet into the designated sets of sheets. At
step 228, the insert sheet is dried in an optional drying system
that can be located immediately downstream from second imaging
system 82. Step 230 is similar to step 188 described above.
[0076] In accordance with the invention, an alternative embodiment
of a system for producing personalized printed material is
illustrated in FIG. 8. The system includes a first collator 232
coupled to a first re-feeder 234. A second collator 236 is coupled
to a second re-feeder 238. In accordance with the invention, first
collator 232 includes more bins then second collator 236. A first
imaging system 240 is coupled to first re-feeder 234 and a second
imaging system 242 is coupled to second re-feeder 238. The first
imaging system 240 and the second imaging system 242 transfer
sheets with personalized information imaged thereon to a reassembly
station 244. Reassembly station 244 includes a merging station 246
where sets of sheets originating from first collator 232 and imaged
with personalized information by imaging system 240 and sheets
originating from second collator 236 and image with personalized
information by second imaging system 242 are merged together.
Merging station 246 transfers the merged sets of sheets to a final
processing system 248. Final processing system 248 can include a
turnover device 250 and, in one embodiment of the invention, a
packaging system 252 that packages the sets of sheets in one of the
packaging types described above. The packaging system is coupled to
a transport system 254 that transports the packaged sets of sheets
to a staging area for storage or delivery.
[0077] In accordance with the embodiment of the invention
illustrated in FIG. 8, second collator 236 is loaded with stock
sheets that are intended for insertion into the set of sheets to
identify special matters to be included within the designated sets
of sheets. For example, the stock sheet loaded in second collator
236 can be generic sheets that are intended to be inserted within
all designated sets of sheets that are produced under one or more
job requests.
[0078] In accordance with the invention, yet another alternative
embodiment of a system for producing personalized printed material
is illustrated in FIG. 9. In similarity with the embodiment
illustrated in FIG. 8, the system includes a first collator 232, a
first re-feeder 234, and a first imaging system 240. Also included
are a second collator 236, a second re-feeder 238, and a second
imaging system 242. In the system illustrated in FIG. 9, merging
station 246 is positioned in line with first collator 232.
Reassembly station 244 transfer sets of sheets from second imaging
system 242 to merging station 246. Final processing station 248 is
also aligned with first collator 232. Those skilled in the art will
recognize that other arrangements are possible for the dual-lane
illustrated in FIG. 8. For example, in accordance with the
invention, additional collators could be added and coupled to
reassembly station 244 and their output merged at merging station
246.
[0079] FIG. 10 illustrates a process control sequence for a
dual-lane machine as illustrated in FIGS. 8 and 9. At step 260,
operations controller 40 receives instructions from a system
operator to assembly sets of personalized sheets according to a
user job request. At step 262, first and second re-feeders 234 and
238 are programmed to assemble a maximum number of inserts or stock
sheets into each designated set. Each of collators 232 and 236 are
then directed according to processing command sequences 264 and
266, respectively. Each of the individual processing steps within
command sequences 264 and 266 are similar to the steps previously
described. At step 268, operations controller 40 instructs merging
station 246 to re-gather the sheets from imaging systems 240 and
242. The merged sets of sheets are then turned over, if necessary,
by a turnover system 250 at step 270. Final processing as
previously described is then carried out a step 272.
[0080] A process control sequence for a dual-lane machine in
accordance with another embodiment of the invention is illustrated
in FIG. 11. The processing sequence illustrated in FIG. 11 provides
operating instructions for a dual-lane machine as illustrated in
FIGS. 8 or 9. The system, however, also includes an insertion
system and imaging system as illustrated in FIG. 4d. Steps 274 and
278 are the same as steps 260 and 262 described above. Also,
processing control sequences 280 and 282 are the same as processing
control sequences 264 and 266. Steps 284 and 286 are the same as
steps 268 and 270. At step 288 operations controller 40 instructs
the insertion system and the imaging system to provide a
personalized sheet for each set of sheets that can be used, for
example, for addressing purposes. An optional drying step for the
insert sheets is performed at step 290 and final processing is
carried out at step 292.
[0081] In an alternative embodiment of the invention, stock sheets
are individually fed directly from a collator and sequentially
imaged. The alternative embodiment differs from the embodiment
described above in that the stock sheets are not gathered into sets
of sheets nor processed by a re-feeder prior to imaging. Rather
than gather the sheets into sets, the sheets are sequentially fed
one at a time to the imaging system directly from a collator. In
the alternative embodiment, the sheets can be gathered after
imaging and before final processing.
[0082] The method in accordance with the alternative embodiment
further includes sequentially finishing the imaged sheets. In the
finishing process, the sheets are processed one at a time. The
finishing process can include simply folding the imaged sheets.
