Abstract:
Method for producing multiple small custom envelope jobs using a sheet fed envelope machine. Multiple different envelope jobs are provided as stacks of sheets of envelope stock to a high volume envelope machine for processing into folded envelopes. Each envelope job stack includes a first sheet that, when processed by the machine, yields an envelope with visually distinctive edges. At the output of the envelope machine, the group of envelopes in an envelope job is indicated by the distinctive envelopes formed from first sheets.

Description:
FIELD OF THE INVENTION 
       [0001]    This invention relates to the creation and processing of folded envelopes. 
       BACKGROUND OF THE INVENTION 
       [0002]    High volume envelope machines capable of accepting stacks of cut sheets of paper or other suitable envelope stock and performing cutting, gluing, and folding operations to produce hundreds of folded envelopes per minute are commercially available from various vendors, for example Winkler+Dünnebier AG. Typically, a human operator of the envelope machine will manually load stacks of envelope paper stock in the machine&#39;s feed mechanism and a human operator will manually remove the folded envelopes for packaging or other processing as they completed and made available by the machine. 
         [0003]    High volume envelope machines are well suited for the production of long runs of thousands of identical envelopes, but these machines have not been considered practical or efficient for short envelope print jobs, for example a print job of 100 envelopes. It can be appreciated that if a machine were to be running at a rate that produces hundreds of envelopes each minute with every hundred envelopes produced being a different job printed with different information for a different customer, the operator could find it stressful, or impossible, to keep up with that production pace while still correctly locating and removing the set of folded envelopes associated with each individual envelope job for packaging or other processing. 
         [0004]    Therefore, there is a need for an envelope production and processing method that is capable of assisting an envelope machine operator in quickly and efficiently identifying the beginning and end of each different envelope order such that the operator can reliably and quickly manually separate each envelope order for further processing. 
       SUMMARY  
       [0005]    The present invention is directed at satisfying the need for guides and processes that facilitate the ability of an envelope machine operator to quickly identify groups of folded envelopes belonging to individual envelope orders. 
         [0006]    In accordance with one aspect of the invention, multiple different envelope jobs are provided to an envelope machine as stacks of sheets of envelope stock. The first sheet of each envelope job stack yields an envelope with visually distinctive edges, such that the group of envelopes in an envelope job can be identified by their position between the envelope formed by the first sheet of the stack and the envelope formed by the first sheet of the next envelope job stack. 
         [0007]    It is an advantage of the invention that the folded envelopes in an envelope order can be quickly identified. 
         [0008]    It is another advantage of the invention that envelope machines having high envelope output rates can be employed to produce small envelope orders. 
         [0009]    These and other objects, features and advantages of the invention will be better understood with reference to the accompanying drawings, description and claims. 
     
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0010]      FIG. 1  illustrates the outside of an envelope prior to undergoing trimming, folding, and gluing. 
           [0011]      FIG. 2  is an illustrative envelope job sheet  200 . 
           [0012]      FIG. 3  depicts job sheet  200  after envelope processing. 
           [0013]      FIG. 4  is a schematic depiction of envelope processing flow using job sheets. 
       
    
    
