U.S. patent application number 11/981364 was filed with the patent office on 2009-04-30 for system for integrated production of envelopes and contents thereof.
Invention is credited to Donato C. Farole, William G. Hart, Joseph J. Keane, Andrew N. Percival, Hersch Reich, Karl H. Schumacher, Clare E. Woodman.
Application Number | 20090107086 11/981364 |
Document ID | / |
Family ID | 40581062 |
Filed Date | 2009-04-30 |
United States Patent
Application |
20090107086 |
Kind Code |
A1 |
Keane; Joseph J. ; et
al. |
April 30, 2009 |
System for integrated production of envelopes and contents
thereof
Abstract
A system for providing real-time, integrated production of
individually addressed sealed envelopes containing personalized
printed material matched to individual addresses, the system
including at least one printing controller capable of receiving
personalized printing data from at least one data source, the
personalized printing data including envelope address information
for a multiplicity of envelopes and personalized envelope contents
information which varies for the multiplicity of envelopes and is
matched to individual envelope addresses, the at least one printing
controller being operative to merge and order the personalized
printing data from the at least one data source such that it is
printed in a desired distribution sorting order, selected to
optimize postal savings in bulk mailings and at least one
production facility for the individually addressed sealed envelopes
containing personalized printed material matched to individual
addresses, each of the at least one production facility including
at least one digital printer operative to print the personalized
printing data including the envelope address information for a
plurality of envelopes to be formed from a substrate and the
personalized envelope contents information for contents of the
plurality of envelopes, at least one cutting stage receiving a
printed output from the at least one digital printer and being
operative to cut at least one of envelope sheets according to an
envelope shaped blank and envelope contents sheets, at least one
content-containing envelope formation stage operative to wrap the
envelope sheets over the envelope contents sheets and thereby
create sealed individually addressed envelopes containing
personalized content matched thereto and a bundling stage,
gathering and bundling the sealed individually addressed envelopes
containing personalized contents matched thereto in the desired
distribution sorting order.
Inventors: |
Keane; Joseph J.;
(Souderton, PA) ; Farole; Donato C.; (Lehighton,
PA) ; Woodman; Clare E.; (Norwalk, CT) ;
Schumacher; Karl H.; (Guildford, CT) ; Hart; William
G.; (Sandy Hook, CT) ; Percival; Andrew N.;
(Teston, GB) ; Reich; Hersch; (Antwerpen,
BE) |
Correspondence
Address: |
ABELMAN, FRAYNE & SCHWAB
666 THIRD AVENUE, 10TH FLOOR
NEW YORK
NY
10017
US
|
Family ID: |
40581062 |
Appl. No.: |
11/981364 |
Filed: |
October 30, 2007 |
Current U.S.
Class: |
53/206 ;
53/460 |
Current CPC
Class: |
B65H 39/02 20130101;
B43M 5/04 20130101; B65H 2801/66 20130101; B65H 2701/1916 20130101;
B65H 2301/4311 20130101 |
Class at
Publication: |
53/206 ;
53/460 |
International
Class: |
B65B 11/48 20060101
B65B011/48 |
Claims
1. A system for providing real-time, integrated production of
individually addressed sealed envelopes containing personalized
printed material matched to individual addresses, the system
comprising: at least one printing controller capable of receiving
personalized printing data from at least one data source, said
personalized printing data including envelope address information
for a multiplicity of envelopes and personalized envelope contents
information which varies for said multiplicity of envelopes and is
matched to individual envelope addresses, said at least one
printing controller being operative to merge and order said
personalized printing data from said at least one data source such
that it is printed in a desired distribution sorting order,
selected to optimize postal savings in bulk mailings; and at least
one production facility for said individually addressed sealed
envelopes containing personalized printed material matched to
individual addresses, each of said at least one production facility
comprising: at least one digital printer operative to print said
personalized printing data including said envelope address
information for a plurality of envelopes to be formed from a
substrate and said personalized envelope contents information for
contents of said plurality of envelopes; at least one cutting stage
receiving a printed output from said at least one digital printer
and being operative to cut at least one of envelope sheets
according to an envelope shaped blank and envelope contents sheets;
at least one content-containing envelope formation stage operative
to wrap said envelope sheets over said envelope contents sheets and
thereby create sealed individually addressed envelopes containing
personalized content matched thereto; and a bundling stage,
gathering and bundling said sealed individually addressed envelopes
containing personalized contents matched thereto in said desired
distribution sorting order.
2. A system according to claim 1 and wherein said at least one
printing controller is capable of receiving multiple printing jobs
from disparate sources and combining them in a single pre-sorted
print run.
3. A system according to claim 1 and wherein said desired
distribution sorting order is according to postal code.
4. A system according to claim 3 and wherein said desired
distribution sorting order is according to the delivery order of a
mailman's route.
5. A system according to claim 1 and wherein said at least one
production facility comprises a plurality of production facilities
geographically distributed close to correspondingly geographically
distributed bulk mail drop-off locations.
6. A system according to claim 1 and wherein said at least one
content-containing envelope formation stage is operative to wrap
said envelope sheets over said contents sheets in a manner such
that side flaps of said envelope are glued to a surface of said
envelope.
7. A system according to claim 1 and wherein said at least one
cutting stage is capable of receiving said printed output from said
at least one digital printer in at least two of roll, sheet and
fan-fold form.
8. A system according to claim 1 and wherein said at least one
cutting stage operates asynchronously to the operation of said at
least one content-containing envelope formation stage.
9. A system according to claim 1 and wherein said at least one
cutting stage includes an envelope/envelope contents
differentiation stage, receiving said printed output from said at
least one digital printer and being operative to differentiate said
envelope sheets from said envelope contents sheets prior to cutting
said at least one of envelope sheets and envelope contents
sheets.
10. A system according to claim 1 and wherein said envelopes
include personalized printing both on the front and the back
thereof.
11. A system according to claim 1 and wherein said contents of said
envelopes is printed on a different substrate than said
substrate.
12. A system according to claim 1 and wherein said envelope
contents sheets are folded prior to said at least one
content-containing envelope formation stage, such that said at
least one content-containing envelope formation stage is operative
to wrap said envelope sheets over suitably folded envelope contents
sheets.
13. A system according to claim 1 and wherein: said at least one
digital printer is operative to print said envelope address
information separately from printing said personalized envelope
contents information, said at least one cutting stage comprises a
plurality of cutting stages, at least one of said plurality of
cutting stages receiving a first printed output corresponding to
said envelope address information and being operative to cut said
first printed output into said envelope sheets and at least one
other of said plurality of cutting stages receiving a second
printed output corresponding to said personalized envelope contents
information and being operative to cut said second printed output
into said envelope contents sheets, and wherein said envelope
sheets formed of said first printed output and said envelope
contents sheets formed of said second printed output are merged in
said at least one content-containing envelope formation stage.
