Patent Publication Number: US-2003230626-A1

Title: Mailer, method and device for automatically inserting media therein

Description:
BACKGROUND  
       [0001] The direct mail industry has historically utilized envelopes with single pockets for automated insertion of mailing components. In the past, mailing components historically have only included paper or like materials. To maximize efficiency, the direct mail industry has utilized automated machine-based processes for preparing mailings, including inserting materials, sealing, and addressing the envelopes and applying postage. However, with the rapid growth of Internet usage and personal computing at the household level, there is a growing necessity to mail outnumbers of electronic and optical media discs and devices to be included in direct mailers. Most of the computers being used by consumers at the household level, whether PC or Macintosh, are installed with optical media disc drives, which can read from and wrote onto removable media discs of various formats. These formats include the ubiquitous CD-ROM format, as well as the increasingly utilized CD-R, CD-RW, DVD-ROM, DVD-R, DVD-RW, DVD+RW formats, as well as compact discs of other removable media types. Currently there is a growing need felt by the direct mail industry for a means to prepare and deliver, in a cost effective automated insertion manner removable media and/or plastic media included with paper inserts or like materials through the mail to consumers. This is being driven by the growing awareness among Direct Mail marketers of the advantages of mailed removable media discs as sales and marketing vehicles. These advantages stem mainly from 1) the large capacity of such discs, such as CDROM and DVDROM discs, and 2) their ability to function dynamically as two-way communication devices. A description of these advantages is in order.  
       [0002] The digital capacity of a standard 12 cm CDROM disc, for example, is close to 700 megabytes. With this capacity, a marketer can advertise a product with over 60 minutes of video and thousands of pages of high-quality graphics and text. In other words, a marketer could place an entire catalogue on such a disc, use only the highest quality graphics, and support each product and/or service with video vignettes. The capacity would be even larger for a DVDROM disc. For the same marketer to mail the equivalent content without the benefit of such a disc, one or more bulky VHS tapes would be required, along with one or more thick and fairly heavy catalogues. All combined, the mailer without the disc would likely be impractically large and would incur a significantly higher postage rate.  
       [0003] The other main advantage of removable media discs is their ability to dynamically capture data. The same CDROM disc described above would be able to connect to the Internet via an Internet connection on the computer in which it is played. The marketer could therefore generate e-commerce sales and collect valuable marketing data from the consumer without the need and costs associated therewith for 1-800 number support or pre-printed reply/mail-in cards.  
       [0004] With the above advantages considered, the reader may presume there has been an explosion of Direct Mail that incorporates removable media. This has not, however, been the case. The reason for this is the relative newness of the removable media as sales and marketing devices, to which the Direct Mail industry has not yet reacted.  
       [0005] There is also a need in the Direct Mail industry for additional printable “real estate” or surfaces of envelopes to enhance the ability of advertisers to get their message across. Advertisers for years have used traditional printed paper media in their direct mail advertising campaigns. Advertisers have balked, however, at utilizing optical media solely in their advertising campaigns because of the perception that if the recipient does not place the optical media in their computer, the advertiser&#39;s message has not been delivered. Advertisers perceive a need, therefor, to combine printed paper media with optical media in their advertising campaigns so as to assure their advertiser&#39;s message is delivered.  
       [0006] Current service providers and original equipment manufacturers in the direct mail industry offer few, if any, options for direct mailers to keep up with technological advances by incorporating removable media, such as optical media discs. The direct mailing processes include inserting of objects into envelopes, ink jet printing on the envelopes, sealing the envelopes, and applying postage. These traditional activities do not accommodate removable media discs, using direct mail equipment. The processes do not support the use of removable media discs in the same automated manner. For example, the current insertion machines that automate the direct mailing processes, such as that described and disclosed in U.S. Pat. No. 4,955,185 (hereinafter the &#39;185 patent), are not designed for removable media disc insertion into envelopes typically used in direct mail. The result is that service providers in the direct mail industry have to employ manual labor, such as hand insertion, in order to fulfill customer requests for mailers that incorporate removable media such as optical media discs. Moreover, the typical mailers and envelopes themselves, such as the #10 regular, #10 window, #9, 6×9 window, 6×9 regular, 9×12 catalog, 9×12 booklet, and others, unless otherwise custom ordered, are not of a paper weight to prevent the mailer from bending around the edges of the housed disc. These sizes also do not offer a pocket in which media can be automatically placed and in which the disc is protected from breaking, scratching or cracking. The heavier paper stocks, additional materials, and required hand labor for Direct Mail campaigns that incorporate removable media discs, together translate into pronounced higher costs.  
