AN APPARATUS FOR MANUFACTURING SEALED POSTAL MAILS OR THE LIKE ENVELOPE ASSEMBLIES

Abstract: Apparatus for manufacturing sealed postal mails or the like envelope assemblies (E.U.) using discrete envelope blanks (72) split from an envelope-forming continuous sheet (71), intermediate elements (92) split from an intermediate element-forming continuous sheet (91) and having sizes adapted to be enclosed within said envelope blank, and additional inserting elements (101) having sizes adapted to be enclosed within said envelope blank. The apparatus comprises reading means (8) for reading an encoded mark (99) on said intermediate element (92) to produce an output signal corresponding to the number of sheets of said intermediate element (92) to be enclosed together, grouping means (25) located in a said grouping station for stacking a plurality of intermediate elements (92) successively supplied into a group of intermediate elements to be enclosed together, said grouping means being operative in response to said output signal from said reading means (8) and intermediate element group feeder means for feeding a single intermediate element or a group of intermediate elements from said grouping station to an envelope folding and intermediate element inserting station (E.S.).

Description: Background of the Invention Field of the Invention The present invention relates to an apparatus for manufacturing sealed postal mails (packets) or other sealed envelope assemblies each having a see-through window. More particularly, the present invention relates to such an apparatus for manufacturing sealed postal mails and like envelope assemblies containing intermediate elements that remain free after completing the folding and sealing of envelope wherein the apparatus processes such envelopes that can be cut off from a continuous sheet along a transverse line and folded into three parts (three parts comprising front layer, rear layer and sealing flap) at transverse folding lines and also processes such discrete intermediate elements to be cut off from a continuous sheet or to be folded at least along a folding line. The present invention relates to an apparatus for manufacturing sealed postal mails and like envelope assemblies, which first bursts a continuous sheet before forming transverse double-folded envelope blank having a sealing flap in the lengthwise direction, and in conjunction with envelope-sealing process, the apparatus groups and gathers intermediate elements and inserting elements containing preliminarily processed data to be sent to each addressee, and in addition, it also groups those intermediate elements and inserting elements which are to be added selectively before the apparatus eventually inserts these elements between the transverse double-folded blank of the envelope-forming body. Description of Prior Art Conventionally, there are a variety of apparatuses for processing envelopes by allowing insertion of preliminarily data-processed papers into individual envelopes during the envelope-forming process after bursting these envelopes from a continuous sheet designed for making up envelopes. On the other hand, relative to diversification of information to be conveyed, there is a need for changing the documents to be sealed in each envelope while the envelope-forming process is still underway. Actually, any of those conventional apparatuses employed for processing envelopes merely inserts conventional papers and prints into each envelope in the predetermined extent. As a result, any of those conventional apparatuses is not ideally suited for manufacturing envelopes needed for properly conveying constantly diversifying information. EP-A2-0185811 discloses apparatus for the continuous preparation of an envelope, in which an intermediate element to be enclosed is included, by feeding an intermediate element to be enclosed in a folded envelope blank and then closing and sealing the envelope blank. US-A-2 427 839 discloses a collator system in which selective collection of individually prepared sheets can be performed. Summary of the Invention The invention provides a novel apparatus for processing envelope blanks, intermediate elements and inserting elements, while the apparatus related to the invention properly deals with diversified information to be conveyed by inserted documents and envelopes by materialing the following: detection and designation of the amount of intermediate elements by reading and identifying encoded data preliminarily printed on those intermediate elements; collection through grouping of inserting elements according to addresses either on a random basis or on a constant-number basis; and selective collection of inserting elements which are individually and preliminarily prepared according to addresses before eventually inserting these unit papers into each envelope. Another object of the present invention is to provide such a processing unit for the continuous mail sealing, which is suited for the line-printer process using a computer and in addition being particularly effective for the non-impact printing process using heat wherein it comprises such means for