Abstract:
A measuring gauge constructed of a transparent “L” shaped body having an elongated first arm and a second shorter arm disposed at 90 degrees to the first arm and defining a notch therein which forms a triangle with the first leg of the triangle angularly disposed with respect to the outer edge of the second arm. A plurality of indicia are carried by the two legs of the gauge. The indicia each include a center band sandwiched between outer bands with the inner and outer bands being of contrasting colors. The side edges of the gauge are inserted between the flaps and back panels of the envelope into engagement with a gum line and a depth of penetration is observed by determining the intersection of an edge of the envelope with the indicium along a side edge of the gauge thereby determining whether or not the envelope is in or out of specification.

Description:
FIELD OF THE INVENTION 
   The present invention relates generally to the manufacture of envelopes on a production line apparatus and more particularly to an apparatus and method to measure predetermined positions upon the envelope to determine whether the envelope is in or out of specification. 
   BACKGROUND OF THE INVENTION 
   Envelope manufacturing machines which fold the closure, side and bottom flaps or panels of envelope blanks are well known in the prior art. Such machines which manufacture such envelopes on a production line basis are also well known, including such apparatus which automatically applies adhesive or gum to predetermined portions of the envelope blank during the manufacturing process and cuts windows in the envelope blank. 
   While it is known to make envelopes and apply adhesives to various flaps and other portions of the envelope in a continuous production line system, if the gum is incorrectly applied to the predetermined areas of the envelope, then the envelope will not function as designed. Such will in turn negatively affect the basic use of the envelope as well as cause problems with inserting equipment and postal sorting equipment. Traditional ways to validate the correct positioning of gum and the window at predetermined points on the envelope blank have been visual inspection, holding the envelope to a template manually measuring portions of the envelope or the like. Such methods rely on an interpretation of measurement apparatus and standards and specifications and requires a multiplicity of tools and is time consuming and subject to error. 
   There is a need for an apparatus and process which may be utilized by an operator to more quickly and easily validate that window and the gum exist and is in the proper position and length and which is reliable. 
   SUMMARY OF THE INVENTION 
   The present invention is directed to a measuring gauge for determining that an envelope meets predetermined specifications as well as a method of manufacturing envelopes in a high-speed production line utilizing the measuring gauge. 
   The measuring gauge is a flat, transparent “L” shaped body including an elongated first arm forming the long side of the “L” shaped body and a second shorter arm disposed at 90° to the first arm and at one end thereof. There is provided a notch in the second arm with the notch defining a triangle with the first leg angularly disposed with respect to the outer edge of the second arm. A first indicia is carried by the first leg of the triangle for indicating an in or out of specification of a first portion of an envelope, a second indicia is carried by the outer edge of the first arm for indicating an in or out of specification of a second portion of an envelope, a third indicia is carried by the inner edge of the first arm for indicating an in or out of specification of a third portion of an envelope and a scale is carried by the outer edge of the second arm for determining in or out of specification of a window formed in said envelope. 
   The method of manufacturing an envelope in accordance with the present invention comprises establishing a plurality of controllable manufacturing parameters providing a measuring gauge including a triangular element, the measuring gauge having indicia disposed on side edges thereof which may be read by a user to ascertain whether various portions of an envelope are within predetermined specification, selecting envelopes during a production run for measurement to determine whether they are within said predetermined specifications, inserting a first edge of the gauge between the side flap and back panel of an envelope and into engagement with the gum line and reading the depth of penetration of the first edge of the gauge, inserting the terminus of the triangular element of the gauge between the back flap and side flap at the bottom fold line and reading the depth of penetration of the triangular element, opening the side seam fold line of the envelope to expose the side flap on the inside of the envelope and inserting a second edge of the gauge between the back panel and the inside edge of one of the side flaps into engagement with gum and reading the depth of penetration of the second edge of the gauge, and placing the outermost part or tip of the triangular element at the bottom fold of the envelope and reading the distance from the bottom fold to the bottom of the window cutout, and adjusting one or more of the parameters to correct for any out of specification readings obtained. 