14. A system according to claim 1 and wherein prior to said at
least one content-containing envelope formation stage at least one
insert is placed over said envelope sheets, such that during said
at least one content-containing envelope formation stage said
envelope sheets are wrapped over said envelope contents sheets and
said at least one insert.
15. A system for providing real-time, integrated production of
individually addressed sealed envelopes containing personalized
printed material matched to individual addresses, the system
comprising: at least one digital printer operative to print
personalized printing data including envelope address information
for a multiplicity of envelopes to be formed from a substrate and
personalized envelope contents information for contents of said
multiplicity of envelopes, said contents of said multiplicity of
envelopes containing a variable number of sheets, which varies from
one of said multiplicity of envelopes to another of said
multiplicity of envelopes; and at least one content-containing
envelope formation stage operative to wrap envelope sheets over
envelope contents sheets containing a variable number of sheets and
thereby create sealed individually addressed envelopes containing
personalized content matched thereto having a variable number of
sheets.
16. A system according to claim 15 and wherein said at least one
content-containing envelope formation stage is operative to wrap
said envelope sheets over said envelope contents sheets in a manner
such that side flaps of said envelope are glued to a surface of
said envelope.
17. A system according to claim 15 and wherein said envelope
contents sheets are folded prior to said at least one
content-containing envelope formation stage, such that said at
least one content-containing envelope formation stage is operative
to wrap said envelope sheets over suitably folded envelope contents
sheets.
18. A system according to claim 15 and also comprising at least one
cutting stage capable of receiving printed output from said at
least one digital printer in at least two of roll, sheet and
fan-fold form and being operative to cut said printed output into
at least one of said envelope sheets and said envelope contents
sheets, said envelope sheets being cut according to an envelope
shaped blank.
19. A system according to claim 18 and wherein said at least one
cutting stage operates asynchronously to the operation of said at
least one content-containing envelope formation stage.
20. A system according to claim 18 and wherein said at least one
cutting stage includes an envelope/envelope contents
differentiation stage, receiving said printed output and being
operative to differentiate said envelope sheets from said envelope
contents sheets prior to cutting said at least one of said envelope
sheets and said envelope contents sheets.
21. A system according to claim 15 and wherein said sealed
individually addressed envelopes include personalized printing both
on the front and the back thereof.
22. A system according to claim 15 and wherein, prior to said at
least one content-containing envelope formation stage, at least one
insert is placed over said envelope sheets, such that during said
at least one content-containing envelope formation stage said
envelope sheets are wrapped over said envelope contents sheets and
said at least one insert.
23. A system for providing real-time, integrated production of
individually addressed sealed envelopes containing personalized
printed material matched to individual addresses, the system
comprising: at least one digital printer operative to print
personalized printing data including envelope address information
for a multiplicity of envelopes to be formed from a substrate and
personalized envelope contents information for contents of said
multiplicity of envelopes; and at least one content-containing
envelope formation stage operative to wrap envelope sheets over
envelope contents sheets and thereby create sealed individually
addressed envelopes containing personalized content matched
thereto, said sealed individually addressed envelopes including
personalized printing both on the front and the back thereof.
24. A system according to claim 23 and wherein said at least one
content-containing envelope formation stage is operative to wrap
said envelope sheets over said envelope contents sheets in a manner
such that side flaps of said envelope are glued to a surface of
said envelope.
25. A system according to claim 23 and wherein said envelope
contents sheets are folded prior to said at least one
content-containing envelope formation stage, such that said at
least one content-containing envelope formation stage is operative
to wrap said envelope sheets over suitably folded envelope contents
sheets.
26. A system according to claim 23 and also comprising at least one
cutting stage capable of receiving printed output from said at
least one digital printer in at least two of roll, sheet and
fan-fold form, and being operative to cut said printed output into
at least one of said envelope sheets and said envelope contents
sheets, said envelope sheets being cut into according to an
envelope shaped blank.
27. A system according to claim 26 and wherein said at least one
cutting stage operates asynchronously to the operation of said at
least one content-containing envelope formation stage.
28. A system according to claim 26 and wherein said at least one
cutting stage includes an envelope/envelope contents
differentiation stage, receiving said printed output and being
operative to differentiate said envelope sheets from said envelope
contents sheets prior to cutting said at least one of said envelope
sheets and said envelope contents sheets.
29. A system according to claim 23 and wherein, prior to said at
least one content-containing envelope formation stage, at least one
insert is placed over said envelope sheets, such that during said
at least one content-containing envelope formation stage said
envelope sheets are wrapped over said envelope contents sheets and
said at least one insert.
30. A system for providing real-time, integrated production of
individually addressed sealed envelopes containing personalized
printed material matched to individual addresses, the system
comprising: at least one digital printer operative to print
personalized printing data including envelope address information
for a multiplicity of envelopes to be formed from a substrate and
personalized envelope contents information for contents of said
multiplicity of envelopes; at least one cutting stage receiving a
printed output from said at least one digital printer and being
operative to cut at least one of envelope sheets and envelope
contents sheets; at least one content-containing envelope formation
stage operative to wrap said envelope sheets over said envelope
contents sheets and thereby coterminously create envelopes and the
content thereof in sealed individually addressed envelopes
containing personalized content matched thereto.
31. A system according to claim 30 and wherein said at least one
content-containing envelope formation stage is operative to wrap
said envelope sheets over envelope contents sheets containing a
variable number of sheets, such that said sealed individually
addressed envelopes have a variable number of sheets.
32. A system according to claim 30 and wherein said at least one
content-containing envelope formation stage is operative to wrap
said envelope sheets over said envelope contents sheets in a manner
such that side flaps of said envelope are glued to a surface of
said envelope.
33. A system according to claim 30 and wherein said envelope
contents sheets are folded prior to said at least one
content-containing envelope formation stage, such that said at
least one content-containing envelope formation stage is operative
to wrap said envelope sheets over suitably folded envelope contents
sheets.
34. A system according to claim 30 and wherein said at least one
cutting stage is capable of receiving said printed output from said
at least one digital printer in at least two of roll, sheet and
fan-fold form.
35. A system according to claim 30 and wherein said sealed
individually addressed envelopes include personalized printing both
on the front and the back thereof.
36. A system according to claim 30 and wherein said at least one
cutting stage operates asynchronously to the operation of said at
least one content-containing envelope formation stage.
