Abstract:
A system and method for manufacturing printed envelopes provides feeding the web from a source roll into a laser printer. Predetermined envelope information such as address, name, and presort codes may be placed upon the web at selected locations thereon by the printer. The printed web is then output from the laser printer to an output roll. The printed web output roll is subsequently mounted onto an envelope folder in which each of the predetermined printed locations is detected. These predetermined locations are subsequently cut and the sheets derived therefrom are folded into individual envelopes. These envelopes are subsequently output to a collection point in a predetermined sequence. Prior to cutting and folding, additional enhancements such as embossing may be provided to the printed web.

Description:
FIELD OF INVENTION 
     This invention relates to a novel system and method for manufacturing envelopes and more particularly to a system and method involving roll-to roll preprinting of envelope web. 
     BACKGROUND OF INVENTION 
     In volume mailings, it is often desirable to produce individually addressed and marked envelopes. Large numbers of these envelopes may be produced in an average mailing, each of the envelopes requiring its own customized markings including address, date, postal presort and other requirements as well as bar coding for automatic processing. 
     In the past, processing of large number of individually marked envelopes has been accomplished by means of feeding either prefolded envelopes or precut unfolded blank sheets through a laser or other type of printer to add the necessary information. Then, the envelopes undergo final folding or finishing and subsequently, have the correct letters and other inserts added in a separate step. The address could alternatively be applied by means of ink jet or other similar printer once the envelope is completed and input to a letter inserting machine. 
     The disadvantage of the above described techniques is that each envelopes represents a loose sheet of paper, folded or otherwise, that must be tracked throughout the process. Misalignments or other losses of one or more of the sheets as the process progresses results in loss of the entire sequence for printing. If the sequence is lost, it becomes impossible to match each envelope to its proper position in the sequence. Thus, envelopes may become misaddressed or filled with the wrong letters, and, otherwise, may lose the proper zip code presort sequencing required by the post office in order to gain the advantage of lower presort rates. 
     If at some point in the process, foil or other decorative embossing is to be added to the envelopes, it may interfere with or become damaged by subsequent addressing and folding operations. Thus, proper sequencing and production becomes even more difficult owing to the need to subsequently emboss envelopes following addressing. This added step only serves to further raise the risk of sequencing loss. 
     Printing envelopes in connected form on a roll solves a number of potential sequencing problems. One previous attempt to produce envelopes from a roll of web has involved the production of a preprinted roll upon ordinary business form paper that is subsequently cut and formed into envelopes. Machines utilizing this method have only contemplated the use of business form presses to produce standardized envelopes prior to envelope forming. 
     SUMMARY OF INVENTION 
     It is therefore an object of the present unique invention to provide a system and method for manufacturing printed envelopes that allows programmable variation of information on a sequenced set of printed envelopes while still enabling tracking of each envelope. 
     It is another object of this invention to provide a system and method for manufacturing printed envelopes that utilizes variable information or laser printing of some or all print placed upon individual envelopes. 
     It is another object of this invention to provide a system and method for manufacturing printed envelopes that produces preprinted sections of web for use as envelopes that are stored in convenient roll form between production steps. 
     It is yet another object of this invention to provide a system and method for manufacturing printed envelopes that includes checking functions to ensure proper sequencing. 
     A system and method for manufacturing printed envelopes according to this invention provides feeding the web from a source roll into a laser printer or similar type of variable information printer. The printer adds predetermined information including address, postage and presort codes to programmed, or otherwise predetermined, locations upon the web. The printed web is then output from the laser printer into an output roll. The printed web may be subsequently mounted onto an embossing or similar enhancement device and then rerolled into a storage roll. This storage roll is then transferred to a folder cutter device that cuts the web into individual sheets at each of the programmed or otherwise predetermined locations and subsequently folds the sheets into envelopes. These envelopes may then be outputted to a collection point for insertion of contents and further operations. At all times, information sequencing is maintained by means of a central processing unit (CPU) and the sequence is not lost due to the fact that the envelopes remain processed in web form until they are ready for final insertion and shipping. 