concentrically printing information onto a continuous sheet using a computer, while the printable continuous sheet is completely free from the heat-sensitive adhesive layer,and conversely, the heat-sensitive adhesive layer is provided only on the other continuous sheet available for envelopes. A still further object of the present invention is to provide such a processing unit for the continuous mail sealing wherein it comprises such means for manufacturing sealed envelopes from which the inserted paper can be easily and immediately drawn out by opening at least one side of an envelope, while the sealed envelope contains the intermediate elements and inserting elements between the front and rear covers, allowing no part of the inserted elements to adhere to the interior of the sealed envelope. The preferred embodiments of the present invention are summarized below. The present invention relates to such an apparatus that manufactures the sealed postal mails or the like envelope assemblies using a discrete envelope blanks split from an envelope-forming continuous sheet, an intermediate element split from an intermediate element-forming continuous and having sizes adapted to be enclosed within the envelope blank. The envelope-forming continuous sheet having transverse weakening lines at regular intervals formed to define an envelope blank section between each adjoining two of the weakening lines, each of the envelope blank section having first and second transverse folding lines, a first area for forming the front layer of an envelope defined by first and second transverse folding lines, a sceond area for forming the rear layer of the envelope connected to the first area via the second transverse folding line, a third area for forming the sealing flap of the envelope connected to the first area via the first transverse folding line, a first adhesive layer formed on one surface of the envelope blank section along each of the opposite side edges in direction of the length of the envelope blank section, and a second adhesive layer formed on the same one surface of the envelope blank at the third area. The intermediate element-forming continuous sheet having transverse weakening lines at regular intervals formed to define a intermediate element section between each adjoining two of the weakening lines. Each of the intermediate element sections having its own specific information printed to be sent to addressee and each of the intermediate element sections further having thereon an encoded mark printed for indicating the number of sheets to be enclosed together when the intermediate element section is followed by at least one intermediate element which is to be sent to the same addressee. In accordance with the present invention, there is provided an apparatus for manufacturing sealed postal packets or the like envelope assemblies using a discrete envelope blank separated from an envelope-forming continuous sheet and at least one intermediate element split from an intermediate element-forming continuous sheet, each envelope comprising a front layer, a rear layer and a sealing flap, said envelope-forming continuous sheet having transverse lines of weakness at regular intervals formed to define an envelope blank section between each adjoining two of said lines of weakness, said envelope blank section having first and second transverse folding lines, a first area for forming a front layer of said envelope, said first area being defined by said first and second transverse folding lines, a second area for forming a rear layer of said envelope, said second area being connected to said first area via said second transverse folding lines, a third area for forming a sealing flap of said envelope, said third area being connected to said first area via said first transverse folding lines, a first adhesive layer formed on one surface of said envelope blank section along each of the opposite side edges in the direction lengthwise of said envelope blank section, and a second adhesive layer formed on the same surface of said envelope blank at said third area, said intermediate element-forming continuous sheet having transverse lines of weakness at regular intervals formed to define a intermediate element section between each adjoining two of said lines of weakness, each of said intermediate element sections having its own specific information printed to be sent to addressee and each of said intermediate element sections further having thereon an encoded mark printed for indicating the number of sheets to be enclosed together when said intermediate element section is followed by at least one intermediate element which is to be sent to the same addressee, said apparatus including: (a) a stock of said envelope-forming continuous sheet; (b) means for continuously supplying said envelope-forming continuous sheet from said stock; (c) means for successively separating said envelope-forming continuous sheet supplied along said transverse lines of weakness into discrete envelope blanks one by one; (d) envelope blank feeder means for feeding each of said discrete envelope units to an envelope folding and intermediate