       [0007] There does exist holders in which optical media and print media is hand inserted. Such holders are used in the photo developing industry to provide prints to customers along with an optical disc on which is stored the customer&#39;s pictures. These holders are not suited for direct mail purposes because they are not compatible with present automatic paper insertion equipment, nor does equipment exist to accomplish the automatic insertion of the desired optical media into a direct mail envelope along with other marketing media. Additionally, these holders, because they position the optical disc at the edge of the holder, do not protect the optical disc sufficiently to assure their safe processing and delivery by the postal service.  
       [0008] Presently, it is possible in the optical media market to insert industry standard 12 cm and 8 cm discs by machine. However, the machinery used in this industry, such as that disclosed and described in U.S. Pat. No. 5,875,614 (hereinafter referred to as the &#39;614 patent), only support the automated insertion of industry standard discs into a limited number of sleeve sizes. The vast majority of these sleeve sizes are of the 5 in.×5 in. variety such as the 5¼ in.×5 in., 5⅝ in.×5{fraction (1/32)} in., 5¼ in.×5¼ in., 5¼ in.×5{fraction (5/16)} in. size and others. These sleeves function as a protective carrier for optical media discs, and are not typically used as direct mail mailers. These sleeves do not provide sufficient “real estate” to get an advertiser&#39;s message across, nor do these sleeves provide the opportunity for sending marketing media, in a automated, single-pass manner. Such sleeves are constructed from stock which is too flimsy to protect discs from the hazards of mailing through the postal service. Furthermore, because sleeves are invariably manufactured in the two sizes mentioned above, marketers are given few options for size and configuration for direct mail campaigns that incorporate removable media discs. Further complications arise in that these sleeves, when used as mailers or envelopes, are not automation compatible with current postal service requirements, and must be processed in a manner that requires higher postage charges than conventional mailers.  
       [0009] The existing machinery and inline single-pass machine processes used in the direct mail industry do not currently support removable media discs. Conversely, the existing machinery and machine processes used in the optical media industry currently do not support the multitude of different envelope sizes and configurations used in the direct mail industry nor can they include paper inserts to accompany the media. Therefore, mailings that incorporate removable media inserts, such as optical discs, typically incur a much higher cost than those mailings that do not incorporate removable media inserts.  
       [0010] For these reasons, there is a need for a mailer that can accommodate the direct mailing of different types of media, processed in a single-pass automated manner and sent together in one mailer, i.e. removable media, and plastic media, and paper or like materials. There is also a need for direct mailing equipment and processes which provide for the automated single-pass insertion of different types of media together in one mailer, i.e. removable media, discs, plastic media, and paper or like materials.  
       [0011] All publications, including patent documents, referred to in this application are incorporated by reference in their entirety for all purposes. All headings are provided for the convenience of the reader and should not be used to limit the meaning of the text that follows the heading, unless so specified.  
       SUMMARY  
       [0012] The present invention relates to a multiple pocket envelope, and to related methods and equipment for automatic insertion of media therein that satisfies the aforementioned needs. More specifically, the envelope has two pockets that are adjacent, separated by a common wall. The pockets are arranged in a manner so that the rear wall of the outer pocket is the front wall of the inner pocket. The entire envelope is formed from a unitary blank, that can be pre-printed and converted in customizable design and size configurations well known in the envelope converting field. This envelope provides extra printable “real estate” on the walls of the two pockets. The envelope is formed by folding, fastening, and optionally sealing the sides of the unitary blank.  