37. A system according to claim 30 and wherein said at least one
cutting stage includes an envelope/envelope contents
differentiation stage, receiving said printed output and being
operative to differentiate said envelope sheets from said envelope
contents sheets prior to cutting said at least one of said envelope
sheets and said envelope contents sheets.
38. A system according to claim 30 and wherein, prior to said at
least one content-containing envelope formation stage, at least one
insert is placed over said envelope sheets, such that during said
at least one content-containing envelope formation stage said
envelope sheets are wrapped over said envelope contents sheets and
said at least one insert.
39. A system for providing real-time, integrated production of
individually addressed sealed envelopes containing personalized
printed material matched to individual addresses, the system
comprising: at least one printing controller capable of receiving
personalized printing data from at least one data source, said
personalized printing data including envelope address information
for a multiplicity of envelopes and personalized envelope contents
information which varies for said multiplicity of envelopes and is
matched to individual envelope addresses, said at least one
printing controller being operative to order said personalized
printing data from said at least one data source such that it is
printed in a desired distribution sorting order, selected to
optimize postal savings in bulk mailings; and at least one
production facility for producing said individually addressed
sealed envelopes containing personalized printed material matched
to individual addresses, each of said at least one production
facility comprising: at least one printer operative to print said
personalized printing data including envelope address information
for a plurality of envelopes and personalized envelope contents
information for contents of said plurality of envelopes; at least
one envelope/envelope contents differentiation stage receiving a
printed output from said at least one printer and being operative
to provide envelope sheets and envelope contents sheets; at least
one content-containing envelope formation stage operative to wrap
said envelope sheets over said envelope contents sheets and thereby
create sealed individually addressed envelopes containing
personalized content matched thereto; and a bundling stage,
gathering and bundling said sealed individually addressed envelopes
containing personalized contents matched thereto in said desired
distribution sorting order.
40. A system according to claim 39 and wherein said at least one
printing controller is capable of receiving multiple printing jobs
from disparate sources and combining them in a single pre-sorted
print run.
41. A system according to claim 39 and wherein said desired
distribution sorting order is according to postal code.
42. A system according to claim 41 and wherein said desired
distribution sorting order is according to the delivery order of a
mailman's route.
43. A system according to claim 39 and wherein said at least one
production facility comprises a plurality of production facilities
geographically distributed close to correspondingly geographically
distributed bulk mail drop-off locations.
44. A system according to claim 39 and wherein said at least one
content-containing envelope formation stage is operative to wrap
said envelope sheets over said contents sheets in a manner such
that side flaps of said envelope are glued to a surface of said
envelope.
45. A system according to claim 39 and wherein said at least one
envelope/envelope contents differentiation stage is capable of
receiving said printed output in at least two of roll, sheet and
fan-fold form.
46. A system according to claim 39 and wherein said at least one
envelope/envelope contents differentiation stage operates
asynchronously to the operation of said at least one
content-containing envelope formation stage.
47. A system according to claim 39 and wherein said envelopes
include personalized printing both on the front and the back
thereof.
48. A system according to claim 39 and wherein said envelope
contents sheets are folded prior to said at least one
content-containing envelope formation stage, such that said at
least one content-containing envelope formation stage is operative
to wrap said envelope sheets over suitably folded envelope contents
sheets.
49. A system according to claim 39 and wherein, prior to said at
least one content-containing envelope formation stage, at least one
insert is placed over said envelope sheets, such that during said
at least one content-containing envelope formation stage said
envelope sheets are wrapped over said envelope contents sheets and
said at least one insert.
50. A method for providing real-time, integrated production of
individually addressed sealed envelopes containing personalized
printed material matched to individual addresses, the method
comprising: receiving personalized printing data from at least one
data source, said personalized printing data including envelope
address information for a multiplicity of envelopes and
personalized envelope contents information which varies for said
multiplicity of envelopes and is matched to individual envelope
addresses; ordering said personalized printing data from said at
least one data source such that it is printed in a desired
distribution sorting order, selected to optimize postal savings in
bulk mailings; and producing said individually addressed sealed
envelopes containing personalized printed material matched to
individual addresses, said producing comprising: printing said
personalized printing data, thereby providing a multiplicity of
envelope sheets and envelope content sheets for said multiplicity
of envelopes; differentiating said envelope sheets and said
envelope contents sheets; wrapping said envelope sheets over said
envelope contents sheets and thereby creating sealed individually
addressed envelopes containing personalized content matched
thereto; and gathering and bundling said sealed individually
addressed envelopes containing personalized contents matched
thereto in said desired distribution sorting order.
51. A method according to claim 50 and wherein said printing said
personalized printing data comprises digital printing.
52. A method according to claim 50 and wherein said digital
printing comprises digital printing on a continuous substrate.
53. A method according to claim 50 and wherein said receiving
comprises receiving multiple printing jobs from disparate sources
and combining them in a single pre-sorted print run.
54. A method according to claim 50 and wherein said desired
distribution sorting order is according to postal code.
55. A method according to claim 54 and wherein said desired
distribution sorting order is according to the delivery order of a
mailman's route.
56. A method according to claim 50 and wherein said wrapping
comprises wrapping said envelope sheets over contents sheets such
that side flaps of said envelope are glued to a surface of said
envelope.
57. A method according to claim 50 and also comprising, prior to
said wrapping, folding said envelope contents sheets, such that
said wrapping comprises wrapping said envelope sheets over suitably
folded envelope contents sheets.
58. A method according to claim 50 and also comprising, prior to
said wrapping, placing at least one insert is placed over said
envelope sheets, such that said wrapping comprises wrapping said
envelope sheets over said envelope contents sheets and said at
least one insert.
Description
REFERENCE TO RELATED APPLICATIONS
[0001] Reference is hereby made to U.S. Pat. No. 7,100,348,
entitled Continuous Strip of Detachably Interconnected Folded
Products, and to U.S. Published Patent Application 2006/0272295,
which is a continuation of U.S. Pat. No. 7,100,348, the disclosures
of which are hereby incorporated by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to mailing systems and
methodologies generally and more particularly to integrated
production of envelopes and the contents thereof.