   
     BRIEF DESCRIPTION OF THE DRAWING 
       FIG. 1  is a schematic representation of a blank used to form a side seam envelope; 
       FIG. 2  is a top plan view of a measuring gauge constructed in accordance with the principles of the present invention; 
       FIG. 3  shows the gauge of  FIG. 2  being used to measure the bottom of the envelope; 
       FIG. 4  illustrates the gauge of  FIG. 2  being used to measure the top and outside edge of the envelope; 
       FIG. 5  shows the gauge of  FIG. 2  being used to measure the inside edge of the envelope; 
       FIG. 6  shows the gauge of  FIG. 2  being used to measure the window position relative to the bottom of the envelope; and 
       FIG. 7  shows the gauge of  FIG. 2  being used to measure the window position relative to a side fold of the envelope. 
   

   DETAILED DESCRIPTION 
   The present invention is an improved process for manufacturing envelopes that utilizes a novel measuring gauge, and a methodology for using the gauge on samples of product at predetermined intervals. The novel measuring gauge is used manually to measure the location of the seam gum application and the address display window on an envelope. The gauge measures four different locations of seam gum, namely, top, outside, inside, and bottom. The gauge has four indices such as contrasting bands for these four measurements. The contrasting bands may be alternating bands of red and green. When the gauge is properly applied to the envelope, the red indicates the seam gum was applied to incorrect locations, and adjustments to the manufacturing parameters are needed. The green indicates that the seam gum application was in the correct region. The gauge also includes a scale along one side which is used to measure the position of the window and the size of the flap on the envelope. 
   Preferably, the margin of error is +/− 1/16 inch, which is reflected by the green width of the bands on the gauge. The monitoring measurement is preferably taken at least once every 30 minutes. Preferably, three consecutive envelopes are taken for measurement during each sampling for consistency, although any number may be taken, and such may be done randomly. If the results show that the seam gum is applied in the correct region, then no adjustment is needed. If the results show that the seam gum is not applied in the correct region, a corrective adjustment is taken to reduce or eliminate the error. 
   The improved process comprises initially establishing a plurality of controllable manufacturing parameters of an envelope making apparatus, including the fold locations for side panels or flaps of an envelope, the width of adhesive application from an adhesive applicator associated with the apparatus, the length of adhesive application from the adhesive applicator, the thickness of the applied adhesive from the applicator, the initial location for application of adhesive by the applicator, the distance from the edge of a side flap to a gum or adhesive line, pressure of exit rollers from the applicator and apparatus, the speed of movement of paper stock through the apparatus, and other parameters. The process further includes providing a measuring gauge (a “Go/No-Go” Gauge”) for use in measuring variations of said parameters on manufactured envelopes. The measuring gauge is preferably fabricated from Mylar, about 10 thousands of an inch thick, and is transparent, in the shape of an inverted “L”, and has several predetermined human-readable indicia operative to provide a measurement of in-spec and out-of-spec tolerance for various parameters. Each of the four sides of the gauge is labeled with an appropriate name for the part of an envelope to be checked against the measurements of the gauge, namely, top, bottom, inside, and outside. The gauge has colored regions or bands that are sized to represent an in-spec measurement and warn of out-of-spec measurements, plus or minus 1/16 inch. 
   For one typical side seam gummed envelope, the bottom or lower leg of the “L” of the gauge is 1½ inches, while the long side or leg of the “L” is 4 inches, with a top 2½ inches wide. The dogleg or short leg of the “L,” is 1 inch long by 1 inch wide, with the remainder of the gauge being 2½ inches long. These dimensions may vary depending upon the size of the envelope to be measured. 
   One indicium on the gauge  10  indicates “Check at least 3 samples every 30 minutes”. 
   A first measuring indicia comprises a legend INSIDE, positioned proximate to a three-layer band along an outer edge of the “L”, and extending about ⅔ of the distance from the top of the “L.” The band includes a central band of 0.125 inches indicative of “in spec”, positioned between two outer bands of 0.125 inches indicative of “out of spec”. 