       [0013] The rear panel of the envelope is generally rectangular and has four sides that are defined by fold lines for four other integrally connected panels of the envelope which are defined as the two opposing side panels, the top panel and the bottom panel. The rear panel has both an inside and an outside surface as defined by the final configuration of the envelope. There are two opposed side panels that are integrally connected or joined to the rear panel, along the fold lines, and which are folded over to form an inner pocket leaving a portion of the rear panel inside surface uncovered or exposed and the edges or “buckles” of the opposed side panels “kiss” or touch each other. Optionally, the side panels overlap and are connected together at one or more glueable areas located on the buckles or on the panels. The inner pocket so formed has its mouth near the upper edge of the inside rear panel. The bottom panel is folded over and connected to the two opposed side panels at two glueable areas located on the lower panel to form an outer pocket suitable for insertion of removable media or other inserts. The bottom panel partially covers the folded opposed side panels and forms an outer pocket suitable for the insertion of removable media or other inserts. This outer pocket similarly has a mouth that is near the upper edge of the inside of the rear panel. The top panel is folded over the inner and outer pockets and acts to seal the inner and outer pockets. The top panel partially covers the bottom panel upon folding. Similarly, flaps of the inner pocket can be connected to the inside of the rear panel to form an inner pocket suitable for insertion of removable media or other inserts. Removable discs can, thus, optionally be inserted into the inner pocket and the printed inserts inserted into the outer pocket. Windows can optionally be included in either or both the bottom and rear panels to expose additional “real estate” on the inserted media to show through on the face of the envelope.  
       [0014] The method relates to a means of inserting media inside of an envelope, in an inline, single-pass, automated process. More specifically, the method includes a means for feeding an envelope, a means for feeding media to be inserted into the envelope, and inserting the media into the envelope.  
       [0015] The related equipment comprises a means for moving an envelope on or through the equipment. Furthermore, the equipment includes a means for feeding an envelope with one or more pockets onto the moving means. The equipment also includes a means for conveying the media, and for feeding the media towards the envelope on the moving means. The equipment also provides a means for inserting the media inside the envelope pocket or pockets. Finally the equipment provides a means for connecting with and between the moving means, the envelope and media feeding means, the conveying means, and the inserting means so that the equipment operates in a coordinated fashion.  
       [0016] The principal objects of the present invention are: to provide a dual pocket envelope; to provide a dual pocket envelope with additional printable “real estate”; to provide such an envelope which is adapted for use with automatic mail insertion equipment; to provide a method of insertion with such automatic mail insertion equipment; to provide automatic mail insertion equipment to accomplish automatic insertion of media into envelopes, to provide such an envelope which is well adapted for use with automatic mail processing equipment; to provide such an envelope that is adapted for in line, single-pass automated insertion with a plurality of media inserts; and to provide such an envelope that is particularly well adapted for use with optical and other removable media inserts. Other objects and advantages of this invention will become apparent from the following description taken in conjunction with the accompanying drawings wherein are set forth, by way of illustration and example, embodiments of this invention.  
       [0017] The drawings constitute apart of this specification and include exemplary embodiments of the present invention and illustrate various objects and features thereof. 
     
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
     [0018]FIG. 1 is a plan view of the envelope.  
     [0019]FIG. 2 is a cross-sectional view of the envelope  
     [0020]FIG. 3 is a view of the inside of the envelope blank  
     [0021]FIG. 4 is a view of the outside of the envelope blank  
     [0022]FIG. 5 is a view of the multiple station automated insertion device for media  
     [0023]FIG. 6 is a sectional view of the removable media insertion device  
    
    
     DETAILED DESCRIPTION  
     [0024] Definitions  
     [0025] “Connecting” means a method for fastening, including but not limited to the use of booger glue, rewettable glue, or glue strip.  
     [0026] “Envelope” refers to an envelope already containing inserted media or, alternatively, an envelope devoid  6  of any inserted media.  
     [0027] “Media” means a type of material that can be inserted into and is otherwise removable from an envelope, including removable media defined herein, whether the material is (1) traditional paper or like materials or (2) electronic media, or optical media discs, or other computer-readable object, or equivalent; (3) plastic media such as credit cards, identification cards or related cards.  