BACKGROUND OF THE INVENTION
[0003] The following publications are believed to represent the
current state of the art:
[0004] U.S. Pat. Nos. 1,801,155; 2,464,490; 2,610,784; 2,776,085;
2,783,935; 3,028,069; 3,228,586; 3,332,604; 3,557,519; 3,559,875;
3,626,821; 3,790,068; 3,897,720; 3,980,006; 3,998,138; 4,063,398;
4,066,206; 4,091,987; 4,437,852; 4,454,980; 4,497,509; 4,600,141;
4,630,768; 4,651,920; 4,694,632; 4,731,048; 4,804,135; 4,886,205;
4,896,821; 5,051,914; 5,072,401; 5,068,797; 5,069,384; 5,161,109;
5,398,867; 5,568,717; 5,640,831; 5,971,260; 7,231,750 and
7,254,931.
SUMMARY OF THE INVENTION
[0005] The present invention seeks to provide improved, cost
effective mailing systems and methodologies. There is thus provided
in accordance with a preferred embodiment of the present invention
a system for providing real-time, integrated production of
individually addressed sealed envelopes containing personalized
printed material matched to individual addresses, the system
including at least one printing controller capable of receiving
personalized printing data from at least one data source, the
personalized printing data including envelope address information
for a multiplicity of envelopes and personalized envelope contents
information which varies for the multiplicity of envelopes and is
matched to individual envelope addresses, the at least one printing
controller being operative to merge and order the personalized
printing data from the at least one data source such that it is
printed in a desired distribution sorting order, selected to
optimize postal savings in bulk mailings and at least one
production facility for the individually addressed sealed envelopes
containing personalized printed material matched to individual
addresses, each of the at least one production facility including
at least one digital printer operative to print the personalized
printing data including the envelope address information for a
plurality of envelopes to be formed from a substrate and the
personalized envelope contents information for contents of the
plurality of envelopes, at least one cutting stage receiving a
printed output from the at least one digital printer and being
operative to cut at least one of envelope sheets according to an
envelope shaped blank and envelope contents sheets, at least one
content-containing envelope formation stage operative to wrap the
envelope sheets over the envelope contents sheets and thereby
create sealed individually addressed envelopes containing
personalized content matched thereto and a bundling stage,
gathering and bundling the sealed individually addressed envelopes
containing personalized contents matched thereto in the desired
distribution sorting order.
[0006] In accordance with a preferred embodiment of the present
invention the at least one printing controller is capable of
receiving multiple printing jobs from disparate sources and
combining them in a single pre-sorted print run. Preferably, the
desired distribution sorting order is according to postal code.
Additionally or alternatively, the desired distribution sorting
order is according to the delivery order of a mailman's route.
[0007] In accordance with another preferred embodiment of the
present invention the at least one production facility includes a
plurality of production facilities geographically distributed close
to correspondingly geographically distributed bulk mail drop-off
locations. Preferably, the at least one content-containing envelope
formation stage is operative to wrap the envelope sheets over the
contents sheets in a manner such that side flaps of the envelope
are glued to a surface of the envelope. Additionally or
alternatively, the at least one cutting stage is capable of
receiving the printed output from the at least one digital printer
in at least two of roll, sheet and fan-fold form.
[0008] In accordance with yet another preferred embodiment of the
present invention the at least one cutting stage operates
asynchronously to the operation of the at least one
content-containing envelope formation stage. Preferably, the at
least one cutting stage includes an envelope/envelope contents
differentiation stage, receiving the printed output from the at
least one digital printer and being operative to differentiate the
envelope sheets from the envelope contents sheets prior to cutting
the at least one of envelope sheets and envelope contents sheets.
Additionally or alternatively, the envelopes include personalized
printing both on the front and the back thereof.
[0009] In accordance with a further preferred embodiment of the
present invention the contents of the envelopes is printed on a
different substrate than the substrate. Preferably, envelope
contents sheets are folded prior to the at least one
content-containing envelope formation stage, such that the at least
one content-containing envelope formation stage is operative to
wrap the envelope sheets over suitably folded envelope contents
sheets. Additionally or alternatively, prior to the at least one
content-containing envelope formation stage at least one insert is
placed over the envelope sheets, such that during the at least one
content-containing envelope formation stage the envelope sheets are
wrapped over the envelope contents sheets and the at least one
insert.
[0010] In accordance with yet a further preferred embodiment of the
present invention the at least one digital printer is operative to
print the envelope address information separately from printing the
personalized envelope contents information, the at least one
cutting stage includes a plurality of cutting stages, at least one
of the plurality of cutting stages receiving a first printed output
corresponding to the envelope address information and being
operative to cut the first printed output into the envelope sheets
and at least one other of the plurality of cutting stages receiving
a second printed output corresponding to the personalized envelope
contents information and being operative to cut the second printed
output-into the envelope contents sheets, and wherein the envelope
sheets formed of the first printed output and the envelope contents
sheets formed of the second printed output are merged in the at
least one content-containing envelope formation stage.
[0011] There is further provided in accordance with a further
preferred embodiment of the present invention a system for
providing real-time, integrated production of individually
addressed sealed envelopes containing personalized printed material
matched to individual addresses, the system including at least one
digital printer operative to print personalized printing data
including envelope address information for a multiplicity of
envelopes to be formed from a substrate and personalized envelope
contents information for contents of the multiplicity of envelopes,
the contents of the multiplicity of envelopes containing a variable
number of sheets, which varies from one of the multiplicity of
envelopes to another of the multiplicity of envelopes and at least
one content-containing envelope formation stage operative to wrap
envelope sheets over envelope contents sheets containing a variable
number of sheets and thereby create sealed individually addressed
envelopes containing personalized content matched thereto having a
variable number of sheets.
[0012] In accordance with a preferred embodiment of the present
invention the at least one content-containing envelope formation
stage is operative to wrap the envelope sheets over the envelope
contents sheets in a manner such that side flaps of the envelope
are glued to a surface of the envelope. Preferably, envelope
contents sheets are folded prior to the at least one
content-containing envelope formation stage, such that the at least
one content-containing envelope formation stage is operative to
wrap the envelope sheets over suitably folded envelope contents
sheets.
[0013] In accordance with another preferred embodiment of the
present invention the system also includes at least one cutting
stage capable of receiving printed output from the at least one
digital printer in at least two of roll, sheet and fan-fold form
and being operative to cut the printed output into at least one of
the envelope sheets and the envelope contents sheets, the envelope
sheets being cut according to an envelope shaped blank. Preferably,
the at least one cutting stage operates asynchronously to the
operation of the at least one content-containing envelope formation
stage. Additionally or alternatively, the at least one cutting
stage includes an envelope/envelope contents differentiation stage,
receiving the printed output and being operative to differentiate
the envelope sheets from the envelope contents sheets prior to
cutting the at least one of the envelope sheets and the envelope
contents sheets.
