Abstract:
The present invention is directed to a method of using a sealing nip configuration to produce a sealed business communication having at least one insert. The sealing nip is constructed from a pair of rollers, with at least one roller having a smooth surface and the other roller having a series of circumferentially extending raised areas that are used to apply directed pressure to marginal areas containing a cohesive.

Description:
CROSS-REFERENCES TO RELATED APPLICATIONS  
       [0001]     None.  
       FIELD OF THE INVENTION  
       [0002]     The present invention relates to a novel sealing roller configuration that is used in processing business communication documents having segmented cohesive patterns. More preferably, the sealer roller configuration utilized in forming the completed business form documents includes a number of raised surface areas that extend circumferentially about the roller element and which are spaced from one another to engage cohesive patterns on the mailer document and to avoid contact of a raised insert if one is provided in connection with the business communication.  
       BACKGROUND OF THE INVENTION  
       [0003]     There are currently a plethora of office products, business form constructions and other stationery items that are available in the market today and yet with this inordinately large selection of offerings and permutations, there remains a continuing need to develop new products due to changes in technology, societal trends, diversification and new information handling needs of businesses and consumers alike.  
         [0004]     The market for printed materials is also changing and becoming significantly more sophisticated. Conventional business forms manufacturers have normally produced product runs that range in the hundreds of thousands to millions or even tens of millions of pieces for a single order. The equipment associated with such production levels is often unable to readily adapt to accommodating different scopes and types of products to be produced.  
         [0005]     It is believed that one of the reasons for such far reaching changes in the printing industry is that end users want more from each piece that is produced rather than relying on the quantity of pieces to generate the desired result. In addition, marketers want to make a greater impact at every turn in the retail chain to try and maximize the chances for purchases of a particular product being offered by the printed piece. This demand must be weighed in combination with the ever present demand to keep costs as low as possible while attempting to deliver value to the customer.  
         [0006]     With the change in focus to quality as opposed to quantity there are a number of products or applications that to date are still out of reach of conventional manufacturers in that certain items simply cannot be handled by conventional printing equipment and forms processing apparatus.  
         [0007]     There are many business form products that carry inserts, such as direct mail pieces in which an external envelope is provided and one or more pieces can be inserted within the outer envelope and delivered to the intended end user. Mailing sheets have also been created which can be easily printed, folded and sealed to create a mailing piece that can be easily processed by the US Postal Service as well as handled by offices ranging from the small office/home office to large statement printing companies that render hundreds of thousands of statements, invoices and the like.  
         [0008]     Cards, including plastic and laminated cards and tags, are generally well known and come in a variety of sizes and shapes depending on the particular needs of the issuer or end user. Wallet sized cards have become fairly common place and due to the popularity of such cards, the products have been used for identification cards, credit card, key cards and a host of other applications. Wallet sized cards have a size of about 3⅜ inches wide to 2⅛ inches in length.  
         [0009]     Problems have developed when trying to position cards on mailing sheets in order to take advantage of the simplicity associated with those types of constructions. Typically, self sealing mailing sheets have not carried cards, magnets or other relatively thick materials as when the mailing sheet is processed through sealing equipment, the thickness of insert causes distortions in the mailing sheet when the sheet is processed through the sealer unit. That is, the sealing units typically use a “steam roller” type sealing configuration that simply crushes the mailing sheet in an attempt to create a seal on the product. In addition, the insert can actually puncture or rip the mailing sheet due the edges of the insert punching through the mailing sheet as the sheet is pressed into contact with the insert while being processed through the sealing unit.  
         [0010]     In either of the prior art situations, confidentiality of the insert is compromised as either any individual that comes into contact with the mailing piece can see what is contained in the mailing sheet or alternatively, if the insert has broken through the surface of the mailing sheet, the insert can be readily viewed thus allowing any information printed on the surface of the card to be witnessed by an individual coming into possession of the mailer.  