     [0028] “Perforated” refers to any structurally weakened area or line. The weakening of this area or line can be accomplished by scoring, punching, folding, embossing or other like method.  
     [0029] “Unitary blank” means a single completely intact cut sheet of paper that is converted into an envelope.  
     [0030] “Business reply card” means a paper unit that can be removed from the envelope along a perforated line and separately filled out and mailed to a pre-printed address, or a coupon with pre-printed information, or other such equivalent.  
     [0031] “Removable media” means any type of electronic media such as optical discs, magnetic discs, magneto-optical discs, solid-state memory discs, discs of other formats, memory cards, memory sticks, or any other computer-readable storage object.  
     [0032] “Optical media” means discs removable discs of the various optical media formats, such as, but not limited to, CD-ROM, CD-R, CD-RW, CD-Video, DVD-Video, DVD-ROM, DVD-RAM, DVD-R DVD-RW, DVD+RW, DVD-R/CD-RW combo, DVD-RW/CD-RW combo, or other like equivalent.  
     [0033] “Suction cup” means a vacuum-operated pickup head which generates a suction force at its surface area that is calibrated to firmly pick up or move media, envelopes, or envelope panels. The suction cup is enabled by a motorized air compressor.  
     [0034] As required, detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention, which may be embodied in varying forms. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims as a representative basis for teaching one skilled in the art to variously employ the present invention in virtually any appropriately detailed structure.  
     [0035]FIG. 3 illustrates a one-piece unitary envelope blank prior to assembly into a dual pocket envelope as shown in FIGS. 1 and 2. With reference to FIG. 1, the envelope is constructed by well known methods of cutting from a larger unitary piece of stock and various lines of weakness which facilitate folding along the lines are formed on the envelope blank by conventional and well known methods. The stock for the blank can be composed of varying materials such as those commonly used for direct mailing envelopes, including but not limited to paper, cardboard, plastic, glycine, polymers, and combinations of said materials. The stock can be blank, to be printed upon later. The stock can also be pre-printed, with text, figures, diagrams, drawings, and other pertinent information printed in a variety of manners to accommodate varying methods of folding, angles, and viewing.  
     [0036] With reference to FIG. 3, the envelope includes a rear panel  2  that is generally rectangular in shape. The four sides of rear panel  2  are defined by four lines of weakness that facilitate folding or bending. The lines of weakness are represented by lines  16 ,  31 ,  46 , and  64 .  
     [0037] The side panels  15  and  30  designate the right and left side panels respectively, and are connected to the rear panel at lines of weakness  16  and  31  respectively which facilitate folding or bending. The side panels  15  and  30  are folded or bent inward over the inside surface of rear panel  2  to create an inner pocket. The mouth of the inner pocket is formed by the upper edges  19  and  34  of side panels  15  and  30  respectively. The side panels  15  and  30  can be of a size and shape as to cover the inside surface of rear panel  2  either partially or completely. Side panels  15  and  30  can be alternatively be fastened or connected together, utilizing a variety of methods including remoistened glue or booger glue, along overlapping right buckle area  20  and left buckle area  21 . A variety of fastening methods allow for the side panels  15  and  30  to form a customizable inner pocket. The inside surfaces of side flaps  15  and  30  allow for increased printable areas, maximizing the amount of printed information that is contained therein.  
     [0038] Alternatively the side panels  15  and  30  can be of such as size and shape as to substantially cover said rear panel  2  inside surface and to have their free side edges of the right and left side panels  17 ,  18  and  32 ,  33  touching so that no portion of the inside surface of the rear panel is exposed there between. Alternatively either or both side panels  15  and  30  can comprise a perforated line, wherein a portion of all of said side panels  15  and  30  can be detached at said perforated line and the detached portion can be used as a return postcard, a business reply card or equivalent. The side panels  15  and  30  can alternatively be of such a size and shape as to totally cover said rear panel  2  and to have their side edges  17 ,  18  and  32 ,  33  touching so that no portion of the inside surface of the rear panel is exposed there between.  