   A second measuring indicia comprises a legend OUTSIDE, positioned proximate to a three-layer “L” shaped band, along an inner edge of the longer leg of the “L”. The second band also includes a central outer band of 0.125 inches indicative of “in spec”, positioned between two-outer bands of 0.0625 &amp; 0.125 inches indicative of “out of spec”. 
   A third measuring indicia comprises a legend TOP, positioned proximate to a three-layer “L” shaped band:, along an inner edge of the shorter leg of the “L”, and intersecting with the band of the longer leg. The third band also includes a central band of 0.125 inches indicative of “in spec”, positioned between two outer bands of 0.0625 &amp; 0.125 inches indicative of “out of spec”. 
   A fourth measuring indicia comprises a legend BOTTOM, positioned proximate to a two-region triangular element, having an apex generally aligned with the edge of the shorter leg of the “L”, and having a triangular notch defined along the edge of the shorter leg of the “L” of the gauge. Along the hypotenuse edge of the triangle, the three-region colored element includes an inner or central band which is preferable a green portion and an outer band which is a preferable red portion on either side and extending to the apex. Measuring from the outside vertical edge and along the hypotenuse edge, the red portion is 0.9375 inches indicative of “out of spec”, the inner green portion is 0.350 inches indicative of “in spec”, and the second red portion is 0.30 inches and indicative of “out of spec”. 
   A fifth measuring indicia includes a scale along the bottom of the shorter leg of “L” to measure the location of the address display window. 
   A user of the gauge uses the gauge preferably on three consecutive envelopes to ensure that clearances are within spec. If the gauge shows that the gum or adhesive line is within spec on the three consecutive envelopes, no adjustments are indicated. 
   All specs—top, bottom, outside, and inside clearance and window location—are checked preferably at a maximum interval of 30 minutes, during normal quality control inspections. Preferably, at least three sequential envelopes are checked before any settings are adjusted. 
   By way of illustration a side seam envelope upon which the apparatus and method of the present invention may be used is found in  FIG. 1  which is prior art and is well known to the industry. As is shown an envelope blank  10  is provided from which the envelope is manufactured. As is shown the envelope blank  10  includes a front panel  12 , a back panel  14  joined to the front panel by a bottom or intermediate fold line  16 . Side flaps  18  and  20  are joined to the front panel by side fold lines  22  and  24  respectively. A closure flap  26  is joined to the front panel  12  by a fold line  28 . An address display window  30  is formed in the front panel  12  and is usually covered by a transparent layer of material such as plastic. To secure the envelope together in its completed form a layer of adhesive is applied to the opposite side (from that illustrated in  FIG. 1 ) of the side flaps  18  and  20  as is illustrated by the dotted lines  32  and  34  respectively on the side flaps  18  and  20 . That is, when the side flaps  18  and  20  are folded along their fold lines  22  and  24  to lie over the front panel  12 , the adhesive  32  and  34  will be present so that when the back panel  14  is folded along the bottom fold line  16  over the front panel  12  the back panel  14  will be secured by the adhesive  32  and  34  to the side flaps  18  and  20  thus completing the envelope and providing an inner pocket for receipt of desired materials. The closing flap  26  also has a layer of adhesive  36  which is typically remoistenable adhesive so that the user may apply liquid to the adhesive  36  and secure the closure flap  26  to the outside of the back panel  14 . Typically the adhesive layers  32  and  34  are hot melt adhesive applied during the manufacturing process in a high speed production apparatus. As above pointed out, if the adhesive layers or gum lines  32  and  34  are not properly applied, the envelope may not function as designed. As a result the measuring gauge of the present intention is utilized to be capable of quickly and easily measuring various portions of the envelope in its completed form to determine whether or not the envelope meets the desired specifications. 