         [0011]     In addition, such processing situations are also less desirable in that the package when received by the intended end user appears to be damaged or dirty creating less than appealing image or perception in the mind of the recipient which takes away from the message intended by the sender.  
         [0012]     Other sealing unit scenarios have been tried in which resilient bands are applied to one roller in an attempt to accommodate the thickness of the insert. However, problems develop with this type of solution in that bands tend to wear out after continuing use or alternatively, the bands may shift from the intended orientation which may lead to the problems identified about or alternatively, the mailing sheet not being effectively sealed during processing.  
         [0013]     What is needed therefore is a process by which mailing sheets or business forms having relatively thick inserts can be effectively sealed without destroying the business communication while at the same time creating an effective seal on a business form in order to preserve the integrity of the information.  
       BRIEF SUMMARY OF THE INVENTION  
       [0014]     The embodiments of the present invention described below are not intended to be exhaustive or to limit the invention to the precise forms disclosed in the following detailed description. Rather, the embodiments are chosen and described so that others skilled in the art may appreciate and understand the principles and practices of the present invention.  
         [0015]     The present invention relates to the use of a sealing nip having at least a pair of spaced apart, raised sealing areas that can apply sufficient sealing pressure directly to marginal areas of a business communication having patterns of cohesive disposed in the marginal areas. The use of raised sealing areas on the surface of a roller permits the business communication document to carry an insert that has a thickness that is greater than thickness of the document.  
         [0016]     In one exemplary embodiment, a method for creating a sealed business communication document is disclosed and includes the steps of initially supplying at least one business form blank. The blank has a thickness, first and second faces, first and second longitudinally extending sides and first and second transversely extending edges. The blank includes first and second longitudinally extending lines of weakness each of which are spaced inwardly from first the first and second longitudinally extending sides to create first and second longitudinally extending marginal areas. First and second transversely extending lines of weakness are also included and each of which are spaced inwardly from the first and second transversely extending edges to form first and second transversely extending marginal areas. Each of the first and second longitudinally extending marginal areas and the first and second transversely extending marginal areas have a pattern of cohesive. The blank includes an insert that is applied to one of the first and second faces.  
         [0017]     Next, a sealing nip configuration is provided such as in the case of a small or home office sealing unit. The sealing nip configuration consists of a first roller that has a substantially continuous surface and a second roller that has at least first and second raised surface areas. Each of the surface areas has a width of less than about one quarter of an inch and the first and second raised areas are spaced a distance from one another such that the insert on the one of the first and second faces of the blank can pass between the raised surface areas without contact.  
         [0018]     Then the at least one business form blank is folded such that at least a portion of the first and second longitudinally extending marginal areas are in contact with one another to form a folded blank. At least one business form blank is then inserted into the sealing nip configuration and then at least a portion of the first and second longitudinally extending marginal areas is sealed by contacting the marginal areas with the first and second raised surface areas to form a sealed business communication document.  
         [0019]     In a still further exemplary embodiment, a method of sealing an insert carrying business form is described and includes of the steps of initially supplying a business form blank having first and second faces. The business form blank has a first thickness and first and second longitudinally extending marginal areas, first and second transversely extending areas with each of the areas having a pattern of cohesive.  
         [0020]     Next, an insert is positioned on one of the first and second faces. The insert has a second thickness that is greater than the first thickness. The insert is disposed inwardly of each of the longitudinally extending marginal areas and the first and second transversely extending marginal areas. The insert has a first length and width.  
         [0021]     The blank is then folded so that the patterns of cohesive in each of the marginal areas are in contact with one another to create a folded blank. Then the folded blank is inserted in to a sealing nip assembly. The sealing nip includes a first substantially smooth roller and a second roller that has a series of circumferentially extending ridges that are spaced from one another a distance greater than one of the first length or width of the insert. Each of the ridges has a width of less than about one quarter of an inch. Then, the folded blank is sealed about the marginal areas to form a sealed business communication having the insert.  