     [0039] Bottom panel  45  is connected to rear panel  2  at line of weakness  46  that facilitates folding or bending. Bottom panel  45  is bent or folded upwards over the inner pocket formed by side panels  15  and  30 . The outer pocket has a mouth at the lower edge  47  of the bottom panel  45 . Bottom panel  45  can be fastened or connected to a combination of side panel edges  17 ,  18 ,  19 ,  32 ,  33 , and/or  34  utilizing a plurality of methods including remoistened glue or booger glue, along the right and left edges respectively of edges  48  and  49  thus forming an outer pocket. The bottom panel  45  can alternatively be fastened or connected at glueable areas  51  and  52  to the outer surface of the right panel  15  and the left panel  30  thus forming an outer pocket. Bottom panel  45  can be of a shape and size to partially cover the wall of the inner pocket, formed by side panels  15  and  30 . Alternatively, the bottom panel  45  can be of such size and shape as to totally cover said opposed side panels  15  and  30 . An optional recess  53  substantially semicircular in shape facilitates insertion and removal of materials contained within the pockets.  
     [0040] Top panel  65  is connected to rear panel  2  at line of weakness  64  that facilitates folding or bending. Top panel  65  is bent or folded downwards over the mouths of the inner and outer pockets, and provides a means for sealing said pockets. Top panel  65  is of a shape and size to partially or fully cover bottom flap  45 . Top panel  65  can be fastened or connected to the lower edge  47  of bottom panel  45  utilizing a plurality of methods, including remoistened glue or booger glue, at glueable area  69 . The top panel can be opened to expose the mouths of the contained inner and outer pockets. Alternatively, the top panel  65  can be of such as size and shape as to totally cover said bottom panel  45 .  
     [0041] The outer pocket can be sealed, or fastened in a manner as to allow a person to unseal or unfasten the envelope, exposing the materials therein, and allow a person to view the inside of bottom panel  45 . This inside surface of bottom panel  45  and outer surface of the inner pocket present additional printable areas and thus maximize the amount of printed information that is contained therein especially when the glue used is translucent or clear.  
     [0042] The envelope can additionally have an optional window as shown in FIG. 4 on bottom flap  45  to reveal the contents of the outer pocket. This window can remain open and unsealed, or can have an  6  optional translucent or transparent covering to protect the contents of the outer pocket. Such translucent or transparent coverings are well known in the art and can include various polymers or plastic sheets.  
     [0043]FIG. 5 illustrates one possible embodiment of the method of insertion and the equipment necessary to accomplish such insertion. With regards to FIG. 5, the multiple station insertion device  3  disclosed therein can be constructed using well known methods in the inserter manufacturing industry such as described and disclosed in the &#39;185 patent. The multiple insertion device  3  can comprise an envelope feeding station  4 ; a first media insertion station  5 ; a second media insertion station  6 ; and an envelope sealing/receiving station  7 . FIG. 6 indicates one possible embodiment of the second media insertion station  6  that can be incorporated into existing inserters, or utilized separately. The embodiment disclosed in FIG. 5 can comprise the envelope feeding station  4 , first media or envelope insertion station  5  and envelope  16  sealing station  7  as described and disclosed in the &#39;185 patent. Furthermore, the second media insertion station  6  as shown in FIG. 5 can represent an optical media insertion station as disclosed in the &#39;614 patent. With reference to FIG. 5, the envelope is fed into envelope insertion station  4  along an envelope moving means  8 . One embodiment of the moving means is the insert track structure which is described and disclosed in the &#39;185 patent. Another embodiment of the moving means is comprised of the envelope moving track  145  a shown in FIG. 6. The moving means guides the envelope along movement path  180 . The first media insertion station  5  includes a supply of media (not illustrated) for insertion into the inner pocket of the envelope. The insertion of the media occurs as described and disclosed in the &#39;614 patent.  
     [0044] The second media insertion station  6  includes a media supply, one embodiment which is the disc supply as described and disclosed in the &#39;614 patent. Another embodiment of the media supply is illustrated in FIGS. 5 and 6 which indicates a media supply  70 , comprised of a plurality of media  75 , which provides media  75 .  