   Such a measuring gauge  40  is shown in  FIG. 2 . The measuring gauge  40  is manufactured from a thin transparent material typically plastic such as Mylar having a thickness of approximately 0.0010 inches and is constructed in the form of an “L” shaped device. Measuring gauge  40  has a first elongated leg or arm  42  which provides the long side or leg of the L and second shorter arm or leg  43  which is disposed at 90 degrees to the leg  42  and at the end  44  thereof. The short leg  43  defines a triangular notch  46  having a hypotenuse  48  and a leg  50 . The notch generates a triangular element  52  at the bottom of the arm  43  which has a terminus  54 . Along the hypotenuse  48  there is provided an indicium  56  which may be used to ascertain whether or not a particular portion of the envelope is within desired specifications and such will be described further particularly in conjunction with  FIG. 3 . Along the lower portion  58  of the arm  43  there is provided a scale  60  which may be utilized to measure distance from the terminus  54  to ascertain whether or not another portion of the envelope is within appropriate specifications and such will be described more fully in conjunction with  FIGS. 6 and 7 . 
   Along a first edge  62  of the elongated arm  42  of the gauge  40  there is provided an indicium  64  which is utilized to ascertain whether or not another portion of the envelope is within specification and such will be described more fully in conjunction with  FIG. 5  below. On the opposite side  66  of the arm  42  there is provided an indicium  68  which may be utilized to determine whether or not another portion of the envelope meets specification and this will be described more fully in conjunction with  FIG. 4  below. The indicia  64  and  68  preferably take the form of contrasting bands such as shown at  70 ,  72  and  74  of the indicium  64 . For example, in one preferred embodiment, the bands  70  and  74  may be of a particular color such as red while the band  72  may be of a contrasting color such as green. Alternatively, the bands  70  and  74  may, for example, be black with the center section or band  72  being white or transparent. Obviously, any system utilizing contrasting bands irrespective of color may be utilized in accordance with the preferred embodiment of the present invention. When the envelope meets the desire specifications the intermediate band such as that shown at  72  will be readily apparent to the user of the gauge  40  whereas if the bands  70  or  74  appear in a particular measurement the envelope is considered out of specification. 
   A similar contrasting arrangement is used for the indicium  56  as is illustrated along the hypotenuse  48 . The indicium  56  contains first and second bands  76  and  78  which sandwich a contrasting band  80 , there between. As indicated above, when the band  80  appears during the utilization of the gauge to measure a particular portion of the envelope that portion of the envelope is within specification. If either band  76  or  78  appear then that portion of the envelope is out of specification. 
   Additional indicia also appear on the gauge  40  such as the legends top, bottom, inside and outside. These refer to various portions of the envelope that are to be measured by that part of the gauge. These indicia guide the user of the gauge  40  as to where that particular portion of the gauge is to be placed for a specific measurement. It should also be noted that there appears on the gauge the additional legend “check at least three samples every 30 minutes”. This is a reminder to the user of the gauge that at least three envelopes are to be secured from the production run taking place every 30 minutes and these three envelopes are to be measured to determine whether or not the production run is generating envelopes which meet the desired specifications. 
     FIG. 3  illustrates the gauge  40  being used to measure the bottom of the envelope. In order to accomplish this measurement the terminus  54  of the triangular element  52  is inserted along the bottom fold  16  of the envelope  10  between the back panel  14  and the side flap  18  until the top or hypotenuse  46  of the triangular element comes into contact of the line of adhesive securing the back panel  14  to the side flap  18 . When such occurs, the user of the gauge  40  will read the position of the indicium  56 . If the band portion  80  is intersected by the edge of the back panel  14  this portion of the envelope is considered within specification. If however, either of the other contrasting portions  76  or  78  of the indicium  56  are intersected by the edge of the back panel  14  that portion of the envelope is considered out of specification and an adjustment of the manufacturing apparatus to properly apply the adhesive layer  32  must be made. 