         [0022]     In yet a still further exemplary embodiment, a method of producing a sealed business communication containing an insert is described and includes the steps of initially providing a business form intermediate that has a first thickness. The intermediate has first and second faces and a marginal area extending substantially entirely about a perimeter of the intermediate. The perimeter is defined by first and second longitudinally extending sides, first and second transversely extending edges and a line of weakness spaced inwardly of the longitudinally extending sides and transversely extending edges.  
         [0023]     Next, an insert is placed on the first face and inwardly of the marginal area. The insert has a second thickness that is greater than the first thickness.  
         [0024]     Indicia is then printed on the first face of the intermediate and printing substantially simultaneously matching indicia on the insert. The intermediate is then folded about the insert such that the cohesive in the marginal areas is in contact with itself to create a folded blank.  
         [0025]     Next, the folded blank is placed into a sealing nip. The sealing nip has first and second rollers with the second roller having at least first, second, third and fourth circumferentially extending raised areas, with each of the areas having a width of less than one quarter of an inch. Each of the areas is spaced from one another a distance of greater than one quarter of inch and the third and fourth raised areas positioned inwardly of the first and second raised areas. The folded blank is then sealed by contacting at least first and second raised areas of the second roller to the marginal areas.  
         [0026]     The form assembly of the present invention, after sealing along one axis, may then be reoriented or shifted ninety degrees in order to seal the business form assembly along the unsealed side(s) of the business form.  
         [0027]     In addition, the foregoing exemplary embodiments may include the step of printing on the business form blank or intermediate as well as simultaneously printing on the insert matching indicia.  
         [0028]     The sealing nip assembly may also include third and fourth raised areas on the second sealing roll which may be used to seal the business form blank or intermediate, after the blank or intermediate is reoriented ninety degrees, along the additional axis that has not been previously sealed.  
         [0029]     The raised areas of the second sealing roll of the sealing nip have a width of less than one quarter of an inch and preferably around one thirty second of an inch. The first and second raised areas of the second roll are preferably spaced more than four inches apart and the third and fourth raised areas of the second roller are spaced apart a distance greater than about two inches.  
         [0030]     These and other objects of the invention will become clear from an inspection of the detailed description of the invention and from the appended claims. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0031]     These, as well as other objects and advantages of this invention, will be more completely understood and appreciated by referring to the following more detailed description of the presently preferred exemplary embodiments of the invention in conjunction with the accompanying drawings, of which:  
         [0032]      FIG. 1  depicts a schematic of the process utilized in forming the business form described in the present invention;  
         [0033]      FIG. 2  shows a top view of an exemplary business form used in practicing the present invention;  
         [0034]      FIG. 2B  provides a cross sectional view of the exemplary business form used in practicing the present invention;  
         [0035]      FIG. 3  illustrates a block diagram presenting one method for carrying out the presently described invention;  
         [0036]      FIG. 4  depicts an exemplary roller configuration that is used in carrying out the method of the present invention;  
         [0037]      FIG. 5  provides a further exemplary block diagram illustrating practice of the present invention. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0038]     The present invention is now illustrated in greater detail by way of the following detailed description which represents the best presently known mode of carrying out the invention. However, it should be understood that this description is not to be used to limit the present invention, but rather, is provided for the purpose of illustrating the general features of the invention.  
         [0039]     Surprisingly, it has been discovered that there is no readily available method by which to create a business communication having a relatively thick insert in a cost effective manner. The sealing nip assembly and method can be practiced efficiently by small offices/home offices (“SOHO”) by providing an economical sealing apparatus that can accommodate various substrates with different insert possibilities.  
         [0040]     As used herein the term “business communication” is used to refer to a printed or imaged piece, document or substrate that when used as described in the present invention will convey a particular message, image or provide information about a particular product or service that is available from the provider of such pieces or documents. Business communication documents or pieces can include advertising, sales and marketing collateral and such other items used to convey information.  