[0014] In accordance with yet another preferred embodiment of the
present invention sealed individually addressed envelopes include
personalized printing both on the front and the back thereof.
Preferably, prior to the at least one content-containing envelope
formation stage, at least one insert is placed over the envelope
sheets, such that during the at least one content-containing
envelope formation stage the envelope sheets are wrapped over the
envelope contents sheets and the at least one insert.
[0015] There is additionally provided in accordance with an
additional preferred embodiment of the present invention a system
for providing real-time, integrated production of individually
addressed sealed envelopes containing personalized printed material
matched to individual addresses, the system including at least one
digital printer operative to print personalized printing data
including envelope address information for a multiplicity of
envelopes to be formed from a substrate and personalized envelope
contents information for contents of the multiplicity of envelopes
and at least one content-containing envelope formation stage
operative to wrap envelope sheets over envelope contents sheets and
thereby create sealed individually addressed envelopes containing
personalized content matched thereto, the sealed individually
addressed envelopes including personalized printing both on the
front and the back thereof.
[0016] In accordance with a preferred embodiment of the present
invention the at least one content-containing envelope formation
stage is operative to wrap the envelope sheets over the envelope
contents sheets in a manner such that side flaps of the envelope
are glued to a surface of the envelope. Preferably, the envelope
contents sheets are folded prior to the at least one
content-containing envelope formation stage, such that the at least
one content-containing envelope formation stage is operative to
wrap the envelope sheets over suitably folded envelope contents
sheets.
[0017] In accordance with another preferred embodiment of the
present invention the system also includes at least one cutting
stage capable of receiving printed output from the at least one
digital printer in at least two of roll, sheet and fan-fold form,
and being operative to cut the printed output into at least one of
the envelope sheets and the envelope contents sheets. Preferably,
the at least one cutting stage operates asynchronously to the
operation of the at least one content-containing envelope formation
stage. Additionally or alternatively, the at least one cutting
stage includes an envelope/envelope contents differentiation stage,
receiving the printed output and being operative to differentiate
the envelope sheets from the envelope contents sheets prior to
cutting the at least one of the envelope sheets and the envelope
contents sheets.
[0018] In accordance with a further preferred embodiment of the
present invention, prior to the at least one content-containing
envelope formation stage, at least one insert is placed over the
envelope sheets, such that during the at least one
content-containing envelope formation stage the envelope sheets are
wrapped over the envelope contents sheets and the at least one
insert.
[0019] There is also provided in accordance with another preferred
embodiment of the present invention a system for providing
real-time, integrated production of individually addressed sealed
envelopes containing personalized printed material matched to
individual addresses, the system including at least one digital
printer operative to print personalized printing data including
envelope address information for a multiplicity of envelopes to be
formed from a substrate and personalized envelope contents
information for contents of the multiplicity of envelopes, at least
one cutting stage receiving a printed output from the at least one
digital printer and being operative to cut at least one of envelope
sheets and envelope contents sheets, at least one
content-containing envelope formation stage operative to wrap the
envelope sheets over the envelope contents sheets and thereby
coterminously create envelopes and the content thereof in sealed
individually addressed envelopes containing personalized content
matched thereto.
[0020] In accordance with a preferred embodiment of the present
invention the at least one content-containing envelope formation
stage is operative to wrap the envelope sheets over envelope
contents sheets containing a variable number of sheets, such that
the sealed individually addressed envelopes have a variable number
of sheets. Preferably, the at least one content-containing envelope
formation stage is operative to wrap the envelope sheets over the
envelope contents sheets in a manner such that side flaps of the
envelope are glued to a surface of the envelope. Additionally or
alternatively, the envelope contents sheets are folded prior to the
at least one content-containing envelope formation stage, such that
the at least one content-containing envelope formation stage is
operative to wrap the envelope sheets over suitably folded envelope
contents sheets.
[0021] In accordance with another preferred embodiment of the
present invention the at least one cutting stage is capable of
receiving the printed output from the at least one digital printer
in at least two of roll, sheet and fan-fold form. Preferably, the
sealed individually addressed envelopes include personalized
printing both on the front and the back thereof. Additionally or
alternatively, the at least one cutting stage operates
asynchronously to the operation of the at least one
content-containing envelope formation stage.
[0022] In accordance with a further preferred embodiment of the
present invention the at least one cutting stage includes an
envelope/envelope contents differentiation stage, receiving the
printed output and being operative to differentiate the envelope
sheets from the envelope contents sheets prior to cutting the at
least one of the envelope sheets and the envelope contents sheets.
Preferably, prior to the at least one content-containing envelope
formation stage, at least one insert is placed over the envelope
sheets, such that during the at least one content-containing
envelope formation stage the envelope sheets are wrapped over the
envelope contents sheets and the at least one insert.
[0023] There is further provided in accordance with a further
preferred embodiment of the present invention a system for
providing real-time, integrated production of individually
addressed sealed envelopes containing personalized printed material
matched to individual addresses, the system including at least one
printing controller capable of receiving personalized printing data
from at least one data source, the personalized printing data
including envelope address information for a multiplicity of
envelopes and personalized envelope contents information which
varies for the multiplicity of envelopes and is matched to
individual envelope addresses, the at least one printing controller
being operative to order the personalized printing data from the at
least one data source such that it is printed in a desired
distribution sorting order, selected to optimize postal savings in
bulk mailings and at least one production facility for producing
the individually addressed sealed envelopes containing personalized
printed material matched to individual addresses, each of the at
least one production facility including at least one printer
operative to print the personalized printing data including
envelope address information for a plurality of envelopes and
personalized envelope contents information for contents of the
plurality of envelopes, at least one envelope/envelope contents
differentiation stage receiving a printed output from the at least
one printer and being operative to provide envelope sheets and
envelope contents sheets, at least one content-containing envelope
formation stage operative to wrap the envelope sheets over the
envelope contents sheets and thereby create sealed individually
addressed envelopes containing personalized content matched thereto
and a bundling stage, gathering and bundling the sealed
individually addressed envelopes containing personalized contents
matched thereto in the desired distribution sorting order.
[0024] In accordance with a preferred embodiment of the present
invention the at least one printing controller is capable of
receiving multiple printing jobs from disparate sources and
combining them in a single pre-sorted print run. Preferably, the
desired distribution sorting order is according to postal code.
Additionally or alternatively, the desired distribution sorting
order is according to the delivery order of a mailman's route.