     [0045] The second media insertion station  6  includes a media transfer assembly  9 , one embodiment which is the disc transfer assembly which is described and disclosed in the &#39;614 patent. Another embodiment of the media transfer assembly  9  is depicted in FIG. 6. With reference to FIG. 6, the media transfer assembly is supported in a cantilever fashion by vertical support  95 , and is comprised of a conveying arm  85 , an optional rotatable hinge  195 , to which is rotatably mounted the conveying arm  85  to the vertical support  95 . One end of conveying arm  85  has at least one suction cup  80  through which vacuum is selectively applied. The suction cup  80  can be vertically and horizontally movable with respect to the conveying arm  85 . The suction cup  80  communicates with a source of vacuum (not illustrated) through the conveying arm  85  and vacuum hose  90 , which is controlled by an unillustrated controller. The conveying arm  85  is rotatable through at least 90 degrees by a pneumatic piston-driven or equivalent rotary actuator (not illustrated) which serves to rotate the suction cup  80  into a position substantially vertically aligned with the media  75  from the media supply  70 . In one optional embodiment, an unillustrated printing mechanism prints an address or like data on media  75  prior to transfer by the media transfer assembly  9 . With vacuum applied to the suction cup  80 , the conveying arm  85  is then raised to remove the topmost media  75  from the media supply  70 , and then the conveying arm  85  is rotated at the rotatable hinge  195  through about 90 degrees of arc to position media  75  above media rest  250  of feeding chute  200 . The conveying arm  85  is optionally lowered to bring the media  75  into engagement with feeding chute  200 . Vacuum is released to cause suction cup  80  to release the media  75  onto the media rest  250 . The media transfer assembly  9  is optionally controlled by an unillustrated controller.  
     [0046] The feeding chute  200  of second media insertion station  6  is now described. The feeding chute  200  functions to take media deposited onto media rest  250  by the media transfer assembly  9  and move that media into position for insertion into the envelope. Feeding chute  200  is formed by base  120 , whose width is greater than the diameter of media  75 . Base  120  may optionally be comprised of such materials as to facilitate the flow of media along path  210  and to minimize damage such as scratches to media  75 . Such materials can include polymers, felt, wood, and similar relatively soft materials. Base  120  may optionally be comprised of an unillustrated air suspension system, which is attached to an unillustrated air pump system. The unillustrated air suspension system creates an unillustrated air cushion through a plurality of vents  130 , which facilitates movement of media  75  along path  210 , further protecting the media  75  from damage. Feeding chute  200  is defined on one end by edge  220 , and an optionally recessed groove  215  to facilitate contact between feeding piston  100  and media  75 . Lip  135  defines the end of feeding chute  200 , which lip is positioned to optimally allow insertion of media  75  into an envelope. Feeding chute  200  is further defined by a first and second guide wall  110  and  115  respectively, which further aid in directing media  75  along path  210 . Guide walls  110  and  115  of feeding chute  200  may optionally be adjusted to accommodate varying sizes of media. Feeding chute  200  may optionally be adjusted vertically to accommodate varying dimensions, thickness, and composition of envelopes.  
     [0047] The pusher assembly  10  of second media insertion station  6  is now described. One embodiment of the pusher assembly is the pusher assembly as described and disclosed in the &#39;614 patent. Another embodiment of the pusher assembly is the pusher finger assembly as described and disclosed in the &#39;185 patent. Another embodiment of the pusher assembly is depicted in FIG. 6. Feeding piston  100 , with optional sensor  105 , is activated by pneumatic pusher  205 , which pushes media  75  along path  210 . The pusher assembly is timed and coordinated in a manner as to insert media into an open outer pocket of an envelope positioned at the lip  135  of the feeding chute  200 . Feeding piston  100 , the optional sensor  105 , and the pneumatic pusher  205 , are controlled by an unillustrated controller.  