         [0041]     The term “personalized information” refers to information that is printed or imaged onto a substrate or document which is generally variable or unique and which may change from document to document so as to create a customized message or communication for each recipient. Examples of personalized information may include names, addresses, descriptions, plans, coding, numbering, promotional text, recipes based on contents, etc. that may have been acquired from the intended recipient through surveys, questionnaires or answers given to various inquiries generated in response to a request for goods or services.  
         [0042]     The term “static or fixed” information refers to printed or imaged information that generally does not change from document to document and may include a general description or body of information about particular products, services, places, etc. that may be of interest to the intended recipient and represents a standard message that the manufacturing or supplier wishes to convey to an end user or customer of the offering.  
         [0043]     The term “intermediate” as used herein refers to a product that undergoes one or more processing steps prior to the intermediate reaching a final condition, that of being ready for end use or application. The additional processing steps may include printing, imaging, folding, forming, sealing, separating, cutting, perforating, scoring, adhering and the like. Typically, a product such as with the present invention is provided in an intermediate condition so that a user or downstream manufacturer can add or manipulate the intermediate to create the final or desired end product. Thus, in accordance with the present invention, the intermediate segment for example, could be subject to die cutting or additional printing, such as through ink jetting, over laminating, coating or embossment, and then applied to a container, carton, consumer package good or the like.  
         [0044]     Attention is now directed to  FIG. 1  which presents a schematic of an exemplary method of practicing the present invention.  FIG. 1  shows a business form blank or intermediate  10 . The blank includes first and second longitudinally extending sides  12  and  14 , first and second transversely extending edges  16  and  18  and lines of weakness  20  that extend around a periphery of the business form construction. The lines of weakness  20  and the longitudinally extending sides  12  and  14  and transversely extending edges  16  and  18  form marginal areas in which patterns of cohesive  22  have been applied. The blank or intermediate  10  may have a medial fold line  24  about which the intermediate or blank  10  may be folded.  
         [0045]     It should be understood that while a business form blank or intermediate  10  shown will be folded into a “V” folded configuration, the present invention may be used in connection with “C” or “Z” folded blanks and simply requires that the third and fourth raised areas of the sealing nip, to be described herein are positioned at different points on the surface of the roller assembly.  
         [0046]     The intermediate or blank  10  also shows an insert  26  that is positioned inwardly of the longitudinally extending sides  12  and  14  and transversely extending edges  16  and  18  as well as the marginal areas. The insert  26  may be any number of available products such as cards, tags, magnets and the like. In the present example, a wallet sized card is provided. Wallet sized cards have a size of about 3⅜ inches wide to 2⅛ inches in length.  
         [0047]     The form intermediate or blank  10  is folded medially about line  24  such that the cohesive patterns are brought into substantial juxtaposition with one another. That is, in order for the cohesive patterns to seal effectively, the patterns must be brought into a mating pattern such that upon application of sufficient pressure, the cohesive will form a permanent or semi-permanent bond which creates a sealed enclosure thereby protecting the indicia imaged or printed on the face of the intermediate or blank business form assembly. Folding creates a folded blank  28 .  
         [0048]      FIG. 1  also shows the second roller  30  of the sealing nip used in practicing the present invention. The second roller  30  is with first and second raised areas  32  and  34  and third and fourth raised areas  36  and  38 . Each of the areas preferably has a width of less than about one quarter of an inch and more preferably about one thirty second of an inch. The raised areas  32 ,  34 ,  36  and  38  have a height of about one sixty fourth of an inch to about one quarter of an inch from the surrounding surface of the second roller  30 .  