[0025] In accordance with another preferred embodiment of the
present invention the at least one production facility includes a
plurality of production facilities geographically distributed close
to correspondingly geographically distributed bulk mail drop-off
locations. Preferably, the at least one content-containing envelope
formation stage is operative to wrap the envelope sheets over the
contents sheets in a manner such that side flaps of the envelope
are glued to a surface of the envelope. Additionally or
alternatively, the at least one envelope/envelope contents
differentiation stage is capable of receiving the printed output in
at least two of roll, sheet and fan-fold form.
[0026] In accordance with a further preferred embodiment of the
present invention the at least one envelope/envelope contents
differentiation stage operates asynchronously to the operation of
the at least one content-containing envelope formation stage.
Preferably, the envelopes include personalized printing both on the
front and the back thereof. Additionally or alternatively, the
envelope contents sheets are folded prior to the at least one
content-containing envelope formation stage, such that the at least
one content-containing envelope formation stage is operative to
wrap the envelope sheets over suitably folded envelope contents
sheets.
[0027] In accordance with yet a further preferred embodiment of the
present invention, prior to the at least one content-containing
envelope formation stage, at least one insert is placed over the
envelope sheets, such that during the at least one
content-containing envelope formation stage the envelope sheets are
wrapped over the envelope contents sheets and the at least one
insert.
[0028] There is additionally provided in accordance with an
additional preferred embodiment of the present invention a method
for providing real-time, integrated production of individually
addressed sealed envelopes containing personalized printed material
matched to individual addresses, the method including receiving
personalized printing data from at least one data source, the
personalized printing data including envelope address information
for a multiplicity of envelopes and personalized envelope contents
information which varies for the multiplicity of envelopes and is
matched to individual envelope addresses, ordering the personalized
printing data from the at least one data source such that it is
printed in a desired distribution sorting order, selected to
optimize postal savings in bulk mailings and producing the
individually addressed sealed envelopes containing personalized
printed material matched to individual addresses, the producing
including printing the personalized printing data, thereby
providing a multiplicity of envelope sheets and envelope content
sheets for the multiplicity of envelopes, differentiating the
envelope sheets and the envelope contents sheets, wrapping the
envelope sheets over the envelope contents sheets and thereby
creating sealed individually addressed envelopes containing
personalized content matched thereto and gathering and bundling the
sealed individually addressed envelopes containing personalized
contents matched thereto in the desired distribution sorting
order.
[0029] In accordance with a preferred embodiment of the present
invention the printing the personalized printing data includes
digital printing. Preferably, the digital printing includes digital
printing on a continuous substrate. Additionally or alternatively,
the receiving includes receiving multiple printing jobs from
disparate sources and combining them in a single pre-sorted print
run.
[0030] In accordance with another preferred embodiment of the
present invention the desired distribution sorting order is
according to postal code. Preferably, the desired distribution
sorting order is according to the delivery order of a mailman's
route. Additionally or alternatively, the wrapping includes
wrapping the envelope sheets over contents sheets such that side
flaps of the envelope are glued to a surface of the envelope.
[0031] In accordance with yet another preferred embodiment of the
present invention the method also includes, prior to the wrapping,
folding the envelope contents sheets, such that the wrapping
includes wrapping the envelope sheets over suitably folded envelope
contents sheets. Preferably, the method also includes, prior to the
wrapping, placing at least one insert is placed over the envelope
sheets, such that the wrapping includes wrapping the envelope
sheets over the envelope contents sheets and the at least one
insert.
BRIEF DESCRIPTION OF THE DRAWINGS
[0032] The present invention will be understood and appreciated
more fully from the following detailed description, taken in
conjunction with the drawings in which:
[0033] FIG. 1 is a simplified schematic illustration of a system
providing real-time, integrated production of envelopes and the
contents thereof in accordance with a preferred embodiment of the
present invention;
[0034] FIGS. 2A and 2B are simplified, schematic illustrations of
two alternative embodiments of a cutting and/or envelope/envelope
contents differentiation stage forming part of the system of FIG.
1;
[0035] FIGS. 3A and 3B are simplified, schematic illustrations of
two alternative embodiments of an envelope formation stage forming
part of the system of FIG. 1; and
[0036] FIG. 4 is a simplified, schematic illustration of a sealing
stage and a bundling stage forming part of the system of FIG.
1.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0037] Reference is now made to FIG. 1, which is a simplified
schematic illustration of a system providing real-time, integrated
production of envelopes and the contents thereof in accordance with
a preferred embodiment of the present invention. The system of FIG.
1 preferably comprises at least one production facility 100 for the
production of individually addressed sealed envelopes containing
personalized printed material matched to individual addresses.
[0038] Preferably, the production facilities 100 may be
geographically distributed so as to be adjacent to bulk mail
drop-off locations of postal authorities or delivery contractors.
It is appreciated that such locations may be in different countries
or in different regions of a single country. The postal authorities
or delivery contractors at different ones of such locations may
require different franking. It is a particular feature of the
present invention that due to the real-time operation of the
system, a given production facility 100 may be selected at a given
time in order to take advantage of beneficial spot pricing of bulk
mail delivery services by a postal authority or delivery
contractor.
[0039] Each production facility 100 preferably includes at least
one high speed digital printer 101, such as, for example, a IBM
infoprint 2105ES, commercially available from IBM Corporation of
Armonk, N.Y., a Konica Minolta Bizhub Pro 1050P, commercially
available from Konica Minolta Holdings Inc. of Tokyo, Japan, or a
Ricoh DDP184, commercially available from Ricoh Corporation of
Tokyo, Japan, which is capable of printing on a substrate, such as
paper on one or more white rolls 102. Alternatively, the paper may
be provided to printer 101 as cut sheets, fan-fold stacks or in any
other suitable form, and may be of any suitable color, thickness or
width. Each digital printer 101 preferably receives printing
instructions from at least one printing controller 110, which, in
turn, receives personalized printing data from one or more data
sources 112. The personalized printing data includes envelope
addresses and often includes personalized envelope contents which
vary and are keyed to specific envelope addresses.
[0040] In accordance with a preferred embodiment of the present
invention the controller 110 imposes the envelope addresses and
other envelope information into the stream of information provided
to one or more printers 101, such that the envelope information is
printed onto an envelope or into an envelope information sheet to
be inserted into a windowed envelope.
[0041] It is a particular embodiment of the present invention that
the envelope information may be printed onto the envelope or onto
the envelope information sheet via a different printing stream than
the stream that prints envelope contents pages, or alternatively,
that the envelope information and envelope contents pages are
printed in a single stream.