element inserting station; (e) a folding operation unit in said envelope folding and intermediate element inserting station, said folding operation unit comprising folding means for folding said discrete envelope blank along said second transverse folding line; (f) a stock of said intermediate element-forming continuous sheet; (g) means for continuously supplying said intermediate element-forming continuous sheet from said stock; (h) reading bans for reading said encoded mark on said intermediate element continuous sheet to produce an output signal corresponding to the number of sheets of said intermediate element to be enclosed together; and (i) means for successively separating said intermediate element-forming continuous sheet along said transverse lines of weakness into discrete intermediate elements; said apparatus being characterised by: (I) intermediate element feeder means for feeding said discrete intermediate elements to an intermediate element grouping station; (II) grouping means located in said grouping station for stacking a plurality of intermediate elements successively supplied to be enclosed together into a group of intermediate elements to be enclosed together, said grouping means being operative in response to said output signal from said reading means; (III) intermediate element group feeder means for feeding a single intermediate element or a group of intermediate elements from said grouping station to said envelope folding and intermediate element inserting station; (IV) first sensor means for detecting the delivery timing of said envelope blank delivered by said envelope-blank feeder means; (V) second sensor means for detecting the delivery timing of said intermediate element or said intermediate element group delivered by said intermediate element group feeder means; (VI) means for controlling the delivery of said envelope blank to said envelope folding and intermediate element inserting station based on output signals from said first and second sensor means so that said intermediate element or intermediate element group can be enclosed within said discrete envelope blank during its folding operation; (VII) first sealing means for sealing said envelope blank along said first adhesive layers of said envelope blank; (VIII) flap folding means for folding said sealing flap of said envelope blank along said first transverse folding line of said envelope blank; and (IX) second sealing means for sealing said envelope blank along said second adhesive layer of said envelope blank folded to form a completed envelope assembly. Brief Description of the Drawings The invention will be better understood with reference to the description which follows taken in conjunction with the annexed drawings in which; Fig. 1 is the simplified schematic lateral diagram of the envelope/intermediate element manufacturing and sealing apparatus related to the invention; Fig. 2 is a schematic plan of the apparatus shown in Fig. 1; Fig. 3 is the lateral view of part of the apparatus corresponding to the arrowed portion of Fig. 2; Fig. 4 is a partial plan view of the envelope-forming continuous sheet already processed for application to the apparatus embodied by the invention; Fig. 5-A, -B, -C and -D are respectively the plans denoting different types of intermediate elements forming continuous sheets and the perspective views of the corresponding intermediate elements; Fig. 6-A, -B and -C are respectively the plans denoting different types of additional inserting elements and the perspective views of the corresponding inserting elements; Fig. 7 is the lateral view of the detailed constitution of the intermediate-element folding means; and Fig. 8 is an overall schematic/perspective view denoting the systematic flow of the envelope-forming continuous sheet, the intermediate element forming continuous sheet, and the additional inserting elements. Description of Preferred Embodiments Referring now to the preferred embodiments shown in the attached drawings, details of the apparatus for manufacturing sealed postal mails or like envelope assemblies reflecting the present invention are described below. Basically, the sealed mail manufacturing apparatus embodied by the present invention is designed to continuously make up envelope units (E.U) by individually feeding the following into the apparatus; discrete envelopes (72) split from a continuous sheet (71) available for envelopes, discrete intermediate elements (92) made from intermediate-forming continuous sheet (91) available for intermediate elements and additional inserting elements (101) selectively insertable as required. An example of the envelope forming continuous sheet (71) is shown in Fig. 4. This envelope forming continuous sheet (71) is provided with marginal perforation lines (73) along opposite edges in the direction of its length and also with the marginal perforation split lines (74) and (74) so that the marginal perforation lines (73) can be cut off along the internal line of these lines (73). Said envelope-forming continuous sheet (71) is provided with tearable transverse weakening line (75) at regular interval in the