     In one embodiment, finished envelopes may be stored in sequentially ordered boxes. In another embodiment, the envelopes may be rolled, using a roll core and opposing strap allowing quick unrolling for further operations and final shipping. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The foregoing objects and other advantages will become apparent from the following detailed description of the preferred embodiments in which: 
     FIG. 1 is a schematic diagram of a system and method for manufacturing printed envelopes utilizing roll to-roll processing according to this invention; 
     FIG. 2 is a somewhat schematic diagram of one embodiment of a system and method for packaging a plurality of completed folded envelopes produced using the system and method of FIG. 1 in sequential order according to this invention; 
     FIG. 3 is a alternative embodiment of a system and method for packing envelopes produced according to the system and method of FIG. 1 utilizing a roll and strap for storing a plurality of completed envelopes in sequence; 
     FIG. 4 is a somewhat schematic view detailing the positioning of printed check digits on envelopes and corresponding letters to be inserted into the envelopes that ensures proper sequencing according to this invention; and 
     FIG. 5 is a schematic diagram of the tracking of envelopes and corresponding letters utilizing the check digits as shown in FIG. 4 for proper sequential insertion of the letters into respective envelopes according to this invention. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     FIG. 1 schematically illustrates a system and method for manufacturing printed envelopes according to this invention. Unlike traditional methods that first manufacture the envelope then print it and then finally emboss it, the depicted system begins with a roll 10 of unprinted web 12 (paper in this example). This roll 10 is fed continuously through a laser printer 14 that is interfaced with a CPU 16. The CPU 16 carries a programmed routine that sequentially instructs the laser (or similar variable information) printer 14 to lay down programmed, or otherwise predetermined, text at given web locations 18 as the web is passed through the laser printer 14. By variable information, it is meant a printer having readily alterable text format through, for example, a computer program. Such a printer generally utilizes toner to form print text on a sheet. 
     One advantage of utilizing a laser or other variable information printer is that it retains the ability to access all portions of the web presented to it with variable information. As such, the full body of the web may be printed upon. A further advantage is that the envelope size can be varied depending on the programmed plan for size and amount of subsequent inserts. An additional advantage is that postal rates (stamps) can be printed based on such items as size, weight of future contents, and postal discounts. A multiplicity of laser printers having a plurality of possible toner colors may be contemplated according to this invention each connected in unison to access a certain portion of the web as it is passed therethrouqh. Such accessing involves direct feedback (handshaking) with the CPU 16 which determines when a given location upon the web is presented to the particular laser printer. As illustrated, printing 20 is laid down upon the web 12 at programmed or otherwise predetermined intervals therealong. Each of these intervals corresponds to the sheet size necessary to fold each envelope. 
     Printing, as noted, may include a variety of information that is tailored to each individual envelope based upon stored CPU information relative to its contents. Additionally, the postage amount to be applied may be indicated thereon based upon weight, size, content and any applicable postal discounts. 
     Following the initial printing of web sections 18 by the laser printer unit(s), the continuous web 12 may be rerolled (22) at an output side of the printer 14 for convenient storage. At this point, the CPU 16 has stored therein an accurate record of the sequence of printed web sections contained on the storage roll 22. Of course, when the storage roll 22 is unwound again, the sequence will be reversed (i.e. last in first out). The CPU 16, may easily accommodate this reversal of order by inverting the order of its programmed sequence. An advantage of this system is that, despite sequence inversion, at no time does the sequence of web sections 18 become disordered since each section remains part of a continuous unbroken web 12. 
     The initial printed storage roll 22 is subsequently removed, according to this example, and transferred (24) to be remounted (25) onto an optional enhancement device 26. Such enhancements (27) may include further printing, embossing, cutting, imprinting, lithography, adhesive placement and application of foil to the sheet. Note, none of the web sections has yet been folded into an envelope which contrasts directly with conventional envelope construction in which the folding generally occurs first, rather than later, in the overall process. The enhancement device 26 may be linked with the CPU 16, or may otherwise examine particular text upon each web section 18, in order to determine (by comparing with sequenced programmed instructions) when that particular section is at the proper location within the enhancement device 26 and which type of enhancement, if any, is to be applied to that particular section. In any event, since the sequence is fixed by virtue of the continuous roll 22 of web, each web section may be accurately and individually a located and personalized with appropriate enhancements. Again, note that while one enhancement unit is depicted, several enhancement processes may be undertaken at once. 
     Subsequent to the enhancement process, the web is again taken up by a second storage roll 28 according to this example. The second storage roll 28 is then, similarly, transferred (29) to be remounted (30) upon an envelope sheet cutting and folding unit 32. As depicted in FIG. 1, the printed storage roll 22, without enhancements, could have been directly mounted (33) upon an envelope sheet cutting and folding unit 32 if no further enhancements were desired. The cutting and folding unit 32 is, again, adapted to detect (or recognize based upon feedback with the CPU indicating web position within the unit) section breaks 34 between various web 12 sheet sections 18 and cuts the web 12 at these locations 34. Each sheet is then folded into a completed envelope 36. Any adhesives applied during prior operations to hold the folded parts of the envelope together may also, at this point, be sealed. Since the envelope 36 has not been filled, however, the main flap 38 (if any) may remain unsealed in order to allow subsequent insertion of contents. 