[0042] It is a particular feature of the present invention that
printing controller 110 may receive personalized printing data from
multiple disparate sources 112, such as banks, utilities, insurance
companies and other customers, each relating to a printing piece
which may vary in its dimensions, number of pages of content and
other parameters. Preferably, the printing controller 110
commingles the data received from multiple disparate sources 112
and orders the personalized printing data from such multiple
disparate sources 112 such that it is printed and thus output in a
desired distribution sorting order. The distribution sorting order
is preferably selected to maximize savings in postage and may be
according to postal code and even more preferably in the delivery
order of a mailman's route. Ordering the printing in such an order
enables very significant discounts in postage to be realized
without requiring downstream sorting. The amount of such discounts
may exceed the cost of producing the mailing piece.
[0043] Alternatively, printing controller 110 may receive
personalized printing data from a single source 112, relating to a
printing piece which may vary in its dimensions, number of pages of
content and other parameters. In this embodiment, printing
controller 110 orders the personalized printing data from the
single source 112 such that it is printed and thus output in a
desired distribution sorting order. The distribution sorting order
is preferably selected to maximize savings in postage and may be
according to postal code and even more preferably in the delivery
order of a mailman's route. Ordering the printing in such an order
enables very significant discounts in postage to be realized
without requiring downstream sorting. The amount of such discounts
may exceed the cost of producing the mailing piece.
[0044] It is also a particular feature of the present invention
that multiple digital printers 101 may be located adjacent multiple
mailing locations and that a digital printer 101 may be selected
according to its propinquity to a bulk mail drop off location, in
order to provide additional cost savings in transport. It is
appreciated that a printing controller 110 may divide a printing
job from a given source 112 into multiple printing jobs to be
handled by various digital printers 101, each optimally located
nearby a bulk mail drop off location for a given group of
addresses.
[0045] It is appreciated that the digital printer 101 prints
personalized envelope and envelope contents information on one or
both sides of the substrate, prior to envelope formation, thus
enabling, inter alia, printing on the interior of envelopes. The
digital printer 101 may provide a printed output in one or more
forms, such as fan-folded stacks 114, cut stacks of sheets 116 and
rolls 118. The digital printer 101 may operate asynchronously with
respect to the remainder of the system.
[0046] Referring additionally now to FIGS. 2A and 2B, which
illustrate two alternative embodiments of a cutting and/or
envelope/envelope contents differentiation stage forming part of
the system of FIG. 1.
[0047] As seen in FIGS. 2A, downstream of each digital printer 101
there is preferably provided a cutting and envelope/envelope
contents differentiation stage 120 at which printed envelope sheets
122 are cut, preferably according to an envelope blank and
preferably by a suitable die cutter 123, and the printed envelope
contents are cut into one or more envelope contents sheets 124 and
trimmed as necessary by a side trimmer 126. Preferably, a scanning
functionality (not shown), identifies pages coming out of the
printer as envelope sheets or as envelope contents sheets, and
directs them toward the suitable trimming device, such as the die
cutter 123 or the side trimmer 126. A preferred scanning
functionality is that described in U.S. Pat. No. 5,008,520, the
contents of which are hereby incorporated by reference. It is
appreciated that any suitable cutting method is suitable, such as
laser cutting or water jet cutting.
[0048] In the illustrated embodiment of FIG. 2A, envelope sheets
122 are separated from envelope contents sheets 124 prior to die
cutting and trimming. Paper scraps are removed preferably by
vacuum. Alternatively, the envelope sheets 122 may be joined to the
envelope contents sheets 124 as described in U.S. Pat. No.
7,100,348, the disclosure of which is hereby incorporated by
reference.
[0049] Turning to FIG. 2B, it is seen that downstream of each
digital printer 101 there is preferably provided a cutting stage
120. As seen in FIG. 2B, the printed envelope sheets 122 are
provided in a first stream, having a first cutting stage 127, at
which printed envelope sheets 122 are cut, preferably according to
an envelope blank and preferably by suitable die cutter 123, and
the printed envelope contents are provided in a second stream
having a second cutting stage 128, at which the envelope contents
are cut into one or more envelope contents sheets 124 and trimmed
as necessary by side trimmer 126. It is appreciated that the
envelope sheets and envelope content sheets may be printed and cut
out of different substrates, here shown as a fan fold stack of
sheets and a roll of sheets, and as substrates of different colors.
It is appreciated that any suitable cutting method is suitable,
such as laser cutting or water jet cutting.
[0050] In the illustrated embodiment of FIG. 2B, paper scraps are
removed preferably by vacuum. Alternatively, the envelope sheets
122 may be joined to the envelope contents sheets 124 as described
in U.S. Pat. No. 7,100,348, the disclosure of which is hereby
incorporated by reference.
[0051] It is appreciated that, as seen in FIGS. 2A and 2B, the
number of envelope contents sheets 124 may vary from envelope to
envelope. All the envelope contents sheet 124 belonging to a
specific envelope are preferably accumulated by an accumulator 129,
and then continue to move through the system as a group of
accumulated envelope contents sheets 124. Envelope contents sheets
124 belonging to a single envelope are preferably identified by a
scanning functionality (not shown), preferably that described in
U.S. Pat. No. 5,008,520, the contents of which are hereby
incorporated by reference. It is further appreciated that the die
cutter 123 of stage 120 preferably operates asynchronously from the
envelope formation stage which follows.
[0052] Alternatively, envelope sheets 122 and envelope content
sheets 124 may be produced by any other suitable means and supplied
to the envelope formation stage which follows.
[0053] Returning to FIG. 1, it is seen that downstream of the
cutting and/or envelope/envelope contents differentiation stage 120
is a content containing envelope formation stage 130 at which the
envelope 132 is formed by folding the envelope sheet 122 over the
envelope contents sheet or sheets 124 and gluing a back flap of the
envelope sheet 122 and side flaps of the envelope sheet 122
respectively. At this stage externally produced inserts may be
added to the envelope contents. Envelope formation stage 130 is
described further hereinbelow with reference to FIGS. 3A, 3B and
4.
[0054] In accordance with a preferred embodiment of the present
invention, at a bundling stage 140, the finished mailers 142, each
including an envelope 132 and its content sheets 124, are gathered
and bundled in a desired distribution order for delivery to the
postal delivery contractor. A suitable stacking and bundling system
is described in U.S. Pat. No. 6,682,067, the disclosure of which is
hereby incorporated by reference. It is noted that where multiple
printing jobs from disparate sources are preferably combined in a
single print run, bundles 150 may contain mailers of differing
sizes and configurations, multiple ones of which may be directed to
the same addressee from different senders.
[0055] Reference is now made additionally to FIGS. 3A and 3B, which
illustrate two alternative embodiments of the structure and
operation of envelope formation stage 130.