         [0049]     The folded blank  28  is fed through the sealing nip such that the cohesive patterns disposed along the longitudinally extending sides  12  and  14  are contacted by the first and second raised areas  32  and  34  of the second roller. The folded blank  28  will have been rotated ninety degrees from the open configuration shown in  FIG. 1 . After insertion into the sealing nip containing the second roller  30 , a partially sealed business form  40  emerges from the end opposite the insertion end. The insert  26  provided on the business form blank  10  will have passed through the sealing nip and second roller  30  such that the insert  26  is not contacted by any of the raised areas on the second roller  30 . That is, each of the raised areas  32 ,  34 ,  36  and  38  are spaced sufficiently apart that the raised areas do not contact the insert  26  on the form intermediate  10 .  
         [0050]     The partially sealed form assembly  40 , the form is sealed only along two sides of the form assembly, is then rotated ninety degrees so that the unsealed edges of the form assembly  40  may be brought into contact with additional raised areas  36  and  38  of the second roller  30 . For example, in a SOHO application an inexpensive unit may be provided and the user after receiving the partially sealed form would then take the form, reorient it ninety degrees and reinsert the form assembly into the sealing unit thereby creating a fully sealed business communication assembly  42 . It should be noted that the insert  26  which is shown by phantom lines in subsequent processing steps, passes through the sealing nip and second roller relatively unaffected by the sealing activity.  
         [0051]     For greater clarity, the business form intermediate is depicted in  FIG. 2  of the present invention. The intermediate  50  has first and second faces. First face  52  is shown and second face (not shown is opposite the first face). The intermediate  50  has first and second longitudinally extending sides  54  and  56  and first and second transversely extending edges  58  and  60 . The intermediate  50  also has lines of weakness, two of which extend parallel to the first and second longitudinally extending sides  54 * and  56 * and two of which extend along the transversely extending edges  58 * and  60 *. Each of the lines of weakness extends inwardly of the sides and edges. The sides and edges along with the lines of weakness form marginal areas  62 ,  64 ,  66  and  68 .  
         [0052]     Each of the marginal areas  62 ,  64 ,  66  and  68  are provided with patterns of cohesive  63 ,  65 ,  67  and  69  which once brought into overlapping contact with one another will form a substantially permanent or permanent bond which will seal the business form in a folded condition.  
         [0053]     The first face  52  of the business form intermediate  50  is shown as being provided with personalized and static indicia  70  and  72  respectively. In addition, during the printing of the face of the business form intermediate  50 , the insert  74  is printed substantially simultaneously with personalized indicia  76  as well as static indicia  78 . At least a portion of the indicia printed on the insert  74  matches the indicia printed on the first face  52  of the business form intermediate  50 .  
         [0054]     Reference is now directed to  FIG. 2B  which presents a cross sectional view of the business form intermediate shown in  FIG. 2 . In this depiction, a substrate  80  which forms the business form intermediate is provided and shows the cohesive pattern  82  and  84  shown on each end of the substrate and separated from the medial portion of the substrate by lines of weakness  86  and  88  that extend through the substrate  80 . In addition,  FIG. 2B  also illustrates a medial fold line  90  around which the substrate can be folded to conceal the insert  92 . The insert  92  as shown in  FIG. 2B  is substantially thicker than the substrate  80  upon which the insert is provided. The insert  92  may be applied directly to the surface of the substrate  80  or alternatively, may be set in a well or hole in the substrate depending on the manufacturing specification or end user demands presented.  
         [0055]      FIG. 3  is provided to illustrate a block diagram of one exemplary method of carrying out the present invention. Once the process has been started, such as by supplying a business form blank at step  100 , the blank may be printed at step  110 . The printing may include the production of personalized and static information on one or both faces of the substrate depending on the requirements of the particular job. Then a sealing nip is provided at step  120 . The sealing nip may be contained in a suitable housing along with other relevant equipment such as a drive motor, belts, conveyors, support plates and the like in order to facilitate the processing of the business form intermediate. The sealing nip as will be described in a latter FIGURE will preferably consist of first and second rollers that cooperate with one another to form a sealing nip assembly.  