     While envelopes depicted are generally of equal size, the CPU may be programmed to detect particular envelopes at cutting and folding locations for which odd-sized contents are to be inserted, those envelopes may then be formed to a different size depending upon the particular contents to be inserted. 
     The completed envelopes 36 are then transferred to a unit 40 that stores them in a sequence corresponding to the original CPU 16 program sequence or its inverted analog. The particular completed envelope storage method may depend upon the number and size of envelopes to be stored. Examples of such storage patterns are depicted schematically in FIGS. 2 and 3 respectively. FIG. 2 illustrates the sequential storage of envelopes 42 in boxes 44. As envelopes 44 are outputted from the cutter/folder unit (32), they are inserted into a box 44. Each box 44, once full, is moved out of position relative to a box filler to be presented at an output location. The fullness of a box 44 may determined by the CPU 16 by counting the number of envelopes output and comparing this number to a maximum box capacity. Fullness may also be based upon a particular common characteristic shared by all envelopes in a set such as presort zip code. The final result in this instance is that each box is output in order containing therein envelopes also in their own sequential order. 
     Alternatively, the stream of finished unfilled envelopes 46 sequentially output from the cutter/folder unit (32), may be conveyed (47) to a roll forming device 48 as depicted in FIG. 3. The roll forming device 48 utilizes a roll core 50 and an opposing reusable flexible (plastic) tape or strap 52 that is paid out to support the undersides of the envelopes 46 against the roll 54 as the roll advances. This roll 54 and the tape 52 incorporated therewith may be subsequently remounted onto a contents insertion machine 56 (FIG. 5) for quick output of the sequenced completed envelopes 58 for final insertion of letter contents 60 and sealing 61. The boxes 44 of FIG. 2 may otherwise be loaded onto an insertion machine 56 for sequenced output of their envelopes 42 into the insertion machine 56. 
     While the CPU 16 may effectively track the sequence of each web section and the subsequent corresponding folded envelope, it may desirable to provide secondary means for checking the proper sequencing of envelopes. To this end, the CPU 16 may instruct the laser printer 14 to apply specific markings at predetermined intervals to printed web sections. Such markings 64 are illustrated in FIG. 1. Additional secondary and even tertiary markings may be provided for larger multiples of intervals. For example, as depicted in FIG. 4, the envelopes 63 may include regularly spaced markings 64 every 10 envelopes (spacing d) and may also include secondary markings 66 every 50 envelopes (spacing D). The markings are, in this example, applied as part of the initial printing process when the sequence is first established and layed down. At any time thereafter, these markings may be scanned by detectors to insure that subsequent processes are proceeding in the correct sequence. If at any time the sequence is lost, the CPU 16 may be instructed to stop the system or otherwise indicate a loss of sequence so that corrective action may be taken. In this manner, an ongoing check and cross-check of sequencing is possible. Corresponding markings 68, 70 may be applied to letters 72 intended for insertion into particular envelopes 63 as also illustrated in FIG. 4. These markings 68, 70 may again denote, respectively, 10 letter intervals (spacing 1) and secondarily denote 50 letter intervals (spacing L). 
     The markings upon letters and envelopes particularly assist in ensuring proper insertion of letters into envelopes. Such a process, as discussed above, is depicted in FIG. 5. Finished envelopes 58 are transferred to an insertion unit 56. Simultaneously, letters 60 that in this example are cut (71) from a continuous web 78 thereof in response to CPU instructions, are also fed into the insertion unit 56. Both the letters 60 and envelopes 58 undergo a scan by respective detectors 80, 82 to ensure that the proper sequence of letters 60 and envelopes 58 is maintained. In the insertion unit 56 each corresponding letter 60 is then placed into an envelope 58. The filled envelopes 84 are then subsequently sealed by either the insertion unit 56 or another device (61) and then the final filled and sealed sequenced envelope 72 is boxed, rolled or otherwise stored in final output form 74 that maintains the appropriate sequence (box, strap/roll, etc.). This sequence, as noted, may be structured in such a way as to facilitate adherence to the postal service presort requirements or other predetermined parameters. 
     This unique process allows a wide range of previously impossible customizations of an envelope and its contents while facilitating rapid processing of large volumes of envelopes. The types and combinations of customization are limitless in the pursuit of a unique item to attract or accommodate an individual&#39;s or postal service needs. 
     It should be understood that the foregoing description of the invention is intended merely to be illustrative of the preferred embodiments and that other embodiments, modifications and equivalents may be apparent to those skilled in the art without departing from the spirit and scope of this invention.