direction of length, thus defining the area available for the discrete envelope blank (72). Each envelope blank (72) sectioned by said transverse weakening line (75) is provided with a first folding line (76) and a second folding line (77) parallel with said transverse weakening line (75). The envelope blank (72) is also provided with a sealing flap (78) formed between one of the transverse weakening lines (75) and the first folding line (76), a front area (79) formed between the first folding line (76) and the second folding line (77), and a rear area (80) formed between the second folding line (77) and the other transverse weakening line (75). Length (LA) in the lengthwise direction of the front area (79) substantially constitutes one side (a short side of the envelope of the envelope shown in Fig. 4) of the envelope itself. When actually designing envelopes, the length (LA′) in the lengthwise direction of the rear area (80) is slightly shorter than (LA). The dimensions (LA) and (LB) of the sealed envelope unit (EU) are optionally chosen, i.e., the dimension may be LA < LB as shown in the illustrated preferred embodiment, or it may conversely be LA ≧ LB. The envelope blank of the continuous sheet (71) is provided with the first and second adhesive-agent coated zones (81) and (82) for sealing the envelope itself in the direction of folding the second folding line (77) into inner surface (71a). The first adhesive-agent coated zones (81) are respectively formed in parallel with each other along the inner edge of said marginal perforation split lines (74), (74), whereas the second adhesive-agent coated zones (82) are respectively formed in the direction of traversing the sealing flap (78). Either thermally pressing type adhesive agent, or pressure-applied adhesive agent, or water-soluble starch may also be used for making up those adhesive-agent coated zones (81). Referring now to the sealing flap (78), an isosceles triangular diecut (83) is provided in conjunction with the transverse weakening line (75) and the marginal perforation split line (74). The length of each side of isosceles forming the diecut (83) almost matches the length of the sealing flap 78). Portion (79) making up the front area of the envelope-forming continuous sheet (71) is provided with a see-through window (84) at an optional location. Such a see-through window (84) may be formed by bonding a transparent sheet (86) to the opening (85) on the front area (79) from the inner surface (71a) of the envelope-forming continuous sheet (71) using adhesive agent for example. Alternatively, the see-through window (84) may be of such a constitution which allows only limited portion of information (i.e., address and addressee) written on the inserted document to be externally visible. Perforated line (87) shown in Fig. 4 used for opening the sealed envelope is provided in parallel with the inner edge of either of the first adhesive-agent coated zones (81). Fig. 5-A, -B, -C and -D, respectively denote styles of a variety of continuous sheets (91) for the intermediate elements to be inserted into envelopes. Each of those continuous sheets (91) is used for making up intermediate elements. Those continuous sheets (91A), (91B), (91C) and (91D) are respectively provided with marginal perforation lines (93) along both sides in the lengthwise direction. In addition, these continuous sheets (91A), (91B), (91C) and (91D) are also provided with split lines (94) to cut off those marginal perforation lines (93) along the inner side of these perforation lines. Continuous sheet (91A) shown in Fig. 5-A continuously forms a transverse double-folded intermediate element (92A) having a transverse folding line (96). Continuous sheet (91B) shown in Fig. 5-B continuously forms a transverse triple-folded intermediate element (92B) having a pair of transverse folding lines (96) between transverse weakening lines (95). Continuous sheet (91C) shown in Fig. 5-C continuously forms a cross-folding (double-folding in the transversal and longitudinal directions) intermediate element (92C) having the central folding line (97) in the lengthwise direction and transverse folding line (96) between transverse weakening lines (95) and (95). Continuous sheet (91D) shown in Fig. 5-D continuously forms a cross-folding (triple folding in the transverse direction and double-folding in the longitudinal direction) intermediate element (92D) having a central folding line (97) in the lengthwise direction and a pair of transverse folding lines (96) between transverse weakening lines (95) and 95). When being folded, side length (La) of each of these intermediate elements (92A), (92B), (92C) and (92D) is slightly shorter than the length (LA) of the sealed envelope unit (EU), and likewise, the other side length (Lb) is also slightly shorter than the inner length of the first adhesive-agent coated zones (81) of the sealed envelope unit (EU). Space for printing address and addressee (98) is provided for the external surface of any of those intermediate elements (92A), (92B), (92C)and (92D). Identification encoded mark (99) is preliminarily printed on each of these intermediate