Also, the finishing process can include placing personalized
indicia on either an inner surface of the sheets or an outer
surface of the folded sheets, or on both the inner surface and the
outer surface. Alternatively, the finishing process can also
include packaging the imaged sheets with selectively gathered
sheets into a package. Additionally, one or more additional items
can be associated with the package. For example, an object such as
a promotional item can be associated with package. The sequential
processing is controlled by the control system described above.
[0083] Illustrated in FIG. 12 is a schematic diagram of a
sequential collation and imaging system arranged in accordance with
the alternative embodiment of the invention. A sequential collator
300 is coupled to an aligning system 302, which is in turn coupled
to an imaging system 304. In similarity to collator 102, collator
300 includes a series of bins 306 that hold stock sheets 308. Each
bin includes sheet feeding apparatus for delivering stock sheets to
a conveyor system 310. In contrast to the operation of the collator
illustrated in FIG. 4a, collator 300 sequentially ejects sheets
from the sheet feeders onto conveyer system 310 for delivery one at
a time to alignment system 302.
[0084] Alignment system 302 aligns each sequentially feed sheet and
delivers each sheet by means of a conveyor system 312 to imaging
system 304. Imaging system 304 is similar to imaging system 74 and
includes an imaging device 314 and an optional scanning device 316.
In accordance with the previous embodiment described above,
personalized indicia is imaged onto the sheets by transferring the
sheets past imaging system 314 on a conveyor system 318 to produce
personalized sheets 320. Scanning device 316 communicates with the
control system and verifies that the correct sheet is about to be
imaged. After imaging, personalized sheets 320 are transferred by
conveyor system 318 a finishing system, where personalized sheets
320 are sequentially processed into a final form.
[0085] As described above, the present invention also contemplates
processes in which not all of the sheets are imaged. In some cases
it may not be desirable to image personalized information on each
sheet. Accordingly, it is within the scope of the present invention
that certain ones of stock sheet 308 are transferred through
imaging system 304 without being imaged.
[0086] The finishing system coupled to imaging system 304 can be
similar to finishing system 78 described above, with the exception
that the sheets are entirely sequentially processed to their final
form. One embodiment of a finishing system is illustrated in FIG.
13. The finishing system includes a folding system 322, a labeling
system 324, and an imaging system 326.
[0087] Folding system 322 can be any of a number of different sheet
handling systems that manipulate flat sheets into a folded form. In
the embodiment illustrated in FIG. 13, folding system 322 is a plow
fold that receives personalized sheets 320 from conveyor system 318
and folds the sheets in a bifold by forcing one half of each sheet
over on itself producing folded sheets 334. Personalized sheets 320
are propelled through folding system 322 by a conveyor 328.
[0088] A top view illustrating the folding, sealing, and imaging
operation is illustrated in FIG. 14. Each sheet is folded along a
folding line 336. In one embodiment of the invention, folding line
336 is a perforated line formed on or near a center line in the
stock sheets.
[0089] Once the personalized sheets are folded, labeling system 324
forms a wafer seal 330 to secure the fold. In the illustrated
embodiment, labeling system 324 is a labeling device that applies
wafer seal 330 to the outside edge of the folded sheets opposite
from folding line 336.
[0090] Following seal formation, imaging system 326 images personal
information 332 on an outer surface of folded sheets 334. Imaging
system 326 is similar to the imaging systems described above.
Information 332 can be a variety of personalized information, such
as specialized advertising, discount offers, recipient address
information, and the like. Where personalized indicia is to be
placed on an inner surface of personalized sheets 320, an
additional imaging system (not shown) is employed to place the
indicia on the sheets prior to processing the sheets though folding
system 322.
[0091] Although the foregoing finishing process is described in the
context of a fully automated process, those skilled in the art will
recognize that manual handling operations can be performed at
various stages of the process. For example, operators can be used
to collect stacks of sheets from the previous operation and
transfer the sheets to the next operation. As the sheets are imaged
by imaging system 304, an operator can collect the sheets and place
the sheets in transfer bins. The sheets can then be taken by the
operator to a folding system and be sequentially processed from the
bins through folding system. Accordingly, the present invention
contemplates human intervention to assist processing operations,
for example, where machine cost is prohibitive or where mechanical
interfacing is impractical.
[0092] Those skilled in the art will recognize that the finishing
operation illustrated in FIGS. 13 and 14 is one of many different
kinds of finishing operations that can be carried out with the
personalized sheets prepared in accordance with the invention. For
example, various types of packaging operations can also be
performed. In one embodiment of the invention, personalized sheets
prepared by any of the foregoing methods are placed in a package.
The package can be an envelope, such as envelope 140 or a plastic
package, or the like.
[0093] As part of the finishing process, the personalized sheets
can be packaged with one or more additional items. For example, an
object can be attached to the package or inserted into the package
with the personalized sheet or sheets. Further, the object can be
attached directly to the personalized sheets. The objects can
include, for example, product samples, vouchers, marketing aids,
such as games, and the like.