     FIG. 4  illustrates the measuring gauge  40  being utilized to measure the outside of the envelope  10 . As is shown the edge  66  of the gauge is inserted between the back panel  14  and the side flap  20  until the edge  66  encounters the adhesive line which secures the back panel  14  to the side flap  20 . The operator then observes the indicium along the edge  66  to determine whether or not the inner band portion  68  is intersected by the edge of the back panel  14 . If such occurs then that portion of the envelope is within specification and no action needs to be taken. If however, either of the outer contrasting bands which are positioned on opposite sides of the inner band  68  are intersected by the edge of the back panel  14  the envelope is considered out of specification and appropriate adjustments of the adhesive applying apparatus or other portions of the manufacturing apparatus must be made accordingly. It should be apparent to those skilled in the art that the gauge  40  may be applied in a similar manner between the opposite side of the back panel  14  and the side flap  18  by turning the gauge  40  over from that shown in  FIG. 4  and inserting it in a like manner. In addition, the edge  67  of gauge  40  is inserted at the top of the panel  14  and moved downwardly until the adhesive line is engaged. The position of the top edge of the panel  14  is observed, and if it intersects the inner band  68 , then the length of the adhesive line is correct. 
   It is also desirable to check the inside of the envelope to determine whether or not the adhesive line on the side flaps  18  and  20  is positioned properly. This can be accomplished by utilizing the gauge  40  in the manner shown in  FIG. 5 . To accomplish this the side edges along the fold lines  22  and  24  for the side flaps are slit carefully so as not to destroy the side flaps  18  and  20 . The envelope is then opened so that it appears substantially as a blank as shown in  FIG. 1  but with the side flaps attached to the back panel  14 . The portion of the gauge marked inside is then inserted between the side flap  18  and the back panel  14  until the edge  62  thereof engages the adhesive line which secures the side flap  18  to the back panel  14 . If the center portion  72  of the contrasting bands is intersected by the edge  82  of the side flap  18  then the envelope is within specification. If either of the bands  70  or  74  are intersected by the side edge  82  then this portion of the envelope is out of specification and the manufacturing apparatus must be adjusted accordingly. 
   As shown in  FIGS. 6 and 7  the gauge  40  may be utilized to measure the position of the address display window  30  with respect to the envelope. As shown in  FIG. 6  the outer edge or terminus  54  of the triangular element  52  is positioned along the lower fold line  16  of the envelope and the scale  60  is read to determine how far the bottom  84  of the window  30  is from the fold line  16 . As is indicated particularly in  FIG. 2  the readings ½ and ⅝ and ⅞ are predominantly displayed on the scale. These measurements from the terminus  54  are standard in the industry for the proper positioning of the bottom of the window  30  from the fold line  16 . In a similar manner the position of the address display window  30  from the left edge of the envelope could be measured as is illustrated in  FIG. 7 . This is accomplished by placing the terminus  54  of the arm  43  against the left side of the envelope as illustrated and then measuring, using the scale  60 , the distance from the left edge or fold line  22  to the edge of the window  30 . Again the designations ½, ⅝ and ⅞ are standard for most side seam envelopes. 
   There has thus been described a measuring gauge and the method of using the same to measure various portions of an envelope to determine whether or not they are within specifications determined by the manufacturing parameters of an envelope manufacturing apparatus. It should be evident to those skilled in the art, that a single tool, the gauge, is used by the operator or to measure several portions of the envelope. This can be done quickly and easily and provides a reliable indication on a go/no go basis as to the in or out of specification status of a production run of envelopes. If the measurements illustrate that the portions of the envelope or any of them which are measured do not fall within the desired specifications as initially generated then the controllable parameters of the manufacturing apparatus are adjusted to bring the envelopes being manufactured within the specifications desired. As is indicated, this may require adjusting the fold locations for the side flaps, the width of the strip of adhesive which is being applied, the start or stop point of the strip of adhesive, the length of the adhesive, the distance from the edge of a side flap to the line of adhesive or the like to bring the envelope within the desired set of specifications. 
   While the fundamental novel features of the invention have been shown and described in accordance with the above-preferred embodiments thereof, it should be understood that various substitutions, modifications and variations made by made by those skilled in the art without departing from the spirit or scope of the invention. Accordingly, all such modifications or variations are included in the scope of the invention as defined by the claims.