     [0048] The moving means positions an envelope at lip  135  prior to receiving media  75 . The lip  135  contacts the upper edge  19  of the right side panel  15  and/or the upper edge  34  of the left side panel  30 . The lip  35  thus acts to hold down the panels so that the envelope opening mechanism  11  can open only the outer pocket and not the inner pocket. The envelope opening mechanism  11  of second media insertion station  6  is now described. One embodiment of the envelope opening mechanism  11  is the envelope opening station described and disclosed in the &#39;185 patent. Another embodiment of the envelope opening mechanism is depicted in FIG. 6. The moving means positions the envelope in a manner in which lip  135  is situated to allow insertion of media  75  into the outer pocket of the waiting envelope. Envelope opening mechanism  11  is comprised of at least one and preferably a plurality of elongated stems  165 . At one end of each elongated stem  165  is a suction cup  170  through which a vacuum is selectively applied. Each suction cup communicates with a source of vacuum through the attached elongated stem  165 , which optionally is hollow, and an un-illustrated flexible hose, and is controlled by an un-illustrated controller. Near its other end each elongated stem  165  is mounted to a vertically erect post  185 . The four posts  185 A through  185 D shown in FIG. 6 are carried on a carriage means  245 . The elongated stems  165 A through D serve to position the suction cups  170 A through  170 D over the envelope. Optionally, elongated stems  165 A through D can be positioned or rotated horizontally at vertically erect posts  185 A through  185 D to position suction cups  170 A through  170 D over the envelope. Elongated stems  165 A through  165 D are rotated vertically to position suction cups  170 A through  170 D near the envelope so that suction cups  170 A through  170 D can open the outer pocket of the envelope by application of vacuum there through. Elongated stems  165 A through  165 D are optionally positioned or rotated vertically to further engage with and open the outer pocket of the envelope. The envelope opening mechanism is timed and coordinated to be open to receive media  75  from the pusher assembly  10 . The envelope opening mechanism  11  is controlled by an unillustrated controller.  
     [0049] Upon insertion of media  75  into the outer pocket of the envelope, the envelope is moved along movement path  180  by the moving means. The envelope is then sealed by a device and in a such manner as the envelope sealing structure described and disclosed in the &#39;185 patent.  
     [0050] Optionally, the second media insertion station  6  further comprises one or more detecting means. One such error detection means, an error detection structure  175 , generates at least one and preferably a plurality of optical error detection beams  230 , which beams provide an indication whether or not media has been properly inserted into an envelope. The error detection means detect media insertion and media and envelope positioning errors near their physical placement and optimally throughout the entire second media insertion station  6 . The second media insertion station  6  optionally can include an unillustrated jam detection structure as described and disclosed in the &#39;185 patent. This unillustrated jam detection structure functions to detect media and/or envelopes that have become jammed.  
     [0051] Additionally shown in FIG. 6 is an envelope sealing unit  225  which may optionally comprise a part of the second media insertion station  6  or alternatively comprise a part of the envelope sealing/receiving station  7 . One embodiment of the envelope sealing unit  225  is the envelope sealing mechanism described and disclosed in the &#39;185 patent  
     [0052] The entire second media insertion station  6  is connected to and driven by an unillustrated motor or other equivalent motivational means, in a manner well known in the art. One embodiment is the motor described and disclosed in the &#39;185 patent. Another embodiment is the drive motors as described and disclosed in the &#39;614 patent. The entire second media insertion station  6  is controlled by an unillustrated controller, in a manner well known in the art. One embodiment is the pusher finger orientation control means as described and disclosed in the &#39;185 patent. Another embodiment is the controller as described and disclosed in the &#39;614 patent. The un-illustrated controller may optionally include a timer mechanism. The un-illustrated controller optionally is connected to the un-illustrated motor, the un-illustrated timer, the error detection structures, the un-illustrated printing mechanism, and the un-illustrated jam detection structure so as to provide a means for coordinating and controlling the envelope feeding, first media insertion, second media insertion, envelope sealing and receiving functions.  