element-forming continuous sheets (91A), (91B), (91C) and (91D) in order that intermediate elements can properly be grouped and gathered according to addresses and addressees. The identification encode mark (99) is provided for each unit of intermediate element (92) and composed of 7-bit bar code for example. The identification encode mark (99) is read and identified by an encode-mark sensor set to the apparatus related to the invention, and based on the identified encode mark, instructions are generated to group and gather intermediate elements (92) as per addresses and addressees, selectively insert additional inserting elements (101), and divert the non-printed intermediate elements. Fig. 6-A, -B and -C respectively denote examples of a variety of additional inserting elements (101). These elements (101)are not split from a continuous sheet, but each of these elements (101) consists of either a single leaf (101A) or a preliminarily folded and cut sheet (101B) or (101C) for example. Fig. 6-A represents a single-leaf additional inserting element (101A). Fig. 6-B represents a transverse double-folded additional inserting element (101B) having a transversely folding line (102). Fig. 6-C represents a transverse triple-folded additional inserting element (101C) having a pair of transverse folding lines (102) and (102). Next, referring more particularly to those preferred embodiments shown in Fig. 1, Fig. 2 and Fig. 3, the constitution of the apparatus related to the invention is described below. The intermediate-element supplying system (1) is composed of stocker (2) which stocks the intermediate-element forming continuous sheet (91), separating means (3) which separates the continuous sheet (91) into intermediate element (92), and feeding means (4) which feeds the intermediate elements. Following the printing process executed with computer means, first, the intermediate-element forming continuous sheet (91) shown in Fig. 5 is split into intermediate elements by the separating means (3) which is provided with marginal slitter (6) and bursting device (7). The OMR (optical mark reading) sensor (8) reads and identifies encode mark (99) preliminarily printed on each of those intermediate elements. The feeding means (4) is connected to the outlet of the separating means (3). When activating the apparatus related to the invention, non-printed intermediate element (92) is detected by OMR sensor (8) which reads and identifies encode mark (99) printed on each of the intermediate elements. Those inserted non-printed elements (92) are then removed from the intermediate element feeding line and collected by non-printed element tray (9). In conjunction with the intermediate element feeding means (4), transverse-folding means (10) is provided for transverse folding those intermediate elements (92). Fig. 7 denotes an example of the transverse-folding means (10) which is composed of intermediate-element introducing guide member (11), insertable-intermediate-element forwarding guide member (12), the first to fourth rollers (13) to (16), and the first and second guide stoppers (17) and (18), respectively. Guide stoppers (17) and (18) are respectively provided with stoppers (19) and (20) which adjust their positions to stop the movement of the intermediate elements (92). Each of the intermediate elements (92) is led between a pair of rollers (13) and (14) along the introduction guide member (11) before being led to the first guide stopper (17) by rollers (13) and (14). Each of intermediate elements (92) bends itself at the inlet portion of rollers (13) and (15) with its tip edge being in contact with stopper (19) and then the insertable paper itself is pressed by rollers (13) and (15) before eventually being folded transversely. Transverse double-folded intermediate element (92A) shown in Fig. 5-A dispenses with the secondary folding otherwise to be done in the transverse direction. In this case, after passing through a pair of rollers (13) and (15), intermediate element paper (92) is then directly led by guide member (21) provided in place of the guide stopper (18) so that the intermediate element (92) can pass through rollers (13) and (16) before being discharged to the feeding line. Those intermediate elements (92C) and (92D) each having a longitudinal folding line shown in Fig. 5-C and 5-D are preliminarily provided with vertical folding process by the longitudinal folding unit (not shown). The transverse folding means (10) turns the fed intermediate element (92) upside down using guide member (21). In this case, the distance between stopper (19) of the first guide stopper (17) and rollers (13) and (14) is extended in order that the distance can be longer than the length of the intermediate element (92) itself. The intermediate element (92) carried into the first guide stopper (17) is then delivered to a pair of rollers (13) and (15) by a pair of back rollers (B.R). On the other hand, in conjunction with the inserting-element feeding line, additional inserting-element feeding means (22) is provided. This means (22) is provided with the first and second feeding units (23) and (24) for example, which