[0056] In the embodiment illustrated in FIG. 3A, envelope 132 is
formed by transversely scoring envelope sheet 122 and subsequently
folding the envelope sheet 122 over the suitably folded envelope
contents sheet or sheets 124 and gluing a back flap 155 and side
flaps 156, respectively. It is appreciated that at the envelope
formation stage 130 an inside flap envelope or an outside flap
envelope may be formed, depending on the order in which the back
flap 155 and side flaps 156 are glued to each other and on the
surface of each of the flaps to which the glue is applied.
[0057] As seen in FIG. 3A, suitably die cut envelope sheets 122 are
received along a first conveyor 200, back flap 155 facing
forwardly, and envelope contents sheets 124, to be enclosed within
the envelope to be formed from a corresponding envelope sheet 122,
are received along a second conveyor 202 by accumulator 129. The
accumulated envelope contents sheets 124 are then folded as
desired, typically in half or into three portions, by an envelope
contents sheet folder 204, which is typically a buckle shoot
folder.
[0058] The envelope sheet 122 is preferably transversely scored by
a scoring mechanism 205. The folded envelope contents sheets 124
are positioned over a middle panel of the envelope sheet 122,
preferably by a suitable positioner, such as a positioner including
servo controlled nips (not shown), and released in synchronization
with the location of corresponding envelope sheet 122.
Alternatively, the envelope contents sheet folder 204 may also
function as a positioner for the envelope contents sheets 124.
Optionally, one or more inserts 158 may be placed onto the envelope
sheet 122 by an insert feeder 208. Preferably, inserts 158 are also
positioned by a suitable positioner (not shown), such as a
positioner including servo controlled nips.
[0059] In accordance with a preferred embodiment of the present
invention, envelope sheet 122 and the envelope contents sheets 124
are merged together precisely by the positioner to allow for a high
degree of placement precision, regardless of the envelope
processing speed. This is preferably achieved by varying the speed
of conveyor 202 such that the envelope contents sheets 124 meet the
appropriate envelope and are merged together precisely. The
positioner also provides a high degree of placement precision
independent of the size of the content pages vis-a-vis the envelope
size and allows for a varying number of contents sheets 124 to be
placed in each envelope.
[0060] The envelope sheet 122, having thereon the folded envelope
contents sheets 124, and optionally inserts 158, is then folded
around content sheets 124 and optional inserts 158 by a suitable
folder 210.
[0061] Alternatively, as shown in FIG. 3B, envelope 132 is formed
by folding the envelope sheet 122 together with the envelope
contents sheet or sheets 124 and gluing back flap 155 and side
flaps 156, respectively. It is appreciated that at the envelope
formation stage 130 an inside flap envelope or an outside flap
envelope may be formed, depending on the order in which the back
flap 155 and side flaps 156 are glued to each other and on the
surface of each of the flaps to which the glue is applied.
[0062] Suitably die cut envelope sheets 122 are received along a
first conveyor 200, back flap 155 forwardly, and envelope contents
sheets 124, to be enclosed within the envelope to be formed from a
corresponding envelope sheet 122, are received along a second
conveyor 202 by accumulator 129 and released by a positioner 212,
including servo controlled nips, in synchronization with the
location of corresponding envelope sheet 122. Such synchronization
is preferably achieved by varying the speed of conveyor 202 in
accordance with the speed of conveyor 200. This synchronization
preferably results in precise positioning of the envelope contents
sheets 124.
[0063] Optionally, one or more inserts 158 may be placed onto the
envelope sheet 122 by insert feeder 208. Preferably, inserts 158
are also positioned by a suitable positioner, such as a positioner
including servo controlled nips.
[0064] Positioner 212 preferably allows for a high degree of
placement precision, regardless of the envelope processing speed.
The positioner 212 provides a high degree of placement precision
independent of the size of the content pages vis-a-vis the envelope
size and also allows for a varying number of contents sheets 124 to
be placed in each envelope.
[0065] The envelope sheet 122 having the envelope contents sheets
124, and optionally inserts 158 thereon, enter buckle chute folder
214, which folds the envelope sheet 122, content sheets 124 and
optional inserts 158.
[0066] Reference is now made additionally to FIG. 4, which
illustrates a sealing stage and a bundling stage forming part of
the system of FIG. 1. As seen in FIG. 4, side flaps 156 are scored
by a scoring mechanism 216, and glue is then applied to side flaps
156, such as by glue applicator 218. Alternatively, the glue may be
applied to the back flap 155. Glue can be applied in the form of
hot or cold melt glue, or using any suitable method, including
strip application. Side flaps 156 are then folded over contents
sheets 124 and envelope sheet 122 by any suitable folding method,
such as by using a plow folder. Alternatively, as shown in the
embodiment of FIG. 3B, glue is applied to side flaps 156 or to back
flap 155 as the last part of the buckle folding process.
[0067] In another alternative embodiment, scoring is performed
upstream, in either the cutting or the merging modules, glue is
applied to back flap 155 or to side flaps 156 in the folder module
or in a separate module, and side flaps 156 are folded under the
back flap 155 of the envelope sheet 122, yielding an envelope with
"inside flaps" or over the back flap 155 of the envelope sheet 122,
yielding an envelope with "outside flaps".
[0068] As seen further in FIG. 4, the direction of envelope travel
is changed by 90 degrees, a top flap 222 of the envelope sheet 122
is scored by scoring mechanism 230, glue is applied thereto, such
as by applicator 232, and top flap 222 is folded over, by any
suitable folding method, such as by using a plow folder 234, thus
sealing the envelope. Alternatively, glue may be applied to the
back flap 155, onto which the top flap 222 is folded. Finished
mailers 142 are preferably laying flat while they are scored, glued
and sealed to facilitate operation for postal franking machines. It
is appreciated that finished mailers 142 may need to be flipped
prior to franking.
[0069] As seen further in FIG. 4, finished mailers 142 are
preferably turned up on edge and moved into a vertical stacking
mechanism. Alternatively, envelopes are turned on edge prior to
scoring and gluing of top flaps 222, which are scored and glued
while the envelopes are in a vertical position. The finished
mailers 142 are then preferably stacked on edge and grouped into
bundles 150 as seen in FIG. 3B.
[0070] It will be appreciated by persons skilled in the art that
the present invention is not limited to what has been particularly
shown and described hereinabove. Rather the scope of the invention
includes both combinations and subcombinations of the various
features described hereinabove as well as modifications and
variations thereof which would occur to persons skilled in the art
upon reading the foregoing description and which are not in the
prior art.
* * * * *