     [0053] In one embodiment of the invention the insertion method occurs in steps. In another embodiment of the invention, one or more of the steps occur automatically. In another embodiment of the invention all the steps occur in a continuous stream. In a further embodiment the feeding steps occur in an automatic, continuous stream and in a step-wise movement. In again another embodiment of the invention, after the insertion of the media inside the envelope there is a step to verify proper insertion of the media inside the envelope. In a further embodiment, an address or like data is printed on the outside face of the envelope before the insertion of said media of said envelope. Similarly, in another embodiment, an address or like data is printed on the media prior to being fed automatically and wherein said address or like data corresponds to an address or like data printed on the outside face of the envelope. In one optional embodiment, an unillustrated printing mechanism prints an address or like data on the outer surface of the envelope after insertion of the media.  
     EXAMPLE  
     [0054] A dual pocket envelope is fed into the envelope insertion station  4  and is moved along an envelope moving means  8 . The moving means  8  guides the envelope along movement path  180  to the first media insertion station  5  wherein the inner pocket of the envelope can optionally be opened and inserted with media such as promotional material such as printed paper. Whether or not media is inserted at the first media insertion station the moving means  8  then guides the envelope along movement path  180  to the second media insertion station. Prior to, concurrent with or thereafter, the envelope&#39;s arrival at the second media insertion stations, the conveying arm  85  rotates through at least 90 degrees so as to rotate the suction cup  80  into a position substantially vertically aligned with the optical media disc  75  sitting on the media source  70 . A vacuum is applied to the suction cup  80 , the conveying arm  85  is then raised to remove the topmost optical media disc  75  from the optical media supply  70 , and then the conveying arm  85  is rotated at the rotatable hinge  195  through about 90 degrees of arc to position the optical media disc  75  above the media rest  250  of the feeding chute  200 . The vacuum is released to cause suction cup  80  to release the optical media disc  75  onto the media rest  250 .  
     [0055] An air suspension system creates an air cushion through a plurality of vents  130  in the feeding chute  200 , which facilitates the movement of the optical media disc  75  along path  210 , further protecting the optical media disc  75  from damage. The first and second guide wall  110  and  115  respectively direct the optical media disc  75  along path  210 .  
     [0056] To begin the movement of the optical media disc, the feeding piston  100  is activated by pneumatic pusher  205 , which pushes the optical media disc  75  from the media rest  250  along path  210 . The pusher assembly  10  is timed and coordinated in a manner as to insert the optical media disc into the outer pocket of the envelope positioned at the lip  135  of the feeding chute  200 . All the actions of the second media insertion station are controlled by a controller.  
     [0057] The moving means positions the envelope at lip  135  prior to receiving the optical media disc  75 . The lip  135  contacts the upper edge  19  of the right side panel  15  and the upper edge  34  of the left side panel  30 . The lip  135  holds down the panels so that the envelope opening mechanism  11  can open only the outer pocket and not the inner pocket. The elongated stems  165 A through  165 D are rotated vertically to position suction cups  170 A through  170 D near the envelope and thereafter the suction cups  170 A through  170 D engage and open the outer pocket of the envelope by application of vacuum prior to and during the time period during which the optical media disc is inserted into the outer pocket of the envelope. Upon insertion of the optical media disc  75  into the outer pocket of the envelope, the suction cups  170 A through  170 D disengage and the envelope is moved along the movement path  180  by the moving means towards the envelope sealing/receiving station  7 .  
     [0058] Prior to reaching the envelope sealing/receiving station  7  the envelope passes under the detection beams  230  of the error detection structure  175 . If the beams are broken by any part of an improperly inserted envelope, a controller steps in to stop the further operation of the equipment. If, on the other hand, the envelope is properly inserted, the envelope passes under the error detection beams  230  and the top panel  65  of the envelope is sealed by the sealing structure  225 .  
     [0059] Next, after passing through the sealing structure  225 , a printing mechanism prints an address on the outer surface of the envelope after insertion of the media. Finally, after printing the envelope is moved along the movement path  180  to arrive at the end of the envelope sealing/receiving station  7  where the envelope is positioned for removal from the multiple station insertion device  3 .  
     [0060] It is to be understood that while certain forms of the present invention have been illustrated and described herein, the present invention is not to be limited to the specific forms or arrangement of parts described and shown.