     DETAILED DESCRIPTION 
       [0014]      FIG. 1  depicts sheet  100  prior to being processed into a finished envelope by trimming, gluing and folding. The envelope design and proportions depicted in  FIG. 1  are merely representative for purposes of discussion. It will be understood by those of ordinary skill in the art that envelopes can be of various sizes, shapes, and materials and that the systems and methods disclosed herein are not limited to any particular envelope size, shape, material or trimming details. It will be further understood that envelopes are generally ordered in volume. In fulfilling an order for a requested quantity of custom envelopes, the appropriate number of sheets  100  with the customer&#39;s desired images and other information are printed and fed into the envelope machine for processing into folded envelopes. For custom printed envelopes, each sheet  100  is preprinted with return address information  113  and may also be preprinted with additional materials, not shown, such as images, graphics, patterns, or text. 
         [0015]    In processing sheet  100  into a finished envelope, the areas identified as  101 - 104  of sheet  100  are cut away and discarded. The removal of areas  101 - 104  creates side flaps  105  and  106 , bottom flap  107  and seal flap  108 . During processing of sheet  100  by the envelope machine, side flaps  105  and  106  will be folded along the lines indicated by dashed lines  109  and  110 , bottom flap  107  will be folded along the line indicated by dashed line  111 , and seal flap  108  will be folded along the line indicated by dashed line  112 . Adhesive is applied to firmly attach back flap  107  to side flaps  105  and  106 . For the typical envelope for business and consumer use, an appropriate adhesive is applied to the appropriate side of seal flap  108  to allow the user of the envelope to seal the envelope after the user&#39;s materials have been placed inside. 
         [0016]      FIG. 2  depicts job sheet  200 , which has been printed with indicators  201 - 204 . Indicators  201 - 204  are relatively wide indicia printed at the envelope fold lines such that an envelope created from job sheet  200  will be visually distinctive from regular production envelopes and, therefore, will be readily identifiable by the machine operator. Indicators are positioned on job sheet  200  such that indicator  201  corresponds to the position of fold line  109 , indicator  202  corresponds to the position of fold line  110 , indicator  203  corresponds to fold line  111 , and indicator  204  corresponds to fold line  112 . 
         [0017]    In the disclosed illustrative embodiment, job sheet  200  is also printed with bar code  205  having an individual envelope order identifier for order tracking and shipping purposes. Job sheet  200  may also have various additional printed content, collectively indicated in  FIG. 2  as Job information  206 , that the envelope manufacturer deems to be useful during the processing of the order. Job information  206  might include, for example, the order date, the envelope printing date, processing instructions, and/or customer information. 
         [0018]    In addition to operating as an aid for post production identification and processing of envelope jobs, the bar code  205  and information  206  on the job sheet are also useful in the event of an envelope machine jam or other malfunction while envelope jobs are being produced. At the time of a malfunction, one or more different envelope jobs may be fully or partially in process in the machine and one or more sheets of envelope stock in one or more different envelope jobs may have been damaged or improperly processed such that the envelope job will need to be reprinted and reprocessed. The bar code  205  and information  206  allows the envelope manufacturer to quickly identify the damaged or potentially damaged jobs and initiate reprinting with a minimum of delay. For example, as sheets are being cleared from the machine by the operator after a jam or malfunction, the information  206  or the bar code  205  on the job sheets found in the machine can be read and those envelope jobs can be immediately scheduled to be reprinted such that the likelihood of the delivery to the customer being delayed is minimized. 
         [0019]      FIG. 3  illustrates a folded envelope  300  produced from job sheet  200 . Because indicators  201 - 204  were positioned to correspond to the locations of fold lines  109 - 112 , indicators  201 - 204  will be wrapped over the edges of envelope  300  and will create a visually distinctive envelope  300  edge appearance that allows envelope  300  to be visually identified among a group of other envelopes. 
         [0020]    While an alternating dark and light pattern is depicted herein as indicators  201 - 204 , it will be understood that any other indicator design that is suitable to create a distinctive and easily recognized edge could be employed. For example, the envelope vendor may want to use the envelope created from job sheet  200  to further communicate with or market to the envelope customer by printing additional images and text on the job sheet and packaging the envelope created from the job sheet with the customer&#39;s envelopes. For example, content such as the logo of the envelope manufacturer, a thank you message, or a promotional offer for a future purchase, could be printed on sheet  200 . Some of this additional image content could be specifically designed and positioned on job sheet  200  such that a portion of the image content crosses one or more of the fold lines  109 - 112  and yields a visually distinctive envelope edge that serves the function of indicators  201 - 204 . 
         [0021]      FIG. 4  shows an illustrative schematic representation of an envelope manufacturing process according to an embodiment of the invention. The process flow conceptually proceeds in the direction indicated by arrow  400 . Each envelope job is fed into envelope machine  405  as a stack of preprinted sheets, such as envelope job stacks  402  and  404 , for processing into folded envelopes. A preprinted job sheet, as discussed above in connection with  FIG. 2 , is positioned on top of the associated stack of preprinted sheets before the sheets are processed by the envelope machine. For example, in  FIG. 4 , job sheet  401  associated with stack  402  is positioned on top of the stack, job sheet  403  is positioned on top of its corresponding stack of printed sheets  404 , and so forth. It will be understood that if the envelope manufacture has a large number of envelope jobs to produce, the envelope manufacturer may operate the envelope machine continuously for an extended period of time with the machine operator adding additional stacks of envelope jobs to the machine feed mechanism from time to time as required to maintain a continuous supply of input material to the machine such that many stacks are sequentially processed. 
         [0022]    While machine  405  is operating, the folded envelopes produced by the machine are continuously being transferred by the machine into an output area that is accessible to an operator such that the operator can manual remove the envelopes for packaging or other interim processing. The envelopes produced by the machine are positioned by the machine in the machine&#39;s output area such that the edges of the folded envelopes are visible to the operator. 
         [0023]    In the situation depicted in  FIG. 4 , a plurality of envelopes are available in output queue  406  for removal by an operator. While machine  405  is operating, unfolded sheets are continuously being fed into the machine and folded envelopes are continuously entering output queue  406 . Because the physical space for the folded envelopes is limited, the operator must frequently remove envelope jobs from the queue. In output queue  406  depicted in  FIG. 4 , each rectangle, such as  410 , represents an edge of a folded envelope. Envelopes created from job sheets, such as envelopes  407  and  408 , can be quickly visually identified by the operator by their visually distinctive edges and serve as dividers between different envelope jobs. 
         [0024]    Referring to  FIG. 4 , the operator can quickly view the output envelope queue  406  and see that all envelopes from  407  through  410  are a single envelope print job, with envelope  408  indicating the beginning of the next job. The operator can manually remove all envelopes  409  for packaging or other processing. Because the indicator is printed such that it appears on the top, sides and bottom edges of the folded envelope, any edge that is visible to the operator will provide the visual cue. 
         [0025]    While an exemplary embodiment of the invention has been discussed, the described embodiment is to be considered as illustrative rather than restrictive. The scope of the invention is as indicated in the following claims and all equivalent methods and systems.