[0094] A schematic diagram of a system and method for associating
an item with the personalized sheets according to one embodiment of
the invention is illustrated in FIG. 15. A package attaching system
340 includes first and second package delivery systems 342 and 344,
respectively. Each of package delivery systems 342 and 344 includes
a feed station 346 and a rotary placement device 348. A conveyor
system 350 transports personalized sheets 320 past the package
delivery systems. A number of objects to be attached to
personalized sheets 320 are loaded into feed stations 346.
[0095] In accordance with an embodiment of the invention, package
attaching system 342 can deliver more than one type of object can
be attached to the personalized sheets. For example, package
delivery system 342 can provide a product sample 352 for attachment
to designated personalized sheets 354, while package delivery
system 344 provides vouchers 356 for attachment to designated
personalized sheets 358. In a process where objects are attached to
the personalized sheets, a gluing system 359 applies glue at a
designated location on the upper surface of personalized sheets 230
as the sheets are received from the preceding operation and
transported by conveyor system 350.
[0096] In addition to objects such as product sample, marketing
aids, vouchers, and the like, additional personalized sheets can be
associated with personalized sheets 374. For example, coupons
previously processed to image personalized information for a
particular recipient can be inserted into a package and the package
attached to personalized sheets 374. Further, instead of attaching
an item to personalized sheets 320, the items can be inserted into
a package by a package insertion system, or over wrapped or shrink
wrapped as described above.
[0097] Although only two package delivery systems are illustrated
in FIG. 15, those skilled in the art will recognize that numerous
such package delivery systems can be employed for delivery of a
variety of objects for attachment or package insertion. Further,
the package delivery systems can be employed to attach two
different objects to the same sheet or insert two different objects
into the same package. In a process where objects are attached to
personalized sheets 320, package attaching system 340 can be
coupled to folding system 322 to prepare folded sheets 334 that
include an object attached inside the folded sheet.
[0098] A process for sequentially imaging and finishing
personalized sheets is illustrated in FIGS. 16a-16c. In accordance
with the process described above, a collator, such as collator 300
sequentially places stock sheets 360 into spaces 362 between lugs
364 on a conveying device 366. Each stock sheet 360 includes
previously placed indicia 368 thereon. A control system, such as
the control system illustrated in FIGS. 3a-3c, directs collator 300
to eject a particular stock sheet 360 onto a particular one of
spaces 362 on conveying device 366. Under the direction of the
control system, stock sheets 360 are arranged in a pre-designated,
sequential order on conveying device 366. As illustrated in FIG.
16a, each stock sheet contains different indicia 368 thereon.
[0099] An alignment system, such as alignment system 302, aligns
the stock sheets on a vacuum belt 370 and a scanning device, such
as scanning device 316, communicates with the control system and
verifies that the scanned stock sheet is the correct stock sheet
for its occupied position in the sequence. An imaging system, such
as imaging system 304, images personalized information 372 onto
each stock sheet to produce personalized sheets 374. As described
above, the present invention also contemplates processes in which
not all of the sheets are imaged with personalized information.
[0100] Once personalized sheets 374 are imaged, objects are
attached to the personalized sheets, as illustrated in FIG. 16b.
Gluing system 359 applies glue 376 to one or more predetermined
locations on personalized sheets 374. Glue 376 is positioned above
folding line 336 so that objects can be attached generally opposite
to personalized information 372.
[0101] In accordance the illustrated embodiment of the invention,
different objects can be attached to personalized sheets 374
depending upon the content of indicia 368 and the content of
personalized information 372. For example, object 378 is attached
to personalized sheet 380, while object 382 is attached to
personalized sheet 384. In this way, a particular recipient can
receive a mailing, for example, that contains a personalized
advertising sheet having a store logo, a personal message directed
to the particular recipient, and an item, such as a product sample,
that is related to a particular retailer or to product information
in the personal message.
[0102] Once objects are attached, personalized sheets 374 are
folded using a folding device, such as folding system 322, and
sealed using a labeling device, such as labeling system 324, to
place wafer seals 330 on folded sheets 386. An imaging system, such
as imaging system 304, is used to place information 388, such as
name and address information, and the like, on the outer surface of
folded sheets 386.
[0103] Those skilled in the art will recognize that the order of
the process steps described above can be varied to carry out a
number of different finishing processes. For example, instead of
attaching an object and folding the personalized sheet over the
object, the object can be attached to an outside surface of the
folded sheets.
[0104] Thus is apparent that there has been described a system and
method for producing personalized imaged material that fully
provides the advantages set forth above. Those skilled in the art
will recognize that numerous modifications and variations can be
made without departing from the spirit of the invention. For
example, the collators and insertion systems can be configured in a
variety of layout formats to accommodate varying floor space
requirements. Accordingly, all such variations and modifications
are within the scope of the appended claims and equivalents
thereof.
* * * * *