respectively insert printed papers into envelopes. Furthermore, the apparatus related to the invention is provided with paper grouping and collecting means (25), which first reads and identifies encode marks printed on the intermediate elements, and then stores those intermediate elements by each inserting unit. In addition, this grouping means (25) selectively adds additional inserting elements stored in the additional inserting element feeding means (22) to the original intermediate element (92), and finally, it groups and collects those intermediate elements according to addresses and addressees. The paper grouping and collecting means (25) is provided with function for randomly collecting intermediate elements, precisely collecting intermediate elements by the predetermined number, and selectively inserting additional elements into each envelope, respectively. When the apparatus related to the invention activates the random paper grouping and collecting function, the OMR sensor reads and identifies the encode marks on the intermediate elements according to the predetermined rule, and then, acting on the instruction signal, grouping and collection of intermediate elements by random number can be executed. Grouping and collection of the intermediate elements by the predetermined number can be executed without referring to encode marks on those elements, but merely by inserting a specific number of those intermediate elements of each lot. When activating function for selectively inserting additional inserting elements, a specific mechanism having two of the additional inserting element feeding means generates instructions for selecting any of four functional operations including delivery of the first and second additional inserting elements, executing independent delivery of only the first additional inserting elements and only the second additional inserting elements, and withholding delivery of both the first and second additional inserting elements, respectively. All of these instructions are generated as a result of reading and identifying encode marks on each of intermediate elements (92). The apparatus related to the invention feeds additional inserting elements (101) to the original intermediate element (92). Both the grouped original intermediate elements (92) and additional inserting elements (101) are then delivered to the inserting-unit delivery means (26) which is provided with sensor (S₁) for detecting the envelope blank (72) held by the envelope-blank holder means (27). Gate (G) and roller (28) of the delivery means (26) are activated on receipt of detect signal from sensor (S₁). Sensor means (S₁) available for detecting the predetermined delivery timing of the discrete envelope blanks (72) is provided between the envelope blank feeder means (31) and the folding and inserting station (E.S), which outputs a detect signal (e1) when detecting the delivery timing of the discrete envelope blanks (72). In conjunction with the intermediate feeder means (4), another sensor (S₂) is provided, which outputs a detect signal (e2) when detecting the delivery timing of the intermediate elements (92). The intermediate feeder means (4) is designed to operate at a constant speed synchronous with other parts driven by a main motor (M), and if any difference occurs in the calculated values between the timing detect signals (e1) and (e2), the intermediate feeder means (4) instantly accelerates or decelerates its operation speed using its own pulse motor (not shown). The paper-forwarding roller (28) classifies and collects each group of intermediate element and inserting elements, and finally, it forwards each of the grouped inserting unit in order that each of these can come into contact with the second folding line (77) of the envelope blank (72). The apparatus is also provided with an envelope-blank supplying system (30) which first activates separating means (29) to separate the envelope-forming continuous sheet (71) into individual envelope blanks (72) and then conveys these envelope blanks (72) to the inserting station (E.S). Discrete envelope blank (72) is then fed to the predetermined inserting station (E.S) by feeding means (31). The inserting station (E.S) is provided with the envelope-blank holder means (27). This holder means holds the envelope blank (72) almost at right angle against the intermediate elements (92) which are horizontally forwarded by the intermediate element delivery means (26). Then, the envelope-blank holder means (27) aligns the position of the second transverse folding line (77) of the envelope blank (72) in order that the transverse folding line (77) can correctly match the paper-inserting line. This allows each envelope blank (72) to be held at standby posture at the predetermined position. The envelope-blank holder means (27) is also provided with a sensor which detects the condition in which each envelope blank (72) is correctly held at the predetermined position. In addition, folding roller means (32) is installed to the rear stage of the envelope-blank holder means (27). The folding roller means (32) is composed of a pair of rollers (34) to