         [0056]     The blank is initially provided in a flat condition so that the blank can be easily printed such as at step  110 . Once the blank is printed, the blank may be folded at step  130  so that the insert contained on the blank is concealed from view. The blank is then inserted in to the sealing nip at step  140 . After the blank is inserted into the sealing nip at step  140 , the form may be at least partially sealed at step  150 . Alternatively, the form may received after an initial sealing step and then reoriented ninety degrees at step  155  and then reinserted into the sealing mechanism at step  160  so that each edge and side of the business form intermediate is sealed into a final sealed form document configuration protecting the internally imaged information.  
         [0057]      FIG. 4  illustrates a rough schematic of the sealing nip configuration  200  that is used in carrying out the present invention. The unit will preferably include a housing  210 . The housing  210  will contain at least first and second rollers  220  and  230 . The rollers  220  and  230  will for example be driven by a belt  235  and motor  240 .  
         [0058]     The second roller  230  has first and second raised areas  232  and  234  and third and fourth raised areas  236  and  238 . Each of the raised areas have a width of less than about one quarter of an inch and preferably about one thirty second of an inch. The raised areas, rise from the surface of the roller an amount ranging from about one sixty fourth of an inch to about one quarter of an inch.  
         [0059]     As shown in  FIG. 4 , a business form intermediate  250  has been inserted into the nip, that is the area between rollers  220  and  230  to seal the cohesive patterns  252  and  254  that are disposed near the edges of the business form intermediate  250 . In use, once the form has traversed the sealing rollers in a first direction (as shown in  FIG. 1 ) the user of the device then collects the form, rotates the form ninety degrees and reinserts the form intermediate so as to be able to seal the perpendicular sides of the business form intermediate.  
         [0060]     The unit shown in  FIG. 4  will preferably be small and portable so that it can be used in SOHO applications. Ideally, the unit will also be economical to construct as well as to operate.  
         [0061]     Attention is now directed to  FIG. 5  of the present invention in which another block diagram is provided illustrating a further exemplary embodiment for practicing the present invention.  
         [0062]     The process is again started such as by providing a business form intermediate at step  300 . The intermediate may be as shown in  FIG. 2 , e.g. a blank that is folded in a “V” shaped configuration, or may take any other configuration of self mailers such as product that is intended to be “C” or “Z” folded to render the final assembly. An insert, such as a card, magnet, tag, chip or the like is placed on the blank or intermediate at step  310 . Placement may occur by any suitable placer mechanism as is well known in the art. The insert may be held in position through the use of a frangible bond or alternatively, through adhesive such as a cold spot adhesive or the like.  
         [0063]     Next, indicia is printed on the intermediate and substantially simultaneously on the insert at step  320 . Indicia may include both personalized and static/fixed information. If a non-printable substance is provided, such as a magnet, a printable overlay may be adhered to the surface of the material to provide a print receptive substrate.  
         [0064]     Next, the blank is placed at the beginning of the sealing nip at step  330  and then the intermediate blank is sealed at step  340 . Typically, sealing will occur along one axis of the form assembly, and as such in order to fully or completely seal the form assembly, the form will need to be removed from the exit end of the assembly, reoriented ninety degrees and then reinserted into the sealing nip to seal the form along the remaining axis of the assembly.  
         [0065]     It will thus be seen according to the present invention a highly advantageous pressure seal roller configuration has been provided. While the invention has been described in connection with what is presently considered to be the most practical and preferred embodiment, it will be apparent to those of ordinary skill in the art that the invention is not to be limited to the disclosed embodiment, and that many modifications and equivalent arrangements may be made thereof within the scope of the invention, which scope is to be accorded the broadest interpretation of the appended claims so as to encompass all equivalent structures and products.  
         [0066]     The inventors hereby state their intent to rely on the Doctrine of Equivalents to determine and assess the reasonably fair scope of their invention as it pertains to any apparatus, system, method or article not materially departing from but outside the literal scope of the invention as set out in the following claims.