Note: Descriptions are shown in the official language in which they were submitted.
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r~his invention pertains to a dual-feed enveloper system
that can continuously fabricate and envelope single or multiple
page letters therein automatically. It also pertains to a cont-
inuous self mailer system wherein the letter becomes a self
mailer, if desired.
This invention is also a subsystem of an overall elec-
tronic message system. The printing and paper handling equipment,
the subject of this invention, both input and output, represent
a more gradually changing state of the art than the progress
in the electronic fie~ld. The throughput rates, reliability,
overall unctions and the ability of the invention to intermit-
tantly make an envelope or a self mailer, as desired, is a system
that is not available in the market place, yet is necessary
if the success of an overall electronic message system is to
become viable.
This invention relates to a dual-feed enveloper system
for fabricating envelopes and enveloping single or multiple
page letters automatically when said letters are received from
a scanner that processes electronic messages. The novel approach
to continuous enveloping in this instance comprises feeding
envelope web blanks alternately from two stacks of fan-folded
envelope blanks to feed rollers. The web blanks are maintained
under tension to keep the blanks f lat to assist in maintaining
synchronization and registration with the incoming letters
throughout the system. The web blanks are then advanced over
a Bernoulli plate for proper placement upon arrival at burster
rollers which separate the web blanks. The web blank speed
is continuously synchronized with the speed of the letter speed
for merging each envelope with each letter. Each web blank
and letter are folded. Each web blank upon folding, envelopes
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e~c~l ~etter. ~rhe envelope~ are stacked for easy removal or
processed o-ilerwise for subsequent delivery.
It is an objection of this invention to provide a
continuous enveloper system for fabricating envelopes that sub-
stantially concurrently envelope a single or multiple page letter
automatically.
It is another object of thi~ invention to provide
a continuous self m~iler system wherein a letter becomes a self
mailer.
It is a further object of this invention -to provide
an enveloper system for fabricating envelopes that substantlally
concurrently envelope a single or multiple page lettter auto-
matically and at a high rate of speed.
It is yet another object of this invention to provide
a continuous system for fabricating envelopes for enveloping
a single, multiple page letter or other insert received from
an electronic message process scanner automatically.
These and other objects of the invention will be better
understood and become more apparent with reference to the follow-
ing detailed description taken in conjunction with the attacheddrawing, in which:
The Figure is a schematic of the enveloper system
of this invention.
According to one aspect of the invention there is
provided a method of enveloping documents comprising the steps
of: providing a flow of documents to be enveloped; providing
two sources of envelope webs, alternately feeding the envelope
webs from the two sources, alternately bursting the envelope
webs to provide envelope blanks, merging the documents with
the envelope blanks, and enveloping the documents by enfolding
,
them in the ~nvelop~ blanks.
Accor~in~3 to another aspect of the invention, there
is provided a continuous enve'oper system which comprises: feed-
ing envelope web blanks toward continuously, uninterrupted feed
roll.ers, tensi.oning the web blanks to keep the web blanks flat
for maintaining system synchronization, advancing the web blanks
over a Bernoulli plate to insure the lead edge of the web blanks
iY properly placed upon arriving at the burster rollers for
assisting in controJ.ling the web blanks travel for system syn-
chronizing, synchroni~ing the continuous enveloper system bysensing the lead edge of the web blanks and feeding the sensing
information to a clutch brake controlling the feed rollers,
bursting the envelope web blanks as the lead edge of the web
blanks is engaged by burst rollers, activating the adhes.ive
on the web blanks for subsequent adherence, merging the web
blank with a folded letter for subsequent enveloping; enveloping
the folded letter by folding the non longitudinal adhesive con-
taining side of the web blanks prior to folding the opposite
side of the web blanks, and sealing the envelope by passing
through sealing rollers.
Referring to Figure 1, two stacks of fan-folded envelope
blanks 122 are fed across two stationary bars 104 to knurled
feed rollers 101 and 102. The envelope blanks are drlven against
the feed rollers by identical pressure roller assemblies consisting
of two D-shaped rollers 103 geared together.
The tension of the driven webs is maintained by the
drag supplied by two sets of adjustable brushes 105 which ride
against the envelope blanks 122. The feed rollers 101 and 102
are driven alternately on demand by identical clutch/brake units,
now shown, supplying blanks at high operating speeds and thereby
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allevi~ltil)g llle e~fect of lag in clutch/brake response time.
The clutch/~)r~ke ~)perdtion is triggered by a photodetector,
now ~hown, in tlle mailstream which operates in conjunction with
processor control, not shown.
Envelope blanks are fed out alternately alony declcs
123 dn~ 1~4 to take away rollers 107 which run continuously
at speeds 1.~7 times faster than web feed. This sp~ed differ-
ential is sufficient to draw the unbroken web tightly against
blades 106 which burst or separate the we~ into envelope blanks.
In this manner the dual station burster maintains synchronization
or registration between the incoming letters and the envelope
blanks at high operating speeds, particularly when enveloping
a long series of single-page letters is called for. In effect,
if a machine operating speed of ten (10) pages per second is
set, each web feeds alternately at five (5) pages per second.
Demand feed of either web is topped by a logic system, not shown,
which senses the lead edge of the web photo-optically at a point
just before the take-away rollers.
The envelope blank, now separated from the web proceeds
through the transport 108 where it may be scored. The blank
then proceeds into a turn-around transport system 109, 110 and
111 where belt moisteners 112 activate the glue in preparation
for folding.
The moistener belts are supplied with water by dual
pumps 118 which are connected to a remote reservoir 119 and
moistener tanks 113. Water is picked up directly on the belt,
providing immediate tanks 113, building up to a pre-determined
level while the pumps 118 are operating. The moistener tanks
113 drain completely when the pumps 118 stop, returning accumulated
sludge and paper dust to remote reservoir 119.
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The envelope blank merges with the document between
transport 110 and 111 prior to folding. The merged packet, con-
sisting of the letter or letter set and the envelope blank enters
the plow folding trans~ort 11~ which turns the inner flap of
the envelope blank 180 over the letter; the inner flap is then
sealed to itself as it passes through two compliant rollers
115. The outer flap of the blank enters plow folding transports
116 which turn the outer flap 180 onto its~lf and the inner
flap. Final sealing is done by two compliant rollers 117, com-
pleting the cycle of enveloping.
The advantages of the enveloper of this invention
produces an envelope which is substantially conventional in
appearance, thus giving an envelope made of paper; a stiffer
mail-piece which allows better subsequent machine handling,
better appearance and better customer acceptability. Moreover,
the enveloper of this invention is completely asynchrouous and
in-line; therefore, mailpieces not designated for enveloping
(that is, self-mailers) can pass directly through the enveloper
without the need for complex gating mechanisms.
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