allow the inlet aperture (33) to open itself in order that these rollers (34) correctly align the second transverse folding line (77) of the envelope blank (72) with the aperture (33). In conjunction with the movement of the intermediate element delivery means (26) to forward intermediate elements the envelope blank (72) is folded along the second transverse folding line (77), and then, the envelope blank (72) is led into the rear-stage rollers (34) before eventually being folded when passing through the rollers (34). The first sealing means (35) is installed to the rear stage of the folding roller means (32). The first sealing means (35) is composed of a pair of heaters (36) and pressurized conveyer belt (37). Heaters (36) are respectively installed along the predetermined path of the first adhesive-agent coated zones (81) of the envelope body, i.e., in the manner of facing both sides of the envelope in the forwarding direction. Each envelope with both sides being fused by the first sealing mechanism (35) is then led into the movement-path changing means (38) to allow either of the fused sides to precede by changing the direction of the movement of envelope by 90 degrees. Then, the envelope body is delivered to the flap-enveloping unit (F.E) which is provided with the flap-folding means (39) and the second sealing means (40). By operating the flap-folding means (39), the flap-enveloping unit (F.E) folds the envelope flap (78) along the first transverse folding line (76) before fully sealing the envelope body with the second sealing means (40). Finally, each of the completely sealed envelopes is conveyed to the following workshop via the delivery unit (41) according to purposes. When automatically inserting and enveloping documents or the like into individual envelopes by operating the automatic envelope and insertable paper processing apparatus embodied by the invention featuring the novel constitution thus far described, by virtue of reading and identifying encode marks preliminarily printed on each of intermediate elements and inserting elements, the apparatus can correctly detect and instruct the amount of papers to be inserted into each envelope before effectively classifying these papers and envelopes according to addressees. The grouping operation of envelope-intermediate elements can be executed either randomly or on the basis of constant number, and yet, whenever necessity arises, the apparatus related to the invention selectively classifies and collects each of preliminarily prepared additional inserting elements before fully enclosing them as a unit into the designated envelopes. These functions constitutes a novel envelope and intermediate element processing apparatus which securely deals with diversification of information to be sent. Furthermore, the envelope and intermediate element processing apparatus related to the invention changes the direction of feeding each envelope by 90 degrees before fully sealing envelope bodies. When executing final sealing operation, the apparatus discretely uses different heater units for thermally sealing each envelope along the vertical and lateral edges so that thermal sealing can locally be achieved. This effectively prevents the paper-inserted portion of each envelope from adversely being affected by heating and pressurized effect, thus totally eliminating adverse influence otherwise incurring to the enclosed computer-processed printed documents.

Claims: An apparatus for manufacturing sealed postal packets or the like envelope assemblies using a discrete envelope blank (72) separated from an envelope-forming continuous sheet (71) and at least one intermediate element (92) split from an intermediate element-forming continuous sheet (91), each envelope (72) comprising a front layer (79), a rear layer (80) and a sealing flap (78), said envelope-forming continuous sheet (71) having transverse lines of weakness (75,75) at regular intervals formed to define an envelope blank section between each adjoining two of said lines of weakness (75,75), said envelope blank section (72) having first and second transverse folding lines (76,77), a first area for forming a front layer (79) of said envelope (72), said first area being defined by said first and second transverse folding lines (76,77), a second area for forming a rear layer (80) of said envelope (72), said second area being connected to said first area via said second transverse folding lines (77), a third area for forming a sealing flap (78) of said envelope (72), said third area being connected to said first area via said first transverse folding lines (76), a first adhesive layer (81) formed on one surface of said envelope (72) blank section along each of the opposite side edges in the direction lengthwise of said envelope blank section (72), and a second adhesive layer (82) formed on the same surface of said envelope blank (72) at said third area (78), said intermediate element-forming continuous sheet (91) having transverse lines of weakness (95,95) at regular intervals formed to define a intermediate element section (92) between each adjoining two of said lines of weakness (95,95), each of said intermediate element sections (92) having its own specific information printed to be sent to addressee and each of said intermediate element sections (92) further having thereon an encoded mark (99) printed for indicating the number of sheets to be enclosed together when said intermediate element section (92) is followed by at least one intermediate element which is to be sent to the same addressee, said apparatus including: (a) a stock (ST) of said envelope-forming continuous sheet (71); (b) means (PT₂) for continuously supplying said envelope-forming continuous sheet (71) from said stock (ST); (c) means (29) for successively separating said envelope-forming continuous sheet (71) supplied along said transverse lines of weakness (95) into discrete envelope blanks (72) one by one; (d) envelope blank feeder means (31) for feeding each of said discrete envelope units to an envelope folding and intermediate element inserting station (E.S.); (e) a folding operation unit (32) in said envelope folding and intermediate element inserting station (E.S.), said folding operation unit (72) comprising folding means for folding said discrete envelope blank (72) along said second transverse folding line (77); (f) a stock (2) of said intermediate element-forming continuous sheet; (g) means (1) for continuously supplying said intermediate element-forming continuous sheet (91) from said stock (2); (h) reading means (8) for reading said encoded mark (99) on said intermediate element continuous sheet (91) to produce an output signal corresponding to the number of sheets of said intermediate element to be enclosed together; and (i) means for successively separating said intermediate element-forming continuous sheet (91) along said transverse lines of weakness (95) into discrete intermediate elements (92); said apparatus being characterised by: (I) intermediate element feeder means (4) for feeding said discrete intermediate elements (92) to an intermediate element grouping station; (II) grouping means (25) located in said grouping station for stacking a plurality of intermediate elements (92) successively supplied to be enclosed together into a group of intermediate elements (92) to be enclosed together, said grouping means (25) being operative in response to said output signal from said reading means (8); (III) intermediate element group feeder means (26) for feeding a single intermediate element (101) or a group of intermediate elements (92) from said grouping station to said envelope folding and intermediate element inserting station (E.S.); (IV) first sensor means (S₁) for detecting the delivery timing of said envelope blank delivered by said envelope-blank feeder means (31); (V) second sensor means (S₂) for detecting the delivery timing of said intermediate element or said intermediate element group delivered by said intermediate element group feeder means; (VI) means (G) for controlling the delivery of said envelope blank (72) to said envelope folding and intermediate element inserting station (E.S.) based on output signals from said first and second sensor means (S₁, S₂) so that said intermediate element or intermediate element group can be enclosed within said discrete envelope blank (72) during its folding operation; (VII) first sealing means (35) for sealing said envelope blank (72) along said first adhesive layers (81) of said envelope blank (72); (VIII) flap folding means (39) for folding said sealing flap of said envelope blank along said first transverse folding line of said envelope blank (72); and (IX) second sealing means (40) for sealing said envelope blank (72) along said second adhesive layer (82) of said envelope blank (72) folded to form a completed envelope assembly. Apparatus defined in Claim 1, further including; non-printed intermediate element detecting means (8) for detecting any non-printed intermediate element (92) to produce an output signal; and means (R.M.) responsive to said signal from said non-printed intermediate element detecting means (8) and located in said grouping station for removing said non-printed intermediate element (92) from an intermediate element feeding line. Apparatus defined in Claim 1 or 2, further including; means (22) for supplying other intermediate elements to said grouping station to prepare a further group of intermediate elements of different kinds to be enclosed together. Apparatus defined in Claim 3, wherein said other intermediate elements (92) are separately prepared and have common information prints. Apparatus defind in Claim 3, wherein a plurality of means for supplying a plurality of other intermediate elements of different information prints to said grouping station are provided. Apparatus defined in any of Claims 2 to 5, wherein said encoded mark is capable of indicating selective addition of said another intermediate element (101) and said means supplying said another intermediate element (101) is operative in response to the output signal from said reading means (8).

Inventors: OGAWA, TAKAO
Applicants: ISETO SHIKO CO. LIMITED
Application year: 1988
Main classification: B31B41
IPC codes: B31B41, B31B27, B43M5